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T640 Integrated loop processor Reference manual & User guide

1. DIGITAL INPUTS Site 2 Bit 3 Parallel In Serial Out Site 2 Bit 2 Site 2 Bit Site 2 Bit 0 Site 1 Bit 3 Site 1 Bit 2 Site 1 Bit 1 Site 1 Bit 0 5V Dig LATCH ee 1P 400K _ Latching pulses y lt gt flows JL 100K L Digital ground A 1 0 MICRO ny CONTROLLER nZ Digital ground common to 1 0 Serial data IN 24V nom 2K7 2 OUT ext input ae e loc or X Mise 15V nom internal output Digital supply Site 2 Bit 3 Site 2 Bit 2 3 Site 2 Bit Site 2 Bit 0 mml Site 1 Bit 3 Site 1 Bit 2 _ Site 1 Bit 1 Site 1 Bit 0 m OUTPUT V LATCH 2K2 1T 68R C pmt b Serial In Parallel Out Digital ground DIGITAL OUTPUTS Figure 11 3 Digital input amp output block schematic Gain drift 30ppm C Offset drift 65uV C Input impedance Break detection Sample rate 1 MQ pull down to 1 2V within 1 sample Protection strategy selected from within the configuration up scale down scale etc 9ms per configured input Only the configured inputs are scanned The fastest loop update cannot be less than 20ms 1142 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications
2. LOOP 1 INPUT NI PNE aoa TRANSMITTED sws iwFiearere OUTPUT TX PSU 1C Transmitter area Pe 3 i PVOP1 TX PSU supply SEES Se e re c n z I 1D y PID CONTROL i L p analogue 7 1M PvisPour BV l area E output j analogue P E block i PV 1E input i Se a Pts Fee Des block p SETP1 LPV Q IEEE E G setpoint i mit L4 block LSP CONTROL B analogue a SP TRIM 1H QH ipit tee area 3 block v j E OUTP1 D 3T OUT psa Sem i analogue 1A Jem E analogue D D REM SP 1F O ioe block block A 1B sTouT block i i 1 y i TRCKi MANS1 i OP 1 TRACK 1J S ge manuali o p 1IL sr our 010V block block block f COMP EN 1P S ii PROCESS REM SP EN 1 1 DIN 1 i ALARM oS dgia 7 i 1 OUTPUT area Z 1T HIALMOUTO Alarm Inpui sex H TRACK EN 1 1R S mL J d DOP 1 1U Lo au outo f UUs HOLD EN 1 18 QU e IEE output F A 1V REMAUTOUT O Cascade i control IIIA LO 1W HOLD MAN OUT 0 J interlocks NOTE SYSTEM ALARM LOOP 4 9 oraraa terminal designation ted USR_ALM OUTPUT area ienotes tha e designated state Is asserte fm ak oe 7 when the signal is low or high respectively edocti eds o Watchdog i ba
3. High evel I O CURRENT OUTPUTS Med 1A Q9 e 28V isolated apy Isolated ec ZN Pulse width i modulated 1B 2 9 output 1 DC e m recovery Y a Be n P 220R OV isolated OV isolated Isolated power 1 0 MICRO supplies 60V VO card CONTROLLER Isolation PSU Isolated power supplies CURRENT OUTPUTS 2A e 28V isolated 5V isolated e A Pulse width Q e modulated B output a lt poc INUL eee ad cy recovery hi E y 4M A n 220R OV isolated OV isolated TRANSMITTER PSU 22R 10 Q r Y F PSU OUTPUT Vick X 1D TX TRANSMITTER PSU 2c e Kk alg wit wx TX 2D Figure 11 4 Current output amp transmitter PSU block schematic T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 13 High level I O Specifications Internal burden resistors Values Power Tolerance Temperature coefficient HIB option 250R HGB option 62R 0 25W 0 1 15ppm C NOTE Tolerances and temperature coefficients must be added to the specified analogue input tolerances Transmitter power supplies Channels Voltage Current Current limit Isolat
4. sss 4 6 Alarm display amp inspection sess 4 7 Alarm inspection via the ALM button eere 4 7 Quitting alarm inspection modes seen 4 7 Security KEY RT 4 9 Key parameters setate euenit Dr eeu 4 9 Using the Key i tear EPI GR RR C e NIRE 4 9 Battery replacement L5 uie ettet hee epi 4 10 Chapter 5 STANDARD STRATEGIES Purpose of the standard strategies sess 5 1 Summary of the standard strategies sess 5 1 Strategy tyD6S cien eemper eot ane e a E chaos 5 1 Strategies supplied in EEPROM sss 5 2 Strategies supplied in EPROM ROM sse 5 2 Further information on Standard strategies eee 5 3 Complete strategy specification via LINtools 5 3 Text files on the strategies supplied in EEPROM 5 3 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents 5 Contents Creating your own standard strategies sess 5 3 Other documents a teer de cpcecteen a a e a 5 4 Running a default standard strategy sss 5 4 Fixed function strategy design principles sss 5 6 Fixed function strategies Motherboard customer terminals sese 5 6 Strategy 1 Single control loop see 5 7 Strategy 41 sche
5. Figure 3 10 Inspect button functions IN S 3 16 T640 Reference M anual amp User Guide Issue 5 Tutorial NOTE Ifyou now press either A or V you will see another loop LOOP 4 in the tag display Loop 4 is not actually a control loop but is a second inde pendently running section of the database user task 4 that you can access via the INS button Loop 4 contains among other items configuration data on T640 communications which do not concern us here With LOOP 1 in the display press INS again The units display changes to BLOCK denoting block access mode and the tag display now shows the name of the first block in the Loop 1 i e User task 1 area of the database This block may or may not be the one you want SETP1 depending on how the T640 s memory module has been programmed at the factory In any case now press the W button to move down to the next block in Loop 1 and see its name in the tag display Press W again repeatedly to see all the blocks in Loop 1 that you can access for in spection or modification There are 13 altogether Use A to move up the list again if you go past the block you require Access the SETP1 block With SETP1 in the tag display press INS again This gets you into field access mode as shown by FIELD in the units display The tag display now shows the first accessible field in the SETP1 block which is called HR SP This field stores
6. csesesesee 11 19 Hardware configuration LIN blocks parameters not supported Break detection amp break protection sess Hardware organisation eese mV thermocouple inputs essen Low level mV input mode eene Thermocouple input mode eene Analogue Inp t erected tet rte aaae aeiiae Voltage input mode sees Frequency input mode esee Totalisation un tb n ir ERE EE ERA GUNI EEUU Process OUEDUt 1 e te eae nS Analogue output 5 ete eee eene eere te i Digital inputs Digital outputs Contents 10 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents eus cscs cosas vancvaces o a EEEE a deat asevasandens EE ATE 11 27 V O calibration procedure sse 11 28 Partial re calibration eene 11 28 Chapter 12 ORDERING INFORMATION Ordering OPUONS resserre anois a ect eere conte cescovienssecatostuarstsenves 12 1 T640 Order codes e tette tti 12 1 T710 Sleeve ordered separately sess 12 2 T950 Security Key i5 oce oO de n eH SIDES 12 3 T901 Memory module ordered separately 12 4 Burden resistor diode amp ALIN terminator kits 12 4 Appendix A SETTING UP EARLY BOARDS T640
7. 3T OUT Interlocking signals REM SP SLAVE Local setpoint Figure 5 6 Example P amp I diagram for strategy 3 524 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 3 The purpose of the interlocking signals indicated in the Figure is to provide bumpless pro cedureless transfer between modes of operation Table 5 9 shows the pin assignments cor responding to these interlocks with Loop 2 as the master controller and Loop 1 the slave For completeness the Figure also lists the 3T OUT to REM SP connection not strictly an interlock signal MASTER SLAVE Pin Function Pin Function 2L 3T OUT 1F REM SP 2 TRACK c 1M PV OUT 2W HOLD MAN OUT 0 1Q REM SPEN 1 2R TRACK EN 1 c 1V REM AUTOUT 0 Table 5 9 Cascade interlocking signals strategy 3 Note that Table 5 9 is given for information only All the interconnections shown have been made within the strategy in software so you do not need to wire them externally Cascading a pair of loops Although you don t need to physically wire the interlock signals between Loops 1 and 2 if you are using strategy 3 as supplied you will find Table 5 9 useful if you want to cascade a different pair of loops As examples you may want to cascade the disconnected pair of loops supplied in strategy 2 dual loop or even two loops running in diff
8. So m o INT STI wn e m DC EARTH ai 7 DC ve m 8 DC ve Figure 3 2 Customer terminals MAINS left and DC right options T640 Reference M anual amp User Guide Issue 5 3 3 Tutorial SWITCH SETTINGS A bank of eight on board switches must be configured for this tutorial To access them you have to remove the T640 from its sleeve Removing the T640 from its sleeve Caution Handling precautions Some of the circuit boards inside the T640 contain elec trostatically sensitive components To avoid damage before you remove or han dle any board ensure that you the working area and the board are electrostatically grounded Handle boards only by their edges and do not touch the connectors Connector erosion Repeated removal replacement of the T640 under power erodes edge connectors Check connectors periodically and replace a board if ex cessive burning or pitting is seen See Figure 3 3 To unlock the T640 insert a small screwdriver blade into the slot in the retaining clip at the bottom of the fascia and slide the clip to the left as far as it will go Repeat this for the clip at the top of the fascia but slide it to the right To withdraw the unit use the extractor tool supplied in the accessory kit Part No BD 082253 Hold the tool at an angle of about 45 insert the hook
9. T950 SECURITY KEY CODE DESCRIPTION Base unit T950 Infrared security key Access FULL Full access to all parameters provided PARTIAL Partial access to parameters provided Area AREAn Key operates only instruments with specified area code n or zero area code n 1 to 8 Key operates only instruments with zero area code Labelling language EN English FR French GE German IT Italian SN Swedish SP Spanish PO Notyetavailable CY Notyetavailable US American Example T950 PARTIAL AREA 3 EN Table 12 3 1950 security key order codes T640 Reference M anual amp User Guide Issue 5 12 3 T901 codes Ordering information T901 MEMORY MODULE ORDERED SEPARATELY CODE DESCRIPTION Base unit T901 M emory module Controller function M001 24oop control M002 44oop control M003 Notyetavailable M004 44oop control with sequencing MOO6 Fixed function Integrated Loop Processor M007 Advanced features Required to support the AGA8DATA block M101 105 Pre packaged applications Contact Eurotherm Sales O ffice for details Labelling language EN English FR French GE German IT Italian SN Swedish SP Spanish PO Notyetavailable CY Notyetavailable US American Example T901 M001 EN Table 12 4 T901 memory module order codes BURDEN RESISTOR DIODE amp ALIN TERMINATOR KITS Encapsulated plug in modules for insertion in T640 s rear panel customer screw terminals are orderable u
10. T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents T640 REFERENCEMANUAL amp USER GUIDE Chapter 1 INTRODUCTION page T he T640 5 ee tee en aee Rep tiun 1 1 Summary of T640 s main features sss 1 2 What s in this manual eese 1 2 What s not in this manual eere 1 2 Get rig Started ie e ode fee eei antes 1 3 Chapter 2 INSTALLATION amp STARTUP Safety amp EMC information sse 2 1 Installation requirements for EMC sse 2 1 Installation safety requirements een 2 2 Personnel enses nene e eI t ete en 2 2 Protective earth connection sseseseeeeeeeee 2 2 Protection from hazardous voltages sss 2 3 WINE ie notet eie er OO Ea 2 3 Disconnecting device essere 2 3 Overcurrent protection seeseseseseeeeeeeneenen nentes 2 3 Installation category voltages sese 2 3 Conductive pollution sese 2 4 Ventilation 3 en P EANN 2 4 Electrostatic discharge handling precautions 2 4 Safety symbols marked on the unit eerie 2 4 Keeping the product safe essere 2 4 Misuse of equipment sess 2 4 Service and Tepalts o enero rettet per A etna 2 5 Cleaning
11. Caution Electrostatic sensitivity Some circuit boards inside the unit contain electro statically sensitive components To avoid damage before you remove or handle any board ensure that you the working area and the board are electrostatically grounded Handle boards only by their edges and do not touch the connectors Safety symbols marked on the unit Various safety warning symbols are marked on the unit which have the following mean ings T fe se onan Protective ert Caution Maing documents terminal voltages present N Alternating current TT Direct current 24 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Keeping the product safe To maintain the unit in a safe condition observe the following instructions Misuse of equipment Note that if the equipment is used in a manner not specified in this handbook or by Euro therm Process Automation the protection provided by the equipment may be impaired Service and repairs This unit has no user serviceable parts except for the power supply fuse which should be replaced by authorised personnel only Contact your nearest Eurotherm Process Automa tion agent for repair Cleaning instructions Use a suitable antistatic vacuum cleaner to keep the unit and all associated air inlets out lets clear of dust buildup Wipe the front panel with a damp cloth to keep it clean and the operator legends and displays clearly visible Mi
12. Unused 2Y Digital Gnd Reference ground for digital signals 22 Digital Gnd Reference ground for digital signals Table 5 7 Site 2 I O customer terminal assignments Strategy 2 function blocks and parameters This strategy has three user tasks seen as LOOP 1 LOOP 2 and LOOP 4 in the tag display that you can access via the INS pushbutton to configure their function blocks The parameters in Loops 1 and 2 deal with configuration of the respective control loops themselves and those in Loop 4 cover system alarms and general instrument setup When you come to configure these parameters you will find the setup sheets helpful be cause they list the default values of all fields and include a spare column for you to record your customised values where required You may want to use photocopies of the printed setup sheets as your working documents The setup sheets for this strategy are found un der Setup sheets all strategies on page 5 34 Loop 1 Loop 1 parameters are identical to those given for strategy 1 see Table 5 5 on page 5 10 Loop2 Table 5 8 lists the Loop 2 parameters for strategy 2 together with explanations of their functions NOTE The order of the blocks in the table may not match their order of appear ance when you access them via the INS button T640 Reference M anual amp User Guide Issue 5 Strategy 2 Standard strategies Block Field Subfield Description SL6
13. 1 2 T640 software structure The T640 communications keep a copy of relevant parameters in MODBUS tables which may be individually configured for either digital or register data This copy is updated from the LIN database by a scanner task running in the T640 The T640 supports 16 separate tables whose size is configurable The MODBUS data area does not detract from the space available for the continuous database Figure B 1 schematises the T640 software structure 1 3 MODBUSJ JBUS function codes supported Table B 1 lists the MODBUS function codes supported by the T640 together with their maximum scan counts i e the maximum number of registers or bits that can be read or written in a single MODBUS transmission of this type For full details on MODBUS messages and functions please refer to the Gould Modicon MODBUS Protocol Reference Guide Code Function 1 Read digital output status Read digital input status Read output registers Read input registers W rite single digital output W rite single output register Fast read of single byte nor configurable in master Diagnostics nor configurable in master supports subcodes 0 1 2 3 4 A C D E F 10 11 12 see Table B 3 15 W rite multiple digital outputs 16 W rite multiple output registers Table B l MODBUS function codes supported CO OC Ui 4 wn Note that the T640 makes no distinction between inputs and outputs Thus any register or bit assig
14. 2 Switch off the power to the T640 either at source or by withdrawing the instrument from its sleeve 3 Restore the power after a few minutes The message WarmStrt Trying flashes in the tag display and after a few moments the fascia adopts the state it had at power down i e a warm start has been performed Cold start Now try interrupting the power with the warm start enable switch OFF 1 Access the interior of the T640 and set SW1 switch 4 to OFF but leave switch 3 ON 2 Re insert the T640 in its sleeve to restore power A cold start is performed and the strategy starts in its default state having forgotten your modifications to it Tepid start A tepid start is a type of warm start but not quite as good because only some of the data base values are restored at power up including local setpoints control outputs and op erating modes Tepid starts occur when the RAM database has been corrupted it s possi ble that you may have seen one when you powered up the T640 at the start of this tutorial For more information please refer to Chapter 2 under Power up routine 3 14 T640 Reference M anual amp User Guide Issue 5 Tutorial INSPECTING amp EDITING THE DATABASE Using INS This section of the tutorial shows you how to inspect and modify parts of the database to tailor the strategy to your particular needs The first thing you will look at is ranging the setpoint and process variable eng
15. Relay outputs When using relay or triac outputs it may be necessary to fit a fil ter suitable for suppressing the conducted emissions The filter requirements will de pend on the type of load For typical applications we recommend Schaffner FN321 or FN612 Use with standard mains socket Ifthe unit is plugged into a standard power socket it is likely that compliance to the commercial and light industrial emissions standard is required In this case to meet the conducted emissions requirement a suit able mains filter should be installed We recommend Schaffner types FN321 and FN612 Routing of wires To minimise the pickup of electrical noise the low voltage DC connections and the sensor input wiring should be routed away from high current power cables Where it is impractical to do this use shielded cables with the shield grounded at both ends Installation safety requirements This controller complies with the European Low Voltage Directive 73 23 EEC amended by 93 68 EEC by the application of the safety standard EN61010 1 1993 A2 1995 Personnel Installation must be carried out only by authorised personnel Protective earth connection NOTE A protective earth terminal see symbol inset in contrast to a functional earth terminal is one that is bonded to conductive parts of an equipment for safety purposes and is intended to be connected to an ex ternal protective earthing system The following safety measures should be
16. 221 A 1 loading user e 7 1 peerto peer COMMS ccce 9 3 terminator kits 124 Alkaline manganese batteries 2 5 BUM ru reset E eo e ver ran as Crea utes 44 ALM alarm button wu 38 104 ALM SET cisci tet t eret 44 Analogue inputs and outputs 220 Antistatic bag ceccecccceeeeeesssseeeeseneeaes 2 9 Application programs transferring 223 KRC NETS iniecto errori a recs Area iie Area number Automatic dynamic tuning 7 1 Automatic mode sssssseeeeee 343 B Background task 7 3 Badi Key csse ies det decis 4410 Bargraph segment ccce 4 3 Bargraph span c ee cere s 4 2 Bargraphs Balteries oet et dt oos Battery replacement sssess 4 10 Batterytest LED ccc 4 10 Binary RS422 configuration 227 BISY NC sisi cime eae 221 BiSynC POIt ic Hace eso eds 9 3 BISYNC protocol ssseem 11 6 BIO CK eer i nex 4 6 Block Access mode ccn 4 6 Block updates iennich 8 2 Board specific parameters 1140 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B D Index Boards setting up older versions Ad Control strategies amp sequences 2 29 Break detection amp break protection 11 19 Control strategy filename 2 28 92 Burden resistor diode COSHH statement cecen 25 amp AUN terminator kits 124 CRU dtu debes d eMe SUN cafe 9 1 Burden resistors ec
17. POWER UP DISPLAYS This section describes the messages normally displayed on T640 s front panel during power up For full details of all the front panel displays and controls refer to Chapter 4 User interface The hands on tutorial presented in Chapter 3 also familiarises you with the front panel power up messages Normal power up Figure 2 16 shows the principal features of T640 s front panel A Power on Reset message normally flashes briefly in the red tag display when T640 is powered up while the front panel awaits communications from the main CPU Then WarmStrt Trying TepidSrt Trying or ColdStrt Trying flash to tell you the type of startup procedure T640 is attempting If a standard strategy is being loaded for the very first time Un Pack DataBase flashes in the tag display as the PKn file is being decom pressed Finally the fascia adopts the normal display as described in Chapter 4 Error conditions A number of error conditions can arise during the power up process which are reported on the front panel displays as messages or error codes These are described in Chapter 10 Error conditions amp diagnostics Please refer there for details 2 334 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter 3 HANDS ON TUTORIAL PREPARING THE T640 FOR THIS TUTORIAL As supplied your T640 has the strategy on which this tutorial is based stored in its ROM area ina file called SINGLE PK1 To make access t
18. Yi Panel aperture we mm Yj DIN 2 5 43700 A Terminal cover Terminal screw e Z L o 2 ae 68 07 z I 10 6 258 7 cest E S OOOO OOOO JERE aa ie Panel section 15 25 Mounting clamp Cable access Figure 2 1 1640 principal dimensions T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Panel mounting Installation amp startup Panel mounting Insert the sleeve in the aperture and fit the two clamps as shown in Figure 2 2 To fit a clamp position it flat on the sleeve locating the hook in the slot Slide the clamp away from the panel to engage the hook firmly and snap the two feet into the two small re cesses Screw the clamp rod in to hold the sleeve lightly in position Fit the second clamp in the same way Finally tighten up both clamps to exert a moderate retaining force To avoid panel distortion do not overtighten The maximum recommended torque is 0 6Nm Feet Hook eS SS eS SS C aS SS Cu S R SS Fitting a clamp to the sleeve Figure 2 2 Clamp removal tween the feet at the end of the clamp body Lift the screwdriver handle to lever the clamp See Figure 2 3 Slacken off the clamp by at least 2mm and insert a screwdriver blade be towards the panel and disengage it Do not press downwards this could cause dam age LIFT
19. cccccecsscceeessseeeeeeesseeeeees 5 31 Normal amp inverse ratios sess 5 31 Modes see etes aee a dat RI e es 5 31 Ratio setpoint trinh seria eerte ttes etes 5 31 Contents 6 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents DOULEUR 5 31 Iulias a 5 31 Loop Update rates teet etri 5 32 Strategy 4 operator interface sss 5 32 Strategy 4 I O customer terminals seseeese 5 32 Strategy 4 function blocks and parameters 5 32 Communicating on the ALIN eee 5 39 TCS binary Bisync protocol sse 5 39 MODBUS IBUS 4 nectit tete rh teris 5 39 Chapter 6 CHANGES LOGFILE Ei e 6 1 Logfile organisation sese 6 1 Losgfile records eet mr Ottone 6 1 Example logfile record sss 6 2 Logfile Saving eren ERR E 6 2 Chapter 7 T640 TASK ORGANISATION amp TUNING Task schedulitig eerte Rr ert Ei 7 1 TT640 tasks E E ee eee ees 7 1 PriOFllles e AE dee edo eti E PE rie ETE SERCFe eR E ed 7 1 Functions of tasks ccccccccccesseceessceesseeceeseeeeseeecssseceeseseeseeeeeaees 7 1 Network t sk nnne eee iere costes yis 7 1 Pront p nel task aao eene etes 7 2 User task 1 server user task 4 server ssesssese 7 2 Cache block server task cccccccsssccesseccesscesesseceeseseeesseeesaees 7 2 DEG
20. 6 Unused 7 Count of error messages sent by slave 8 Unused 9 Unused 10 Unused 11 Master polling task cycle period in 4 ms ticks 12 Scanner task time to check all tables in 4 ms ticks 13 Scanner task time used lasttime scheduled in 4 ms ticks 14 Scanner task time used for last delay in 4 ms ticks 15 Unused Table B 2 Internal diagnostic registers 0 15 4 2 MODBUS table status and control registers The second set of registers with default addresses 16 to 31 lets you monitor and control individual tables in the configuration Each register in the diagnostic table is automati cally allocated to an entire table in the configuration Specifically the diagnostic register at default address 16 is assigned to table 1 the register at address 17 is assigned to table 2 and so on up to table 16 The functions of this second set of registers depends on whether the system is working in master or slave mode T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 13 AppB 4 2 2 MO DBUS JBUS LIN communications F E D C B A 9 8 7 6 5 4 3 2 1 0 SS Ye Reserved Ss Disable write Reserved Online Figure B 5 Slave mode diagnostic registers 4 2 1 Slave mode diagnostic table registers The slave mode diagnostic register includes bits that allow monitoring and control of the associated MODBUS table by an application running in the database Figure B 5 shows the alloc
21. PVO P1 This block processes the retransmitted process variable or setpoint See SW S 1 W Field1 Bi HR out The output voltage representing high range LR out The output voltage representing low range 3TRM1 This block performs PID 34erm control The default values of XP TI and TD allow a measure of control but should be set to more appropriate values for your application TimeBase This sets the time units for Tl and TD XP This set the proportional band for control TI This sets the integral time constant TD This sets the derivative time constant Deadband This sets the hysteresis band if O n O ff control is selected See SWS 1 W Field1 Bit3 The value set is applied symmetrically above and below the setpoint TRCK1 This input processes the TRACK input If TRACK is not required all parameters in this block can be left as default MODE e track inputis being provided as an input signal this should be left AUTO Selecting MAN UAL will cause the control output to adopt the value set in PV if TRACK EN 1 goes high PY ODE is set to MAN UAL this input may be used to manually inputa TRACK value HR in The input voltage representing 100 output LR in The input voltage representing 0 output continued T640 Reference M anual amp User Guide Issue 5 5 13 Strategy 1 Standard strategies continued Block Field Subfield Description MANS1 This block provides output processing from 3TRM 1 The
22. State amp colour Clear liquid Black powder Grey powder FIRE AND EXPLOSION DATA Flash point method used N A Extinguishing media N A Flammable limits LEL amp PEL N A Special fire fighting procedures and unusual fire hazards Fire fighters should use self contained breathing apparatus when a large number of cells are involved in a fire Cells may release toxic zinc fumes when exposed to fire HEALTH HAZARD DATA NOTE These compounds and metals are contained in a sealed can Potential for exposure should not exist unless the battery leaks is exposed to high temperature is swallowed or is mechanically physically or electrically abused Routes of entry Inhalation YES Skin YES Ingestion YES Acute chronic health hazards The most likely risk is acute exposure when a cell leaks Potassium hydroxide KOH is caustic and skin contact can cause burns Eye contact with KOH may cause permanent eye injury Potential does not exist for chronic exposure Carcinogenity NTP NO IARC Monograph NO OSHA Regulated NO Signs symptoms of exposure Skin and eye contact with KOH may cause chemical burns Medical conditions generally aggravated by exposure An acute exposure will not generally aggravate any medical condition continued T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 1 Installation amp startup cont
23. T640 Integrated loop processor Reference manual amp User guide 1993 1996 2002 Eurotherm Limited All Rights Reserved No part of this document may be stored in a retrieval system or transmitted in any form without prior permission of the copyright holder Eurotherm Limited pursues a policy of continuous development and product improvement The specifications in this document may be changed without notice The information in this Invensys document is given in good faith but is intended for guidance only Eurotherm limited will accept no responsibility for any losses arising from errors in the document February 2002 An Invensys company T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 ISSUE STATUS OF THIS MANUAL Section Issue Title page Contents Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 3 A Chapter 8 3 A Chapter 9 3 A Chapter 10 5 Chapter 11 Chapter 12 Appendix A Appendix B Appendix C Index U1U1U1U1U01U01 Ui ul Un Ui Ui Ui Ui Ui Notes l Sections are up dated independently and so may be at different issues 2 The Title page and the manual as a whole always take the issue number of the most recently up issued section 3 Within a section some pages in this manual may be at later issues than others This happens if those pages have been individually up issued and retro fitted into the exist ing manual to bring it up to date However
24. appears in the green units display because PV has reached its configured limit T640 Reference M anual amp User Guide Issue 5 3 13 Tutorial Remote mode Pressing the R button cannot select remote mode in this simple loop simulation Instead the A button s green LED and the letter A below the deviation bargraph flashes indicat ing that forced automatic mode has been adopted This happens if you try to select re mote when it has not been enabled or if the remote setpoint is invalid Control action is still exerted in this mode If you don t want remote mode to be selectable you can disable mask the R button This is explained later under Pushbutton masking on page 3 24 Press A to restore normal automatic mode POWERINTERRUPTIONS Warm start Remember when you powered up the T640 at the start of the tutorial you saw the message ColdStrt Trying and the instrument performed a cold start After a cold start the data base is initialised and therefore in its default state Remember also that you set the SW1 switches to enable both cold and warm starts This enables the T640 to perform a warm start if possible After a successful warm start the instrument resumes running the control strategy having remembered or regenerated all the database values as they were at the mo ment of power interruption Try a warm start now 1 Check that you have automatic mode selected and a PV value other than the default of 0 00
25. Refer there if you want more comprehensive information HARDWARE REQUIRED FOR THE TUTORIAL M T640 instrument prepared for use in the tutorial as described in the previous section E Short wire link terminated ideally with bootlace ferrules WB Terminal screwdriver B Digital multimeter optional W An appropriate power supply DC 19 55V 25W MAINS 90 265 Vac 45 65Hz INSTALLING YOUR T640 If you have not already done so please refer to Chapter 2 Installation amp startup for de tails on unpacking your T640 Note that for this tutorial there is no need to panel mount the instrument it can simply rest on a bench in its sleeve with the rear terminal cover removed Connecting the pow er supply Remove the terminal cover and cable clamp from the rear of the T640 to access the cus tomer terminals Figure 3 1 shows the cover and clamp First determine which option you have DC or AC mains You can see this from Figure 3 2 and also from the order code label on the sleeve the second field is DC or MAINS respectively With the power switched off wire the power supply to the terminals shown in the figure according to your option Do not power up yet 32 T640 Reference M anual amp User Guide Issue 5 Tutorial Figure 3 1 Terminal cover removal Mains EARTH L Mains LIVE N Mains N EUTRA Site 11 0 customer terminals 1A 1Z L gr
26. Relays Alarm relay Watchdog relay Power supplies Mains version Input voltage range Input frequency range Maximum peak input current Power rating Holdup time Power supply fuse DC version Number of inputs Input voltage range SPST Max contact voltage 30Vrms 60Vdc Max current 1A at 24V ac dc Isolation 60Vrms 60Vdc SPST Max contact voltage 30Vrms 60Vdc Max current 1A at 24V ac dc Isolation 60Vrms 60Vdc 90 265 Vac rms 45 65 Hz 1 14 25VA 20ms T type IEC 127 time lag type UL recognised 20 x 5 mm 250Vac antisurge cartridge 500mA 2 Channel 1 main input channel 2 backup 19 55 V including rectified 48Vac NOTE Installation must ensure that neither positive nor negative rails of the DC supply can exceed 100V peak with reference to safety earth Power rating Holdup time Power supply fuse T950 Security key Battery 25VA 20ms T type IEC 127 time lag type UL recognised 20 x 5 mm 250Vac antisurge cartridge 2A 12V alkaline manganese dioxide type of overall length 27 5 28 5 mm diameter 9 62 10 62 mm E g Duracell MN21 Panasonic RV08 or equivalent Refer to Ch2 for safety precautions 114 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Specifications ALIN The ALIN runs on screened twisted pair Phase A pin 21 should be bussed to other Phase A signals and likewise Phase B pin 22 The cable screen should be
27. See next section NOTE The ALIN cable screen and the RS422 485 cable screen should each be grounded at one point only T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 A l T640 zero volts schematics Setting up early boards 5V j M 422 485 422 485 p eer zole Main a NET CPU umb 15 e EXISB EXISB Ab A 13 e RS422 RS485 e 45V ground De DN oo 11 Terminal func vA u tions depend i 12 C on SW 1 set tings Y x Te 4 2 2 f RS422 485 RUN ws PO phaseA 21 T i Main AUN CPU 22 phase B i i T4 ALIN interface AUN M ground 20 t circuitry ALIN Figure A 1 T640 communications zero volts schematic A 2 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Setting up early boards Hardware configuration Memory I O expansion Retaining clip module board module DIL socket switchbank 1 switchbank 2 M otherboard I O board Figure A 2 1640 internal layout example HARDWARE CONFIGURATION Internal layout Figure A 2 shows T64
28. in the opposite direction via an AN CONN block for example This is illustrated in Figure 8 1 where block A coherently connects to block B across the LIN via the AN CONN block bold lines but the connection is non coherent when routed via cached block B Coherent block update 1 coherent AN CONN cached A local 3 non coherent 2 coherent B local Non coherent field write B cached Figure 8 1 Coherent amp non coherent data flow across the network 8 2 T640 Reference M anual amp User Guide Issue 3 A Chapter9 INSIDET640 INTERN ALLAYOUT Please refer to Chapter 2 Installation amp startup for details of T640 s dimensions internal physical and electrical layout and hardware configuration The present chapter deals with the software and hardware blocks functioning within the T640 FUNCTIONALBLOCKS Figure 9 1 shows a functional block schematic of the T640 The main functional blocks are the motherboard the front panel the I O sub assemblies up to two and the rear panel customer screw terminals FRONT PANEL op ott i2 wa MOTHERBOARD connectors P4 5 PU health line 1 Display m c pr
29. loaded to RAM and if possible run in the T640 The strategy selected is the sum of the values of the three switches OFF 0 ON value as shown in Figure 2 12 E g strategy 3 has been selected in the figure Setting these three switches all OFF pre vents any standard strategy being loaded Running standard strategies is explained in Chapter 5 Standard strategies Switchbank 2 Figure 2 13 shows the ALIN address DIL switchbank 2 and an example setup 7A hex y a Vem j PX SW2 ALIN Address hex 7 A address Anu binary 1 1 1 1 0 1 OF aadress BINARY HEX 0000 0 0001 1 0010 2 0011 3 0100 4 0101 5 0110 6 0111 7 1000 8 1001 9 1010 A 1011 B 1100 C 1101 B NOTE Addresses 00 and FF are reserved and must not be used 1119 N p Figure2 13 SW2 AUN address setup example This bank of switches is used to set up the address of the T640 on the ALIN Figure 2 13 shows how to set them up and read them using the hexadecimal address 7A as an exam ple Note that switch 1 is the least significant bit and switch 8 the most significant i e they are in reverse order Note also that addresses 00 and FF must not be used 226 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup MO DBUS conf
30. transfer new value from copy update from remote Slave Figure B 3 LIN master mode operation The scanner task looks at each value in the copy If it finds that the value has been changed by the polling task it transfers the new value to the database If it finds that the value in the database is different from the value in the image it requests that the value is changed by writing across the MODBUS In master mode the user can define for each table the MODBUS function codes available to the MODBUS interface This allows global read or write protection if required for data in a particular slave device In addition the user can write protect each connection be tween the database and a register or set of digitals This allows the system to protect either the value in the database or the value in the MODBUS from unwanted changes 2 3 Master mode polling sequence 2 3 1 Read operations The master cycles consecutively through the tables in its MODBUS configuration and polls the slaves allocated to these tables across the MODBUS serial link For each table only one poll is made per cycle The time to do a complete cycle of all the tables is called the polling period Thus if a table is longer than the maximum count specified in the con figuration i e Count exceeds Scan count it will take two or more polling periods to up date all the data in that table Clearly if a table has to be read in several parts its overall update
31. user tasks seen as LOOP 1 LOOP 2 and LOOP 4 in the tag display that you can access via the INS pushbutton to configure their function blocks The parameters in Loops 1 and 2 deal with configuration of the respective control loops themselves and those in Loop 4 cover system alarms and general instrument setup The three loops are almost the same as those of strategy 2 which were tabulated in Tables 5 5 5 8 and 5 6 The exceptions are that E The block RSP_1 and its input REM SP pin IF are present but have no function WB The block TRCK2 and its input TRACK pin 2J are present but have no function When you come to configure these parameters you will find the setup sheets for this strat egy helpful because they list the default values of all fields and include a spare column for you to record your customised values where required You may want to use photocop ies of the printed setup sheets as your working documents The setup sheets for this strat egy are found under Setup sheets all strategies on page 5 34 5 28 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 4 Ratio pair STRATEGY 4 DUAL CONTROL LOOP RATIO Strategy 4 is a dual loop controller Loops 1 and 2 having in addition a ratio station in Loop 3 All loop interconnections are internally pre wired in the database Figure 5 8 shows a P amp I diagram for the strategy in which by way of exam
