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1/8-DIN & 1/16-DIN PLASTICS CONTROLLERS Product Manual

1. 5 ag E 2909 09 zHo9 os N VV 8 A LL 92 96 4 e 5 Indino 10 8404S PIOS J NOILO3NNOO 5 ADIS Indino ioeig 40 JO WOJNY Jeulle si e INdINO I pijos 10 ss Aoje Indino pi d55 YOSIg 1o eibis PIOS Jo XSS z woy eos Dilos asny 16 elpudoiddo so 279770 93675 0105 uss ole FOND ole Indino LO vos s LNdLNO 1009 Aubpuooes s z Rear Terminal Connections DIN Controllers Figure 1 5 5075 1 1 4 0075 1 3 1 Mains Line Input The Controller will operate on 96 264V AC 50 60Hz mains line supply The power consumption is approximately 4 VA CAUTION This equipment is designed for installation in an enclosure which provides adequate protection against electric shock Local regulations regarding electrical installation should be rigidly observed Consideration should be given to prevention of access to the power terminations by unauthorised personnel Power should be connected via a two pole isolating switch preferably situated near the equipment and a 1A fuse as shown in Figures 1 4 and If the Controller has relay outputs in which the contacts are to mains line voltage it is recommended that the rela
2. Function MODBUS Function Number Read Coil Status Read n Bits 01 02 Read Holding Registers Read n Words 03 04 Force Single Coil Write 1 Bit 05 Preset Single Register Write 1 Word 06 Loopback Diagnostic Test 08 Preset Multiple Registers Write n Words 16 The Controller will identify itself in response to a Read Holding Registers message which enquires the values of word parameters 121 and 122 see Table MODBUS Function 17 Report Slave ID is not supported 4 3 1 Message Formats The first character of every message is the Controller address in the range 1 128 standard RS485 or 1 255 enhanced 5485 and 0 for broadcast messages The second character is always the Function Number The contents of the remainder of the message depends upon this Function Number In most cases the Controller is required to reply to the message by echoing the address and Function Number together with an echo of all or part of the message received in the case of a request to write a value or carry out a or the information requested in the case of a Read Parameter operation Broadcast messages are supported at address 0 to which the Controller responds by taking some action without sending back any reply Data is transmitted as eight bit binary bytes with one start bit one stop bit and optional parity checking none even or odd A message is terminated simply by a delay of more than three character lengths
3. Output 2 _ Output 1 Process Variable Overlap positive value Proportional Proportional 1 Band Output 2 Output Power 96 Output 2 Output 1 lt gt Process Variable Deadband negative value 5 Proportional amp Output 1 WW Proportional Band 2 0 uL Output 2 S 8 j Q e A d a Output 2 Oo O Output 1 Process Variable ON OFF Differential ener Overlap Deadband Figure 3 1 Proportional Band and Deadband Overlap 0075 3 3 7 0075 3 2 8 Rate Derivative Time Constant This parameter is adjustable in the range 00 seconds to 99 minutes 59 seconds This parameter is not applicable if Proportional Band 1 see Subsection 83 2 5 is set to 0 ON OFF control 3 2 9 Overlap Deadband This defines the portion of the Proportional Band Proportional Band 1 Proportional Band 2 over which both outputs are active or in the case of a deadband neither output is active It is adjustable within the range 20 to 20 negative value deadband The default value is 0 The function of the overlap deadband is illustrated in This parameter is not applicable if Proportional Band 1 0 or if Output 2 is not fitted Note that with Output 2 set to ON OFF control Overlap Deadband parameter has effect of moving the ON Differential band of Output 2 to create an overlap positive values or a dea
4. 2 ab cd 7 ab cd Table 5 2 Commands Parameters and Identifiers Identifier Parameter Command Identifier Parameter Command A Setpoint High Limit W Output Power Read Only if not in Manual Control B Output 1 Power Limit Z Controller Commands 3 Alarm 1 value Recorder Output Scale Max D Rate Derivative Time Constant Recorder Output Scale Min E Alarm 2 value Scan Table F ON OFF Differential Setpoint Ramp Rate G Scale Range Max Read Only a Alarm 1 Hysteresis value H Scale Range Min Read Only b Alarm 2 Hysteresis value Reset Integral Time Constant Heater Current High Scale Limit J Manual Reset Bias d Heater Current Nominal Value K Overlap Deadband e Heater Current Read Only L Controller Status f High Heater Break Alarm value M Process Variable g Low Heater Break Alarm value N Output 1 Cycle Time h AM Key Usage Read Only O Output 2 Cycle Time i Control Setpoint value Read Only P Proportional Band 1 j Soft Start Setpoint value Q Scale Range Decimal Point Position k Soft Start Time value Read Only 5 Setpoint value Soft Start Time Remaining Read Only T Setpoint Low Limit m Input Filter Time Constant U Proportional Band 2 V Process Variable Offset value V Deviation value 0075 5 5 5 0075 NOTES ON TABLE 5 2 1 These parameters cannot be modified whilst either the Pre Tune facility or the Self Tune facility is activated 2 The Controller
5. Hex 49 indicating that the Controller is ready to implement the command If the parameter specified is invalid or is not modifiable or if the desired value is outside the permitted range for that parameter the Controller replies with a negative acknowledgement in the form L N P DATA N 5 2 7 Type 4 Message L N P 1 This type of message is sent by the master device to the addressed slave Controller following a successful Type 3 message transmission and reply to from the same slave Controller Provided that the DATA content and the parameter specified in the preceding Type 3 message are still valid the slave Controller will then set the parameter to the desired value and will reply in the form L N P DATA where DATA is the new value of the parameter If the new value or parameter specified is invalid the slave Controller will reply with a negative acknowledgement in the form 5 4 0075 5 0075 L N P DATA N where DATA is indeterminate If the immediately preceding message received by the slave Controller was not a Type 3 message the Type 4 message is ignored Table 5 1 DATA Element Sign and decimal Point Position DATA Content Sign Decimal Point Position DATA Content Sign Decimal Point Position abcd5 abcd abc d abcd abc d
6. 63Hz 0 01 1A full cycle rms on state 25 C derates linearly above 40 C to 0 5A 80 C 25A peak 500V us 1mA rms 1 5V 600V minimum A 6 DC Resolution Accuracy Update Rate Ranges PM 0075 Eight bits in 250mS 10 bits in 1 second typical gt 10 bits in gt 1 second typical 0 25 mA at 2500 V at 2 ko Degrades linearly to 0 5 for increasing load burden to limit as stated below Every control algorithm execution 0 20mA 4 20mA 0 5V 0 10V Changes between V and mA require link jumper movement Load Impedance Isolation Range Selection Method A 7 LOOP CONTROL Automatic Tuning Types Proportional Bands Reset Integral Time Constant Rate Derivative Time Constant Manual Reset Bias Deadband Overlap ON OFF Differential 20mA 5002 maximum 4 20mA 5000 maximum 0 5V 5000 minimum 10V 5000 minimum Isolated from all other inputs and outputs Link jumper Pre Tune and Self Tune 0 OFF 0 5 999 9 of input span at 0 196 increments 1s 99min 59s and OFF 0 OFF 99 min 59 s Added each control algorithm execution Adjustable in the range 0 100 of output power single output or 100 to 100 of output power dual output 20 to 20 of Proportional Band 1 Proportional Band 2 0 1 to 10 0 of input span S075 A 0075 Auto Manual Control Cycle Times Setpoi
7. A 8 AY A 10 A 12 A 13 A 14 ii UNIVERSAL INPUT DUAL SETPOINT QUICK TRANSFER SELECTION INPUT OPTION HEATER CURRENT INPUT OUTPUT 1 OUTPUT 2 OUTPUT 3 LOOP CONTROL SOFT START PV ALARMS HEATER BREAK ALARMS PERFORMANCE COMMUNICATIONS ENVIRONMENTAL PHYSICAL PM 0075 a 5 Q1 N N Ej E GG D GJ D E aa E P A 1 N _ N S075 V2 0075 INSTALLATION 1 1 UNPACKING PROCEDURE 1 Remove the Controller 929mm 0 5 0 0 from its packing The Controller is supplied with a panel gasket and 45mm 0 5 0 0 push fit fixing strap Retain the packing for future use should it be necessary to transport the Controller to 45mm D 5 0 0 q different site or to return it to the supplier for repair testing 1 16 DIN 45mm 0 5 0 0 2 Examine the delivered items for damage or deficiencies If any is 1 8 DIN found notify the carrier Figure 1 1 Cut out Dimensions immediately 1 2 PANEL MOUNTING THE CONTROLLER The panel on which the Controller is to be mounted must be rigid and may be up to 6 0mm 0 25 inches thick The cut out required for a single Controller is as shown in Figure 1 1 Several controllers may be installed in a single cut out side by side For n Controllers mounted side by side the width of the cut out would be 48n 4 millimetres or 3 78n 0 16 inches The Controller is 110mm deep measured from the rear face of the fr
8. e LO cn w __ 9 wa m M NN 1 8 DIN amp 1 16 DIN PLASTICS CONTROLLERS Product Manual PREFACE This manual comprises two volumes Volume 1 Volume 2 This supports normal operation of the 1 8 DIN and 1 16 DIN Plastics Controllers In normal operation all actions taken by the user are to be in front of the front panel This supports the installation commissioning and configuring of the 1 8 DIN and 1 16 DIN Plastics Controllers It is intended for use only by personnel who are trained equipped and authorised to carry out these functions 0075 1 DIN amp DIN PLASTICS CONTROLLERS PRODUCT MANUAL VOLUME 1 OPERATING INSTRUCTIONS In normal operation the operator must not remove the Controller from its housing or have unrestricted access to the rear terminals as this would provide potential contact with hazardous live parts Installation and configuration must be undertaken by technically competent servicing personnel This is covered in Volume 2 of this manual Contents Volume 1 1 INTRODUCTION ki 1 1 TAILORING THE CONTROLLER TO SUIT YOUR NEEDS 1 2 1 2 HOW IT WORKS 2 OPERATOR MODE 2 1 2 1 INTRODUCTION 2 2 2 SELECTING THE PARAMETER TO BE DISPLAYED ADJUSTED 2 3 ADJUSTING THE DISPLAYED PARAMETER 2 3 2 4 SOFT START 2 5 INDICATION OF AN ALARM GOING ACTIVE 2 4 2 6 ALARM STATUS DISPLAY 2 7 OVER RANGE UNDER RANGE DISPLAYS 2 8 SENSOR BREAK INDICATION
9. Can use a unique two wire SCRi connection to dedicated silicon controlled rectifier stacks Also supports standard four wire connection via a separate current transformer Heater Break alarms high low and short circuit to cater for most requirements Unique Quick Transfer for easy set up of heater break alarms This can be initiated from the front panel digital input or via the communications link Soft Start with dedicated setpoint timer and Output 1 power limit Adjustable alarm hysteresis 90 264V AC power supply Certified to EN50081 1 1992 and EN50081 2 1994 Emission and to EN50082 1 1992 and EN50082 2 1995 Immunity EMC specifications Complies with EN61010 1 1993 Safety Standard Front panel sealing to IP66 NEMA 4 standard CE rated UL pending Auto Manual Control and Auto Zero Power Pre Tune and Self Tune Setpoint ramping 0075 4 1 1 0075 Programmable input filter Alarm type selected from front panel Sensor Break protection Setpoint maximum and minimum limits user defined and its many optional features include 1 1 MODBUS and ASCII selectable communications with up to 128 zone address capability Output 2 secondary COOL control output relay SSR drive or solid state Alarm 2 output Heater Break alarm output or logical combination of Alarm 1 and Alarm 2 Output 3 Alarm 1 output Heater Break Alarm output DC recorder output setpoint or process variable or logica
10. inhibited the alarm indication is suppressed and the alarm will remain inactive This will prevail until the alarm condition returns to the inactive state whereafter the alarm will operate normally Also during dual setpoint operation whenever there is switching from Setpoint 1 to Setpoint 2 or vice versa similar alarm suppression will occur if the pertinent alarm is inhibited NOTE The Alarm Inhibit function is not applied to any of the Heater Break Alarms 3 7 5075 3 0075 3 3 6 Heater Break Alarm Strategy This defines the terms in which the heater break alarm level is expressed Percentage of Absolute Amps Nominal Current Selection confirmation is as previously described NOTE When this parameter is set to the Absolute Amps mode the Heater Nominal Current parameter Set Up Mode see Volume 1 is not available and Quick Transfer see Volume 1 Subsection is disabled 3 3 7 Output 2 Usage The displays for this item are of the form in which the upper display indicates the usage which will be one of the following COOL output Alarm 1 with Alarm 2 Reverse acting Alarm 2 output Alarm 1 with Alarm 2 Direct actin reverse acting Alarm 1 with Alarm 2 ien Reverse acting Pap u Logical AND of irect acting Alarm 1 with Alarm 2 Heater Break Alarm output reverse acting S075 3 3 8 0075 This setting can be changed and confirmed in manner previously described Th
11. thermocouple inputs 2 Serial Communications Address selection of 3 11 Baud rate selection of Serial Communications Connections l 7 A terminal 1 7 B terminal 1 7 U Unpacking Procedure 1 1 S075 IDX
12. 1 Cyclic Redundancy Check Algorithm 0075 4 4 3 0075 Read Coil Status Read Bits 01 02 The message sent to the Controller consists of eight bytes The normal reply will echo the first two characters of the message received followed by a single byte data byte count which will not include itself or the CRC For this message there will be one byte of data per eight bits worth of information requested with the least significant bit of the first data byte transmitted depicting the state of the lowest numbered bit required This function is used mostly to report controller status information thus a bit set to 1 indicates that the corresponding feature is currently active enabled and a bit set to 0 indicates that the corresponding feature is currently inactive disabled If an exact multiple of eight bits is not requested the data padding with trailing zeros is used to preserve the eight bit format After the data has been transmitted CRC16 value is sent Read Holding Registers Read n Words 03 04 The message sent to the Controller to obtain the value of one or more registers comprises the following eight bytes The normal reply will echo the first two characters of the message received followed by a single byte data byte count which will not include itself or the CRC For this message the count value equals the number of parameter values read multiplied by two Following the byte count the specified number of pa
13. 2 5 2 9 OUTPUT TURN OFF 2 5 0075 1 iii 2 10 2 11 2 12 2 13 2 14 2 15 2 16 5 3 1 3 2 3 3 3 4 3 5 3 6 4 4 1 4 2 4 3 4 4 5 5 1 5 2 5 3 5 4 iv MANUAL CONTROL MODE HEATER CURRENT DISPLAY SOFT START IN PROGRESS QUICK TRANSFER OF HEATER CURRENT TO NOMINAL VALUE PRE TUNE SELF TUNE TO VIEW THE HARDWARE DEFINITION CODE SET UP MODE ENTRY INTO SET UP MODE SET UP MODE PARAMETERS OPERATOR MODE DISPLAYS TUNING THE CONTROLLER MANUALLY SELF TUNE EXIT FROM SET UP MODE MODBUS RTU COMMUNICATIONS COMMUNICATIONS WRITE ENABLE DISABLE PHYSICAL REQUIREMENTS MODBUS RTU PROTOCOL INDIVIDUAL PARAMETERS ASCII COMMUNICATIONS COMMUNICATIONS WRITE ENABLE DISABLE PHYSICAL REQUIREMENTS INDIVIDUAL PARAMETERS ERROR RESPONSE PM 0075 a DQ a x S oo P e E m E S S SI S E 0075 1 0075 INTRODUCTION The DIN and 3 DIN Plastics Controllers are economical microprocessor based temperature controller specially designed for use in plastics applications They incorporate the latest in surface mount and CMOS technology The standard features include Dual four digit LED display upper display red lower display green Thermocouple or three wire RTD sensor input Relay SSR drive 10V or solid state Output 1 Input range selected from the front panel Heater current ammeter on front panel
14. Controller into position CAUTION Ensure that the instrument is correctly orientated A stop will operate if an attempt is made to insert the instrument in the wrong orientation e g upside down This stop must not be over ridden 2 5 SELECTION OF OUTPUT 1 TYPE The Output 1 type is selected by Link Jumpers LJ5 and LJ7 on the Ovtput 1 Type Link Jumpers Fitted CPU PCB 5 DIN Controllers see Relay or Solid State LJ5 amp LJ Figure 2 4 or the PSU PCB DIN Controllers see Figure SSR Drive amp LJ7 Figure 2 4 CPU PCB Link Jumpers DIN Controllers 5075 2 2 4 0075 Figure 2 5 PSU PCB Link Jumpers DIN Controllers 2 6 OUTPUT 2 TYPE OUTPUT 3 TYPE The type of output for Output 2 and Output 3 is determined by the Option PCB fitted in the appropriate position see Figure 2 1 and in the case of the DC Output 3 Option PCB being fitted the setting of Link Jumpers LJ8 and LJ9 on that Option PCB see Figure 2 5 and table There are five types of option PCB which may be used 1 Relay Output Option PCB Output 2 or Output 3 no link jumpers 2 Solid State Output Option PCB Output 2 or Output 3 no link jumpers 3 Dual Relay Output 2 Option PCB with Output 4 no link jumpers 4 SSR Drive Output 2 Option PCB no link jumpers 5 DC Output 3 Option PCB link jumpers as shown in Figure D 5 WARNING D
15. Heater Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for 0 1A resolution and 2A for 1A resolution 3 2 32 High Heater Break Alarm Value The Controller monitors two current values ON current when Output 1 is on and OFF current when Output 1 is off This parameter defines a heater ON current value above which the High Heater Break Alarm will become active It may be adjusted in the following ranges above the heater current nominal value If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank High Heater Alarm forced inactive Default value is 0 OFF Hysteresis is half the High Heater Break Alarm value NOTE Unless the High Heater Break Alarm is set OFF if the heater current exceeds the Heater Current High Scale Limit the High Heater Break Alarm will be forced active even if the effective Alarm level is set higher than the Heater Current High Scale Limit If Heater Break Alarm Strategy Absolute Mode 0 1A 1A dependent upon display resolution Heater Current High Scale Limit and 0 OFF value display blank High Heater Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for 0 1A resolution and 2A for 1A resolution 3 2 33 Short Circuit Heater Break Alarm Enable Disable This parameter enables disables the Short Circuit Heater break Alarm 1 enabled 0 disabled The default setting is 1 enabled The Controller monitors two
