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PCU Manual PDF - Red Lion Controls

1. 39 Configure Module 1 Input Parameters 1 IN 4 39 Configure Module 2 Output Parameters 2 OP 40 Configure Module 3 Lockout Parameters 22 41 Configure Module 4 Alarms 4 AL 42 Configure Module 5 Secondary Output Parameters 5 O2 43 Configure Module 6 Serial Communications 6 SC 41 44 Configure Module 7 Second Analog Input 7 2N 45 Configure Module 8 Valve Positioner 8 VP 45 Configure Module 9 Factory Service Operations 9 FS 46 RS485 SERIAL COMMUNICATIONS INTERFACE 47 Communication Format dr diritta d a eden nte CES 47 Sending Commands And Data tne e RT Aeneas ede ae Ye pr PEE RETE 47 Output Stats ccce 9 9 Ra TS e edes cu mes sd pir 48 Receiving Dati EAE ATA 50 Serial Connections dts as edad ose es pau loves dS UE ls qe iE 52 Terminal DGSCEIDUOHS za pirlo pattes Re Ri e Bua idR 52 Connecting
2. 36 Second Analog Input Scaling Points dSP1 dSP2 2 36 Display Values ASP amp dSP2 catania ati Naka eec dace 36 Signal Input Values NPI amp INP2 Y siii ie Oodd 36 Keyqin Methods de CO eX OU Seb eer wind aon cds 36 signal Input Method ew swe ede RR ERO EE QR Ord s 36 Local Remote Setpoint Transfer Modes SPtr 2 2 37 Secondary Output Power Dampening OPd2 37 Valve Positioner Module 8e VB wena pe cep AUR UR Recte egeo od OR 37 Valve Position 1 And Valve Position 2 VPSI 2 37 Valve Update Time VUdt Position And Velocity Mode 38 Valve Position Deadband VPdb Position 1 38 Valve Fail Time Alarm VFAL Position Mode 38 Valve Motor Open Time And Valve Motor Close Time VOPt VCLt Velocity mode 38 Valve Minimum On Time VONt Velocity Mode 1 38 Factory Service Operations Module 9 FS 38 Reference Tables Configuration Parameter Modules
3. These alarm modes latch the outputs when the output is ON when selected for latched operation Caution In applications where equipment or material damage or risk to personnel due to controller malfunction could occur an independent and redundant process limit indicator with alarm outputs is strongly recommended Red Lion Controls offers various units such as an IMP IMD1 or IMD2 that may be used for this purpose The indicators should have input and AC power feeds independent from the other equipment Alarm Action Act1 2 The alarm s may be independently configured for one of the following modes Absolute High Acting A Hi Absolute Low Acting A LO Deviation High Acting d Hi Deviation Low Acting 9 10 Relative to Setpoint Band Inside Acting b in Local or Remote Band Outside Acting b Ot Second Analog Input Alarm On models equipped with the Second Analog Input the alarm s may be configured to monitor the second input reading in addition to the main input Refer to the corresponding alarm operation figures for operation modes Note that deviation and band alarm modes are only valid for Internal Cascade operation Absolute High Acting 2 2 Absolute Low Acting 2 210 Deviation High Acting 2 d2HI Deviation Low Acting 2 9210 Relative to SP 2 Second Band Inside Acting 2 b2IN Input Internal Cascade Band Outside Acting 2 6201 29 Valve Fail Alarm VFAL On mod
4. 11 OPERATION OVERVIEW ee 9 yes UNES ea 12 Controller PO Wer Wp NOT Bondoc ro E GE Eu 12 Controller PowerDown 24 20 00 e dune 12 Process Start Up ici 24h oe sra e pelle datas ss a ss 12 Manual User amp Automatic Operation 1 12 Remote And Local Setpoint Op ration eos ee LER Up RR RR 13 Conmfigtiration OF Parameters 425 2 a a e aie ne A 14 Parameter EMEY pap os 15 Normal Display Mode TTL 15 Modifying A Secondary Display Parameter From The Front 1 15 UNPROTECTED PARAMETER MODE 4 4 16 Unprotected Parameter Mode Reference Table 16 PROTECTED PARAMETER MODE x eher REESE EIE REPE aU 18 Protected Parameter Mode Reference Tables sc cscs wees Re RES 4 40 18 FRONT PANEL PROGRAM DISABLE 19 Models With User Input es fc ccs eR t RR Per wus Shade Rew ET ee aus Red 19 Models With Pr
5. 100 1 100 100 1 amp 2 100 If secondary output is installed Set gt OPLO If secondary output is installed Input overdrive power preset 0 to 100 OP 1 100 to 100 OP1 amp OP2 0 Set to a value to safely control the process in the event of input overdrive condition Output power dampening filtering time ON OFF control hysteresis Auto tune dampening mode 0 to 250 seconds 3 in 1 to 250 Hysteresis for OP1 1 0 0 to 4 0 0 off no dampening Set in range of to of integral time 0 fastest response 4 slowest response Display Parameter Linear DC output assignment Range and Units Factory Setting Value OP output power INP scaled display value SP setpoint value dEv deviation dE 2 Internal Cascade Secondary deviation SP 2 Internal Cascade Directed Setpoint OP Description Comments This parameter appears if analog option is installed Linear DC output low scaling value 999 to 9999 0 0 Units depend on ANAS selection This parameter appears if analog option is installed Linear DC output high scaling value 999 to 9999 100 0 Units depend on ANAS selection This parameter appears if analog option is installed Linear DC output deadband Linear DC update time 40 0 0 to 25 0 0 0 0 to 250 seconds 0 Only used when ANAS OP 0 0 n
6. Host Terminal 1 esee iii e Re 53 Troubleshooting Serial Communications 2 53 VALVE POSITION OPTION 21 da e ern sae iR xy ER Ore Ee Ea 54 Position Mode Valve Control 4 cada cng Rr Re RR SEES es 54 Velocity Mode Valve ed b du Bets aden RES ETE 55 SECOND ANALOG INPUT OPTION 56 Remote SELDOM eas ede dp dot aie ere popa ates 56 Flow Ratio Control ne x BRUT E PE SR ver aa go 56 Process Remote Setpoint Slave Control si i RR EN RR 56 Cascade Control soca CHE EEG edes s UR RE UR Rs 56 External Cascade Control 502200220 bed eae NR UR RARUS I ha 57 Internal Cascade Control visier aa eee oe e pes Race deeds 58 EID CONTROL ride EE Dn REUNIR ES ue da S REI ONE RUE Ede EUN 59 Proportional Band cha um bos ean Ins Es nega A Bae 59 Integral cuts Mu M M NEN 59 Derivative usines E Ne ete Hc 60 Output Power Offset Manual Reset essere ROLES RR CNN E AN UE 60 PID Adg st
7. 42 Alarm 2 operation mode Alarm 2 reset mode Range and Units Factory Setting Value A HI absolute high A LO absolute low d HI deviation high d LO deviation low b IN band inside b ot band outside A2HI absolute high second input A2LO absolute low second input d2HI deviation high second input cascade d2LO deviation low second input cascade b2lN band in second input cascade b20t band out second input cascade Auto automatic LAtc manual reset Auto Description Comments If changed check alarm values Manual reset via hidden mode Alarm 2 standby function delay yes no no Power up standby delay Alarm 2 value 999 to 9999 0 0 If band alarm action then only a positive value can be entered AHYS Alarm Hysteresis 1 to 250 Applies to both value 0 1 alarms Set to eliminate chatter Configure Module 5 Secondary Output Parameters 5 02 Unit returns to configuration access point if secondary output option is not installed Display Parameter 2 Secondary output cycle time Relative gain Range and Units Factory Setting Value 0 to 250 sec Description Comments 0 turns OP2 off 0 0 places secondary output into ON OFF control mode and db 2 becomes hysteresis value Overlap deadband 999 to 9999 0 0 Positive value is deadband Negative value is overlap If GAN2 0 this
8. CALIBRATION 78 Calibration Checle A Ne 78 bici 78 Current Reading Check 52255 44 pedes Seen HERR AR aed e ep 78 Linear DC Output Check oes nog None BEL eae ie er dod ea 78 AO 20 TWA ses grex ei I dog dere 78 VDE es sets aes done DERE ee dee a he 78 Second 25 4 glee warned Ghee Puro de ede Ced qum 78 Second Analog Input Check rece dice eS 78 Valve Positioner Check ta dead aa ade es 78 Calibratioli 2422 cits reale cha pre adda dyes pp ere RES UM Ee aiebat sis 79 Configure Step 9 Factory Service Operations 9 Fs 79 Voltage Calibration sr usino vr EGER X a ares ete nre Fab d eg eines 79 Current Calibration iii bee seals cab aden ie bed LUE VER OR ds s 79 Analog Output Calibration ANCL Popp Re xao ERROR RAI Fs 79 ised Aue 79 Oto tans doe hee 79 Second Analog Input Calibration 2CAL 2 80
9. 0 0 is off This parameter does not appear if proportional band 2 0 0 Second Analog Input models only Display Units Factory pi Setting Value Derivative 0 to 9999 015 off This parameter does not Time 2 0 appear if proportional band 2 0 0 Secondary Second Analog Input models only Internal 999 to 9999 Second Analog Input models only Cascade N A Read only parameter Directed 0 001 to 9 999 Second Analog Input models Setpoint ratio 1 000 multiplier Remote n to 9999 Second Analog Input models Setpoint bias offset m to 9999 This parameter does not appear if the Value 0 alarm option is not specified the secondary output option is installed or if locked LOC Configuration Return to normal display mode Access Point Enter Configuration modules Configure input parameters Configure output parameters Configure parameter lockouts Configure alarm parameters opt Configure secondary output opt Configure serial communication parameters optional Configure second analog input parameters optional Configure valve positioner parameters optional service operations Qualified End Unit returns da display message to Normal Display Mode 417 PROTECTED PARAMETER MODE The Protected Parameter Mode is accessed from the normal display mode by pressing the PAR button with program disable active In this mode the operator
10. Second Analog Input Remote Setpoint 80 Motorized Valve Positioner oed esr be Eq ads SY ES da eae eee 80 APPENDIX F USER PARAMETER VALUE CHART 81 APPENDIX ORDERING INFORMATION 84 vi GENERAL DESCRIPTION The PCU Controller accepts either a 0 to 10 VDC or a 4 to 20 mA DC input signal precisely scales the process signal according to programmable scaling points and provides an accurate output control signal time proportional linear or valve positioning to maintain a process at the desired control point Acomprehensive set of easy to use steps allows the controller to solve various application requirements The controller can operate in the PID control mode for both the main output and optional secondary output On demand auto tune establishes the tuning constants The PID tuning constants may be fine tuned by the operator at any time and locked out from further modification The controller employs a unique overshoot suppression feature that allows the quickest response without excessive overshoot The unit can be transferred to operate in the manual mode providing the operator with direct control of the output The controller can also be programmed to operate in the ON OFF control mode with adjustable hysteresis Dual 4 digit displays allow viewing of the measured val
11. the parameter must be called to alter the value PAR The Parameter PAR button is used to access enter the change and scroll through the available parameters in any mode 411 OPERATION OVERVIEW CONTROLLER POWER UP Upon applying power the controller delays control action and process indication for five seconds to perform several self diagnostic tests and display basic controller information Initially the controller illuminates both displays and all annunciators to verify that all display elements are functioning The controller then displays the programmed input type in the main display Concurrently it displays the current revision number of the operating system software in the bottom display The controller checks for correct internal operation and displays an error message E XX if an internal fault is detected see Troubleshooting page 73 for further information Upon completion of this sequence the controller begins control action by displaying the process value and updating the outputs based upon the PID control calculation CONTROLLER POWER DOWN At power down the steady state control value as well as all parameters and control modes are saved to provide a quick and predictable process response on the next power up When powering down the process it is important to power down the controller at the same time This prevents the reset action of the controller from shifting the proportional band while the process signa
12. 09 DRAWING NO LP0265 Red Lion Controls China Unit 101 XinAn Plaza Building 13 No 99 Tianzhou Road ShangHai P R China 200223 Tel 86 21 6113 3688 Fax 86 21 6113 3683
13. 17 Print Proportional Band 2 18 Print Integral Time 2 19 Print Derivative Time 2 Print Second Input Reading 2 Print Remote Setpoint Reading Print Secondary Setpoint Value A print out from PCU unit with an address of 1 and all print options selected is shown below 1 INP 500U SET 525U PWR 20 0 PBD 4 0 INT 1205 DER 30S ALI 6000 AL2 475U DEV 25U OFP 0 0 RMP 0 0R CRG 1 0G CDB OU OSt 1001 RAt 1 000R BIAS 0U Pb2 4 0 It2 120S dt2 305 IN2 100 0U RSP 00 SP2 0 0U Bee ee ee Note If the secondary output option is installed AL2 is not printed or functional SERIAL CONNECTIONS When wiring the terminal block at the rear of the unit refer to the label with the terminal description for installing each wire in its proper location It is recommended that shielded screened cable be used for serial communications This unit meets the EMC specifications using Alpha 2404 cable or equivalent There are higher grades of shielded cable such as four conductor twisted pair that offer an even higher degree of noise immunity Only two transceiver wires and a common are needed The two data transceiver wires connect to the TX RX and TX RX terminals appropriately The cable should consist of a shielded twisted pair and in some applications a signal ground may be required to establish a ground reference The signal ground is required if the equipment does not ha
14. COMMUNICATIONS If problems are encountered when interfacing the PCU s and host device or printer the following check list can be used to help find a solution 1 Check all wiring Refer to the previous application examples and use them as a guide to check your serial communication wiring Proper polarity of all units and other peripherals must be observed 2 the PCU is connected to a host computer device or printer make sure that the computer or device is configured with the same baud rate and communication format as the PCU The communication format the PCU accepts 15 1 start bit 7 data bits no parity or 1 parity bit odd or even and 1 stop bit 3 Check the PCU s unit address If the Address command is not used when transmitting a command to the PCU the PCU s address must be set to 0 See Sending Commands amp Data page 47 for command structure 4 If two way communications are to be established between the PCU and a computer the computer must receive a transmission from the PCU first Activating the User Input programmed for the print request function initiates transmissions from the PCU 5 When sending commands to the PCU an asterisk 2Ah must terminate the command After system power up an asterisk must be sent to clear the PCU input buffer 6 In multiple unit configurations each unit must have a different address other than zero 7 If all of the above has been done try reversing the polarity of the transceiver
15. DERIVATIVE TIME DECREASE DERIVATIVE TIME CHECK CYCLE TIME Figure 32 Process Response Extremes 61 ON OFF CONTROL The controller operates in the ON OFF control mode by setting the proportional band 0 0 The ON OFF control hysteresis band CHYS parameter eliminates output chatter around setpoint The Secondary output can also be used in the ON OFF control by setting the relative gain 0 0 GAN2 Additionally the deadband parameter db 2 determines the amount of operational deadband or overlap between the two outputs The phase of the control action can be reversed by the output control action parameter ON OFF control is usually characterized by signal oscillations about the setpoint value Large hysteresis values make the oscillations larger ON OFF control should only be used where the constant oscillations are acceptable REVERSE ACTING PROCESS OUTPUT OFF OUTPUT OFF TPUT ON LED OFF 1 LED OFF Se FORWARD ACTING 4 LA OUTPUT OFF OUTPUT OFF LED OFF era LED OFF Figure 33 OP1 On Off Action 62 REVERSE ACTING PROCESS Pam HYS OUTPUT OFF OUTPUT OFF LED OFF ae ON LED OFF BEGGESS FORWARD ACTING OUTPUT OFF OUTPUT OFF TPUT ON LED OFF EL DN LED OFF Figure 34 OP2 On Off Action ON OFF and PID control can be used for the main output and the DEADBAND db 2 gt 0 secondary out
16. Figure 9 Valve Positioner Wiring Although RC snubbers are employed inside the controller to suppress inductive kicks from the motor it may be necessary to take further action to reduce noise effects 1 Use Triac Output Modules wherever possible The Triac device significantly reduces radiated EMI Electromagnetic Interference The Triac Output Module also does not suffer from mechanical wear of the contacts 2 Use RC snubbers directly across the valve motor 3 Use a separate AC supply for the valve motor Where possible the valve motor control outputs and the slidewire feedback input routing should be physically separated Noise interference from the outputs could couple into the slidewire feedback inputs disrupting proper operation The slidewire feedback inputs connect to the terminals labeled Slidewire Feedback Inputs The terminal placement varies with each model see the controller label for the actual terminals For Velocity mode valve control the slidewire feedback inputs are not necessary In some cases it may be desirable to have an independent valve position indicator Red Lion Controls Model IMDI be wired in parallel with the slidewire input s Wiper and Comm terminals for this purpose The approximate 0 to 0 9V signal can be scaled to indicate percent valve position Linear DC Output Wiring Units with Linear DC output option have two terminals to output a 4 to 20 mA or0 to 10 VDC signal The type
17. INt Integral Time yes no no Setpoint no Second Analog Input yes no no P2 IN2 44 Configure Module 7 Second Analog Input 7 2N Unit returns to configuration access point if Second Analog Input option is not installed Display Parameter Second Analog Input operation mode Square root linearization Second Input decimal point position Range and Units Factory Setting Value CSCd Internal Cascade mode rSP Remote Setpoint mode 0 0 0 0 00 or 0 000 0 0 Description Comments Remote Setpoint mode also for External Cascade Linearization applies to the Second Input Normally same position as main input for Remote Setpoint Second Input scaling point 1 displ Second input scaling point 1 input value 999 to 9999 0 0 9 99 to 99 99 4 00 Normally key in process low value Either key in value or press DSP for measure record mode Second Input scaling point 2 displ Second input scaling point 2 input value Local Remote Setpoint transfer action 999 to 9999 100 0 9 99 to 99 99 20 00 nor normal Auto automatic trAC track nor Normally key in process high value Either key in value or press DSP for measure record mode Applies only to Remote Setpoint mode Secondary output power dampening 0 to 250 seconds O off 45 Configure Module 8 Valve Positioner 8 VP Unit returns to config
18. VPdb Valve Positioner Deadband VFAL Valve Positioner Fail Time Alarm VOPt Valve Positioner Motor Open Transit Time VCLt Valve Positioner Motor Close Transit Time VONt Valve Positioner Minimum On Time CONTROLLER OPERATING MODE Local or Remote Setpoint Automatic or Manual Auto tune Invoked at 83 APPENDIX ORDERING INFORMATION MODELS WITHOUT SECOND INPUT OPTIONS 4to 20 mA 0 to 10 VDC PART ANALOG ANALOG ALARM SECONDARY NUMBER OUTPUT output OUTPUTS OUTPUT 115 230 VAC NEMA 4X IP65 PCU01000 PCU01001 PCU10000 PCU10001 PCU10002 PCU11000 PCU11001 PCU11002 PCU11004 PCU1100 PCU12001 PCU12004 PCU1200 These models have dual alarm outputs or single alarm with secondary outputs with shared common terminals Form A Type As a result these outputs should be fitted with the same type of output module The main output OP1 may be fitted with any type of output module SECOND ANALOG INPUT MODELS ANA NEMA 4to 20 mA 0 to 10 VDC PART 4X IP65 ANALOG ANALOG ALARM SECONDARY NUMBER BEZEL OUTPUT OUTPUT OUTPUTS OUTPUT 115 230 VAC YES NO NO 2 NO YES PCU10104 YES NO YES 2 NO NO PCU12108 These models have dual alarm outputs or single alarm with secondary outputs with shared common terminals Form A Type As a result these outputs should be fitted with the same type of output module The main output OP1 may be fitted with any type of output m
19. and record these positions To engage this mode press the DSP button while either VPS1 or VPS2 parameters are called PW and DEV annunciators flash to indicate this mode The valve may then be positioned directly through the use of the front panel UP and DOWN buttons The UP button causes the valve to move open and the DOWN button causes the valve to move closed Simultaneously the controller indicates the slidewire position After the valve has been moved to the desired position by use of the button and observing the display press PAR to record the position This technique is preferred because it compensates for leadwire resistance errors Valve Position 1 And Valve Position 2 VPS1 VPS2 2 Use the specifications provided by the valve manufacturer Divide the closed and open position resistance values by the total slidewire resistance to yield percentage values Directly key in the values as a percentage 3 Measure the resistance of the open and closed positions and divide by the total slidewire resistance to yield percentage values Directly key in the percentage values Valve Update Time VUdt Position And Velocity Mode The valve update time is the time interval in which the valve position outputs are updated The update time may be increased to reduce valve activity Valve update times up to 1 10 of the integral time or process time constant may be used with good results Longer update times may adversely affect con
20. close to control the direction of motor rotation The motor position defines the opening position at the valve Two control modes are possible position control which makes use of the slidewire feedback signal supplied with the positioner and velocity control in which no slidewire feedback signal is used Parameters are provided to adjust the operation of the valve These include Valve activity hysteresis Valve update time Variable control dampening Slidewire signal fail action Adjustable valve position limits The Valve Positioner PCU achieves tight process control yet minimizes unnecessary valve activity An alarm event output or display alarm can be programmed under loss of slidewire feedback or under valve fail detection The optional Second Analog Input 0 to 20 mA DC can be configured as a Remote Setpoint signal or as a Secondary Process signal Configuration of the Second Analog Input as a Remote Setpoint signal allows ratio control master setpoint multiple slave operation and the ability to cascade the PCU with another controller External Cascade Configuration of the Second Input as a Secondary Process signal allows operation as a two process cascade controller within a single unit Internal Cascade In either control mode parameters are provided to scale configure communicate and monitor the activity of both analog inputs A square law linearizer function can be used to linearize signals derived from flow trans
21. has access to the list of the most commonly modified controller parameters that have been unlocked in the configuration parameter module access to the unprotected parameter mode and hence the configuration parameter modules is possible The controller returns to the normal display mode if the unprotected mode and configuration modules cannot be accessed This mode cannot be accessed if all parameters are locked lockouts module Depending on the code number entered in the lockout PROTECTED PARAMETER MODE REFERENCE TABLE Parameter Display Proportional Band Integral Time Range and units Factory Setting Value 0 0 to 999 9 of scaled input range 4 0 0 to 9999 sec 120 Description Comments 0 0 is ON OFF control If using ON OFF mode set control hysteresis appropriately This parameter does not appear if locked LOC 0 is off This parameter does not appear if proportional band 0 0 or locked LOC Derivative Time 0 to 9999 sec 30 0 is off This parameter does not appear if proportional band 0 0 or locked LOC Proportional Band 2 Secondary 0 0 to 999 9 of scaled input range 4 0 0 0 is ON OFF control Second Analog Input models only Integral Time 2 Secondary Derivative Time 2 Secondary Internal Cascade Directed Setpoint 0 to 9999 sec 0 0 to 9999 sec 0 999 to 9999 N A 0 is off This parameter does not a