32. ww 3 term OA lt j Figure 5 4 Example P amp diagram for strategy 2 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 2 LOOP 1 BUT RE area TRANSMITTED OUTPUT power i TX PSU supply DARAN ERU CULA E r PVOP1 PID CONTROL analogue 1M vise our PV 3 area output analogue block pv 1E input 3PAUSE eet block p SETP py o Vs up UL RR setpoint i TRIM1 block gp TAUT se TRM 1H OH ood TRUE 3 area block y OUTP1 3T OUT RSP 1 peak NEXT analogue 1A 4 20mA REMSP 1F Sj drea lt block puni A 1B srour block Y v TRCK1 MANS1 OP 1 tack 4 QH eg dd pe yw stour on block block block COMP EN 0 1P Q PROCESS mE ALARM REM SP EN 1 18 S digital OUTPUT area Z TT HIALM OUTO A TRACK EN 1 1R Q 7 block ial C 1U Lo AL our o J P HOLDEN 18 OH output 1 1V REMAUTOUT cascade TOO NEE control poA d SR SIR L Z 1W HOLD MAN sono iene LOOP 2 I UAE area T
33. 1 amp 2 and the non isolated high level ana logue input channel 3 Volts mode all support input break detection As such the BrkDetct bit in the Options field should be set to TRUE when using these inputs A break detection is annunciated by the TRUE state of BrkDtctd in the Status field Note that the BadBrk bit will be TRUE in the Status field if detection is not enabled on these inputs Upon detection of an input break the AN IN block adopts a protection strategy according to the setup of two Options bits namely BreakUp and HoldDect If HoldDect is TRUE the processed input PV holds its last good value and will do so until the input break is cor rected If HoldDect is FALSE and BreakUp is TRUE PV goes to highscale HR If both HoldDect and BreakUp are FALSE PV goes to lowscale LR These actions are summa rised in Table 11 5 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 19 Thermocouple O Specifications Block type Parameter Support AN IP InType mV options only on Ch 1 amp Ch2 V or Hz options on Ch 3 LeadRes Not supported STATUS PSUshort Not supported BrkW arn Not supported BrkDtctd mV amp V modes only OPTIONS BrkDetct mV amp V modes only BreakUp mV amp V modes only HoldDect mV amp V modes only AN OUT STATUS FaultC ct Ch 1 only current output open circuit only O verDrv Ch 1 only current output Killed Ch 1 only current output ALARMS CctFault Ch 1 only current out
34. 1 en hanced filing system does not suffer from this corruption problem it is still strongly recommended that power is not removed during file save operations 6 2 T640 Reference M anual amp User Guide Issue 5 Chapter7 T640 TASK ORGANISATION amp TUNING The T640 performs all its in built and user programmed instructions serially i e one at a time The first section of this chapter describes these various software functions tasks and their scheduling within the instrument An understanding of the timings and priori ties of these helps you to use the instrument at maximum efficiency The next section describes user tasks and their associated loops and servers User task software structure and server operation is also outlined Finally user task tuning by varying minimum repeat rates via the T600 block is de scribed TASK SCHEDULING T640 tasks A task is a unit of software in the T640 that is responsible for carrying out particular duties at certain times usually while the database is running There are fifteen recognisable tasks in the T640 Most tasks are fixed and cannot be varied by the user Others the user tasks are programmable these are discussed in more detail in the next section Priorities Each task has a running priority based on its importance to the efficient and safe operation of the T640 Priorities are numbered from 1 highest to 15 lowest A task once started will run to completion unl
35. 15 diagramas esr to eet edes 35 Ratio Package contents 2 9 normal amp inverse escenes 531 Packed format 5 1 setpoint trim Panel cutout amp dimensions 114 station Panel mounting the T640 2 10 Re alibration Parameter change ssseseeee 6 1 Realtime clock Para Meters anrr ute pits vistos xoti 4 4 Rear panel Pattial i iene etn e 4 9 customer connections 11 9 Partial access mode ccecce 44 plugin module kits 124 PID xc o o rRNA TONER 35 Record file scr ceva bree PID CONN blocks seeeeeeeenee 5 39 Records logfile Polling cycle ccce B 6 Refresh tates sco tio Re Polling ita sk oec ettet B 5 Relay Power alarm eres 104 Tie 2 12 Watchdo2 uite eterni 10 5 iriterruptions ceca nee 3 14 Relays ista Wii 114 supply s 248 32 93 114 Remote mode ccecce 344 43 Power on Reset 2 34 3 7 10 1 REMOUESP ict eects da c en the 4 3 Power up Repeat rates Tavia a rn et ee 7 2 amp powerfail mode sssss 322 Repeat times ccecce 7 1 displayss scs 2 34 10 1 ROMY cie dte a tet o es 4 6 MESSAGES iiec tita e tas 3 7 RS422 communications 115 OUllhe certet etes 2 29 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Index 5 R S Index RS422 485 Sleeve labels cccccesecsesseeeeetenseseanees COMMS connectio
36. 2 34 HANDS ON TUTORIAL Preparing the T640 for this tutorial sese 3 1 Deleting the T640C1 PK1 file sees 3 1 Aims Of this tutorial 2 aac ere aeter e ENa 3 2 Hardware required for the tutorial sese 3 2 Installing your T640 rrr err tert nete o 3 2 Connecting the power supply seseeeeeeeee 3 2 SWIUCH settings scere ere tere DR covenants ER ER REN SEE YE HERE 3 4 Removing the T640 from its sleeve sess 3 4 Setting the switches aine e eth teet etn 3 4 Strategy 1 Single loop controller sese 3 5 PONWEL UD eder OP CERRO ERWIN PT d 3 7 Power up messages e eeen eirs areari einer aats Eer riea enera 3 7 The mitaldisplay 4 5 nerina epe tet tes 3 8 Investigating the alarm condition esses 3 8 Watchdog relay iate ett rh Ania HER IE rh Gide 3 10 Functioniblocks erp rro iet E KARA 3 10 his c M 3 10 Fields amp s bfields nto eee ttn 3 10 Alarm tields toe eee Hee eU eore impe ies 3 11 Block f nctions ete p tede i ERR 3 11 PVanput area one ioedudioieii decer iet teneris 3 11 PID controlarea i oiede iie E d 3 11 Control output area sess 3 12 Simulating a feedback loop sess 3 12 Displaying amp altering the local setpoint sess 3 12 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents 3 Cont
37. 5 RS422 COMMUNICATIONS eese nennen 11 5 RS485 communications isenana iniia iis 11 5 BISYNC protocol ranya a e Peer estre les 11 6 MODBUS protocol iriirihia enti keia a a n 11 6 SOWAT sie Po rede eO e E de 11 6 Maximum resources supported sss 11 6 Maximum sequencing resources supported 11 7 Function blocks supported esee 11 7 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents 9 Contents Highslevel WO isc coves ettet etr rettet ert oro enini 11 9 La VOUb M n 11 9 T640 rear panel customer connections sse 11 9 Input ranges ree t tene Er a RENE NR 11 9 LIN blocks parameters not supported sss 11 10 Hardware organisation eese 11 11 Analogue inputs sesenta 11 11 Internal burden resistors sese 11 14 Transmitter power supplies seen 11 14 Voltage analogue outputs eene 11 14 Current analogue outputs sse 11 14 Digital puts 2 53 0 ete ree rens 11 15 Digital OUtpuls 1 erret rene etae UR ES 11 15 General sss ss dense eoe beber eee e e a mes 11 15 I O calibration procedure sese 11 15 Complete re calibration sess 11 15 Limited calibration sese 11 16 T640 Rear panel customer connections
38. EEPRO M filing system The sequence is relatively complex to make it unlikely that the EEPRO M is reformatted accidentally E2Form2 See previous Table 5 6 Loop 4 parameters T640 Reference M anual amp User Guide Issue 5 Strategy 2 Standard strategies STRATEGY 2 DUAL CONTROL LOOP Strategy 2 is a dual loop controller The difference between the single loop strategy 1 and the dual loop controllers is simply the inclusion of the second loop This loop is iden tical to the first except that its I O is assigned to site 2 of the T640 terminals 2A to 2Z Note that terminal 2P is unused as COMP EN 0 because 1P is used to disable communi cations for the whole instrument Onelooportwo If only one loop is needed the single loop controller should be chosen in preference to the dual for the following reasons W With only one loop implemented the single loop has a faster update rate approxi mately 160ms The update rate of each loop in the dual loop controller is around 300ms W If the second loop in the dual loop strategy is not connected to anything Loop 2 proc ess variable alarms will appear and remain permanently annunciated Figure 5 4 shows a P amp I diagram for the strategy involving flow control valves and ori fice plate flow sensors by way of example Local setpoint PV w 3 term SO A d T Rr Local setpoint
39. Reference M anual amp User Guide Issue 5 3 7 Tutorial The initial display Refer to Figure 3 7 FIC 001 in the red tag display is the loop s tagname appropriate to a flow controller Note that you can select an alternative tagname if you wish see Table 5 5 in Chapter 5 but FIC 001 will do for this tutorial The green 0 00 appearing in the units display accompanied by the glowing green SP W legend shows the loop s setpoint SP value The red 5 digit display shows the current PV value also 0 00 ac companied by the glowing red PV X legend The two bargraphs at the left of the fascia sharing a 0 100 scale also display PV and SP as red and green vertical bars respectively They presently indicate zero only the bottom LEDs are lit Note the brownish yellow letter M flashing above the green arrowhead just above the set of pushbuttons together with the flashing yellow LED in the M Manual pushbutton The brown letter M means that the loop displayed on the fascia is in Manual mode and its flashing together with the flashing button yellow LED means that manual mode se lection has been forced by an alarm condition Finally note that the ALM alarm button shows a steadily glowing red LED This draws your attention to the fact that an alarm condition exists somewhere in the instrument INVESTIGATING THE ALARM CONDITION Whenever the ALM button LED is lit you can quickly trace the source of
40. Zero output will be forced FALSE the last output will be maintained Zero means low electrical output 0V or 4mA irrespective of any ranging or loop inversion Bit TRUE inverts the output action and hence the control action after the manual station 100 OP 4mA 0 OP 2 20mA This should be set TRUE if the actuator has reverse control ac tion for safety reasons This bit affects both the 4 20mA and voltage contro outputs It does not affectPV SP O UT BiB This inverts the control action before the manual station It does not affect the relationship between the output reading and the true electrical output This may be set true to reverse the action of the oop Bitt This selects O n 0 ff control See also 3TRM 1 Deadband Bit FALSE the local setpoint will remain unchanged TRUE the local setpoint will track the process variable if the controller is notin AUTO N ote the ocal setpoint will always track the remote setpoint when remote is selected NB If the HOLD EN 1 input is high at power up hold mode wins and the last output is maintained despite BitO s being TRUE continued 5 10 T640 Reference Manual amp User Guide Issue 5 Standard strategies Strategy 1 continued Block Field Subfield Desaiption Bit FALSE the second analogue output will be the retransmitted PV TRUE the second analogue output will be the retransmitted SP orm D TRUE Inverse
41. a flashing CPU FAIL message The I O cards can be programmed with action to be performed on main processor fail e g outputs hold or outputs low If the database stops either due to a fault or as a result of a command over the LIN this will also cause the I O cards to adopt their CPU fail state Forced manual mode In user tasks with MODE blocks the block adopts forced manual mode under error condi tions i e sumcheck open circuit PV or other strategy defined conditions T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 10 5 Contents This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Base unit Chapter 11 SPECIFICATIONS T640 BASE UNIT Panel cut out amp dimensions Please refer to Chapter 2 under Installation for details Mechanical Fascia dimensions Mounting panel aperture Behind mounting panel Front of mounting panel Weight Environmental Storage temperature Operating temperature Atmosphere Front panel sealing EMC emissions EMC immunity Electrical safety Isolation Vibration Shock height 144mm width 72mm height 138 1 0 mm width 68 0 7 0 mm depth 258mm measured from panel front depth 10 6mm 2 15kg 10 C to 85 C at humidity of 5 95 non condensing 0 C to 50 C The enclosure must provide adequate ventilation and heating if required to avoid condensation at low temper
42. access only to zero AreaNo databases E ID Code Identifies each key with a unique 13 bit number 0 8191 Every time the key is used to change a database a record is logged in a file that includes all the key s parameters This means that all changes are traceable to a particular keyholder See Chapter 6 Changes logfile for details Using the key Figure 4 4 shows the T950 security key Press to operate Red battery test LED Infrared LED Figure 4 4 Security key operation l Press INS on the front panel If no key is needed for access loop access mode is im mediately entered and LOOP shows in the units display Otherwise No Key appears in the tag display and you proceed to step 2 T640 Reference M anual amp User Guide Issue 5 4 9 Battery replacement User interface 2 Hold the key about 15cm from T640 s front panel aiming the infrared LED at the OUT Y legend to the left of the output bargraph see Figure 4 1 The IR sensor is here behind the fascia Press INS then squeeze the key briefly to click the internal switch If the security key is valid the tag display replies with LOOP and loop access mode is entered Invalid keys display Bad Key NOTE The battery test LED on the case should glow when the switch is pressed indicating a healthy key battery If not replace the battery described be low While the T640 is in INSpect mode the key is not needed But if no pushbuttons are pressed
43. can be driven from a single non isolated digital output none 11 26 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications Thermocouple O ISOLATED DIGITAL INPUTS fae e 5V 250V Isolation 6K6 e 900 nM D 15K V d K T e oV sv Z nN 7 T 5V 250V I O MICRO Isolation CONTROLLER 6K6 Bit nP 2 gt 15K V ov Ke ISB BV Z t nQ D e 5V 250V Isolation 6K6 4 Bt nR 2 15K Ve di e oV sZ nS D 250V Isolation Figure 11 11 Isolated digital inputs block schematic n 1 2 General The environment physical and electrical specifications for the Thermocouple I O assem bly are the same as for the base unit The confidence limit specifications quoted above have been generated in accordance with BS4889 Appendix A T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 11 27 Thermocouple O Specifications NON ISOLATED DIGITAL OUTPUTS QL 24V Site n Bit 2 External Site n Bit 1 ov Site n Bit 0 Padus iladesuseaceascsseases Pullup nY V select VO MICRO e nx CONTROLLER Q 3K6 nw ag Bite ISB Ly i Bit 1 1 a Bit 0 nZ NC WA Digital ground
44. condition disappears but remain active until manually acknowl edged M 11 15 top priority annunciated with manual acknowledge and alarm relay These alarms work in the same way as priority 6 10 alarms but in addition they trip the T640 hardware alarm relay see below and set the T600 block s Status Alarm bit Alarm annunciation Annunciated alarms are indicated on the controller front panel by means of the red LED in the ALM button and also via the tag display Please refer to Chapter 4 for further details Alarm events As an alarm state changes into or out of alarm occurring at block execution time this event is advised to an alarm event system where it is date time stamped not implemented at Issue 1 A supervisor may attach to the alarm events of an instrument not at Issue 1 Once so attached the instrument checks at regular intervals to see if any new alarm events have occurred and transmits them to the supervisor To ensure consistent date time stamping the date time is regularly copied across the peer to peer communications link via the T221 bridge not implemented at Issue 1 Alarm relay The alarm relay s contacts are closed when energised and in the no alarm condition When a priority 11 15 alarm occurs in the T640 or if the database halts the contacts open They also open if the relay is de energised i e fail safe operation 104 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Error co
45. connections are dealt with by a snapshot copying at the start of the lower priority task B Lower to higher priority A low priority task may be interrupted by a higher priority task before completion and so be caught with an incoherent set of output values To avoid these invalid values being passed on the last action of task execution is for the lower priority task to copy its set of coherent connections as a snapshot to the higher priority task In this way the values passed on are always the last set of co herent values from a complete task execution T640 Reference M anual amp User Guide Issue 3 A 8 1 Data coherence 2 Connections into this task from other tasks in other physical instruments Connections between nodes are actually effected by the use of cached blocks The process of cached block transmission and reception at the destination end is coherent for all the data within that block At the destination end the cached block exists on a cached block server Connections from this cached block to other blocks effectively become inter server connections within the same node the coherence of which is guaranteed see 1 above 3 Connections outof this task to another node This type of connection results in data flow that is not coherent because the data is trans mitted across the network as individual field writes rather than as whole block updates If coherence is required cache the block s
46. cre ated Thus the T600 block logfile number defines a file that may be safely uploaded If Log File is 0 there is no file to upload Only the two most recent logfiles are retained in memory the currently open file and the last closed one A logfile can be closed before it is full if another type of file e g a strategy file is added to EEPROM to make the logfile no longer the latest file This is because T640 s filing system allows data to be appended only to the last file in EEPROM Logfile records There are two possible records in a log file B Inspect Mode entry This record shows the date of entry into Database Inspect mode and which security key was used to access the mode One of these records is written to file only if parameter changes were actually made Each record is a single text line of the format dd mm yy T aakkkk where dd mm yy the date in day month year representation T type of security key P partial F full G global ignoring area no aa area number 0 63 kkkk security key number 0 4095 T640 Reference M anual amp User Guide Issue 5 6 1 Log changes file B Parameter Change entry This record shows a single instance of parameter up dating In order to control file size when the operator is nudging to the value there must be a significant time gap between nudges to result in more than one record Where a change in direction occurs the peaks in each direction are lo
47. data base By using the techniques of block caching the communications may have access to data in other nodes distributed on the LIN as well as blocks in the local database The product operates in one of two modes BH MODBUS slave This allows a PLC or supervisory system configured as a MODBUS master and connected to MODBUS to access data in the T640 LIN data base and in nodes connected to the LIN BN MODBUS master This allows the T640 to acquire data from MODBUS slaves such as PLCs and incorporate it into its display or control strategies 1 1 Main features W The mapping between the database and the MODBUS address space is entirely user configurable for both digitals and registers W Digitals may be mapped as single bits 8 bit bytes or 16 bit words W Analogue Values map to single 16 bit registers with definable decimal point Floating point numbers as well as Integers M Long Integer 32 bit totals may be mapped to a pair of registers T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 1 AppB 1 3 M O DBUS JBUS LIN communications W Configuration can be done using the T500 LINtools MODBUS configurator running on a PC see the T500 LINtools Product Manual Part No HA 082 377 U999 E Diagnostic and status registers allow the database to control the MODBUS interface HM The communications support the MODBUS RTU 8 bit transmission mode Note that support for the ASCII 7 bit mode is not provided
48. diagnostic counters and re enables responses if the slave had been placed in Listen only mode by sub code 4 0002 XXXX Returns the diagnostic register In the current versions the returned data is always zero Table B 3 continued T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 15 AppB 6 1 M O DBUS JBUS LIN communications Table B 3 continued Diagnostic Data Description sub code sent 0003 ABxx Changes ASCII delimiter This echoes the data sent 0004 0000 Forces Listen only mode There is NO response to this function 000A 0000 Resets all counters 000B Not supported 000C 0000 Returns the number of CRC errors detected in messages addressed to this slave 000D 0000 Returns the number of error messages returned by this slave 000E 0000 Returns the number of correct messages addressed to this slave 000F 0000 Returns a count of the number of times the slave has not responded to a valid message e g due to an unsupported function or a buffering problem in the slave 0010 0000 Always returns 0 0011 0000 Always returns 0 0012 0000 Returns the count of character errors received atthe slave i e over run parity framing errors 0013 Not supported 0014 Not supported Table B 3 MODBUS diagnostic function codes 6 MODBUS EXCEPTION RESPONSES 6 1 Slave mode error codes Table B 4 lists the error codes that may be returned in an exception response from a T640
49. e 18V 270R Pulse width modulation a DC JUUL y recovery V nU 2 e 22K 12V NON ISOLATED VOLTAGE OUTPUTS Figure 11 9 Nondsolated analogue input output block schematic n 1 2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 1123 Thermocouple I O Specifications Break detection 50 60Hz rejection Block type Input ranges Over range capability Input threshold Input range operating Over under range capability Input impedance Resolution Min pulse length Response time Accuracy Timebase accuracy Gain drift Totalisation Max totalisation rate Process output Block type Channels Output range Isolation Accuracy 25 C Resolution Temperature drift within 1 sample period with options to go high scale low scale or retain last good value 60dB SMR software selectable between 50 and 60 Hz Frequency input mode AN_IP 0 01Hz to 30kHz 0 01Hz to 3kHz 0 01Hz to 300Hz 0 01Hz to 30Hz software selectable up to 48kHz 1 5 to 3 5 V up to 15V 9 to 18 V 1 5MQ for in range signal 1KQ for out of range signal gt 14 bits 8us above 20Hz 200ms maximum below 20Hz waveform period 200ms maximum 0 02 of reading 0 05 over 5 years lt lppm C 1kHz with simultaneous frequency measurement LoFloTot TRUE 48kHz without simultaneous frequency measurement HiFloTot TRUE AN_OUT 1 0 to 20mA can b
50. field With no TAG block the PID PID CONN block name or SETPOINT block name or the default LOOP n message appears Special displays can override the normal display as described in later sections PV X bargraph display Red display normally showing the SETPOINT or PID block s PV value in 2 steps SP W bargraph display Green display normally showing the SETPOINT or PID block s SP value in 2 steps 5 digitdisplay Red display normally showing the PV value of the SETPOINT or PID block in engineer ing units The PV X legend see Figure 4 1 glows red only when PV is being displayed Units display Green display normally showing the engineering units associated with the 5 digit display It can also show the SETPOINT block s SP value Show_SP TRUE In this case the SP W legend glows green NOTE Pressing A or V displays units in this case 4 2 T640 Reference M anual amp User Guide Issue 5 User interface Displays amp controls Outputbargraph Yellow display normally showing the loop s control output i e the MAN_STAT block s MeasPos value or its OP value if MPosDisp is FALSE or if absent the PID block s OP value All segments lit represents 95 of full range Note that each bargraph segment can also be driven individually via the MAN_STAT block s UserBar parameter Mode changes You interact with the main display loop via the eight front panel pushbuttons Press M anual A uto or R emote to select the re
51. for chosen PKn file Copy DBF name from it Find unique RUN file amp copy DBF name from it Search EEPROM for DBF file amp load it to RAM Yes Successful DBF file load Standard strategy selected Unpack PKn file and load to RAM RUN DATABASE No Yes e match No NULL DATABASE Figure 2 14 T640 power up routine 2 30 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 nstallation amp startup W arm start routine WARM START EEPROM RUN filename match RAM database filename memory module changed RAM OK v s No Get DBF file that matches RUN file EEPROM Overlay RETURN FAIL Tepid Data No Derive time elapsed since power down T600 block s ColdStrt 0 T600 block s ColdStrt 0 Cold Start time exceeded Flag Brownout Brownout time exceeded RETURN FAIL Yes RETURN SUCCESS Flag Brownout RETURN SUCCESS RETURN FAIL Figure 2 15 T640 warm start routine amp see Figure 2 14 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Tepid data Installation amp startup Figure 2 14 charts the events that occur when T640 is powered up Figure 2 15 shows the warm start routine that may be called d
52. high4evel I O options Site 2 left amp Site 1 right 2 16 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Customer terminals Thermocouple I O boards Table 2 3 shows Site 1 amp 2 terminal designations for the thermocouple I O board options together with their associated software function blocks Terminal SteNo 2 Linked block Terminal SteNo 1 Linked block 2A Current output 1A Current output ZO AN OUT AW AN OUT 2B SN Output kill input Channel 1 Outlype mA 1B Output kill input Channel 1 OutType mA 2C S Current output 1C S Current output 2D Do not connect 1D Do not connect S AN IP S AN IP 2E SN Thermocouple a 1E N Thermocouple Channel 1 InType Chanel InType 2F _ GC sensor mV Int mV Ext IF QCsensor t
53. in Auto with its remote setpoint DOP 1 selected In cascade this signal should be connected from the slave to the TRACK EN 1 of the master to allow bumpless transfer from local control to cascade tis also necessary to connect the retransmitted process variable PV SP O UT of the slave to the TRACK input of the master IW HOLD MAN OUT 0 This digital output goes low if the controller is in Hold or Manual modes DOP 1 cascade this signal should be connected from the master to the REM SP EN 1 of the slave to allow procedureless changes of mode It also ensures that if the master is removed that the slave goes into local control 1X ExtSupply In The digital outputs pull to 15V If 24V is connected to this pin the digital outputs 24 volts pull up to 24V If not used as an input this pin may be used as a low current 15V source to drive inputs via relays or opto couplers lY Digital Gnd Reference ground for digital signals lZ Digital Gnd Reference ground for digital signals 0 or 1 denotes bit asserted when low or high respectively Table 5 4 Site 1 I O customer terminal assignments T640 Reference M anual amp User Guide Issue 5 5 9 Strategy 1 Standard strategies Strategy 1 function blocks and parameters This strategy has two user tasks seen as LOOP 1 and LOOP 4 in the tag display that you can access via the INS pushbutton to configure their function blocks The param eters in Loop 1 deal with configu
54. in engineering units is added to the setpoint Whether itis local or re mote If no trim is required all parameters in this block can be left as default MODE This should be left at MAN UAL if a manual trim or no trim are required Set this input to AUTO if a trim is to be provided as an input signal SP TRIM PY O DE is set to MAN UAL this input may be used to manually inputa setpoint trim HR This sets the high range in engineering units HR in maps to HR Because trim works in engineering units HR and LR are used to scale the trim input against SETP1 HR SP and LR SP LR This sets the low range in engineering units LR in maps to LR It would not be unusual for LR to be the same value as HR but negative to give a symmetrical trim Filter A first order filter with the time constant set applied to the input HR in The input voltage representing high range LR in The input voltage representing low range O ptions O nly options believed relevant are described Some options have defaults relevant to the I O hard ware and should not be changed Invert TRUE maps HR in to LR and LR in to HR Sqrt TRUE applies a square root function to the input SETP2 This block provides all the setpoint processing and alarms HR SP The high range of the process variable and setpoint in engineering units The block is internally connected so that the process variable and remote setpoint share the same ranges as HR SP and LR SP IR SP The low range of the process variable and setpoin
55. in slave mode Code Name Meaning current implementation 01 Illegal function The function is illegal or not supported within the MO D BUS interface 02 Illegal data address The address referenced does not exist in the slave device 03 Illegal data value The value in the data field is invalid 04 Failure in associated device 05 Acknowledge 06 Busy rejected message 07 N AK negative acknowledgement 08 Write error The data has been write protected via a bitin the appro priate table diagnostic register Table B 4 continued B 16 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 MO DBUS JBUS LIN communications AppB 87 1 Table B 4 continued Code Name Meaning current implementation 09 Zone overlap 0A Header error 0B Slave absent oct CRC error 0D Transmission blocked Table B 4 Exception responses from a slave Codes implemented in the T640 slave mode Supplementary codes defined by the JBUS specification 6 2 Master mode error codes When the T640 is operating in master mode any error codes received from an attached slave are stored in bits 8 to B or C to F of the appropriate diagnostic register see 4 2 2 In addition if the master detects an error it can store one of the codes listed in Table B 5 in these bits Code Name Meaning current implementation 0D W rite inhibited The server has requested that a value is written to a slav
56. into the opening under the SP W pushbut ton then level the tool and pull the unit from the sleeve pn SP MS vy E Lad KU IIIJ Extractor tool Retaining clip Figure 3 3 Removal of T640 from sleeve Setting the switches Figure 3 4 shows the location of switchbank 1 SW1 on the T640 motherboard and also SW1 in detail Set the switches as shown Note that for this tutorial the settings of the switchbank SW2 switches are don t care Replace the unit in its sleeve You are now ready to power up the T640 but before doing this you should be introduced to fixed function strategy 1 a single control loop 34 T640 Reference M anual amp User Guide Issue 5 Tutorial Cold start enable Warm start enable Strategy selection A 1 selected p p Figure 3 4 SW 1 location and settings STRATEGY 1 SINGLE LOOP CONTROLLER This simple strategy is a single loop controller using one I O site i e the column of ter minals labelled 1A to 1Z Figure 3 5 shows an example P amp I piping and instrumenta tion diagram for the strategy with the T640 connected to a flow control valve and an ori fice plate flow sensor The measured flow PV is input to the T640 where a PID propor tional integral derivative calculation compares PV with the setpoint to produce a 3 term control output 3T OUT This is fed to the valve controlling the flow Figure
57. level I O only M007 Advanced features Required to support the AGA8DATA block M101 105 Pre packaged applications Contact Eurotherm Sales O ffice for details N one fitted Sleeve T710 Supplied in a T710 sleeve T750 Supplied in a T750 sleeve None supplied Calibration certificate CERT Calibration certificate supplied N one supplied Configuration sheet CONF Factory configured to supplied configuration sheet Supplied with I O settings as specified in the I O codes Labelling language EN English FR French GE German IT Italian SN Swedish SP Spanish PO Notyetavailable CY Notyetavailable US American Example T640 MAIN S H HI M 001 T710 EN Table 12 1 T640 order codes T1710 SLEEVE ORDERED SEPARATELY CODE DESCRIPTION Base unit T710 DIN sleeve Power supply connector assembly MAINS Universal mains 90 to 265 volts ac rms DC 19 to 55 volts dc power supply continued T640 Reference Manual amp User Guide Issue 5 Ordering information T950 codes continued CODE DESCRIPTION Site 1 connector assembly H High level O Site 2 connector assembly H High level I O Only if H specified in Site 1 No I O specified for Site 2 Labelling language EN English FR French GE German IT Italian SN Swedish SP Spanish PO Notyetavailable CY Notyetavailable US American Example T710 DC H H EN Table 12 2 1710 sleeve order codes
58. loops in alarm are accessed Press ALM again to display the name of the block with the highest priority alarm in the entered loop BLOCK appears in the units display The units display will show NoAIm if the loop has since cleared itself of alarms and you remain in loop mode In this case you can select another loop in alarm using A or V Press ALM again The tag display shows the alarm name within the block The units display shows SubFd and the 5 digit display indicates UnAcd if the alarm is unac knowledged or is blank if acknowledged Press ALM again to enter Alarm Acknowledge mode indicated by AlAck in the units display To acknowledge the alarm press A or V Press ALM again to return to Loop Alarm Inspect mode Quitting alarm inspection modes Pressing R A M or SP W immediately reverts the T640 to standard operation A time out in the T600 block can also be set for automatic reversion after a defined period of no button activity T640 Reference M anual amp User Guide Issue 5 4 7 ALM button User interface Enter ALARM INSPECT mode Select other LOOP in alarm LOOP 1 A LOOP 2 MP LOOP 4 LOOP gt ALI TON Select other BLOCK in alarm PVI via SWSi tv a gt TRAMIT amp J9 SETP BLOCK NOM a pHi ghAb Select other Alarm SUBFIELD in alarm Hardware H v C
59. mV Int mV Ext 26 Y Themocouple 1G Y Thermocouple 2H N Do not connect 1H N Do not connect 2 y Thermocouple ar 1J YQ Thermocouple ANTE E Channel 2 InType Channel 2 InType 2K _ GCsensor mV Int mV Ext IK QCsasor t mV Int mV Ext 2L N Themocouple 1L i Thermocouple 2MIRS Isolated digital input 1M Isolated digital input 9 conn Bit V T Bit 2N N Isolated digital input 1N N Isolated digital input 2P Isolated digital input 1P Isolated digital input y TA TP ait DG IN ipe Volt O PE DPE Bil DG IN inType Volts 2Q N Isolated digital input 1Q N Isolated digital input 2R N Isolated digital input Bip 1R S Isolated digital input Bb 28 Isolated digital input 1S N Isolated digital input 2T N Analogueinput Channel 3 AN IP nType Volts Hz 1T N Analogueinput Channel 3 AN IP InType Volts Hz 2U N Analogue output Channel 2 AN OUT OutIype Volts 1U N Analogue output Channel 2 AN OUT Outlype Volts 2V Analogue ground 1V SJ Analogue ground 2W N Digital output Bit pG OUT DGPULS 4 1W N Digital output Bit0 pc OUT DGPULS 4 igi i Digital t XOY Pital output EDS vns IER Pil outpu NB In DGPULS 4 block 2Y N Digital output Bit2 Bit Bit2 correspond to 1Y N Digital output Bit2 pit Bit2 correspond to p Chan1 Chan3 resp EE Chan1 Chan3 resp 2Z S Digital ground 1Z AN Digital ground NB SiteNo Channel amp Bit numbers refer to the associated I O function block s corresp
60. minimum value of 100ms scan period m x nt r x 3 5 d x 3 5 w x 100 ms where m minimum period 100ms nt number of tables r number of registers d number of digitals or sets of digitals w number of writes to remote cached blocks per scan period Example For a system with a table of 16 registers and a table with 16 digital descriptors but no val ues connected to cached blocks the scan period is 100 x 2 16 x 3 5 16 x 3 5 0 x 100 312ms 2 4 2 T640 master mode timing There are two factors to consider here M The time to update the copy images by polling the slave devices across the MODBUS network E The time to update the database from the copy data collected by the polling routines In the T640 the functions are handled by two separate tasks and so they are effectively independent provided that only a limited number of change data transmissions are oc curring across the MODBUS link B 8 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 M O DBUS JBUS UN communications AppB 2 4 2 Poll period The following formula gives an approximation for the poll period assum ing that no values are being written poll period n x m1 nr x tr nd x td ms where n number of messages involved in acquisition ml message overheads and turnaround time nr number of registers to scan tr time to transmit register nd number of digitals to scan t
61. observed Before any other power input connection is made the protective earth terminal shall be connected to an external protective earthing system Wherever it is likely that protection has been impaired the unit shall be made inopera tive Seek advice from the nearest manufacturer s service centre The mains supply wiring must be terminated in such a way that should it slip in the cable clamp the earth wire is the last wire to become disconnected WARNING Any interruption of the protective conductor inside the unit or of the external pro tective earthing system or disconnection of the protective earth terminal is likely to make the unit dangerous under some fault conditions Intentional interruption is prohibited 2 2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Protection from hazardous voltages In order to meet the requirements of EN61010 and UL3121 1 in terms of protection from hazardous voltages the following installation conditions are mandatory E The unit must be mounted in a cabinet or enclosure requiring a tool or key to gain ac cess to wiring terminals W Wiring to all I O terminals must not be capable of subjecting the terminals to voltages outside their isolation capability In the case of ports having an isolation specified as none voltages at these terminals must not be allowed to exceed 30V rms and 42 4V peak or 60Vac Wiring It is imp