16. JO jg uogoesqnsg ees JO N O 101 o p o m NOILOJNNOO YAMOd 300 Bt bi B j PE ZHO9 0S 2409 05 Oe NE Nu N9C96 _ _ UO 1 3 2 c 104110 hejal T ON eyejs plos I 9L ASS ON O N w Alaa s LNdino UNIVERSAL INPUT RTD Cu Thermocouple gt B 3 x 2 x 4J9 5 a 8 eo 10 45 19 Od Indino JO Auo ADSI IndinO 19JDeH JO ndino si IndinO AYOJs POs Jo SAUD ass Indino WIKI oeig JSJOSH JO Indino z WIKIY 1009 5 Aiopuoo es si Rear Terminal Connections DIN Controllers Figure 1 4 1 3 5075 1 0075 c LNdLno c 21215 01105 LNdino LAdLNO I I ANTAN 9 N 9 O N Edd OG JO PIOS SALI USS AOS Indino Iv3H z 02 Jouuoo Su sl jndino A g E n x F lt b S 4 C sB L Q p om gegen E 04955 4 gIN00 0Z zm ui p gt Qe gt 2 B N 61 e in NOD 8L ve NOILdO 4433SNV21 L Ss pvc rs 5 25 LNdNI iniodias wna T g inaaano B g L7
17. Rate Derivative Time 00s to 99m 595 1m 15s Constant Overlap Deadband _20 to 20 of Proportional 0 Band 1 Proportional Band 2 Manual Reset Bias 3 0 to 100 single output 25 100 to 100 dual output ON OFF Differential 0 1 to 10 of input span 0 5 Output 1 only Output 2 Outputs 1 amp 2 ci FF Setpoint High Limit setpoint to Range Max Range Max Setpoint Low Limit Range Min Setpoint Range Min 3 2 0075 3 0075 Table 3 1 Cont Set Up Parameters Parameter Legend Adjustment Range Default Recorder Output PTI _1999 to 9999 Range Max Scale Max Recorder Output 1999 to 9999 Range Min Scale Min Output 1 Power Limit o to 100 of full power 100 Output 1 Cycle Time EBENE 0 5 1 2 4 8 16 32 64 128 32seconds 256 or 512 seconds Output 2 Cycle Time 0 5 1 2 4 8 16 32 64 128 32seconds 256 or 512 seconds Process High Alarm 1 WIIIII Range Min To Range Range Max value Process Low Alarm 1 ill Range Min To Range Range Min value Band Alarm 1 value 2 to span from Setpoint 5 units Deviation Alarm 1 span from Setpoint 5 units value Alarm 1 Hysteresis wixE llNl1 250 units 1 unit Process High Alarm 2 Range Min To Range Max Range Max value Process Low Alarm 2 Range Min To Range Max Range M
18. SSR Drive TTL Drive Capability SSR gt 4 5V DC into 2500 minimum Isolation Not isolated from input or other SSR outputs Dual Relay Output 2 and Output 4 Contact Type Single pole single throw normally open Both relays share a single common terminal Rating 2A resistive at 120 240V AC Lifetime gt 500 000 at rated voltage current Isolation Inherent Solid State Operating Voltage Range 20 280Vrms 47 63Hz Current Rating 0 01 1A full cycle rms on state 25 C derates linearly above 40 C to 0 5A 80 C Max Non repetitive Surge 25A peak Current 16 6ms Min OFF State Rated 500V us Voltage A 5 5075 0075 Max OFF State leakage Rated Voltage Max ON State Voltage Drop Rated Current Repetitive Peak OFF state Voltage Vdrm A 6 OUTPUT 3 General Types Available Relay Contact Type Rating Lifetime Isolation Solid State Operating Voltage Range Current Rating Max Non repetitive Surge Current 16 6ms Min OFF State Rated Voltage Max OFF State leakage Rated Voltage Max ON State Voltage Drop Rated Current Repetitive Peak OFF state Voltage Vdrm 5075 1mA rms 1 5V peak 600V minimum Relay or Solid State Alarm only or DC linear Recorder Output only Single pole double throw SPDT 2A resistive at 120 240V AC gt 500 000 operations at rated voltage current Inherent 20 280Vrms 47
19. Status byte has the following format Bo nae ene S 0 activated 1 safe Bit 1 Alarm 2 Status 0 activated 1 safe Bit 2 Self Tune Status 0 disabled 1 enabled Bit 3 Change Indicator 1 A parameter other than Controller Status Process Variable Heater Current or Output Power has been changed since the last time the Status Byte was read 0 no change has occurred Bit 4 RS485 Write Status 0 disabled 1 enabled Bit 5 Auto Manual Control 0 Auto 1 Manual Bit 6 Output 1 Turn Off Status 0 disabled 1 enabled Bit 7 Pre Tune Status 0 disabled 1 enabled Bit 8 High Heater Break Alarm Status 0 activated 1 safe Bit 9 Low Heater Break Alarm Status 0 activated 1 safe Bit 10 Short Circuit Heater Break Alarm Status 0 activated 1 safe Bit 11 Short Circuit Heater Break Enabled Disabled 0 disabled 1 enabled Bit 12 Soft Start Status 0 inactive 1 active 3 Only Type 3 or Type 4 messages are allowed with this parameter In the Type 3 message the DATA field must be one of eleven five digit numbers The reply from the Controller also contains the DATA field with the same content When the master device issues the Type 4 message the Controller responds with the same DATA field content The commands corresponding to the DATA field value are 00010 Activate Manual Control 00020 Activate Automatic Control 00030 Activate the Self Tune facilit
20. alarms is explained in the table above 3 9 5075 3 0075 3 3 9 Output 4 Usage The displays for this item are of the form in which the upper display indicates the usage which will be one of the following Heater Break Alarm direct acting Relay SSR Drive or Solid State output only WWE Heater Break Alarm reverse acting Relay SSR Drive or Solid State output only 3 3 10 Communications Link Baud Rate When this item is selected the initial display is of the form The Baud rate may be selected and confirmed as described earlier in this Section The Baud rates available are 1200 2400 4800 and 9600 3 3 11 Communications Protocol This determines the protocol used over the communications link Four options are available MODBUS RTU MODBUS RTU MODBUS RTU ASCII no parity odd parity even parity Selection confirmation is as previously described 5075 3 3 10 0075 3 3 12 Communications Address The unique communications address assigned to the Controller can be selected using this item for which the displays are of the form The address can be selected and confirmed in the manner previously described Any value in the following ranges can be used subject to the total receiver loading restrictions detailed in NOTE 2 in Subsection 1 3 12 MODBUS RTU protocol 1 128 standard RS485 option 1 255 enhanced RS485 option ASCII protocol 1 99 standard and enhanced RS485 options 3 3 13
21. as a cooling output if required The Controller has a special Soft Start feature used when a gentle start up phase is required in order to avoid damage to the process An adjustable Soft Start Setpoint is used by the Controller during a Soft Start The duration of the Soft Start phase is determined by an adjustable Soft Start Time parameter During this phase Ouput 1 power is kept within an adjustable limit and the Output 1 cycle time is reduced to a quarter of its normal value but never less than 0 5 seconds to reduce further the risk of thermal shock to the process The Controller can be put into Manual Control if selected by the operator In this mode the operator adjusts manually the Controller s output power When switching between automatic control and manual control the Controller minimises any sudden power changes this is known as a bumpless transfer and avoids thermal shocks to the process Manual Control mode can be configured to be a non adjustable zero power value or disabled completely 0075 4 1 3 0075 1 2 2 Alarms Alarms allow early warning and automatic corrective action if necessary in the event of abnormal process conditions heater failure sensor failure human error etc In addition to giving visual indication of such conditions alarms can be connected to outputs the Controller can intervene automatically as soon as it detects a problem in the plant Two standard alarms are provided which warn if t
22. current values ON current when Output 1 is on and OFF current when Output 1 is off The Short Circuit Heater Break Alarm becomes active if the heater OFF current exceeds 5 of Heater Current High Scale Limit NOTE This parameter is not available if Heater Break Input Type is configured to be SCRI 3 2 34 Soft Start Setpoint The use and operation of Soft Start are described in Subsection 2 4 The value of this parameter is adjustable between Input Range Maximum and Input Range Minimum in Set Up Mode only and is in force for the duration of the Soft Start 0075 3 3 15 0075 When the Soft Start Time expires the normal setpoint value is restored Default value is Input Range Minimum 3 2 35 Soft Start Time This parameter defines the duration of the Soft Start from power up After this time expires normal setpoint values will prevail This parameter is adjustable in the range 15 seconds to 59 minutes 45 seconds in 15 second increments and OFF less than 15 seconds the default value is OFF 3 2 36 Auto Pre Tune Enable Disable This parameter determines whether or not Pre Tune is activated automatically on power up or not 0 Disabled 1 Enabled The default setting is 0 Disabled 3 2 37 AM Key Usage This parameter may be set to one of three options Output Turn off Pressing the AM key ET causes the Controller to change from automatic control to control output s being switched off or vice versa Auto Ma
23. for all except the 0 5s value 00051 NOTE Cycle Time values must be written correctly if a Type 3 4 message sequence is used i e the value must be a power of 2 in the range 0 5 512 0 5 1 2 4 8 etc 5 3 2 4 OUTPUT 2 CYCLE TIME Pj O This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence The value to which this is set is dependent upon the output type and the nature of the process to be controlled For relay outputs this parameter should be set to as large a value as possible consistent with satisfactory control of the process in order that the life of the relay be maximised For SSR Drive and Solid State outputs lower values may be used The decimal point position is set to 0 for all except the 0 5s value 00051 NOTE Cycle Time values must be written correctly if a Type 3 4 message sequence is used i e the value must be a power of 2 in the range 0 5 512 0 5 1 2 4 8 etc 5 3 2 5 RECORDER OUTPUT SCALE MAXIMUM VALUE Pj This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the maximum scale value for the Controller s Recorder Output and may be adjusted within the range 1999 to 9999 This value corresponds to the Input Scale Maximum and the decimal point position will always be the same as that for the input NOTE If this parameter is set to a value less than the Recorder Output Minimum Value the Recorder Out
24. heater current value above which the High Heater Break Alarm will become active It may be adjusted in the following ranges above the Heater Nominal Current If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank High Heater Break Alarm forced inactive Default value 0 OFF Hysteresis is half the High Heater Break Alarm value NOTE Unless the High Heater Break Alarm is set OFF if the heater current exceeds the Heater Current High Scale Limit the High Heater Break Alarm will be forced active even if the High Heater Break Alarm level is set higher than the Heater Current High Scale Limit If Heater Break Alarm Strategy Absolute Mode dependent upon display resolution Heater Current High Scale Limit and 0 OFF value display blank High Heater Break Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for 0 1A resolution and 2A for 1A resolution 4 4 7 Tuning Parameters 4 4 7 1 RATE DERIVATIVE TIME CONSTANT Word Parameter 9 This word parameter may be modified interrogated It defines the derivative time constant for the control algorithm The decimal point is used as the separator between the minutes and seconds digits i e set to 2 decimal places the decimal point position must be as described otherwise modification will not occur 4 4 7 2 RESET INTEGRAL TIME CONSTANT Word Parameter 8 This word parameter may be modified int
25. process variable signal but no larger 5 3 2 Output Parameters 5 3 2 1 OUTPUT POWER VALUE P W The value of this parameter may range between 0 and 100 for a single output Controller or 100 and 100 for a dual output Controller If Manual control is not selected this parameter may be interrogated only using a Type 2 message if Manual control is selected this parameter may be adjusted using Type 2 message or a Type 3 4 message sequence 5 3 2 2 OUTPUT 1 POWER LIMIT P B This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the power limit for Universal Output 1 and may be set in the range 0 to 100 of full power The default value is 100 The decimal point position is set to O If Soft Start is used this power limit is applicable only during Soft Start When Soft Start is completed Output 1 power can go to 100 5 8 0075 5 0075 5 3 2 3 OUTPUT 1 CYCLE TIME P N This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence The value to which this is set is dependent upon the output type and the nature of the process to be controlled For relay outputs this parameter should be set to as large a value as possible consistent with satisfactory control of the process in order that the life of the relay be maximised For SSR Drive and Solid State outputs lower values may be used The decimal point position is set to 0
26. quickly the process variable heater current regardless of the original display The heater current display is in the format Flashes when heater current is over range Press the AM key again to display the process variable setpoint i e the first Operator Mode display Subsequent AM key presses will switch between these two displays 0075 2 2 5 0075 2 12 SOFT START IN PROGRESS If a Soft Start is in progress the heater current display will show in the lower display The normal heater current display will be restored as soon as the Soft Start time has expired 2 13 QUICK TRANSFER OF HEATER CURRENT TO NOMINAL VALUE The nominal value of the heater current is manually adjustable in Set Up Mode However to set the nominal value to the prevailing heater current value in Operator Mode process variable heater current display shows NN CD Cn D I E 2 HOLD e Quick Transfer then starts NOTE During Quick Transfer this decimal point in the lower display flashes When flashing stops transfer is complete RELEASE THEN PRESS ONCE 2 6 0075 2 0075 2 14 PRE TUNE To tune approximately the Controller s PID parameters activate Pre Tune UNTIL p FLASHES ONCE Numeric displays will flash SIMULTANEOUSLY while these keys are pressed UNTIL Fi GOES ON DOWN The AT indicator will flash whilst Pre Tune is operating To dis engage Pre Tune rep
27. start up phase is required before going to full working temperature During Soft Start a dedicated setpoint is used to control the process to a lower temperature than normal A power limit can be applied to Output 1 during Soft Start constraining the average Output 1 power During Soft Start the Output 1 cycle time is automatically reduced to give added protection against thermal shock NOTE because of the nature of time proportioned outputs Output 1 will still be fully on for part of each output cycle Output 1 not limited Output 1 limited Setpoint Setpoint ramping allowed ramping inhibited Output 1 cycle time x 1 4 used for Output 1 0 5s min Soff Start Setpoint Soft Start Time Soff Start ends Switch on 0075 2 2 3 0075 Soft Start Time Soft Start Setpoint and power limit are all adjustable in Set Up Mode Soft Start is aborted at start up if the process variable exceeds the Soft Start Setpoint Setpoint ramping is inhibited during Soft Start During a Soft Start the Soft Start time remaining at any moment may be read from the front panel 2 5 INDICATION OF AN ALARM GOING ACTIVE If any of the Heater Break Alarms High Low or Short Circuit Alarm 1 or Alarm 2 goes active the HB AL indicator will flash 2 6 ALARM STATUS DISPLAY available if one or more alarms are active The alarm status display is in the following format H High Heater Break Alarm active L Low Heater B
28. the selected rate 1200 2400 4800 or 9600 Baud over the required distance Transmitters receivers conform to the recommendations in the Standard RS485 The A terminal on the Controller should be connected to the A terminal on the master device the B terminal on the Controller should be connected to the B terminal on the master device Where several Controllers are connected to one master port the master port transceiver in the active state should be capable of driving load of 12ko per Controller the master port transceiver in the passive state must have pull up pull down resistors of sufficiently low impedance to ensure that it remains in the quiescent state whilst supplying up to 100uA each to Controller transceivers in the high impedance state NOTES 1 The 5485 Serial Communications option and the Dual Setpoint Quick Transfer option are mutually exclusive 2 The Controller receiver presents 4 standard RS485 unit load The total receiver load on the communications system must not exceed 32 standard RS485 unit loads 5075 1 1 7 0075 2 INTERNAL LINKS AND SWITCHES 2 1 REMOVING THE CONTROLLER FROM ITS HOUSING CAUTION Before removing the Controller from its housing ensure that all power has been removed from the rear terminals To withdraw the Controller from its housing simply grip the side edges of the front panel there is a finger grip on each edge and pull the Controller forwards This
29. the voltage free contacts of a switch or relay or b a TIL compatible voltage The transfer will occur when this input detects an Open Closed transition in the switch relay contacts or a rising edge in the TTL level TIL compatible level voltages are as for the Dual Setpoint Selection input see above NOTE The Dual Setpoint Quick Transfer option and the RS485 Serial Communications option are mutually exclusive 1 3 7 Heater Current Input Terminals 7 and 8 DIN Controllers or Terminals 6 and 7 3 DIN Controllers are for connection to the secondary winding of an external current transformer the 1 6 5075 1 0075 primary winding of which carries heater current current carried by primary winding and the transformer ratio are then taken into account when setting the Heater Current parameters see Volume 1 Section 3 1 3 8 Relay Outputs The contacts are rated at 2A resistive at 120 240V AC 1 3 9 SSR Drive Outputs These outputs produce a time proportioned non isolated DC signal Output 1 gt 10V DC into 5000 minimum Output 2 gt 4 5V DC into 2500 minimum 1 3 10 Solid State Outputs These outputs provide up to 1A AC drive with a longer lifetime than an electromechanical relay For further details refer to Appendix A 1 3 11 DC Outputs Only Output 3 may be a DC output Recorder Output only See 1 3 12 RS485 Serial Communications Link The cable used should be suitable for data transfer at