22. leads of the appropriate resistor and remove it from the unit Be sure to remove the resistor for only the problem alarm channel leave the other channel s snubber functional in case it is needed The above stated leakage currents are valid when using the Relay Module OMD00000 The Triac Module OMD00001 has it s own built in snubber and will introduce additional leakage current into the circuit The Triac Module has leakage current of 2 1 mA nominal at a line voltage of 120 VAC and 4 3 mA nominal at 240 VAC Note The Snubber Network will be in one of the two configurations shown at right depending on model ordered 75 Figure 40 Snubber Locations APPENDIX MANUAL TUNING OPEN LOOP STEP RESPONSE METHOD The Open Loop Step Response Method is a tuning procedure that does not induce process oscillations This method involves making a step change to the process and observing the process reaction A strip paper recorder or other high resolution data logging equipment is required for this procedure This procedure requires that all disturbances to the process are minimized because the data is influenced by these disturbances 1 Connect a chart recorder to log the process value and set the paper speed appropriate for the process 2 Set the controller to manual user control mode 3 Allow the process to stabilize line out 4 Make a step change of 10 or more in the controller output It may be necessary to increase t
23. of Linear DC output is determined by the model ordered See Ordering Information page 84 for available models These terminals are labeled 4 20 mA or 0 10 VDC Analog Output Option Out and Out The common of this output is isolated from main input common but is not isolated from the Second Analog Input Option common For proper operation always keep these commons isolated Second Analog Input Wiring Units with Second Analog Input option have two input terminals to receive a4 to 20 mA signal These terminals are labeled Second Input 4 20 mA and 4 20 mA Terminal placement varies with model See unit label for actual terminals The common of this input is isolated from main input common but is not isolated from the Linear DC Output common For proper operation always keep these commons isolated Program Disable User Input Wiring Some models have Terminal 7 as the User Input which is programmable for a variety of functions Other models have Terminal 7 dedicated to the program disable function Any form of mechanical switch may be connected to terminal 7 Sinking open collector logic with less than 0 7 V saturation may also be used no pull up resistance is necessary Note Do not tie the commons of multiple units to a single switch Use either a multiple pole switch for ganged operation or a single switch for each unit 10 AC Power Wiring Primary AC power is connected to the separate two position terminal bloc
24. parameter is OP2 ON OFF control hysteresis 43 Configure Module 6 Serial Communications 6 SC Range and Units Unit returns to configuration access point if 5485 serial option is not Display Parameter Factory Setting Description installed Value Comments i AL2 Alarm 2 es no Range and Units Description y Display Parameter Factory Setting Comments no Value dEv Deviation From yes no bAUd Baud rate 300 to 9600 Baud rate of unit must Setpoint no h 1200 4 Output Power Offset PArb Parity bit odd even no parity Parity of unit must odd match other equipment Setpoint Ramp Rate yes no Unit address 0 to 99 For multiple units each no 0 unit must have a unique Crg Relative Gain yes no address no Abbreviated or yes no Selecting yes the Cdb Deadband full transmission no controller does not transmit mnemonics Auto print rate 0 to 9999 0 disables auto print 0 function Print options yes no Selecting yes allows rAt Remote Setpoint Ratio yes no no print options shown no below to be DIA Remote Setpoint Bias Ost Output Status INP Input Process yes no Value es SEt Setpoint yes no es Pb2 Secondary Proportional yes no Secondary Integral yes no OPr Output Power yes no Time no es dt2 Secondary Derivative programmed Proportional yes no 5 dEr Derivative Time yes no no AL1 Alarm 1 yes no no
25. rear of the unit so that the tabs of the panel latch engage in the slots on the case The panel latch should be engaged in the farthest forward slots possible Tighten the screws evenly until the unit is snug in the panel 4 NEMA 4X IP65 UNIT INSTALLATION The optional NEMA 4X IP65 PCU Controller provides a watertight seal in panels with a minimum thickness of 1 8 inch The units meet NEMA 4X IP65 requirements for indoor use when properly installed The units are intended to be mounted into an enclosed panel Prepare the panel cutout to the dimensions shown in Figure 1 Panel Installation amp Removal Carefully apply the adhesive side of the panel gasket to the panel cutout Remove the panel latch and cardboard sleeve from the unit Discard the cardboard sleeve The unit should be installed with the bezel assembly in place and the bezel screws tightened slightly Insert the unit into the panel cutout While holding the front of the unit in place push the panel latch over the rear of the unit so that the tabs of the panel latch engage in the slots on the case The panel latch should be engaged in the farthest forward slot possible To achieve a proper seal tighten the latch screws evenly until the unitis snug in the panel Torque to approximately 7 in lbs 79 N cm Do NOT over tighten the screws Note The installation location of the controller is important Be sure to keep it away from heat sources ovens furnaces etc away from direct c
26. secondary display parameters The Setpoint value and output power in manual mode are the two parameters which may be modified The other parameters are read out values only Setpoint Value Use the up and down arrow buttons to modify the setpoint value when viewed if not locked If locked the setpoint can be changed in the unprotected mode when SP is viewed independent of viewing in the secondary display The setpoint value is confined to the programmable setpoint limit values SPLO amp SPHI Input Module 1 Output Power The Output Power can only be changed when the unit is in the manual mode See Manual User and Automatic Operations page 12 The annunciator 6 PW lights and the Manual annunciator flashes when viewed Use the up and down arrow buttons to modify the Output Power if not locked If locked the output power can be changed in the unprotected mode when is viewed independent of viewing the secondary display The output poweris not confined to the programmable output power limit values OPLO amp OPHI Output Module 2 UNPROTECTED PARAMETER MODE The Unprotected Parameter Mode is accessed by pressing the PAR button from the normal display mode with program disable inactive In this mode the operator has access to the list of the most commonly modified controller parameters At the end of the list a configuration access point allows the operator to enter the configuration paramet
27. shown with the output in the automatic reset mode Note Select the alarm action with care In some configurations the front panel indicator LED might be OFF while the output is ON Alarm Action Figures DEVIATION HIGH ACTING WITH POSITIVE ALARM VALUE d HI PROCESS A ABSOLUTE HIGH ACTING ALARM A HI PROCESS 1 HYS SP v OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON V OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON A T W ACTING ALARM BSOLUTE LO CTING AL DEVIATION HIGH ACTING WITH NEGATIVE ALARM VALUE d HI PROCESS A PROCESS SP Buys SP AL Tu V OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF LED OFF LED ON LED OFF LED ON 30 BAND INSIDE ACTING b IN DEVIATION LOW ACTING WITH POSITIVE ALARM VALUE d LO PROCESS PROCESS OUTPUT OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON LED OFF LED ON LED OFF LED ON LED OFF DEVIATION LOW ACTING WITH NEGATIVE ALARM VALUE 4 10 PROCESS PROCESS BAND OUTSIDE ACTING b Ot SP AL SP SP AL v OUTPUT OFF OUTPUT ON OUTPUT OFF OU
28. standard single loop control Since the Primary and Secondary see different processes they normally have different tuning values with the Secondary normally faster responding The PCU is capable of two modes of Cascade control External Cascade and Internal Cascade External cascade involves the use of two controller units one of which is a Remote Setpoint controller Internal Cascade has both the Primary and Secondary control loops implemented within one controller unit External Cascade Control External Cascade Control involves the use of two controllers one of which has a Remote Setpoint Input The outer loop controller Primary controller directs the setpoint of the inner loop controller Secondary controller through the linear DC 4 to 20 mA output The Secondary controller has a Second Analog Input option configured as a Remote Setpoint RSP in order to receive the directed setpoint See Figure 26 for more details The Remote Setpoint of the Secondary controller must be scaled prior to tuning the controllers Normally the Remote Setpoint is scaled to equal the actual process range of the secondary Scaled in this way the Primary controller can direct the setpoint of the Secondary controller over its operating range The internal Remote Setpoint value is as follows Remote Setpoint Scaled Second Analog Input Ratio Parameter Bias Parameter Example A TCU temperature input and PCU process input are used in an Exte
29. there is a 100 msec minimum to 200 msec maximum built in time delay after each transmission string and after each block of transmission When interfacing to a printer sending mnemonics are usually desirable 50 Examples of transmissions are shown below 1 INP 500U lt CR gt lt LF gt 100 200 msec 1 SET 525U lt CR gt lt LF gt 100 200 msec 1 PWR 20 lt SP gt lt CR gt lt LF gt lt SP gt lt CR gt lt LF gt 100 200 msec 673 5 lt CR gt lt LF gt 100 200 msec The Print Options provide a choice of which PCU data values are to be transmitted The PCU transmits the Print Options when either the User Input programmed for the print request function is activated a P Transmit Print Options command is sent to the PCU via the serial port or the Automatic Print Rate is set for a specific time The Print Options are programmed in the Serial Communications Module 6 SC with the available options Mnemonics Sent No Mnemonics Sent 1 Print Input Display Value 2 Print Setpoint Value 3 Print Output Power Value 4 Print Proportional Band Value 5 Print Integral Time Value 6 Print Derivative Time Value 7 Print Alarm 1 Value 8 Print Alarm 2 Value 9 Print Deviation From Setpoint Value 10 Print Output Power Offset Value 11 Print Setpoint Ramp Rate Value 12 Print Relative Gain Value 13 Print Deadband Value 14 Print Output Status 15 Print Remote Setpoint Ratio 16 Print Remote Setpoint Bias
30. wires between the PCU s and the RS485 interface card Some cards have the polarity reversed 53 c a a lt 2 a PCU ADDR 3 PCU ADDR 5 TX RX TX RX RS 485 COMM TX RX TX RX RS 485 COMM TX RX TX RX RS 485 COMM OFFICE COMPUTER x TO SERIAL PORT ON COMPUTER WITH RS485 INTERFACE CARD INSTALLED TX RX TX RX TX RX TX RX EAE BE Bee TX RX 0 0 0 ERMINAL NUMBERS ARE MODEL DE SEE LABEL ON UNIT FOR DESCRIP DENT Figure 24 Connecting To A Host Terminal 5 485 COMM Rs 485 comm RS 485 COMM PCU ADDR 2 PCU ADDR 4 PCU ADDR 6 VALVE POSITION OPTION The Valve Position option of the PCU directly controls the position of a valve The Valve Motor Open and Valve Motor Close outputs independently activate the valve motor to position the valve for closed loop control The PCU is capable of two Valve Position control modes Position mode in which valve position slidewire feedback is used by the controller and Velocity mode a special positioning algorithm in which no slidewire signal is required POSITION MODE VALVE CONTROL In Position mode valve control the slidewire resistance representing the valve position i
31. 0 Alarm Reset rSt Ly St2 ease ees oed dene ae i deam s S E AI 32 Alarm Standby Delay Stbl Stb2 cui sedet eer rd ea Up Ro niet ele ce 32 Alarm Value 1 ALI i e etat sls ra oa a e Be Ch ER IE RU ded 32 Alarm Hysteresis AHYS iced resa eer E p pb Ee RE RA E AUR eb Ra d deg 33 Secondary Output Module 5 02 Optional 2 33 Time Proportionins Cycle Time CYC2 rus era aee p oC e ERE D 33 Relative Gain GAN2 2 52 eiae Nu Rer eR OD CRI e t I ck RA cron 33 Overlap Deadband db 2 ere ger RR e 33 Serial Communications Module 6 SC Optional 34 Baud Rate DAUGd ners ORT ees A ue ER HERES REE E URP ET OSEE 34 Parity Bit PATDI din nU pU PEE SEC US OR 34 Address Number Addi sess esee Ie een Sao ses weed bibdate das 34 Abbreviated or Full Transmission 1 34 Print Rate boa alari e SS SS Ea 34 Print Options POPL cirie e ts cR E dig i oe 35 Second Analog Input Module 7 2N Optional 2 2 2 39 Operation mode OPEL sas lia a RA A 35 Square Root Linearization FOOL as LR LARE AR 35 D cimal Point Position dPt2 assesses nese vo UR Ue dede
32. 0 resistors connected in series as 75 Second Analog Input Remote Setpoint shown in Figure 43 Resistor aen Connect precision DC milliampere source 0 01 accuracy to rear Divider Connect one end of the terminals labeled Second Analog Input 4 to 20 and 4 to 20 mA resistor string to the rear 5056 WIPER terminal labeled Slidewire 2500 Display Parameter Description Comments Feedback Inputs Comm and the 25 0 00 mA step Apply 0 00 mA DC press PAR other end to Excitation The 2500 StP2 5 00 mA step Apply 5 00 mA DC press PAR OOO NEED 10 00 mA step 10 00 mA DC press PAR ai points of COMMON the resistor string 15 00 mA step Apply 15 00 mA DC press PAR Figure 43 Resistor Divider 20 00 mA step Apply 20 00 mA DC press PAR Display Parameter Description Comments StP1 0 0 step Connect wiper input to 0 point of divider Comm wait 10 seconds press PAR 25 0 step Connect wiper input to 25 point of divider wait 10 seconds press PAR 50 0 step Connect wiper input to 50 point of divider wait 10 seconds press PAR 75 0 step Connect wiper input to 75 point of divider wait 10 seconds press PAR 100 0 step Connect wiper input to 100 point of divider Excitation wait 10 seconds press PAR 80 APPENDIX F USER PARAMETER VALUE CHART UNIT NUMBER MNEMONIC PARAMETER USER SETTING SP Setpoint OPOF Output Power Offset OP Output Power ProP Proportiona
33. 2 can be entered to gain access to the unprotected mode and configuration modules independent of the programmed code number HIDDEN FUNCTION MODE The Hidden Function Mode is only accessible from the normal display mode by pressing and holding the PAR button for three seconds These functions must be unlocked in Configuration Module 3 Factory settings are locked In this mode these controller functions can be performed Local Remote Setpoint Selection Automatic Manual Transfer Initiate Cancel Auto tune Reset Alarm Events Each function may be locked out in the Configuration parameter lockouts module The PAR button is used to scroll to the desired function and the up and down buttons are used to select the operation Pressing the PAR button while the function is displayed executes the function and returns the unit to the normal display mode Pressing the DSP button exits this mode with no action taken The unit automatically returns to the normal display mode if no action is taken 20 HIDDEN FUNCTION MODE REFERENCE TABLE Display Parameter Range and Units Factory Setting Value Description Comments Select Local or Remote Setpoint LOC Local Setpoint rE t Remote Setpoint LOC Appears only for models with Second Analog Input SPtr determines nature of controller response Transfer mode of operation Auto tune invocation Auto Automatic control User Manual control Auto Y
34. 20 WEIGHT 1 3 lbs 0 6 kgs APPENDIX TROUBLESHOOTING The majority of problems can be traced to improper connections or incorrect set up parameters Be sure all connections are clean and tight that the correct output module is fitted and that the set up parameters are correct For further technical assistance contact technical support at the numbers listed on the back cover of the instruction manual PROBLEMS POSSIBLE CAUSE REMEDIES NO DISPLAY 1 Power off 2 Voltage selector switch in the wrong position 3 Brown out condition 4 Loose connection or improperly wired 5 Bezel assembly not fully seated into rear of unit 1 Check power 2 Check selector switch position 3 Verify power reading 4 Check connections 5 Check installation INDICATOR NOT WORKING 1 Incorrect parameter set up 1 Check set up parameters a Power up unit for self test E FP IN DISPLAY E E2 IN DISPLAY OR IN DISPLAY SENS IN DISPLAY OLOL IN DISPLAY 1 Defective front panel button 1 Loss of set up parameters due to noise spike 1 Input display out of range 2 Loss of set up parameters 3 Internal malfunction 1 Incorrect input wiring 2 Defective transmitter 3 Internal malfunction 1 Input signal overload 2 Loss of set up parameters 1 Press DSP to escape then check all buttons for proper operation 2 Replace unit E UP
35. 20 VAC inductive load Life Expectancy 100 000 cycles at maximum load rating Decreasing load and or increasing cycle time increases life expectancy 12VDC A UNREG 4 sR NOT v B POWER POWER 3 UNIT 2 C ISOLATED m DO NOT CONNECT O LOAD Figure 4 Logic SSR Drive Module Logic SSR Drive Type Non isolated switched DC 12 VDC typical Drive 45 mA Max Can drive multiple SSR Power Units 120VAC TT 11 RELAY OR XV AT TRIAC POWER 120 240 Q DEVICE DO NOT CONNECT O LOAD lese Figure 5 Triac Module Triac Type Isolated Zero Crossing Detection Rating Voltage 120 240 VAC Max Load Current 1 amp 35 C 0 75 amp 50 C Min Load Current 10 mA Off State Leakage Current 7 mA maximum 60 Hz Operating Frequency 20 to 400 Hz Protection Internal Transient Snubber Fused SELECT AC POWER 115 230 VAC The AC power to the unit must be selected for either 115 VAC or 230 VAC The selector switch is located inside the case near the rear of the unit on the main circuit board see Figure 6 Hardware or label on outside of case The unit is shipped from the factory with the switch in the 230 VAC position Caution Damage to the controller may occur if the AC selector switch is set incorrectly OPTIONAL ALARM 2 OR SECONDARY OUTPUT MODULE AL2 0P2 VALVE POSITIONER CLOSE OUTPUT MAIN CONTROL OUTPU
36. 3 4 of the distance between the current process signal value at the instant Auto Tune is started and the setpoint The 3 4 control point was selected to reduce the chance of signal overshoot at setpoint when Auto Tuning at start up If Auto Tuning from setpoint and signal overshoot is unacceptable temporarily lower the setpoint by an amount of the oscillation and then Auto Tune Reset the setpoint to the original value when Auto Tune is complete After starting Auto Tune the secondary display indicates the current phase Autl Aut2 Aut3 amp Aut4 If the controller remains in an Auto Tune phase unusually long the process or connections may be faulty Additionally during Auto Tune it is important that disturbances to the system be minimized as these may have an effect on the parameter determination INITIATE AUTO TUNE Auto Tune may be initiated at start up from setpoint or at any other process signal point To Initiate Auto Tune 1 Make sure that Auto Tuning is enabled in parameter lockouts module 2 Place the controller into the normal display mode 3 Press PAR for 3 seconds from normal display mode 4 Scroll to tUNE by use of PAR if necessary 5 Select YES and press PAR Auto Tune is initiated To Cancel Auto Tune Old PID settings remain in effect A Make sure that Auto Tuning is enabled in parameter lockouts module 1 Place the controller into the normal display mode 2 Press PAR for 3 seconds from normal display mo
37. 300 600 1200 2400 4800 or 9600 baud 7 DATA B 1 STOP BIT PARITY BIT ODD m o lt 2 TO T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 Figure 21 10 Bit Data Format 47 Before serial communication can take place the unit must be programmed to the same baud rate and parity as the connected equipment In addition the loop address number and print options should be known When used with a terminal or host computer and only one unit is employed an address of zero may be used to eliminate the requirement for the address specifier when sending a command If more than one unit is on the line each unit should be assigned a different address number SENDING COMMANDS AND DATA When sending commands to a PCU unit a command string must be constructed The command string may consist of command codes value identifiers and numerical data Below is a list of commands and value identifiers that are used when communicating with the PCU unit Description Address command Followed by a one or two digit address number 0 99 Transmit print options command Transmits the options selected in the Program Options PoPt section Command Reset command Followed by one of the Value Identifiers G or H Transmit value command Followed by one of the Value Identifiers A M O Q W Z AA or BB Control action command Followed by the Value Identifier S or U and number Change val
38. A 0 2 V typ Accuracy 0 15 of reading 10 uA 1 LSD Scale Range 999 to 9999 12 SERIAL COMMUNICATION Type RS485 Multi point Balanced Interface Communication Format Baud Rate Programmable from 300 to 9600 Parity Programmable for odd even or no parity Frame start bit 7 data bits 1 or no parity bit 1 stop bit Unit Address Programmable from 0 to 99 max of 32 units per line Transmit Delay 100 msec min 200 msec max RS485 Common Isolated from signal input common Auto Print Time Off to 9999 seconds between print outs 13 USER INPUT Optional Internally pulled up to 5 VDC Vin 5 25 VDC 0 85 Vmax Vin 3 0 Vum Available on all second input MVP and ANA models and on models with RS485 Response time 100 msec max Functions Program Lock Auto Manual Mode Select Setpoint Ramp Select Print Request Integral Action Lock Reset Alarms Local Remote Setpoint Select 71 14 ALARMS Optional Hardware Plug in replaceable output module Modes Absolute high acting Absolute low acting Deviation high acting Deviation low acting Inside band acting Outside band acting Valve fail Second Analog Input monitoring Reset Action Programmable automatic or latched Standby Mode Programmable enable or disable Hysteresis Programmable Signal Overdrive Action Upscale Annunciator LED backlight for AL2 Alarm 2 not available with secondary output or motorized valve position option 15 ENVIRONMENTAL CONDITI ON
39. DERIVATIVE TIME PROPORTIONAL BAND 2 NORMAL DISPLAY MODE MAIN DISPLAY INDICATES PROCESS VALUE ACTIVE PROGRAM DISABLE PROTECTED PARAMETER MODE PROPORTIONAL BAND INTEGRAL TIME DERIVATIVE TIME PROPORTIONAL BAND 2 INTEGRAL TIME 2 DERIVATIVE TIME 2 DIRECTED SETPOINT RATIO BIAS ALARM 1 ALARM 2 ENTER CODE NUMBER SECONDARY DISPLAY INDICATES ONE OF THE FOLLOWING SETPOINT OUTPUT POWER SECONDARY ANALOG INPUT DEVIATION BLANK DISPLAY INTEGRAL TIME 2 DERIVATIVE TIME 2 DIRECTED SETPOINT RATIO BIAS ALARM 1 ALARM 2 ACCESS CONFIGURATION MODULES INVALID CODE MODEL OR PROGRAMMING DEPENDENT CONFIGURATION PARAMETER MODULES INPUT PARAMETER MODULE OUTPUT PARAMETER MODULE PARAMETER LOCKOUT MODULE ALARM PARAMETER MODULE SECONDARY OUTPUT PARAMETER MODULE SERIAL COMMUNICATIONS MODULE SECOND ANALOG INPUT PARAMETERS MODULE VALVE POSITIONER PARAMETERS MODULE FACTORY SERVICE OPERATIONS MODULE VALID CODE Figure 11 Operational Programming Modes 14 PARAMETER ENTRY The PAR button is used to select the desired parameter To modify the parameter setting use the UP and DOWN buttons Press PAR to enter the new value The controller progresses to the next parameter In a Configuration Parameter Module pressing the DSP button causes the new value to be rejected the controller d