62. of this relay are connected to customer terminals 16 and 17 The watchdog relay is normally closed when the T640 is running and its CPU is healthy It opens on CPU or power failure but has also been con figured to open if an alarm occurs and remains open until the alarm condition has been cleared You can check this by connecting a multimeter set to measure resistance across terminals 16 and 17 These will be open circuit indicating an alarm condition the hardware alarm in the PV__1 block FUNCTION BLOCKS Blocks Figure 3 6 on page 3 6 divided the control database into three broad areas In fact each of these areas is further subdivided into pre defined packages of software having defined and specialised functions in the running of the control strategy These are the function blocks or blocks for short Every block has a tagname for reference and can perform its own specific task in the strategy e g the block called PV__1 is an analogue input block type that takes in analogue signals from the plant processes them and passes the results on to other blocks in the strategy via wiring between the blocks Other block types perform such tasks as setpoint generation PID calculation digital input analogue output mathematical and logical operations and so on Fields amp subfields Each block includes a collection of database values fields some of which are subdi vided into subfields Note that in the four f
63. out of cached blocks It is repeat driven at a minimum rate of once per 100ms The actual repeat rate derived by the T640 depends on the available CPU power after allowing for the user tasks 7 2 T640 Reference M anual amp User Guide Issue 3 A Task organisation LLC task This task runs every 100ms approximately and monitors the low level status of the ALIN link It applies timeouts to transmitted messages and also reprograms the ALIN hardware if error conditions are detected Load task This task is event driven and is run only when a remote request to load a database is re ceived NFStask Network Filing System This task processes ALIN filing system requests and is event driven Note that owing to the low position of the NFS task in the priority structure filing system requests get a much larger share of CPU time when the database is halted Scan task This task is run continuously while the database is running Its purpose is to collate alarm information and sumchecking of the database Bgnd task This background task performs no specific operation Its only purpose is to provide a task environment for the CPU to execute in while there are no other tasks running Bgnd task is not run at all while the database is running USER TASKS Terms A user task is an element of strategy i e a piece of software programmed into the T640 by the control engineer which is nominally associated with a loop By loop is mea
64. preserved may be connected to a pair of MODBUS regis ters The two parts are stored in standard PC format in two consecutive registers of which the first must be at an even address This method of linking is enabled by enter ing D double precision in the DP field of the first register The scanner task ensures data coherency 32 bit totals Two register mapping of long integers is used for the Total and Tar get fields of the TOTAL and TOT CONN blocks 3 DOWNLOADING THE CONFIGURATION The T640 database and MODBUS configurations can be downloaded from any device ca pable of downloading a database to a standard T640 Note that the database and MOD BUS configurations should both be stored on the same device and have the same root filenames but with different extensions DBF and GWF respectively The operator flags the appropriate DBF file or specifies its name depending on the downloading device then initiates the download operation as normal This causes the downloading device to send a command to the target T640 giving the name and location of the specified database file The T640 now takes over the loading of the new system It stops the current system loads the specified database file and saves it to EEROM The T640 then uses the name of the database file but with a GWF extension to load the new MODBUS configuration When the file has been loaded into memory and saved to EEROM the T640 restarts the system with the new
65. protocol and via MODBUS JBUS Please refer to Chapter 2 un der Hardware Configuration for communications configuration information Communicating on the ALIN This is always available and gives tight integration into the Eurotherm Process Automa tion LIN system Blocks have been included in the fixed function strategies specifically for caching The most important of these are PID CONN blocks which allow interaction with the control loops The names of the PID CONN blocks are PIDC1 for Loop 1 PIDC2 for Loop 2 and PIDC3 for Loop 3 where is the instrument node number For example if the ALIN address of the instru ment were 88 Loop 1 s control block would be named PIDC188 T640 automatically substitutes the node number for Furthermore eleven diagnostic blocks are provided for the instrument as a whole For de tails on the operation of these blocks please refer to the LIN Blocks Reference Manual Part No HA 082 375 U003 Table 5 15 lists these block types and their names Block type Block name DB DIAG DDIAG EDB DIAG EDIAG LIN DEXT LDEXT AUN DIAG AUN D_ XEC_DIAG XDIAG T600TUN E T600T EDB TBL ETBL RO UTETBL ROUTE RTB DIAG RDIAG ISB DIAG IDIAG ISB DEXT IDEXT Table 5 15 Diagnostic blocks in the T640 fixed function strategies TCS binary Bisync protocol As an option the T640 can be fitted with RS422 RS485 communications Each loop will emulate a 6366 as far as c
66. sections 2 14 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 nstallation amp startup Customer terminals GND GND L Earth screw terminal M4 Kd Earth screw terminal M4 1 N Internal earth 1 N Internal earth 2 RS Internal earth 2 D Internal earth L 3 Mains live N S Mains neutral 7 IQ DC input 1 8 Sy Dc input 1 9 S DC input 2 10 DC input 2 TM RS422 TX 11N RS422 TX 12 IR RS422 TX 12 RS422 TX 131 RS422 amp RS485 Gnd 13 N RS422 amp RS485 Gnd 14 1 RS422 RX amp RS485 14 R5 RS422 RX amp RS485 15 RS422 RX amp RS485 15 RS422 RX amp RS485 16 Watchdog User relay 16 S Watchdog User relay 171 OPEN fail 17 S L amp OPEN fail 18 A Alarm relay 181 Alarm relay 19 fod OPEN fail 19 OPEN fai 20 R5 ALIN Ground 20 S ALIN Ground 211 ALIN phase A 2119 ALIN phase A 22 Sj ALIN phase B 22 ALIN phase B Factory connected externally Table 2 1 Customer terminals for AC left amp DC right T640 motherboard options T640 R
67. supported by the hardware Setting them will have no effect Bit FALSE inverts HI ALM O UT 0 Bitl FALSE inverts LO ALM O UT 0 Bit TRUE inverts REM AUT O UT 0 Bit3 TRUE inverts HOLD MAN OUT 0 PVO P2 This block processes the retransmitted process variable or setpoint See SW S 2 W Field Bits HR_out The output voltage representing high range 3TRM 2 is block performs PID control The defaults for XP Tl and TD are provided only to allow control to RI RI h h LR_out The output voltage representing low range h h h h h happen These require setting to appropriate values TimeBase This sets the time units for Tl and TD XP This set the proportional band for control TI This sets the integral time constant TD This sets the derivative time constant Deadband This sets the hysteresis band if O n O ff control is selected See SWS 2 W Field1 Bit3 The value setis applied symmetrically above and below the setpoint TRCK2 This input processes the TRACK input If TRACK is not required all parameters in this block can be left as default track inputis being provided as an input signal this should be left AUTO Selecting M AN UAL will cause the control output to adopt the value set in PV if TRACK EN 1 goes high ce ju m Oo PY ODE is set to MAN UAL this input may be used to manually inputa TRACK value HR in The input voltage representin
68. switches 3 and 4 determine how T640 starts up after a power inter ruption as charted in Figures 2 14 and 2 15 For normal T640 operation both switches should be ON to provide full warm start and cold start capability The location of SW1 was shown in Figure 2 12 and the functions of switches 3 and 4 briefly summarised Table 2 6 below provides more detail on the effect of the four possi ble switch setting combinations Sw3 Sw4 T640 power up routine amp final state OFF OFF T640 idle database not loaded OFF ON Do warm start i e checksum database in memory If OK run database from where it stopped If corrupted try tepid start i e get RUN file if possible overlay tepid data and run database If tepid start fails clear memory and idle without running database ON OFF Do cold start i e count xxx RUN files If exactly one exists try to load and run xxx DBF If this fails or unique xxx RUN file does not exist idle without running database ON ON Power interruption lt ColdStrt do warm or tepid start If this fails do cold start as above Power interruption 2 ColdStrt do cold start Table 2 6 T640 switchbank SW 1 switches 3 amp 4 functions T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 33 Power up displays Installation amp startup Brow nout alarm A brownout time is specified in the T600 block which sets the BrownOut alarm bit if power is lost for more than this time
69. the T640 s EEPROM and EPROM ROM memory areas Some of these files are supplied already installed those marked with in the table Others appear automatically when you use the instrument or may be downloaded from a PC EEPROM and ROM reside in a removable memory module which allows a new strategy to be plugged directly into an existing controller or con versely allows a strategy to remain if the controller must be changed Accessing and re placing the memory module was described earlier in this chapter in the section Hardware configuration T640 s internal architecture is described in Chapter 9 Inside T640 Further details on these files are given in the relevant sections of this manual Filename Extension File type Control strategy name DBF Control strategy database parameters connections etc Control strategy name RUN T640 coldstart filename i e last database run Control strategy name 6WF MO DBUS configuration file GateW ay File Sequence name SDB Sequence database System filename UB Library of system routines in ROM area Factory set filename PKn Standard strategy in compressed format n 1 7 the strategy no Control strategy name current TPD Tepid data file Control strategy name Lnn Logfile of database changes via the INS pushbutton nn 01 99 language name ANG Non English language frontpanel messages Acton filename STO Compiled version of all actions in an action file Record file
70. the high range in engineering units for SP and PV Its current default value is shown in the red 5 digit display as 100 00 In the next step you will alter this value but before do ing this try accessing the other fields in the SETPI block using the A and W buttons to move around the list There are 12 fields in all see Table 3 1 Get back to HR SP for the next step With the HR SP field selected press INS again VALUE appears in the units display telling you that you can update the field value Press A to raise the value or W to lower it to the one you require subject to any configured limits For this tutorial lower the high range to 75 000 engineering units You now want to move on to the HL SL field in the block which specifies a high limit value for the local setpoint SL Press INS three times to return to field access mode with HR SP still accessed T640 has remembered your selections Then press V once to access LR SP which you will leave at zero and then three more times to reach HL SL Adjust this to 60 000 by pressing INS to get into value update mode as before then use A or V as needed Then return to field access mode by pressing INS three times T640 Reference M anual amp User Guide Issue 5 3 17 Tutorial Configuring absolute and deviation alarms In this stage of the tutorial you set new values for the high and low absolute and deviation alarms 1 Access the HAA field in the SETPI bl
71. the time constant set will be applied to the input RomC har This is used to select input linearisation The common thermocouple and resistance thermometer inputs are available Alarms Although other alarms than those listed below are available their priority should left at 0 Process alarms may be set in SETP2 The alarms listed below should be left at the priority set unless there is a reason to change them A reason to change them might be to stop individual alarms affecting the W atch Dog relay N ote if a zero priority is set the alarm condition will no longer select Forced anual Hardware Default 2 OutRange Default 2 OCctdel Default 2 HR in The input voltage representing high range LR in The input voltage representing low range 0 ptions Only options believed relevant are described Some options have defaults relevant to the 1 0 hard ware and should not be changed Invert TRUE maps HR in to SETP2 LR_SP and LR in to SETP2 HR SP TRUE will also have the effect of inverting the control loop Sqrt TRUE applies a square root function to the input continued T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 2 continued Block Field Subfield Description TRIM 2 This input provides a trim to the setpoint This trim input
72. 0 s internal layout example The motherboard is the main elec tronics board on which all I O board options are mounted It carries two configuration DIL switchbanks 1 and 2 and the memory module in its socket The figure shows an I O board in Site 1 and an expansion type I O board in Site 2 Other I O options and arrange ments are possible depending what was ordered Memory module removal See Figure A 2 Use a screwdriver blade to slide the retaining clip towards the front panel as far as it will go then pull the module out of its socket Replacement is the reverse pro cedure Caution The module can be pushed fully home only if it is the right way round Check this before applying excessive force which can damage the pins T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 A 3 Hardware configuration Setting up early boards Daughter board Jumper links note polarity Power supply fuseholder Figure A 3 1640 motherboard showing fuse amp jumper locations NOTE Refer to the Memory module compatibility section under Hardware con figuration Chapter 2 for important information on transferring memory modules between T640s Main fuse See Figure A 3 The motherboard carries the T640 power supply fuseholder The fuse is a 20 x 5 mm 250Vac antisurge cartridge fuse rated at 500mA AC option or 2A DC op tion Unscrew the fuse cap anticlockwise to remove The fuse should be replace
73. 11 7 Digital input contactsensing using customer s PSU 11 18 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications Thermocouple O THERMOCOUPLE I O Layout The thermocouple I O electronics resides on a single card mounted next to the mother board plugging into the central rear panel 22 way terminal block I O site 1 A second thermocouple I O card identical to the first but independently configurable may be fitted to the left hand rear panel 22 way terminal block I O site 2 T640 Rear panel customer connections Please refer to Table 2 3 in Chapter 2 in the Connections amp wiring Customer terminals section for details Hardware configuration There is no hardware configuration required on the thermocouple I O board The appro priate input and output ranges are automatically selected when you configure the corre sponding input or output block in the control database LIN blocks parameters not supported The LIN Blocks Reference Manual lists the LIN I O blocks supported by the T640 and de scribes in generic terms every parameter in those blocks However certain parameters are not supported or are only partially supported by the thermocouple I O board Table 11 4 lists these parameters Break detection amp break protection This information is given in addition to that appearing in the LIN Blocks Reference Manual AN_IP block section The isolated thermocouple inputs channels
74. 113 114 n5 16 117 N8 19 120 121 122 123 124 125 126 127 A BBTAE X3 HA K AM HO II 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 P C T y o x nun uigprlHi b BH b 93 IO 8H 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 i 20 p y 6 g n OAUV xpo t 160 161 162 163 164 165 166 167 168 169 170 171 172 3173 174 175 x vol A0AzrEoVvvOos txi i 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 e E c e 6 i i 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 ii Nn N O9 o o 6 o 208 209 2710 211 212 213 214 215 216 21 218 219 220 271 222 223 a amp x yf t 2825 2 4 2 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 597610 2 v 27 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 Table 11 1 Dotmatrix display character set representational T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 ALIN Specifications Dot matrix display character set Table 11 1 shows in representative typefaces the complete set of characters displayable by the two dot matrix front panel displays the Tag display and the Units display The number under each character is its decimal code used to specify that character for display via the LINtools configuration package Codes 0 to 31 are reserved and are not user ac cessible Please refer to the 7500 LINtools User Guide for further details
75. 20B Verify error 820C File locked already in use 820D File read only 8301 Bad template 8302 Bad block number 8303 N o free blocks 8304 N o free database memory 8305 Notallowed by block create 8306 n use 8307 Database already exists 8308 N o spare databases 8309 N ot enough memory 8320 Bad library file corrupt ROM file 8321 nvalid template in library 8322 Bad server corrupt file when loading 8323 Cannot create EDB entry 8324 Bad file version 8325 Bad template spec 8326 Unable to make block remote 8327 Invalid parent 8328 Corrupt data in DBF file 8329 Corrupt block spec 832A Corrupt block data 832B Corrupt pool data 832C N o free resources 832D Template not found 832E Template resource fault 8330 Cannot start continued 10 2 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Error conditions amp diagnostics continued Error Meaning 8331 Cannot stop 8332 Empty database 8333 Configurator in use 8340 DBF file write failed 8341 ore than one RUN file found 8342 RUN file not found 834A Connection source is not an output 834B ultiple connection to same input 834C Connection destination not input 834D No free connection resources 834E Bad connection source destination block field 834F nvalid connection destination 8350 W armstart switch is disabled 8351 No database was running 8352 Realtime clock is not running 8353 Root block clock is not running 8354 Coldstart time was exc
76. 28 Q Gott OUTPUT area Z 2T HIALMOUT O is block i DOP_2 outputs TRACK EN 1 2R QJ n ra 2U tou our output PV pins Z 2V REM AUT OUT 0 Cascade CC LD 2W HOLD MAN OUT 0 J interlocks LOOP 3 Calculate R ti t ti RORIS gt measured filter PV ratio atio station beck y pron SETP3 Derive Inverse Slaves PV RAT SP TRIM 1F N input gt setpoint gt Slave s block block REM SP Normal Ratio FALSE PROCESS ALARM OUTPUT area DOP 1 digital output block 1V REM AUT OUT 0 CO 1U LO ALM OUT 0 A 1T HIALM OUTO 1W HOLD MAN OUT 0 INPUT area TRIM1 RATIO BIAS 1H Z noni block PV 1 andogue 5 PV 1E D input block TRCK1 analogue TRACK 4J S9 put i block COMP EN 0 1P Qu REM SP EN 1 10 3 uom TRACK EN G 1R Q input HOLD EN 1 1 area PID CONTROL Slave s Remote SP RE TRANSMITTED SWS_1 W Field1 Bit6 OUTPUT area PVOP1 analogue 1M output block PV SP OUT SETP1 ko oun ae CONTROL ock SP O Aa3mg OUTPUT area i y i OUTP1 D iam pl analogue s MARNE 4 20mA block output j 1B block D 3T OUT OP 1 analogue MANS1 output AD 1L 3TOUT 0 10V ma
77. 3 6 shows the same control scheme but highlights very schematically the three main areas of software inside the T640 that are responsible for running the strategy The PV input software takes in the measured PV as an analogue voltage and applies ranging conditioning limiting and alarms before passing the signal to the PID control area Here the setpoint and PV are fed into the PID algorithm which calculates a value for the control output needed to be applied to the valve to achieve optimum flow control Other operations done in the PID control area include ranging limiting alarm detection control mode selection manual intervention and application of PID algorithm tuning constants T640 Reference M anual amp User Guide Issue 5 3 5 Tutorial Local setpoint PV 3 term output Ca a Figure 3 5 Example P amp diagram for strategy 1 PV PID CONTROL INPUT gt CONTROL gt OUTPUT area area area Flow sensor Flow control orifice plate valve Figure 3 6 Main software areas strategy 1 The last area Control output handles output conditioning ranging power up and failure modes This tutorial will show you how to access these software areas via T640 s front panel buttons and displays and configure their parameters to suit your particular plant control requirements 3 6 T640
78. 6 bit integers booleans alarms and bitfields Long signed 32 bit integers When these values are transferred from the data base to a MODBUS register they are truncated and only the low order 16 bits are written When the register is being transferred from the MODBUS to the database the value is sign extended into the high order 16 bits T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 11 AppB 84 M O DBUS JBUS LIN communications Long unsigned 32 bit integers When these values are transferred from the database to a single MODBUS register they are truncated and only the low order 16 bits are written When the register is being transferred from the MODBUS to the data base the high order 16 bits are assumed to be zero Floating point numbers When these values are transferred from the database to a MODBUS register they are scaled according to the decimal point you specify converted to an integer with rounding limited to the range 65536 to 465535 and then truncated to 16 bits This allows applications to work either with signed numbers 32768 to 32767 or with unsigned numbers 0 to 465535 When the register is being transferred from the MODBUS to the database it is treated as a signed number in the range 32768 to 32767 scaled according to the decimal point specified and then written to the database B Values requiring up to 32 bits of storage 32 bit fields representing val ues where precision must be
79. 62 This block needs attentio n only if Bisync communications are to be used Slave address of the con This is a set of optiona Instr No SWS 2 trol loop s 6366 emulation on the Bisync communications bus switches for setting up the loop W Field1 Bito This defines the power TRUE the loop goes in FALSE the loop mainta Zero n u 0 p mode manual on power up with zero output ins its last mode and output on power up eans low electrical output irrespective of any ranging or oop inversion Bitl On PV fail the loop wil control output TRUE Zero output wil FALSE the last output wi Zero n go from AUTO into FORCED MANUAL th eans low electrical output irrespective of any ranging or is bit determines the action of the be forced ll be maintained oop inversion Bit TRUE inverts the output a affectPV SP OUT 100 OP 4mA 0 OP 2 20mA This should be set TRUE if th tion for safety reasons Thi C r the manual station e actuator has reverse control ac ge control outputs It does not jon and hence the control action afte s bit affects both the 4 20mA and volta Thi the output readi oop 5 inverts the control action before the manual station It does n ot affect the relationship between ng and the true electrical output This may be set true to reverse the action of the This selects O n 0 ff contr ol See also 3TRM 2 Deadband FA
80. ALSE tru Mask A BitA FALSE tru Mask M BitB tru Tag FIC 001 BitC FALSE Tag UC 001 BitD FALSE Tag PIC 001 BitE FALSE Tag TIC 001 BitF FALSE Tag AIC 001 RSP_2 Filter 0 00 Input filter HR in 10 00 Input voltage high LR in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning DIN 2 Invert BitO FALSE Unused Bitl tru FALSE inverts REM SP EN 1 Bit2 FALSE tru inverts TRACK EN 1 Bit3 FALSE tru inverts HO LD EN 1 PV 2 Filter 1 00 Input filter RomChar None Input conditioning Alarms Hardware 2 Alarm priority OutRange 2 Alarm priority OCctdel 2 Alarm priority HR_in 10 00 Input voltage high LR in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning TRIM2 MODE MANUAL Operating mode AUTO or MANUAL PV 0 00 Trim setting if MANUAL HR 100 00 Engineering units high LR 0 00 Engineering units low Filter 0 00 Input filter HR_in 10 00 Input voltage high continued 5 36 T640 Reference M anual amp User Guide Issue 5 Standard strategies Setup sheets continued Block Field Subfield Default Setting Description LR_in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning SETP2 HR_SP 100 00 Engineering unitshigh for SP and PV LR_SP 0 00 Engineering units low for SP and PV HL SP 100 00 High limit on SP LL
81. BitE FALSE Tag TIC 001 BitF FALSE Tag AIC 001 Table 3 3 Configurable fields in the SW S 1 digital connection block T640 Reference M anual amp User Guide Issue 5 Tutorial 4 5 Press INS and alter BitO s value to tru then return to the normal display by pressing A Now simulate a power interruption by switching the power off then on and watch the front panel displays The T640 powers up in manual mode and the control output falls to zero Check this by pressing the M button and reading the 5 digit display which should indicate 0 00 output Restore control by re selecting auto mode press A Restore BitO to FALSE PV fail mode 1 6 Use the INS button to access Bit1 of the SWS 1 block This bit determines what hap pens to the control output should the process variable input PV fail In Bitl s default state FALSE the control output holds at its last value on PV failure With Bit1 TRUE however the output falls to electrical zero i e OV or 4mA on PV fail Set Bit to tru and press A to return to automatic mode While A is pressed note the control output value in the 5 digit display Now simulate a PV failure by disconnecting the wire attached to terminal 1E Notice that the control loop adopts forced manual mode indicated by the flashing yellow LED in the M button and that the control output drops immediately to zero Press M to check this Reconnect terminal 1E and press A to restore con
82. DCpl3 This block filters SETP2 PV before calculating the remote setpoint for SETP1 The filter is also applied prior to the measured ratio calculation Filter Firstorder filter time constant continued 5 32 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 4 Ratio pair continued Block Field Subfield Description TRIM3 This input provides a trim to the ratio setpoint This trim input is added to the setpoint directly If no trim is required all parameters in this block can be left as default MODE This should be left at MAN UAL if a manual trim or no trim are required Set this input to AUTO if a trim is to be provided as an input signal SP TRIM PY ODE is set to MAN UAL this input may be used to manually input a ratio setpoint trim HR This sets the high range HR_in maps to HR Because trim works by direct addition to the setpoint HR and LR are used to scale the trim input against SETP1 HR SP and IR SP LR This sets the low range LR in maps to LR Itwould not be unusual for LR to be the same value as HR but negative to give a symmetrical trim Filter A firstorder filter with the time constant set applied to the input HR in The input voltage representing high range LR in The input voltage representing low range 0 ptions Only options believe
83. Decoupling Filter TRIM 3 ODE MANUAL Operating mode AUTO or MANUAL PV 0 00 Trim setting if MANUAL HR 100 00 Ratio trim high LR 0 00 Ratio trim low Filter 0 00 Input filter HR_in 10 00 Input voltage high LR_in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning SETP3 HR_SP 100 00 Ratio high range for SP and PV LR_SP 0 00 Ratio low range for SP and PV HL SP 100 00 High limit on SP LL SP 0 00 Low limit on SP HL SL 100 00 High limit on SL LL SL 0 00 Low limit on SL Alarms HighAbs 2 Alarm priority on HAA LowAbs 2 Alarm priority on LAA HighDev 2 Alarm priority on HDA Low Dev 2 Alarm priority on LDA HAA 100 00 High absolute alarm on PV measured ratio LAA 0 00 Low absolute alarm on PV HDA 100 00 High deviation alarm on PV LDA 100 00 Low deviation alarm on PV Dis DP 3 Decimal point position Table 5 13 Setup sheet for Loop 3 strategy 4 ratio Loop 4 Block Field Subfield Default Setting Description USR ALM Priority 2 W atch dog relay alarm setting 0 15 T60 Options NoKeyPrt tru FALSE key required NoKeyFul FALSE FALSE key required BinSpd1 FALSE Bisynch baud rate BinSpd2 FALSE Default gives 9600 baud Table 5 14 Setup sheet for Loop 4 all strategies 5 38 T640 Reference M anual amp User Guide Issue 5 Standard strategies Communications COMMUNICATING WITH THE T640 There are three ways in which the T640 may be integrated into a system via the ALIN via TCS binary Bisync
84. LED AF Relay Site 1 e ini outputs digital 4 iugo P outputs to plant CAUTION 1X Q Digital outputs power up LOW so Digital f 1Y relays will beON ground 1z 2 till strategy starts running up to 3s 2T 2 O O AF Relay Site 2 ini outputs digital 4 og A P outputs to plant i O i AF e bd n RELAY UNITS Digital les 8 channel PN LA083451 U008 amp 4 channel ground LA083451 U004 relay units complete with indicating LEDs protective and blocking diodes are available from Eurotherm Figure 11 6 Digital outputs operating relays current sinks with pullup via customer s PSU T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 17 High level O Specifications Customer s 1P O e o PSU R 7 5V 28V 1Q e oo Site 1 2 digital Inputs 1 3v 1S 2 e No e Digital 1Y ground 1z 2 SW 2P D e No R 2Q e So Site 2 2 digital NOTE H Select resistors R to ensure at inputs 2R Q e No least 2mA wetting current via contacts SW E g W ith 24V supply inputim 28 Q e ovo pedance 100kQ see spec so max current without using resistor 24V 100kQ 0 24mA which is too small Use R 24V 2mA 12kQ Digital J 2Y for 2 24mA wetting current ground 22 2 Figure
85. LSE the local setpoint TRUE the local ocal setpoint w setpoint w ill always track the remote setpoint when remote is selected will remain unchanged ill track the process variable if the controller is not in AUTO N ote the FALSE the seco TRUE the secon nd analo gue output will be the retransmitted PV d analogue output will be the retransmitted SP TRUE Inverse ratio setti orm Loop only Ratio controll n a g is used loop1 SP loop2 PV ratio setpoint Inverse loop1 SP loop2 PV ratio setpoint ler only TRUE ask R push button ask A push bu on h button S F G5 65 R R RU R E E Mask M pus UE loop tag is F lso loop 2 tags are C00 Fl gt 1 Note BitC has priority over BitB BitD has priority over BitC and BitB etc C002 etc UE loop tag is LI C901 UE loop tag is P C901 loop tag is TIC 00 tC RI D RI E R F R a rn rn rn rn loop tag is A NB If the HOLD EN 1 input is high at power up C901 old mode wins and the last output is maintained despite BitO s being TRUE continued T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 2 continued Block Field Subfield Desaiption RSP 2 This block proc
86. N eee pre ERR eth RNE B 11 2 6 1 Data conversion of digitals ssss B 11 2 6 2 Data conversion of registers eects B 11 Downloading the configuration eene B 12 Using the diagnostic table sss B 12 4 1 Internal diagnostic registers esses B 13 4 2 MODBUS table status and control registers B 13 4 2 1 Slave mode diagnostic table registers B 14 4 2 20 Master mode diagnostic table registers B 14 MODBUS diagnostic function codes sessssss B 15 MODBUS exception responses esses B 16 6 1 Slave mode error codes B 16 6 2 Master mode error codes 0 eee ese eceeeeeeseeeteeeeenees B 17 Notes on MODBUS JBUS implementation B 17 7 1 MODBUS AEG MODICON eee B 17 42 JBUS APRID ethic eget tont den B 18 1 3 Other products een eon Ee ene ter det B 18 FRONT PANEL FOREIGN LANGUAGE SUPPORT Hile Str Cture asian er re ter eee Aa C 1 Index ene rt a E Re en ARE elem nca OUR IND 1 Contents 12 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter1 INTRODUCTION THET640 The T640 is the first in the range of T600 Series controllers It is a multi purpose 2 or 4 loop controller with a high speed peer to peer communications link and a well established block structured database allowing it to integrate tightly into a Net
87. NOTE Outputs to high impedance logic During power up lt 3s output transistor is O FF till database takes control To prevent logic 1 being output OV temporarily connected automatically Figure 11 12 Nondsolated digital outputs block schematic n 1 2 I O calibration procedure Please refer to Chapter 2 of the LIN Blocks Reference Manual Part No HA 082 375 U003 for generic information on calibrating I O using the AI CALIB and AO CALIB function blocks The following information relates specifically to the thermocouple board Partial re calibration To calibrate a particular channel of the thermocouple I O board you need not completely re calibrate the whole card The following channels are calibrated as separate operations mV thermocouple input 1 the input 1 CJC facility must be calibrated at this time mV thermocouple input 2 the input 2 CJC facility must be calibrated at this time Analogue input voltage mode Analogue input frequency mode Process output Analogue output 11 28 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 T640 codes Chapter 12 ORDERING INFORMATION ORDERING OPTIONS The T640 can be ordered as a complete package including sleeve and memory module The order codes required for this are given in Table 12 1 Sleeves T710 security keys T950 memory modules T901 burden resistor diode kits and ALIN terminator kits are separately orderable using the order codes
88. P gt Ses Select BLOCK v A swsi v A gt TRL f SETEI BLOCK SUM mau Te 0 ptions Select FIELD Alarms A HR_in ey a lin FIELD gt IE gt Hardware Select SUBFIELD Software vja Combined Mw Y AUC harer A SubFd OS VALUE Display Select VALUE Certain high precision Software fields may appear in VALUE IN CREM EN T value or set TRUE AERE ia instead of in the 5 digit display RON M007 memory d module only Figure 4 2 Inspect button functions IN S DECREM ENT value or set FALSE T640 Reference M anual amp User Guide Issue 5 4 5 Database access User interface 2 Block Access mode The second INS press selects this mode and BLOCK appears in the units display Press A or V to select a block for inspection Block tagnames appear in the tag display in execution order Press ALM to see the block Type in the Tag display 3 Field Access mode The third INS press selects this mode and FIELD appears in the units display Press A or V to select a field for inspection The tag display shows the field s name and the 5 digit display shows its value format permitting Press ALM to see the field s units in the Tag display 4 Value Update mode Connection Enquiry mode Subfield Access mode The fourth INS press selects one of these three modes depending on the type of field ac cessed B Value Update mode
89. P still at about 50 units press the A button to select automatic mode Its green LED lights confirming that auto mode has been adopted and the M button s yellow LED goes out As soon as auto is selected the control output begins to rise due to the action of the PID algorithm in the PID control area of the strategy NOTE While A is pressed OUTPUT appears in the tag display and the fascia shows the current control output value and its units You can see the control output displayed in the horizontal output bargraph labelled OUT Y Each of its yellow segments represents about 10 of full range output The simulated PV value also rises of course and shows itself on the red PV X vertical bargraph at the left of the fascia and also in the 5 digit display Once the controller has settled down in auto PV and SP should adopt the same value in this simulation The deviation bargraph now shows zero deviation with just the central green LED lit The letter A glows in green below the deviation bargraph denoting automatic mode for this loop Manual mode You can press the M button at any time to select manual mode Note that pressing M also displays the control output value and units But in manual mode you can alter the output not just display it Try raising the control output to 100 by pressing M and at the same time pressing the A button You will see the PV and deviation bargraphs rise to their maximum indications Limit
90. RANSMITTED OUTPUT gt TXPSU 2C REC Transmitter area power TX PSU supply Pens Satin oh E PVOP2 2 O PID CONTROL analogue 2M euse out EC area output analogue block Pv 2E input FFALSE ro e eee E block p SETP2 PV O setpoint 5 i TRIM2 block I SP i is SP TRIM 2H S deos ARMED i area block Y i OUTP2 y 7 3T OUT RSP 2 pass I analogue 2A s 4 20mA REM SP 2F O ood block Ok 2B arour block Y v i TRCK2 MANS2 OP_2 d TRACK 2J S pied manual prd I f 2L stour 010V block block block s REM SP EN 1 2Q S DN 2 RANE S digital d TRACK ENG 2R input OUTPUT area P 2T HIALMOUTIO Aus block HOLD EN 1 2S CO rue p A 2U Lo alm outo P t output 2V REM AUT OUT 0 Cascade Paina Rae Oe Z 2W HOLD MAN our o J interlocks SYSTEM ALARM LOOP 4 OUTPUT area USR ALM alarm Teo o 4 D 16 WATCHDOG 1 collection Oot tesessssskues Watc hdog block block relay 17 WATCHDOG2 Priority 2 oD 18 ALARM 1 m 2 19 ALARM2 Figure 5 5 Strategy 2 schematic T640 Reference M anual amp User Guide Issue 5 5 17 Strategy 2 Standard strategies Strategy 2 schematic Figure 5 5 shows schematically the main function blocks in the strategy the principal sig nal flows between them and their associated customer terminals Details of each terminal and block are given in the tables that follow
91. Reference M anual amp User Guide Issue 5 Tutorial POWER UP Power up messages Switch on the power to the instrument You may be quick enough to see the message Power on flashing briefly in the red tag display at the top of the fascia see Figure 3 7 Then ColdStrt Trying flashes telling you that T640 is attempting a cold startup of the single loop database strategy 1 Next if the strategy is being loaded for the very first time you will see Un Pack Database flashing in the tag display as the strategy 1 file which you selected via SW1 is being decompressed from storage in ROM You may also hear the clicking of a relay closing and opening just after these messages Finally the fascia adopts the normal display shown in Figure 3 7 NOTES 1 Slightly different power up messages may appear if someone else has used the T640 before you e g TepidSrt Trying or WarmStrt Trying 2 If what has just been described fails to happen and you get an error message e g Err 6001 first check that you have set SW1 correctly If neces sary refer to Chapter 10 Error conditions amp diagnostics for further information Tag display io HI Units display z 5 digit display O utput bargraph PV bargraph SP bargraph Er Deviation bargraphs M ode letter HLL LL Displayed loop arrowhead Pushbuttons EE P we ll Figure 3 7 1640 front panel initial power up T640