30. then from 21A to 100A increments The default value is 50A Heater current range minimum is fixed at OA NOTE If this parameter value is changed the Heater Nominal Current Low Heater Break Alarm Value and High Heater Break Alarm Value parameters are set to their default values 4 4 3 2 HEATER NOMINAL CURRENT Word Parameter 30 This word parameter defines a nominal value for the heater current It may be adjusted in the range OA to Heater Current High Scale Limit value The default value is the Heater Current High Scale Limit value This parameter is accessible only if Heater Break Alarm Strategy is configured to Percentage Mode 4 4 3 3 HEATER CURRENT Word Parameter 33 This Read Only word parameter indicates the most recent valid heater current value at the instant the message is received it is equivalent to calling up the heater current display from the front panel 4 4 4 Setpoint Parameters 4 4 4 1 SETPOINT VALUE Word Parameter 2 This word parameter may be modified interrogated It can be set to any value and Setpoint Low Limit see between Setpoint High Limit see Subsection Subsection When the setpoint is ramping this is the target setpoint value 4 4 4 2 SETPOINT RAMP RATE Word Parameter 24 This word parameter may be modified interrogated It defines the rate at which the current setpoint can be made to ramp and can be set to a value in the range 4 12 0075 4 0075 1 9999 increments per hour 0
31. to peak variation P of the first cycle i e the difference between the highest value of the first overshoot and the lowest value of the first undershoot see b The cycle time T of this oscillation in minutes see 4 The control parameters should then be set at follows P ___ XI BIN ScaleRange oe T minutes minutes NOTE After setting up the parameters set the Coniroller to Operator Mode see Subsection 8 6 to prevent unauthorised adjustment to the values 3 18 0075 3 0075 Process Variable Time Figure 3 4 Manual Tuning Parameters Output 1 only 3 4 2 Controllers Fitted with Output 1 and Output 2 Before starting to tune the Controller to the load check that the Setpoint High and Low Limits SPhi and SPLo are set to safe levels see Subsections and The following simple technique may be used to determine values for proportional band Pb1 derivative time constant rAtE and integral time constant rSEt NOTE This technique is suitable for use only with processes which are not harmed by large fluctuations in the process variable It provides an acceptable basis from which to start fine tuning for a wide range of processes 1 Tune the Controller using Output 1 only as described in Subsection 3 4 1 2 Set Pb2 to the same value as Pb1 and monitor the operation of the Controller in dual output mode If there is a tendency to oscillate as control pas
32. 1 POWER LIMIT Word Parameter 20 This word parameter may be modified interrogated It defines the power limit for Output 1 and may be set in the range 0 to 100 of full power The default value is 100 The decimal point position is fixed at 1 decimal place If Soft Start is used this power limit is applicable only during Soft Start When Soft Start is completed Output 1 power can go to 100 4 4 2 3 OUTPUT 1 CYCLE TIME Word Parameter 10 This parameter may be modified interrogated The value to which this is set is dependent upon the output type and the nature of the process to be controlled For relay outputs this parameter should be set to as large a value as possible consistent with satisfactory control of the process in order that the life of the relay be maximised For SSR Drive and Solid State outputs lower values may be used The decimal point position is set at 1 decimal place NOTE Cycle Time values must be written correctly i e the value must be a power of 2 in the range 0 5 512 0 5 1 2 4 8 etc 4 4 2 4 OUTPUT 2 CYCLE TIME Word Parameter 19 This parameter may be modified interrogated The value to which this is set is dependent upon the output type and the nature of the process to be controlled For relay outputs this parameter should be set to as large a value as possible consistent with satisfactory control of the process in order that the life of the relay be maximised For SSR Drive and Solid State output
33. 4 ALARM 2 HYSTERESIS Word Parameter 36 This word parameter applies a hysteresis band on the safe side of the Alarm 2 value Thus Alarm 2 will become active when the Alarm 2 value is exceeded Alarm 2 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 2 value Alarm 2 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per Heater Current High Scale Limit The effect of the hysteresis value on the operation of the different types of alarm is illustrated in Figure 4 4 6 5 LOW HEATER BREAK ALARM VALUE Word Parameter 31 This word parameter defines a heater current value below which the Low Heater Break Alarm will become active It may be adjusted in the following ranges below the Heater Nominal Current If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank Low Heater Alarm forced inactive Default value 20 below heater nominal current Hysteresis is half the Low Heater Break Alarm value If Heater Break Alarm Strategy Absolute Mode 0 1A 1A dependent upon display resolution Heater Current High Scale Limit and 0 OFF value display blank Low Heater Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for 0 1A resolution and 2A for 1A resolution 4 14 0075 4 0075 4 4 6 6 HIGH HEATER BREAK ALARM VALUE Word Parameter 32 This word parameter defines a
34. 61010 1 1993 90 264V AC 50 60Hz standard 20 50V AC 50 60Hz or 22 65V DC option 4 watts approximately To IP66 similar to NEMA 4 Depth 110mm Width 48mm Height 48mm DIN Width 48mm Height 96mm 1 DIN Mounting Terminals Weight PM 0075 Plug in with panel mounting sleeve Panel cut out 45mm x 45mm DIN Panel Cutout 45mm x 92mm DIN Screw type combination head 0 21kg maximum 5075 0075 ALPHABETICAL INDEX VOLUME 2 A H AC DC 24V Supply Option Hardware Definition Code Fuse rating Adjustment of 3 3 Terminal connections 1 5 Display of 3 2 Voltage range 1 5 Explanation of Alarm 1 Type Input Output Type Selection of 3 6 selection 8 3 Alarm 2 Type Hardware Option Selection Selection of 3 7 Alarm Inhibit Heater Break Alarm Strategy Description of operation Selection of 3 8 Selection of 3 7 Heater Break Input Type Selection of C Heater Current Input Terminal connections Cold Junction Compensation Enabling disabling Cold Junction Compensation Disabled Indication of Inhibiting Alarms 8 7 Operator Mode 3 11 Input Connections Communications Address Range Dual Setpoint Selection MODBUS RTU protocol 3 11 RTD Communications Protocol Thermocouple 1 8 Selection of 3 10 Input Range Configuration Mode 3 1 Selection of Automatic exit from 3 12 Installation 1 1 Entry into 3 1 Exit from 3 12 L Controller Dimensions Current Transformer Link Jumpers Connection
35. ATA string in the negative acknowledgement reply will be indeterminate If the process variable or the deviation is interrogated whilst the process variable is outside the range of the Controller the reply is P lt 227 gt 0A if the process variable is over range L N lt gt 5A if the process variable is under range 0075 5 5 3 0075 Scan Tables A parameter identifier character in the message from the master device indicates that a Scan Table operation is required This provides a facility for interrogating the values of a group of parameters and status in a single message from the master device The reply to such a command would be in the form L N xx bbbbb ccccc ddddd eeeee A where xx is the number of data digits to follow this is 20 for a single control output instrument and 25 for a dual control output instrument The digits are expressed as shown in Table 5 1 For further information refer to Subsection 5 2 6 Type 3 Message L N P DATA This message type is used by the master device to set a parameter to the value specified in DATA The command is not implemented immediately by the slave Controller the slave will receive this command and will then wait for a Type 4 message see below Upon receipt of a Type 3 message if the DATA content and the specified parameter are valid the slave Controller reply is of the form L N DATA where
36. Cold Junction Compensation Enable Disable The display for this item is either of CJC enabled CJC disabled This setting can be changed and confirmed in the manner previously described The default setting is Enabled This parameter is omitted from the Configuration Mode display sequence if the input type selected is not thermocouple see Subsection If the CJC facility is disabled the initial display in Operator Mode will show flashing in the lower display 3 11 5075 3 0075 3 3 14 Lock Code When this item is selected the displays will be of the form where the upper display shows the current Set Up Mode Lock Code a Read Only display it cannot be edited in Configuration Mode This serves as a reminder in case the Lock Code has been forgotten see also Volume 1 Subsection 3 4 EXIT FROM CONFIGURATION MODE To leave Configuration Mode depress the Raise and Function keys simultaneously This will cause a return to the Operator Mode to be made NOTE An automatic exit to Operator Mode will be made if in Configuration Mode there is no front panel key activity for two minutes The exit is made via the power up self test routines which include a lamp test 5075 3 3 12 A 1 PM 0075 PRODUCT SPECIFICATION UNIVERSAL INPUT General Maximum per Controller Input Sample Rate Digital Input Filter Input Resolution Input Impedance Isolation Process Variable Offset One Fou
37. Current High Scale Limit and 0 OFF value display blank Low Heater Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for 0 1A resolution and 2A for 1A resolution 5 3 6 6 HIGH HEATER BREAK ALARM VALUE Pj f This parameter which may be modified interrogated using a Type 2 message or a Type 3 4 message sequence defines a heater current value above which the High Heater Break Alarm will become active It may be adjusted in the following ranges above the Heater Nominal Current If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank High Heater Break Alarm forced inactive Default value 0 OFF Hysteresis is half the High Heater Break Alarm value NOTE Unless the High Heater Break Alarm is set OFF if the heater current exceeds the Heater Current High Scale Limit the High Heater Break Alarm will be forced active even if the High Heater Break Alarm level is set higher than the Heater Current High Scale Limit If Heater Break Alarm Strategy Absolute Mode 0 1A 1A dependent upon display resolution Heater Current High Scale Limit and 0 OFF value display blank High Heater Break Alarm forced inactive Default value 0 OFF Hysteresis is 0 5A for resolution and 2A for 1A resolution 5 3 7 Tuning Parameters 5 3 7 1 RATE DERIVATIVE TIME CONSTANT P D This parameter may be modified interrogated using a Type 2 message or a Type 3 4 mes
38. Current High Scale Limit value This parameter is accessible only if Heater Break Alarm Strategy is set to Percentage Mode 5 3 3 3 HEATER ACTUAL CURRENT P e This parameter indicates the most recent valid heater current value at the instant message is received it is equivalent to calling up the heater current display from the front panel This parameter may be interrogated only using a Type 2 message 5 3 4 Setpoint Parameters 5 3 4 1 SETPOINT VALUE Pj S This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It can be set to any value between Setpoint High Limit see Subsection 5 3 4 3 and Setpoint Low Limit see Subsection 5 3 4 4 5 3 4 2 SETPOINT RAMP RATE Pj This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the rate at which the current setpoint can be made to ramp and can be set to a value in the range 1 9999 increments per hour If it is desired to switch setpoint ramping OFF a Type 3 4 message sequence should be used in which the DATA element of the Type 3 message should be set to 0000 If setpoint ramping is OFF the DATA element in the response to an interrogation will be set to 0000 The decimal point position is as for the input range 5 10 0075 5 0075 5 3 4 3 SETPOINT HIGH LIMIT P A This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It d
39. E MAXIMUM Word Parameter 12 This Read Only word parameter indicates the maximum process input value 4 4 1 4 SCALE RANGE MINIMUM Word Parameter 11 This Read Only word parameter indicates the minimum process input value 4 4 1 5 DECIMAL POINT POSITION Word Parameter 18 This Read Only word parameter indicates the input range decimal point position 4 4 1 6 INPUT FILTER TIME CONSTANT Word Parameter 25 This word parameter may be modified interrogated The Controller input is equipped with a digital filter which is used to filter out any extraneous impulses on process variable This filtered PV is used for all PV dependent functions control alarms etc The time constant for this filter may be adjusted in the range 0 0 seconds filter OFF to 100 0 seconds in 0 5 second increments The default setting is 2 0 seconds CAUTION If this parameter is set to an excessively high value the control quality may be significantly impaired The value chosen should be sufficiently large to attenuate stray noise on the process variable signal but no larger 4 4 2 Output Parameters 4 4 2 1 OUTPUT POWER VALUE Word Parameter 3 The value of this word parameter may range between 0 and 100 for a single output Controller or 100 and 100 for a dual output Controller If 4 10 0075 4 0075 Manual control is not selected this word parameter is Read Only if Manual control is selected this parameter may be adjusted 4 4 2 2 OUTPUT
40. Hz 8 bits over 250ms rolling window 10 bits over 1s rolling window Via external current transformer 150 Adjustable 10 0A 20 0A rms in 0 1A increments 21A 100A rms in increments Fixed at OA 50mA rms assuming sinusoidal input current waveform 5075 0075 A 4 OUTPUT 1 General Types Available Relay Contact Type Rating Lifetime Isolation SSR Drive TTL Drive Capability Isolation Solid State Operating Voltage Range Current Rating Max Non repetitive Surge Current 16 6ms Min OFF State o Rated Voltage Max OFF State leakage Rated Voltage Max ON State Voltage Drop Rated Current Repetitive Peak OFF state Voltage Vdrm S075 A Relay SSR Drive TTL and Solid State Single pole double throw SPDT 2A resistive at 120 240V AC gt 500 000 operations at rated voltage current Inherent SSR gt 10V DC into 5000 minimum Not isolated from input or other SSR outputs 20 280Vrms 47 63Hz 0 01 1A full cycle rms on state 25 C derates linearly above 40 C to 0 5 o 80 C 25A peak 500V us 1mA rms 1 5V 600V minimum A 4 0075 A 5 OUTPUT 2 General Types Available Relay Dual Relay with Output 4 SSR Drive and Solid State Relay Contact Type Single pole double throw SPDT Rating 2A resistive at 120 240V AC Lifetime gt 500 000 operations at rated voltage current Isolation Inherent
41. Low 11 Read Only Scale Range High 12 Read Only Alarm 1 value 13 Alarm 2 value 14 Manual Reset Bias 15 Overlap Deadband 16 ON OFF Differential 17 Decimal Point Position 18 Read Only Output 2 Cycle Time 19 Output 1 Power Limit 20 Control Setpoint value 21 Read Only ramping setpoint if ramping Setpoint High Limit 22 Setpoint Low Limit 23 Setpoint Ramp Rate 24 Input Filter Time Constant 25 Process Variable Offset 26 Recorder Output Maximum 27 Recorder Output Minimum 28 Heater Current High Scale Limit 29 Heater Nominal Current 30 Accessible only if Heater Break Alarm Strategy is set to Percentage Mode 4 8 0075 4 0075 Table 4 3 MODBUS Word Parameters Cont Parameter No Notes Low Heater Break Alarm value 31 0 100 and OFF or 0 1A 1A Heater Current High Scale Limit see Subsection 4 4 6 5 High Heater Break Alarm value 32 100 and OFF or O 1A 1A Heater Current High Scale Limit see Subsection Heater Current 33 Read Only AM Key Usage 34 Read Only Alarm 1 Hysteresis 35 1 250 or 0 1 25 0 as per Heater Current High Scale Limit Alarm 2 Hysteresis 36 250 or 0 1 25 0 as per Heater Current High Scale Limit Soft Start Setpoint 37 Soft Start Time 38 Soft Start Time Remaining 39 Read Only Returns O if not in Soft Start Manufacturer ID 121 Read Only 231 representing W1 Equipment ID 122
42. MODBUS RTU protocol Cycle Time Definition of Cyclic Redundancy Checksum Description of 4 2 Cyclic Redundancy Checksum CRC Description of 4 2 1 2 1 3 5 14 0075 IDX 0075 D Heater Current Display Selection of Data Padding 4 4 Operator Mode Selection de selection Deadband 4 16 5 14 Heater Current High Scale Limit Decimal Point Position _ 4 10 Derivative Time Constant 4 12 Derivative Time Constant Heater Nominal Current Heater Nominal Current Automatic setting to default 8 14 High Heater Break Alarm 8 15 See Also Rate Deviation Alarm 1 3 12 Deviation Alarm 2 E Automatic setting to default 5 14 Responses High Heater Break Alarm Value 4 15 ASCII protocol x MODBUS RTU protocol 4 5 Hysteresis Exception Responses See Also ON OFF Differentia MODBUS RTU protocol 4 5 Inactive Setpoint Front Panel Keys Indication of 2 3 Illustration of indicators Function Number Illustration of MODBUS RTU message Input Filter Time Constant format 4 2 Input Over Range H Indication of 2 4 Input Type Hardware Definition Code Indication of Operator Mode Display of Operator Mode ec Integral Time Constant nb MNT Integral Time Constant Hardware Definition Code See Also Automatic cancellation of display internal setpoint 4 13 p 4 13 Heater Actual Current J Heater Break Alarms usec JBUS Function Names 4 1 Heater Current Quck Transfer to nominal value 2 6 Heat
43. Read Only number 6600 NOTES 1 The values of Word Parameters 29 and 30 are always to 0 1A resolution 2 If Heater Break Alarms are set to Absolute Current Mode values of Word Parameters 31 and 32 will be to resolution 3 If Heater Current High Scale Limit Word Parameter 29 is set to gt 20A the Controller operates to 1A resolution in which case all the above Word Parameters least significant decimal digit will return and in Write operations that digit will be truncated 4 4 INDIVIDUAL PARAMETERS 4 4 1 Input Parameters 4 4 1 1 PROCESS VARIABLE Word Parameter 1 This Read Only word parameter indicates the current value of the process variable 0075 4 4 9 0075 4 4 1 2 PROCESS VARIABLE OFFSET Word Parameter 26 This word parameter may be modified interrogated It modifies the actual process variable value as measured at the Controller s input terminals in the following manner Modified PV value Actual PV value process variable offset value The modified PV value is limited by Range Maximum and Range Minimum and is used for display and alarm purposes and for recorder outputs NOTE This parameter value should be selected with care Any adjustment to this parameter is in effect an adjustment to the Controller s calibration Injudicious application of values to this parameter could lead to the displayed PV value having no meaningful relationship to the actual PV value 4 4 1 3 SCALE RANG