40. E CLOSE OUTPUT SECOND INPUT VALVE POSITION PAR 55 Figure 25 Motorized Valve Positioner VELOCITY MODE VALVE CONTROL The Velocity mode of the Valve Positioner option is a special valve control algorithm that does not use a slidewire feedback signal In this control mode the controller responds with changes in output power instead of responding to the output power directly as in Position mode Subsequently as long as there is process error the controller activates the motor control outputs periodically to eliminate the error The valve motor open and close transit time and minimum motor on time are required parameters for Velocity mode The valve motor transit times should be measured in actual use as they frequently differ from the nominal valve motor times The minimum on time is another Velocity mode parameter It establishes the control deadband of the controller Minimum on times that are too short could cause excessive valve activity Minimum on times that are too long may cause too much error Velocity mode of the controller is engaged by setting both Valve Position parameters to 0 0 55 Example Steam is used to heat water by passing it through a heat exchanger Variations in inlet water temperature steam pressure hot water demand etc all contribute to the need for closed loop control The steam pressure is controlled by a PCU with
41. EMI suppression devices or equivalent are recommended Ferrite Suppression Cores for signal and control cables Fair Rite 0443167251 RLC FCOR0000 TDK ZCAT3035 1330A Steward 28B2029 0A0 Line Filters for input power cables Schaffner FN610 1 07 RLC LFIL0000 Schaffner FN670 1 8 07 Corcom 1VR3 Note Reference manufacturer instructions when installing a line filter 6 Long cable runs are more susceptible to EMI pickup than short cable runs Therefore keep cable runs as short as possible 7 Switching of inductive loads produces high EMI Use of snubbers across inductive loads suppresses EMI Snubbers RLC SNUB0000 WIRING CONNECTIONS After the unit has been mechanically mounted it is ready to be wired All conductors should meet voltage and current ratings for each terminal Also cabling should conform to appropriate standards of good installation local codes and regulations It is recommended that power supplied to the unit AC or DC be protected by a fuse or circuit breaker All wiring connections are made on a fixed terminal block When wiring the unit use the numbers on the label to identify the position number with the proper function Strip the wire leaving approximately 1 4 6 mm bare wire exposed stranded wires should be tinned with solder Insert the wire into the terminal and tighten the screw until the wire is clamped tightly Each terminal can accept up to two 18 gage wires Wire each terminal block in t
42. IN DISPLAY 1 Internal problem with controller 1 Replace unit 1 Press DSP to clear then check all set up parameters a Check input and AC line for excessive noise b If fault persists replace unit 1 Check unit scaling 2 Check set up parameters 3 Check calibration 1 Check input wiring 2 Check signal calibration 3 Check calibration 1 Check input signal set up 2 Check set up parameters ULUL IN DISPLAY 1 Input signal overload 2 Loss of set up parameters 73 1 Check input signal set up 2 Check set up parameters APPENDIX TROUBLESHOOTING Cont d PROBLEMS VALV IN DISPLAY Valve Fail Alarm SLId IN DISPLAY POSSIBLE CAUSE Valve or valve motor jammed Loss of power to valve motor Slidewire feedback signal lost Slidewire feedback signal lost REMEDIES Check valve or valve motor for operation Check power to valve motor Increase valve fail time Check slidewire feedback signal DISPLAY INCORRECT OR DISPLAY WANDERS PROCESS SLUGGISH OR NOT STABLE Loose or corroded connections Signal source in noisy environment Controller needs calibration Incorrect PID values Check connections Evaluate signal source location a Increase digital input filtering Check calibration See PID Control EXCESSIVE VALVE ACTIVITY OR HUNTING Insufficient valve control deadband Insufficient outp
43. L Enable Local Remote Setpoint Selection trnF Enable Auto Man Transfer tUNE Enable Auto tune CONFIGURE ALARMS MNEMONIC PARAMETER USER SETTING Act Alarm 1 Operation Mode rSti Alarm 1 Reset Mode Stb1 Alarm 1 Standby Enabled AL 1 Alarm 1 Value Act2 Alarm 2 Operation Mode rSt2 Alarm 2 Reset Mode Stb2 Alarm 2 Standby Enabled AL 2 Alarm 2 Value AHYS Alarm Hysteresis Value CONFIGURE SECONDARY OUTPUT MNEMONIC CYC2 GAN2 db 2 PARAMETER USER SETTING OP2 Output Cycle Time Relative Gain Overlap Deadband 82 CONFIGURE SERIAL COMMUNICATIONS MNEMONIC PARAMETER USER SETTING bAUd Baud Rate PArb Parity Bit Addr Unit Address Abrv Abbrev or Full Transmission PrAt Automatic Print Rate PoPt Print Options INP SEt OPr Pbd INt dEr AL1 AL2 dEv OFP OSt rAt bIA RSP IN2 Pb2 2 dt2 SP2 CONFIGURE SECOND ANALOG INPUT MNEMONIC PARAMETER USER SETTING OPEr Second Input Operating Mode root Second Input Square Root Linearization dPt2 Second Input Decimal Point Position dSP1 Second Input Display Scale Point 1 INP1 Second Input Input Scale Point 1 dSP2 Second Input Display Scale Point 2 INP2 Second Input Input Scale Point 2 SPtr Local Remote Setpoint Select Action OPd2 Secondary PID Output Power Dampening CONFIGURE VALVE POSITIONER MNEMONIC PARAMETER USER SETTING VPS1 Valve Positioner Scale Point 1 VPS2 Valve Positioner Scale Point 2 VUat Valve Positioner Update Time
44. Linear Control Output 4 to 20 mA A linear DC input power control unit is used for process control An output control deadband of 2 0 and an output update time of 10 seconds is desired The following set up values illustrate the configuration ANAS ANLO 0 0 ANHI 100 0 ANdb 2 0 ANUt 10 seconds ANALOG OUTPUT mA 20 1 DISPLAY UNIS ANLO ANHI Figure 15 Linear DC Output 27 LOCKOUTS MODULE 3 LC The controller can be programmed to limit operator access to various parameters control modes and display contents The configuration of the lockouts is grouped into three sections Lower Display Lockouts Protected Mode Lockouts and Hidden Mode Lockouts Lower Display Lockouts SP OP IN 2 dEv bdSP The contents of the secondary display can be changed in the normal display mode by successively pressing the DSP button This action scrolls through the possible display parameters when enabled The parameters can be set for one of the following LOC Lockout Prevents the parameter from appearing in the secondary display Parameter appears but cannot be modified Parameter appears and can be modified rEd Read only Ent Entry lower display content possibilities are SP Setpoint Value OP Output Power IN 2 Second analog input Remote setpoint dEv Setpoint Deviation bdSP Blank Display If all parameters are set to lock LOC the d
45. N Flashing Controller is in Manual control mode line variation effect 48 62 Hz 10 VA REM ON controller is in remote setpoint mode Second Analog Input option OFF controller is in local setpoint mode Second Analog Input option Flashing controller is in Manual control mode Second Analog Input optional DIMENSIONS In inches mm Note Recommended minimum clearance behind the panel for panel latch installation is 5 5 140 H x 2 1 53 4 W 5 41 137 4 1 77 0 45 t 35 62 00 PW MAN AL1 92 55 DEV OP1 AL2 ISSSSSSSSsssssss v Figure 39 Dimensions 69 CONTROLS Four front panel push buttons for modifying and setup of controller functions and one external input for parameter lockout or other functions SIGNAL INPUT Sample Period 100 msec typ Response Time 300 msec typ to within 99 of final value w step input Signal Overdrive Threshold 10 V Range 13 00 V typ 20 mA Range 26 00 mA typ Signal Overdrive Response Main Control Output s Programmable preset output Display SENS Alarms Upscale drive DC Linear Programmable preset output Normal Mode Rejection 40 dB typ 50 60 Hz improves with increased digital filtering Common Mode Rejection 100 dB typ DC to 60 Hz Protection Input overloa
46. PR OCESS ALARM MODE ABSOLUTE LOW ACTING W AUTO RESET SHOWN ALARM VALUE UNIT TIME STANDBY ENABLED OFF ON OFF ON STANDBY DISABLED ON OFF ON OFF ON Figure 17 Alarm Standby Delay Sequence Alarm Value AL 1 AL 2 The alarm values are either absolute absolute alarms or relative to the setpoint value deviation and band alarms An absolute alarm value is the value that is entered A relative alarm value is offset from the process setpoint value by the amount entered and tracks the setpoint value as it is changed AL 1 AL 2 999 to 9999 If the alarm action is set as a Band Alarm then only a positive value can be entered AL 1 and AL 2 0 to 9999 Alarm Hysteresis AHYS The alarm s values have a programmable hysteresis band to prevent alarm output chatter near the alarm trigger setpoint The hysteresis value should be set to eliminate this effect A value of 2 to 5 is usually sufficient for most applications A single alarm hysteresis value applies to both alarms See the Alarm Action Figures page 30 for the effect of hysteresis on the various alarm types AHYS 110250 SECONDARY OUTPUT MODULE 5 02 OPTIONAL The optional secondary output OP2 operates as an independent output for systems that require a second output One of the three types of output modules Relay Logic SSR Drive or Triac must be ordered separately and installed into th
47. S BEZEL SECURING SCREWS 2 NEMA 4X IP65 MODEL ONLY MAIN DISPLAY DISPLAYS SCALED PROCESS VALUE ALSO DISPLAYS MNEMONIC OF SELECTED PARAMETER IN CONFIGURATION MODE DECIMAL POINT FLASHES WHEN LOCAL SETPOINT IS RAMPING FLASHES WHEN UNIT IS IN MANUAL MODE ILLUMINATES IN REMOTE SETPOINT MODE OFF IN LOCAL SETPOINT MODE FLASHES WHEN UNIT IS IN MANUAL MODE AL ILLUMINATES WHEN OPTIONAL ALARM 1 IS ILLUMINATES WHEN VALVE POSITIONER OPEN OUTPUT IS ON AL2 ILLUMINATES WHEN OPTIONAL ALARM 2 IS ON OP2 ILLUMINATES WHEN OPTIONAL SECONDARY OUTPUT IS ON CLS ILLUMINATES WHEN VALVE POSITION CLOSE OUTPUT IS ON SECOND ANALOG INPUT REMOTE SETPOINT ILLUMINATES WHEN MAIN CONTROL OUTPUT IS ON 1 ILLUMINATES WHEN ALARM 1 IS ON MODEL DEPENDENT BUTTON FUNCTIONS DSP In the normal operating mode the Display DSP button is used to select one of the operational parameters in the secondary display In the Configuration Parameter Modes pressing this button causes the unit to exit escape to the normal operating mode with no changes made to the selected parameter UP DN In the normal operating mode the Up Down buttons can be used to directly modify the setpoint value or output power manual mode only BEZEL RELEASE LATCH STANDARD MODEL ONLY Figure 10 Front Panel when viewed in the secondary display Otherwise
48. S Operating Range 0 to 50 Storage Range 40 to 80 Vibration According to I EC 68 2 6 Operational 5 to 150 Hz in X Y Z direction for 1 5 hours 1 g Shock According to IEC 68 2 27 Operational 5 g s 11 msec in 3 directions SpanDrift maximum 100 ppm C main input 150 ppm C second input Zero Drift maximum 4 to 20 mA DC Range 0 5 uA C 0 10 VDC Range 0 2 mV C Second Input 2 RedativeHumidity Less than 85 RH non condensing from 0 C to 50 C Altitude Up to 2000 meters 16 ISOLATION BREAKDOWN RATINGS inputs and outputs with respect to AC line 2300 Vy Analog Output Second Analog nput or Slidewirel nput with respect to Main Input 500V 17 CERTIFICATIONS AND COMPLIANCES SAFETY UL Listed File E137808 11 508 CSA C22 2 14 M95 LISTED by Und Lab Inc to U S and Canadian safety standards UL Recognized Component File E156876 UL873 CSA C22 2 No 24 Recognized to U S and Canadian requirements under the Component Recognition Program of Underwriters Laboratories Inc 2 or 4X Enclosure rating Face only 1 50 IECEE CB Scheme Test Certificate 4UL1239 156876 US A CB Scheme Test Report 96ME50279 070794 Issued by Underwriters Laboratories Inc IEC 1010 1 EN 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 IP65 Enclosure rating Face only IEC 529 ELECTROMAGNETIC COMPATIBILITY Immunity to EN 50082 2 Electrost
49. T MODULE OP1 VALVE POSITIONER ALARM OUTPUT VAC POWER SELECTION SWITCH UP 115VAC DN 230VAC OPTIONAL ALARM 1 OUTPUT MODULE ALI VALVE POSITIONER OPEN OUTPUT NOTE FOR VALVE POSITIONER MODELS CIRCUIT BOARD MARKINGS HAVE THE FOLLOWING MEANING AL1 OPEN OUTPUT AL2 0P2 CLOSE OUTPUT OP1 ALARM 1 OUTPUT Figure 6 Hardware EMC INSTALLATION GUIDELINES Although this unit is designed with a high degree of immunity to ElectroMagnetic Interference EMI proper installation and wiring methods must be followed to ensure compatibility in each application The type of electrical noise source or coupling method into the unit may be different for various installations In extremely high EMI environments additional measures may be needed The unit becomes more immune to EMI with fewer I O connections Cable length routing and shield termination are very important and can mean the difference between a successful or a troublesome installation Listed below are some EMC guidelines for successful installation in an industrial environment 1 The unit should be mounted in a metal enclosure which is properly connected to protective earth 2 Use shielded screened cables for all Signal and Control inputs The shield screen pigtail connection should be made as short as possible The connection point for the shield depends somewhat upon the application Listed below are the recommended methods of conn
50. THE PROCESS CONTROL UNIT MODEL PCU INSTRUCTION MANUAL INTRODUCTION The Process Control Unit PCU is a multi purpose series of industrial control products that are field programmable for solving various applications This series of products is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements The PCU unit which you have purchased has the same high quality workmanship and advanced technological capabilities that have made Red Lion Controls the leader in today s industrial market Red Lion Controls has a complete line of industrial indication and control equipment and we look forward to servicing you now and in the future CE C US LISTED IND CONT EQ 51 CAUTION Read complete CAUTION Risk of electric shock instructions prior to installation and operation of the unit Table of Contents GENERAL DESCRIPTION ise 25555590046 1 Safety SUMMARY 5 scs mE Dre ib es ete 2 INSTALLATION amp CONNECTIONS esse ae use Peak DE RR erases 3 Installation Environment 4 au e exe REA eese ec d er mere ee E 3 Standard Unit Installation wh a exe dde eee EVR ea RE Rex SUD Fa ne DER OR 3 NEMA 4X IP65 Unit Installation 1 e emt a c e cd inde ad
51. TPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF LED OFF LED ON LED OFF LED ON LED OFF LED ON LED OFF LED ON LED OFF 31 Alarm Reset rSt1 rSt2 Each alarm reset action may be independently configured LAtC Latching Auto Automatic Latched alarms require operator acknowledgment to reset the alarm condition The front panel buttons can be used to reset an alarm when the controller is in the hidden mode see Hidden Function Mode page 20 An Alarm condition may also be reset via the RS485 serial interface or by the user input Automatic Auto reset alarms are reset by the controller when the alarm condition clears Figure 16 Alarm Reset Sequence depicts the reset types PROCESS ALARM MODE i ABSOLUTE LOW ACTING SHOWN ALARM VALUE TIME ON ON RESET OFF OFF OFF MANUAL OFF ON MANUAL RESET PERFORMED BY OPERATOR Figure 16 Alarm Reset Sequence 32 Alarm Standby Delay Stb1 Stb2 The alarm s may be independently configured to exhibit a power on standby delay which suppresses the alarm output from turning until the process first stabilizes outside the alarm region After this condition is satisfied the alarm standby delay is canceled and the alarm triggers normally until the next controller power on 17 Alarm Standby Delay Sequence depicts a typical operation sequence
52. Transmission String 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 5 4 CR SP CR Lr 8 L JLJUL L UNT ij MNEMONICSZ 5 FOUR DIGITS BZ 8 ADDRESS x E rs 5 0 LAST LINE z lt TRANSMISSION m a c lt Figure 23 Typical Transmission String The first two digits transmitted are the unit address If the unit address is 0 the first two digits are blank A space follows the unit address digits The next three characters are the mnemonics followed by one or more blank spaces The numerical data value is transmitted next followed by the identifying units Negative values are indicated by a sign The decimal point position floats within the data field depending on the actual value it represents The numeric data is right justified without leading zeros When a command or print request is issued the above character string is sent for each line of a block transmission An extra lt SP gt lt CR gt lt LF gt is transmitted following the last line of transmission from a print request to provide separation between print outs If abbreviated transmission is selected only numeric data is sent If abbreviated transmission is not selected the unit transmits mnemonics and the numeric data If more than one string is transmitted
53. Valve Positioner option The PCU maintains constant hot water temperature by controlling the position of the valve No slidewire feedback is used Given the time constant of the process is 60 seconds the Valve Update Time VUdt of the controller is set at five seconds to reduce valve activity The valve motor open and close transit times were measured at 20 and 25 seconds respectively The minimum on time pulse is set at 0 5 seconds to allow for valve motor overrun and backlash and also to provide for a control deadband The effective control deadband expressed in percent of controller output is Vont 0 5 Vopt VCLt Effective deadband in percent 05 __ 0 5 20 25 2 2 The following data is used to configure the Velocity mode valve control parameters of the PCU VPS1 0 0 Set valve position 1 to 0 0 to engage Velocity mode VPS2 0 0 Set valve position 2 to 0 0 to engage Velocity mode VUdt 5 Update valve position at most once every 5 seconds VOPt 20 Set valve motor open time to 20 seconds VCLt 25 Set valve motor close time to 25 seconds Vont 0 5 Set valve motor minimum on time deadband to 0 5 seconds SECOND ANALOG INPUT OPTION The Second Analog Input option is an additional analog input used for Remote Setpoint or Internal Cascade operation The mode of operation is selected by programming The Second Analog Input reading can be viewed in the secondary display Front panel annunciator SEC illuminates to ind
54. alues may require re tuning The following procedure may be used to initially tune an Internal Cascade controller 1 Place the controller into Manual USEr mode of operation 2 Adjust output power level until primary variable is close to primary setpoint 10 of range 3 Auto Tune the secondary 4 Auto Tune the primary 5 Place controller into Automatic Auto mode of operation 6 Initial tuning is complete After the process has stabilized the primary and secondary may be re tuned in Automatic mode of operation Normally the primary requires re tuning whenever the secondary PID constants are changed 66 AUTO TUNE OF EXTERNAL CASCADE SYSTEMS REMOTE SETPOINT External Cascade systems involve the use of two controllers the Primary and the Secondary that have a Remote Setpoint Input In such a system the Secondary controller is normally tuned first followed by tuning of the primary controller Prior to tuning the Secondary controller it is essential that the Remote Setpoint is scaled to match the actual secondary process range This is important for proper Auto Tuning of the primary controller Subsequent changes made to scaling values may require re tuning The following procedure may be used to initially tune an External Cascade controller 1 Place the Secondary controller into Local Setpoint mode and Manual USEr mode of operation 2 Adjust output power level of the secondary until primary variable is close to p
55. ame as the main input For Internal Cascade operation the decimal point may be different from the main input Example If main input 500 degrees FS Second Input 15 00 PSI FS then dCPt 0 and dPt2 0 00 Second Analog Input Scaling Points dSP1 INP1 dSP2 INP2 Prior to installing and operating the indicator it may be necessary to change the scaling to suit the display units particular to the application The indicator is unique in that two different scaling methods are available The operator may choose the method that yields the easier or more accurate calibration The two scaling procedures are similar in that the operator keys in the display values and either keys in or applies a signal value that corresponds to those display value points The location of the scaling points should be near the process end limits for the best possible accuracy Once these values are programmed the indicator calculates the slope and intercept of the signal display graph automatically No span zero interaction occurs making scaling a one pass exercise Before programming the indicator organize all the data for the programming steps to avoid confusion To scale the indicator two signal values and two display values that correspond to the signal values must be known These four values are used to complete the scaling operation An example is listed below Example Scaling Point 1 0 0 4 00 mA Display Values dSP1 amp dSP2 Key in the d
56. ange and Units Factory Setting Value Description Comments INP2 Scaling point 2 input signal value key in method Signal input method 4 to 20 mA 0 10 VDC 999 to 9999 20 00 0 00 to 20 00 0 00 to 10 00 Normally key in input high value Press DSP button to select signal input method Normally apply input high value Lower limit setpoint range 999 to 9999 0 0 Set low limit below high limit Upper limit setpoint range Setpoint ramp rate 999 to 9999 0 0 to 999 9 units minute 0 0 Set high limit above low limit 0 0 is off no ramping This parameter also ramps Remote Setpoint User input PLOC Program disable ILOC Integral action on off trnf auto manual select SPrP Setpoint ramp rate on off ALrS Reset alarm output s Prnt print request SPSL Remote Local Setpoint select PLOC Available on all second input MVP and ANA models and on models with RS485 Configure Module 2 Output Parameters 2 Display Parameter Cycle time Control Action Range and Units Factory Setting Value 0 to 250 seconds 2 drct rEv rev Description Comments 0 turns OP1 off This parameter does not appear if Valve Positioner option is installed For both PID amp ON OFF control Output power lower limit range Output power upper limit range 096 to 10096 OP1 Set OPLO OPHI 100 to 100 00 0
57. arameter from appearing in the hidden mode Allows operator to perform the selected hidden mode function Enable The functions available in the hidden mode are accessible independent of the status of program disable ALrS Reset override the alarm output s SPSL Select Local or Remote Setpoint operation trnf Select Automatic or Manual operation tUNE nvoke or cancel Auto Tune Note These parameters are model specific and may not appear in the programming sequence 28 ALARM MODULE 4 AL OPTIONAL The controller may be optionally fitted with the dual alarm option ALI AL2 Some models are equipped only with a single alarm AL 1 One of three types of output modules Relay Logic SSR Drive or Triac must be ordered separately and installed into the appropriate alarm channel socket The output modules may be replaced or interchanged with appropriate wiring considerations at any time without re programming the controller The alarm values can be accessed in configuration module 4 AL the unprotected mode and in the protected mode if not locked A front panel annunciator illuminates to indicate that the alarm output is on ALI for alarm 1 and AL2 for alarm 2 Note When deviation low acting with positive alarm value d LO deviation high acting with negative value d HI or Band inside acting b IN is selected for the alarm action the indicator is OFF when the alarm output is