92. Removing a clamp from the sleeve Figure 2 3 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Connections amp wiring Installation amp startup Removing T640 from sleeve Withdrawing the T640 from its sleeve is done entirely from the front of the mounting panel without disturbing any of the system wiring Caution Repeated removal replacement of the T640 under power erodes edge connectors Check connectors periodically and replace a board if excessive burning or pitting is seen Anti static precautions must be observed when handling the unit out of its sleeve See Figure 2 4 To unlock the T640 insert a small screwdriver blade into the slot in the retaining clip at the bottom of the fascia and slide the clip to the left as far as it will go Repeat this for the clip at the top of the fascia but slide it to the right To withdraw the unit use the extractor tool supplied in the accessory kit Part No BD 082253 Hold the tool at an angle of about 45 insert the hook into the opening under the SP W pushbut ton then level the tool and pull the unit from the sleeve Remember to lock both retaining clips after refitting the unit in the sleeve we DAE Extractor tool Slot in O pening retaining clip Figure 2 4 W ithdrawing T640 from the sleeve CONNECTIONS amp WIRING Electrical connections to the T640 are made via three blocks of customer screw terminals at th
93. S NoChange SansC hgt Attempting to change displayed loop when prohibited by strategy No Key Cle abs Attempting to enter database inspect mode without a security key Bad Area MauvZone Attempting to enter database inspect mode with a key having the wrong area number Bad Key M auv Cle Attempting to enter database inspect mode with an invalid key oBlock SansBloc Attempting to enter database inspect mode when there are no blocks in the currentloop LOOP1 BOUCLE 1 Indicate the current loop number cached LO O P2 BO UCLE 2 in database loop inspect mode LO O P3 BO UCLE 3 LOO P4 BO UCLE 4 CACHED IMAGE LP 1 ALM ALM BCL Indicate an alarm in a loop LP 2 ALM ALM BCO other than the currently displayed loop LP 3 ALM ALM BCL3 LP 4 ALM ALM BCL4 CACH ALM ALM IMAG SAVING SAUVEG Indicate a database FullSave or PartSave in progress Save OK SAUV OK TRUE VRAI TAG block is being used to generate the tag display FALSE FAUX for the display of boolean fields BadField M auv PRM or where a bad fieldname is given NoAlm ssA LM Attempting to enter alarm inspect mode when there are no alarms LOOP BO UCL Indicate which database inspect mode is operative BLO CK BLOC FIELD PARAM Ronly LECT SubFd PRM Se Conn CONN VALUE VALEU AlAck ACQAL N oPrt ssPrt Attempting to enter block inspect mode in partial database inspect when there are no blocks in this loop with partial inspect fields Limit Limit Limit reached on raise lower Ta
94. SP 0 00 Low limit on SP HLSL 100 00 High limit on SL LL SL 0 00 Low limit on SL Alarms HighAbs 2 Alarm priority on HAA LowAbs 2 Alarm priority on LAA HighDev 2 Alarm priority on HDA LowDev 2 Alarm priority on LDA HAA 100 00 High absolute alarm on PV LAA 0 00 Low absolute alarm on PV HDA 100 00 High deviation alarm on PV LDA 100 00 Low deviation alarm on PV Dis DP 2 Decimal point position DOP2 Invert BitO tru FALSE inverts HI ALM O UT 0 Bitl tru FALSE inverts LO ALM OUT 0 Bit2 FALSE tru inverts REM AUT AUT 0 Bit3 FALSE tru inverts HO LD XM AN OUT 0 PVOP2 HR out 10 00 O utput voltage high LR out 0 00 O utput voltage low 3TRM2 TimeBase Secs Control settings time base TI amp TD XP 100 00 Proportional band TI 10 00 Integral time TD 0 00 Derivative time Deadband 0 00 Hysteresis for O n O ff control TRK2 ODE AUTO O perating mode AUTO orMANUAL PV 0 00 Track setting if MAN UAL HR in 10 00 Input voltage high LR in 0 00 Input voltage low MANS2 HLOP 100 00 High limit on control output LL OP 0 00 Low limit on control output OP 2 HR out 10 00 O utput voltage high LR out 0 00 O utput voltage low Table 5 12 Setup sheet for Loop 2 T640 Reference M anual amp User Guide Issue 5 5 37 Standard strategies Setup sheets Loop 3 Block Field Subfield Default Setting Description 51663 nstr No 1 BiSync address DCpl3 Filter 0 00 Ratio
95. SetLocal or RemoteSP appears in the tag display Changing the setpoint To vary the value of SL press SP W together with A or V Full range change takes about 30 seconds T640 Reference M anual amp User Guide Issue 5 4 3 Database access User interface Setpoint parameters quick access With SP W pressed press INS repeatedly to scroll the 5 digit display through the primary setpoint parameter values These are SL SetLocal SP SetPoint RemoteSP ComRemSP and TrimSP identified in the tag display ComRemSP is not available from simple PID blocks Absolute amp deviation alarm settings viewing Press A and V together to superimpose the absolute alarm settings on the PV X bargraph and the deviation alarm settings on the SP W bargraph as pairs of reverse lit LEDs The tag display shows ALM_SET Absolute amp deviation alarm annunciation For the main loop on the display an absolute alarm flashes the red PV X bargraph and a deviation alarm flashes the green SP W bargraph For the four summary loop displays either alarm flashes the relevant summary deviation bargraph DATABASEACCESS The INS button lets you inspect and edit database parameters Two access modes are available Full and Partial requiring a Full or Partial security key unless the need for a key is overridden in the T600 block If necessary refer to the Security key sec tion at the end of this chapter for how to use the k
96. Strategy 2 I O customer terminals Strategy 2 uses a pair of I O boards located in sites 1 and 2 of the T640 accessible via customer terminals 1A to 1Z site 1 and 2A to 2Z site 2 Site 1 terminals are identical to those given for strategy 1 see Table 5 4 on page 5 9 Table 5 7 lists site 2 termina tions and their functions and also where relevant the names of function blocks having pa rameters that affect the operation of the corresponding I O Pin Assignment Description Blocks 2A 3TOUT VE Isolated 4 20 mA output signal This is the control output SWS 2B 3TOUT VE 2C TX Power Supply Isolated 24 volt transmitter power supply 2D TX Power Supply 2E PN Process variable voltage input M 2 2F REM SP Remote Setpoint voltage input If the remote setpoint input is broken or not RSP 2 connected the loop reverts to its local setpoint RATTRIM Ratio trim input See under Strategy 4 Ratio control for details TRIM 3 2G Analogue G nd Reference ground for analogue signals 2H SPTRIM Setpoint trim voltage input TRIM 2 2 TRACK The control output is forced to this value if the TRACK EN 1 signal is high TRCK2 2K Analogue Gnd Reference ground for analogue signals 2L 3TOUT Control output signal as a voltage 0P 2 SWS2 2M PV SPOUT Retransmitted process variable or setpoint output as a voltage PVO P2 Process variable is the defa ult SWS 2 2N Analogue Gnd Referenc
97. T TRIM2 ied a lock S analogue TRUE PTRIM 2H input RENE EL block 3TRM2 rE ete Set Cae eee 3 te i RSP_2 black PROCESS analogue ju DOO ALARM c rem sp 2F S po Y OUTPUT area 2T HIALMOUTO loci MAN22 f BENSEENI ZG AM manual nia C 2U Lo AM co Qu a station 7 HOLDEN 1 25 S i pure POR TRACK Hook le 2 2V REM AUT OUT 0 m vee input Meche oun Z 2W HOLD MAN OUT 0 Fb loci is REMOTE Cascade Sis HENS Re SETPOINT p conto ENABLE interlocks REMOTE PROCESS ALARM 4 SETPOINT LOOP 1 OUTPUT area rA Z 1V REM AUT OUTO oe ag et E Pope Slave DOP 1 TRANSMITTED digi Lo 1U LOALM OUT 0 SLAVE SMITTED output M PID CONTROL OUTPUT block 1T HALM OUTO area E OE area ti eae L Z 1W HOLD MAN OUT 0 seri lev ig PvoPt SER eRe EER Oi 4 tpoint analogue codem pert D 1M PvisP OUT OE EU yd gt TRUE block INPUT area Waa MD Tera eee eres TRIM STRM Atay CONTROL 3A SPTRIM 1H Qo aoit block OUTPUT block j area j PV 1 MANS1 OUTP1 i Pv IEG analogue manual analogue gt 1A 3T MEL input station cb output f block block block t Y 1B 3TOUT ona 0i 007775707007 Y COMP EN 0 1P Qa digital mie TRACK EN 1 1R O oe output O 1L 3TOUT 0 10V i loci HOLDEN 4S Q llo L D SYSTEM ALARM LOOP 4 USR_ALM OUTPUT area l o 2 WATCHDOG collection Hoo 16 Eu black block 17 WATCHDOG 2 Priority 2 L i
98. T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Hardware configuration Communications zero volts schematic Figure 2 9 shows the RS422 485 and ALIN comms connections with associated customer screw terminals The main CPU is opto isolated from the RS422 485 transmit receive ter minals NOTE The ALIN cable screen and the RS422 485 cable screen should each be grounded at one point only HARDWARE CONFIGURATION Status level information The information given in this chapter refers to T640s with hardware status levels of 12 or higher For older hardware please refer to Appendix A Setting Up Early Boards as well as the present chapter To view status level information remove the T640 from its sleeve see Figure 2 4 and check the printed label on the side of the unit Below the order code is a line of code end ing with a letter the software status level and a number the hardware status level E g in the code W29073 001 1 2900 J12 the software status level is J and the hardware sta tus level is 12 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 221 Memory module compatibility Installation amp startup Internal layout Figure 2 10 shows T640 s internal layout example The motherboard is the main elec tronics board on which all I O board options are mounted It carries two configuration DIL switchbanks 1 and 2 and the memory module in its soc
99. V minimum 15 5V maximum 7mA sourced via 2K7 resistor Allows hardware pullup of up to 8 digital inputs logic0 68Q 25mA maximum sink current to maintain logic 0 output level 37mA absolute maximum sink current logic 1 2 2kQ none The environmental physical and electrical specifications for this assembly are the same as for the base unit I O calibration procedure Please refer to the LIN Blocks Reference Manual under Calibration methods for generic information on calibrating I O using the AI_CALIB and AO_CALIB blocks The follow ing information relates specifically to the high level I O board Complete re calibration In order to perform a complete re calibration of the instrument you need not calibrate all channels Only the following four I O points need to be re calibrated W One analogue input channel e g channel 1 site 1 terminal 1E board is fitted One analogue output channel e g channel 1 site 1 terminal 1L Current output channel 3 site 1 terminals 1A 1B Current output channel 3 site 2 terminals 2A 2B only if the expansion I O T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 1145 High level O Specifications NOTE Power the instrument off then on to ensure that the new calibration data is applied to all channels Limited calibration Re calibration of only one of the above points does not affect the calibration state of the others
100. VALUE appears in the units display or Ronly read only if update is not permitted Press A or W to vary the field value indicated in the 5 digit display or in the tag display if text Limit in the units display indicates that a limit has been reached Pressing INS at this point returns you to Loop Access mode Further INS pressing cycles through the access mode hierarchy retaining your latest selections NOTE Some high precision AGA8DATA block fields supported by the T640 M007 memory module may display in the Tag display with 8 digit resolution instead of in the 5 digit display The display format is standard form with a multiplier displayed in the 5 digit display E g 2 18000 in the Tag display with E 2 in the 5 digit display represents a field value of 0 0218000 Press A or V to increment or decrement the value B Connection Enquiry mode Ifthe field has a connection into it barring manual update Conn appears in the units display The tag display shows the first 8 characters defining the source point Press A or W to see the rest Press INS to return to Loop Access mode B Subfield Access mode If this is a subfield SubFd appears in the units display Press A or V to select a subfield within the current field The tag display shows the field s name and the 5 digit display shows its value format permitting 5 Subfields If this is a subfield the fifth INS press selects subfield VALUE or Conn modes used as a
101. W Switches 3 and 4 configure the way the T640 powers up and are usually both set to ON for normal operation T640 s power up routine is explained in detail later in the section Power up routine 2 24 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 nstallation amp startup Switchbank 1 a N Comms selection see Table 2 4 on value HS uid Cold start enable Strategy selection Warm start enable Enable loop database watchdog 3 4 Action atstartup ON ON W arm start if possible else cold start if possible else idle ON OFF Cold start if possible else idle OFF ON W arm start if possible else idle OFF OFF Idle ES See Table 2 6 for a more detailed summary J Figure 2 12 SW 1 location and functions Wi Switch 5 when set to ON causes the watchdog relay contacts customer terminals 16 amp 17 to open if a loop user task stops running or if the database halts This function is in addition to the relay s normal actions i e CPU failure watchdog closed healthy open failure and user alarm via the T600 block s UsrAIm field With switch 5 OFF the relay does not respond to loop or database halts T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 25 Switchbank 2 Installation amp startup W Switches 6 7 and 8 select the number of a preconfigured standard strategy to be
102. a E i block block oe relay 17 WATCHDOG 2 xamp es Priority 2 TRACK EN 1 means that track mode is o 2 18 ALARM enabled by a high input Verret ia For HI ALM OUT 0 a ow output signifies a game of prions ie relay 19 ALARM2 high absolute or high deviation alarm fs 0 Figure 5 3 Strategy 1 schematic Strategy 1 I O customer terminals Strategy 1 uses a single I O board located in site 1 of the T640 accessible via customer terminals 1A to 1Z Table 5 4 lists these terminations and their functions and also where relevant the names of function blocks having parameters that affect the operation of the corresponding I O 5 8 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 1 Pin Assignment Description Blocks 1A 3T OUT VE Isolated 4 20mA output signal This is the control output limited by the SWS 1 1B 3TOUT VE manual station block MAN S1 1C TX Power Supply Isolated 24 volt transmitter power supply 1D TXPowerSupply lE PV Process variable voltage input PV d 1F REM SP Remote Setpoint voltage input If the remote setpoint input is broken or not RSP 1 connected the loop reverts to its local setpoint N ot Strategy 4 RAT TRIM Ratio trim input Strategy 4
103. abase allowing it to emulate a TCS System 6000 instrument or to be supervised by a T1000 or other suitable instrument over the serial link Addresses instrument numbers 0 127 are allocated via the S6000 block s Instr No parameter and baud rates via the T600 header block s BinSpd1 and BinSpd2 parameters Refer to the LIN Blocks Reference Manual for details on S6000 and T600 function blocks MODBUS RS422 485 CONFIGURATION To configure the hardware for MODBUS comms set up the motherboard switches and jumper links as shown in Table 2 4 Note that jumper link J2 determines the medium used RS422 or RS485 A MODBUS configuration gateway file must be created and downloaded to the T640 to run alongside the regular LIN control database This gateway file GWF filename extension defines the communication between the LIN database DBF file and T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 221 Software file types Installation amp startup the MODBUS device s connected to the T640 via the serial link The MODBUS con figuration also specifies slave master status slave address comms data rate and parity stop bits For more data see Appendix B MODBUS JBUS LIN communications Using the LINtools MODBUS configurator is fully described in the T500 LINtools User Guide together with general information on MODBUS SOFTWARE FILE TYPES Table 2 5 lists the different file types that are found in
104. absolute alarm on PV LAA 0 00 30 00 Low absolute alarm on PV HDA 100 00 10 00 High deviation alarm on PV LDA 100 00 10 00 Low deviation alarm on PV Dis DP 2 3 Decimal point position Table 3 1 Configurable fields in the SETP1 setpoint block Configuring ranges and limits Figure 3 10 shows how the INS button works 1 Press the INS button briefly LOOP 1 appears in the tag display this is the loop ready to be inspected and it is the loop that contains the SETP1 block The green units display shows LOOP meaning loop access mode T640 Reference M anual amp User Guide Issue 5 3 15 Tutorial K Enter INSPECT mode LOOP 4 Select LOOP LOOP 1 A LOOP 2 v YA plo oP 3 LOOP gt S Select BLOCK via SW S1 tv a gt TMI 9 SETPI BIOCK CON em ssp 0 ptions Select FIELD Alarms A HR_in tv a gt LR_in FIELD gt sone Hardware Select SUBFIELD Software via Combined H A UCharerr A SubFd gt A VALUE Display Certain high precision Software Select VALUE fields may appear in VALUE IN CREM ENT value or set TRUE ne Teel 1 instead of in the DECREM ENT value or set FALSE 5 digit display TON M007 memory d module only
105. al block with safety cover and Site 1 I O and Site 2 I O terminal blocks Wire connectors securing screws and terminal identification labels are also shown Connect a good local earth to the M4 screw terminal Do not connect an external earth directly to terminals 1 and 2 Mains safety cover This fits over the mains screw terminals to prevent accidental contact with the live screws To remove the cover loosen the two screws and pull it off To replace the cover insert its two legs fully into the corresponding terminals and tighten up the screws securely T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 13 Customer terminals Installation amp startup Internal earth Earth screw connection 3 terminal wires M4 IN Mo Ly LENT m Safety cover screws IN i ND 3 uri E 1 Sii EE n url m fe ions PT i1 mm acm Sen See MIE Safety cover Eon E Bou mn i Ea an 1 on fe ne aA io 13 micis Nm IN pi 1 mm I3 Oe ioe i ATI fe Eiis N DE fs STI MAIN Soption Site 2 I O Site 1 1 0 motherboard terminals terminals terminal block Figure 2 6 Customer terminals example Terminal designations Motherboards Table 2 1 shows the terminal designations for two motherboard terminal block options with the ac MAINS option on the left and the DC option on the right of the table The uses of these terminals and how they connect to T640 s internal circuitry are de scribed in later
106. al display segments individually addressable 5 digit red 7 segment lit red when PV indicated in Numeric display 8 character red dot matrix user configurable 5 character green dot matrix eng units or SP lit green when SP indicated in Units display 4 off red 7 segment vertical displays settable via block to 1 2 396 1 5 1096 or 10 20 30 deviation or to 100 PV Central bicolour LED glows green when deviation shown A uto R emote ratio green lit single letters M anual H old T rack orange lit single letters green lit arrow symbol under deviation PV bargraph 6 off membrane pushbuttons with symbols R R with green LED te i A A with green LED 2 M M with orange LED Ill M SP w SP E raise A lower v INS pushbutton 22 ALM ALM pushbutton with red LED d 112 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications Base unit space d amp D 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 12 3 4 5 6 7 8 9 lt gt 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 A B C D E F GHI JEK Z amp MN O 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 P QRS TU VWXYz v1 L 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 abc d e g h i j k 1m n o 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 1H pars t uvwxyz lt A 112
107. amp STARTUP This chapter presents important safety and EMC information and describes how to install configure and power up the loop processor The main topics covered are Safety amp EMC information Unpacking your T640 Installation Connections amp wiring Hardware configuration Binary RS422 configuration Modbus RS422 485 configuration Software file types Control strategies amp sequences Powerup routine Powerup displays SAFETY amp EMC INFORMATION Please read this section before installing the processor This unit meets the requirements of the European Directives on Safety and EMC It is also a UL recognised component meeting the requirements of UL3121 1 However it is the responsibility of the installer to ensure the safety and EMC compliance of any particu lar installation Installation requirements for EMC This unit conforms with the essential protection requirements of the EMC Directive 89 336 EEC amended by 93 68 EEC by the application of a technical construction file This unit satisfies the emissions and immunity standards for industrial environments To ensure compliance with the European EMC directive certain installation precautions are necessary as follows B General guidance For general guidance refer to the Eurotherm Process Auto mation EMC Installation Guide Part No HG 083 635 U001 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 1 Installation amp startup
108. amp jumpers 15 RS422 RX RS485 16 Watchdog1 Relay output whose contacts are closed in normal operation USR_ALM 17 Watchdog2 They open on power loss or CPU failure They have been configured to also open on alarm 18 Alarm 1 Relay output whose contacts are closed in normal operation They open on power 19 Alarm 2 loss or CPU failure They also open if any alarm of priority 11 to 15 occurs 20 AUN Gnd ALIN peer to peer communications connections 21 AUN Phase A Connections should be made Gnd to Gnd Phase A to Phase A 22 AUN Phase B and Phase B to Phase B Table 5 3 otherboard terminal assignments M AIN S amp DC options 5 6 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 1 STRATEGY 1 SINGLE CONTROL LOOP Strategy 1 is a single loop controller with a repeat time of about 160ms per scan Figure 5 2 shows a P amp I diagram for the strategy involving a flow control valve and an orifice plate flow sensor by way of example Local setpoint J Figure 5 2 Example P amp I diagram for strategy 1 T640 Reference M anual amp User Guide Issue 5 5 7 Strategy 1 Standard strategies Strategy 1 schematic Figure 5 3 shows schematically the main function blocks in the strategy the principal sig nal flows between them and their associated customer terminals Details of each terminal and block are given in the tables that follow
109. and limits Memory for tables 4 Kbytes Maximum number of tables 16 Minimum entries per table 1 Maximum entries per table Digital bits 999 limited by memory usage Registers 200 2 5 2 Memory requirements for the tables Overhead 18 bytes per table Image data registers 2 bytes per register Image data digitals 1 bit per digital rounded up see below Descriptors registers 6 bytes entry whether connected or not Descriptors digitals 8 bytes entry whether connected or not Digital image data The storage requirement of digital image data is calculated by converting the total number of bits in the table to 8 bit bytes then rounding this number of bytes up to the nearest 2 byte boundary i e the nearest even number This means that total bit counts of from 1 to 16 need 2 bytes of storage space from 17 to 32 bits need 4 bytes from 33 to 48 bits need 6 bytes and so on B 10 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 M O DBUS JBUS UN communications AppB 2 6 2 The calculation can be done using the following formula assuming truncation and integer arithmetic 2 x INT bitcount 15 16 bytes Examples l Aregister table with 40 values occupies 18 overhead 40 x 2 data 40 x 6 descriptors 338 bytes 2 Therequirements for a digital table depend on how the data is mapped between the MODBUS and the database The examples below show the two extremes for
110. andard strategies This is described later in the section User created standard strategies SUMMARY OF THESTAN DARD STRATEGIES Strategy types The strategy databases are of two types a set of relatively basic fixed function strate gies stored in T640 s ROM and a more advanced and adaptable set stored in EEPROM Copies of all the strategies are also supplied on floppy disk and can if required be down loaded to the T640 via an ALIN link using LINtools LINfiler utility The strategies are supplied in a compressed packed format in files called name PKn where name is the strategy database name and n is the number that must be set up on switches 6 7 and 8 of SWI to select the strategy The T640 unpacks a PKn file to create a regular DBF file with the same root filename ready to be downloaded to RAM and run T640 Reference M anual amp User Guide Issue 5 5 1 Standard strategies Strategies supplied in EEPROM Seven pre configured strategies are supplied in T640 s EEPROM summarised in Table 5 1 Sources of further information are given in the next section n Name Summary 1 T640C1 Two simple PID control loops each acting as a standalone controller or as a cas cade slave or master to another controller Both analogue amp time proportioned digital outputs are provided 2 T640C2 Two cascade pairs of PID controllers Pair 1 has loop 1 as slave amp loop 2 as mas ter Pair 2 has loo
111. ar The first subfield accessed is shown in the tag display Software and its cur rent value appears in the 5 digit display 1 This is the priority of the Software alarm which you should not alter at this stage You would alter it in the same way as described above using the INS and A buttons Still in subfield access mode press W to move to the next subfield in the Alarms field HighAbs This is the PV high absolute alarm which trips if PV exceeds the high limit specified in the HAA parameter Its priority of 2 should be left as is Go on to inspect the rest of the Alarm subfields in the same way Finally return to the normal fascia display by pressing the A button You may have noticed that if you do nothing for two minutes a timeout operates automatically to escape from inspect mode T640 Reference M anual amp User Guide Issue 5 Tutorial EFFECT OF THE ALARM SETTINGS AND LIMITS ON THE FRONT PANELDISPLAYS You can see the effects on the fascia displays of the limits and alarm levels just config ured Start by setting SP to about 50 units with the loop in auto Let the displays settle Inspecting absolute and deviation alarm settings l To see these values directly on the PV X and SP W bargraphs press and hold down A and W together ALM SET alarm settings appears on the tag display On the PV bargraph the upper and lower limits HAA and LAA appear as a pair of reverse lit segments superimpose
112. ata running database with setpoints etc The RAM is maintained by a Supercap This obviates the need for a battery in the instrument and means that the T640 resumes its exact control conditions in the event of a power failure of up to 24 hours Key operating parameters controller modes setpoints etc are passed to EEPROM on power down to ensure that the controller returns to its correct operating conditions if the power fails for more than 24 hours Refer to Chapter 2 for details of T640 s power up routines The EEPROM and EPROM memory resides in a removable memory module This al lows a new strategy to be plugged directly into an existing controller or conversely allows a strategy to remain if the controller must be changed Chapter 2 describes memory mod ule and T640 unit replacement Table 9 1 summarises the major T640 file types Further details on these files are given in the relevant sections of this manual Filename Extension Filetype Control strategy name DBF Control strategy database parameters connections etc Control strategy name RUN T640 coldstart filename System filename LIB Library of system routines in EPROM area Factory set filename PKn Standard strategy in compressed format n 1 7 the strategy no Control strategy name current TPD Tepid data file Control strategy name Lnn Logfile of database changes via the INS pushbutton nn 01 99 Language name LNG Non English language front panel me
113. ation of the bits in the register The values in the register are used in the following way E Disable write Setting this bit disables writes across the MODBUS serial link to the associated table The slave will return error code 8 see Table B 4 Exception re sponses B Online This bit is set to 1 if the table has been written to or read from in the period defined in Time out in the SETUP menu 4 2 2 Master mode diagnostic table registers The master mode diagnostic register Figure B 6 includes bits which allow control by a database sequence of read write operations when required by the application F E D C B A 9 8 7 6 5 4 3 2 1 0 SS eS E DE CUEUEGUERES W rite error m Read error code Reserved Disable write Scan completed Single scan Disable continuous scan Online Figure B 6 Master mode diagnostic registers The values in the register are used in the following way B Write error code Normally zero Otherwise it contains the error code associated with the last write to this table see Table B 4 Exception responses B 14 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 M O DBUS JBUS UN communications AppB 85 Read error code Normally zero Otherwise it contains an error code associated with the reading of this table see Table B 5 Disable write Setting this bit to 1 stops the master writing to the slave across the seriallink Note that when this
114. atures Unsuitable for use above 2000m or in explosive or corrosive atmospheres to meet EN60529 IP65 to meet EN50081 2 Group 1 Class A to meet EN50082 2 to meet EN61010 and UL3121 1 Installation category II Voltage transients on any mains power connected to the unit must not exceed 2 5kV Electrically conductive pollution must be excluded from the cabinet in which the unit is mounted All isolated inputs and outputs are double insulated as specified in EN61010 to provide protection against electric shock Isolation levels for particular I O types are stated in the relevant section of the specification for the I O board concerned to meet BS2011 Part 2 1 Test Fc Table CI Equipment intended for large power plant and general industrial use 2g 10 55 Hz to meet BS2011 Part2 1 Test Ea Table II General test for robustness handling and transport 15g 11ms T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 1 Base unit Specifications Front panel displays PV bargraph SP bargraph Output bargraph Numeric display PV X legend Tag display Units display SP W legend Loop status summary deviation PV bargraph loop mode loop selected Pushbuttons loop control parameter access alarm acknowledge red 51 segment vertical display flashable via block green 51 segment vertical display flashable via block yellow 10 segment horizont
115. ault as supplied in compressed format standard strategy is a particular case of powering up the T640 and running any other strategy For a more complete pic ture of what happens when you power up the instrument refer to Chapter 2 in the section Power up routine To run one of the standard strategies for the first time l First determine if the required PKn compressed strategy file is stored in EEPROM or in ROM see Tables 5 1 and 5 2 If in EEPROM go to step 3 2 Because of the order in which T640 searches its memory areas at power up if the strategy required is in ROM you must erase the PKn file in EEPROM that has the same n value if one exists E g to run the fixed function strategy called SINGLE stored as SINGLE PK1 in ROM first erase the file T640C1 PK1 in EEPROM us ing LINtools LINfiler utility You can always restore the erased file later if required from the backup copy supplied on disk 3 Withdraw the T640 from its sleeve taking the necessary anti static precautions see Chapter 2 and set switches 6 7 and 8 of switchbank 1 to the strategy number re quired Figure 5 1 reminds you of their location and how to set them 4 Set switch 3 of SW1 ON to enable a cold start Other SWI switches Switch 4 should also be ON if you want warm start capability Leave other switches as required for your T640 configuration 5 Power up the T640 Assuming that the selected strategy was not previously being ru
116. bit is reset to O a write is forced to all the values in the table Scan completed This sets to 1 when the master has completed a scan of the slave When operating in single scan mode it indicates that the scan is finished and the data is available for use It resets when the single scan bit is set as described in the example below Single scan This is used in conjunction with the disable continuous scan bit Tt allows a database sequence to initialise a single scan Disable continuous scan Setting this bit to 1 stops the master polling the slave across the serial link Online This sets to 1 when the slave is responding to the scanning routines The single scan and scan completed bits are used together when a slave can be polled only under specific circumstances A small sequence must be implemented to ensure that these bits are used correctly In addition the disable continuous scan bit must be set The suggested sequence for these operations is OU RUN H Reset the single scan bit Wait till scan completed reset Set the single scan bit Wait till scan completed set The data is now valid Loop back to step 1 MODBUS DIAGNOSTIC FUNCTION CODES Table B 3 summarises how the common MODBUS diagnostic function codes have been supported by the T640 in slave mode The diagnostics are accessed via MODBUS func tion code 8 Diagnostic Data Description sub code sent 0000 XXXX Echoes the data sent 0001 0000 Restarts FF00 Resets the
117. bject to hold off by User Tasks T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 7 AppB 2 4 2 M O DBUS JBUS LIN communications The cycle time depends on the T640 slave response time and the transit time on the serial link which is about 14ms plus 1 15ms per byte at 9600 baud It also depends on the ex ecution time of the master NOTE In order to achieve coherence the MODBUS task is at a lower priority than the User Tasks Heavily loaded User Tasks can delay the T640 replies Use the T600TUNE block to monitor the repeat rate of the lowest priority User Task in use If this is being held off owing to heavy loading similar hold offs will occur to the MODBUS task and response times will be affected accordingly Scan period The scan period is the time for all the data in the copy areas of all the tables to be updated This is a function of the number of parameters mapped onto the MODBUS address space and the number of writes made from the master to blocks that are cached within the slave Writing to local blocks does not affect this figure But the data is updated in only one di rection each scan so that if data is written from the copy to the database it is not updated from the database to the copy until the following scan Data is transferred from the MODBUS image to the database only if the value has been changed by the master The scan period is calculated from the following formula with a
118. bleC 1 FormatoftheFrenchlanguage LNG file C2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Symbols B Index Symbols SAD files cni De ma vs 53 DB toic arouses dot bdo teens 2 28 54 DOC files te e end 5 3 GW Fotita oana in 2 28 ONE END Ee pp E pate 228 ING cst eer Ce ted a e ai 228 ENG flle a ot rt Pr tet tet C4 lj ER 2 28 6 1 PKI aa nTa TDI 2 28 PKI Tienen inaa ets 5 1 Mops 2 28 RUN a m dete desit tate 228 229 SDBt bi datis ema a Ato s 228 STO scssveet ecu ten cct PEE P 228 DPD asiste t er er cb t e ed 228 SIPD fiGs etes otim Aero e cte 232 5 digit display eee 3 8 42 A Absolute amp deviation alarms annunciation sesers 3 19 config ring a rentes 3 18 A CCOSS sd A dco utente ciate 2 9 49 level rosca vean ed Sa n 44 Accessory kit 2 12 34 ACUON filera ee cet eiie 228 AGAB8DATA block fields 4 6 ACK qeu pr teat eo vost aun ena her 4 7 Alarm absolute amp deviation annunciation cccceeeeeeeeeeeeeeeeeees 44 viewing settings ccecce 44 absolute deviation sess 42 DAO WNOUE iere Pec 2 34 conditionis ein dean 38 display amp inspection via ALM button 4 7 fielde o cct tea ced 3 11 priorities eos ceri eren a a 104 T640 REFEREN CE MAN UAL amp USER GUIDE Leld sind seo t t s strategy subfields AUN ierit tm Cote emer address DIL switchbank 2 226 channel oot ttem 9 2 comms connections
119. ce 119 FAIL eR meme 10 1 105 loa GING ici ont dtes 7 7 C Watchdog orce decin e eerte 105 Cable screens sse 221 A4 Customer Cable size screw terminals 2 12 2 13 94 Cabla mea er terminal designations 5 25 Cache block server task 72 terminals sse 54 Cached ji scu nec wii eset Mae 4 4 Cached blocks nts 82 D Calibration ino nete oes 1140 1146 Data coherence ccce 84 pfocedUure kuriasi es 11 15 Data conversion cececeeeeseeeeeeeeseeaes B 11 Cascade operation sssssss 524 Database Cascading a pair of loops 525 ACCESS c cerco de Od e 44 Changes logfile nee 6 1 acquisition nisin 2 29 Character set dotmatrix display 114 Ala LMS ciue cete ette el ed 104 Glamp rermioVal errare 241 hi lb ct E ee OR RE ts 104 Clamp Sni ness ice re inn 241 inspect mode s nce tct 64 Cleaning instructions ccc 2 5 inspecting amp editing nccc 3 15 Clock speed 3 nes eren 222 parameters simae 44 Coherence oet tae dens 8 1 saving of data flow cccecseseeeeceseeeeeeeeneeees 7 6 startup Cold Startseite 2 29 3 14 Databases accessible to a keyholder 4 9 Coldstart filename 228 92 Date time stamped alarms 104 ColdStrt Trying 2 34 3 7 10 1 DCO DU ON i cete oec eco tent 2 12 COMMUNICATING ccce 5 39 Detailed display area sssss 75 Communications sssesese B 1 Deviation option jumper lin
120. completed their execution Data coherence by definition refers to connections that are remote i e linking different tasks Connections that are limited to within a task i e local are simply dealt with by being copied from source to destination immediately before executing the destination block For any task there are three important types of remote connection These types and the way in which the T640 ensures their data coherence are as follows Connections into this task from other tasks in the same instrument node In order to ensure that multiple uses in this task of the same value from another task always use the same iteration of the value such connections are copied prior to the execu tion of all the executable blocks of this task i e a snapshot is taken of all values exter nal to this task Two types of connection apply here those from higher priority tasks to lower priority tasks and those from lower priority tasks to higher priority tasks B Higher to lower priority For coherence it is clear that whenever connections out of a task are used all their values must result from the same iteration of that task Owing to the priority structuring of the tasks any connections from a higher priority task into a lower priority task will meet this requirement This is because a lower pri ority task cannot interrupt a higher priority task which therefore always runs to com pletion Hence these