44. Transfer This bit will always be 0 when read Short Circuit Heater Break 14 0 disable d Alarm Enable Disable Reserved 15 Reserved 16 NOTES 1 Not available if AM Key Usage see Subsection is not set to Auto Manual Control Selection 2 This indicates whether a parameter has been changed from the front panel since the last interrogation via the communications link Every interrogation of this bit resets it to 0 3 Not available if AM Key Usage see Subsection is not set to Auto Output Turn Off Selection 4 If Setpoint Ramping is enabled an Activate Self Tune command will not take effect until the setpoint has reached its target value 5 An Activate Pre Tune command will fail if the process variable is within 5 of input span from the setpoint 6 Not available if Heater Break Input Type is configured to be SCRi 7 Available only if Heater Break Alarm Strategy is set to Percentage Mode 0075 4 4 7 0075 Table 4 2 MODBUS Word Parameters Parameter No Notes Process Variable 1 Read Only Setpoint 2 Target setpoint if ramping Output Power 3 Read Only if not in Manual Control mode Arithmetic Deviation 4 Read Only Proportional Band 2 5 Proportional Band 1 6 Status 7 Read Only see Table Reset Integral Time Constant 8 Rate Derivative Time Constant 9 Output 1 Cycle Time 10 Scale Range
45. alue PV lt PV gt Setpoint Alarm Operation 0075 3 2 22 Deviation High Low Alarm 1 Value This parameter applicable only if Alarm 1 is selected to be a Deviation High Low Alarm defines a value above positive value Deviation High alarm or below negative value Deviation Low alarm the setpoint if the process variable deviates from the setpoint by a margin greater than that defined by this parameter Alarm 1 goes active This parameter value may be adjusted in the range input range from setpoint The default value is five input range units The operation of Deviation Alarms is illustrated in 3 2 23 Alarm 1 Hysteresis This parameter applies a hysteresis band on the safe side of the Alarm 1 value Thus Alarm 1 will become active when the Alarm 1 value is exceeded Alarm 1 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 1 value Alarm 1 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per input resolution The effect of the value on operation of the different types of alarm is illustrated in 3 2 24 Process High Alarm 2 Value This parameter applicable only when Alarm 2 is selected to be a Process High alarm defines the process variable value at or above which Alarm 2 will be active Its value may be adjusted between Input Range Maximum and Input Range Mini
46. at the Baud rate used any character received after such a delay is considered to be the potential address at the start of a new message Since only the RTU form of the protocol is supported each message is followed by a two byte CRC 16 a 16 bit cyclic redundancy checksum This checksum is calculated in accordance with a formula which involves recursive division of the data by a polynomial with the input to each division being the remainder of the results of the previous division The dividing polynomial is 2 6 275 2 1 Hex 18005 but this is modified in two ways a because the bit order is reversed the binary pattern is also reversed making the most significant bit MSB the right most bit and 4 2 0075 4 0075 b because only the remainder is of interest the right most most significant bit can be discarded Thus the polynomial has the value Hex A001 The CRC algorithm is shown in Figure 4 1 XOR st 8 bits of data with MSB of result Pre load 16 bit result with OxOFF XOR next 8 bits of data with MSB of result All 8 bits shifted 16 bits of result to data Is bit shifted out set XOR result with polynomial Most Normal Bit Order Teast significant Most significant byte Least significant byte I significant bit bit Least Reversed Bit Order Most significant Least significant byte Most significant byte significant bit bit REVERSED BIT ORDER USED Figure 4
47. ause the slave controller to issue no reply and await the Start of Message character 5 2 0075 5 0075 5 2 4 Type 1 Message L N This message is used by master device to determine whether the addressed slave Controller is active The reply from the slave Controller if it is active is LIN A An inactive Controller will give no reply 5 2 5 Type 2 Message L N P C This type of message is used by the master device to interrogate or modify a parameter in the addressed Controller P identifies the parameter as defined in Table 5 2 and C represents the command to be executed which may be one of the following Hex 2B Increment the value of the parameter defined by P Hex 2D Decrement the value of the parameter defined by P Hex 3F Determine the current value of the parameter defined by P The reply from the addressed Controller is of the form L N P DATA A where DATA comprises five ASCII coded digits whose format is shown in Table The data is the value requested in a query message or the new value of the parameter after modification If the action requested by the message from the master device would result in an invalid value for that parameter either because the requested new value would be outside the permitted range for that parameter or because the parameter is not modifiable the Controller replies with a negative acknowledgement L N P DATA N The D
48. byte word count always set to 1 a single byte byte count always set to 2 the value to be written and the CRC16 bytes The Controller normally responds with the following eight bit reply 4 3 2 Error and Exception Responses If a received message contains a corrupted character parity check failure framing error etc or if the CRC16 check fails or if the received message is otherwise syntactically flawed e g byte count or word count is incorrect the Controller will ignore that message If the received message is syntactically correct but nonetheless contains an illegal value the Controller will send a five byte exception response as follows The Function Number byte contains the function number contained in the message which caused the error with its top bit set i e Function 3 becomes 0x83 and the Exception Number is on of the following codes For error and exception responses specific to a parameter see notes in Table 4 1 and Table 4 2 NOTE Writing a parameter value equal to its current value is a valid transaction this will not cause an error response 4 3 3 Address Range With standard 5485 communications configured the selectable address range is 1 128 With enhanced 5485 communications configured selectable address range is 1 255 The Controller will respond appropriately to Address 0 broadcast messages no matter what address is selected NOTE The total receiver load on RS485 link must n
49. control output instrument only this parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It may be set to positive and negative values a positive value indicates overlap a negative value indicates The decimal point position 0 5 3 7 6 PROPORTIONAL BAND 1 VALUE Pj P This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence This may be set to 0 0 for On Off control or to a value in range 0 5 999 9 of Output 1 power range The decimal point position is set to 1 5 3 7 7 PROPORTIONAL BAND 2 VALUE Pj U For a dual control output instrument this parameter may be modified interrogated using Type 2 message or a Type 3 4 message sequence This may be set to 0 0 for On Off control or to a value in the range 0 5 999 9 of Output 2 power range The decimal point position is set to 1 5 3 8 Status Parameters 5 3 8 1 CONTROLLER STATUS P L This parameter may be interrogated only using a Type 2 message The status information is encoded in the four digits as the decimal representation of a binary number Each bit in the binary number has a particular significance see NOTES ON TABLE 5 3 8 2 ARITHMETIC DEVIATION PROCESS VARIABLE SETPOINT VALUE P V This parameter may be interrogated only using a Type 2 message It is the difference between the current process variable value and the current setpoint valu
50. d by the master device via the serial communications link If communications Writes are disabled Controller will not adjust or change any parameters in response to commands received from the master device and will send a negative acknowledgement in response to such commands Whether communications Writes are enabled or disabled the Controller will return the requested information in response to interrogation from the master device 4 2 PHYSICAL REQUIREMENTS 4 2 1 Character Transmission The data format is fixed to be one start bit eight data bits and one stop bit The Baud rate may be selected to be 1200 2400 4800 default or 9600 Baud The parity is selectable to be even odd or none 4 2 2 Line Turn round The line turn round timings adhere to the industry standard 4 3 MODBUS RTU PROTOCOL The standard RS485 Communications Option and the Enhanced 65485 Communications option both use the industry standard MODBUS protocol The following restrictions are imposed Baud rates may be set to 1200 2400 4800 or 9600 Baud only Support for Write operations is limited to support of the Multi Word Write Function Number 16 but permits writing of one parameter only per message The multi parameter Read operations support a maximum of 10 parameters per message The following MODBUS functions are supported JBUS names where applicable are given in italics 0075 4 4 1 0075
51. dband negative values When Overlap Deadband 0 the Output 2 OFF edge of the Output 2 ON OFF Differential band coincides with the point at which Output 1 reaches 0 3 2 10 Bias Manual Reset This bias to the output power is expressed as a percentage of output power and is adjustable in the range 0 to 100 if only Output 1 is fitted or 100 to 100 if both outputs are fitted Its default value is 25 This parameter is not applicable if Proportional Band 1 0 3 2 11 ON OFF Differential Hysteresis This is a switching differential used when one or both outputs have been set to ON OFF control i e Proportional Band 1 or Proportional Band 2 or both 0 This parameter may be adjusted within the range 0 1 to 10 0 of the input span of the Controller The default value is 0 5 3 2 12 Setpoint High Limit This is the maximum limit for setpoint adjustment It should be set to a value which prevents the setpoint being given a value which will cause damage to the process being controlled The Setpoint High Limit may be adjusted between the current setpoint value and Input Range Maximum The default value is Input Range Maximum 3 2 13 Setpoint Low Limit This is the minimum limit for setpoint adjustment It should be set to a value which prevents the setpoint being given a value which will cause damage to the 3 8 0075 3 0075 process being controlled The Setpoint Low Limit may be adjusted between Input Ra
52. e 5 14 0075 5 0075 5 3 8 3 AM KEY USAGE P h This parameter which may be interrogated only using a Type 2 message indicates the usage selected for the front panel AM key 0 Output Turnoff 1 Auto Manual Control selection 2 Heater Current display See also Subsection 3 2 37 5 3 8 4 SCAN TABLE Pj The Scan Table operation takes the form of a Type 2 interrogation command which accesses a set of information held in the DATA element in the response The response would be in the form L N xx bbbbb ccccc ddddd eeeee A where xx is the number of data digits in the DATA element to follow this is 20 for a single control output instrument and 25 for a dual control output instrument These digits are as described in Table 5 2 and may comprise The current setpoint value bbbbb The current process variable value The current value of Output 1 Power 0 100 ddddd The current value of Output 2 Power 0 100 if applicable The Controller Status see Note 2 on Table 5 2 5 4 ERROR RESPONSE The circumstances under which a received message is ignored are Parity error detected Syntax error detected Timeout elapsed Receipt of a Type 4 message without a preceding Type 3 message Negative acknowledgements will be returned if in spite of the received message being notionally correct the Controller cannot supply the requested information or perform t
53. e Better than 1 C Negligible Negligible Thermocouple 1000 0 126 of span error Thermocouple 10000 lt 0 5 of span error RTD Pt100 50 0 526 of span error Serial asynchronous UART to UART link MODBUS RTU or ASCII selectable MODBUS RTU One start bit odd even no parity eight bit data one stop bit ASCII One start bit even parity seven bit data one stop bit 05485 5075 0075 Transmitter Drive Capability Receiver Bus Loading Baud rate Zone Address Select 13 ENVIRONMENTAL Operating Conditions Approvals EMI Susceptibility EMI Emissions Safety Considerations Supply Voltage Power Consumption Front Panel Sealing A 14 PHYSICAL Dimensions Front Panel S075 A 32 standard RS485 unit loads 1 4 standard RS485 unit load Selectable from front panel to be 1200 2400 4800 or 9600 Baud MODBUS RTU Selectable from front panel in the range 1 128 standard RS485 or 1 255 enhanced RS485 plus 0 broadcast ASCII Selectable from front panel in the range 1 99 for both standard 65485 and enhanced RS485 See PERFORMANCE CE UL pending ULC pending Certified to EN50082 1 1992 and EN50082 2 1995 NOTE For line conducted disturbances induced by RF fields 80 AM 1KkHz the product is self recoverable in the frequency band 0 15 80MHz Certified to EN50081 1 1992 and EN50081 2 1994 Complies with EN
54. e default setting is Alarm 2 hardware output direct acting The operation of the different alarm types is illustrated in Volume 1 Figure 3 2 The operation of logically combined AND OR alarms is explained in the table above 3 3 8 Output 3 Usage The displays for this item are of the form in which the upper display indicates the usage which will be one of the following Alarm 1 output Reverse acting logical Al od direct acting Ad_ AND of Alarms 1 amp 2 Relay SSR Drive or Relay SSR Drive or Solid State only Solid State only Alarm 1 output Heater Break Alarm reverse acting WE direct acting Relay Relay SSR Drive SSR Drive or Solid or Solid State only State only Direct acting logical Heater Break Alarm OR of Alarms 1 amp 2 W reverse acting Relay Relay SSR Drive or SSR Drive or Solid Solid State only State only Reverse acting logical Recorder Output WISE OR of Alarms 1 amp 2 rEc5 Setpoint DC only Relay SSR Drive or Solid State only Direct acting logical Recorder Output AND of Alarms 1 amp 2 HEP Process Variable Relay SSR Drive or DC only Solid State only This setting can be changed and confirmed in the manner previously described The default setting is Alarm 1 direct acting for a relay SSR output or Process Variable Recorder Output for a DC output The operation of the different alarm types is illustrated in Volume 1 Figure The operation of logically combined AND OR
55. eat this procedure the AT indicator will go OFF Within 2 seconds e of AT flashing 2 15 SELF TUNE To optimise tuning whilst the Controller is operating activate Self Tune g UNTIL E FLASHES ONCE Numeric displays will flash lt LSIMULTANEOUSLY while these keys are pressed UNTIL E GOES DOWN To dis engage Self Tune repeat this procedure the AT indicator will go OFF 0075 2 2 7 2 16 TO VIEW THE HARDWARE DEFINITION CODE PM 0075 The Hardware Definition Code indicates the input type and output type s fitted see below To view this Code After the Controller has been powered up for at least 30 seconds PRESS SIMULTANEOUSLY lt NOTE Use the same two key operation to return fo Operator Mode An automatic return is made after 30 seconds The same key action causes a return to the normal Operator Mode display An automatic return is made to the normal Operator Mode display after 30 seconds The Hardware Definition Code has the following significance 2 8 Valve 0 1 2 3 4 5 7 8 9 RTD Thermo Input Input couple Input Relay SSR Solid Output Output Drive State 1 Output Output Not Relay SSR Solid Relay Output fitted Output Drive State Output 2 amp 4 2 Output Output 2 amp 4 2 2 Output Not Relay DC DC DC DC Solid P fitted Output 0 10V 0 20mA 0 5V 4 20mA State 3 Outpu
56. ecorder Output Scale Maximum see Subsection 3 2 14 the relationship between the process variable value and the Recorder Output is reversed 3 2 16 Output 1 Power Limit This parameter is used to limit the power level of Output 1 and may be used to protect the process being controlled If no protection is required this parameter may be set to 100 the default value It may be adjusted between 0 and 100 This parameter is not applicable if Proportional Band 1 is set to 0 If Soft Start is used this power limit is applicable ony during Soft Start When Soft Start is completed Output 1 power can go to 100 3 2 17 Output 1 Cycle Time The cycle time value required is dependent upon the process being controlled and the type of output being used for Output 1 For a Relay Output the cycle time should be as large as possible whilst remaining compatible with the process 0075 3 3 9 0075 control requirements in order to maximise relay life For an SSR Drive Output cycle time may have a lower value and thus satisfy the requirements of a fast changing process variable e g flow or pressure The permitted range of values is 0 5 1 2 4 8 16 32 64 128 256 or 512 seconds The default value is 32 seconds This parameter is not applicable if Proportional Band 1 is set to O 3 2 18 Output 2 Cycle Time The cycle time value required is dependent upon the process being controlled and the type of output being used for O