58. ariations in inlet water temperature steam pressure hot water demand etc all contribute to the need for closed loop control The steam pressure is controlled by a PCU with Valve Positioner option A valve positioner with 1 000 ohm slidewire feedback is used The PCU maintains constant hot water temperature by controlling the position of the valve Given the time 54 constant of the process is 60 seconds the Valve Update Time VUdt ofthe controller is set at five seconds to reduce valve activity Adding Valve Update Time to the valve motor transit time 20 seconds the valve fail time is set at 50 seconds 2 20 5 to alert for a valve fail condition The valve position hysteresis is set at 2 0 to allow for valve motor overrun and backlash and also to provide a control deadband to reduce valve activity minimum valve position is setto 20 to allow a minimum amount of steam flow into the heat exchanger The maximum valve position is set at 100 The following data is used to configure the Position mode valve control parameters of the PCU VPS1 20 0 Scale minimum valve position to 20 096 VPS2 100 0 Scale maximum valve position to 100 0 VUdt 5 Update valve position at most once every 5 seconds VPdb 2 0 Set valve position deadband to 2 0 VFAL 50 Set valve fail timer to 50 seconds AL1 OUTPUT VALVE FAIL ALARM 1500 1500 PW OPN DEV AL1 CLS STEAM FLOW VALVE OPEN OUTPUT VALV
59. arm is silenced in these ways 1 Set the valve fail time to 0 2 The output power and slidewire signals subsequently agree 3 Cycle power to the controller VFAL 0109999 Valve Motor Open Time And Valve Motor Close Time VOPt VCLt Velocity mode For velocity mode control the valve motor open transit time VOPt and valve motor close transit time VCLt must be known In many cases these transit times differ from the valve specification The actual transmit times under load are normally measured for best results In some cases the open and close times may be different The transit time range is 1 to 9999 seconds Valve Minimum On Time VONt Velocity Mode As a result of the pulsed type algorithm used in velocity mode control a minimum on time pulse threshold is required for proper valve control The control does not update the outputs until the calculated on time pulse exceeds this value Normally set this value to the minimum on time of the valve motor If not given or otherwise unsuitable set this value approximately equal to 2 0 to 5 0 of valve open or valve close time The minimum on time range is 0 1 to 25 0 seconds FACTORY SERVICE OPERATIONS MODULE 9 FS The Factory Service Operations are programming functions which are performed on an infrequent basis They include controller calibration and reset programming to factory configuration setting Given the ramifications of these operations access to each is protected by a
60. arm set for latching Disable alarm during power up Set alarm value for 20 0 Alarm activation hysteresis set for 0 1 APPENDIX SPECIFICATIONS AND DIMENSIONS 1 DISPLAY Dual 4 digit 3 ANNUNCIATORS Upper Process Display 0 4 10 2 mm high red LED LED Backlight Status Indicators Model dependent Lower Auxiliary Display 0 3 7 6 mm high green LED PW Lower auxiliary display shows power output DEV Lower auxiliary display shows deviation error from setpoint OP1 Main control output is active AL1 Alarm 1 is active AL2 Alarm 2 is active for Dual Alarm Option OP2 Secondary output is active for Secondary Output Option Display Messages Model dependent OLOL Appears when measurement exceeds 105 input range ULUL Appears when measurement exceeds 5 input range SENS Appears when measurement exceeds OLOL amp ULUL range am 2 Appears when display display range OPN Valve positioner OPEN output is active for Valve Positioner option o 1 Appears valuas BKoead de play range CLS Valve positioner CLOSE output is active for Valve Positioner option SLid Appears when loss of slidewire signal is detected SEC Lower auxiliary display shows second analog input for Second VALV Appears when valve actuator error is detected Analog Input option 2 POWER Switch selectable 115 230 VAC 41096 15 no observable MA
61. ars in the main display 5 Press the DSP key once the PW amp DEV annunciators will flash 6 The secondary display will indicate the current applied at Terminals 9 amp 10 7 Compare the controller read out to the standard at various points over the range 4 to 20 mA The tolerance is 0 15 of reading 1 LSD 8 Calibrate the controller if the readings are out of tolerance SAD 78 LINEAR DC OUTPUT CHECK 4 to 20 mA 1 Connect an ammeter to the linear output 11 amp 12 with an accuracy of 0 1 or better 2 Set ANAS Analog Assignment to INP in Configure Input Parameters 3 Drive the input signal level below the programmed ANLO value Check for 4 mA 0 02 mA 4 Drive the input signal level above the programmed ANHI value Check for 20 mA 0 03 mA 5 Calibrate the controller linear DC output if out of tolerance 0 to 10 VDC 1 Connect a voltmeter to the linear output 11 amp 12 2 Set ANAS Analog Assignment to INP in Configure Input Parameters 3 Drive the input signal level below the programmed ANLO value Check for 0 VDC 20 mV 4 Drive the input signal level above the programmed ANHI value Check for 10 VDC 30 mV 5 Calibrate the controller linear DC output if out of tolerance SECOND INPUT CHECK The Second Input Check applies to those models that have the Second Analog Input Remote Setpoint and Valve Posit
62. atic discharge EN 61000 4 2 Level 2 4 Kv contact Level 3 8 Kv air Electromagnetic RF fields EN 61000 4 3 Level 3 10 V m 80 MHz 1 GHz Fast transients burst EN 61000 4 4 Level 4 2 Kv I O Level 3 2 Kv power RF conducted interference EN 61000 4 6 Level 3 10 V rms 150 KHz 80 MHz Emissions to EN 50081 2 RF interference EN 55011 Enclosure class A Power mains class A Notes 1 Self recoverable loss of performance during EMI disturbance at 10 V m Measurement input and or analog output signal may deviate during EMI disturbance For operation without loss of performance Install power line filter RLC LFIL0000 or equivalent 72 2 Self recoverable loss of performance during EMI disturbance at 10 Vrms Measurement input and or analog output signal may deviate during disturbance For operation without loss of performance Install power line filter RLC LFIL0000 or equivalent Refer to the EMC Installation Guidelines section of the manual for additional information 18 CONNECTION Jaw type terminal block Wire Range 12 30 AWG copper wire Torque 5 7 inch lbs 56 79 N cm 19 CONSTRUCTION NEMA 2 for standard models Front Panel Flame and scratch resistant tinted plastic Case High impact black plastic Mounting collar included NEMA 4X IP65 model only Sealed bezel utilizing two captive mounting screws panel gasket included This unit is rated for NEMA 4X IP65 indoor use Installation Category II Pollution Degree 2
63. ay interfere with the unit doing the switching and other nearby equipment causing erratic operation and accelerate relay contact wear The Snubber Network is specifically designed with a capacitor and resistor connected in series and installed across relay contacts The network will have a small amount of AC leakage current even when the PCU s Relay Module is off The leakage current is 2 1 mA nominal at a line voltage of 120 VAC and 4 3 mA nominal at 240 VAC respectively Leakage current may cause some loads to stay on or to turn on when the Relay Module is turned off This would only occur in unusual applications such as with a relay with unusually low holding current or an LED The leakage current may be eliminated by disabling the snubber however doing so will degrade the EMC performance of the unit First determine which output is associated with the leakage current either or AL2 OP2 Remove the Bezel Assembly from the case see Removing Bezel Assembly page 5 The snubbers are located on the Option PCB on the right side of the unit when viewed from the front The snubbers consist of a capacitor and a resistor The two resistors are located along the upper rear edge ofthe Option PCB They are green in color and have color code stripes of yellow violet black and gold There will be markings on the PCB close to the resistors that say SNUBI and SNUB2 for ALI and AL2 OP2 respectively Using a pair of diagonal cutters cut both
64. cept the print request function that requires 110 to 200 msec fora response A function is performed when the User Input Terminal 7 is used in conjunction with common Terminal 10 Note Do not tie the commons of multiple units to a single switch Use either a multiple pole switch for ganged operation or a single switch for each unit Below is a list of the available functions PLOC Program Lock A low level enables the program disable function which places the unit in the Protected Parameter Mode Note Front panel disable is possible without using this program lock function see Front Panel Program Disable page 19 ILOC Integral Action Lock A low level disables the integral action of the PID computation A high level resumes the integral action trnF Auto Manual Transfer A negative transition places the unit in the manual user mode and a positive transition places the unit in the automatic operating mode The output is bumpless when transferring to either operating mode User Input InPt Cont d SPrP Setpoint Ramp A low level terminates setpoint ramping and the controller operates at the target setpoint Terminating setpoint ramping is the same as setting the ramp rate to zero SPrP 0 0 A high level enables the programmed setpoint ramp rate ALrS Alarm Reset If the alarm option is installed a low level resets the alarm s to their inactive state as long as the user input is low Prnt Print Request A
65. d 120 VAC for 30 seconds Range and Accuracy Maximum Input Accuracy of Unscaled Reading Input Impedance 1MQ Resolution 0 10 VDC 0 15 3 mV 1 LSD 300 VDC 0 20 mA DC 0 15 6 uA 1 LSD 200 ma pe 100 10 mV 10 uA 6 OUTPUT MODULES Optional For All Output Channels Relay Type Form C Form A with some models See Ordering Information Rating 5 Amps 120 240 VAC or 28 VDC resistive load 1 8 HP 120 VAC max inductive load Life Expectancy 100 000 cycles at max load rating Decreasing load and or increasing cycle time increases life expectancy Logic SSR Drive Can drive multiple SSR Power Units Type Non isolated switched DC 12 VDC typical Drive 45 mA maximum Triac Type Isolated Zero Crossing Detection Rating Voltage 120 to 240 VAC 70 Max Load Current 1 Amp 35 0 75 Amp 50 Min Load Current 10 mA Offstate Leakage Current 7 mA max 60 Hz Operating Frequency 20 to 400 Hz Protection Internal Transient Snubber Fused 7 MAIN CONTROL OUTPUT Control PID or ON OFF Output Time proportioning or linear DC Hardware Plug in replaceable output modules Cycle time Programmable Auto tune When selected sets proportional band integral time and derivative time values Signal Overdrive Action Programmable 8 SECONDARY OUTPUT Optional Control PID or ON OFF Output Time proportioning or linear DC Hardware Plug in replaceable output modules Cyc
66. d for Valve Positioner models Output Control Action OPAC The main control output OP1 channel is programmable for reverse acting or direct acting Most control applications use reverse acting See ON OFF Control page 62 OPAC rEv Reverse acting drct Direct acting If drct direct acting is selected the main output OP1 is direct acting and the secondary output OP2 is reverse acting The secondary output always maintains the opposite setting of the main output Note When using a relay output module the control action may also be reversed by using the normally closed contacts The linear DC analog output when assigned to output power OP for control purposes tracks the controller output power demand A direct acting linear output signal can be implemented in two ways 1 Use direct for output control action OPAC 2 Interchange the two analog output scaling points ANLO amp ANHI See Linear DC Analog Output page 26 Output Power Limits OPLO amp Enter the safe output power limits for the process These parameters may also be used to limit the minimum and maximum controller power due to process disturbances or setpoint changes to reduce overshoots by limiting the process approach level OPLO amp OPHI 0 to 100 If the secondary output option is installed the limits range from OPLO amp OPHI 100 to 100 With the secondary output option installed the Lower Limit can be set to less t
67. d to operate in either Position Mode or Velocity Mode Position Mode requires a slidewire feedback signal from the valve or valve positioner Velocity Mode does not require a slidewire feedback signal See Valve Position Option page 54 for an overview of valve position control Valve Position 1 And Valve Position 2 VPS1 VPS2 The full closed valve position and the full open valve position are represented by parameters VPS1 and VPS2 respectively These values are expressed as a percentage of the valve open position They do not represent slidewire resistance Normally for position mode control VPS1 0 0 and VPS2 100 0 In some processes it may be necessary to limit the range over which the controller positions the valve In such a case VPS1 defines the minimum open position and VPS2 defines the maximum open position The controller then scales the valve position values to represent 0 and 100 output power In this way the valve is confined to work over a smaller portion of its total range Setting both parameters to 0 0 engages velocity mode control Slidewire feedback is not required for velocity mode Additionally slightly different controller parameters are required for this mode VPSI amp 52 99 9 to 999 9 For position mode control there are several ways to determine the valve position values 1 Position the valve to the closed or open positions by use of the controller or manually and have the controller measure
68. de 3 Scroll to tUNE by use of PAR if necessary 4 Select and press PAR 5 Auto Tune canceled B Or reset the controller by disconnecting AC power Note If using the linear DC output for control full power is applied 100 or 100 OP2 regardless of the output power limit settings Set the Linear DC Output scaling points to limit the magnitude of the output if desired AUTO TUNE OF SECONDARY OUTPUT OP2 MAIN OUTPUT OP1 SYSTEMS During Auto Tune of OP2 OP1 systems the controller switches the secondary output OP2 on and off in addition to the main output The deadband parameter db 2 determines the amount of overlap or deadband between the two outputs during Auto Tune Refer to ON OFF CONTROL page 62 for the operation of this parameter The deadband parameter remains unchanged after Auto Tune is complete Therefore when proportional control is started after the completion of Auto Tune this parameter may need to be reset Itis important that external load disturbances be minimized and if present other zone controllers idled as these may have an effect on the PID constant determination The controller additionally sets the Relative Gain parameter GAN2 for 2 systems AUTO TUNE OF INTERNAL CASCADE CONTROLLERS Auto Tune of Internal Cascade controllers involves tuning of the Primary PID and Secondary PID parameters Each set of parameters is tuned individually with the secondary
69. det Rose oe elu ate 3 Unt Removal Procedure 1 5 DE dos ge es Son Rea die UN ac T e Robe cR UR Au 5 Removing Assembly e RA ae pd s COR che n geld ec polt epos Installing Bezel Assembly ERE deep anda 5 Output MOdules ii see eR EHE i een ia bea Seb hes bed 3 4 52522 55 br Ub ETE HR eo dec sek Installing Output Modules sda RRR dre 6 Typical Connections amine de we Redes E UR OI ARCU ue OOM adn eee 6 Select AC Power 115 230 VAC successes cee 658 ene e Ra EGER YU gk ER He eee ee 6 EMC Installation Guidelines iui Rie Rer e RYE Bane PEG PER UP RE a 7 Ware Connections Ey eE pee oi ae nays eme mod ice gems 8 Valve Positioner WIFE ss ated ERN eases 9 Lear DC Output ivy eer Ine RAN C EU wea des a pif 9 second Analog Input WIM ovo esed x oa c EP PES 9 Program Disable Or User Input rem Hin E mons ee 6 10 AC Power Witing Licio ida 10 FRONT PANEL DESCRIPTION 4 9 e e pra ERREUR REESE RESI TE RETE STE 11 Button Functions siii aoa e Nace de E E ST euet s
70. dified the unit returns to the configuration access point allowing access to other modules INPUT MODULE 1 IN The controller has several input set up parameters that must be programmed prior to setting any other controller parameters Input Type tYPE Select the signal input type Voltage VOLt or Current Curr The appropriate signal input terminal for voltage is 8 and for current is 9 Square Root Linearization root Optional The main input can be linearized by use of the square root function See Square Root Linearization page 35 for a complete description of the square root function The root parameter in Program Module applies to the main input and the root parameter in Program Module 7 applies to the Second Analog Input Decimal Point Position dCPt Select the desired decimal point position for the scaled display The selected decimal point position appears in the following parameters rnd dSP1 dSP2 SPLO SPHI SP AL1 AL2 db 2 AHYS and CHYS 0 0 0 0 00 0 000 21 Rounding Increment rnd Rounding values other than 1 causes the scaled number to round to the nearest rounding increment selected ie rounding of 5 cause 122 to round to 120 and 123 to round to 125 If the process is inherently jittery the display value may be rounded to a higher value than 1 If the range of the process exceeds the required resolution ex 0 1000 PSI but only 10 PSI re
71. e OP2 channel socket The output modules may be replaced or interchanged with appropriate wiring considerations at any time without re programming the controller The front panel indicator OP2 illuminates when the secondary output is on See Output Module OUTPUT ON State Table page 6 for definition Secondary output power is defined as ranging from 100 full on to 0 off unless a deadband overlap is used Time Proportioning Cycle Time CYC2 A value of 0 turns off the secondary output independent of power demand CYC2 0 to 250 seconds Relative Gain GAN2 This parameter defines the gain of the secondary band relative to the main output band A value of 0 0 places the secondary output into ON OFF control mode with the parameter db 2 becoming the secondary output hysteresis This may be done independent of the main output control mode PID or ON OFF Relative gain is generally set to balance the effects of OP2 to that of for best control GAN2 0 0 to 10 0 33 Overlap Deadband db 2 This parameter defines the area in which both the main control output and secondary output are active negative value or the deadband area between the bands positive value If an overlap is specified the displayed percent output power is the sum of the main power and the secondary power 2 db 2 999 to 9999 If relative gain is zero the secondary output operates in the ON OFF mode with this parameter becomin
72. e four values are used to complete the scaling operation An example is listed below Scaling Point 1 Scaling Point 2 0 0 4 00 mA amp 100 0 20 00 mA Reverse acting indication can be accomplished by either reversing the two signal points or the display value points but not both If both are reversed then forward normal acting indication will occur In either case do not reverse the input wires to correct the action Display Values dSP1 amp dSP2 Key in the display value for scaling point one and scaling point two dSP1 999 to 9999 Ex 0 0 dSP2 999 to 9999 Ex 100 0 Signal Input Values INP1 amp INP2 The signal input value can either be keyed in via the front panel buttons or an input signal can be applied to the appropriate signal input terminals When entering the signal input parameter the unit is in the key in mode Key in Method Key in the signal value for scaling point one and scaling point two INPI 999 to 9999 0 00 VDC or 4 00 mA DC INP2 999 to 9999 Ex 10 00 VDC or 20 00 mA DC Signal Input Method To change to the apply signal method press the DSP button Front panel annunciators PW and DEV will flash and the display indicates the signal value applied to the input terminals The unit can be toggled to the key in method by pressing the DSP button again Signal Range 4 00 to 20 0 mA DC 0 00 to 20 00 0 00 to 10 00 VDC 0 00 to 10 00 When the desired value is indicated on the display press t
73. ecting the shield in order of their effectiveness a Connect the shield only at the panel where the unit is mounted to earth ground protective earth b Connect the shield to earth ground at both ends of the cable usually when the noise source frequency is above 1 MHz c Connect the shield to common of the unit and leave the other end of the shield unconnected and insulated from earth ground 3 Never run Signal or Control cables the same conduit or raceway with AC power lines conductors feeding motors solenoids SCR controls and heaters etc The cables should be run in metal conduit that is properly grounded This is especially useful in applications where cable runs are long and portable two way radios are used in close proximity or if the installation is near a commercial radio transmitter 4 Signal or Control cables within an enclosure should be routed as far away as possible from contactors control relays transformers and other noisy components 5 In extremely high EMI environments the use of external EMI suppression devices such as ferrite suppression cores is effective Install them on Signal and Control cables as close to the unit as possible Loop the cable through the core several times or use multiple cores on each cable for additional protection Install line filters on the power input cable to the unit to suppress power line interference Install them near the power entry point of the enclosure The following
74. els equipped with Valve Positioner Position mode control only Alarm 1 may be configured as a valve fail alarm 1 valv This alarm mode is useful to provide early detection of valve failure before significant process errors occur In this mode the usual alarm function is disabled The alarm triggers under the two following conditions 1 The valve slidewire feedback position does not match the controller output power within the valve position deadband after the valve fail time has expired The alarm indicates that the valve cannot be properly positioned due to a malfunction of the valve or valve positioner 2 The slidewire feedback signal is broken or out of range In this case the valve position controller cannot position the valve Message display alarms valv and slid appear when conditions and 2 occur respectively whether or not the alarm is configured as a valve fail alarm This alarm mode also applies to linear DC output used for valve positioning In this case a slidewire signal must be supplied to the controller for valve fail detection To silence a triggered Valve Fail alarm see Valve Fail Time Alarm VFAL parameter page 38 The alarm action figures describe the status of the alarm output and the front panel indicator for various over under process conditions See Output Module OUTPUT State Table page 6 for definitions under installing output modules section The alarm output wave form is
75. er modules These modules allow access to the fundamental set up parameters of the controller When the program list has been scrolled through the controller displays End and returns to the normal display mode The unit automatically returns to the normal display mode if no action is taken 16 UNPROTECTED PARAMETER MODE REFERENCE TABLE Range and PSE Display Parameter Units Factory iss edd Setting Value Confined to range of limits SPLO SPHI 0 Appears only if setpoint value is locked LOC or read only rEd SP Setpoint OPOF Output Power Offset Proportional Band Integral Time 99 9 to 100 0 99 9 to 100 0 0 0 0 0 to 999 9 of scaled input 0 to 9999 sec 120 Appears only if integral time Intt 0 and controller is in automatic mode Appears only if controller is in user manual mode and output power is locked LOC or read only rEd This parameter is not limited to output power limits 8 OPHI 0 0 is ON OFF control If using ON OFF mode set control hysteresis appropriately 0 is off This parameter does not appear if proportional band 0 0 Derivative Time 0 to 9999 sec 30 0 is off This parameter does not appear if proportional band 0 0 Proportional Band 2 Secondary 0 0 to 999 9 of Scaled input range 4 0 0 0 is ON OFF control Second Analog Input models only Secondary 0 to 9999 sec