121. configuration 4 USING THE DIAGNOSTIC TABLE The diagnostic table is a special set of registers fixed at 32 containing status and control bits to allow the database to interact with the MODBUS drivers A diagnostic ta ble allows you to control the MODBUS operation or present diagnostic information to the database Generally you need configure only one diagnostic table per MODBUS configu ration B 12 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 MO DBUS JBUS LUN communications AppB 4 2 The registers of a diagnostic table are in two distinct sets The first sixteen the internal diagnostic registers at default addresses 0 15 The last sixteen the MODBUS table status and control registers are at addresses 16 31 These two sets of registers are described next 4 1 Internal diagnostic registers The first set of registers with default addresses 0 to 15 are for internal diagnostic use and are read only to the user They present general information on the operation of the MODBUS and their functions are independent of whether the instrument is operating as a master or a slave Table B 2 lists these registers and their functions Offset Function 0 Unused 1 Unused 2 Diagnostic register bits currently allocated Bit5 Slave in listen only mode 3 Q uery data as transmitted by function code 8 sub code 0 4 Input delimiter as transmitted by function code 8 sub code 3 5 Unused
122. connected to ALIN Gnd pin 20 The ALIN connections are galvanically isolated within the T640 to assist with noise rejection and simplify system wiring The key specifications of the ALIN are summarised as follows Cable type screened twisted pair Line impedance 100Q nominal Network topology single non branching network Network terminations 100Q at each end Maximum load 16 nodes With active hubs 8 per hub port Maximum length 100 metres Grounding single point ground per system RS422 COMMUNICATIONS Selection Via motherboard DIL SW1 amp jumper link see Chapter 2 Protocols supported MODBUS and BISYNC Transmission standard 5 wire RS422 0 5V Line impedance 120Q 240Q twisted pair Line length 1220m 4000ft maximum at 9600 baud Units per line 16 instruments electrical maximum expandable to 128 electrical maximum by nesting of 8245 Comms Buffers Port isolation 75V max with reference to safety earth RS485 COMMUNICATIONS Selection Via motherboard DIL SW1 amp jumper link see Chapter 2 Protocols supported MODBUS Transmission standard 3 wire RS485 0 5V Line impedance 120Q 240Q twisted pair Line length 1220m 4000ft maximum at 9600 baud Units per line 16 instruments electrical maximum Port isolation 75V max with reference to safety earth T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 11 5 Software Specifications BISYNC PROTOCOL Select
123. control loop sees 3 25 Chapter 4 USER INTERFACE Operator displays amp controls sess 4 2 Summary loop displays esee 4 2 Main loop display esee 4 2 Fag displaye iude II rer ettet 4 2 PV X bargraph display eere 4 2 SP W bargraph display sss 4 2 Contents 4 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Contents 2 digit display 2i o ee prre retro ors 4 2 Units display ss eerta otro re bep tenet tunt 4 2 Output bargraph tera o echte Poe HR 4 3 Mode changes eet re He RR E eet 4 3 Output display ied e po e eot 4 3 Changing the output sese 4 3 Output parameters quick access sse 4 3 Setpoint display sse 4 3 Changing the setpoint sse 4 3 Setpoint parameters quick access sss 4 4 Absolute amp deviation alarm settings viewing 4 4 Absolute amp deviation alarm annunciation 4 4 Database ACCESS uera IR NU EXTERNES E CHE E 4 4 1 Loop Access mode eene 4 4 2 Block Access mode sse 4 6 3 Field Access mode sss 4 6 4 Value Update mode Connection Enquiry mode Subfield Access mode sss 4 6 2 S bfields zai rete qe eet ts 4 6 Quitting database access modes
124. cuit condition rather than to any other hard ware fault though this would not always be the case 3 8 T640 Reference M anual amp User Guide Issue 5 Tutorial AL Enter ALARM INSPECT mode Select other LOOP in alarm LOOP 1 BO ment OE LOOP 4 LOOP LM co S Select other BLOCK in alarm PVI MU C SWSi v TAIMI amp J99 SETP BLOCK amp Ky e M9 HighAbs Selec other Alarm SUBFIELD in alarm Hardware SubFc UnAcd LM TRON Hardware Hardware AlAck A AlAck UnAcd i ACKNOWLEDGE Alarm 9 L Figure 3 8 Alarm inspect button functions ALM T640 Reference M anual amp User Guide Issue 5 3 9 Tutorial 6 Press V again Combined appears in the display This is the combined or com mon alarm that is always asserted when any other alarm in a block trips 7 Finally escape from the alarm inspect mode by briefly pressing any one of the R A M or SP W buttons If you do nothing for two minutes a timeout will in any case op erate to revert the fascia to its normal display automatically WATCHDOG RELAY The clicking you may have heard when you powered up the T640 was due in part to the closing and opening of the Watchdog relay The contacts
125. d time to transmit one bit This is the best case when the master is only polling slaves on the MODBUS network If the system is also writing it performs a maximum of one write between each poll opera tion The time to write a value is approximately ml tl ms where ml message overheads and turnaround time tl time to transmit value Scan period The scan period is the time for all the data in all the tables to be updated with respect to the database This is a function of the number of parameters mapped onto the MODBUS address space the number of writes made to blocks that are cached and the number of writes made to slaves across the MODBUS network Data is transferred to the database or transmitted to the slaves only if the value has been changed The scan period is calculated from the following formula with a minimum value of 100ms scan period m X nt r x 3 5 d X 3 5 we x 100 wm x 100 ms where m minimum period 100ms nt number of tables r number of registers d number of digitals or sets of digitals wc number of writes to remote cached blocks per scan period wm number of writes across the MODBUS per scan period Example For a system with a table of 16 registers and a table with 16 digital descriptors scan period 100 x 2 16 x 3 5 16 x 3 5 0 x100 0 x100 312ms To calculate the cycle time i e poll period for the task polling the slaves assume the sys tem ru
126. d VW buttons Press INS three times to return to field inspect mode Access the RomChar field and inspect its contents by pressing INS again to access VALUE mode and using A W As you edit the ROM based characterisation func tions stored in the RomChar field you may notice the front panel displays altering to re establish control under the new conditions you are creating Return the RomChar value to None the default before continuing Access the Options field in the usual way This field lets you apply an inversion to the input signal and or a square root function Press INS to see the Options subfields The first is Invert which is FALSE by default i e no inversion Press W to move to the second subfield Sqrt square root Press INS again and set the value to tru TRUE using A V restores FALSE You will see the front panel respond as PV changes value 10 Finally press the A button to return to the normal display T640 Reference M anual amp User Guide Issue 5 Tutorial SAVING A DATABASE Now that you have reconfigured several of the fields in the control strategy you will want to save it to EEPROM where it will be safe and effectively permanent At the moment your customised strategy exists only in RAM which although battery backed in the T640 is inherently a volatile memory medium To save your database currently in RAM you must access a function block called T60_00 The last two digits are the node n
127. d also enable disable a loop failure watchdog alarm Refer to Chap ter 2 for switchbank functions Chapter 5 details the pre configured standard strategies stored in the T640 T640 Reference M anual amp User Guide Issue 3 A 9 3 Inside T640 Front panel The front panel display sub assembly is an intelligent unit controlled by its own micro processor It communicates with the main CPU on the motherboard via the internal serial bus see Figure 9 1 The display features are specified in Chapter 11 Using the front panel and the security key are described in Chapter 4 User interface I O sub assemblies The T640 can be supplied with several I O options in the form of I O boards that mount on the motherboard and communicate with it via the ISB Note that a T640 s I O is not restricted to its own direct inputs as it can access data from other instruments across the ALIN For full descriptions and specifications of the available I O see Chapter 11 Speci fications Chapter 2 Hardware configuration section shows an example of how I O boards fit inside the T640 Customer screw terminals Full details of the rear panel screw terminals are given in Chapter 2 in the Connections amp wiring section 9 4 T640 Reference M anual amp User Guide Issue 3 A Chapter 10 ERROR CONDITIONS amp DIAGNOSTICS This chapter deals with T640 s error conditions diagnostic messages safety features and alarm strategy Power up m
128. d by au thorised personnel only Note that a fuse may fail owing to ageing but if it fails because of a fault with the unit please refer to your nearest Eurotherm Process Automation agent A4 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Setting up early boards Hardware configuration Comms selection see Table A 1 on value MORUE oid fon Cold start enable Strategy selection Warm start enable Enable loop database watchdog 3 4 Action at startup ON ON W arm start if possible else cold start if possible else idle ON OFF Cold startif possible else idle OFF ON W arm start if possible else idle OFF OFF Idle i See Chapter 2 Table 2 6 for a more detailed summary p Figure A4 SW 1 location and functions Switchbank 1 Figure A 4 shows the location and functions of the eight switches in DIL switchbank 1 W Switches 1 and 2 together with four jumper links configure the type of communica tions used by the T640 via its serial port See Table A 1 below in the section Serial communications jumper links amp switches These switches and links are set at the fac tory according to the comms option ordered and should generally be left as supplied T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 A 5 Hardware configuration Setting up early boards Serial communications jumper link
129. d find LowAbs and Combined alarms in the SETPI block 3 Finally restore the setpoint to about 50 units to clear all alarms T640 Reference M anual amp User Guide Issue 5 3 19 Tutorial INSPECTING amp EDITING THE PV INPUT AREA This section gives you some more practice at using the INS button to access the fields in the PV__1 analogue input block Remember PV__1 takes in and conditions the signal from the orifice plate in this example Specifically you will inspect and edit the input filter time constant and apply a square root function to the signal from the orifice plate Table 3 2 lists the PV__1 block s configurable fields and target settings Block Field Subfield Default Setting Description PV__1 Filter 1 00 2 00 nput filter RomChar N one nput conditioning Alarms Hardware 2 Alarm priority OutRange 2 Alarm priority OCctdel 2 Alarm priority HR in 10 00 nput voltage high LR_in 0 00 nput voltage low Options Invert FALSE nput conditioning Sqrt FALSE TRUE nput conditioning Table 3 2 Configurable fields in the PV 1 analogue input block Start this section with the T640 set up as at the end of the previous section 1 2 3 Press INS twice to access block inspect mode then press W if needed to bring up the PV 1 block Press INS again to access the first field in the PV 1 block Filter Press INS again then increase the value of the filter time to 2 00 seconds using the A an
130. d on the bar This display lets you see immediately where PV is in relation to the limits At the same time the high and low deviation limits HDA and LDA are superimposed on the SP bargraph as reverse lit segments These mark the levels above and below the current SP value which move up and down with it If PV goes outside these levels a deviation alarm trips Effect of local setpoint limit The setpoint limit you set up in HL SL shows itself when you try to adjust the local set point l Raise the setpoint as far as possible by pressing SP w together with A When the value reaches 60 000 Limit appears in the units display Annunciation of absolute and deviation alarms Produce alarm conditions and see the effects on the displays l Lower the setpoint from 60 to about 20 engineering units The green SP W bar graph starts to flash as soon as the setpoint has fallen far enough to trip the high devia tion alarm At the same time the deviation bargraph also flashes and the ALM button light comes on Shortly after this when PV has fallen below its low limit in LAA the PV X bargraph starts flashing to warn you that the low absolute alarm has tripped NOTE You may also have heard the watchdog relay click open which it is con figured to do by any priority 2 alarm 2 After a while when the fascia has settled and control has been regained PV SP only the low absolute alarm remains Trace this alarm via the ALM button You shoul
131. d relevant are described Some options have defaults relevant to the 1 0 hard ware and should not be changed Invert TRUE maps HR in to LR and LR in to HR TRUE also inverts the effect of the trim signal Sqrt TRUE applies a square root function to the input SETP3 This block is used to enter the ratio setpoint and calculate the measured ratio for display HR SP The high range of the ratio setpoint HR SP and LR SP should be chosen to give a clear display on the PV and SP bargraphs of loop 3 which take their ranges from these parameters R SP The low range of the ratio setpoint HL SP This sets a high limit for the setpoint including any trim LL SP This sets a low limit for the setpoint including any trim HL SL This sets a high limit for the local setpoint LL SL This sets a low limit for the local setpoint Alarms These are the process alarms of the control loop N ote Priority 0 disables the alarm completely Priority 6 15 need to be acknowledged Priority 11 15 open the Alarm relay Alarms of priority equal to USR_ALM Priority will open the W atchdog relay HighAbs The measured ratio exceeds HAA lowAbs The measured ratio is less than LAA HighDev e measured ratio exceeds the set ratio by HDA lowDev The measured ratio is less than the set ratio by LDA HAA High absolute alarm setting LAA Low absolute alarm setting HDA High deviation alarm setting LDA Low deviation alarm setting Dis DP Sets the number of digits displayed to the ri
132. e but none of the write codes has been enabled for the table OE Incorrect length The length of the response message does not correspond with that expected OF Slave Time out N o response was detected in the period defined in the Time out pa rameter Table B5 Error codes stored by master in diagnostic status register bits 8 B or CF 7 NOTES ON MODBUS J BUS IMPLEMENTATION Although based on the original MODBUS specification other manufacturers implemen tations vary slightly in the correspondence between the actual register or bit addresses in the PLC and the MODBUS JBUS address i e the protocol address It is the protocol address that you configure in the Eurotherm Process Automation MODBUS interface 7 1 MODBUS AEG MODICON Read only input and read write output registers and bits are assigned to separate ta bles each with its own address offset relative to the MODBUS protocol address Table B 6 summarises this T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 17 AppB 87 3 M O DBUS JBUS LIN communications Data type MODBUS function codes PLC address Protocol address Read Write O utput bits 01 05 15 00001 X X Input bits 02 10001 X X O utput registers 03 06 16 40001 X X Input registers 04 30001 X X Table B 6 PLC address offsets for different data types It is the MODBUS function code that determines the value of the offset required and therefore whether a
133. e 5 nstallation amp startup Zero volt schematics Power supply bus External zero volts power bar L PSU 5V V0 i N CP boards panel RS422 485 Ol IO 2 GND e e Z 13 ov RS422 485 PSU 2 Instrument case Figure 2 7 1640 internal zero volts amp power supplies schematic External ISB zero volts CO TPUPEVYIs vl yep fae oe Er OEE Ay vy ww NOVY EET a reference A ure Vo giaa bar pP N control NE Non Zr circuit N on isolated J DAN isolated analogue analogue inputs outputs Analogue 797 o I AES ee sedes GND o i terminals N on isolate isolated digital digital wite inputs pupu Digital Figure 2 8 T640 l O zero volts amp power supplies schematic T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Zero volt schematics Installation amp startup I O zero volts schematic Figure 2 8 shows the generalised I O zero volts and power supply arrangements and as sociated customer screw terminals The number and designations of t
134. e T600TUNE block lets you monitor execution times and repeat times for all the user tasks and the cached block server It also shows the percentage CPU usage by the various user and system tasks in the instrument Bear in mind the prioritised nature of the user tasks when adjusting repeat rates 1 is the highest priority 4 the lowest The reported ex ecution time for a user task may include a period of suspension whilst higher priority tasks execute Rapidly fluctuating repeat times for the lower priority tasks usually indicates an attempt to allocate too much total CPU time to the user tasks A slight increase in some or all of the MinRptn values should cure this The percentage CPU power allocated to the four user tasks should total approximately 65 T600TUNE displays units of 0 196 If the sum is less than this it should be safe to reduce MinRptn values T640 Reference M anual amp User Guide Issue 3 A 7 1 Contents This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter8 DATA COHERENCE DATA FLOW BETWEEN TASKS Coherence is an important aspect of control strategies involving more than one user task i e loop Data flow is defined as being coherent if during any single execution of a task the data input into it from outside the task is a snapshot unchanging during the execu tion of the task and represents the values output from other tasks that have
135. e ground for analogue signals 2P Unused 2Q REM SPEN 1 W hen high this digital input allows the remote setpoint to be selected from the DIN 2 front panel provided a signal is connected to REM SP 2R TRACKEN 1 W hen high this digital input forces the control output to follow the TRACK input DIN 2 25 HOLD EN 1 W hen high this digital input forces the control output to freeze DIN 2 2T HIALM OUT O This digital signal goes low if the controller is in high absolute alarm DOP 2 or high deviation alarm 2U LO ALM OUT 0 This digital signal goes low if the controller is in low absolute alarm DOP 2 or low deviation alarm continued T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 2 continued Pin Assignment Description Blocks 2V REM AUTOUT O This digital output goes low if the controller is not in Auto with its remote setpoint DOP 2 selected In cascade this signal should be connected from the slave to the TRACK EN 1 o allow bumpless transfer from local control to cascade lt is also necessary to connect the retransmitted process variable PV SP O UT of the slave to the TRACK input of the master 2W HOLD MAN OUT 0 TI if the controller is in Hold or Manual modes DOP 2 be connected from the master to the REM SP EN 1 of the slave to allow procedureless changes of mode It also ensures that if the master is ren ave goes into local control 2X
136. e rear of the sleeve protected by a terminal cover Wiring passes through the opening in the base of the terminal cover All connections are low current and a 16 0 20 cable size is adequate The maximum cable size for these terminals is 2 5mm Bootlace type fer rules are strongly recommended Power input The instrument supply should be fused externally in accordance with local wiring regulations The mains option accepts 90 265 Vac 45 65 Hz the DC op tion 19 55 Vdc Power input depends on the application and configuration and on the I O cards fitted but is a nominal maximum of 25VA per T640 Please refer to Chapter 11 Specifications for further details 242 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Customer terminals Terminal cover removal See Figure 2 5 With the sleeve upright unscrew the retaining screw and pull the cover away from the cover bracket and cable clamp assembly To remove the bracket lift it to free the hooks from the tabs then withdraw it from the sleeve Refitting the bracket and cover is the reverse procedure Hooks Retaining screw Cable clamp Cover Cover bracket Tab Figure 2 5 Removing the terminal cover Customer terminals Figure 2 6 shows the customer terminals example Other configurations are possible de pending on the I O and power supply ordered The Figure shows the MAINS option motherboard termin
137. e software ranged as 0 10mA 0 20mA 4 20mA etc 50V ac rms or dc working 0 196 of scale 12 bits 5LA lt 0 4uA 0 008 of reading C 99 confidence lt 0 2UA 0 004 of reading C typically 11 24 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Specifications Thermocouple O Output drive capability Output fault detection Output kill Analogue output Block type Channels Output range Accuracy Resolution Temperature drift Output current drive Isolation Digital inputs Block type Channels Input isolation Input type Input voltage Threshold tolerance Input current Digital outputs Block types Channels 0 to 1kQ Load fail detect triggered if the output cannot maintain the desired current level Over driven detect triggered if the output is overdriven by a larger current forces the output to low scale current output and to a low impedance state 1V drop at 20mA Kill activated by connecting Kill terminal to I terminal reported in flag Status Killed AN OUT 1 0 to 10V can be software ranged as 0 10V 0 5V 1 5V etc 0 196 of scale 12 bits 2 5mV lt 160LV 0 009 of reading C 99 confidence lt 60LV 0 004 of reading C typically 5mA source 0 3mA sink none DG_IN 3 individually isolated 250V rms ac or de working current sinking pola
138. e supported by v3 5 and 4 x software Note that although v4 x software does run on original hardware status level 5 or earlier it does so with limited functionality see Memory requirements section below If transfer ring application programs between the two using the T901 memory module you are strongly recommended to upgrade all existing T640s to v3 5 or 4 x software according to the functionality required T640 v3 5 software provides a smooth upgrade path for v3 x software users This version allows movement of T901 memory modules containing user application software across T640 hardware with 12 5MHz original and 25MHz current processor clock speeds Note that the T901 contains both Eurotherm software and the user application program NOTE There are no application problems if you copy your strategy e g using LINfiler from v3 x to v4 x software when running on the appropriate T640 hard ware Memory requirements Many existing T640s up to hardware status level 4 are fitted with 128K of RAM but some very early units are fitted with only 64K V4 x software needs 256K of RAM status level 5 onwards to support all the optional functionality although it does func tion with 128K if the sequencing option M004 is not required The memory requirement situation is summarised as follows RAM pre v4 x software status level A v4 x software status level B 64K All features function except sequencing Does no
139. eeded 8355 Root block is invalid 8356 More than two PID or 3 TERM blocks in a 2 oop controller 8357 Coldstart switch is disabled 8360 Unsynchronised Block Types 8361 DB Filing system mismatch 8362 Unsynchronised Secondary 8363 O peration forbidden whilst CPUs synchronising 8364 Power up data inhibits run 8365 PO ST hardware failure 8366 N ot fixed function strategy 8367 Default strategy missing 8901 N etwork timeout 8902 Rejected by local node 8903 Rejected by remote node 8904 N ot implemented 8905 N otactive on local node 8906 N ot active on remote node 8907 Transmit failure 8908 Failed to get memory 8909 Decode packet 890A Remote file system busy 8999 N etwork node invalid FFFF Unspecified error Table 10 1 T640 Error numbers amp their meanings T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 10 3 Error conditions amp diagnostics ALARM STRATEGY Alarm priorities Alarm priorities in the T640 follow the convention established in all LIN based instru ments They can be set in individual blocks via their Alarms fields and are defined as WO lowest priority alarm disabled M 1 5 annunciated with auto acknowledge These alarms are annunciated only while the alarm condition persists and clear themselves when the alarm condition clears without needing manual acknowledgement W 6 10 annunciated with manual acknowledge These alarms do not automatically clear when the alarm
140. eference M anual amp User Guide HA 082 468 U003 Issue 5 Customer terminals Installation amp startup High level I O boards Table 2 2 shows terminal designations for the high level I O board options fitted in sites 1 right and 2 left Note that Site 1 terminals are labelled 1Ato 1Z and Site 2 terminals are 2A to 2Z The table also shows the software function blocks in the control database that link to each terminal or set of terminals These are explained below Terminal SteNo 2 Linked block Terminal SteNo 1 Linked block 2A D Current outpu poss AN OUT 1 NI Current outpu ana AN OUT 2B 9 Current output Outlype mA 1B N Current output Outlype mA LIY TX power supply 1C N TX power supply 2D STE powers pply 1D TE powers pply 2E S Analogueinput Channel 1 AN IP InType Volts 1E N Analogueinput Channel 1 AN IP InType Volts 2F N Analogueinput Channel 2 AN IP InType Volts 1F N Analogueinput Channel2 AN IP InType Volts 2G IK Analogue ground 1G N Analogue ground 2H A
141. eld Description Alarms Although other alarms than those listed below are available their priority should left at 0 Process alarms may be set in SETP1 The alarms listed below should be left at the priority set unless there is a reason to change them A reason to change them might be to stop individual alarms affecting the Watchdog relay or to make alarm acknowledgement necessary priority 26 ote ifa zero priority is set the alarm condition will no longer select Forced M anual Hardware Default 2 OutRange Default 2 OCctdel Default 2 HR in The input voltage representing high range LR in The input voltage representing low range 0 ptions O nly options believed relevant are described Some options have defaults relevant to the I O hard ware and should not be changed Invert TRUE maps HR in to SETP1 LR_SP and LR in to SETP1 HR SP TRUE will also have the effect of inverting the control loop Sqrt TRUE applies a square root function to the input TRIM 1 This input provides a trim to the setpoint This trim input in engineering units is added to the setpoint Whether itis local or re mote Zfno trim is required all parameters in this block can be left as default MODE This should be left at M AN UAL if a manual trim or no trim are required Set this input to AUTO if a trim is to be prov
142. ents Selecting another operating mode sse Automatic mode epos otn tese tien EISE Manual miode o e o en tete RR Te EE RE Remote mode no ee HR e e ties Power intetruptions eoe E RRRREBINEM RUM Warmi SUAE o onde iid ee e iei tan Cold statta oie eoe tero eite Tepid Start iie noe roD E netten Ret n Inspecting amp editing the database sss Using INS etu ote e dao oro a e e e E ees Configuring ranges and limits Configuring absolute and deviation alarms 3 18 Configuring the decimal point sss 3 18 Alarmrsubfields iier eerte 3 18 Effect of the alarm settings and limits on the front panel displays 3 19 Inspecting absolute and deviation alarm settings 3 19 Effect of local setpoint limit seseeeee 3 19 Annunciation of absolute and deviation alarms 3 19 Inspecting amp editing the PV input area sse 3 20 Saving a database marrin aran EORR OR e e Ie 3 21 Saved databases insido rinn taa e eoe neo esie 3 21 Investigating the loop setup switches sess 3 22 Power up power fail mode sese 3 22 PV fail modesina teo ore rer RH 3 23 On off control os o oe tete e a on UR 3 23 Tracking of PV by the setpoint ssseseseeee 3 23 Pushbutton masking sese 3 24 Handling more than one
143. er Guide HA 082 468 U003 Issue 5 Specifications Software Resource Default Maximum Blocks 256 Templates 50 Libraries 32 EDBs 8 Featts 128 Teatts 10 Servers 5 Connections 512 Note that if a database is loaded having more resources than the default maximum the maximum is set to the new value which may mean there is not enough memory to load the whole database In this case it is the connections that disappear first Featts are an ex ception When a database is saved there are generally no Featts present because they are created dynamically at runtime preventing the default maximum from being overridden Maximum sequencing resources supported Resource Maximum Simultaneous independent sequences 10 SFC actions 50 Steps 150 Action associations 600 Actions 300 Transitions 225 Servers 5 Sequence execution rate determined by repeat rate of User Task 4 loop Function blocks supported T640 supports the level of block structuring normally only found in advanced DCS sys tems Each of the four control loops occupies its own task which allows it to be set via the T600 block s MinRptn parameters to run at a rate appropriate to its function in the strategy see Chapter 7 on T640 task organisation amp tuning for details The general pur pose blocks can be distributed between these tasks T640 s internal architecture ensuring data coherence See Chapter 8 for details on data coherence and how it i
144. erent instru ments NOTE All Eurotherm Process Automation controllers have these interlocks available In these cases you decide which loop is to be the master and which the slave then wire link the customer terminals associated with each loop as indicated in Table 5 9 Re member that the number prefix in customer terminal designations must match the T O site involved e g 2L is the 3 term output for site 2 I O but 1L is the 3 term output for site 1 T O so you will have to interpret the table according to your I O sites Strategy 3 schematic Figure 5 7 shows schematically the main function blocks in the strategy the principal sig nal flows between them and their associated customer terminals Details of each terminal and block are given in the tables that follow T640 Reference M anual amp User Guide Issue 5 5 25 Standard strategies Strategy 3 LOOP 2 Master vdd un aah Mois ond 1 i RE INPUT area MASTER TRANSMITTED PID CONTROL OUTPUT pais area E area PV 2E X input Seri ESV FALSE VOP block gt setpoint analogue GZ 2M PV SP OU
145. erminals associated with the non isolated analogue inputs and outputs depend on what I O options are fitted Tables 2 2 and 2 3 show those currently available The I O control circuit communicates via the ISB Internal Serial Bus Connect the analogue ground terminal s to an external zero volts reference bar as shown The number and designations of terminals associated with the non isolated digital inputs and digital outputs also vary with I O option Connect the digital ground s to an external zero volts power bar which should be connected to a clean instrument earth 45V Selector Selector logic logic i Bi 422 485 422 485 14 v 4 Main Q MT e CPU bi 15 EXISB EXISB ee o 13 o RS422 RS485 45V ground TX4 zx gs Terminal functions Vv J i depend on SW 1 12 Settings A CU TX i bd d f RS422 485 AUN 21 i hase A F Main i AUN 55 CPU phase B l p TU ALIN interface AUN iren ground 20 i circuitry Figure 2 9 1640 communications zero volts schematic 2 20
146. ess it is interrupted at any time by a task of higher priority In this case the lower priority task suspends activities until the higher priority task has run to completion at which point it resumes running These interruptions are hierarchical sev eral tasks may be held in suspension by higher priority tasks at any one time Table 7 1 lists all T640 s tasks in priority order summarising their functions and schedul ing More detail is given for some of these tasks in the following sections Functions of tasks Networktask This task is repeat driven approximately every 15ms It performs housekeeping for all transactions over the ALIN whether initiated by this node or as replies to messages from other nodes T640 Reference M anual amp User Guide Issue 3 A 7 1 Task organisation Task Function Schedule 1 Rx Processes received messages over the ALIN Event driven 2 Binary Processes received messages over the RS422 binary comms Event driven 3 Network Housekeeping for all transactions over the ALIN Every 15ms approx 4 Front panel Scans front panel pushbuttons Generates front panel displays Every 80ms and security key logfiles 5 MODBUS receive Processes received RS422 485 MODBUS comms Event driven 6 User task 1 server Runs user task 1 loop 1 Every MinRpt secs 7 User task 2 server Runs user task 2 loop 2 Every MinRpt2 secs 8 User task 3 server Runs user task 3 loop 3 Every MinRpt3 secs 9 User ta
147. essages tell you what T640 is doing or attempting to do when power is restored and subsequently database alarms and hardware software faults are sig nalled as special front panel messages or 4 digit hex codes which can be looked up in Ta ble 10 1 The aims of T640 s safety features are to report abnormal and fault conditions to the out side world to prevent as far as is practicable unsafe conditions occurring and if they do occur to restore the system to a safe state as quickly as possible POWER UP DISPLAYS Normal power up Power on Reset normally flashes briefly in the red tag display when T640 is powered up while the front panel awaits communications from the main CPU Then WarmStrt Try ing TepidSrt Trying or ColdStrt Trying flash to tell you the type of startup procedure T640 is attempting If a standard strategy is being loaded for the very first time Un Pack Database flashes in the tag display as the file is being decompressed Finally the fascia adopts the normal display as described in Chapter 4 ERRORCONDITIONS W CPU FAIL flashes in the 5 digit display if the CPU fails to establish comms to the fascia This message can also mean a watchdog failure see later under CPU watch dog incorrect motherboard comms option SW 1 2 setting see Table 2 4 in Chapter 2 Hardware configuration section or an absent faulty memory module B HALTED in the tag display with Error flashing in the 5 digit display means the
148. esses the remote setpoint input Status BrkDtctd is used in conjunction with the input REM SP EN 1 to enable the remote setpoint If the remote setpoint input is broken the loop reverts to its local setpoint f no remote setpoint is required all parameters in this block can be left as default Filter A first order filter with the time constant set will be applied to the input HR in The input voltage representing high range LR in The input voltage representing low range 0 ptions Only options believed relevant are described Some options have defaults relevant to the 1 0 hard ware and should not be changed Invert TRUE maps HR in to SETP2 LR_SP and LR in to SETP2 HR SP Sqrt TRUE applies a square root function to the input DIN 2 This block processes the digital inputs Invert This field inverts the sense of the digital inputs on a bitby bit basis Bit4 to Bit are not supported by the hardware Setting them will have no effect Bito Unused Bitl FALSE inverts REM SP EN 1 It should not be necessary to alter the default Bi TRUE inverts TRACK EN 1 It should not be necessary to alter the default BiB TRUE inverts HO LD EN 1 If this input is unused do not alter the default If this input is used it will be normal to invert its action PV 2 This block processes the process variable input Alarms Combined will cause the controller to go into Forced Manual if an alarm with non zero priority occurs See SW S 2 W Field Bit0 Filter A first order filter with
149. ey Both modes work in the same way but Partial mode can access only a limited set of blocks and fields Parameter changes during database access are automatically logged by the T640 in a special EEPROM file see Chapter 6 Changes logfile To access the current database press INS repeatedly as required to cycle through the fol lowing hierarchy of database access modes the green units display shows the access level reached Figure 4 2 shows how the INS button works 1 Loop Access mode The first INS press selects this mode and LOOP appears in the green units display Un less overridden a security key must be active for initial entry into this mode NOTE Ifthe message No Key appears in the tag display you will not be per mitted to access inspect mode without a valid security key see below in the section Security key for details Press A or V to select a loop for inspection indicated as LOOP n or Cached in the red tag display The initially selected loop is the same as the main display loop Press ALM to see the loop repeat rate in seconds in the 5 digit display 4 4 T640 Reference Manual amp User Guide Issue 5 User interface IN S button y Enter INSPECT mode 7 LOOP 4 Select LOOP LOOP 1 A LOOP 74 v O ma 3 LOO
150. for a time specified by the T600 block s TimeOut parameter the fascia reverts to the normal display Re entering INSpect mode then needs a security key again Battery replacement Caution Observe anti static precautions when handling the security key with its lid open Replace the battery if the battery test LED fails to light when the key is operated and at least every two years Use a 12V alkaline manganese battery e g Duracell MN21 Panasonic RV08 or equivalent of overall length 27 5 28 5 diameter 9 62 10 62 mm 2 Hinge back lid Battery PCB Test LED amp remove CE M Z NS 1 Press below catch Tray Switch Figure 4 5 Security key battery replacement l See Figure 4 5 Press just below the lid catch hinge back the lid and remove it com pletely The interior of the key is shown on the right of the figure 2 Extract the battery and fit a replacement ensuring correct polarity This is marked on the tray underneath the battery and also on the printed circuit board Test the new bat tery by pressing the switch The battery test LED should light 3 Replace the lid by positioning it over the pair of hinges then snapping it shut securely over the lid catch 4 10 T640 Reference M anual amp User Guide Issue 5 Chapter5 STANDARD STRATEGIES This chapter describes the preconfigured standard control strategies supplied with your T640 The four fixed function strategies s