57. ed at the Controller s input terminals in the following manner Modified PV value Actual PV value process variable offset value The modified PV value is limited by Range Maximum and Range Minimum and is used for display and alarm purposes and for recorder outputs NOTE This parameter value should be selected with care Any adjustment to this parameter is in effect an adjustment to the Controller s calibration Injudicious application of values to this 0075 5 5 7 0075 parameter could lead to displayed PV value having no meaningful relationship to the actual PV value 5 3 1 3 SCALE RANGE MAXIMUM Pj This parameter may be interrogated only using a Type 2 message The decimal point position is as for the input range 5 3 1 4 SCALE RANGE MINIMUM P This parameter may be interrogated only using a Type 2 message The decimal point position is as for the input range 5 3 1 5 SCALE RANGE DECIMAL POINT POSITION Pj This parameter may be interrogated only using a Type 2 message The value of this parameter indicates the decimal point position 0 abcd 1 5 3 1 6 INPUT FILTER TIME CONSTANT Pj m This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence CAUTION If this parameter is set to an excessively high value the control quality may be significantly impaired The value chosen should be sufficiently large to attenuate stray noise on the
58. ed process variable or setpoint output The displayed code may be adjusted and new values confirmed as described on the previous page The maximum setting available for this code is 2898 For 3 3 5075 3 0075 example code for a thermocouple input relay primary output Output 1 and relay Output 3 would be 2101 NOTE It is essential that this code is changed promptly whenever there is a change to the Controller s hardware configuration change of input output type alarm recorder output added removed etc The Controller software depends upon this code to ensure that the Controller operates correctly This code may be viewed as a Read Only display in Operator Mode see Volume 1 Subsection 3 2 2 Option Selection This indicates the option fitted if any Using the Raise Lower keys the display may be set to one of No option fitted Dual Setpoint Option fitted Terminals 11 and 12 used to select Setpoint 1 or Setpoint 2 see Subsection 1 3 5 Heater Current Quick Transfer Option fitted Terminals 11 and 12 used to instigate transfer of the current Heater Current value to the Heater Nominal Current parameter see Subsection 1 3 6 Standard RS485 Communications maximum address range 1 128 MODBUS or 1 99 ASCII Enhanced RS485 Communications maximum address range 1 255 MODBUS or 1 99 ASCII The displayed option selection may be adjusted and new values confirmed as described pr
59. efines the maximum value which may be assigned to the setpoint The default value is Inout Range Maximum The permissible range is between the current setpoint value and Input Range Maximum The decimal point position is as for the input range 5 3 4 4 SETPOINT LOW LIMIT Pj T This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the minimum value which may be assigned to the setpoint The default value is Inout Range Minimum It may be set to a value between Input Range Minimum and the current value of the setpoint The decimal point position is as for the input range 5 3 4 5 CONTROL SETPOINT P i This parameter which may be interrogated only using a Type 2 message is the setpoint value being used by the Controller af the instant the message is received When the setpoint is ramping this is the current value 5 3 5 Soft Start Parameters 5 3 5 1 SOFT START SETPOINT P j This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the value of setpoint to be used during a Soft Start It may be adjusted between Input Range Minimum and Input Range Maximum The default value is Input Range Minimum 5 3 5 2 SOFT START TIME P This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the duration of the Soft Start It may be adjusted in 15 second increments within the ra
60. er Current Control Summary description 1 3 0075 IDX Line Turn Round ASCII protocol PB 1 MODBUS RTU protocol _ Lock Value 3 17 Low Heater Break Alarm B 14 Automatic setting to default B 14 Low Heater Break Alarm Value Manual Control Mode Decsription of operation Manual Control Mode Selection of Manual Reset See Also Bias Manual Tuning Controllers with Output 1 and Output 2 Controllers with Output 1 only Dual output Single Output Message Formats MODBUS RTU protocol 4 2 MODBUS Functions Supported 4 1 MODBUS RTU Protocol 4 1 Multi Word Write Function MODBUS protocol 4 1 3 18 ON OFF Differential See Also Operator Mode Summary description 1 3 Output 1 Use of 1 3 Output 1 Cycle Time PM 0075 Output 1 Power Limit Output 2 Use of 1 3 Output 2 Cycle Time 5 9 Output Power 3 6 Output Power2 3 6 Output Power Value Output Turn Off Description of operation Output Turn Off Selection of Output Type Indication of Operator Mode Overlap Parameter Adjustment Operator Mode 2 3 Parameter List ASCII Protocol Parameter Selection Operator Mode 2 1 Parity ASCII protocol 5 1 MODBUS RTU protocol PID Control 1 3 Pre Tune Dis engagement of 2 7 Pre Tune Active Indication of Pre Tune Facility Activation of 2 7 Process High Alarm 1 Process High Alarm 2 3 12 Process Low Alarm 1 Process Low Alarm 2 3 12 Process Variable Definition of 1 3 Process Va
61. eresis Operation 3 13 0075 3 0075 3 2 27 Deviation High Low Alarm 2 Value This parameter applicable only if Alarm 2 is selected to be a Deviation High Low Alarm defines a value above positive value Deviation High alarm or below negative value Deviation Low alarm the setpoint if the process variable deviates from the setpoint by a margin greater than that defined by this parameter Alarm 2 goes active This parameter value may be adjusted in the range input range from setpoint The default value is five input range units The operation of Deviation Alarms is illustrated in 3 2 28 Alarm 2 Hysteresis This parameter applies a hysteresis band on the safe side of the Alarm 2 value Thus Alarm 2 will become active when the Alarm 2 value is exceeded Alarm 2 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 2 value Alarm 2 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per input resolution The effect of the SOR value on the operation of the different types of alarm is illustrated in 3 2 29 Heater Current High Scale Limit This parameter defines the full scale value for the heater current range It may be adjusted from 10 0A to 20 0A in 0 1A increments and then from 21A to 100A in 1A increments The default value is 50A Heafer current range minimum is fixed at OA This value also determines the Short Circuit Heater Break Alarm l
62. erminals 4 and 5 Z DIN Controllers or terminals 2 and 3 DIN Controllers should be linked The extension leads should be of copper and the resistance of the wires connecting the resistance element should not exceed 5 ohms per lead the leads should be of equal length 1 3 5 Dual Setpoint Selection Input With the Dual Setpoint Quick Transfer option fitted and Hardware Option parameter set to duAL see Subsection 3 2 Terminals 11 and 12 DIN Controllers or Terminals 16 and 17 DIN Controllers are used for external selection of the active setpoint These terminals may be connected to a the voltage free contacts of a switch or relay or b a TIL compatible voltage Setpoint selection is as follows Voltage Free Contacts open Setpoint 1 selected Contacts closed Setpoint 2 selected TTIL compattible gt 2 0V Setpoint 1 selected lt 0 8V Setpoint 2 selected NOTE The Dual Setpoint Quick Transfer option and the RS485 Serial Communications option are mutually exclusive 1 3 6 Remote Heater Current Transfer Input Quick Transfer With the Dual Setpoint Quick Transfer option fitted and hardware Option parameter set to trAn see Subsection 3 2 2 Terminals 11 and 12 4Z DIN Controllers or Terminals 16 and 17 i DIN Controllers are used to instigate externally transfer of the currently displayed heater current value to the Heater Nominal Current parameter see Volume 1 Subsection These terminals may be connected to a
63. errogated The DATA element is in a format in which the first two digits represent minutes and the second two digits represent seconds The decimal point position complies with this format and the decimal point is used as a separator between the minutes digits and the seconds digits The decimal point must be in the correct position for modification to occur 4 4 7 3 MANUAL RESET BIAS Word Parameter 15 This word parameter may be modified interrogated The decimal point position is as for the input range 0075 4 4 15 0075 4 4 7 4 ON OFF DIFFERENTIAL Word Parameter 17 This word parameter may be modified interrogated It defines the switching hysteresis for Controllers with an ON OFF control output primary or secondary output The decimal point position 1 decimal place 4 4 7 5 OVERLAP DEADBAND Word Parameter 16 Applicable to a dual control output instrument only this word parameter may be modified interrogated It may be set to positive and negative values a positive value indicates overlap a negative value indicates deadband The decimal point position 0 decimal places 4 4 7 6 PROPORTIONAL BAND 1 VALUE Word Parameter 6 This word parameter may be modified interrogated This may be set to 0 0 for On Off control or to a value in the range 0 5 999 9 of Output 1 power range The decimal point position is set to 1 decimal place 4 4 7 7 PROPORTIONAL BAND 2 VALUE Word Parameter 5 For a dual control
64. es hardware option fitted Heater Break Input Type Defines the type of input used for heater break sensing These facilities are accessed as follows Controller in Configuration Mode Hardware Definition Code see Subsection 3 2 1 Option Selection see Subsection 3 2 2 Heater Break PRESS SIMULTANEOUSLY 5075 3 3 2 0075 3 2 1 Hardware Definition Code The Hardware Definition Code is displayed in the following format Table 3 1 Hardware Definition Code Input Output Selection Value 0 1 2 3 4 5 7 8 9 RTD Thermo Input Input couple Input Relay SSR Solid Output Output Drive State 1 Output Output Not Relay SSR Solid Relay Output fitted Output Drive State Output 2 amp 4 2 Output Output 2 amp 4 2 2 Output Not Relay DC DC DC DC Solid P fitted Output 0 10V 0 20mA 0 5V 4 20mA State 3 Output Output Output Output Output Dual Relay Option PCB must be fitted NOTES 1 If Output 2 is set to relay SSR Drive Solid State output it may be a control output COOL or an alarm output if it is set to be a Dual Relay output it includes Output 4 Heater Break Alarm output 2 If Output 3 is set to be a relay or solid state output it can only be an alarm output if it is set to be a DC output it can only be a recorder output i e re transmitt
65. essage sequence It defines the level at which Alarm 2 will go active The decimal point position is as for the input range 5 3 6 4 ALARM 2 HYSTERESIS P b This parameter which may be modified interrogated using a Type 2 message or a Type 3 4 message sequence applies a hysteresis band on the safe side of the Alarm 2 value Thus Alarm 2 will become active when the Alarm 2 value is exceeded Alarm 2 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 2 value Alarm 2 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per Heater Current High Scale Limit The effect of the hysteresis value on the operation of the different types of alarm is illustrated in Figure 5 3 6 5 LOW HEATER BREAK ALARM VALUE Pj g This parameter which may be modified interrogated using a Type 2 message or a Type 3 4 message sequence defines a heater current value below which the Low Heater Break Alarm will become active It may be adjusted in the following ranges below the Heater Nominal Current If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank Low Heater Alarm forced inactive Default value 20 below heater nominal current Hysteresis is half the Low Heater Break Alarm value 5 12 0075 5 0075 If Heater Break Alarm Strategy Absolute Mode dependent upon display resolution Heater
66. etpoint Note 2 Setpoint Ramp Rate P Remaining Use Scroll key to select display Displays in white boxes revert fo the PV SP display if there is no key activity for one minute NOTES zT adjustable Subsection 2 11 Use Scroll key select display PM 0075 DUAL SETPOINT Process Variable Active Setpoint Subsection 2 11 Process Variable Heater Current Setpoint 1 GI JI i Setpoint 2 Setpoint SPrP Setpoint Ramp Rate 1 Setpoint is not adjustable if Setpoint Strategy 1 see Subsection but is adjustable if Setpoint Strategy 2 Active setpoint is one of Setpoint Setpoint 1 Setpoint 2 or Soft Start Setpoint as appropriate 2 Appears only if setpoint ramping is enabled and ramp rate is in the range 1 9999 3 Ramp rate is adjustable in the range 1 9999 On and Off blank 2 2 0075 2 0075 NOTES continued 4 Only appears if a Soft Start is in progress see Subsection 5 Appears only if an alarm is active see Subsection 2 6 6 In dual setpoint operation the lower display distinguishes between the active and inactive setpoints in the following manner Active Setpoint Inactive Sefpoint 2 3 ADJUSTING THE DISPLAYED PARAMETER Decreases value Increases value If either of these keys is held down for 10 seconds or more the adjustment rate changes to high speed mode 2 4 SOFT START Soft Start is used when a gentle
67. evel see below NOTE If this parameter value is changed the Heater Nominal Current Low Heater Break Alarm Value and High Heater Break Alarm Value parameters are set to their default values see Table 3 1 3 2 30 Heater Nominal Current This parameter defines a nominal value for the heater current and is only applicable if Heater Break Alarm Strategy is configured to Percentage Mode It may be adjusted in the range OA to Heater Current High Scale Limit The default value is the Heater Current High Scale Limit It can also be set automatically in Operator Mode or Set Up Mode to the heater current value at any instant by using Quick Transfer see Subsection 3 2 31 Low Heater Break Alarm Value The Controller monitors two current values ON current when Output 1 is on and OFF current when Output 1 is off This parameter defines a heater ON current value below which the Low Heater Break Alarm will become active It may be adjusted in the following ranges below the heater current nominal value 3 14 0075 3 0075 If Heater Break Alarm Strategy Percentage Mode 0 100 of Heater Nominal Current 0 OFF value display blank Low Heater Alarm forced inactive Default value 20 below heater nominal current Hysteresis is half the Low Heater Break Alarm value If Heater Break Alarm Strategy Absolute Mode 0 1A 1A dependent upon display resolution Heater Current High Scale Limit and 0 OFF value display blank Low
68. eviously 5075 3 3 4 0075 3 2 3 Heater Break Input Type The following input types are available Standard Heater Break Alarm using an external current transformer Terminals 7 and 8 This permits the use of the Low Heater Break Alarm High Heater Break Alarm and Short Circuit Heater Break Alarm Two wire connection to special thyristor unit SCRs via Terminals 7 and 8 This permits the use of the Low Heater Break Alarm and the High Heater Break Alarm but not the Short Circuit Heater Break Alarm Selection confirmation is achieved with the Raise Lower and AM keys as previously described 3 3 CONFIGURATION MODE PARAMETERS 3 3 1 Input Range When Configuration Mode is first entered this parameter will be displayed in the form The default setting is dependent upon the input hardware fitted as indicated by the first left most digit of the Hardware Definition Code see Subsection 3 2 1 Input Hardware Fitted Default Setting Thermocouple 1419 Type J 0 to 760 C RTD Pt100 7220 RTD Pt100 0 to 800 C If the Hardware Definition Code is at its default setting input code 1419 will be displayed The input ranges and codes available are listed in Appendix 3 5 5075 3 0075 3 3 2 Output 1 Action When this item is selected the displays will be either of Output 1 reverse acting Output 1 direct acting The setting can be changed and confirmed a
69. he process variable value is outside this band the alarm will be active This parameter may be adjusted to be within span from the setpoint The default value is five input units The operation of a band alarm is illustrated in 3 10 0075 3 0075 Process High Alarm direct acting Relay OFF Z Relay 2 NN 2 Alarm value Process High Alarm reverse acting RelayON Relay OFF gt py 2 Alarm value Process Low Alarm i MELEE direct acting ZZ Relay ZA Relay OFF Alarm value Process Low Alarm 22 ELI Relay OFEZ _ Relay ON Alarm value D gt 7 Band Alarm ON Z Relay OFF Relay ON direct acting 22 value PY Band Alarm A Relay OFF Relay ON ZFReloy OFF reverse acting value value 2 PV Deviation High Alarm Rey OFF 7 Relay ON direct acting PV positive value Deviation Low Alarm _ 77 ty i direct acting Po A BEIE negative value gt PV ort Deviation High Alarm RelayON _ Z Relay OFF reverse acting gt py positive value amp gt IKAlorm value Deviation Low Alarm 7 Pole ON reverse acting Rey 4 py negative value ALM LED flashes ALM LED off Figure 3 2 0075 3 v
70. he process variable temperature moves outside prescribed limits These alarms can be set to react if the process variable goes above or below specific temperatures or moves too far away from the setpoint In the latter case the alarm settings need no re adjustment if the setpoint is changed Heater break alarms allow prompt detection of heater failure minimising the risk of damage to the process Three different types of alarm are provided permitting the majority of heater failures to be handled effectively The actual heater current can be displayed on the front panel 1 4 0075 4 0075 2 OPERATOR 2 1 INTRODUCTION This Section covers the routine operation of the Controller once it has been installed and configured The Controller front panel indicators and keys are shown in Figure 2 1 1 16 DIN 1 8 DIN Auto Manual key v Lower key Raise key Scroll key Figure 2 1 Front Panel Indicators and Control Keys 2 2 SELECTING THE PARAMETER TO BE DISPLAYED ADJUSTED After the Controller has performed its power up self test the initial displays appear The Scroll key may then be used to step through the available displays These displays are dependent upon whether the Controller has been configured for Single Setpoint operation or Dual Setpoint operation 0075 2 2 1 SINGLE SETPOINT Process Variable Active Setpoint See Process Variable Heater Current Setpoint Ramping i sig S