76. es starts the auto tune sequence No terminates the auto tune sequence Prl tune primary Cascade SEC tune secondary Cascade NO This step does not appear if locked LOC Exits to normal display mode if executed This step does not appear if locked LOC or exits to normal display mode if executed These parameters appear only if Second Analog Input Internal Cascade is selected Alarm reset UP key resets Alarm 1 DOWN key resets Alarm 2 This step does not appear if alarm option not installed if locked LOC or previous step performed CONFIGURATION PARAMETER MODULES Accessible from the unprotected parameter mode the configuration parameter modules allow the operator access to the controller s fundamental set up parameters There are nine possible configuration stages that can be accessed At the configuration stage access point CNFP the operator uses the UP amp DOWN arrow buttons to select the desired configuration parameter module Press the PAR button to enter the module where the settings can be viewed or modified The PAR button is used to scroll through the parameters and the UP and DOWN buttons are used to modify the parameter value The PAR button enters the desired choice advancing to the next parameter The operator can press the DSP button to exit escape without modifying the parameter The unit returns to the normal display mode After the parameters in a module are viewed or mo
77. eters used for control purposes ANAS OP The deadband parameter requires that the output power in percent must change more than the deadband amount in order for the output to update A value of 0 0 disables the deadband action The linear output update time updates the output at the time interval specified A value of 0 seconds updates the output at the controller s scan rate 10 sec In the manual mode of operation both parameters are overridden The front panel indicator OPI and main output can be disabled by setting the time proportioning cycle time equal to zero CYCt 0 Note Valve Position controllers disable the OPEN and CLOSE outputs when the linear DC output is assigned to output power In this case the slidewire feedback signal may be used to verify valve position ANdb 0 0 to 25 0 ANUt 010250 seconds For setpoint transmission external cascade control used with another controller the controller transmits the instantaneous ramping setpoint not the target value when the controller is ramping the setpoint For models with Remote Setpoint the linear output transmits the active setpoint local or remote Example Chart Record Process Display Value 0 to 10 VDC The process range is 300 700 Programming 300 for ANLO 0 VDC value and 700 for ANHI 10 VDC value yields full scale deflection for a chart recorder 0 to 10 VDC The 0 to 10 VDC output is assigned to transmit the input reading ANAS INP Example
78. flow The PCU with Remote Setpoint programmed for a ratio value of 1 500 rtio and a bias value of 0 bias suits this application 56 Process Remote Setpoint Slave Control Example Multiple PCUs are used to regulate the temperature zones of a continuous drying oven To reduce thermal shock to the product the setpoint levels of incoming zone controllers are low while the other controllers have setpoints that are increasingly ramped up to the ideal drying temperature The PCUs are slave controllers that have Remote Setpoint with unique bias values to implement the ramp in setpoint values of the drying oven One PCU is the master controller The master controller re transmits the setpoint value via the linear DC output 4 to 20 mA to the slave zone controllers The slave zone controllers receive the 4 to 20 mA signal as a Remote Setpoint CASCADE CONTROL Cascade control involves the separation of a process into two control loops the Primary and the Secondary The Secondary control loop is designed to regulate the manipulated variable which is normally the faster responding variable The Primary loop controller establishes this setpoint to the Secondary to maintain Primary loop regulation Disturbances occurring to the Secondary control loop are quickly compensated for before the effect appears in the Primary loop output This early loop compensation or feed forward action of Cascade control can improve control quality compared with
79. flow of by the main input Both inputs are scaled independently during initial setup B main display and programming The only task left to the operator is to enter the desired ratio of B to A 120 VAC FLOW B FLOW A X RATIO B Ik AC POWER a BIAS 0 AL1 OP2 AL2 0P2 B ALI B 1 OP1 B MAIN CONTROL OUTPUT OP1 C USER INPUT 0 10V 4 20mA DC INPUTS COMM OUT OUT N C N C 4 20mA 4 20 1 ALARM 2 OUTPUT 2 OPTION ON A GUN fe fa fs ff FLOW B CONTROL SIGNAL 4 20mA ANALOG OUTPUT N SSSSSSSSSSSSSSSS M SECOND INPUT Figure 38 Chemical Mixing Flow Ratio Application 67 FLOW RATE PROGRAMMING EXAMPLE A plastics manufacturer needs to maintain a constant flow rate on a feed stock pipeline to insure their product stays within specification A PCU is installed to maintain the flow by controlling a proportional control valve The output of the flow meter is 0 to 10 VDC The control valve is positioned by an electric actuator that requires a 4 to 20 mA control signal The following is a list of the parameter values keyed in to the controller Configure Input Parameters Set input signal for voltage Scaled disp
80. g the secondary output hysteresis positive value only The Operation Figures illustrate the effects of different deadbands 2X PROPORTIONAL BAND i OP1 OP2 100 100 POWER UNITS MAIN SECONDARY OUTPUT OUTPUT SETPOINT Figure 18 Operation db 0 DEADBAND POSITIVE VALUE RELATIVE GAIN 100 2 1 5 2 100 OUTPUT POWER 24 La MAIN RELATIVE GAIN 5 PUIPUI la SECONDARY SETPOINT OUTPUT Figure 19 Operation db gt 0 Overlap Deadband db 2 DEADBAND NEGATIVE VALUE ma RELATIVE 1 2 1 5 2 100 100 OUTPUT POWER UNITS RELATIVE GAIN 5 SECONDARY MAIN OUTPUT OUTPUT SETPOINT Figure 20 Operation db lt 0 In practice with the secondary output observe the controlled process characteristics and if the process remains above setpoint with a sluggish return increase the relative gain Similarly if the process drops too sharply with an overall saw tooth pattern decrease the relative gain Alter the deadband overlap until a smooth response in the controlled process is observed during band transition 34 SERIAL COMMUNICATIONS MODULE 6 SC OPTIONAL When communicating with a PCU unit via the serial port the data formats of both units must be identical A print operation occurs when the user input programmed for the print request fu
81. gral time are seconds per repeat Integral action also known as automatic reset changes the output power to bring the process to setpoint Integral times that are too fast small times do not allow the process to respond to the new output value This causes over compensation and leads to an unstable process with excessive overshoot Integral times that are too slow large times cause a slow response to steady state errors Integral action may be disabled by setting the time to zero If time is set to zero the previous integral output power value is maintained If integral action is disabled manual reset is available by modifying the output power offset OPOF initially set to zero to eliminate steady state errors This parameter appears in unprotected parameter mode when integral time is set to zero The controller has this feature to prevent integral action when operating outside the proportional band This prevents reset wind up Note The Proportional band shift due to integral action may itself be reset by temporarily setting the controller into the ON OFF control mode proportional band 0 DEVIATION TIME OUTPUT INTEGRAL OUTPUT POWER PROPORTIONAL OUTPUT TIME NOTE TOTAL OUTPUT POWER IS THE SUM OF THE THREE PID SETTINGS INTEGRAL TIME Figure 29 Integral Time DERIVATIVE TIME Derivative time is defined as the time in seconds in which the output due to pr
82. han 0 to limit maximum secondary output power or set to greater than 0 to limit minimum main control output power Set the High Limit to less than 0 to limit minimum secondary output power or greater than 0 to limit maximum main control output power When controlling power in the manual mode the output power limits do not take effect Input Overdrive Preset Power OPFL If an input overdrive signal is detected the control output s default to a preset power output 0 OPI output full off to 100 output full on If the secondary output option is installed the range is extended from OPFL 100 to 100 At 0 both outputs are off at 100 is on and OP2 is off and at 100 OP2 is on and is off The alarm outputs always an up scale drive 9999 independent of this setting for an input overdrive signal For position mode valve controllers the valve is positioned according to the setting of this parameter For velocity mode valve controllers the following actions occur Velocity mode OPFL 0 valve CLOSE output activates OPFL 100 valve OPEN output activates OPFL any other setting both valve outputs disable Output Power Dampening OPdP The output power calculated by the PID controller can be dampened filtered to reduce the controller output activity Those processes with high gain and or derivative times or those processes with a relatively high noise content can benefi
83. he PAR button to store the value and advance to the next parameter Display Range Setpoint Limit Values SPLO amp SPHI The controller has programmable high and low setpoint limit values to restrict the setting range of the setpoint Set the limit values so that the setpoint value cannot be set outside the safe operating area of the process On models equipped with Second Analog Input configured as a Remote Setpoint the Remote Setpoint reading is also restricted to these limits SPLO 999 to 9999 SPHI 999 to 9999 Setpoint Ramp Rate SPrP The setpoint can be programmed to ramp independent of the controller s decimal point position and rounding increment The setpoint ramp rate can reduce sudden shock to the process reduce overshoot on start up or setpoint changes or ramp the process at a controlled rate SPrP 0 1 to 999 9 units minute ramp value of zero disables setpoint ramping If the optional user input is programmed for setpoint ramp it affects the enabling and disabling of setpoint ramping See User Input page 23 Setpoint ramping is initiated on power up or when the setpoint value is changed and is indicated by a decimal point flashing in the far right corner of the main display SETPOINT 500 TERMINATED INITIAL 200 SETPOINT CHANGED l 10 MINUTES Figure 13 Setpoint Ramp Rate Once the ramping setpoint reaches the target setpoint the setpo
84. he size of the step to yield a sufficient process reaction curve 5 Record the response of the process Use the information from the table to calculate the controller tuning values The PID tuning parameters are determined graphically from Figure 41 Process Reaction Curve Draw a vertical line at the moment the step change was made Draw a line labeled tangent through the process reaction curve at its maximum upward slope Extend this line to intersect the vertical line Example From the Process reaction Curve a 30 t 300 sec step 10 display range 0 to 1000 Parameter Fast Response Damped Response Slow Response Proportional Band 20000a 40000a 60000a Range x Step Range x Step Range x Step Integral Time Sec 3t 4t 5t Derivative Time Sec 0 41 0 41 0 41 Output Power Dampening Sec PROCESS OUTPUT 350 20 5 Am 10 1 15 1 10 BASE LINE For fast response Prop 60 0 Intt 900 sec t 300 SEC dert 120 sec 15 500 600 900 1200 1500 TIME SECONDS Figure 41 Process Reaction Curve 76 CLOSED LOOP CYCLING METHOD An alternative to auto tuning is manual tuning This tuning method induces PROCESS oscillations into the process in the same way as the controller s auto tune OUTPUT function If oscillations are not acceptable the open loop tuni
85. hecked for indication accuracy without disturbing the factory calibration The parameters to be checked are voltage reading mA reading linear DC output Second Input and Valve Position Feedback The following procedures may be used for this purpose Note Allow 1 2 hour warm up with the controller in an upright position to allow adequate ventilation to the case before checking these parameters VOLTAGE READING CHECK Connect a DC volt source with an accuracy of 0 01 or better to terminal 8 and terminal 10 2 Advance to the configuration parameter modules from the normal display mode Set the controller to indicate voltage VOLt in the input parameter module Press the PAR key until INP 1 appears in the main display Press the DSP key once the PW amp DEV annunciators will flash The secondary display will indicate voltage applied at Terminals 8 amp 10 Compare the controller read out to the standard at various points over the range 0 10 V The tolerance is 0 15 of reading 1 LSD 8 Calibrate the controller if the readings are out of tolerance CURRENT READING CHECK 1 Connect a current source with an accuracy of 0 01 or better to terminal 9 and terminal 10 2 Advance to the configuration parameter modules from the normal display mode 3 Set the controller to indicate current Curr in the input parameter module 4 Press the PAR key until INP 1 appe
86. his manner zB SIGNAL SOURCE SIGNAL SOURCE gt 7 or USER INPUT 8 0 0 10 9 10 4 20ma 10 comm 7 V POM DIS or USER INPUT 8 10 o 10v 9 4 20m 110 0 comm AC POWER 115 or 230VAC SWITCH SELECTABLE INTERNALLY AC POWER 115 or 230VAC SWITCH SELECTABLE INTERNALLY Figure 8 0 10 V Connection Valve Positioner Wiring Units with Valve Positioner option have three output connections for controlling the valve motor and three input connections for slidewire feedback The valve motor output connects to terminals labeled Valve Position Outputs terminals 1 2 and 3 See Figure 9 Valve Positioner Wiring for more details Terminal is the Valve motor supply common Terminal 2 is the Valve Close or CW output Terminal 3 is the Valve Open or CCW output The valve motor must be fused with a suitable value 120 240 NEUTRAL LINE VALVE POSITION OUTPUTS CW CLOSED CCW OPEN Mei N EXCITATION WIPER WIPER FULL CW CLOSED COMM POSITION 0A SLIDEWIRE FEEDBACK INPUTS TERMINAL NUMBERS ARE MODEL DEPENDENT SEE LABEL ON UNIT FOR DESCRIPTION
87. i id S ERU OR beta ess 24 Output Control Action OPAC sser ere dence tre VENE CAREER EH a 24 Output Power Limits OPLO amp OPHD d rare QE 25 Input Overdrive Preset Power OPEL o eue eret ERA ible 25 Output Power Dampening 2 25 ON OFF Control Hysteresis Band CHYS re Re grass P RR P eae 25 Auto Tune Dampening Code tcod SASS ae walk AM ee Ue 26 Linear DC Analog Output ANAS ANLO ANHI ANdb ANUt Optional 26 Lockouts Module SEC 322 teen aa ie oie ae dae ded 27 Lower Display Lockouts SP IN 2 dEv bdSP 27 Protected Mode Lockouts Code PID PID2 rtbS 28 Hidden Mode Lockouts ALrS trnF tUNE and SPSL 28 Alarm Module 4 AL Optional 5 2525 4494 mes wea GaN Eb e Re Hae 28 Alarm Action Act2 isle mg ey EEA EG we He dos CM ARE Aw 28 Second Analog Input Alari wean UU Ras C aa Rd RE Reed 29 Valve Fail Alarm VEALE Aba Sed eae E DN 29 Alarm ACH OPT SURES A 3
88. icate this display mode REMOTE SETPOINT The PCU with Second Analog Input can be configured as a Remote Setpoint This mode of operation enables Cascade control external Ratio control and Process Setpoint Slave control among others The Remote Setpoint value used internally by the controller is Scaled Second Analog Input rtio bIAS where rtio 0 000 to 9 999 bIAS 999 to 9999 The rtio and bIAS parameters offer on line scaling of the Remote Setpoint to adjust control ratios or biases among related processes In Remote Setpoint mode the front panel annunciator REM is illuminated When in Local Setpoint mode this annunciator is off In either Local or Remote Setpoint mode the Manual USEr mode is indicated by the REM annunciator flashing The Remote Setpoint is restricted to the setpoint limit values SPLO and SPHI These parameters may be used to limit the range of the Remote Setpoint to a safe or more stable control range For Remote Setpoint signal sources that change wildly or are too sensitive to process upsets the Setpoint Ramp parameter SPrP can be used to ramp rate limit the Remote Setpoint reading This can subsequently reduce the fluctuations of the Secondary control loop Remote Setpoint Flow Ratio Control Example For processing purposes it is necessary to control the flow of one process with respect to the flow rate of another The PCU is to control the flow at a ratio of 1 5x that of the uncontrolled
89. inearize the Second Analog input by use of the square root function Selection of yES results in the square root linearization of the Second Analog Input only Selection of NO results in linear scaling The square root linearization exhibits a 3 low cut point 1796 of scaled reading to eliminate reading jitter at low flow rates The following example illustrates the scaling of the Second Analog Input with square root linearization Example It is necessary to square root linearize the output of a differential pressure transmitter to indicate and control flow The defining equation is 278 JA p where A P 0 500 PSI transmitted linearly by a4 20 mA transducer At full flow rate A P 500 PSI the flow is 6216 ft hr The following scaling information is used with the controller dPt2 0 root yES dSP1 0 4 00 mA dSP2 6216 F hr INP2 20 00mA Square Root Linearization root Cont d As a result of the scaling and square root linearization the following represents the readings at various inputs Delta Transmitter Flow PSI mA ft hr 0 00 4 00 0 15 63 4 50 1099 31 25 5 00 1554 62 50 6 00 2198 125 00 8 00 3108 187 50 10 00 3807 250 00 12 00 4396 312 50 14 00 4914 375 00 16 00 5383 437 50 18 00 5815 500 00 20 00 6216 Decimal Point Position dPt2 For Remote Setpoint operation the decimal point position is normally programmed to be the s
90. int ramp rate disengages until the setpoint is changed again If the ramp value is changed during ramping the new ramp rate takes effect If the setpoint is ramping prior to invoking Auto Tune the ramping is suspended during Auto Tune and then resumed afterward using the current display as a starting value Deviation and band alarms are relative to the target setpoint not the ramping setpoint If the analog output is programmed to transmit the setpoint value the instantaneous ramping setpoint value is transmitted Note Depending on the ramp rate relative to the process dynamics the actual scaled process value may not track the ramping setpoint value On models equipped with Second Analog Input configured as Remote Setpoint this parameter may be used to establish a maximum rate of change of the Remote Setpoint reading If the controller or transmitter that supplies the Remote Setpoint reading is swinging too wildly or changing too fast resulting in control problems the ramp rate can be used to reduce the rate of change of the Remote Setpoint reading When ramping in Remote Setpoint operation the flashing decimal point is suppressed The units of ramping for Remote Setpoint operation are 0 1 to 999 9 LSD minute User Input InPt The user input may be programmed to perform a variety of controller functions The input must be in its active state for 100 msec minimum to perform the function The unit executes all functions in 100 msec ex
91. invoking Auto Tune the dampening code should be set to achieve the desired dampening level under PID control After Auto tune is complete changes to tcod parameter have no effect until Auto tune is re started When set to 0 this yields the fastest process response with possible overshoot A setting of 4 yields the slowest response with the least amount of overshoot Dampening codes of 0 1 are recommended for most processes PROCESS 4 TYPICAL RESPONSE CURVES WITH AUTOTUNE DAMPENING CODES 0 TO 4 Figure 14 Dampening Code 26 Linear DC Analog Output ANAS ANLO ANHI ANdb ANUt Optional The Linear DC output can be programmed to transmit one of the following controller parameters ASSIGN DC OUTPUT ANAS OP Percent output power INP Scaled input process value dEV Process setpoint deviation SP Process setpoint value dE 2 Process deviation of secondary loop Internal Cascade only SP 2 Process setpoint of secondary loop Internal Cascade only With high and low digital scaling points the range of the Linear DC output can be set independent of the controller s range This allows interfacing directly with chart recorders remote indicators slave controllers or linear power control units ANLO 4 mA or 0 VDC 999 to 9999 ANHI 20 mA or 10 VDC 999 to 9999 Linear DC output deadband ANdb and linear DC output update time ANUt parameters are additional param
92. ioner options Different signals are required for each option Second Analog Input Check 1 Apply signals over the range of 0 to 20 mA DC to the terminals labeled Second Input 4 20 mA and 4 20 mA The tolerance is 0 2 of full scale 1LSD 2 Calibrate the Second Analog Input if out of tolerance Valve Positioner Check 1 Apply signals derived from the resistor string as described in Valve Positioner Calibration The tolerance is 0 2 of full scale 1 LSD 2 Calibrate the Second Analog Input if out of tolerance CALIBRATION When re calibration is required generally every two years this procedure should be performed by qualified technicians using appropriate equipment Equipment source accuracy of 0 01 or better is required The procedure consists of applying accurate voltage signals applying precision mA current and measuring accurate mA currents among others Allow a 30 minute warm up period before starting this procedure This procedure may be aborted by disconnecting power to the controller before exiting the configuration mode The existing calibration settings remain in affect Configure Step 9 Factory Service Operations 9 Fs Parameter Enter factory service function code Voltage and Current Calibration Analog Output Calibration Second Analog Input Calibration Voltage Calibration 48 yes no yes no yes no Description Comments Calibrate instrument Calibration of voltage input
93. is done first This parameter will not appear if analog output option is not installed This parameter will not appear if second analog input is not installed Connect precision voltage source with an accuracy of 0 01 to terminals 8 and 10 for voltage calibration Displa Parameter Description Comments StP1 0 000 V step Apply 0 000 V wait 10 seconds press PAR StP2 StP3 StP4 1 667 V step 3 333 V step 5 000 V step Appl Appl 1 667 V wait 10 seconds press PAR 3 333 V wait 10 seconds press PAR Apply 5 000 V wait 10 seconds press PAR StP5 StP6 8 333 V step Apply 8 333 V Wait 10 seconds press PAR 6 667 V step 10 000 V step Appl 6 667 V wait 10 seconds press PAR Apply 10 000 V wait 10 seconds press PAR Pause The controller imposes a 5 sec delay Keep the 10 000 V signal applied The unit automaticall advances to StPA 79 Current Calibration Connect a precision current source with an accuracy of 0 0146 to terminals 9 and 10 for current calibration when step A appears Display Parameter Description Comments StPA 0 000 mA Apply 0 000 mA wait 10 seconds press PAR StPB 20 000 mA Apply 20 000 mA wait 10 seconds press PAR The unit automatically advances to analog output calibration if the option is installed Analog Output Calibration ANCL 4 to 20 mA Press PAR until ANCL appears in the display C
94. isplay remains on the last parameter that was viewed Note These parameters are model specific and may not appear in the programming sequence Note If a parameter is active in the lower display and is then subsequently locked out press DSP once in the normal display mode to remove it from the display Protected Mode Lockouts Code PID PID2 rtbS amp AL The protected mode is active when program disable is active The parameters in the protected mode can be set for one of the following modes LOC Lockout Prevents the parameter from appearing in the protected mode Parameter appears but cannot be modified Parameter appears and can be modified rEd Read only Ent Entry The code number allows access to the unprotected mode To enter the unprotected mode from the protected mode the code number entered must match the code number entered here See Front Panel Program Disable page 19 for a description of the various program access levels Code 010250 PID Permits access to the main PID parameters PID2 Permits access to the secondary PID parameters rtbS Permits access to Remote Setpoint ratio and bias parameters Permits access to the alarm value s Hidden Mode Lockouts ALrS trnF tUNE and SPSL The hidden mode is accessible from the normal display mode by pressing and holding the PAR button for three seconds The parameters can be set for LOC Lockout Prevents the p