151. g 100 output LR in The input voltage representing 0 output MANS2 This block provides output processing from 3TRM2 The output range is fixed at0 100 HL OP High limit for the control output in LL OP Low limit for the control output in 0P 2 This block processes the control voltage output It follows the 4 20mA output O utput inversion can not be performed by reversing the values in HR outand LR out SWS 2 W Field1 Bitl does this HR out The output voltage representing 100 0 if SW S 2 W Field1 Bit2 is TRUE LR out The output voltage representing 0 100 if SW S 2 W Field1 Bit2 is TRUE Table 5 8 Loop 2 parameters Loop4 Loop 4 parameters are identical to those given for strategy 1 see Table 5 6 on page 4 10 T640 Reference M anual amp User Guide Issue 5 523 Strategy 3 Standard strategies STRATEGY 3 DUAL CONTROL LOOP CASCADE Strategy 3 is a dual loop controller The difference between it and strategy 2 is that the two controllers are internally pre wired for remote setpoint cascade operation with bump less transfer Figure 5 6 shows a P amp I diagram for the strategy in which by way of example the outflow from a tank is controlled by the slave loop according to a remote setpoint output from the master loop The master loop derives its output from a local setpoint and a meas ured variable from the tank e g fluid level MASTER Loop 2 Local setpoint
152. g SP w pressed hold down the A button and watch the local setpoint value increase slowly at first then more and more rapidly Raise it to about 50 units then release both buttons The new resultant setpoint shows in the green units display it should equal the local setpoint you just configured Also the green SP vertical bar graph now displays the resultant setpoint in percentage units These happen to equal the engineering units with the default ranges currently configured Note the negative value now displayed by the Loop 1 deviation bargraph i e the red LEDs are lit below the central green zero LED Full scale all 3 segments lit rep resents about 10 deviation PV SP 3 12 T640 Reference M anual amp User Guide Issue 5 Tutorial 3 Try lowering SP again to zero by pressing SP w and W together Note how the green units display shows Limit if you try to reduce SP below zero This tells you that you have hit a configured low limit of 0 00 on the setpoint value Similarly you meet an other limit if you try to raise SP above 100 00 units 4 Finally restore SP to about 50 units NOTE While you have been varying SP the PV value as shown by the PV bargraph and the red 5 digit display has remained at zero This is because the control loop is still in manual mode and is therefore exerting no control action Automatic mode will be looked at next SELECTING ANOTHER OPERATING MODE Automaticmode With S
153. g the M button then attempt to change the local setpoint by pressing SP w together with either A or W You won t be able to 4 Get back to auto mode and try again Alter the setpoint to be as far as possible from the current PV value e g to zero then quickly switch back to manual mode Note how the setpoint rapidly equalises with PV 5 Now raise the control output by pressing M and A together Remember that in this simulation the output is being used as a PV input so you are also raising PV Notice how the green SP bargraph tracks the rising red PV bargraph but not further than the limit you configured earlier Pushbutton masking This may be necessary if you want to prevent an operator selecting a particular mode via the front panel pushbuttons Note that button masking does not prevent modes being changed by other means e g automatically during a failure mode or over the comms net work When TRUE Bit8 Bit9 and BitA disable the R emote A uto and M anual mode select pushbuttons respectively 1 2 3 Access the Bit9 subfield of the SWS 1 block and alter its value to tru Return to the normal display by pressing M Now try to select auto by pressing A You will not succeed and the message MASKED appears in the tag display for about 3 seconds to tell you why NOTE You may have seen the MASKED message at the start of this tutorial if you pressed R or A before you connected the piece of wire to close the control lo
154. gged as a mini mum The time logged is the time that the final value was written Each record is a single text line of the format hh mm ss block field subfield value or for a change of mode hh mm ss LOOP n X where hh mm ss the time in hours minutes seconds 24hr representa tion block the full path of the point being modified value the new value n the loop number X the new mode i e M A or R Example logfile record 21 01 93 F 3 2345 01 12 15 T640C6C3 Options FPdisl TRUE 01 12 18 T640C6C3 Options NoKeyFul FALSE 01 12 25 LOOP 4 M Logfile saving The recording of database changes via the front panel to a logfile normally occurs invis ibly as a background operation However sometimes the T640 must re order its filing system e g when a logfile becomes full or after a database download or save This proc ess can take a noticeable amount of time and can cause an apparent sluggishness in re sponse when operators try to make database changes via the front panel Version 4 1 software has an enhanced filing system that does not suffer from this problem V3 3 of the software includes a front panel message to advise the operator when this proc ess is occurring The message LOG SAVE is displayed in the tag display followed by Save OK NOTE During this file saving operation the T640 power must not be inter rupted Doing so could possibly corrupt the filing system Although the v4
155. ght of the decimal point This parameter is for display purposes only and has no effect on the ranging Table 5 10 Loop 3 parameters strategy 4 ratio station T640 Reference M anual amp User Guide Issue 5 5 33 Setup sheets Standard strategies SETUP SHEETS ALL STRATEGIES Tables 5 11 to 5 14 list all four strategies configurable fields and their default values to gether with a very brief description of their function The loops apply to all the strategies except where indicated You may want to photocopy these pages and record your custom ised parameter values on them Loop 1 Block Field Subfield Default Setting Description SL661 Inst No 1 BiSynch address SWS 1 W Field1 Bit FALSE Power up mode Bitl FALSE PV fail mode Bit2 FALSE tru inverse output action Bi FALSE tru inverse PID Bit4 FALSE tru On Off control Bib FALSE tru setpoint tracks PV if not AUTO Bit6 FALSE tru PV SP O ut SP Bit7 FALSE tru inverse ratio setting Bit8 FALSE tru Mask R Bit9 FALSE tru Mask A BitA FALSE tru Mask M BitB tru Tag FIC 001 BitC FALSE Tag UC 001 BitD FALSE Tag PIC 001 BitE FALSE Tag TIC 001 BitF FALSE Tag AIC 001 RSP 1 Filter 0 00 nput filter HR in 10 00 nput voltage high LR in 0 00 nput voltage low Options Invert FALSE nput conditioning Sqrt FALSE nput conditioning DIN 1 Invert Bito FALSE tru
156. given MODBUS protocol address is directed at an input or output in a bit or register table 7 2 JBUS APRIL In the JBUS implementation there is a direct correspondence between a register or bit ad dress and the MODBUS protocol address and no distinction is made between input and output or indeed internal PLC registers Thus MODBUS function codes 01 and 02 are treated identically as are codes 03 and 04 All PLC data thus conforms to a single address range 7 3 Other products Other manufacturers MODBUS interface implementations e g Siemens S5 and TSX7 Series of PLCs conform to the MODICON principle of separate tables for different types of data exchange but the correspondence between PLC base address and MODBUS pro tocol address is user configurable B 18 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Appc Appendix C FRONT PANEL FOREIGN LANGUAGE SUPPORT The standard messages displayed on the T640 front panel can be reconfigured Alternative front panel messages are defined within a LNG file stored in EEPROM If the T640 finds a LNG file at power up it uses the messages contained in the file for the front panel If no LNG file is found the default English language messages are used This facility is intended to allow the T640 to display messages in languages other than English Currently a French language LNG file is supplied with the T640 FILE STRUCTURE The front panel message f
157. h 10 1 Normal power up tr e rer eret e e qon 10 1 Error conditons erre rp e ee et re exe ert 10 1 Contents 8 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents Alarm Strate gy ree tertie e Fere rore ca ene Monrose yard 10 4 Alarmi prioriti Si ttis reo ar tete i ee re tuere a 10 4 Alarm annunciation essere enne 10 4 Alarm events 9o ote tanh wine Rebus 10 4 Alarm relay duc eed tet RR REN ON etg 10 4 CBU watchdog 1 aede nir Dr e e Pr en reir 10 5 Watchdog output esses 10 5 Watchdog relay ireira teret e ree non 10 5 Loop tall 55 set ntsc RE Roh 10 5 User larm 5u ait e n e DR R ERAN 10 5 Main processor CPU fail esee 10 5 Forced marival mode eee tete ne den 10 5 Chapter 11 SPECIFICATIONS T640 base unt ne Saee un E RUE 11 1 Panel cut out amp dimensions eee 11 1 Mechanical rtt retient eee cetero eet 11 1 Envitonmental ritmo eh cavstavesencey 11 1 Front panel displays eene 11 2 Loop status summary eere 11 2 P shbU ttOns 5 5 redeo reet e PE De 11 2 Dot matrix display character set esses 11 4 RELAYS tet ee rore iere teet ln m Re e des 11 4 Power supplies nee RU EROR Rd 11 4 Mains VeIslIODi aee ten eod iO RE 11 4 DC NeIsIOll nte eub RENE RIA 11 4 T950 Secutity Key rrr eet eee 11 4 ATIN ess E E REEE 11
158. h connection ssssssssseese 2 2 G Edge connector erosion 242 34 GateW ay File ie te 228 EEPRO M i t t ta 92 G ateway file Electrostatic discharge GN D terminal vis aeree riter res 2418 handling precautions 24 Electrostatically sensitive H components vean 24 2 9 HALTED eeee eene 10 1 EMC information vce 241 Handling precautions 24 29 34 Engineering units 4 2 Hardware Erosion of edge connectors 242 34 alarmitelay tette cts Err hhhh sussssssssssee eee 10 1 build level 5er s Error configuration conditions oie deeds 2 34 organisation messages T 101 Hardware status level 221 Exception responses from a slave B 17 Hardware software faults 104 Execution times esse 7 7 High precision displays cecce 4 6 Expansion I O board scr 11 9 High level lf O ssseseese 2 18 119 Expansiontype O board 222 A3 Highdevell O boards 2416 External faceplates 92 Extractor tool 242 34 l 1 0 F boards eneun eed 2 18 Ferrules poloniat ee 2 12 calibration procedure 1145 FIELD tse tete eter RE RURS 4 6 OPU eet ette 2 20 Field Access Moden icun tiiin 4 6 site Field WATES cien eoat oinin ea 8 2 sites Fields amp subfields 3 10 software function blocks 2418 File yp eSa a ans eirt 2 28 9 2 subassemblies 9 4 Filtering 531 zero volts schematic osc 220 Fixed function
159. he I O customer terminals 1A 1Z SIMULATING A FEEDBACK LOOP Figure 3 9 shows that the 0 10V control output appears on terminal 1L which could in a real plant be connected to a suitable control valve The PV input from the orifice plate would be connected to terminal 1E for input to the PV__1 block You can simulate this control loop by feeding the control output back to the PV input Do this by simply con necting a wire between terminals 1L and 1E Note that within a few moments of connecting the wire the red ALM button light goes out showing the alarm condition has cleared the M button s yellow LED stops flashing meaning that normal un forced manual mode now operates and the watchdog relay closes which you may see on the multimeter if still connected If you now press the ALM button the message NoAIm appears in the tag display mean ing no detected alarm condition now exists in the instrument With the control loop complete you can now investigate the strategy further DISPLAYING amp ALTERING THE LOCAL SETPOINT The resultant setpoint is currently 0 00 units as shown in the green units display see Fig ure 3 7 Alter this to about 50 units as follows l Press the SP w button to display the local setpoint 0 00 in the red 5 digit display With SP w pressed SetLocal appears in the tag display to remind you what is being displayed The setpoint s units Eng1 are shown in the green units display 2 Keepin
160. heat and loop 4 cool 7 T640T1 Two simple PID control loops acting standalone or together as a cascade pair Loop 1 has two inputs mV to suit direct plant wiring and V to suit a Hi Level input rom a transmitter 1 5 V etc The control output is a current source Only one input should be used in any strategy the other is put in manual with PV configured low Loop 1 is the Slave if Cascade control is enabled Loop 2 has one mV input to suit direct plant wiring The control output is a voltage source 0 10V etc Loop 2 is the Master if Cascade control is enabled Table 5 1 Summary of the strategies supplied in EEPROM as PKn files Strategies supplied in EPROM ROM Four pre configured fixed function strategies are supplied in T640 s ROM Note that the files stored in ROM are write protected Table 5 2 summarises these strategies Name Summary SIN G LE A single loop controller DUAL A dual loop controller DUAL CS A dual loop controller internally pre wired in cascade DUAL RT A dual loop controller with ratio station Table 5 2 Summary of the fixed function strategies supplied in ROM as PKn files PWNeF j5 5 2 T640 Reference Manual amp User Guide Issue 5 Standard strategies FURTHER INFORMATION ON STANDARD STRATEGIES This chapter concentrates on the four fixed function strategies supplied in ROM and says no more about the strategies supplied in the T640 s EEPROM You can find out m
161. here is a risk that at power up a new strategy will replace your customised one in EEPROM Itis OK to power up with the switches set to the original strategy that you subsequently customised 1 in this case This is because when the T640 sees that the EEPROM al ready contains the strategy indicated by the switches it loads it directly from EEPROM to RAM and runs it without unpacking decompressing a default database from ROM You can test the effect of your save as follows 1 Remove the T640 from its sleeve and set the warm start enable switch to OFF Leave the cold start enable switch at ON and the strategy select switches at 1 Figure 3 4 shows the required SW1 switches This action now ensures that the T640 cannot do a warm start only a cold start T640 Reference M anual amp User Guide Issue 5 321 Tutorial Power up again by replacing the T640 in its sleeve You will see a cold start per formed but all your saved field values are preserved in your customised strategy Check this using INS Finally return the warm start enable switch to ON INVESTIGATING THE LOOP SETUP SWITCHES There is a set of 16 software switches or bits within a block called SWS_1 in the PID control area of the strategy You can use them to specify the way the control loop oper ates The SWS_1 bits select such things as the T640 power up mode inversion of control output action on off control action pushbutton disabling mask
162. i 18 ALARM1 Risse CERA EC o 19 ALARM2 Figure 5 7 Strategy 3 schematic 5 26 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 3 Strategy 3 organisation Master amp slave The strategy has been internally connected to make Loop 2 the master controller and Loop 1 the slave controller Blocks amp connections Strategy 3 is similarly structured to strategy 2 but has the following additions that work behind the scenes Wi Two extra database interconnections are present 3TRMI Status HiLimFre to 3TRM2 Options FrcHiLim 3TRM1 Status LoLimFre to 3TRM2 Options FrcLoLim These cause the master Loop 2 to behave as if in output limit when the slave Loop 1 goes into output limit This has the effect of inhibiting integral term wind up in the master controller and gives faster return to control W Range blocks have been added to re range the analogue internal connections be tween the loops Loop 2 s output is still ranged 0 100 and loop 1 s PV and SP ranges are chosen to represent engineering units Note that these range blocks are not accessible via the INS button for configuration Loop update rates The loop update rates have been chosen to let the slave run faster than the master The up date rate of Loop 1 is 220ms and of Loop 2 is 420mS Strategy 3 operator interface Cascade control is selected by putting the slave Loop into Remote mode press the R but
163. ided as an input signal SP TRIM PY ODE is set to MAN UAL this input may be used to manually inputa setpoint trim HR This sets the high range in engineering units HR in maps to HR Because trim works in engineering units HR and LR are used to scale the trim input against SETP1 HR SP and LR SP LR This sets the low range in engineering units LR in maps to LR would not be unusual for LR to be the same value as HR but negative to give a symmetrical trim Filter A firstorder filter with the time constant set applied to the input HR in The input voltage representing high range LR in The input voltage representing low range 0 ptions O nly options believed relevant are described Some options have defaults relevant to the 1 0 hard ware and should not be changed Invert TRUE maps HR in to LR and LR in to HR Sqrt TRUE applies a square root function to the input SETP1 This block provides all the setpoint processing and alarms HR SP The high range of the process variable and setpoint in engineering units The block is internally connected so that the process variable and remote setpoint share the same ranges as HR SP and R SP R SP The low range of the process variable and setpoint in engineering units HL SP This sets a high limit for the setpoint including any trim whether the setpoint is local or remote LL SP This sets a low limit for the setpoint including any trim whether the setpoint is local or remote HL SL This sets a high limit for the local setpoi
164. ifically by connecting together the two pins of Jumper 1 and those of Jumper 2 on the main high level I O board These are located as shown in Figure 11 1 Both analogue inputs and voltage analogue outputs are forced to the 1 25V range by these jumper links Burden resistors If internal burden resistors have been specified HIB and HGB op tions or if external burden resistors are fitted to the customer screw terminals the ana logue input block s range parameters LR in and HR in must be appropriately con figured to suit the plant s current input range Consult Table 11 2 Jumper 1 Jumper 2 Figure 11 1 High level I O board showing 0 1 25V range jumpers T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 9 High level 1 O Specifications Burden Plant AN IP block setup Option resistor input LR in HR in HIB 2500 0 20 mA ov 5V 4 20 mA 1V 5V HGB 622 0 20 mA 0v 1 24V 4 20 mA 0 248V 1 24V External 2500 0 20 mA 0v 5V 4 20 mA 1V 5V 502 0 20 mA 0v 1V 4 20 mA 0 2V 1V Table 11 2 Range settings for burden resistors Calibration The 1 25V range is supplied with a nominal calibration accuracy of bet ter than 5 If required the board may be recalibrated to an accuracy of 0 05 via the AI_CALIB and AO_CALIB blocks see the LIN Blocks Reference Manual NOTE In the T640 HI and HIB options the 1 25V range is uncalibrated at the present i
165. igital I O and Figure 11 4 shows the current outputs and transmitter power supplies Analogue inputs Channels 8 Input range 0 5 V and 0 10 V with software selectable range 0 1 25 V range jumper selectable see Input ranges above Absolute max input 15V 0 25W with internal burdens Isolation None Resolution 0 025 Accuracy 0 05 of range ANALOGUE INPUTS Site 2 Chn 4 Site 2 Chn 3 Site 2 Chn 2 Site 2Chni Input select Site 1 Chn 4 Site 1 Chn 3 Mux f Site 1 Chn 2 e Site 1 Chn 1 r Ato D HE 10K re Q e i2 E Break 1M detect RE Threshold s An gnd e 1 2V HIB HGB options nG QA EEPROM VO MICRO nK 2 9 Analogue gt nN Qe calibration data CONTROLLER Analogue ground Output select Mux Site 2 Chn 2 o Site 2 Chn 1 Site 1 Chn 2 T gt ae Site 1 Chn 1 p vere H 1L Mux I Li Sample amp hold j E DtoA E ae Analogue ground ANALOGUE OUTPUTS Figure 11 2 Analogue input amp output block schematic T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 11 High level O Specifications
166. iguration Serial communications jumper link amp switches NOTE The following applies to boards at hardware status level 12 or later For older boards please refer to Appendix A Setting up early boards You can deter mine the status level of your T640 by consulting its internal data label see the Status level information section on page 2 21 A jumper link J2 together with switches 1 and 2 of Switchbank 1 are factory set to con figure the motherboard according to what serial comms option was ordered You can check that these are set as required the jumper and switches are located on the mother board where shown in Figure 2 11 Table 2 4 shows the switch settings and jumper links for the five possible comms options Required DIL switch Jumper link J2 comms option SW1 1 SW1 2 daughter b d fitted no daughter b d Binary RS422 OFF OFF N ot fitted 121 or Not fitted Modbus RS422 ON OFF N ot fitted 1210rNotfitted Modbus RS485 ON O FF 12 23 External ISB RS422 Don t care ON N ot fitted 121 or Not fitted External ISB RS485 Don t care ON 12 2 3 11 2 non functional parked position Not implemented at current issue Table 2 4 Comms option switch amp jumper link settings BINARY RS422 CONFIGURATION Table 2 4 shows the hardware settings required for communication via an RS422 serial link using binary BISYNC protocol The T640 must also have an appropriate S6000 category function block running in the da t
167. ile contains a number of null terminated strings from the ASCII character set with the T640 character code extension There are forty one 8 character plus null terminator strings and ten 5 character plus null terminator strings Table C 1 lists the English language strings and their equivalents for the French language LNG file Brief explanations of the displays are also given English French When displayed Trying TEST Alternates with W arm Tepid ColdStart W armStrt DemC haud Indicates type of database start being attempted TepidStrt DemTiede ColdStrt DemFroid Un Pack DeCompr Alternates to indicate a standard strategy is being decompressed Database B donnee HALTED ARRET Loop not running IN VALID IN VA LIDE Invalid button combination pressed ALM_SET VISU ALM Pressing raise amp lower buttons together to display absolute amp deviation alarm settings OUTPUT SO RTIE O utput Inspect messages M A R pressed MS Dmnd DEMANDE M easPos PO SITIO N MS Input EN TREE MS Track PO URSUIT MASKED MASQUE Attempting a masked mode change Table C 1 continued T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 C4 AppC Frontpanel foreign language support Table C 1 continued English French When displayed SetLocal CONS L Setpoint Inspect messages SP pressed SetPoint CONSIGN RemoteSP CONS E ComRemSP CONS C TrimSP DecaCON
168. in the TPD file to be transferred rapidly to EEPROM ready to be used if required during a subsequent warm start routine see Figure 2 15 The tepid data is coherent see Chapter 8 Data Coher ence because it is assembled only from completed tasks Also contained in the tepid data package are any of the up to eight fields named in a single TP_CONN block in the database whose block name is specified in the T600 header block s AnConBlk parameter Alternatively an AN_CONN and a DG_CONN block specified in the T600 block s AnConBlk and DgConBlk parameters respectively can be used to define tepid data but only if a TP_CONN block is not being used In this case the tepid data consists of all PVn analogue values of the AN_CONN block and all W Fieldn and B Fieldn bit values of the DG_CONN block By wiring these two blocks to a selection of important parameters that must survive a warm start and writing to these parameters via the two blocks you ensure that their values are held as tepid data during a power down 2 32 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 nstallation amp startup DIL switchbanks Tag display Units display 5 digit display O utput bargraph PV bargraph SP bargraph Deviation bargraphs Mode letter Displayed loop arrowhead Pushbuttons Figure 2 16 1640 front panel principal features Motherboard DIL switchbanks DIL switchbank SW1
169. ineering units After that you will go on to apply high and low limits to the local setpoint SL and then configure absolute and deviation alarms on PV Finally in this section you will set up a new decimal point position for the front panel display The function block concerned with this part of the control strategy is the SETP1 setpoint block which was shown in Figure 3 9 in the PID control area of the database To carry out modifications you must access the relevant fields inside the SETP1 block To do this you use the INS inspect pushbutton on the front panel Table 3 1 lists each of the configurable fields within the SETP1 block together with its default value target setting and a brief description of its function in the strategy This list will be useful when you are navigating around the fields to configure them Note that a complete list of blocks and fields for each of the fixed function strategies is given in the setup sheet included in this manual at the end of Chapter 5 Block Field Subfield Default Setting Description SETP1 HR SP 100 00 75 00 Engineering unitshigh for SP and PV LR_SP 0 00 Engineering units low for SP and PV HL SP 100 00 High limit on SP LL SP 0 00 Low limit on SP HL SL 100 00 60 00 High limit on SL LL SL 0 00 Low limit on SL Alarms HighAbs 2 Alarm priority on HAA LowAbs 2 Alarm priority on LAA HighDev 2 Alarm priority on HDA Low Dev 2 Alarm priority on LDA HAA 100 00 70 00 High
170. ing and the tagname that appears in the loop s tag display Table 3 3 lists the SWS_1 bitfields Try switching some of these bits from their default states all but one are FALSE to see how they affect the control action Power up power fail mode 1 Press INS twice to access block inspect mode then press W as required to bring up the SWS 1 block 2 Press INS again to see the only accessible field in the SWS 1 block W Field1 This consists of 16 subfields called Bit0 to BitF hexadecimal F is decimal 15 3 Press INS again to access Bit0 Table 3 3 tells you that this bit selects the power up mode Remember that power up occurs after unexpected power interruptions not just when you switch on the T640 TRUE causes the loop to adopt manual mode on power up with zero electrical output for safety i e OV or 4mA FALSE the de fault causes the loop to maintain its last mode and output value on power up Block Field Subfield Default Setting Description SWS 1 W Field1 Bit0 FALSE tru Power up mode Bitl FALSE PV fail mode Bit2 FALSE tru inverse output action BIB FALSE tru inverse PID Bit4 FALSE tru tru On Off control Bib FALSE tru setpoint tracks PV if not AUTO Bit6 FALSE tru PV SP Out SP Bit7 FALSE tru inverse ratio setting Bit8 FALSE tru Mask R Bit9 FALSE tru MaskA BitA FALSE tru Mask M BitB tru Tag FIC 001 BitC FALSE Tag LIC 001 BitD FALSE Tag PIC 001 Ifall bits FALSE tag is LOOP 1
171. ing gt A to D V E e CJC High resolution Data ov e 0V integratin m P Aqo D encoder e 45V Ds 1 F ov V K ov e ov 1 0 MICRO CONTROLLER ISB Figure 11 8 Analogue input Block type Channels AN_IP 1 non isolated software selectable between voltage and frequency input modes Thermocouple inputs block schematic n 1 2 Absolute max input 20V Isolation none 11 22 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Specifications Thermocouple O Voltage input mode Block type Input ranges Out of range capability Accuracy 25 C Resolution Temperature drift AN_IP 0 to 10 V 0 to 5 V 0 to 2 5 V and 0 to 1 25 V software selectable 10 0 1 of scale gt 14 bits for 0 10V 0 5V and 1 5V rangings lt 100LV 0 008 of reading C 99 confidence lt 40uV 0 004 of reading C typically NON ISOLATED ANALOGUE INPUTS V Hz e 18V Break protection 1M5 Internal clock Vonly LJ s Low pass LL Volts to X d 3 1K RU pulse train e a Counter ess timer M o Dun up Hz i I y Counter Y timer p p Synchroniser L V low Hz high nV 2 e e ISB Analogue ground l O MICRO CONTROLLER
172. instructions sese 2 5 Safe usage of alkaline manganese batteries 2 5 Alkaline manganese batteries COSHH statement 2 7 Unpacking your T640 5 ae rre debetis eR EE 2 9 Handling precatio Seniai nania aans 2 9 Package contents eicere a a R 2 9 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Contents 1 Contents Installation entree Inr tr ri toi Er e 2 10 DIMENSIONS ee rte o OR RE ro tansdaesrevesses 2 10 Panel mounting secet essen ede eren 2 11 Clamp removal esie ee ar RM 2 11 Removing T640 from sleeve sss 2 12 Connections amp wiring sese 2 12 Terminal cover removal sese 2 13 Customer terminals essere 2 13 Mains safety Cover essere 2 13 Terminal designations esee 2 14 Motherboards t prog en o en qe eara 2 14 High level I O boards sess 2 16 Thermocouple I O boards sse 2 17 Linking the terminals to I O software function blocks 2 18 Examples high level I O option ss 2 18 Examples thermocouple I O option 2 18 T640 zero volts schematic sesee 2 18 I O zero volts schematic seseseeeeeeeee 2 20 Communications zero volts schematic sse 2 21 Hardware co
173. inued FIRST AID PROCEDURES Skin contact If leakage from a cell contacts the skin flush immediately with water and cover with dry gauze Eye contact Flush with copious amounts of water for 15 minutes and Seek medical assistance Inhalation of vapour If vapour is inhaled remove to fresh air REACTIVITY DATA Stability Stable Conditions to avoid DO NOT heat disassemble or recharge Hazardous decompositio n or byproducts When heated cells may emit caustic vapours of KOH PRECAUTI ONS FOR SAFE HANDLING USE AND DISPOSAL Spill or leak procedures Avoid skin and eye contact Do not inhale vapours Neutralise leaked material with weak acidic solution e g vinegar and or wash away with copious amounts of water Waste disposal method Dispose of spent batteries in small quantities with normal waste Do not accumulate but if unavoidable quantities of 5 gallons or more should be disposed of in a secure landfill as should leaking cells regardless of quantity Do not incinerate batteries since cells may explode at high temperature Disposal should be in accordance with all applicable national and local regulations Handling and storage Avoid mechanical or electrical abuse Use neoprene rubber or latex nitrile gloves when handling leaking cells Store at room temperature Other precautions Do not attempt to recharge Install cells in accordance with equi
174. inverts CO MP EN 0 Bitl tru FALSE inverts REM SP EN 1 Bit2 FALSE tru inverts TRACK EN 1 BiB FALSE tru inverts HO LD EN 1 PV 1 Filter 1 00 Input filter RomChar None Input conditioning Alarms Hardware 2 Alarm priority OutRange 2 Alarm priority OCctdel 2 Alarm priority HR_in 10 00 Input voltage high LR_in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning continued 5 34 T640 Reference M anual amp User Guide Issue 5 Standard strategies Setup sheets continued Block Field Subfield Default Setting Description TRIM1 MODE MANUAL O perating mode AUTO orMANUAL PV 0 00 Trim setting if MANUAL HR 100 00 Engineering units high LR 0 00 Engineering units low Filter 0 00 Input filter HR_in 10 00 Input voltage high LR_in 0 00 Input voltage low Options Invert FALSE Input conditioning Sqrt FALSE Input conditioning SETP1 HR SP 100 00 Engineering unitshigh for SP and PV LR_SP 0 00 Engineering units low for SP and PV HL SP 100 00 High limit on SP LL SP 0 00 Low limit on SP HL SL 100 00 High limit on SL LL SL 0 00 Low limit on SL Alarms HighAbs 2 Alarm priority on HAA LowAbs 2 Alarm priority on LAA HighDev 2 Alarm priority on HDA Low Dev 2 Alarm priority on LDA HAA 100 00 High absolute alarm on PV LAA 0 00 Low absolute alarm on PV HDA 100 00 High deviation ala
175. ion 2 24V 45 0 22 mA 30mA maximum 60V ac rms or dc working Voltage analogue outputs Channels Output range Resolution Accuracy Gain drift Offset drift Current drive Overload detection Isolation 4 0 5 V and 0 10 V with software selectable range 0 1 25 V range jumper selectable see Input ranges above 12 bits 1 25 and 2 5 mV for the 5 and 10 V ranges resp 0 0596 of range 30ppm C TOM VC t5 mA triggered if the output cannot maintain the desired voltage none Current analogue outputs Channels Output range Over range Resolution Accuracy Gain drift Offset drift Output drive Isolation 2 0 20 mA Rangeable 0 10 mA 0 20 mA 4 20 mA etc 22mA 5UA 0 1 80ppm C 0 9L A C 0 1 KQ 60V ac rms or de working 11 14 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications Digital inputs Channels Thresholds Hysteresis Input voltage Input impedance Isolation Digital outputs Channels Output levels External supply Drive impedance Isolation General High level I O 8 logic 1 7 5V minimum logic 0 2 5V maximum 1 0V minimum 3 5V maximum 28V maximum 200kQ for inputs 10V 100kQ for inputs gt 10V none 8 logicO OV logic 1 15V 14 0V 15 5V internal supply or external supply dual function as input 15 5V minimum 28V maximum as output 14 0
176. ion Conforms to Medium Implementation Addresses Data rate Character length MODBUS PROTOCOL Selection Transmission mode Medium Implementation Slave addresses Data rate Parity amp stop bits SOFTWARE Via motherboard DIL SW1 amp jumper link see Chapter 2 ANSI X3 28 2 5 A4 Revision 1976 binary version RS422 Via appropriate T6000 category function block running in the T640 see the LIN Blocks Reference Manual 128 maximum software selectable via the S6000 function block s nstr No parameter Software selectable via T600 function block s BinSpd1 amp BinSpd2 parameters from 300 1200 4800 amp 9600 baud 11 bits made up of 1 start 8 data 1 parity even 1 stop Via motherboard DIL SW1 amp jumper links see Chapter 2 MODBUS RTU 8 bit supported RS422 or RS485 Via gateway file GWF configured via T500 LINtools MODBUS configurator and stored in the T640 together with the database file DBF 254 maximum software selectable via T500 LINtools MODBUS configurator Software selectable via LINtools from 110 150 300 600 1200 2400 4800 and 9600 baud Software selectable via LINtools from none odd and even parity with 1 or 2 stop bits Maximum resources supported The table shows the default maximum resources supported by the T640 This informa tion is also available in the local DB_DIAG blocks T640 Reference Manual amp Us
177. is block processes the digital inputs Invert This field inverts the sense of the digital inputs on a bitby bit basis Bit4 to Bit are not supported by the hardware Setting them will have no effect Bit TRUE inverts CO MP EN 0 If this input is unused do not alter the default If this input is used it will be normal to invert its action so that a high input is required to enable parameter changes over the communication ne orks Bitl FALSE inverts REM SP EN 1 It should not be necessary to alter the default Bit TRUE inverts TRACK EN 1 It should not be necessary to alter the default BiB TRUE inverts HO LD EN 1 If this input is unused do not alter the default If this input is used it will be normal to invert its action s This block processes the process variable input Alarms Combined will cause the controller to go into Forced Manual if an alarm with non zero priority occurs See SWS 1 W Field1 Bit Filter gt irst order filter with the time constant set will be applied to the input RomC har inputs are available This is used to select input linearisation The common thermocouple and resistance thermometer The RSP_1 block is absent from Strategy 4 ratio controllers continued T640 Reference M anual amp User Guide Issue 5 5 11 Strategy 1 Standard strategies continued Block Field Subfi
178. ixed function strategies all the necessary blocks have been installed and wired together for you all you need do is set some of the block fields to specific values to tailor the strategy to your own plant requirements 3 10 T640 Reference M anual amp User Guide Issue 5 Tutorial PV INPUT PID CONTROL CONTROL OUTPUT area 2 area area Pi estos SETP1 OUTPI ___ P 1A BIOS lt gt _ setpoint p analogue 20ma 7 t 7 Js c8 S bok ERE output BO renege gene Y j Y 3TRM1 E 3 term block RU EE 1L 0 10V Y block MANS1 po qo ee c ctt manual 4 station block Wal Clean instrument earth i Figure 3 9 Strategy 1 schematic Alarm fields Alarm conditions are represented in each block by an Alarms data field This field is fur ther divided into subfields which become TRUE when the corresponding alarm condition arises It was these subfields that you just inspected via the ALM pushbutton Figure 3 9 shows strategy 1 in a little more detail with some of the blocks named and their block types indicated Also some of the customer terminals are shown where plant can be connected You will need this information to progress with the tutorial Block functions PV inputarea As already stated PV__1 is an analogue input block that takes in a voltage signal from the plant the o
179. k settings 2 27 Af alat iiia oe D et option SW 1 2 setting 104 alarm annunciation acce POMS i Sanaa n oer ee cernit tes 9 2 alarm settings viewing zero volts schematic 221 A4 bargraphs isse mt rs Compressed format 2 28 5 1 9 2 Diagnostic Computer remote mode 4 3 function codes cee B 15 Conductive pollution sss 24 registers Configuration table er coe tete cete ie sizes and limits cc B 10 Diagnostic blocks icsse 5 39 enne E 4 6 Diagnostics sce e teris 104 Connection Enquiry mode 4 6 DIL Connections amp wiring ssese 242 switchbanks 1 and 2 222 A3 Connector erosion ccecce 34 DIL switchbanks wee 2 33 93 Connectors erosion sssssse 242 DIMENSIONS inest ia 240 Control loop Disable write icta tt B 14 handling more than one 325 Disconnecting device sss 23 Control I00pS iin inea ini 117 Index 2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Index E I Dotmatrix display character set 114 Front panel language ccecce C4 Downloading F lle et Wien Reo kat 4 9 Modbus configuration B 12 Full access mode ssseeeee 44 Dynamic WUNING ci enero rete 7 1 F nction blocKs oot cena 3 10 Function blocks supported 11 7 E FUSe ciere 2 12 223 114 A4 Early boards setting up ssssss A l Eart
180. ket The figure shows an I O board in Site 1 and an expansion type I O board in Site 2 Other I O options and arrange ments are possible depending what was ordered Memory I O expansion module board 7 J Retaining clip momen go A y module DIL DIL Site 1 socket switchbank 1 switchbank 2 Motherboard 0 board Figure 2 10 T640 internal layout example Memory module removal See Figure 2 10 Use a screwdriver blade to slide the retaining clip towards the front panel as far as it will go then pull the module out of its socket Replacement is the re verse procedure Caution The module can be pushed fully home only if it is the right way round Check this before applying excessive force which can damage the pins Memory module compatibility If you transfer an application program by moving the T901 memory module from a T640 with v3 4 software or earlier corresponding to a 12 5MHz processor clock speed to a newer T640 25MHz clock speed the T640 will fail to start 222 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Main fuse This is because pre v3 5 software does not recognise the new clock speed and displays POWER ON RESET and CPU on the front panel The 25MHz processor clock speed was introduced at T640 hardware status level 6 see the Status level information section above for how to determine status information 25MHz T640s ar