71. he requested operation The DATA element of a negative acknowledgement will be indeterminate 0075 5 5 15 0075 ALPHABETICAL INDEX VOLUME 1 A Active Alarm Indication of Active Setpoint Indication of Address Range ASCII protocol Address Range Enhanced 5485 Option MODBUS RTU protocol 4 5 Address Range Standard 95485 Option MODBUS RTU protocol Alarm 1 Hysteresis Alarm 1 Value 4 14 Alarm 2 Hysteresis 3 14 Alarm 2 Value Alarm Status Display of 2 4 Alarms Summary description AM Key Usage To select automatic control output turn off 2 5 To select automatic manual 2 4 control 2 5 To select heater current display 2 5 Arithmetic Deviation Arithmetic Deviation Value 5 14 ASCII Communications Protocol 5 1 Auto Pre Tune Enable Disable B 16 Automatic Tuning B Band Alarm 1 Band Alarm 2 Baud Rate ASCII protocol 5 1 MODBUS protocol 4 1 Bias See Also Manual Reset Broadcast Messages MODBUS RTU protocol Bumpless Transfer C 4 2 Character Transmission ASCII protocol 5 1 MODBUS RTU protocol Communications MODBUS bit parameters MODBUS word Communications Data Format ASCII protocol 5 1 MODBUS RTU protocol Communications Line Release Time Maximum Value 5 1 Communications Message Format Configuration Mode Summary description Control Summary description Control Setpoint 5 11 Controller Address MODBUS RTU message Controller Status ASCII Protocol 5 6
72. in value Band Alarm 2 value o to span from Setpoint 5 units Deviation Alarm 2 span from Setpoint 5 units value Alarm 2 Hysteresis 1 250 units 1 unit Heater Current High IEEE 10 to 20 0A in 0 1A steps 50A ScaleLimit 21A to 100A in 1A steps Heater Current SISI 0 to Heater Current High High Scale Nominal Scale Limit Limit Low Heater Break Alarm level or amount below nominal heater current GSE 1 to 100 of nominal and 0 OFF or 0 1A 1A to Heater Current High Scale Limit 20 0 OFF 0075 3 3 3 0075 Table 3 1 Cont Set Up Parameters Parameter Legend Adjustment Range Default High Heater Break Alarm level or amount above nominal heater current EIS 1 to 100 of nominal and 0 OFF OFF or to Heater Current High Scale Limit Short Circuit Heater disabled or 1 enabled 1 enabled Break Alarm Soft Start Setpoint Range Min To Range Max Range Min Soft Start Time 15s to 59m 45s and OFF in 0 OFF 15 second increments Auto Pre Tune Enable Disable amd Li 0 disabled or 1 enabled 0 disabled m AM Key Usage ibubn HOFF Output Turn off ETE Manual Control hEr H Heater Current Enable Disable display Manual Control Disable SP Ramping EIER o disabled or 1 enabled 0 disabled Enable Disable C
73. is parameter 3 2 41 Lock Value This parameter defines the four digit code required to enter Set Up Mode It may be adjusted in the range 0 to 9999 The default setting is 10 3 3 OPERATOR MODE DISPLAYS Once the complete cycle of Set Up Mode parameters has been displayed the user may then step through the Operator Mode displays see making adjustments where required before re starting the Set Up Mode parameter cycle as shown in Table 3 1 0075 3 3 17 0075 3 4 TUNING THE CONTROLLER MANUALLY 3 4 1 Controllers Fitted with Output 1 Before starting to tune the Controller to the load check that the Setpoint High and Low Limits SPhi and SPLo are set to safe levels see Subsections and The following simple technique may be used to determine values for proportional band Pb1 derivative time constant rAtE and integral time constant rSEt NOTE This technique is suitable for use only with processes which are not harmed by large fluctuations in the process variable It provides an acceptable basis from which to start fine tuning for a wide range of processes 1 Set the setpoint to the normal operating process value or to a lower value if overshoot beyond this value is likely to cause damage 2 Select ON OFF Control i e set Pb1 0 3 Switch on the process Under these conditions the process variable will oscillate about the setpoint and the following parameter values should be noted The peak
74. is used for all PV dependent functions control alarms etc The time constant for this filter may be adjusted in the range 0 0 seconds filter OFF to 100 0 seconds in 0 5 second increments The default setting is 2 0 seconds CAUTION If this parameter is set to an excessively high value the control quality may be significantly impaired The value chosen should be sufficiently large to attenuate stray noise on the process variable signal but no larger 3 2 2 Process Variable Offset This parameter is used to modify the actual process variable value measured at the Controller s input terminals in the following manner Offset PV value Actual PV value Process Variable Offset value 0075 3 3 5 0075 The offset process variable value is used for all PV Hependent functions control display alarm recorder output etc NOTE This parameter value should be chosen with care Any adjustment to this parameter is in effect a calibration adjustment Injudicious application of values to this parameter could lead to the displayed process variable value bearing no meaningful relationship to the actual process variable value There is no front panel indication when this parameter is in effect i e has been set to a non zero value The default value is O 3 2 3 Output Power 1 This parameter is the current Output 1 power level It is a Read Only parameter and is not adjustable 3 2 4 Output Power 2 This parameter is
75. isation Accuracy Cold Junction Compensation RTD Inputs Measurement Accuracy Linearisation Accuracy DC Output Accuracy Output 3 Recorder Output 5075 gt 120dB at 50 60Hz giving negligible effect at up to 264V 50 60Hz gt 500 of span at 50 60Hz causes negligible effect 0 25 of span 1LSD Better than 0 2 C any point any 0 1 C range 0 05 C typical Better than 0 5 C any point any 1 C range Better than 0 7 C 0 25 of span 115 Better than 0 2 C any point any 0 1 C range 0 05 C typical Better than 0 5 C any point any 1 C range 0 25 MA 2500 V 2ko Degrades linearly to 0 5 for increasing burden to specification limits Operating Conditions Ambient Temperature Operating Ambient Temperature Storage Relative Humidity Supply Voltage Source Resistance Lead Resistance PM 0075 0 C to 55 C 20 C to 80 C 20 95 non condensing 90 264V AC 50 60Hz standard 20 50V AC 50 60Hz or 22 65V DC option 10000 maximum thermocouple 502 per lead maximum balanced Pt100 Performance Under Operating Conditions Temperature Stability Cold Junction Compensation thermocouple Only Supply Voltage Influence Relative Humidity Influence Sensor Resistance Influence A 12 COMMUNICATIONS Type Presentation Layer Data Format Physical Layer 0 01 of span C change in ambient temperatur
76. l combination of Alarm 1 and Alarm 2 Output 4 Heater Break Alarm output Dual setpoint remotely selectable NOTE The communications option and the dual setpoint quick transfer option are mutually exclusive TAILORING THE CONTROLLER TO SUIT YOUR NEEDS The Controller has three modes in which adjustments can be made via the front panel keys Configuration Mode This is normally used only when the Controller is first configured or when a major change is to be made to the Controller characteristics Entry into this Mode is security protected The Configuration Mode parameters should be set as required before any other adjustments are made Changing Configuration Mode parameters invariably sets other parameters to their default values Adjustments to these parameters should be performed only by personnel competent and authorised to do so Set Up Mode This mode is used when a change to the process set up is required The frequency of use for this mode is dependent upon the process being controlled This mode also determines the scope of adjustments available in Operator Mode Access to this mode is via a user defined password 0075 4 0075 Operator Mode This is mode for day to day use The parameters in this mode are freely available to the operator The adjustment facilities available in this mode are dependent upon the settings of parameters in the Set Up Mode 1 2 HOW IT WORKS The Plastics Controller is tailored to
77. mum Its default value is Inout Range Maximum The operation of a process high alarm is illustrated in 3 2 25 Process Low Alarm 2 Value This parameter applicable only when Alarm 2 is selected to be a Process Low alarm defines the process variable value at or below which Alarm 2 will be active Its value may be adjusted between Input Range Maximum and Input Range Minimum Its default value is Inout Range Minimum The operation of a process low alarm is illustrated in 3 2 26 Band Alarm 2 Value This parameter applicable only if Alarm 2 is selected to be a Band Alarm defines a band of process variable values centred on the setpoint value If the process variable value is outside this band the alarm will be active This parameter may be adjusted to be within span from the setpoint The default value is five input units The operation of a band alarm is illustrated in 3 12 0075 3 0075 Alarm inactive Alarm active Alarm inactive Alarm value ee ee RENE Da Eccc hey E Alarm Hysteresis Alarm inactive Alarm active Alarm inactive a BENED MM Alarm value Alarm inactive Alarm active Alarm inactive NENNEN 29 zi Hysteresis emi value Pees 28 ee eee seeps es Sle Be a M Alarm inactive Alarm inactive Alarm Alarm inactive active active Alarm inactive Hysteresis Alarm value Alarm value Figure 3 3 Alarm Hyst
78. n Progress Indication of 2 6 Soft Start Setpoint Adjustment of 3 1 Summory description Soft Start Time Adjustment of Summary description 1 3 Soft Start Time remaining Soft Start Time Remaining T Thermal shocks Avoidance of 1 3 Three Term Control 1 3 Time Proportioning 1 3 Two wire Communications W Write Operations MODBUS RTU protocol E k i PM 0075 0075 IDX 0075 2 1 2 2 2 3 2 4 2 5 2 6 3 1 1 DIN amp DIN PLASTICS CONTROLLERS PRODUCT MANUAL VOLUME 2 INSTALLATION amp CONFIGURATION INSTRUCTIONS The procedures described in this Volume must be undertaken only by technically competent servicing personnel Contents Volume 2 INSTALLATION 1 1 UNPACKING PROCEDURE 1 PANEL MOUNTING THE CONTROLLER 1 1 CONNECTIONS AND WIRING INTERNAL LINKS AND SWITCHES 2 1 REMOVING THE CONTROLLER FROM ITS HOUSING REMOVING REPLACING THE OUTPUT 2 OUTPUT 3 OPTION PCBs 2 3 REMOVING REPLACING THE RS485 OPTION PCB OR DUAL SETPOINT REMOTE HEATER CURRENT TRANSFER OPTION PCB 2 3 REPLACING THE CONTROLLER IN ITS HOUSING SELECTION OF OUTPUT 1 TYPE 2 4 OUTPUT 2 TYPE OUTPUT 3 TYPE CONFIGURATION MODE 5 1 ENTRY INTO CONFIGURATION MODE 3 1 S075 V2 i 3 2 3 3 3 4 HARDWARE DEFINITION CODE OPTION SELECTION AND HEATER BREAK INPUT TYPE CONFIGURATION MODE PARAMETERS EXIT FROM CONFIGURATION MODE APPENDIX A PRODUCT SPECIFICATION 2 A 3 A 4 A 5 A 6 A 7
79. nge 0 OFF to 59 minutes 45 seconds A value which is not an exact multiple of 15 seconds is treated as an invalid value The default value is O OFF 5 3 5 3 SOFT START TIME REMAINING This parameter which may be interrogated only using a Type 2 message is the time remaining for a Soft Start at the instant message is received When there is no Soft Start currently in effect a value of 0 is returned 0075 5 5 11 0075 5 3 6 Alarm Parameters 5 3 6 1 ALARM 1 VALUE Pj C This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the level at which Alarm 1 will go active The decimal point position is as for the input range 5 3 6 2 ALARM 1 HYSTERESIS Pj This parameter which may be modified interrogated using a Type 2 message or a Type 3 4 message sequence applies a hysteresis band on the safe side of the Alarm 1 value Thus Alarm 1 will become active when the Alarm 1 value is exceeded Alarm 1 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 1 value Alarm 1 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per Heater Current High Scale Limit The effect of the hysteresis value on the operation of the different types of alarm is illustrated in Figure 5 3 6 3 ALARM 2 VALUE P E This parameter may be modified interrogated using a Type 2 message or a Type 3 4 m
80. nge Minimum and the current setpoint value The default value is Input Range Minimum 3 2 14 Recorder Output Scale Maximum This parameter defines the value of process variable or setpoint whichever is applicable at which the Recorder Output reaches its maximum value for example for a 0 5V Recorder Output this value corresponds to 5V It may be adjusted within the range 1999 to 9999 The decimal point position for the Recorder Output is always the same as that for the process variable input range The default value is Input Range Maximum This parameter is not applicable if the Recorder Output option is not fitted NOTE If this parameter is set to a value less than that for the Recorder Output Scale Minimum see Subsection 3 2 15 the relationship between the process variable setpoint value and the Recorder Output is reversed 3 2 15 Recorder Output Scale Minimum This parameter defines the value of the process variable or setpoint whichever is applicable at which the Recorder Output reaches its minimum value for example for a 0 5V Recorder Output this value corresponds to OV It may be adjusted within the range 1999 to 9999 The decimal point position for the Recorder Output is always the same as that for the process variable input range The default value is Input Range Minimum This parameter is not applicable if the Recorder Output option is not fitted NOTE If this parameter is set to a value greater than that for the R
81. nt Range Setpoint Maximum Setpoint Minimum Setpoint Ramp A 8 SOFT START Start up Setpoint Duration Time remaining Power Maximum Output 1 Cycle Time Operating Mode 5075 User selectable as either 0 primary power Out Turnoff or adjustable output power Manual Control with bumpless transfer Selectable from 25 to 512 secs in binary steps Limited by Setpoint Maximum and Setpoint Minimum Limited by Setpoint and Range Maximum Limited by Range Minimum and Setpoint Ramp rate selectable 1 9999 1505 per hour and infinite Number displayed is decimal point aligned with selected range Bounded by Range Maximum and Range Minimum Setpoint ramping is not applied during Soft Start 0 Soft Start disabled 59 mins 45 secs in 15 second increments Starts timing at instrument power up in 1 second increments Soft Start ends when time remaining equals zero Limits Output 1 power Soft Start enabled only limits during Soft Start Soft Start disabled limits at all times Implicit Cycle time used for Output 1 during Soft Start equals displayed value of Output 1 Cycle Time but never less than 0 5 secs Assumes reverse acting control A 8 A 9 PV ALARMS Maximum Number of Alarms Alarm Types Max No of Outputs Available Combinatorial Alarms PM 0075 Two soft alarms Process high low deviation high low deviation band Up to three outputs can be
82. nual Control Selection Pressing the AM key causes the Controller to change from automatic control to manual control operator can then adjust output power from the front panel or vice versa Heater Current Display Manual Control hbEr H Disable Pressing the AM key causes the Controller displays to change from the current display to the Process Variable Heater Current display and thereafter switches between the PV Heater Current dislay and the PV SP display Manual control is disabled The default setting is Output Turn Off 3 2 38 Setpoint Ramp Enable Disable This parameter enables disables use of the setpoint ramping feature at user level 0 Disabled 1 Enabled The default setting is O Disabled 3 16 0075 3 0075 3 2 39 Communications Write Enable Disable This parameter enables disables Write operations i e the changing of parameter values settings via the RS485 communications link if the Communications Option PCB is fitted 0 Disabled 1 Enabled The default setting is 1 Enabled Parameters can be interrogated via the link regardless of the setting of this parameter 3 2 40 Setpoint Strategy This parameter determines whether the active setpoint value shown in the Operator Mode process variable setpoint display is adjustable or not 1 not adjustable 2 adjustable The default setting is 1 NOTE During a Soft Start the active setpoint value cannot be altered regardless of the setting of th
83. o not attempt to fit the Dual Relay Option PCB into the Output 3 upper Option PCB position 2 5 5075 2 0075 Link DC Output 3 Range Jumpers Fitted DC 0 10V LJ8 LJ9 LJ8 DC 0 20mA LJ9 DC 0 5V LJ8 DC 4 20mA LJ9 Figure 2 6 DC Output 3 Option PCB Link Jumpers 5075 2 2 6 0075 3 CONFIGURATION MODE 3 1 ENTRY INTO CONFIGURATION MODE To enter Configuration Mode Power up Controller Within 30 secs as 1st key action after power up o To display ECEE Value Identifier Controller is in Configuration HOLD DOWN Mode and displays current SIMULTANEOUSLY input code In Configuration Mode To confirm new To select To change value value upper parameter display flashes display is static d NOTE Changes to the setting of certain Configuration Mode parameters e g input range output use and type will cause the Set Up Mode parameters to be automatically set to their default values the next time Set Up Mode is entered see also Volume 1 beginning of Section 3 3 1 5075 3 0075 3 2 HARDWARE DEFINITION CODE OPTION SELECTION AND HEATER BREAK INPUT TYPE These are special facilities in Configuration Mode used as follows Hardware Definition Code Represents the hardware fitted input type Output 1 type Output 2 type and Output 3 type must be compatible with the hardware actually fitted Option Selection Defin
84. omms Write Lotnie disabled or 1 enabled 1 enabled Setpoint Strategy EH 1 or 2 1 Lock Value ENT 0 9999 10 PV Active SP See Subsection 2 2 PV Heater Current Read Only SP or SP1 SPHi to SPLo SPLo SP2 Dual SP only BETIS seri to sPLo SPLo Ramping SP value gt Inimiml Read Only SP Ramp Rate 7 EE 9999 and OFF OFF Soft Start Time Remaining SoHE Read Only Alarm Status AL SL Read Only see Subsection 2 6 3 4 0075 3 0075 NOTES ON TABLE 5 1 1 These parameters are not operative if the Proportional Band 0 N Switching differential with ON OFF Control Output 3 These parameters are optional only one legend will appear for each alarm 4 Only applicable if Output 2 is fitted 5 Appears only if ramp rate I D is not switched OFF 6 Applicable only if the Communications Option PCB is fitted 7 Does not appear in Operator Mode unless PEN 1 8 For Single Setpoint operation the legend displayed is SP for Dual Setpoint operation the legend displayed is SP1 9 Applicable only when Heater Break Alarm Strategy is configured to Percentage Mode 10 Does not appear if Heater Break Input Type is configured to be SCRI 3 2 1 Input Filter Time Constant The Controller input is equipped with a digital filter which is used to filter out any extraneous impulses on the process variable This filtered PV