95. isplay value for Scaling Point 1 and Scaling Point 2 dSP1 999 to 9999 Ex 0 0 dSP2 999 to 9999 Ex 100 096 Scaling Point 2 AND 100 096 920 00 mA Signal Input Values INP1 amp INP2 The signal input value can either be keyed via the front panel buttons or an input signal can be applied to the appropriate signal input terminals Initially the unit is in the key in mode Key in Method Key in the signal value for Scaling Point 1 and Scaling Point 2 999 to 9999 4 00 mA DC INP2 999 to 9999 Ex 20 00 mA DC Signal Input Method To change to the signal input method press the DSP button Front panel annunciators PW and SEC flash and the display indicates the signal value applied to the input terminals The unit can be toggled to the key in method by pressing the DSP button again When the desired value is indicated on the display press the PAR button to store the value and advance to the next parameter The scaling of the Remote Setpoint and Internal Cascade units are normally made equal to the physical range of the system Example If the control range of the process is 100 to 400 units the Remote Setpoint is normally scaled to 100 and 400 Example The Secondary variable under internal cascade control is steam pressure over the range of 0 00 to 60 00 PSI The Second Analog input is normally scaled to 0 00 and 60 00 units Local Remote Setpoint Transfer Modes SPir When switching from to Local or Rem
96. isplays End and returns to the Normal Display Mode For those parameters outside the Configuration Parameter Modules the new value takes effect and is committed into controller memory WHILE the value is keyed in The following is a list of commonly modified parameters Setpoint Output Power Output Power Offset Proportional Band Integral Time Derivative Time Proportional Band 2 Integral Time 2 Derivative Time 2 Directed Setpoint Cascade Ratio Bias Alarm 1 Value Alarm 2 Value Note While in a Configuration Parameter Module all new parameters are rejected and the old ones recalled if power is removed from the controller If power is removed while modifying any parameter be certain to check the parameter for the proper value 15 NORMAL DISPLAY MODE In the normal display mode the process value is always displayed in the main display By successively pressing the DSP button one of these operational parameters can be viewed in the secondary display model dependent Setpoint Output Power Second Analog Input Remote Setpoint Process Setpoint Deviation Each of these displays can be independently locked out from appearing or from being modified by the user see Lockouts Module page 27 Only from the normal display mode can access be gained to the other modes Unprotected Protected or Hidden MODIFYING A SECONDARY DISPLAY PARAMETER FROM THE FRONT PANEL The controller must be in the normal display mode to modify the
97. k labeled AC To reduce the chance of noise spikes entering the AC line and affecting the controller an AC feed separate from that of the load should be used to power the controller Be certain that the AC power to the controller is relatively clean and within the 15 10 variation limit Connecting power from heavily loaded circuits or circuits that also power loads that cycle on and off contacts relays motors etc should be avoided FRONT PANEL DESCRIPTION The front panel bezel material is flame and scratch resistant tinted plastic An optional NEMA 4X IP65 bezel version is available that meets NEMA 4X IP65 requirements when properly installed There are two 4 digit LED displays a red upper Main Display and a lower green Secondary Display There are up to six annunciators depending on options installed with red backlighting that illuminate to inform the operator of the controller and output status See Figure 10 Front Panel for a description of the available annunciators Four front panel buttons are used to access different modes and parameters The following is a description of each button SECONDARY DISPLAY DISPLAYS ONE OF THE OPERATIONAL VARIABLES ALSO DISPLAYS MNEMONIC OR NUMERIC VALUE WHEN MODIFYING A PARAMETER ILLUMINATES WHEN SECONDARY DISPLAY SHOWS OUTPUT POWER DEVe ILLUMINATES WHEN SECONDARY DISPLAY SHOWS PROCESS DEVIATION ILLUMINATES WHEN SECONDARY DISPLAY SHOW
98. l Band Intt Integral Time dErt Derivative Time SP 2 Internal Cascade Directed Setpoint Pb 2 Proportional Band 2 secondary It 2 Integral Time 2 secondary dt 2 Derivative Time 2 secondary rtio Remote Setpoint Ratio blAS Remote Setpoint Bias AL 1 Alarm 1 AL 2 Alarm 2 CONFIGURE INPUT MNEMONIC tYPE dCPt root rnd FLtr dSP1 INP1 dSP2 INP2 SPLO SPHI SPrP InPt PARAMETER Input Type Decimal Point Square Root Linearizing Rounding Increment Digital Filtering Display Value 1 Signal Input Value 1 Display Value 2 Signal Input Value 2 Setpoint Lower Limit Setpoint Upper Limit Ramp Rate User Input USER SETTING 81 CONFIGURE OUTPUT MNEMONIC PARAMETER USER SETTING CYCt Cycle Time OPAC Control Action OPLO Output Power Lower Limit Range OPHI Output Power Upper Limit Range OPFL Input Overdrive Power Preset OPdP Output Power Dampening CHYS ON OFF Control Hysteresis tcod Auto Tune Dampening Code ANAS Linear Output Assignment ANLO Linear Output Scale Value ANHI Linear Output Scale Value ANdb Linear Output Deadband ANut Linear Output Update Time CONFIGURE LOCKOUTS MNEMONIC PARAMETER USER SETTING SP Access Setpoint OP Access Output Power dEv Access Deviation Display IN 2 Access Second Analog Input Display bdSP Access Blank Display Code Access Code Number PID Access Primary PID Values PID2 Access Secondary PID Values rtbs Access Ratio and Bias Values AL Access Alarm s Values ALrS Enable Reset Alarm s SPS
99. l is dropping and prevents excessive overshoot on the next process start up PROCESS START UP After starting the process the controller s PID settings must be initially tuned to the process for optimum control Minimal tuning consists of adjusting the Proportional Band Integral Time and Derivative Time parameters to achieve the optimum response to a process disturbance The controller can be tuned once but must be re tuned if the process has been changed significantly Several options exist for tuning these parameters A Use the controller s built in Auto Tune feature see Auto Tune page 64 B Use a manual tuning technique see Manual Tuning page 76 Use a third party tuning software package generally expensive and not always precise D Use values based on control loop experience calculated values or values from a similar process 12 If the controller is a replacement the PID settings from the unit being replaced may be used as good initial values Be sure to consider any differences in the units and the PID settings when replacing The PID settings may be fine tuned by using the techniques outlined in the PID Control section After tuning the controller to the process itis important to power the load and the controller at the same time for best start up response MANUAL USER amp AUTOMATIC OPERATION The controller can be transferred between Automatic control closed loop PID or ON OFF control and Manual co
100. lay to indicate in tenths No rounding of the display Normal input signal filtering Display value for scaling point 1 is 0 0 Signal value for scaling point 1 is 0 00 Display value for scaling point 2 is 100 0 Signal value for scaling point 2 is 10 00 Limit min setpoint value to 0 0 units Limit max setpoint value to 110 0 units Setpoint ramp rate 0 1 units minute Allow remote switching of auto manual mode Configure Output Parameters tYPE VOLT dCPt 0 0 rnd 0 1 FLtr 1 dSP1 0 0 INP1 0 00 dSP2 100 0 INP2 10 00 SPLO 0 0 SPHI 110 0 SPrP 0 1 INPt trnF CYCt 0 OPAC rEV OPLO 0 OPHI 100 OPFL 0 OPdP 2 0 CHYS 0 1 tcod 0 ANAS OP ANLO 0 0 ANHI 100 0 Andb 2 5 ANut 2 Main control output and indicator off Main control output is reverse acting Limit min controller power to 0 Limit max controller power to 100 Controller output power to 0 if input overdrive signal is detected Output power dampening 2 0 Control hysteresis set for 0 1 Select fastest response Linear DC output used for control Control valve provides full deflection for 4 to 20 mA signal range Impose 2 5 deadband on Linear DC output Update output once every 2 seconds 68 Configure Alarm Parameters Acti A HI rst LAtC 5101 YES AL 1 90 0 Act2 A LO rst2 LAtC Stb2 YES AL 2 20 0 AHYS 0 1 Set alarm 1 for absolute high acting Alarm set for latching Disable alarm during power up Set alarm value for 90 0 Set alarm 2 for absolute low acting Al
101. le time Programmable Proportional Gain Adjust Programmable Deadband Overlap Programmable 9 LINEAR DC OUTPUT Optional With digital scale and offset programmable deadband and update time 4 to 20 mA Resolution 1 part in 3500 typ Accuracy 0 196 of reading 25 uA Compliance 10 V 500 max loop impedance 0 to 10 VDC Resolution 1 part in 3500 typ Accuracy 0 1 of reading 35 mV Min Load Resistance 10 KO 7 mA max Source output power setpoint deviation or process value Available for or OP2 but not both 10 MOTORIZED VALVE POSITIONER Optional Two Outputs Valve open and valve close or Linear DC optional Hardware Plug in replaceable output modules Three Inputs Slidewire feedback signal fail detect Isolated from main input Slidewire resistance 100 to 100 KO Slidewire exciting voltage 0 9 VDC typ Slidewire fail action programmable Control mode Position mode with slidewire and Velocity mode w o slidewire Control deadband 0 1 to 25 0 position mode 0 1 to 25 0 seconds velocity mode Updatetime to 250 seconds Motor time open close to 9999 seconds Position limits Adjustable 0 0 to 100 0 of valve stroke Valvefail time Off to 9999 seconds Alarmmode Dual acting loss of slidewire feedback signal and valve fail detection 11 SECOND ANALOG INPUT Range 0 20 mA Isolated from main input Overload 100 mA steady state Input Resistance 10 typ Voltage drop 9 20 m
102. low level transmits the print options selected in the serial communications module 6 SC If the user input is held low after the printing is complete a second print request is issued SPSL Select Local or Remote Setpoint On models equipped with Second Analog Input configured as Remote Setpoint a negative transition engages Remote Setpoint operation and a positive transition engages Local Setpoint operation Select the controller output response to the Local Remote transfer operation bumpless tracking etc by the setpoint transfer parameter SPtr 24 OUTPUT MODULE 2 OP The controller has parameters that affect how the main control output OP1 responds to process changes and signal overdrive actions Time Proportioning Cycle Time CYCt The selection of cycle time depends on the time constant of the process and the type of output module used CYCt to 250 seconds For best control a cycle time equal to 1 10 of the process time constant or less is recommended longer cycle times could degrade process control and shorter cycle times provide little benefit at the expense of shortened relay life When using a Triac module or a Logic SSR drive output module with the SSR Power Unit a relatively short cycle time may be selected A setting of zero keeps the main control output and front panel indicator off Therefore if using the analog output for control the main output and indicator can be disabled This parameter is skippe
103. ltering most input filtering most input filtering and slower 2 sec display update rate outputs update at 10 sec rate Scaling Points Prior to installing and operating the controller it may be necessary to change the scaling to suit the display units particular to the application Although the unit has been programmed at the factory the scaling will generally have to be changed The controller is unique in that two different scaling methods are available The operator may choose the method that yields the easier or more accurate calibration The two scaling procedures are similar in that the operator keys in the display values and either keys in or applies a signal value that corresponds to those scaling points The location of the scaling points should be near the process end limits for the best possible accuracy Once these values are programmed coordinates on a graph the indicator calculates the slope and intercept of the signal display graph automatically No span zero interaction occurs making scaling a one pass exercise DISPLAY INPUT 20 00mA 4 00mA NP1 4 00 DSP1 0 0 NP2 20 00 DSP2 100 0 Figure 12 Scaling Points 22 Before programming the indicator it is advised to organize all the data for the programming steps to avoid possible confusion To scale the indicator two signal values and two display values that correspond to the signal values must be known Thes
104. mehts i sda ex sds ue set asp y Ca eed pter dre eds aac eee Dr bre dates 60 ON OFF CONTROL 259 E eR SR UP pH RE EE EE ME 62 AUTO FUNE x 64 Initiate Autos Tune ae CU URB ORAE da M quc mecs TEMAS C RS 65 Auto Tune Of Secondary Output OP2 Main Output Systems 65 Auto Tune Of Internal Cascade Controllers 65 Auto Tune Of External Cascade Systems Remote Setpoint 66 APPENDIX A APPLICATION 8 67 Chemical Mixing Application ss iis e E PROUVER CERE REG RES s 67 Flow Rate Programming Example 68 APPENDIX SPECIFICATIONS AND 6 69 APPENDIX TROUBLESHOOTING 73 Output Leakage Current urlo 75 APPENDIX D MANUAL TUNING 76 Open Loop Step Response Method 2222 2222 2 2 Wed eee EE Red 76 Closed Loop Cycling Method adore dh ode eR ee UR RO e 77 APPENDIX E
105. mitters The optional RS485 multi drop serial communication interface provides two way communication between a PCU unit and other compatible equipment such as a printer a programmable controller or a host computer In multi point applications the address number of each unit on the line can be programmed from zero to ninety nine Up to thirty two units can be installed single pair of wires The Setpoint value Output Power Setpoint Ramp Rate etc can be interrogated or changed by sending the proper command code via serial communications Alarm output s may also be reset via the serial communications interface option A programmable User Input is available with RS485 Valve Position and Second Analog Input models The User Input can be programmed to perform a variety of controller functions An optional NEMA 4X IP65 rated bezel is available for wash down applications and similar environments when properly installed Modern surface mount technology in house assembly and testing and high immunity to noise interference makes the controller extremely reliable in industrial environments 2 SAFETY SUMMARY AII safety related regulations local codes and instructions that appear in the manual or on equipment must be observed to ensure personal safety and to prevent damage to either the instrument or equipment connected to it If equipment is used in a manner not specified by the manufacturer the protection provided by the equipmen
106. mple Transmit the Input Display Value of the unit with an address of 3 Command String N3TA When writing application programs in BASIC the transmission of spaces or carriage return and line feed should be inhibited by using the semicolon delimiter with the PRINT statement The unit does not accept a carriage Command String RG return or line feed as valid characters It is recommended that a Transmit Value command follow a Change Value Command If this is done the reception of the data can provide a timing reference for sending another command and insures that the change has occurred When a Change Value or Reset command is sent to the unit there is time required for the unit to process the command string Figure 22 Timing Diagrams shows the timing considerations that need to be made Example Reset Alarm Output of the unit with an address of 0 If illegal commands or characters are sent to the PCU the string must be re transmitted 49 RECEIVING DATA Data is transmitted from the PCU when a T Transmit Value or a P Transmit Print Options command is sent to the unit via the serial port Data is also transmitted when the User Input programmed for the Print Request function is activated The print rate feature allows the selected print options to be transmitted at a programmable rate over the serial port The format fora typical transmission string with mnemonics is shown in Figure 23 Typical
107. n access code number Entering code 66 restores all parameters to factory settings the unit indicates the operation after the PAR button is pressed by displaying rSEt in the lower display momentarily The calibration operations are detailed in Calibration page 78 REFERENCE TABLES CONFIGURATION PARAMETER MODULES Configure Module 1 Input Parameters 1 IN Display Parameter Range and Units Factory Setting Value Description Comments tYPE Input type Square root linearization Decimal point VOLt Voltage Curr Current 0 0 0 0 00 or 0 000 0 0 Second Analog Input Models only If 0 000 is selected scaling points must be a positive value Rounding increments Digital filtering for input signal Scaling point 1 Display Value 2 5 10 50 or 100 4 999 to 9999 0 0 Used in conjunction with filtering to stabilize the display reading Increase number for more filtering effect 4 2 sec display update rate Normally key in display low value Scaling point 1 input signal value key in method Signal input method 4to 20 mA 0 10 VDC 999 to 9999 4 00 0 00 to 20 00 0 00 to 10 00 Normally key in input low value Press DSP button to select signal input method Normally apply input low value Scaling point 2 display value 999 to 9999 100 0 Normally key in display high value 39 Display Parameter R
108. n for details 46 5485 SERIAL COMMUNICATIONS INTERFACE RS485 communications allows for transmitting and receiving of data over a single pair of wires This optional feature can be used for monitoring various values resetting output s and changing values all from a remote location Typical devices that are connected to a PCU unit are a printer a terminal a programmable controller or a host computer The RS485 differential balanced design has good noise immunity and allows for communication distances up to 4 000 feet Up to thirty two units can be connected on a pair of wires and acommon The RS485 common is isolated from the controller input signal common to eliminate ground loop problems associated with the input probe The unit s address can be programmed from 0 to 99 An optional RLC Serial Converter Module GCM422 RS 422 to 20 mA current loop can be installed to expand the unit s flexibility COMMUNICATION FORMAT The half duplex communication operation sends data by switching voltage levels on the common pair of wires Data is received by monitoring the levels and interpreting the codes that are transmitted In order for data to be interpreted correctly there must be identical formats and baud rates between the communicating devices The formats available for the PCU unit are start bit 7 data bits No parity parity equals extra stop bit or 1 parity bit odd or even and 1 stop bit The programmable baud rates are
109. nction is activated when a command is sent via the serial communications port or after the time expires for the automatic print rate if enabled Serial communication is covered in detail in RS485 Serial Communications Interface page 47 Baud Rate bAUd The available baud rates are 300 600 1200 2400 4800 or 9600 Parity Bit PArb Parity can be odd even or no parity Address Number Addr Multiple units connected on the same RS485 interface line must each have a different address number A value of 0 does not require the address specifier command when communicating with the PCU The address numbers range from 0 to 99 Abbreviated or Full Transmission Abrv When transmitting data the PCU can be programmed to suppress the address number mnemonics units and some spaces by selecting YES An example of abbreviated and full transmission are shown below NO 65 123 8F lt CR gt lt LF gt Full Transmission YES 123 8 lt CR gt lt LF gt Abbreviated Transmission Print Rate PrAt The PCU can be programmed to automatically transmit the selected print options at the programmed print rate Selecting 0 zero disables the automatic print rate feature PrAt 0109999 seconds Print Options PoPt Selecting YES for the print options allows the operator to scroll through the available options using the PAR button The up and down arrow keys toggle between yes and no with yes enabling the option t
110. ng method can be used The following is a manual tuning procedure for determination of the PID control constants 1 Connect a chart recorder to log process value and set the paper speed appropriate for the process Set the controller to automatic auto control mode Set proportional band to 999 9 maximum setting Set integral time and derivative time to 0 seconds Decrease proportional band increase controller gain by factors of two until process just begins to oscillate and the oscillations are sustained Make a small change in setpoint to provide a stimulus for oscillations Allow adequate time for the process to respond If oscillations appear to grow increase proportional band Adjust the proportional band until steady oscillations appear 6 Note the peak to peak amplitude of the cycle a in degrees and the period of oscillation t in seconds Figure 42 Closed Loop Tuning Proportional Band 200a range 400a range 600a range Integral Time sec it 2t 3t Derivative Time sec 0 2t 0 25t 0 25t Output Power 40 1 30 1 20 Dampening sec 77 APPENDIX E CALIBRATION CALIBRATION CHECK The instrument has been fully calibrated at the factory for the voltage and current inputs If the unit appears to be indicating or controlling incorrectly see Troubleshooting page 73 before attempting this procedure If the controller is suspected of reading incorrectly the instrument may be c
111. nly to the repair or replacement of a defective product at The Company s option The Company disclaims all liability for any affirmation promise or representation with respect to the products The customer agrees to hold Red Lion Controls harmless from defend and indemnify RLC against damages claims and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries deaths property damage lost profits and other matters which Buyer its employees or sub contractors are or may be to any extent liable including without limitation penalties imposed by the Consumer Product Safety Act P L 92 573 and liability imposed upon any person pursuant to the Magnuson Moss Warranty Act P L 93 637 as now in effect or as amended hereafter No warranties expressed or implied are created with respect to The Company s products except those expressly contained herein The Customer acknowledges the disclaimers and limitations contained and relies on no other warranties or affirmations Red Lion Controls Headquarters 20 Willow Springs Circle York PA 17406 Tel 1 717 767 6511 Fax 1 717 764 0839 Red Lion Controls Europe Printerweg 10 NL 3821 AD Amersfoort Tel 31 0 334 723 225 Fax 31 0 334 893 793 Red Lion Controls India 54 Vishvas Tenement GST Road New Ranip Ahmedabad 382480 Gujarat India Tel 91 987 954 0503 Fax 91 79 275 31 350 PCU IM K 11