181. lated mode strategy permitting The but ton s top right LED glows if the mode is adopted both R LEDs glow green in computer remote mode A flashing LED signifies a forced mode If a mode button is inhibited by the MODE block s PBmasks parameter or by a SelMode bit the tag display is over ridden by the word MASKED for 3 seconds and no mode change occurs Outputdisplay Holding down a mode button also displays the current value of the control output in the 5 digit display and its units in the units display The word OUTPUT or MeasPos appears in the tag display with A or R pressed or MS_Dmnd with M pressed For the simple PID block only OUTPUT appears Changing the output With M pressed and the controller in Manual press A or V to vary the value of the MAN_ STAT block s Demand field or the PID block s OP field Full range change takes about 12 seconds Output parameters quick access With any of M A or R pressed press INS Inspect repeatedly to scroll the 5 digit dis play through the MAN_STAT block s primary output parameter values These are OP OUTPUT Demand MS_Dmnd MeasPos MeasPos PV MS Input and Track MS_Track identified in the tag display Only OP and Track are available from simple PID blocks Setpointdisplay Press SP W to display the SETPOINT or PID block s SL value in the 5 digit display When in Remote mode the corresponding remote setpoint is seen With SP W pressed
182. ld detergents may be used to remove grease but do not use abrasive cleaners or aggressive organic solvents Safe usage of alkaline manganese batteries The 12V alkaline manganese batteries used in the T950 security key must be stored in a suitable manner handled and used correctly and disposed of safely when spent Read the information given in the following COSHH statement T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 25 Installation amp startup This page intentionally blank 2 6 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup ALKALINE MANGANESE BATTERIES COSHH STATEMENT 12V ALKALINE MANGANESE DIOXIDE CELLS Duracell MN21 Panasonic RVO8 or equivalents HAZARDOUS INGREDIENTS Product Part numbers Name by weight OSHA PEL ACGIH TLV Potassium hydroxide KOH 8 2mg m C 2mg m C Manganese dioxide MnO 37 5mg m C 5mg m C Zinc Zn 15 10mg m3 C Carbon C 4 3 5mg m C Steel 18 10mg m C Brass 3 2 10mg m3 C Mercury none added 0 05mg m C PHYSICAL DATA Property KOH Zn Boiling point C 1320 907 Vapour pressure mm Hg N A 1mm 487 C Vapour density air 1 N A N A Solubility in water 50 0 Specific gravity water 1 2 0 5 0 7 14 Melting point C 360 420
183. ld rise above 264Vac with respect to ground and the unit would not be safe T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 23 Installation amp startup Voltage transients across the power supply connections and between the power supply and ground must not exceed 2 5kV Where occasional voltage transients over 2 5kV are expected or measured the power installation to both the instrument supply and load cir cuits should include transient limiting devices e g using gas discharge tubes and metal oxide varistors Conductive pollution Electrically conductive pollution e g carbon dust water condensation must be excluded from the cabinet in which the unit is mounted To ensure the atmosphere is suitable in stall an air filter in the air intake of the cabinet Where condensation is likely for example at low temperatures include a thermostatically controlled heater in the cabinet Ventilation Ensure that the enclosure or cabinet housing the unit provides adequate ventilation heating to maintain the operating temperature of the unit within the limits indicated in the Specifi cation see Chapter 11 Current measurement Where the instrument I O is used to measure current provision must be made in the instal lation to prevent hazardous voltages arising at the T640 terminals by failure or removal of burden resistors For example a protected current source could be used Electrostatic discharge handling precautions
184. listed in Tables 12 2 to 12 5 T640 ORDER CODES CODE DESCRIPTION Base unit T640 Integrated Loop Processor Powersupply MAINS Universal mains 90 to 265 volts ac rms DC 19 to 55 volts dc power supply Serial communications 422 RS422 Bi Synch or M O DBUS serial communications 485 RS485 MO DBUS comms ExISB Notyetavailable None fitted Site 1 high level I O board HI 0 5V or 0 10V input range automatically selected by database HG Jumpers set for 0 1 25V fixed input range HIB As HI but with internal burden resistors fitted HGB As HG but with internal burden resistors fitted Site 2 high level I O expansion board Ho Expands board specified in Site 1 but with no burden resistors dues Expands board specified in Site 1 but with internal burden resistors fitted N o board fitted in Site 2 Site 1 low level I O board TC Thermocouple I O option RT Notyetavailable Site 2 low level I O board TC Thermocouple I O option RT Notyetavailable The range specified for Site 2 high level I O I or G code must follow that specified for Site 1 continued T640 Reference M anual amp User Guide Issue 5 124 T710 codes Ordering information continued CODE DESCRIPTION Memory module M001 24oop Integrated Loop Processor M002 44oop Integrated Loop Processor M003 Notyetavailable M004 44oop Integrated Loop Processor with sequencing MOO6 Fixed function Integrated Loop Processor High
185. lready described Quitting database access modes Pressing R A M or SP W immediately reverts the T640 to standard operation A time out can also be set in the T600 block to revert the display after a defined period of no but ton activity 4 6 T640 Reference M anual amp User Guide Issue 5 User interface Alarm inspection ALARM DISPLAY amp INSPECTION Whenever any unacknowledged alarms exist in the loop occupying the main display the highest priority alarm name flashes in alternation with the standard message in the tag dis play Unacknowledged alarms elsewhere display LP n ALM where n is the relevant loop number Any alarm in the instrument in any of the loops lights the red LED in the ALM but ton The LED flashes if any alarm is unacknowledged otherwise it remains steady Alarm inspection via the ALM button The ALM button lets you quickly locate and acknowledge alarms wherever they are Figure 4 3 shows how the ALM button works 1 4 5 Press ALM to enter Loop Alarm Inspect mode indicated by LOOP in the green units display The tag display flashes the highest priority alarm name current in the database and the corresponding loop is entered for inspection whether or not it is in the main display If no alarm exists anywhere ALM button LED unlit NoAlm is displayed and you cannot enter loop mode Once in loop mode you can press A or V to select another loop for inspection if required only
186. mapping 64 bits to the database In case a the bits are mapped onto the database in 16 bit units needing only 4 descriptors In case D each bit is separately mapped to a different point in the database needing a total of 64 descriptors a 18 overhead 8 data 4 x 8 descriptors 58 bytes b 18 overhead 8 data 64 x 8 descriptors 538 bytes 2 6 Data conversion The conversion of data between standard MODBUS format and the LIN database format is described here 2 6 1 Data conversion of digitals MODBUS digital signals can be mapped onto database bitfields booleans and alarms The following rules apply to mapping these types into the MODBUS address space W Bitfields can be mapped individually or as a complete set of 8 or 16 bits onto the MODBUS address space W Booleans are mapped onto a single bit in the MODBUS address space W Alarms are mapped onto a single bit in the MODBUS address space A value of 1 for this bit corresponds to the In alarm status 2 6 2 Data conversion of registers AII data types can be mapped onto single registers in the MODBUS address space How ever special care should be taken when mapping database values that require more than 16 bits in particular 32 bit integers and floating point numbers W Values requiring up to 16 bits of storage Database values that require up to 16 bits of storage one or two bytes are mapped directly onto a single register This includes 8 and 1
187. matic eicere rtr ree tenth 5 8 Strategy 1 I O customer terminals eee 5 8 Strategy 1 function blocks and parameters 5 10 I00pzl 5er peer AE AA OE PEUT 5 10 L00p 4 a dot o eee o rie RE dies 5 15 Strategy 2 Dual control loop sese 5 16 ONE LOOP OF tWO creta heri tox ere rh eere siente 5 16 Strategy 2 schematic Strategy 2 I O customer terminals sees 5 18 Strategy 2 function blocks and parameters 5 19 L00p L4 oie epe ERR IERI lane EEUS 5 19 L60p 2 bim dte pete ER RID rots 5 19 L60p 4 ie NR Rte ien 5 23 Strategy 3 Dual control loop cascade 5 24 Cascading a pair of loops 5 25 Strategy 3 schematic eseessesesssesersesesesesestresestsersseseeeeeeersesesese 5 25 Strategy 3 organisation sss 5 27 Master amp slave 3 ates ep tein ERES 5 27 Blocks amp connections sess 5 27 Loop Update ates eet t ro 5 27 Strategy 3 operator interface sess 5 27 Strategy 3 I O customer terminals sese 5 28 Strategy 3 function blocks and parameters 5 28 Strategy 4 Dual control loop Ratio sss 5 29 Strategy 4 schematic sss 5 31 Strategy 4 organisation sesssseseeeeeeneenees 5 31 Master slave amp ratio station
188. munications Bil d aximum resources supported 11 6 umper links sessie 221 Af aximum sequencing aud RNC A l resources supported sssess 11 7 MeCGSPOS essct er POR Theo WU Soin K Memory x ose crier t Oe eren nena Keeping the product safe sce 24 module 222 228 92 101 A3 Killed Gut Us qu eire pieno Nc 229 ker d serene un module removal 222 A3 use and requirements B 10 Memory requirements 2 23 Misuse of equipment 24 Modbus AEG MO DICON hesse B 17 J BUS address 2 ect B 17 local setpoint JBUS function codes scc B2 displaying SAMENG a cesses 212 JBUS implementation B 17 Ts comms overview E dnd B 1 LOOP diagnostic function codes T B 15 Loop downloading configuration B 12 sconce made i AE MODBUS protocol ued ee 11 6 UR Mood noD a E d Den ee M O DBUS JBUS COMMS B l OPR eae Mode changes crrr 4 3 LO O P N message cen a gt MOda ae a scan he LP n ALM M e LDAP 47 102 Motherboard 222 9 1 A3 Msc 2 gst eg ae sage eee f customer terminals ssss D6 M DIL switchbanks secsec 2 33 Motherboards ccecce 2 14 M Manual pushbutton 38 Mounting clamps 2 10 M004 rerien CRM LT o RM 43 M007 memory module 4 6 7 Main CPU iienaa ed cetus 2 18 9 1 N Hn n T NAH MM UE 42 75 N etwork filing system task 73 Main pr
189. n when power down occurred the T640 searches its EEPROM area for a PKn file with the same n value as that specified by switches 6 7 and 8 If it finds a matching file it uses this to establish the name of the required strategy If no match is found in EEP ROM the T640 then searches the ROM area If a match still cannot be found i e the PKn file is missing the T640 adopts an idle state and no database is run NOTE This memory area search order is why step 2 is necessary 6 Having determined the required filename the T640 then checks if the corresponding DBF file is already in EEPROM It won t be if this is the first time the strategy is being used If it were found the database would be loaded directly to RAM and run If not found the T640 unpacks the compressed PK7 file loads it to RAM and runs it An unpacking database message appears on the front panel while this happens 54 T640 Reference M anual amp User Guide Issue 5 Standard strategies Design principles off off off No new strategy selected on off off Strategy 1 selected off on off Strategy 2 selected on on off Strategy 3 selected off off on Strategy 4 selected on off on Strategy 5 selected off on on Strategy 6 selected on on on Strategy 7 selected other ERROR invalid selection p Figure 5 1 SW 1 switch settings for strategy selection NOTE The SWI strategy selection swi
190. nal CJC Wi To provide a frequency totalisation input via terminals 1T and 1V ground run an AN IP block with SiteNo 1 Channel 3 and InType Hz H To provide digital outputs from a DGPULS 4 block via terminals 2W 2X 2Y and 2Z ground you only have to set SiteNo 2 there are no Channel or OutType param eters in this block The block outputs its Chan Chan2 and Chan3 digital signals via terminals 2W 2X and 2Y respectively relative to 2Z as ground Consult Chapter 11 Specifications for a list of all software blocks supported by the T640 and for information on the level of this support for specific block parameters provided by the various I O boards available The LIN Blocks Reference Manual Part No HA 082 375 U003 gives full details of all LIN based software block parameters but must be read in conjunction with the specific I O board data given in Chapter 11 Some examples of I O circuits are also given in Chapter 11 T640 zero volts schematic Figure 2 7 shows schematically T640 s internal zero volts and power supply arrange ments and associated customer screw terminals The power supply units feed the main CPU I O board s front panel and RS422 485 power supply unit via a low voltage power supply bus The GND terminal connects directly to the instrument case and via wires to terminals 1 and 2 which must not be used for external connection 2418 T640 Reference M anual amp User Guide HA 082 468 U003 Issu
191. nalogue input Channel 3 AN IP InType Volts 1H S Analogueinput Channel 3 AN IP InType Volts 2 N Analogueinput Channel 4 AN IP InType Volts U ogei put Channel 4 AN IP InType Volts K Wh alogue ground 1K S Analogue ground 2L N Analogue output Channel 1 AN OUT OutIype Volts JIL N Analogue output Channel 1 AN OUT OutType Volts MJA alogue output Channel 2 AN OUT OutIype Volts 1M N Analogue output Channel 2 AN OUT OutType Volts 2N N Analogue ground 1N N Analogue ground 2P amp Digital input Bit 1P N Digital inpu Bit0 Cy ee DG IN nType Volts i V ae ba DG IN nType Volts 2R N Digital input Bit2 1R N Digital inpu Bit2 28 N Digital input Bit3 1S N Digital inpu Bit3 2T Digital output Bit0 1T Digital output Bito E Digital output Bitl 1U 3 Digital output Bit res NIK Digital output BO DG OUT 1V N Digtal output Bio Nee AW Disital output Bits IWS Digital output Bi ene 2x NJ Not connected 1X N Pullup 15Vout OR 24Vin Chan1 Chan4 resp 2Y S Digital ground 1Y N Digital ground 27 N Digital ground 1Z S Digital ground NB SiteNo Channel amp Bit numbers refer to the associated I O function block s corresponding parameters Pullup connects internally to digital outputs of both sites Table 2 2 Customer terminals for
192. name RCD Record file used by RECO RD block Table 2 5 1640 file types 8 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Power up routine CONTROL STRATEGIES amp SEQUENCES LINtools Control strategies DBF files actions and action files STO files and sequences SDB files to be run in a T640 may be configured and downloaded using the LINtools package installed in a PC This is described in the T500 Product Manual Part no HA 082 377 U999 You will need to consult the LIN Product Manual Part no HA 082 375 U999 for full details on how to configure the control strategy function blocks to run in the T640 in strument Standard strategies Instead of creating your own control strategies from scratch you can use one of the pre configured standard strategies supplied with the instrument These strategies may be run as supplied with only block parameter values edited to suit your plant requirements This parameter editing can be done directly via T640 s front panel as described in Chapter 4 User interface The tutorial in Chapter 3 also gives you some practice at editing the pa rameter values of a standard strategy via the front panel Alternatively you can use one of the standard strategies as a starting point and more exten sively edit it in LINtools control configurator by adding and removing blocks and con nections to create a new strategy that more exactly meet
193. nditions amp diagnostics CPU WATCHDOG Watchdog output The instrument is provided with a watchdog output on the main processor unit which flags an alarm condition if the processor fails If the watchdog trips the processor is reset and restarted Watchdog relay A relay output is provided to indicate that the watchdog has tripped The contacts are closed when energised and in the healthy condition but open if the CPU fails Addition ally the front panel 5 digit display flashes CPU FAIL until the processor has been re started Loop fail The CPU can also force the watchdog into alarm to flag if a loop user task fails to run or if the database halts This facility may be enabled disabled via the motherboard DIL switchbank SWI switch 5 see Figure 2 12 in Chapter 2 Hardware configuration sec tion If a loop fails to run the outputs assume the state defined in the OPTIONS CPUFILo field of the output block e g low User alarm The watchdog relay can also act as a general purpose user alarm via the T600 block s UsrAlm field A TRUE input to UsrAlm from the control strategy opens the relay con tacts A FALSE input closes them but is overridden by a watchdog alarm Main processor CPU fail Both I O cards and the front panel microprocessor can detect failure of the main CPU by virtue of there being no activity on the internal serial bus In this case the front panel re places the normal 5 digit PV display with
194. ned in the T640 can be accessed as both an input or an output as convenient This follows the JBUS implementation of MODBUS B2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 O DBUS JBUS UN communications AppB 2 INTERRUPT SERVICES INTERRUPTS CIO amp MODBUS PARSER 1 0 INTERFACE Network FILING SYSTEM DATABASE DATABASE TASKS E SERVICES FILING SERVICES Figure B 1 1640 software structure 2 PRINCIPLES OF OPERATION The T640 functions as a standard controller on the LIN and can communicate with other LIN ALIN nodes via cached blocks and communication blocks The T640 operates in one of two modes either as a MODBUS master or a MODBUS slave The configuration and operation in these two modes have a number of similarities but there are also significant differences The operation of the two modes is described here The LIN database groups data into blocks of related data For example a block can repre sent an input an output a controller and so on The LIN configurators and display pack ages recognise different types of block and handle them appropriately T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B 3 AppB 2 1 MO DBUS JBUS LIN communications In contrast the MODBUS registers and bits are simply a list of data points In general there is no predefined structu
195. nel i Task 1 output Task 2 output Front panel task i Task 3 output Task 4 output Front panel loop select Figure 7 2 1640 s logical amp physical front panels T640 Reference M anual amp User Guide Issue 3 A 7 5 Task organisation User task server operation As already explained a higher priority user task server always interrupts the running of a lower priority user task server It follows from this that whenever a given user task is run ning all higher priority user tasks must have run to completion This fact is fundamental to achieving coherence of data flow between tasks Figure 7 3 shows schematically the sequence of events that occurs during the running of a user task server These are as follows 1 7 The user task requests that all I O hardware read the required data and be brought fully up to date The task is suspended until this has been carried out The user task is then marked as busy During the busy period no writes are al lowed to any of the blocks in the user task Any write attempts are directed to a queue with the exception of single connections into cached blocks All connections sourced from higher priority tasks are then copied into their destina tion blocks in this user task This occurs as a single indivisible operation As was noted above all higher priority tasks must have run
196. nfiguration essent 2 21 Status level information cee eee eeeeseteeeeeseeeeseeseeeens 2 21 Internal layout reete teet eene etri hence 2 22 Memory module removal eere 2 22 Memory module compatibility eene 2 22 Memory requirements rer repetere totins 2 23 Main fUSe ao gast RE EIER TE URNEER 2 23 Switchbank 2 ueniet ueniet et eU QD 2 24 Switchbank 2 e irte tee e sie eterne 2 26 Serial communications jumper link amp switches 2 27 Binary RS422 configuration sse 2 27 MODBUS RS422 485 configuration sse 2 27 Software file Types iue cene i anniv EN ARSA 2 28 Control strategies amp sequences sss 2 29 Bhce M 2 29 Standard strategles vi sites er n Tee re aea Eden eus 2 29 Powet up TOULITE 4e mtn ere eer eere e eti 2 29 Contents 2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents Chapter 3 W O Cards cert rtt mh rrt encased eer e Ren 2 29 Database acquisitiOni ucro teet me yeso re teer ein ento eed 2 29 US r task Startup sissies eoe ore ere there edes 2 32 Tepid dat noraa e ente er e meets 2 32 Motherboard DIL switchbanks enne 2 33 Brownout alarmi aisinn nennen nnne 2 34 Power up displays 2 34 Normal power up seseeeeeeseeeeeenneee nennen eene 2 34 Error codis ien rac t A etes
197. ng sess 234 104 T950 infrared operating security key 4 9 W atchdog Tag display cne 3 8 42 failure Task organisation ccccececceseeeeeeeeeees 7 1 relay TCS binary Bisync protocol 5 39 Mining scettr res Tepid W rite operations voces cece BJ da tics niin 2 29 2 32 data file 228 92 Z Start pinea nnne 314 Zero volts schematic 2 18 A 1 TepidSrt Trying scce 234 10 1 Terminal COVE Rite onc eR P RR ela antes 2 10 cover removal secen 2 13 designations 2 14 Terminals irse me aee 94 Thermocouple I O wees 11 19 Thermocouple I O boards 2 17 Time sta mped alarms sssss 9 3 Timing information necer B 7 Transferring application programs 223 TUNING is cete er eda coe rrt cus 7 1 Tuto rial cce ee EE 34 U Un Pack Database 2 34 3 7 10 1 UK GO 4 roh et be ae Ae satt 4 Units display icici Pe 3 8 42 Unlocking the T640 2 12 34 Unpacking cs ins cete ec entro 2 9 User alatis bets alte tas Ee 10 5 lake mie rece 5 10 7 3 8 1 server operation 76 SEVE NS hi aie Nana CL acetate 72 Sta rtu pini oe n eee d Eee 2 32 TUNING escas ete rst tea ettet 7 1 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Index 7
198. nge any parameters in a database you must refer to this list first Check through the entire list to make sure that you also adjust all related parameters appropriately Parameters omitted from the ADJ lists are considered essential for cor rect operation of the database and should not be changed CREATING YOUROWN STANDARD STRATEGIES To convert any strategy residing in EEPROM filename DBF into a switch selectable standard strategy n you must create a dummy file called filename PKn and store it in EEPROM via the LINfiler utility in LINtools in place of the original standard strategy compressed file The dummy PKn file can be empty as its only function is to link n to the chosen root filename When you select standard strategy n via the motherboard DIL switches Figure 5 1 re minds you how to do this your custom strategy will load and run The method works be cause the T640 does not attempt to unpack decompress the dummy PKnz file provided the corresponding DBF file already exists in EEPROM T640 Reference M anual amp User Guide Issue 5 5 3 Running a standard strategy Standard strategies OTHER DOCUMENTS Refer to the 7500 LINtools Product Manual Part No HA 082 377 U999 for full details on how to use LINtools and also to the LIN Product Manual Part No HA 082 375 U999 for information on individual function blocks and LIN ALIN installation RUNNING A DEFAULT STAN DARD STRATEGY Running a def
199. nications schematic The main processor acts as master on this communications bus no other nodes can trans mit without being invited to Each slave node on the bus is given a node number in the range 0 15 Node number 15 is reserved for the front panel and node numbers 0 7 are allocated to I O cards Each I O card has switches for setting up its ISB node number Bisync MODBUS Port This port provides a Bisync slave interface for connection to existing supervisors or to industry standard MODBUS units selectable via SW1 1 via the RS422 485 driver ALIN peer to peer comms A high speed 2 5Mbaud short distance form of the LIN the ALIN is the main communications channel in the instrument used for configura tion supervision and inter instrument communication See Figure 9 2 It supports all current LIN features block attachments field writes file transfers etc except chan nel redundancy ALIN and LIN can be interconnected via a T221 bridge ALIN is provided by an ARCNET physical layer and uses the same though enhanced ap plication layer as the LIN The peer to peer enhancements synchronised realtime clock and time stamped alarms are provided by the T221 bridge Power supplies T640 has two power supply options DC input and AC input See Chapter 11 Specifi cations for details DiLswitchbanks Switchbanks 1 and 2 set T640 s comms function and address startup procedure standard strategy selection an
200. nly to this selected loop 3 Select a different loop for main display by holding down A or V to cycle around the available loops Let go when the required loop is indicated by the green arrowhead The main display now applies to your selected loop whose tagname appears in the tag display 4 Try altering a variable of the current loop e g raise its setpoint by pressing SP w and A together Note that the front panel buttons also work only on the currently se lected loop This applies also to the ALM and INS pushbuttons T640 Reference M anual amp User Guide Issue 5 325 Contents This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter 4 USER INTERFACE This chapter describes how to use the T640 front panel pushbuttons and displays to carry out all the basic operations The front panel can also indicates failure states please refer to Chapter 10 Error conditions amp diagnostics for details The present chapter concen trates on the normal running of the T640 Figure 4 1 shows the front panel with a typical display Tag display 70 Units display 5 digit display PV X 71 i O nf r1 O utput bargraph E JUUL Deviation our v MINI E bargraphs PV bargraph 2 Central SP bargraph green LED 20 Mode letter 0 PV X SF Displayed loop green arrowhead Pushbuttons Raise lower buttons Figure 4 1 1640 front panel the ope
201. ns 221 A4 SOftWate s iiim D ee n RR communications aic 5 39 Software issue number OLIVE Ra ots eed as dre a a 92 Software status level power supply unit 2418 Software structure T640 RS485 communications 11 5 SP W bargraph display SPW leg end istrict S Specifications ooo eie Safe usage of analogue inputs alkaline manganese batteries 25 current analogue outputs are Safety digital inputs cse amp EMC information 2 1 A l digital outputs oer CONG hacen tese eee tte hor ates 2 13 dot matrix display character set 114 requirements sssi 2 2 environmental symbols marked on the unit 24 front panel displays Saving a database acnee 321 highdevel O ccr Scanner task cete es B5 internal burden resistors ae Screw terminals s c 9 4 mechanical ivi iii Security power supplies sese KEY cows S a E 44 49 6 1 FOLDS esee comp rodent cuna key label sssrinin 2 9 transmitter power supplies 11 14 Serial comms voltage analogue outputs 11 14 jumper links tette 226 Standard strategies nc 2 29 option Standard strategy Serial number 2 9 Stats lBvel aussi e e e s Ja B RN 713 Strategy 1 Single control loop 5 1 Service and repairs i 2 5 Strategy 1 Single loop controller 35 Setlocaliiz nest iie i riso ENG 4 3 Strategy 2 Dual c
202. ns at 9600 baud The slave turnaround time is 50ms the T640 turnaround time is about 10ms and the transit time on the serial link is about 14ms plus 1 15ms per byte at 9600 baud which is about 0 14ms per bit Each register contains two bytes and so needs 2 3ms transmission time Two messages are involved in the acquisition T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 B 9 AppB 2 5 2 M O DBUS JBUS LIN communications The best case poll period when the system is only polling the slaves is therefore 2 x 50 10 14 16 x 2 3 16 x 0 14 187ms The time for a write to a slave is 50 10 14 2 3 76ms Thus if the system made one write between each scan the cycle time would be 187 2 x 76 339ms The update period for the scanner to database task 100 x 2 16 x 3 5 16 x 3 5 0x 100 0 x 100 312ms NOTE The T640 turnaround time of about 10ms can be significantly increased by User Task hold off if the User Tasks are heavily loaded 2 5 Memory use and requirements An area of memory is allocated to map the database parameters to the MODBUS address space This memory is allocated to tables each table representing a series of consecutive registers or bits in the MODBUS address space The table contains an image of the data in the MODBUS address space and a descriptor for each register bit or set of bits mapped onto that address space 2 5 1 Current configuration sizes
203. nt LL SL This sets a low limit for the local setpoint continued 5 12 T640 Reference Manual amp User Guide Issue 5 Standard strategies Strategy 1 continued Block Field Subfield Description Alarms These are the process alarms of the control loop N ote Priority 0 disables the alarm completely An alarm with 0 priority no longer affects the digital output HI ALM OUT 0 or LO ALM O UT 0 Priority 6 15 need to be acknowledged Priority 11 15 open the Alarm relay Alarms with priority set equal to USR_ALM Priority open the W atchdog relay HighAbs PVexceedsHAA lowAbs PV is less than LAA HighDev PV SP exceeds HDA lowDev SP PV exceeds LDA HAA High absolute alarm setting LAA Low absolute alarm setting HDA High deviation alarm setting LDA Low deviation alarm setting Dis DP Sets the number of digits displayed to the right of the decimal point This parameter is for display purposes only and has no effect on the ranging DOP 1 This block processes the digital outputs The default values in this block need not normally be al ered Invert This field inverts the sense of the digital outputs on a bit by bit basis Bit4 to Bit are not supported by the hardware Setting them will have no effect Bit FALSE inverts HI ALM O UT 0 Bitl FALSE inverts LO ALM O UT 0 Bit TRUE inverts REM AUT O UT 0 BiB TRUE inverts HOLD MAN OUT 0
204. nt panel overview of all four loops with detail of one selected loop Front panel monitor edit access to all parameter values protected by IR security key Front panel inspection of block interconnections Automatic logging of front panel parameter changes date and time stamped High speed peer to peer communications for easy connection to the LIN via bridge Serial port option for Bisync slave interface or MODBUS or for linking internal serial bus to external fascias and remote I O High level and thermocouple I O options Removable memory module for quick unit replacement and strategy portability IP65 front panel seal with instrument and database access from front of panel DC or universal AC mains supply options Sequencing available as an option Front panel messages can be displayed in languages other than English Support for foreign templates Whats in this manual Table 1 1 summarises the contents of the 7640 Reference Manual amp User Guide in a con cise form Use the Table of Contents at the beginning of the manual for a more detailed breakdown of what s in the individual chapters and or the Index at the back to locate par ticular topics Whats notin this manual If you wish to configure your own strategies for running in the T640 you will need to re fer to the LIN Product Manual Part No HA 082 375 U999 for details on all the LIN based function blocks their parameters and input output connections these are f
205. nt the complete feedback control loop consisting of the unit of plant under control together with its controller Note that it is possible to associate more than one user task with a single loop when more complex control is needed this is the case in standard strategy 6 called T640C6 for example see Chapter 5 A server is a fixed software task within the T640 that executes a user task or that proc esses cached blocks T640 Reference Manual amp User Guide Issue 3 A 7 3 Task organisation User task servers Server interactions There are five servers in the T640 one for each of the user tasks and one for the cached blocks see Table 7 1 The servers are prioritised repeat rate driven and fully coherent as described in Chapter 8 T640 s block structured database is completely compatible with that of the T100 T1000 instruments and supports cached blocks in the same way Server 1 has the highest priority and server 5 the lowest Interruption of one server by an other of higher priority has already been described above under Task Scheduling The user task servers are set to run no more than once every task repeat time as specified by the corresponding T600 block MinRptn parameter Figure 7 1 shows schematically how the five servers interact with each other according to their priorities The shaded bars represent running tasks and the unshaded portions repre sent suspended tasks Note that each user task produces
206. ntiguous table entries for a multi param eter read 2 2 Master mode In master mode the MODBUS interface has two main purposes Wi To allow the T640 as MODBUS master on the serial link to read values from or write values to registers in a remote slave device such as a PLC Wi To read data from a slave and translate it into a standard LIN data block The 16 available MODBUS tables each configurable for digital or register data allow support of up to 16 slave devices subject to data type Figure B 3 shows a possible mapping between a LIN database and MODBUS registers The mapping between the two systems user defined The configuration allows gaps to be left in the MODBUS data registers if required The MODBUS interface functions by keeping a copy of relevant parameters in MODBUS format This copy is updated by a task that polls slaves across the MODBUS network In addition a scanner task compares the values in the database with the copy and is responsi ble for keeping the two sets of data in line When the polling task detects that a value has changed from the previous value in the copy it updates the copy and tells the scanner task to transfer the value to the database T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 B5 AppB 2 3 1 MO DBUS JBUS LIN communications LIN database blocks MODBUS registers or bits in master instrument copy transfer new value from database update to remote Slave
207. nual block 7 station block ow ee ES Figure 5 9 Strategy 4 schematic 5 30 T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 4 Ratio pair Strategy 4 schematic Figure 5 9 shows schematically the main function blocks in the strategy the principal sig nal flows between them and their associated customer terminals Details of each terminal and block are given in the tables that follow Strategy 4 organisation Master slave amp ratio station The strategy has been internally connected to make Loop 2 the master controller Loop 1 the slave and Loop 3 the ratio station Normal amp inverse ratios The ratio value may be entered and displayed as the ratio of Loop 1 s PV to Loop 2 s PV or the other way round See SWS_1 Bit7 in Table 5 5 on page 5 10 Normal and inverse ratio are defined as follows B Normal Loop SP Loop PV ratio setpoint W Inverse Loop SP Loop2 PV ratio setpoint Modes Loop 1 can to go into ratio mode for all operating modes of Loop2 However if Loop 2 s process variable PV becomes invalid Loop 1 reverts to Auto mode Ratio control will only resume once Loop 2 s PV has re established and Loop 1 s R button is re pressed With Loop 2 not used for control the T640 can be used as a single loop controller with ratio input Ratio setpoint trim The ratio Setpoint trim input is customer terminal 1F in place of the unused rem
208. o mean as short as possible At database startup time the T640 estimates the execution time of each user task com pares the estimate with the requested MinRptn time and so derives an estimated percent age of total CPU power required for each task If the required CPU power exceeds what is available T640 automatically increases the user task minimum repeat times to workable values Note that the T640 s estimates can be approximations only Many block types have vary ing execution times that depend on operating parameter values and dynamic changes to ALIN loading e g increasing numbers of remote instruments starting to cache blocks within the local instrument These factors can make the original estimates inaccurate Automaticdynamictuning To compensate for the variable nature of user task execution times T640 continuously monitors the spread of CPU loading across its various tasks both user tasks and system tasks and adjusts user task repeat rates dynamically to ensure a fair spread of CPU allo cation This dynamic tuning is adequate for most applications but where task repeat timing is critical you may want to adjust the MinRptn values in the T600 block to get the best performance for your particular system Dynamic tuning attempts to adjust user task repeat rates to allow the Scan task to complete one database scan typically every 2 seconds but never less often than once every 4 sec onds Manualtuning Th
209. o this file possible you will have to delete another file with the same extension called T640C1 PK1 stored in the T640 s EEP ROM If you don t the EEPROM file will run instead of the ROM file and the tutorial will be impossible to follow Don t worry about deleting the file it is also supplied on the floppy disk accompanying this manual and can easily be reinstated in EEPROM if re quired NOTE The reasons for having to delete this file are to do with the way a T640 powers up This is detailed in Chapter 2 in the section Power up routine and also in Chapter 5 under Running a default standard strategy Deleting the T640C1 PK1 file To do this you will need to run the LINtools package on a PC installed with an ALIN card allowing it to communicate with the T640 Please refer to the 7500 LINtools Product Manual Part No HA 082 377 U999 for details The procedure is briefly 1 Withdraw the T640 from its sleeve and note the ALIN address hex set up on DIL switchbank SW2 on the motherboard Refer to Chapter 2 for details on how to carry out these operations and the precautions to be taken How to read SW2 is explained in Figure 2 13 in the Hardware configuration section Replace the T640 in its sleeve then connect customer terminals 21 and 22 to the ALIN card installed in the PC Use a short twisted pair cable terminated with an RJ11 jack plug for the ALIN card and bootlace ferrules for the T640 Accessing the customer te