85. ons facility adhere to this standard thus provided that the master device conforms similarly to the standard there should be no line contention problems 0075 5 5 1 0075 5 2 3 ASCII Protocol The protocol assumes half duplex communications All communication is initiated by the master device The master sends a command or query to the addressed slave and the slave replies with an acknowledgement of the command or the reply to the query All messages in either direction comprise a A Start of Message character b One or two address characters uniquely defining the slave c A parameter data character string d An End of Message character Messages from the master device may be one of four types Type 1 L N Type 2 L N P C Type 3 L N P DATA Type 4 L N P 1 where all characters are in ASCII code and L is the Start of Message character Hex 4C N is the slave Controller address in the range 1 99 addresses 1 9 may be represented by a single digit e g 7 or in two digit form the first digit being zero e g 07 P is a character which identifies the parameter to be interrogated modified see Table C is the command see below indicates that DATA is to follow Hex 23 DATA is a string of numerical data in ASCII code see Table 5 1 is the End of Message character Hex 2A No space characters are permitted in messages Any syntax errors in a received message will c
86. ont panel When panel mounted the front panel projects 10mm from the mounting panel The main dimensions of the Controller are shown in Figure 5075 1 1 1 0075 110mm gt L approx 48mm 1 16 DIN X 48mm 1 8 DIN X 96mm Figure 1 2 Main Dimensions To panel mount the Controller proceed as shown in Figure 1 3 NOTE Do not remove the panel gasket as this may result in inadequate clamping of the instrument in the panel Once the Controller is installed in its mounting panel it may be subsequently removed from its housing if necessary as described in Subsection Mounting panel Slide mounting clamp over Controller housing towards rear face of mounting panel until tongues engage in ratchets and Controller is clamped firmly in position Controller Housing Ratchets Gasket Hold Controller firmly in position apply pressure to bezel only Figure 1 3 Panel Mounting the Controller 1 2 5075 1 0075 CONNECTIONS AND WIRING 1 3 NOILdO v c AV 134 2 N 2 O N Tuna JO ass ADJ 1 Indino Sul S i NOILdO YSASNWAL MIN 98 j NOI12313S LNIOdL3S _ ox igure 1 4 4L DIN Controllers and The rear terminal connections are illustrated in Fi Figure 1 5 J DIN Controllers Hun JO dol sBujjbu esn ejbuidoudab sO Z E L
87. or Output 2 Option PCB is connected to the CPU PCB and Output 3 Option PCB is connected to the Power Supply PCB see Figure Note the orientation of the PCB in preparation for its replacement Adjustments may now be made to the link jumpers on the CPU PCB the PSU PCB and if fitted the DC Output 3 Option PCB The replacement procedure is a simple reversal of the removal procedure 2 3 REMOVING REPLACING THE RS485 OPTION PCB OR DUAL SETPOINT REMOTE HEATER CURRENT TRANSFER OPTION PCB The 5485 Communications Option PCB or Dual Setpoint Remote Heater Current Transfer Option PCB is mounted on the inner surface of the PSU PCB and can be removed when the Controller is removed from its housing see Subsection 2 1 Figure 2 3 illustrates the removal replacement procedure is nof necessary to remove the Output 2 Output 3 Option PCBs to perform this procedure REMOVAL REPLACEMENT View of Controller from the rear For clarity the Output 2 and Output Option PCBs are nof shown PSU PCB T RS485 Serial Comms Option PCB Dual Setpoint Remote Heater Current Transfer Option PCB Figure 2 3 Removing Replacing the RS485 Communications Option PCB or Dual Setpoint Remote Heater Current Transfer Option PCB 2 3 5075 2 0075 2 4 REPLACING THE CONTROLLER IN ITS HOUSING To replace the Controller simply align the CPU PCB and Power Supply PCB with their guides and connectors in the housing and slowly but firmly push the
88. ot exceed 32 standard RS485 unit loads This applies to both standard and enhanced 25485 communications A Plastics Controller presents 4 standard 25485 load so a maximum of 128 Controllers are permitted With other devices 0075 4 4 5 0075 connected the limit is dictated by the sum total of the 65485 receiver loadings 4 3 4 Bit Parameters The bit parameters are shown in Table 4 3 5 Word Parameters The word parameters are shown in Table 4 6 0075 4 0075 Table 4 1 MODBUS Bit Parameters Parameter No Notes Read Only 1 enabled 0 disabled Comms Write Status Auto Manual Control 2 1 Manual 0 Auto 3 activate d 0 5 4 activate d 0 dis engage d Alarm 1 Status 5 Read Only 1 active 0 inactive Alarm 2 Status 6 Read Only 1 active 0 inactive Setpoint Ramp Enable Disable 7 0 disable d Parameter Changed 8 Read Only 1 change 0 no change Auto Output Turn Off 9 Output Turn Off 0 Auto Control High Heater Break Alarm Status 10 Read Only 1 active 0 inactive Low Heater Break Alarm Status 11 Read Only 1 active 0 inactive Short Circuit Heater Break 12 Read Only 1 active 0 inactive Alarm Status Heater Break Current Transfer 13 1 initiate transfer 0 no transfer Quick
89. output instrument this word parameter may be modified interrogated This may be set to 0 0 for On Off control or to a value in range 0 5 999 9 of Output 2 power range The decimal point position is set to 1 4 4 8 Status Parameters 4 4 8 1 STATUS Word Parameter 7 This Read Only word parameter comprises all 16 bit parameters see Table 4 1 4 4 8 2 ARITHMETIC DEVIATION PROCESS VARIABLE SETPOINT VALUE Word Parameter 4 This Read Only word parameter is the difference between the current process variable value and the current setpoint value at the instant the message is received 4 4 8 3 AM KEY USAGE Word Parameter 34 This Read Only word parameter indicates the current usage selected for the front panel AM key 0 Output Turnoff 1 Auto Manual Control selection 2 Heater Current display See also Subsection 3 2 37 4 16 0075 4 0075 o ASCII COMMUNICATIONS The Plastics Controller may be equipped with a two wire R5485 compatible serial communications facility by which means communication may occur between the Controller and a master device e g a computer or terminal 5 1 COMMUNICATIONS WRITE ENABLE DISABLE When Communication Writes are enabled in Set Up Mode see Subsection Controller parameters may be adjusted by the master device the serial communications link If communications Writes are disabled the Controller will not adjust or change any parameters in response to commands
90. put sense is reversed 5 3 2 6 RECORDER OUTPUT SCALE MINIMUM VALUE Pj This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the minimum scale value for the Controller s Recorder Output and may be adjusted within the range 1999 to 9999 This value corresponds to the Input Scale Minimum and the decimal point position will always be the same as that for the input NOTE If this parameter is set to a value greater than the Recorder Output Maximum Value the Recorder Output sense is reversed 0075 5 5 9 0075 5 3 3 Heater Current Parameters 5 3 3 1 HEATER CURRENT HIGH SCALE LIMIT P c This parameter defines the full scale value for the heater currrent range and may be modified interrogated using a Type 3 4 message sequence only It may be adjusted from 10 0A to 20 0A in 0 1A increments and then from 21A to 100A in 1A increments The default value is 50A Heafer current range minimum is fixed at OA NOTE If this parameter value is changed the Heater Nominal Current Low Heater Break Alarm Value and High Heater Break Alarm Value parameters are set to their default values 5 3 3 2 HEATER NOMINAL CURRENT P d This parameter defines a nominal value for the heater current and may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It may be adjusted in the range OA to Heater Current High Scale Limit value The default value is the Heater
91. r samples second Time constant selectable from front panel 0 0 i e OFF 0 5 to 100 0 seconds in 0 5 second increments 14 bits approximately always at least four times better than display resolution Greater than 100 resistive Universal input isolated from all outputs except SSR at 240V AC Adjustable span Thermocouple Ranges selectable from front panel Type Input Range Dislayed Code Type Input Range Displayed Code R 0 1650 C 1127 J 32 1401 F 1420 R 32 3002 F 1128 T 200 262 C 1525 5 0 1649 1227 328 503 F 1526 5 32 3000 F 1228 0 0 260 6 1541 0 0 205 4 1415 32 0 501 0 F 1542 32 0 401 7 1416 K 200 760 C 6726 0 450 C 1417 K 328 1399 F 6727 J 32 842 F 1418 K 200 1373 C 6709 J 0 761 C 1419 K 328 2503 F 6710 Default not North America Continued overleof T Default North America A 1 5075 0075 Input Range Dislayed Code Type Input Range Displayed Code L 0 0 205 7 C 1815 L 32 1403 F 1820 L 32 0 402 2 F 1816 B 211 3315 F 1934 L 0 450 C 1817 B 100 1824 C 1938 L 32 841 F 1818 N 1399 C 5371 L 0 762 C 1819 N 32 2550 F 5324 Calibration Complies with BS4937 NBS125 and IEC584 Sensor Break Protection Break detected within two seconds Resistance Tempe
92. rameter values are transmitted followed by the CRC16 bytes Force Single Coil Write 1 Bit 05 The message received by the Controller is eight bytes long comprising the standard pre amble and the address of the bit to be forced followed by a two byte word whose most significant byte contains the desired truth value of the bit expressed as OxFF TRUE or OxOO FALSE Normally this function is used to control such features as Auto Manual Control selection and tuning Pre Tune Self Tune The normal reply sent by the Controller will be a byte for byte echo of the message received Preset Single Register Write 1 Word 06 The message sent to the Controller comprises eight bytes the address and Function Number as usual the address of the parameter to be written the two byte value to which the parameter is to be set and the CRC16 bytes The normal response from the Controller is a complete echo of the received message 4 4 0075 4 0075 Loopback Diagnostic Test 08 This is an eight byte message comprising the usual pre amble a two byte diagnostic code two bytes of data and the CRC16 bytes The only diagnostic code supported is 00 The normal response is an exact echo of the received message Preset Multiple Registers Write n Words 16 This is an eleven byte message only one parameter may be written for each received message The usual pre amble is followed by the address of the parameter to be written a two
93. ramping OFF The decimal point position is as for the input range 4 4 4 3 SETPOINT HIGH LIMIT Word Parameter 22 This word parameter may be modified interrogated It defines the maximum value which may be assigned to the setpoint The default value is Input Range Maximum The permissible range is between the current setpoint value and Input Range Maximum The decimal point position is as for the input range 4 4 4 4 SETPOINT LOW LIMIT Word Parameter 23 This word parameter may be modified interrogated It defines the minimum value which may be assigned to the setpoint The default value is Input Range Minimum It may be set to a value between Input Range Minimum and the current value of the setpoint The decimal point position is as for the input range 4 4 4 5 CONTROL SETPOINT Word Parameter 21 This Read Only word parameter is the setpoint value being used by the Controller at the instant the message is received When the setpoint is ramping this is the ramping setpoint value 4 4 5 Soft Start Parameters 4 4 5 1 SOFT START SETPOINT Word Parameter 37 This word parameter may be modified interrogated It defines the value of setpoint to be used during a soft start It may be adjusted between Input Range Minimum and Input Range Maximum The default value is Input Range Minimum 4 4 5 2 SOFT START TIME Word Parameter 38 This word parameter may be modified interrogated It defines the duration of the Soft Start It may be adj
94. rature Detector RTD Ranges selectable from front panel Input Range Displayed Code Input Range Displayed Code 0 800 C 7220 0 0 100 9 C 2295 32 1471 7221 32 0 213 6 F 2296 32 571 F 2229 200 206 C 2297 100 9 100 0 C 2230 328 402 F 2298 149 7 211 9 F 2231 100 9 537 3 C 7222 0 300 C 2251 149 7 999 1 F 7223 Default not North America Default North America Type and Connection Three wire Pt100 Calibration Complies with 51904 and DIN43760 Lead Compensation Automatic scheme RTD Sensor Current 1504A approximately Sensor Break Protection Break detected within two seconds 5075 2 0075 A 2 DUAL SETPOINT QUICK TRANSFER SELECTION INPUT OPTION Type Voltage Free Operation TIL levels Maximum Input Delay OFF ON Minimum Input Delay ON OFF Voltage free or TTL compatible Connection to contacts of external switch relay contacts open Setpoint 1 selected min contact resistance 50000 contacts closed Setpoint 2 selected max contact resistance 500 To select Setpoint 1 0 6V to 0 8V To select Setpoint 2 2 0V to 24 0V second second HEATER CURRENT INPUT Input Sampling Method Input Resolution Isolation Internal Burden Primary Input Range Maximum Primary Input Range Minimum Secondary Input Span A 3 Delta Sigma at 1k
95. reak Alarm active Blank Both inactive SHORT CIRCUIT HEATER BREAK ALARM S active Blank inactive ALARM 1 1 active Blank inactive ALARM 2 2 active Blank inactive 2 7 OVER RANGE UNDER RANGE DISPLAYS If the process variable goes under range or over range the upper display will show the appropriate one of Over range Under Range 2 4 0075 2 0075 2 8 SENSOR BREAK INDICATION If a break is detected in the sensor circuit the upper display will show The reaction of the outputs and alarms to a detected sensor break is dependent upon the input type Larry Press the AM key to switch between automatic control and the control outpult s being permanently turned off A return to automatic control is via a bumpless transfer The SET indicator flashing pattern will be mostly OFF if in Operator Mode or mostly ON if in Set Up Mode 2 9 OUTPUT TURN OFF AM Key Usage Set Up parameter 2 10 MANUAL CONTROL MODE AM Key Usage Set Up parameter 2 Press the AM key to switch between manual control and automatic control In manual control the output power is displayed and may be adjusted The SET indicator flashing pattern will be mostly OFF if in Operator Mode or mosily ON if in Set Up Mode Transfer between automatic control and manual control is bumpless in both directions 2 11 HEATER CURRENT DISPLAY AM Key Usage Set Up parameter WIIUWII Press the AM key to display
96. received from the master device and will send a negative acknowledgement in response to such commands Whether communications Writes are enabled or disabled the Controller will return the requested information in response to a Type 2 Interrogation message see Subsection from the master device 5 2 PHYSICAL REQUIREMENTS 5 2 1 Character Transmission Data format is fixed to be even parity one start bit seven data bits and one stop bit The Baud rate may be selected to be 1200 2400 4800 default or 9600 Baud 5 2 2 Line Turn Round The communications link is operated as a multi drop half duplex system When a device is transmitting it drives the transmission lines to the appropriate levels when it is not transmitting its outputs are set to a high impedance in order that another device can transmit It is important that a transmitter releases the transmission lines before another device starts transmission This imposes the following restraints on the master device The transmitter must release the transmission lines within 6ms of end of the last character of a message being transmitted Note that delays due to buffers such as those used in universal asynchronous receivers trans mitters UARTs within the master device must be taken into account b The transmitter must not start transmission until ms has elapsed since the reception of the last character of a message All Plastics Controllers having an 65485 communicati
97. riable Offset 3 5 0075 IDX 0075 Proportional Band 1 3 6 Proportional Band 1 Value Proportional Band 2 3 6 Proportional 2 Value Q Quick Transfer Heater current to nominal value 2 6 R Rate See Also Derivative Time Constant Recorder Output Maximum Value Recorder Output Minimum Value Recorder Output Scale Maximum Recorder Output Scale Minimum 3 9 Reset See Also RS485 Communications 4 1 RS485 Loading Limits 4 5 RTU Form MODBUS protocol 4 2 S Scale Range Decimal Point Position Scale Range Maximum Scale Range Minimum Scan Table Command 15 Security Protection Configuration Mode 1 2 Self Tune Activation of 2 7 Dis engagement of 2 7 0075 IDX Sensor Break Indication of Serial Communications Enabling disabling 3 1 End of Message character Message Types 5 2 Scan Tables command 5 4 Start of Message character HE Type 2 message Type 3 message 5 4 Type 4 message 5 4 Set Up Mode Automatic exit from 3 20 Entry into 3 1 Exit from 3 20 Summary description 1 2 Set Up Parameters at Default Indication of 3 1 Setpoint Definition of Setpoint High Limit 3 8 4 13 5 11 Setpoint Low Limit 3 8 Setpoint Ramp Rate 4 12 5 10 Setpoint Ramping Enabling disabling 3 16 Setpoint Strategy Selection of 3 17 Setpoint Value 5 10 Short Circuit Heater Break Alarm Enabling disabling T Soft Start Introduction to 2 3 Summary description 1 3 Soft Start i
98. s lower values may be used The decimal point position is set at 1 decimal place NOTE Cycle Time values must be written correctly i e the value must be a power of 2 in the range 0 5 512 0 5 1 2 4 8 etc 4 4 2 5 RECORDER OUTPUT MAXIMUM VALUE Word Parameter 27 This word parameter may be modified interrogated It defines the maximum value for the Controller s Recorder Output and may be adjusted within the range 1999 to 9999 This value corresponds to the Input Scale Maximum and the decimal point position will always be the same as that for the input NOTE If this parameter is set to a value less than the Recorder Output Minimum Value the sense of the Recorder Output is reversed 0075 4 4 11 0075 4 4 2 6 RECORDER OUTPUT MINIMUM VALUE Word Parameter 28 This word parameter may be modified interrogated It defines the minimum scale value for the Controller s Recorder Output and may be adjusted within the range 1999 to 9999 This value corresponds to the Input Scale Minimum and the decimal point position will always be the same as that for the input If this parameter is set to a value greater than the Recorder Output Maximum Value the sense of the Recorder Output is reversed 4 4 3 Heater Current Parameters 4 4 3 1 HEATER CURRENT HIGH SCALE LIMIT Word Parameter 29 This word parameter defines the full scale value for the heater currrent range It may be adjusted from 10 0A to 20 0A in 0 1A increments and