112. ntrol open loop In the Hidden Function Mode the trnf parameter allows the operator to select the desired operating mode To allow front panel switching between control modes program the transfer trnf parameter to Enbl in the Lockout Module The user input or RS485 serial interface option may also be used to perform the auto manual transfer function independent of the setting in the Lockout Module Manual operation provides direct control of the output s from 0 to 10096 or 100 to 100 if the secondary output is installed For Valve Positioner models with slidewire feedback this mode allows manual valve positioning The MAN REM for Remote Setpoint models annunciator flashes to indicate that the unit is in manual operation When transferring the controller mode from to automatic the control power output s remain constant exercising true bumpless transfer When transferring from manual to automatic the power initially remains steady but integral action corrects if necessary the closed loop power demand at a rate proportional to the Integral Time The programmable high and low power limit values are ignored when the unit is in manual operation REMOTE AND LOCAL SETPOINT OPERATION The controller setpoint mode can be switched between Local Setpoint operation and Remote Setpoint operation In the Hidden Function Mode the SPSL parameter allows the operator to select the desired setpoint operating mode To allo
113. o deadband Only used when ANAS OP 0 seconds updates output at a rate of 10 sec Configure Module 3 Lockout Parameters 3 LC Range and Units Factory Setting Description Comments Value Display Parameter Range and Units Display Parameter Factory Setting Description Comments Value Setpoint access Output power access Deviation Second Analog input LOC lockout rED read only Ent enter LOC lockout rED read only Ent enter Ent LOC lockout rEd read only rEd LOC lockout rEd read only rEd Determines access to process setpoint Determines direct access to output power PW indicator illuminates when parameter is selected in display Determines display of deviation DEV indicator illuminates when parameter is selected in display Determines display of Second Analog input Remote Setpoint SEC illuminates Blank display Access code LOC lockout rEd read only 0 to 250 0 Blanks secondary display Refer to front panel disable section for access levels PID values enable Secondary PID values enable LOC lockout rEd read only Ent enter LOC lockout rEd read only Ent enter LOC Protected mode lockout Protected mode lockout Cascade only 41 rtbS Remote Setpoint Ratio amp Bias LOC lockout rEd read only Ent enter LOC LOC lockout rEd read only Ent enter LOC Remote Setp
114. o be printed when a print function occurs INP Print Input Process Value SEt Print Setpoint Value OPr Print Output Power Value Pbd Print Proportional Band Value INt Print Integral Time Value dEr Print Derivative Time Value AL1 Print Alarm 1 Value 12 Print Alarm 2 Value dEv Print Deviation From Setpoint Value OFP Print Output Power Offset Value r P Print Setpoint Ramp Rate Value Crg Print Relative Gain Value Print Deadband Value OSt Print Output Status rAt Print Remote Setpoint Ratio Print Remote Setpoint Bias rSP Print Remote Setpoint Reading 2 Print Second Input Reading Pb2 Print Proportional Band 2 It2 Print Integral Time 2 2 Print Derivative Time 2 SP2 Print Internal Cascade Directed Setpoint 35 SECOND ANALOG INPUT MODULE 7 2N OPTIONAL The Second Analog Input can be configured as a Remote Setpoint Input or as a Secondary Input for Internal Cascade control As a Remote Setpoint the controller can operate as an External Cascade controller Setpoint Slave controller and as a Ratio controller See Cascade Control page 56 for an overview of cascade control Operation mode OPEr The Second Analog Input must be configured for either Remote Setpoint Operation or Internal Cascade Operation single controller cascade rSP Remote Setpoint 5 Internal Cascade Square Root Linearization root In some cases it may be necessary to l
115. o have the program disable function on versions with the User Input even if the User Input is not programmed for program disable PLOC by the use of acode number Versions that do not have the User Input are dedicated to the program disable function The following charts describe the possible program disable settings depending on your model MODELS WITH USER INPUT User Input State_ Code Number Inactive or User Full access to all modes and Input not parameter modules programmed for PLOC Active with User Input programmed Access to protected parameter mode only Code number does not for PLOC appear Active with User Any between Access to protected parameter Input programmed 1 amp 250 mode Correct programmed code for PLOC number allows access to OR unprotected parameter mode and User Input not configuration modules programmed for PLOC Note A universal code number 222 can be entered to gain access to the unprotected mode and configuration modules independent of the programmed code number MODELS WITH PROGRAM DISABLE Program Disable Code Number Inactive Full access to all modes and parameter modules Description Active Access to protected parameter mode only Code number does not appear Active Any between Access to protected parameter 1 8 250 mode Correct programmed code number allows access to unprotected parameter mode and configuration modules Note A universal code number 22
116. odule 84 MOTORIZED VALVE POSITIONER MODELS MVP NEMA 4to 20 mA 0 to 10 VDC PART 4X IP65 ANALOG ANALOG ra emp TE LX SC no R No or ves no ves 1 no NO PCUI2306 ACCESSORIES DESCRIPTION PART NUMBER Relay Module OMD00000 Triac Module OMD00001 Logic SSR Drive Module OMD00003 ISSR Powe r Unit RLY50000 Single Phase 25 A DIN Rail Mount Solid State Relay RLY60000 Single Phase 40 A DIN Rail Mount Solid State Rela RLY6A000 Three Phase DIN Rail Mount Solid State Rela RLY70000 Note Output Modules are NOT supplied with the controller When specifying the controller be sure to purchase the appropriate output module for the Main Control Output and if necessary the alarm output s the secondary output and valve positioner outputs The Logic SSR Drive Module is a switched DC source intended to drive the DC input of an SSR power unit It should never be connected to line voltage All modules are packaged separately and must be installed by the user 85 This page intentionally left blank 86 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from the date of shipment provided the products have been stored handled installed and used under proper conditions The 5 liability under this limited warranty shall extend o
117. ogram Disable es vocem se tote ees Xara eie sakes 19 HIDDEN FUNCTION rx eC ne X e eX E EUR 20 Hidden Function Mode Reference Table RR ia 20 CONFIGURATION PARAMETER MODULES 21 Input Module I Im eub RE ne ERR E tale shee dala e RR V e eg 21 Input Type PRG eu nire eI UR NN EO SO P DPA Re ded 21 Square Root Linearization root Optional 2 21 Decimal Point Position ICP Sess oer racha NATE ee Ro Code pae argu bid d USE 21 Rounding Increment Frid e e e Ue eg xd used e c usto e Ab te deu 21 Input Signal Filter and Display Update Rate FL 22 MEC 22 Display Values dSP1 4245 2 dite a Sa eK e eh eh deed 22 signal Input Values INPT amp INP2 ue EXE eR EET RAN ed 22 qe d bp SON C 22 signal Input Method rena mee peed EEG eed Oda S 22 Setpoint Limit Values SPEO amp SPHI teneo aua een qe s Su A Rc NUR RR lec 23 Ramp Rate SPIP 2 51 d Min dtd cider vedere dp Ree ud e af uds 23 Output Module2 OB nte Sa gett any instet iei CURE rea 24 Time Proportioning Cycle Time CY Ct siep
118. oint Ratio and Bias values enable Protected mode lockout AL Alarm values enable ALrS Reset alarms enable SPSL Remote Local setpoint select enable LOC lockout ENBL enable LOC LOC lockout ENBL enable LOC Hidden mode lockout Hidden mode lockout trnF user mode select enable Automatic Manual LOC lockout ENBL enable LOC Hidden mode lockout tUNE Auto tune enable LOC lockout ENBL enable LOC Hidden mode lockout Configure Module 4 Alarms 4 AL Unit returns to configuration access point if alarm s are not installed Display Parameter Alarm 1 operation mode Alarm 1 reset mode Range and Units Factory Setting Value A HI absolute high A LO absolute low d HI deviation high d LO deviation low b IN band inside b ot band outside Valv valve fail alarm A2HI absolute high second input 210 absolute low second input d2HI deviation high second input cascade d2LO deviation low second input cascade b2lN band in second input cascade b20t band out second input cascade Auto automatic LAtc manual reset Auto Description Comments If changed check alarm values Manual reset via hidden mode Alarm 1 standby function delay yes no no Power up standby delay Alarm 1 value 999 to 9999 0 0 If band alarm action then only a positive value can be entered
119. on OST 1001 Note The output power be changed only if the controller is in the manual mode of operation The command string is constructed by using a command a value identifier and a data value if required The Data value need not contain the decimal point since it is fixed within the unit when programmed at the front panel The PCU accepts the decimal point however it does not interpret them in any way Leading zeros can be eliminated but all trailing zeros must be present Example If an alarm value of 750 0 is to be sent the data value can be transmitted as 750 0 or 7500 If a 750 is transmitted the alarm value changes to 75 0 in the unit The address command allows a transmission string to be directed to a specific unit on the serial communications line When the unit address is zero transmission of the address command is not required For applications that require several units it is recommended that each unit on the line be assigned a specific address If they are assigned the same address a Transmit Value Command causes all the units to respond simultaneously resulting in a communication collision The command string is constructed in a specific logical sequence The PCU does not accept command strings that do not follow this sequence Only one operation can be performed per command string The following procedure should be used when constructing acommand string 1 1 1 COMMAND PCU 1 The first two to three cha
120. onnect precision ammeter 0 1 accuracy to rear terminals 11 and 12 Displa Parameter Description Comments Analog output 4 mA code value Analog output 20 mA code value 0 to 10 VDC Observe current reading If 4 00 mA press PAR If not equal modify existing code value using up and down buttons to achieve 4 00 mA Press PAR Observe current reading If 20 00 mA Press PAR If not equal modify existing code value using up and down buttons to achieve 20 00 mA Press PAR Press PAR until ANCL appears in the display Connect a precision voltmeter 0 1 accuracy to rear terminals 11 and 12 Parameter Analog output 0 VDC code value Displa Description Comments Observe voltage reading If 0 00 VDC press PAR If not equal modify existing code value using up and down buttons to achieve 0 00 VDC Press PAR Analog output 10 VDC code value Observe voltage reading If 10 00 VDC Press PAR If not equal modify existing code value using up and down buttons to achieve 10 00 VDC Press PAR Second Analog Input Calibration 2CAL Motorized Valve Positioner The signals applied to the Second Analog Input for calibration depend on Construct a precision resistor EXCITATION the type of model Second Analog Input and Motorized Valve Positioner divider network consisting of 100 represent the models for which unique calibration signals are required four 2500 0 1 tolerance 250
121. ontact with caustic vapors oils steam or any other process by products in which exposure may affect proper operation Caution Prior to applying power to the controller the internal AC power selector switch must be set Damage to the controller may occur if the switch is set incorrectly BEZEL GASKET FOR NEMA 4X IP65 UNITS ONLY LATCHING FEATURE PANEL LATCH Figure 1 Panel Installation amp Removal 4 UNIT REMOVAL PROCEDURE remove a NEMA 4X IP65 or standard unit from the panel first unscrew and remove the panel latch screws Insert flat blade screwdrivers between the latch and the case on the top and bottom of the unit so that the latches disengage from the grooves in the case Push the unit through the panel from the rear REMOVING BEZEL ASSEMBLY The bezel assembly shown in Figure 2 must be removed from the case to install or replace output modules or to set the 115 230 VAC selector switch Disconnect power to the unit and to the output control circuits to eliminate the potential shock hazard when removing the bezel assembly To remove a standard bezel assembly without bezel securing screws press the latch under the lower bezel lip and withdraw the bezel assembly To remove the sealed NEMA 4X IP65 bezel assembly loosen the two bezel securing screws until a slight click is felt the screws are retained in the bezel and withdraw the assembly Caution The be
122. oportional action alone equals the output due to derivative action with a ramping process error As long as aramping error exists the derivative action is repeated by proportional action every derivative time The units of derivative time are seconds per repeat Derivative action is used to shorten the process response time and helps to stabilize the process by providing an output based on the rate of change of the process In effect derivative action anticipates where the process is headed and changes the output before it actually arrives Increasing the derivative time helps to stabilize the response but too much derivative time coupled with noisy signal processes may cause the output to fluctuate too greatly yielding poor control None or too little derivative action usually results in decreased stability with higher overshoots No derivative action usually requires a wider proportional and slower integral times to maintain the same degree of stability as with derivative action Derivative action is disabled by setting the time to zero DEVIATION TIME output 4 PROPORTIONAL OUTPUT POWER DERIVATIVE OUTPUT TIME NOTE TOTAL OUTPUT POWER IS THE SUM OF THE THREE PID SETTINGS DERIVATIVE TIME Figure 30 Derivative Time OUTPUT POWER OFFSET MANUAL RESET If the integral time is set to zero automatic reset is off it may be necessary to modify the output power to eliminate erro
123. ote Setpoint the response of the controller can be programmed to act in a variety of ways These responses apply to changes in setpoint mode from the controller s front panel User Input or Serial communications The table summarizes the responses for Setpoint transfer operation SPtr parameter Local to Remote Remote to Local nor Output may bump Output may bump Auto No output bump Process output bump Process error eliminated at rate of error eliminated at rate of integral action integral action Output may bump Local setpoint assumes value of Remote setpoint tracks No output bump Note In situations where an output bump may occur the setpoint ramp function SPrP can be used to reduce or eliminate bumping when switching setpoint modes The setpoint ramp feature ramps the setpoint from the old setpoint mode to the new setpoint mode After the initial ramp has been completed the active setpoint Local or Remote remains in the setpoint ramp mode Secondary Output Power Dampening OPd2 The output power of the secondary loop Internal Cascade can be dampened filtered independent of the primary loop The secondary output power is the actual output of the controller The primary output power setpoint to the secondary is dampened by the OPdP parameter The secondary output power is dampened by the OPd2 parameter 37 VALVE POSITIONER MODULE 8 VP The Valve Positioner controller must be configure
124. parameters normally tuned first For Internal Cascade controllers Auto Tune offers the option of tuning the Primary or Secondary tunE no No Auto Tune or abort Auto Tune Pri Start Auto Tune of primary or Auto Tune of primary in progress SEC Start Auto Tune of secondary or Auto Tune of secondary in progress The Auto Tune status display indicates the set of parameters actively Auto Tuned Displ Displ TORE GSS Primary 1 APr1 ASC1 2 APr2 ASC2 3 APr3 5 3 4 APr4 ASC4 The following additional parameters are calculated and set a result of Auto Tuning of the secondary Secondary Proportional Band Pb 2 Secondary Integral Time It 2 Secondary Derivative Time dt 2 Secondary Output Power Dampening OPd2 Auto Tuning of the secondary presents two different control points at which the controller cycles power In Automatic mode of operation the secondary control point is the setpoint directed by the primary at the instant Auto Tune is started In Manual mode of operation the secondary control point is the secondary process value reading at the instant Auto Tune is started The secondary is normally Auto Tuned with the controller in the Manual mode of operation unless the process is reasonably under control Prior to tuning the Secondary it is essential that it is scaled to match the actual secondary process range This is important for proper Auto Tuning of the primary Subsequent changes made to scaling v
125. ppear if proportional band 2 0 0 or if locked LOC Second Analog Input models only 0 is off This parameter does not appear if proportional band 2 0 0 or if locked LOC Second Analog Input models only Second Analog Input models only Read only parameter 18 out in Configuration Module 3 Display Parameter Range and units Factory Setting Value Description Comments Remote setpoint ratio multiplier 0 001 to 9 999 1 000 Second Analog Input models only Remote setpoint bias offset 999 to 9999 0 Second Analog Input models only Alarm 1 value 999 to 9999 0 Alarm option models only Alarm 2 value Access code to unprotected mode Unit returns to normal display mode 999 to 9999 0 This parameter does not appear if the alarm option is not specified the secondary output option is installed or if locked LOC To gain access to unprotected mode enter the same value for Code as entered in parameter lockouts This parameter does not appear if zero is entered in code parameter lockout Brief display message display mode FRONT PANEL PROGRAM DISABLE There are several ways to limit the programming of parameters from the front panel buttons The settings of the parameters in the Lockout Module the code number entered and the state and or function programmed for the User Input Terminal 7 affect front panel access It is possible t
126. put OP2 in several combinations REVERSE ACTING The following lists the valid control modes PROCESS 1 OP2 VALID CONTROL MODES MANUAL MODE OUTPUT POWER RANGE 0 to 100 OP1 TP 100 op1 on 2 MODE OP1 STATE Y Any other setting OP1 OFF Ort OEE SITE PID 100 to 100 OP1 TP__ OP2 TP ON OFF 0 to 100 OP1 TP OP2 OFF GAN2 0 0 _100 to 0 1 _ 2 2 2 ON OFF ON OFF 100 PrOP 0 0 GAN2 0 0 wem Any other setting OP1 OFF OP2 OFF CONTROL OVERLAP db 2 0 PROCESS REVERSE ACTING Time Proportioning Note In manual mode the output power is not limited to the output power limits OPLO amp OPHI OP1 OFF OP1 OFF OP2 ON OP2 OFF OP2 OFF Figure 35 OP1 OP2 On Off Action 63 AUTO TUNE Auto Tune is a user initiated function in which the controller automatically determines the PID settings based upon the process characteristics During Auto Tune the controller temporarily causes the system to oscillate by cycling the output power from 0 to 100 The nature of these oscillations determines the settings of the controller s parameters PROCESS 4 TYPICAL RESPONSE CURVES WITH AUTOTUNE DAMPENING CODES 0 TO 4 Figure 36 Dampening Code Note If the induced oscillation
127. racters of the command string must consist of the CHANGE VAUE STRING PROCESSES Address Command N and the address number of the unit 0 99 If the CONTROL ACTION TRANSMITTED 1 COMMAND T unit address is zero the address command and number need not be sent RESET AT SELECTED 100msec Mox MODE COMMAND BAUD RATE 2 The next character in the command string is the command that the unit is to perform T C or V 3 A Value Identifier is next if it pertains to the command The command P print does not require a Value Identifier GOUMANS Si ANE ADDI TOMALSBATA 4 The numerical data is next in the command string if the Change Value or TRANSMIT STRING 1 PROCESSES TRANSMITS STRINGS OR BLOCKS Mn 2 ANSHIT VALUE TRANSMITTED COMMAND DATA STRING ARE TRANSMITTED AT PCU Control Action command is used PRINT REQUEST THE BAUD RATE WITH IN RECEIVE A AT SELECTED 1 100msec Min AT SELECTED A 100 TO 200msec MODE 5 All command strings must be terminated with an asterisk 2AH This COMMAND BAUD RATE 200msec Max BAUD RATE DELAY character indicates to the unit that the command string is complete and the unit begins processing the command A PCU BEGINS PROCESSING AFTER Below are typical examples of command strings Li Example Change Proportional Band Value to 13 0 on the unit with an address of 2 4 E Command String N2VD130 Figure 22 Timing Diagrams Exa
128. red about the setpoint value depending upon the steady state requirements of the process The band is shifted by manual offset or integral action automatic reset to maintain zero error Proportional band is expressed as percent of scaled display range OUTPUT REVERSE DIRECT POWER ACTING ACTING at A P BAND OP1 100 SIGNAL La SETPOINT Figure 28 Proportional Band The proportional band should be set to obtain the best response to a disturbance while minimizing overshoot Low proportional band settings high gain result in quick controller response at expense of stability and increased overshoot Settings that are excessively low produce continuous oscillations at setpoint High proportional band settings low gain result in a sluggish response with long periods of process droop A proportional band of 0 0 forces the controller into ON OFF control mode with its characteristic cycling at setpoint See ON OFF Control page 62 for more information 59 INTEGRAL TIME Integral time is defined as the time in seconds in which the output due to integral action alone equals the output due to proportional action with a constant process error As long as a constant error exists integral action repeats the proportional action every integral time Integral action shifts the center point position of the proportional band to eliminate error in the steady state The units of inte
129. rimary setpoint 10 of range 3 Key in secondary setpoint value equal to secondary process value 4 Auto Tune the secondary controller while in Local Setpoint mode 5 Place the secondary controller into Remote Setpoint mode and Automatic Auto mode of operation 6 Auto tune the primary controller while the primary is in Automatic mode of operation 7 Initial tuning of system is complete After the process has stabilized the primary and secondary may be re tuned in Automatic mode of operation Normally the primary requires re tuning whenever the secondary PID constants are changed Note For Remote Setpoint controllers the Auto tune control point is derived from the Remote Setpoint when in Remote Setpoint mode and it is derived from the Local Setpoint when in Local Setpoint mode APPENDIX APPLICATION EXAMPLES CHEMICAL MIXING APPLICATION A customer wants to control the ratio of one liquid flow to the other in a The 4 to 20 mA output of the PCU controls the position of a proportional chemical mixing application Each flow is monitored with a flow transducer valve Thus controlling the flow of B As disturbances cause the flow of A to that provides a 4 to 20 mA output signal The PCU monitors the flow of vary the PCU ensures that the proper ratio is always maintained The flow of liquid A via the optional Remote Setpoint Input Liquid is monitored A is shown in the secondary display simultaneously with the
130. rnal Cascade arrangement to regulate the temperature of a large dye vat The PCU is the Secondary controller with Remote Setpoint to regulate steam pressure The TCU is the primary controller with linear DC output which directs the setpoint of the Secondary controller in order to maintain vat temperature The range of the secondary steam process is 0 0 to 200 0 PSI PRIMARY CONTROLLER REMOTE SETPOINT INPUT LINEAR DC SETPOINT The following data configures the Remote Setpoint of the PCU OPEr rSP Select Remote Setpoint mode root NO No square root linearization necessary dPt2 0 0 Select decimal point position to match that of main input dSP1 0 0 Scale Remote Setpoint to match main input range of PCU INP1 4 00 Scale input range to match 4 to 20 mA output of TCU dSP2 200 0 Scale Remote Setpoint to match main input range of PCU INP2 20 00 Scale input range to match 4 to 20 mA output of TCU SPtr Auto Select bumpless Local Remote setpoint transfer In some cases the Remote Setpoint signal may change too rapidly or have excessive process noise This may lead to instability or even oscillation of the Secondary controller The Setpoint Ramp parameter SPrP is effective in limiting the amount of change of the Remote Setpoint The Setpoint Ramp parameter should be set to a minimum ramp value consistent with the response time of the Primary process Additionally Setpoint Limit Low and Setpoint Limit High parameters SPLO SPHI may be u
131. rs in the steady state The output power offset OPOF is used to shift the proportional band to compensate for errors in the steady state The output power offset OPOF parameter appears in the unprotected mode if the integral time equals zero If integral action automatic reset is later invoked the controller continues from the previous output power offset and updates accordingly PID ADJUSTMENTS To aid in the adjustment of the PID parameters for improved process control achart recorder is necessary to provide a visual means of analyzing the process Compare the actual process response to the PID response figures with a step change to the process Make changes to the PID parameters in no more than 20 increments from the starting value and allow the process sufficient time to stabilize before evaluating the effects of the new parameter settings P amp I PROCESS P amp Il amp bD SP TIME Figure 31 Typical Response Curve PID ADJUSTMENTS Cont d OVERSHOOT AND OSCILLATIONS SLOW RESPONSE PROCESS PROCESS A DAMPEN RESPONSE TO QUICKEN RESPONSE INCREASE PROPORTIONAL BAND DECREASE PROPORTIONAL BAND INCREASE INTEGRAL TIME DECREASE INTEGRAL TIME USE SETPOINT RAMPING INCREASE OR DEFEAT SETPOINT RAMPING USE OUTPUT POWER LIMITS EXTEND OUTPUT POWER LIMITS RE INVOKE AUTO TUNE WITH A RE INVOKE AUTO TUNE WITH A HIGHER DAMPENING CODE LOWER DAMPENING CODE INCREASE
132. s caused by Auto Tune can cause system problems or are otherwise unacceptable the Step Response Manual Tuning Procedure can be used as a tuning alternative Prior to initiating Auto Tune it is essential that the controller be configured to the application In particular control hysteresis CHYS and Auto Tune dampening code tcod must be set in the Output Parameters section Generally control hysteresis of 2 to 5 units is adequate The 64 AUTO TUNE OPERATION REVERSE ACTING PROCESS 1 SETPOINT AUTOTUNE CONTROL POINT i CHYS AUTOTUNE COMPLETE PID SETTINGS ARE CALCULATED AND LOADED INTO MEMORY AUTOTUNE INVOKED TIME Aut2 Aut3 1 OP1 OFF PHASE Aut4 DISPLAY MODES OP1 STATUS 1 LINEAR DC OUTPUTS VALVE POSITION 0 Figure 37 Auto Tune Operation dampening code may be set to yield the response characteristics shown in Figure 36 Dampening Code A dampening code setting of zero gives the fastest response with possible overshoot and a code of four gives the slowest response with minimum overshoot The following controller parameters are set by Auto tune according to the characteristics of the process Proportional Band ProP Integral Time Intt Derivative Time dErt Input Filter Fltr Output Power Dampening As shown in Figure 37 Auto Tune Operation Auto Tune cycles the process at a control point
133. s measured by the PCU and scaled internally to equal 0 to 100 The scaled valve position is compared with the output power to determine if the valve needs to be repositioned Since the output power and valve position both range from 0 to 100 and normally equal each other the output power display PW represents valve position Based on this information the valve can be positioned manually from the Manual USEr mode of the controller The output power can be manually ranged from 0 to 100 to position the valve In the event that the valve position feedback and the output power do not agree due to a faulty valve motor binding valve or defective slidewire a valve fail alarm occurs if desired The valve fail alarm is based on a timer in which the output power and valve feedback positions must match within a preset time A display message of VALV occurs in this event Optionally an alarm event output can be programmed to signal the event to other equipment Once the alarm triggers the output power and feedback positions must match to silence the alarm Setting the valve fail time parameter to zero disables this feature and also silences a triggered alarm The controller also senses loss of slidewire feedback signal and can activate the open or close outputs in such an event See Input Overdrive Preset Power OPFL page 25 for a description of this operation Example Steam is used to heat water by passing it through a heat exchanger V
134. sed to constrain the Remote Setpoint value to safe limits or narrow the operating range for stability purposes See Auto Tune page 64 for tuning procedure of External Cascade controllers SECONDARY CONTROLLER PRIMARY PROCESS SECONDARY PROCESS SECONDARY OUTPUT PRIMARY OUTPUT Figure 26 External Cascade 57 Internal Cascade Control The Internal Cascade control mode of the PCU embodies the function of two Cascade controllers into a single unit In all other respects Internal Cascade yields the same control flexibility and control quality as External Cascade In Internal Cascade the Primary loop provides an internal setpoint for the Secondary loop The Primary loop output power 0 100 is scaled internally by the DSP1 and DSP2 scaling parameters to yield the Secondary directed setpoint This setpoint is used by the secondary loop to calculate the actual output physical output The setpoint can be viewed during operation by the SP 2 parameter See Figure 27 for more details For proper Auto Tuning of the Primary loop it it necessary that DSP1 and DSP2 represent the actual process low and process high values respectively of the Secondary process The tuning parameters Prop Intt dErt OPdP pertain to the primary loop and the tuning parameters Pb 2 It 2 dt 2 OPd2 pertain to the secondary loop ERNAL CASCADE CONTROLLER Example A PCU with Second Analog Input is
135. solution required a rounding increment of 10 will effectively make the display more stable This programming step is usually used in conjunction with programmable digital filtering to help stabilize display readings If display stability appears to be a problem and the sacrifice in display resolution is unacceptable program higher levels of digital filtering or increase the level of process dampening Rounding increments of 10 20 50 and 100 may also be used to add dummy zeroes to the scaled readings as desired 100 The rounding increment is for the controller s display only and does not affect degrade the control accuracy of the unit Input Signal Filter and Display Update Rate FLtr Select the relative degree of input signal filtering and display update rate The filter is an adaptive digital filter that discriminates between measurement noise and actual process changes Therefore the influence on step response time is minimal If the signal is varying too greatly due to measurement noise increase the filter value Additionally with large derivative times control action may be too unstable for accurate control Increase the filter value Conversely if the fastest controller response is desired decrease the filter value The Auto tune procedure sets the filter value appropriate to the process characteristics Also see Output Power Dampening parameter OPdP page 25 for filtering the output Fltr 0 to 4 least input fi
136. t from the dampening action 0 to 250 seconds 25 The dampening parameter is expressed as a time constant in seconds Increasing the value increases the dampening or filtering effect A value of zero disables output power dampening The amount of dampening to be used depends primarily on the response time of the process and the amount of final actuator activity desired Generally dampening times in the range of 1 20 to 1 50 of the controller s integral time or process time constant prove to be effective Dampening times longer than these may cause controller instability due to the added lag effect of too much filtering In the case where a relatively high dampening time is desired the controller s proportional band may be increased to restore an adequate stability margin The Auto tune procedure of the controller sets the dampening value appropriate to the characteristics of the process ON OFF Control Hysteresis Band CHYS The controller can be placed in the ON OFF control mode by setting the proportional band to 0 096 The control hysteresis value affects only the main control output CHYS 1 to 250 units The hysteresis band should be set to a minimum value to eliminate output chatter at the setpoint Set the hysteresis band to a sufficient level prior to invoking Auto Tune Internal cascade controllers secondary loop have a fixed hysteresis of 1 5 of scaled range Auto Tune Dampening Code tcod Prior to
137. t may be impaired Do not use the PCU to directly command motors valves or other actuators not equipped with safeguards To do so can be potentially harmful to persons orequipment in the event of a fault to the unit An independent and redundant temperature limit indicator with alarm outputs is strongly recommended Red Lion Controls offers various units such as an IMP IMDI or IMD2 that may be used for this purpose The indicators should have input sensors and AC power feeds independent from other equipment INSTALLATION amp CONNECTIONS INSTALLATION ENVIRONMENT The unit should be installed in a location that does not exceed the maximum operating temperature and provides good air circulation Placing the unit near devices that generate excessive heat should be avoided Continuous exposure to direct sunlight may accelerate the aging process of the bezel The bezel should be cleaned only with a soft cloth and neutral soap product Do not use solvents Do not use tools of any kind screwdrivers pens pencils etc to operate the keypad of the unit STANDARD UNIT INSTALLATION Prepare the panel cutout to the dimensions shown in Figure 1 Panel Installation amp Removal Remove the panel latch and cardboard sleeve from the unit and discard the cardboard sleeve The unit should be installed with the bezel assembly in place Insert the unit into the panel cutout While holding the front of the unit in place push the panel latch over the
138. tional Alarm optional Secondary output and optional Valve Position control output sockets must be fitted with the appropriate output module Output modules are shipped separately and must be installed by the user Output Module Restrictions With some models the Alarm outputs and Valve Position outputs share the same common terminal When using these models the same type of output modules should be installed in these positions Installing Output Modules To install an output module into the controller remove the bezel assembly from the case See Removing Bezel Assembly page 5 Locate the correct output module socket ALI or AL2 OP2 see Figure 6 Hardware or label outside of case and plug the output module into the socket No re programming is required If changing an output module type be sure the appropriate output interface wiring changes are made Re install the bezel assembly when complete Note For Valve Positioner models the circuit board markings have the following meaning ALI Open Output AL2 OP2 Close Output OPI Alarm 1 Output OUTPUT MODULE OUTPUT STATE Normally open contact is closed Source is active Typical Connections e B POWER saws B5 Neo 240 LOAD Figure 3 Relay Module Relay Type Form C Form A with some models See Ordering Information Rating 5 Amps 120 240 VAC or 28 VDC resistive load 1 8 HP 1
139. trol quality The update time is variable from 0 to 250 seconds A value of zero causes the valve position to be updated at the controller s scan rate 10 sec Valve Position Deadband VPdb Position Mode The difference between the power output and the slidewire valve position must exceed the deadband in order for the controller to update the valve position Normally the deadband is set toa minimum to compensate for valve motor overrun and gearing backlash to eliminate hunting Deadband values that are too large may result in excessive errors Values that are too small may result in excessive hunting The Output Power Dampening OPdP parameter can also be used to reduce valve activity Typically set in the range of 1 396 VPdb 0 0 to 25 0 Valve Fail Time Alarm VFAL Position Mode The valve fail time is the maximum time allowed in which the slidewire feedback signal must match the output power before an error message appears If this condition is not met a valve sentry alarm message appears VALV in display indicating a failed valve or failed valve positioner Optionally an alarm can be configured to provide an output event see Alarm Action page 28 This feature also applies to valve positioning with linear DC output The fail time must be set at a minimum larger than the Valve Update Time together with the valve motor transit time A value of zero disables the valve fail feature 38 An active valve fail al
140. ue and setpoint simultaneously Front panel indicators inform the operator of the controller and output status Replaceable and interchangeable output modules Relay SSR Drive or Triac can be installed for the main control output Alarm output s Secondary output and Valve Positioner outputs Optional dual alarms can be configured to activate according to a variety of actions Absolute HI or LO Deviation HI or LO Band IN or OUT and Valve Fail Detect with adjustable hysteresis A standby feature suppresses the output during power up until the process stabilizes outside the alarm region An optional secondary output is available for processes requiring cooling pH balance etc that provides increased control accuracy and response A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface with actuators chart recorders indicators or other controllers The type of Linear DC output is determined by the model ordered See Ordering Information page 84 for available models The output signal can be digitally scaled and selected to transmit one of the following 96 output power measurement value deviation or setpoint value For Linear DC control applications the adjustable output demand dampening output deadband and output update time parameters expand the versatility of the PCU to final control devices The optional Motorized Valve Positioner directly controls the position of a valve by the use of twin outputs open and
141. ue command Followed by one Value Identifier B H J M or X Z then the proper numerical data SENDING COMMANDS AND DATA Cont d IDENTIFIER A Input Display Value B Setpoint Output Power SERIAL DESCRIPTION MNEMONIC Integral Time Derivative Time Alarm 1 121 Deviation Output Power Offset Setpoint Ramp Rate R Relative Gain G Deadband U Remote Setpoint Ratio Remote Setpoint Bias Controller Mode lt BIA 1 Automatic 2 Manual Setpoint Mode 2 Remote Output status Secondary Proportional Band Secondar integral Time Second Input Reading IN2 7 Remote Setpoint Reading RSP or U Secondary Directed Setpoint 5 2 O Q 5 X N 2 Output status transmission format ABCD 0 output off 1 output Note The output power can be changed only if the controller is in the manual mode of operation 48 The output status indicates the status of the controller s outputs The status can only be read see the following table The alarms outputs may be reset by the reset operator R Output Status NON VALVE POSITIONER MODELS VALVE POSITIONER MODELS A_ Main output OP1 A Alarm 1 output AL1 Secondary output OP2 C Alarm 2 output AL2 D Alarm 1 output AL1 D Motor close output CLS Motor open output OPN Example ON OP2 OFF AL2 OFF ALI ON Transmissi
142. uration access point if Valve Positioner option is not installed VPS1 Valve position 1 VPS2 Valve position 2 Range and Units Factory Setting Value 99 9 to 999 9 0 0 99 9 to 999 9 100 0 0 to 250 seconds 10 Description Comments Normally full closed valve position Either key in value or press DSP for measure record mode Normally full open valve position Either key in value or press DSP for measure record mode 0 update at a rate of 10 sec VUdt Valve update time VPdb Valve position deadband 0 1 to 25 0 2 5 0 to 9999 seconds 0 Adjust to reduce hunting and valve activity Position Ozoff set value larger than update time plus motor transit time Position mode only VFAL Valve fail time alarm VOPt Valve motor open time 1 to 9999 seconds 30 1 to 9999 seconds 30 Measure actual valve motor open time Velocity mode onl Measure actual valve motor close time Velocity mode only VCLt Valve motor close time VOnt Valve minimum on time 0 1 to 25 0 seconds 1 0 Adjust to reduce hunting and valve activity Velocity Configure Module 9 Factory Service Operations 9 FS Display Parameter Range and Units Factory Setting Value Description Comments Code Enter factory service 48 Calibrate function code instrument 66 Reset parameters to factory settings Refer to Calibration Sectio
143. used in an Internal Cascade arrangement to regulate the temperature of a large dye vat The Second Analog Input is the input to the Secondary loop This loop regulates steam pressure The Primary loop temperature directs the setpoint of the Secondary to maintain vat temperature The range of the Secondary steam process is 0 0 to 200 0 PSI transmitted by a 4 to 20 mA transducer The following data configures the Internal Cascade controller OPEr CSCd_ Select Internal Cascade mode root NO No square root linearization necessary dPt2 0 0 Select decimal point position for 0 0 PSI dSP1 0 0 Secondary process display low value 0 0 PSI INP1 4 00 Secondary process transmitter low value 4 mA dSP2 200 0 Secondary process display high value 200 0 PSI 2 20 00 Secondary process transmitter high value 20 mA OPd2 2 Secondary output power physical output dampening The Secondary process value can be monitored during operation in the secondary display See Auto Tune page 64 for tuning procedure of Internal Cascade controllers PRIMARY SETPOINT SECOND ANALOG PRIMARY PROCESS SECONDARY PROCESS SECONDARY OUTPUT PRIMARY INPUT OUTPUT Figure 27 Internal Cascade 58 PID CONTROL PROPORTIONAL BAND Proportional band is defined as the band of units the process changes to cause the percent output power to change from 0 to 100 The band may or may not be cente
144. ut dampening Incorrect PID values Valve update time too short Increase valve deadband Increase output dampening See PID Control Increase valve update time OUTPUTS NOT WORKING LINEAR DC OUTPUT NOT WORKING CONTROLLER LOCKS UP OR RESETS 1 2 3 4 1 2 3 4 1 2 3 4 Output module not installed Improperly wired Incorrect output module Defective output module Improper load resistance Incorrect programming or scaling Connections reversed DC voltage source in loop 4 to 20 mA only Noise spikes entering controller due to load switching transients Defective controller 74 1 Install output module Check wiring Check output module Check or replace output module Check load resistance Check programming Check connections This is an active loop Remove all DC voltage sources 4 to 20 mA only Use RC snubber across the load a Use Triac output modules whenever possible b Use separate AC feed line to controller c Locate controller amp signal lines away from noise 2 producing mechanisms solenoids transformers etc Replace Unit OUTPUT LEAKAGE CURRENT The ALI AL2 OP2 outputs of the PCU have an RC Network Snubber on the Normally Open contacts High energy noise spikes are generated whenever current through an inductive load such as motors solenoids or relay coils is interrupted This noise m
145. ve internal bias resistors connected to the RS485 transceiver lines The signal ground is connected at the RS485 common of only one PCU unit to the RS485 equipment If necessary the shield can be used as the signal ground The signal input common is isolated from the RS485 common and the analog output terminal Note Do not connect any of the commons to the analog output terminal Terminal Descriptions RS485 COMM Common may be required for communication hook up TX RX amp TX RX The PCU transmits and receives on these two terminals which are connected to the external device TX EN Used with Red Lion Controls RLC GCM422 Serial Converter Module RS422 to 20 mA Loop Otherwise not normally used Note Some models do not have TX EN This is an output used in conjunction with interface converter Model GCM422 to convert RS485 to 20 mA current loop 52 Connecting A Host Terminal Six PCU units are used to control a process in a plant The PCU units are located at the proper location to optimize the process A communication line is run to an industrial computer located in the production office Figure 24 Connecting To A Host Terminal shows the line connection Each PCU is programmed for a different address and all are programmed for the same baud rate and parity as the computer An application program is written to send and receive data from the units using the proper commands TROUBLESHOOTING SERIAL
146. w front panel switching between setpoint modes program the setpoint select parameter SPSL to Enbl in the Lockout Module The user input or RS485 serial interface option may also be used to perform the setpoint selection function independent of the setting in the Lockout Module Front panel annunciator REM is on for Remote setpoint operation and is off for Local setpoint operation When transferring the controller mode from to the setpoint modes various controller response options are available see SPtr parameter page 37 13 CONFIGURATION OF PARAMETERS As supplied from the factory the controller parameters have been programmed to the values listed in the Programming Quick Reference Tables The user must modify the values if necessary to suit the application Operation and configuration of the controller is divided into five distinct operational programming modes to simplify the operation of the controller Normal Display Mode Unprotected Parameter Mode Protected Parameter Mode Hidden Function Mode and Configuration Parameter Modules See Figure 11 Operational Programming Modes UNPROTECTED PARAMETER MODE SETPOINT OUTPUT POWER OFFSET OUTPUT POWER HIDDEN FUNCTION MODE SELECT LOCAL REMOTE SETPOINT TRANSFER OPERATION AUTO USER INVOKE CANCEL AUTO TUNE RESET ALARM OUTPUT S PRESS amp HOLD BUTTON FOR 5 SECS PROGRAM DISABLE INACTIVE PROPORTIONAL BAND INTEGRAL TIME
147. zel assembly contains electronic circuits that are damaged by static electricity Before removing the assembly discharge stray static electricity on your body by touching an earth ground point It is also important that the bezel assembly be handled only by the bezel itself Additionally if it is necessary to handle a circuit board be certain that hands are free from dirt oil etc to avoid circuit contamination that may lead to malfunction If it becomes necessary to ship the unit for repairs place the unit in its case before shipping it INSTALLING BEZEL ASSEMBLY To install the standard bezel assembly insert the assembly into the case until the bezel latch snaps into position To install the NEMA 4X IP65 bezel assembly insert the assembly into the case and tighten the bezel screws uniformly until the bezel contacts the case and then turn each screw another half turn to insure a watertight seal do not over tighten screws Caution When substituting or replacing a bezel assembly be certain that it is done with the same model using the same Output Modules Damage to the controller may result if the unit s output modules are not the same NEMA 4X IP65 and a standard bezel assembly are NOT interchangeable Bi BEZEL SCREWS TWO NEMA 4X IP65 UNIT ONLY DC EXISTING PANEL BEZEL LATCH STANDARD UNIT ONLY Figure 2 Bezel Assembly OUTPUT MODULES The main control op

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