99. s previously described The default setting is reverse acting NOTE If the secondary output is chosen as Output 2 COOL control output its action is always the complement of the action of Output 1 3 3 3 Alarm 1 Type When this item is selected the displays will be of the form the upper display indicating the current Alarm 1 type which may be one of Band Alarm Alarm Alarm Alarm The setting can be changed and confirmed as previously described The default setting is Process High alarm The operation of the alarm types is shown in Volume 1 Figure 5075 3 3 6 0075 3 3 4 Alarm 2 Type When this item is selected the displays will be of the form the upper display indicating the current Alarm 2 type The alarm types available are as for Alarm 1 see Subsection The setting can be changed and confirmed as previously described The default setting is Process Low alarm The operation of the alarm types is shown in Volume 1 Figure 3 3 5 Alarm Inhibit When this item is selected the displays will be of the form where the upper display can be one of Fl EL l4 EL none BALA AL ACBboth No alarms Alarm 1 Alarm 2 Both alarms inhibited inhibited inhibited inhibited On power up an alarm condition may occur based on the alarm value the process variable value and if appropriate to the alarm type the active setpoint value This would normally activate an alarm however if the pertinent alarm is
100. s to CPUPCB 2 3 DC Output 3 D Option PCB 2 3 Lock Code Dual Setpoint Selection Display of TIL Compatible Input 1 6 Voltage Free Contacts Dual Setpoint Quick Transfer Option PCB Removal replacement 2 3 S075 IDX Mains Line Supply Fuse rating Terminal connections 1 5 Voltage range 1 5 Output 1 Action Selection of 3 6 Output 1 Selection of link jumpers 2 4 Output 2 Option PCB Removal replacement 2 3 Output 2 Type Selection of 2 5 Output 2 Usage Selection of 3 8 Output 3 Option PCB Removal replacement 2 3 Output 3 Type Selection of 2 5 Output 3 Usage Selection of 3 9 Output 4 Usage As Heater Break Alarm Output Connections DC Relay 1 7 SSR Drive 1 7 Panel Mounting Controller dimensions 1 1 Cut out dimensions a installation Cut out dimensions single installation Maximum panel thickness PM 0075 Panel mounting the Controller 1 1 Product Specification A 1 Q Quick Transfer Selection Input Treminal connections 1 4 Quick Transfer Dual Setpoint Option PCB Removal replacement 2 3 Range See Rear Terminal Connections 1 3 Remote Heater Current Transfer Input Terminal connections 1 6 Remote Heater Transfer Option PCB Removal replacement 2 3 Removing the Controller from its Housing Replacing the Controller in its Housing 05485 Communications Option PCB Removal replacement 2 3 S Sensor Break Effect on outputs RTD inputs Effect on outputs
101. sage sequence It defines the derivative time constant for the control algorithm The DATA element is in a format in which the first two digits represent minutes and the second two digits represent seconds The decimal point is used as the separator between the minutes and seconds digits i e set to 2 decimal places the decimal point position must be as described otherwise modification will not occur 5 3 7 2 RESET INTEGRAL TIME CONSTANT P This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence The DATA element is in a format in which the first two digits represent minutes and the second two digits represent seconds The decimal point position complies with this format and the decimal point is used as a separator between the minutes digits and the seconds digits The decimal point must be in the correct position for modification to occur 0075 5 5 13 0075 5 3 7 3 MANUAL RESET BIAS P J This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence The decimal point position is as for the input range 5 3 7 4 ON OFF DIFFERENTIAL Pj F This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It defines the switching hysteresis for Controllers with an ON OFF control output primary or secondary output The decimal point position Eq 5 3 7 5 OVERLAP DEADBAND Pj K Applicable to a dual
102. ses into the Output 2 proportional band increase the value of Pb2 If the process appears to be over damped in the region of the Output 2 proportional band decrease the value of Pb2 3 When values of proportional bands integral time constant and derivative time constant have been determined for tuning if there is a kick as control passes from one output to the other set OL to a positive value to introduce some overlap Adjust the value of OL by trial and error until satisfied 3 5 SELF TUNE Once the Controller has been manually tuned Self Tune may be used in Operator Mode to enhance further the response of the Controller see Subsection 0075 3 3 19 0075 3 6 EXIT FROM SET UP MODE To leave Set Up Mode select the initial Operator Mode display process variable setpoint then depress the Raise and Function keys simultaneously whereupon the Controller will return to Operator Mode NOTE An automatic return to Operator mode will be executed if there is no key activity in Set Up Mode for two minutes 3 20 0075 3 0075 4 MODBUS RTU COMMUNICATIONS The Plastics Controller may be equipped with two wire RS485 compatible serial communications by which means communication may occur between the Controller and a master device e g a computer or terminal 4 1 COMMUNICATIONS WRITE ENABLE DISABLE When Communications Write operations are enabled in Set Up Mode see Subsection the Controller parameters may be adjuste
103. t Output Output Output Output Dual Relay Option PCB must be fitted 0075 2 0075 3 SETUP MODE 3 1 ENTRY INTO SET UP MODE Put Controller in Operator Mode with normal display value CODE VALUE o E value PRESS If the upper disolay does nof show the correct Lock Code value when this key is pressed a return is made original Operator Mode display NOTE If the upper display shows i e all decimal point positions ON parameters are at their default values possibly due to a change in Controller configuration To cancel this indication adjust any Set Up Mode parameter see below It is recommended that all configuration parameters are finalised before any adjustments are made to Set Up Mode parameters 0075 3 3 1 3 2 Parameter value Parameter legend SET UP MODE PARAMETERS Selects parameter see Table 3 1 Adjusts parameter value PM 0075 Table 3 1 Set Up Parameters Parameter Legend Adjustment Range Default Input Filter Time EN OFF 0 5s to 100 0s In 0 5s 2 0s Constant increments Process Variable Offset EES tinput span of Controller 0 Output Power RINSI o 100 Read Only Output Power 2 0 to 100 Read Only Proportional Band 1 0 0 to 999 9 of input span 10 0 Proportional Band 2 0 096 to 999 996 of input span 10 096 Reset Integral Time 1s to 99m 59s and OFF 5m 005 Constant
104. the current Output 2 power level if Output 2 is fitted It is a Read Only parameter and is not adjustable If Output 2 is not fitted this parameter display is not applicable 3 2 5 Proportional Band 1 This parameter is the portion of the input span of the Controller over which the Output 1 power level is proportional to the displayed process variable value It may be adjusted in the range 0 0 i e ON OFF control to 999 9 The default value of this parameter is 10 0 The function of the Proportional Band 1 is illustrated in Figure 3 1 3 2 6 Proportional Band 2 This parameter is the portion of the input span of the Controller over which the Output 2 power level is proportional to the displayed process variable value It may be adjusted in the range 0 0 i e ON OFF control to 999 9 The default value of this parameter is 10 0 This parameter is applicable only if Output 2 is fitted In Proportional Band 2 is shown a with a non zero value Case 1 and Case 2 PID control and b with a zero value Case 3 ON OFF control 3 2 7 Reset Integral Time Constant This parameter is adjustable in the range 1 second to 99 minutes 59 seconds and OFF value greater than 99 minutes 59 seconds This parameter is not applicable if Proportional Band 1 see Subsection 3 2 5 is set to 0 ON OFF control 3 6 0075 3 0075 Proportional 1 Phi Proportional Output Band 2_ Output 2 Output Power 96
105. usted in 15 second increments within the range 0 OFF to 59 minutes 45 seconds A value which is not an exact multiple of 15 seconds is treated as an invalid value The default value is O OFF 4 4 5 3 SOFT START TIME REMAINING Word Parameter 39 This Read Only word parameter is the time remaining for a Soft Start at the instant the message is received When there is no Soft Start currently in effect a value of 0 is returned 0075 4 4 13 0075 4 4 6 Alarm Parameters 4 4 6 1 ALARM 1 VALUE Word Parameter 13 This word parameter may be modified interrogated It defines the level at which Alarm 1 will go active The decimal point position is as for the input range 4 4 6 2 ALARM 1 HYSTERESIS Word Parameter 35 This word parameter applies a hysteresis band on the safe side of the Alarm 1 value Thus Alarm 1 will become active when the Alarm 1 value is exceeded Alarm 1 will become inactive when the process variable value is outside the hysteresis band on the safe side of the Alarm 1 value Alarm 1 Hysteresis may be set to a value in the range 1 250 or 0 1 25 0 as per Heater Current High Scale Limit The effect of the hysteresis value on the operation of the different types of alarm is illustrated in Figure 4 4 6 3 ALARM 2 VALUE Word Parameter 14 This word parameter may be modified interrogated It defines the level at which Alarm 2 will go active The decimal point position is as for the input range 4 4 6
106. utilised for alarm purposes Logical OR or AND of standard alarms to an individual hardware output is available A 10 HEATER BREAK ALARMS Alarm Types Alarm Trip Values Nominal Heater Current Quick Transfer Max No of Outputs Available Combinatorial Alarms A 9 Three dedicated soft alarms Low High and Short Circuit Each can be disabled individually Low High alarms can be absolute Amps or percentage from nominal adjustable Short Circuit alarm is fixed at 5 of Heater High Scale Limit Can be adjusted manually or using Quick Transfer automatically One shot procedure to read heater current and tranfer read value to Heater Nominal Current value Can be initiated locally from front panel or remotely via communications link or digital input Up to three outputs can be utilised for heater break alarms Each output can be reverse acting or direct acting ORing of all enabled heater break alarms is implicit for any output used for heater break alarm 5075 0075 A 11 PERFORMANCE Reference Conditions Generally as EN60546 1 Ambient Temperature Relative Humidity Supply Voltage Source Resistance Lead Resistance 20 C 2 C 60 70 90 264V AC 50Hz 1 lt 100 for thermocouple input lt 0 19 lead balanced Pt100 Performance Under Reference Conditions Common Mode Rejection Series Mode Rejection Thermocouple Inputs Measurement Accuracy Linear
107. utput 2 For a Relay Output the cycle time should be as large as possible whilst remaining compatible with the process control requirements in order to maximise relay life For an SSR Output the cycle time may have a lower value and thus satisfy the requirements of a fast changing process variable e g flow or pressure The permitted range of values is 0 5 1 2 4 8 16 32 64 128 256 or 512 seconds The default value is 32 seconds This parameter is not applicable if Proportional Band 1 or Proportional Band 2 is set to O 3 2 19 Process High Alarm 1 Value This parameter applicable only when Alarm 1 is selected to be a Process High alarm defines the process variable value at or above which Alarm 1 will be active Its value may be adjusted between Input Range Maximum and Input Range Minimum Its default value is Input Range Maximum The operation of a process high alarm is illustrated in 3 2 20 Process Low Alarm 1 Value This parameter applicable only when Alarm 1 is selected to be a Process Low alarm defines the process variable value at or below which Alarm 1 will be active Its value may be adjusted between Input Range Maximum and Input Range Minimum Its default value is Input Range Minimum The operation of a process low alarm is illustrated in 3 2 21 Band Alarm 1 Value This parameter applicable only if Alarm 1 is selected to be a Band Alarm defines a band of process variable values centred on the setpoint value If t
108. wards plastics applications The function of the Controller is best described in terms of the control it exercises over the process and the use of its alarms 1 2 1 Control The temperature at which the process must operate is called the setpoint SP The actual process temperature which is being measured and controlled is called the process variable PV Thus if the setpoint is adjusted to 200 C the Controller endeavours to maintain the process variable at 200 C PID control also known as three term control is a well proven and widely used method for high accuracy automatic control Best results are obtained when the Controller is correctly tuned easily achieved by just letting the Controller tune itself to your process using the automatic tuning features Heater current is controlled via Output 1 Although the heater can only be either fully on or fully off the process reacts only to the average power assuming heater on off periods are sufficiently brief The PID algorithm can control average power very accurately thereby ensuring smooth and accurate control of the process This method of controlling output power is very common and is known as time proportioning An adjustable Cycle Time parameter determines the duration of each on off output cycle Longer cycle times prolong mechanical relay contact life shorter cycle times normally using solid state relays will be needed on processes which react more quickly Output 2 can be used
109. will release the Controller from its rear connectors in the housing and will give access to the Controller PCBs Take note of the orientation of the Controller for subsequent replacement into the housing The positions of the PCBs in the Controller are shown in Figure 2 1 RS485 Communications Option PCB or Front Panel Dual Setpoint Quick Transfer Option PCB Output 3 Option PCB Relay or DC Output DC Output only Output 2 Option PCB Relay SSR Drive Solid State or NOTE Dual Relay with Output 4 For convenience only the 1 16 DIN instrument is shown The 1 8 DIN instrument has an identical PCB arrangement Figure 2 1 PCB Positions 2 1 5075 2 0075 Top of Front Panel Output 3 Option PCB Power Supply PCB Output 2 Option PCB REAR VIEW OF UNHOUSED CONTROLLER Tongues become dis engaged Figure 2 2 Removing the Output 2 Output 3 Option PCBs 5075 2 2 2 0075 2 2 REMOVING REPLACING THE OUTPUT 2 OUTPUT 3 OPTION PCBs With the Controller removed from its housing 1 Gently push the rear ends of the CPU PCB and Power Supply PCB apart slightly until the two tongues on each of the Output 2 Output 3 Option PCBs become dis engaged see Figure 2 28 The Output 2 Option PCB tongues engage in holes in the Power Supply PCB and the Output 3 Option PCB tongues engage in holes on the CPU PCB 2 Carefully pull the required Option PCB Output 2 or Output 3 from its connect
110. y 00040 De activate the Self Tune Facility 00050 Request Pre Tune 2 00060 Abort Pre Tune 00150 Activate Output Turn Off 00160 De activate Output Turn Off 5 6 0075 5 0075 NOTES TABLE 5 2 Cont 00170 Enable Short Circuit Heater Break Alarm 00180 Disable Short Circuit Heater Break Alarm 4 00190 Heater Nominal Current Quick Transfer l Only if AM Key Usage PoEn 2 The Controller will go into Pre Tune Mode only if the process variable is at least 5 of input span from the setpoint 3 Only if AM Key Usage OoFF 4 Not applicable if Heater Break Input Type is configured to be SCRi 5 Only available if Heater Break Alarm Strategy is set to Percentage Mode 5 3 INDIVIDUAL PARAMETERS Unless otherwise stated the DATA element will follow the standard five digit format and the decimal point position must be correct for the new value to be accepted and for modification to occur 5 3 1 Input Parameters 5 3 1 1 PROCESS VARIABLE OR MEASURED VARIABLE Pj M This parameter may be interrogated only using a Type 2 message If the process variable is out of range the five digit DATA field in the reply will not contain a number but will contain lt gt 0 over range or lt gt 5 under range 5 3 1 2 PROCESS VARIABLE OFFSET Pj v This parameter may be modified interrogated using a Type 2 message or a Type 3 4 message sequence It modifies the actual process variable value as measur
111. y contact mains line supply should be switched and fused in a similar manner but should be separate from the Controller mains line supply 1 3 2 24V Nominal AC DC Supply The supply connections for the 24V AC DC option of the Controller are as shown in Figures 1 4 and 1 5 Power should be connected a two pole isolating switch and a 315mA slow blow anti surge Type T fuse With the 24V AC DC supply option fitted these terminals will accept the following supply voltage ranges 24V nominal AC 50 60Hz 20 50V 24 nominal DC 22 65V 1 3 3 Thermocouple Input The correct type of thermocouple extension leadwire or compensating cable must be used for the entire distance between the Controller and the thermocouple ensuring that the correct polarity is observed throughout Joints in the cable should be avoided if possible The Controller s CJC facility must be enabled normal conditions for this input see Subsection NOTE Do not run thermocouple cables adjacent to power carrying conductors If the wiring is run in a conduit use a separate conduit for the thermocouple wiring If the thermocouple is grounded this must be done at one point only If the thermocouple extension lead is shielded the shield must be grounded at one point only 5075 1 1 5 0075 1 3 4 RTD Inputs The compensating lead should be connected to Terminal 4 DIN Controllers or Terminal 3 DIN Controllers For two wire RTD inputs T

1/8-DIN & 1/16-DIN PLASTICS CONTROLLERS Product Manual

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1/8-DIN &amp; 1/16-DIN PLASTICS CONTROLLERS Product Manual

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1/8-DIN & 1/16-DIN PLASTICS CONTROLLERS Product Manual