210. ocessor CPU fail 105 LLENO rketa Ska enaa eni aet js N o K8y iii eeestee een praster A 4 9 ndex 4 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Index N R NOA iot teehee Rs 4 7 Pre configured strategies 5 1 N ode NUMbeEr ccc 9 3 Priorities rosse eed eN 104 N on coherent data transmission 8 2 TASKS oett tit e ues 7 1 Normal amp inverse ratios ssss 5 31 Process variable alarms 5 16 Normal powerdp ncccsser 2 34 Processor clock speed 222 Protective earth connection 2 2 Oo Protocol address sere B 17 On off control 323 Pushbutton masking cere 324 O perating mode PV selectillg ttt acere tats 343 display eects een 42 O perator displays amp controls 42 fail mode sgan 323 Q ptighis decocti eee tte n ded 12 1 tracking of by setpoint 323 Oder Codes cds necis vector 2 9 PV X bargraph display ssuueseesss 4 2 Ordering information scce 124 PV X legend senenin 4 2 QU TPU Ts cocto tt tee pe en a deal 4 3 O utput Q bafgraphi iis vie ma ds 4 3 Q uitting CHANGING 3st dere aient 4 3 alarm inspection modes 4 7 display aeui CEDE 4 3 database access modes 4 6 parameters quick access 4 3 O vercurrent protection 2 3 R RAM Losses bate 223 92 P Ranges amp limits P amp I piping and instrumentation configuring cecer 3
211. ocessor M S Relay 2 Alarm O P trot ip 3 8V Outputs 2 Watchdog O P E IR 45V de A Detector J j lt 5V Power l AC mains d exe up RAM Main CPU m 412V Suppl ik Displays la status CUPPIY 4 Dual DC a ry t Sway status Comme T L aie ALIN isolated connector Interface 5t 5 RS422 485 isol ese C ay eee a oa EPROM bes i connector 22 way terminal OOOO EPROM PS mnis lemory i Pushp ttons EE module ISB 18V 5V pit Switehibanks Y To I O board s Figure 9 1 1640 Functional block schematic Motherboard The motherboard is the main electronics board in the instrument to which all other sub assemblies connect It carries the main CPU communications electronics power supply and the two configuration DIL switchbanks Main CPU The main CPU has its own limited I O to read the configuration DIL switches and the power supply status It also provides a watchdog output to indicate the health of the proc essor and a common alarm output Both these outputs are available at the rear connectors T640 Reference M anual amp User Guide Issue 3 A 9 1 Inside T640 Details on the operation of the watchdog and alarm outputs are given in Chapter 10 Error conditions amp diagnostics Memory Memory consists of EPROM for T640 firmware EEPROM for databases standard strate gies and logfiles and static RAM for the working memory and operational d
212. ock as before If you ve forgotten how to do this have a look at the previous section again to remind yourself HAA specifies the high absolute alarm limit on PV i e the PV value which if exceeded trips the high ab solute alarm which you will inspect soon Its default value is 100 00 Press INS to access value update mode and lower the HAA value to 70 000 units Press INS three times to return to field access mode In the same way set LAA low absolute PV alarm to 30 000 and set HDA amp LDA high and low deviation alarms respectively to 10 000 each Configuring the decimal point 1 Access the Dis DP field which stores the decimal point position used in the 5 digit and the units displays To do this quickly you can once into field access mode just press the A button once to get you directly to the end of the field list which is cyclic 2 SetDis DP to 3 decimal places then press A to return to the normal display and see the effect of this change Alarm subfields In this next stage of the tutorial you inspect the subfields of the Alarms field in the SETP1 block To do this 1 2 Use the INS button as before to access the Alarms field in the SETP1 block Press INS again This time instead of entering value update mode you see SubFd in the green units display denoting subfield access mode This is because the Alarms field consists of a set of subfields unlike the range and limit fields you have met so f
213. ombined v Y A LowAb SubFc UnAcd ALI TON Hardware Hardware AlAck A AlAck UnAcd es ACKNOWLEDGE Alarm gt T 7 TON TON Figure 4 3 Alarm inspect button functions ALM 4 8 T640 Reference Manual amp User Guide Issue 5 User interface Security key SECURITY KEY Access to T640 s database via the INS pushbutton is protected by the T950 infrared oper ating security key Using INS is described in an earlier section Database access Key parameters Each key is factory programmed with three parameters whose values are marked on the key label There is also a space for entering the keyholder s name The parameters are W Access Specifies how much of the database is accessible to the keyholder Full accesses all parameters Partial accesses the limited default set of parameters specific to each function block or a set defined during strategy configuration in LINtools Note that the T600 block s NoKeyFul and NoKeyPrt parameters if set TRUE allow full or partial access respectively without needing a security key E Area Specifies by an area number 1 8 what databases are accessible to the key holder The area number must match the T600 block s AreaNo parameter to gain ac cess except when AreaNo is zero allowing any key access the database A key can also have an Area of zero giving it
214. ommunications is concerned This allows the T640 to be inte grated into existing 6000 instrument based systems Setting up the RS422 node address is done within the SL661 SL662 and SL663 blocks MODBUS J BUS This too requires the RS422 RS485 option To set up and download the MODBUS tables to the T640 you need T500 LINtools A full explanation of the configuration of the MODBUS interface is given in the 7500 User Guide Part No HA 082 377 U005 T640 Reference M anual amp User Guide Issue 5 5 39 Contents This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter6 CHANGES LOGFILE LOGFILES The T640 maintains in EEPROM a logfile of every parameter change made via the front panel database access mechanism 1 e via the INS button Please refer to Chapter 4 User interface for full details on database access and use of this button The logfile contains a complete record of what was changed when it was changed and by whom Logfile organisation The logfile adopts the same root filename as the DBF file from which the database was loaded but with extension Lnn where nn is the logfile number ranging from 01 to 99 When a logfile becomes full i e has reached 1Kbyte it closes and its number is written to the T600 block s Log File parameter The previously held file is deleted When more logfile data is generated a new file with incremented logfile number is automatically
215. onding parameters These terminals are used to factory calibrate the CJC sensors Connecting to them could invalidate the calibration Table 2 3 Way occupied by sensor Customer terminals for thermocouple I O options Site 2 left amp Site 1 right T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Zero volt schematics Installation amp startup Linking the terminals to I O software function blocks To effect the link you must configure where applicable a suitable I O block s SiteNo site number Channel InType or OutType parameters as indicated in Tables 2 2 and 2 3 Other block parameters can be configured to specify operating modes ranges power up states etc as detailed in the LIN Blocks Reference Manual Examples high level I O option HM Table 2 2 shows that to provide an isolated current analogue output via terminals 2A and 2B you must run an AN_OUT block in the T640 with its SiteNo parameter 2 Channel 3 and OutType mA HM To provide a non isolated voltage analogue output via terminals 2L and 2N ground run an AN OUT block with SiteNo 2 Channel 1 and OutType Volts Examples thermocouple I O option WI Table 2 3 shows that to provide a thermocouple input with internal cold junction compensation via terminals 1E and 1G you must run an AN IP block in the T640 with its SiteNo parameter 1 Channel 1 and InType mV Int Setting InType mV Ext specifies exter
216. only see under Strategy 4 Ratio control for details TRIM 3 1G Analogue Gnd Reference ground for analogue signals 1H SPTRI Setpoint trim voltage input TRIM 1 RATIO BIAS Ratio bias input Strategy 4 only see under Strategy 4 Ratio control for details 1 TRACK The contro output is forced to this value if the TRACK EN 1 signal is high TRCK1 1K Analogue Gnd Reference ground for analogue signals IL 3TOUT Control output signal as a voltage OP 1 SWS 1 1M PV SPOUT Retransmitted process variable or setpoint output as a voltage PVOP1 Process variable is the default SWS1 IN Analogue Gnd Reference ground for analogue signals 1P COMPEN 0 W hen high this digital input disables parameter changes via the comms links DIN 1 It does not prevent parameters being read This input does not affect M O DBUS 1Q REM SPEN 1 W hen high this digital input allows the remote setpoint to be selected from the DIN 1 front panel provided a signal is connected to REM SP IR TRACKEN l W hen high this digital input forces the control output to follow the TRACK input DIN 1 1S HOLD EN 1 W hen high this digital input forces the control output to freeze DIN 1 1T HI ALM OUT O This digital signal goes low if the controller is in high absolute alarm DOP 1 or high deviation alarn 1U 10 ALM OUT 0 This digital signal goes low if the controller is in low absolute alarm DOP 1 or low deviation alarm 1V REM AUTOUT O This digital output goes low if the controller is not
217. ontrol loop 5 16 Setpoint Strategy 3 Dual control loop HANGING zeeseeeta tulere 4 3 cascade cseteris 524 display oett eec teta 4 3 Strategy 4 Dual control loop parameters quick access 44 Ratio eere cse Setting up early boards vc A 1 Strategy design principles Setup sheets 5 10 5 36 Eg EE Shipping damage 2 9 Subfield Access mode ssssssse Site 11 0 oae rer een ces 243 SUDTIEINS crece era s 8 2 m E CUO ed ET 5 16 Summary display area terminations oeeccecceceeceeecseceeeesees 5 18 Summary loop displays Site 2 M Q correre ctor Vett t Rm 243 SUpercap acce eae oa Slave Switch settings heyen drea CONTONE re iio er ee 527 Switchbanks 1 amp 2 NOME ESE EEE AEEA NN 9 3 SWITCHES vice nero d vete a ern Slave MO des e oO B4 Symbols marked on the unit 24 diagnostic table registers B 14 System filename vce 2 28 92 error codes ieee B 16 System routines 2 28 UMING iecore rece at ee nates B 7 SIG OVE c oie bic rd ed pcs Dict 242 Index 6 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Index T Z T v T22 T bridge s de peteret 93 VALUE ro Pr rect qe irs 4 6 T640 Value update Mode eee 4 6 base unit eere thes 114 Ventilation tette 24 internal layout sss 222 A3 removing from sleeve ecce 34 W software structure eee B2 W arm start esses 2 29 3 14 T901 memory module 222 WarmStrt Tryi
218. op These buttons are automatically masked in this strategy as a safety precau tion in certain alarm conditions Restore Bit9 to FALSE T640 Reference M anual amp User Guide Issue 5 Tutorial Cold start enable Warm start enable Strategy selection x i 4 selected B J Figure 3 11 SW 1 location and settings strategy 4 HANDLING MORETHAN ONE CONTROLLOOP You have nearly completed this tutorial which has used as its example strategy 1 a single control loop When there are two three or four control loops in a strategy the front panel display is able to show you a summary of the status of all the loops at once together with a more detailed display of one selected loop To see how this works in practice load strategy 4 which has three control loops in it 1 Withdraw the T640 from its sleeve and set the strategy select switches to 4 Figure 3 11 shows the required SW1 switch positions 2 Replace the T640 in its sleeve to power it up After the initial database unpacking strategy 4 starts to run and you now see three deviation bargraph displays illumi nated instead of just one each applying to one of the control loops Under one of the deviation bargraphs will be the green arrowhead this identifies the loop currently selected to occupy the main fascia displays Its loop tagname is dis played in the tag display at the top of the fascia and the rest of the displays refer o
219. ore about the standard strategies via the PC based LINtools package and for the EEPROM strategies by accessing special text files Complete strategy specification via LINtools For a complete specification of any of the standard strategies you should load it from the disk supplied with this manual into the LINtools configurators where you will be able to see and print out all the block structure diagrams and every parameter value and block connection You will also be able to read the in built help comments on each feature of the strategy and modify the strategy as far as required Text files on the strategies supplied in EEPROM Text files are supplied on the floppy disk accompanying this manual that describe the six strategies in Table 5 1 in some detail These are not available for the fixed function strat egies You can view them as simple text files on a PC and print them out on most print ers The files are of two types filename DOC and filename ADJ filename being the name of the strategy DOC files The DOC files contain comprehensive descriptions of the strategies in cluding I O allocation operator amp engineer interfacing control implementation failure responses and power up conditions ADJ files The ADJ files list the strategies user adjustable parameters These have been selected to let you tailor the strategy to your precise needs via T640 s partial inspect mode If you intend to cha
220. ortant to connect the controller in accordance with the wiring data given in this handbook Wiring installations must comply with all local wiring regulations Any wiring that is Hazardous Live as defined in EN61010 and UL3121 1 must be adequately an chored Disconnecting device In order to comply with the requirements of safety standard EN61010 and UL3121 1 the unit shall have one of the following as a disconnecting device fitted within easy reach of the operator and labelled as the disconnecting device for the equipment W A switch or circuit breaker complying with the requirements of IEC947 1 and IEC947 3 WA separable coupler that can be disconnected without the use of a tool WA separable plug without a locking device to mate with a socket outlet in the build ing Overcurrent protection To protect the unit against excessive currents the power supply to the unit and power out puts must be wired through independent external fuses or circuit breakers A minimum of 0 5mm or 16awg wire is recommended Use independent fuses for the instrument supply and each relay output Suitable fuses are T type IEC 127 time lag type UL recognised as follows WB Instrument supply 85 to 264 Vac 2A T Wb Instrument supply 19 to 55 Vdc 5A T E Relay outputs 2A T Installation category voltages The unit should not be wired to a three phase supply with an unearthed star connection Under fault conditions such a supply cou
221. ote Setpoint input Strategy 4 function blocks and parameters This strategy has four user tasks seen as LOOP 1 LOOP 2 LOOP 3 and LOOP 4 in the tag display that you can access via the INS pushbutton to configure their func tion blocks The parameters in Loops 1 and 2 deal with configuration of the respective slave and master control loops those in Loop 3 deal with the ratio station and those in Loop 4 cover system alarms and general instrument setup Loops 1 2 and 4 are the same as those of strategy 2 which were tabulated in Tables 5 5 5 8 and 5 6 Loop 3 s configurable blocks and parameters associated with the ratio station are listed in Table 5 10 below When you come to configure these parameters you will find the setup sheets for this strat egy helpful because they list the default values of all fields and include a spare column for you to record your customised values where required You may want to use photocop ies of the printed setup sheets as your working documents The setup sheets for this strat egy are found under Setup sheets all strategies on page 5 34 NOTE The order of the blocks in the table may not match their order of appear ance when you access them via the INS button Block Field Subfield Description 51663 This block needs attention only if Bisync communications are to be used Instr No Slave address of the control loop s 6366 emulation on the Bisync communications bus
222. ote set point input for Loop 1 The function block RSP_1 does not exist Ratio bias The function of ratio bias is achieved through Loop 1 s SP TRIM This input operates to make the bias function as Ratio bias or 1 Ratio bias depending on the ratio set ting option NOTE Ratio bias does not perform the function 1 Ratio bias Filtering SETP2 PV is filtered before calculating the remote setpoint for SETP1 The filter is also applied prior to the measured ratio calculation The filter prevents open loop disturbances in Loop 2 s PV affecting the closed loop performance of Loop 1 T640 Reference M anual amp User Guide Issue 5 5 31 Strategy 4 Ratio pair Standard strategies Loop update rates The update rate of each loop is 320ms Strategy 4 operator interface The ratio setpoint is adjusted by selecting Loop 3 and raising or lowering the setpoint Ratio control is achieved by pressing the R button when Loop 1 is selected If Loop 1 is not in Remote mode the two loops will act independently although the measured ratio is still shown Strategy 4 I O customer terminals Strategy 4 uses a pair of I O boards located in sites 1 and 2 of the T640 accessible via customer terminals 1A to 1Z site 1 and 2A to 2Z site 2 These terminals and functions are almost the same as those for strategy 2 given in Tables 5 4 and 5 6 The exception is terminal 1F which is here the Ratio Trim input instead of the Rem
223. ound in the LIN Blocks Reference Manual section 1 2 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Introduction Chapter Topics 1 Introduction Summary of T640 features packaging amp place in the wider network 2 Installation amp startup Getting T640 going from unpacking to power up 3 Hands on tutorial Practical experience in using the T640 controls with a real strategy 4 User interface Using T640 frontpanel controls amp displays explained 5 Standard strategies Details of the four simple pre configured control strategies supplied in RO M 6 Changes logfile How T640 records every change to a loaded database 7 T640 task organisation How the running of T640 amp the control strategy interact Timing optimisation 8 Data coherence The concept of data coherence and how T640 achieves it 9 Inside T640 Internal hardware pcbs and communications 10 Error conditions amp diagnostics Error displays amp diagnostic messages 11 Specifications Hardware amp software specs Resources supported Example I O circuits 12 Ordering information How to order T640 with its various options amp accessories Appendix A Setting up early boards Issue 6 and older Appendix B MO DBUS JBUS UN communications Implementation in the T640 Appendix C Frontpanel foreign language support Customising the standard messages Table 1 1 Topics covered by this manual You will need this data to be able to select interconnect and
224. output range is fixed at0 100 HL OP High limit for the control output in LLOP Low limit for the control output in OP 1 This block processes the control voltage output It follows the 4 20mA output O utput inversion can ot be performed by reversing the values in HR outand LR out SWS 1 W Field1 Bitl does this HR out The output voltage representing 100 0 if SW S 1 W Field1 Bit2 is TRUE LR out The output voltage representing 0 100 if SW S 1 W Field1 Bit2 is TRUE Table 5 5 Loop 1 parameters T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 1 Loop 4 Table 5 6 lists the Loop 4 parameters for strategy 1 together with explanations of their functions Block Field Subfield Description USR_ALM This block controls watchdog relay output Priority Range 0 15 The priority of the alarms that are required to open the relay must match this setting T60_ This block contains the basic options of the controller as an instrument The in the name will be replaced by the node number in hex when the strategy is loaded E g C6 O ptions any of the subfields have no relevance to this application They are included here because they appear during use of the INS button FPdisl Leave as default FALSE FPdis2 Leave as default TRUE in the single loop controllers FALSE in the dual loop cont
225. p 3 as slave amp loop 4 as master Each pair can be standalone or can accept a remote setpoint to the master Both analogue amp time proportioned digital outputs are provided 3 T640C3 Two simple PID control loops with raise lower digital outputs each acting as a stan dalone controller or as a cascade slave to another controller The use of position feedback for display purposes or of limit switch feedback signals is optional 4 T640C4 Two PID control loops loop 1 controls to a remote setpoint in ratio to loop 3 s PV The ratio is set and displayed on a ratio station in loop 2 Loop 3 can accepta re mote setpoint from another controller as can the ratio station Both analogue amp time proportioned digital outputs are provided 5 T640C5 Two PID flow control loops with temperature and pressure corrected flow measure ments Each loop can actas a standalone controller or as a cascade slave to an other controller Both analogue amp time proportioned digital outputs are provided 6 T640C6 Two PID control loops with heat cool type outputs each acting as a standalone con troller or as a cascade slave to another controller Both analogue amp time propor tioned digital outputs are provided for the heat and the cool outputs of each loop Note that separate PID control functions and displays are used for the heat and the cool phases of each loop the firstloop uses loop 1 heat and loop 2 cool the second loop uses loop 3
226. parameterise the blocks in your control strategies How to use the PC based LINtools database configurator to create and download control strategies and sequences is described in the 7500 LINtools Product Manual Part No HA 082 377 U999 General information on installing commissioning and using the LIN is given in Section 2 of the product manual you are now reading in the LIN ALIN Installation amp User Guide Part No HA 082 429 U005 Getting started The quickest way to get going with your T640 is to turn directly to Chapter 3 and work through the hands on tutorial set out there For this all you will need is a T640 instru ment a power supply a piece of wire and a screwdriver If you are new to the T640 there is no substitute for actual practical experience with the instrument just reading about it is not the same The tutorial will quickly teach you how to navigate around T640 s user interface the front panel and also introduce you to the simplest of the standard control strategies supplied in the memory module After that you will be ready to start customising a se lected T640 strategy to suit your plant control needs based on the detailed information given in Chapter 5 Standard strategies T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 1 3 Contents This page intentionally blank T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Chapter 2 INSTALLATION
227. ple a pair of flow rates are controlled to maintain a fixed ratio between them MASTER Loop 2 Local setpoint PV 2 3T OUT RATIO STATION Loop 3 Measured ratio display Ratio setpoint trim Peseta hte Mold gt Divide by ratio setpoint SLAVE Local Loop 1 setpoint PV 3T OUT Figure 5 8 Example P amp I diagram for strategy 4 Ratio bias T640 Reference M anual amp User Guide Issue 5 529 Strategy 4 Ratio pair Standard strategies LOOP 2 INPUT T NAE RT i TRANSMITTED Master area l PID CONTROL OUTPUT area PV 2 area PVOP2 analogue PV analogue 2E Q input o FALSE an 2M PvisP OUT block SETP2 PV4O block setpoint i TRIM2 block SP40 R ANS SP TRIM 2H S ey TRUE CONTROL block Y OUTPUT area 3TRM2 OUTP2 2A 3TOUT x Heo tem ENT OZ Jm input block Z 2B srour E Y TRCK2 MANS2 OP 2 f analogue manual analogue i TRACK 2J input gt station output O 2L 3TOUT 0 10V block block block REM SP EN 1 2Q nr T PROCESS pum ALARM digital K HOLDEN
228. pment instructions Do not dispose of in fire Replace all batteries in equipment at the same time Do not mix battery Systems such as alkaline and zinc carbon in the same equipment Do not carry batteries loose in pocket or bag SPECIAL PROTECTION INFORMATION Respiratory protection None under normal conditions Ventilation Subsequent to a fire provide as much ventilation as possible Protective gloves Use neoprene rubber or latex nitrile gloves when handling leaking cells Eye protection Wear safety glasses when handling leaking cells Other protective clothing equipment None AB BREVIATIONS USED IN THIS DOCUMENT ACGIH American Council of Governmental Industrial Hygienists IARC International Agency for Research on Cancer OSHA Occupational Safety and Health Administration US NTP National Toxicology Program US PEL Permissible Exposure Limit TLV Threshold Limit Values 238 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Installation amp startup Unpacking UNPACKING YOUR T640 Unpack the instrument and accessories carefully and inspect the contents for damage Keep the original packing materials in case re shipment is required If there is evidence of shipping damage please notify Eurotherm Process Automation or the carrier within 72 hours and retain the packaging for inspection by the manufacturer s and o
229. put open circuit only O vrDrive Ch 1 only current output DG IN Thresh Not supported InType Only Volts supported DG OUT Pullup Only 24V and External supported DGPULS 4 1 Pullup Only 24V and External supported Mode3 DUAL PLS mode not supported Mode4 Not supported Table 11 4 Thermocouple I O board UN blocks parameter support AN IP Options bitsetting Resulton break BrkDetct BreakUp HoldDect PV to highscale HR TRUE TRUE FALSE PV to lowscale LR TRUE FALSE FALSE PV holds last good value TRUE don t care TRUE Table 11 5 Hardware organisation Direction reversed if Options Invert bit TRUE Thermocouple I O board break modes Figures 11 8 to 11 12 are block schematics outlining the organisation of the low level I O board hardware Figure 11 8 shows the thermocouple inputs Figure 11 9 the non isolated analogue I O Figure 11 10 the isolated current outputs Figure 11 11 the isolated digital inputs and Figure 11 12 shows the non isolated digital outputs 11 20 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications Thermocouple O mV thermocouple inputs Block type Channels Resolution Accuracy 25 C Temperature drift Input Isolation Break detection 50 60Hz rejection AN_IP 2 gt 14 bits 0 1 of mV range lt 0 7mV 0 008 of reading C 99 confidence lt 0 3mV 0 003 of reading C typically 250V ac rms or de working wi
230. r carrier s repre sentative Handling precautions Caution Electrostatic sensitivity Some circuit boards inside the T640 contain electro statically sensitive components To avoid damage before you remove or handle any board ensure that you the working area and the board are electrostatically grounded Handle boards only by their edges and do not touch the connectors Package contents Check the package contents against your order codes using the labels on the components to help you Product labelling includes HM Outer packaging label Shows the full instrument order code instrument serial number hardware build level and software issue number HM Antstatic bag label Shows the full instrument order code instrument serial number and hardware build level HM Sleeve labels Two labels one outside and one inside showing the sleeve order code and sales order number BB Instrument label One on the instrument identical to the antistatic bag label Memory module label One label showing the software issue number M Security key label Shows access area and ID code T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 29 Dimensions Installation amp startup INSTALLATION Dimensions Figure 2 1 shows the DIN size aperture needed for panel mounting the T640 Also shown are the unit s overall dimensions the mounting clamps panel section terminal cover and screw and the access for cabling
231. r future expansion The gaps can be written and read if required and this allows a system of letterboxes to be set up that can be exploited by some systems Note that the data in the gaps does not interact with the standard Unit controller supervisor database The T640 functions by keeping a copy of relevant parameters in MODBUS format This copy is updated from the LIN database by a scanner task running in the T640 This tech nique increases the speed and predictability of transactions on the serial lines but at the expense of a scanner task and memory for the copy data in the T640 When a master writes a value via the MODBUS the data is written into the copy and is transferred to the LIN database asynchronously by the scanner task running in the T640 This data is transferred to the database only if the data written across the MODBUS is dif ferent from the value already in the table The scanner task regularly looks at each value in each table If it finds that the value has been changed across the MODBUS it transfers the new data to the database If the value has not been changed the value in the copy is instead updated from the database When a master reads a value across the MODBUS the data is transmitted from the copy The master is responsible for polling the data to discover when the registers have changed NOTE To minimise communications efficiently it makes sense to group dynamic data together so it will be available in co
232. rate will be reduced B 6 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 O DBUS JBUS UN communications AppB 2 4 1 Cycle 1 Cycle 2 Table 1 40 registers Read 40 registers Read 40 registers Scan count 40 Table 2 y 50 registers Read first 30 registers 4 Read last 20 registers Scan count 30 Table 3 Y 80 digitals Read 80 digitals Read 80 digitais Scan count 80 CL Figure B4 Polling sequence example Figure B 4 illustrates two cycles of an example polling sequence For Table 2 the number of registers it contains 50 exceeds its maximum register count 30 so it takes two poll ing cycles to be fully updated 2 3 2 Write operations If the scan task has detected that a value in one of the MODBUS slaves needs to be up dated it requests the polling task to write the new value across the MODBUS network The polling task is allowed to insert a maximum of one such write operation between con secutive read operations So in the example of Figure B 4 up to three writes could be made per polling cycle 2 4 Refresh rates and timing information This section describes the calculations used for determining refresh rates 2 4 1 T640 slave mode timing Response times Time from end of command until first character of the response Minimum 3 5 character periods Normal 12ms 9600 baud Maximum Probably 50ms 9600 baud Su
233. ratio setting is used loop1 SP loop2 PV ratio setpoint Inverse loop1 SP loop2 PV ratio setpoint Loop only Ratio controller only TRUE Mask R push button TRUE Mask M pus button SF Q5 65 TRU E TRUE Mask A push button E E loop tag is FIC 001 N ote BitC has priority over BitB BitD has priority over BitC and BitB etc Also loop 2 tags are FIC 002 etc If none set tag defaults to LOOP 1 or LOOP 2 TRUE loop tag is LI C901 TRUE loop tag is P C901 C901 ctim E E TRUE loop tag is TI TRUE loop tag is A C901 This block processes the remote setpoint input Status BrkDtctd is used in conjunction with the input RSP 1 REM SP EN 1 to e a able the remote setpoint If the remote setpoint input is broken the loop reverts to ocal setpoint fno remote setpoint is required all parameters in this block can be left as default Filter A first order filter wi th the time constant set will be applied to the input HR in The input voltage representing high range IR in e input voltage representing low range O ptions Only options believed relevant are described Some options have defaults relevant to the 1 0 hard ware and should not be changed Invert TRUE maps HR in to SETP1 LR_SP and LR in to SETP1 HR_SP Sqrt TRUE applies a square root function to the input DIN 1 Th
234. ration of the control loop itself and those in Loop 4 cover system alarms and general instrument setup When you come to configure these parameters you will find the setup sheets helpful be cause they list the default values of all fields and include a spare column for you to record your customised values where required You may want to use photocopies of the printed setup sheets as your working documents The setup sheets for all strategies are found un der Setup sheets all strategies on page 5 33 Loop 1 Table 5 5 lists the Loop 1 parameters for strategy 1 together with explanations of their functions NOTE The order of the blocks in the table may not match their order of appear ance when you access them via the INS button Block Field Subfield Description S661 This block needs attention only if Bisync communications are to be used Instr No Slave address of the control loop s 6366 emulation on the Bisync communications bus SWS1 This is a set of optional switches for setting up the loop W Field1 Bito This defines the power up mode TRUE the loop goes into manual on power up with zero output FALSE the loop maintains its last mode and output on power up Zero means low electrical output irrespective of any ranging or loop inversion Bitl On PV fail the loop will go from AUTO into FORCED MANUAL This bit determines the action of the control output TRUE
235. rator interface T640 Reference M anual amp User Guide Issue 5 4 1 Displays amp controls User interface OPERATOR DISPLAYS amp CONTROLS Summary loop displays Figure 4 1 shows the front panel Four summary displays show red deviation bargraphs of T640 s four loops Loops 1 to 4 from left to right DevnBar in the SETPOINT block specifies the bargraph span as 3 10 default or 30 deviation PV can be displayed instead to 100 of range if DevnBar Abs_PV The central green LED glows if the bar graph is showing deviation the bottom red LED glows if PV is being displayed A flash ing bargraph means the loop is in absolute or deviation alarm Operating mode letters glow to show selected modes for each loop R Remote A Auto M Manual T Track H Hold Flashing signifies a forced mode A to tally blank loop summary display and inaccessible main display mean the loop contains no configured blocks or the related T600 block FPdisn parameter is TRUE Main loop display This details the status of one of the four loops indicated by a green arrowhead under the related summary bargraph To select a loop for main display hold down a raise A or lower W button If a loop s MODE block Se Disp parameter is TRUE it will always oc cupy the main display and cannot be deselected The following features apply only to the loop selected for main display Tagdisplay This red display normally shows the TAG block s TAG
236. rifice plate in this example via terminal 1E PV__1 ranges the input signal to engineering units filters characterises and conditions it e g applies square root for an orifice plate signal PV__1 also checks for alarm conditions including I O hardware out of range and open circuit inputs And as you have just seen the block detected the fact that its input is in open circuit PID control area In the PID control area of the database the SETP1 setpoint block generates a resultant setpoint from the local setpoint you can enter via the front panel and subjects it and PV to ranging high low limits trim rate limits and also provides absolute and deviation alarms The 3TRM1 3 term block generates a 3 term control output from PV and SP and lets you alter the loop s tuning constants The MANSI manual station block applies high and low limits to the control output T640 Reference M anual amp User Guide Issue 5 3411 Tutorial Control outputarea In the control output area OUTP1 is an analogue output block configured to provide an isolated 4 20mA control output to the plant via T640 s hardware This is available on customer terminals 1A and 1B as shown in the Figure Also available via another ana logue output block OP__1 configured to output volts is a 0 10V control output on ter minal 1L Any of terminals 1G 1K and 1N provide the analogue ground The 0 10V output follows the 4 20mA output Figure 3 2 showed t
237. ring of these points into blocks or loops etc and most im plementations define the allocation of registers differently The MODBUS interface involves the mapping of data from the standard T640 database to the MODBUS registers and digitals 2 1 Slave mode In slave mode the MODBUS interface has two main purposes E To allow a remote system a MODBUS master on the serial link to read from and write to fields within standard blocks in the LIN system The slave is passive and can not itself acquire data from or write data to other instruments on the link Wi To allow the master to translate data into a LIN format The mapping between registers and blocks is inherently bidirectional it is up to the master to manage how it interacts with a particular register or point Figure B 2 shows a possible mapping of MODBUS registers to points in a LIN database where the mapping between the two systems is completely defined by the user MODBUS registers or bits LIN database blocks copy in slave instrument update value from database S to remote Master transfer new value from copy S from remote Master PV XP TI TD Op 7 Mode OP Mode aa XP u TD Figure B 2 LIN slave mode operation B4 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 M O DBUS JBUS UN communications AppB 2 2 The configuration allows gaps to be left in the MODBUS data areas fo
238. rised but accepts ac nominally 24V absolute max 40V min input for logic 1 13 7V max input for logic 0 5 8V max current for logic 0 0 1mA min current for logic 1 0 9mA max current at 30V 4 0mA DG_OUT or DGPULS_4 3 non isolated T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 1125 Thermocouple O Specifications 30V ISOLATED CURRENT OUTPUTS 60V Isolation 5V isolated e P 15V isolated e 0V isolated DC Tabs OK uM recovery took Z kubi T y P 4 nB Contact z OV isolated sense I OK Killed nc 9 p i OK or O C n Fault Oe 220R unuuunnnnnnnnnnnnnnnnnnnnn p encoder Killed V 4 OV isolated e Pulse width modulated output 4 V e 5V Isolated power y ra supplies 60V Isolation VO MICRO CONTROLLER ISB Figure 11 10 Output levels Internal pull up External pull up Sink current Fan in fan out Isolation software selectable between 24V nom internal pull up or external pull up open drain 21 5V to 24 6V via 3 6kQ 60V absolute maximum 120mA maximum 1V drop at 40mA Isolated current output block schematic n 1 2 Maximum of 2 isolated digital inputs
239. rm on PV LDA 100 00 Low deviation alarm on PV Dis DP 2 Decimal point position DOP 1 Invert Bitd tru FALSE inverts HI ALM OUT 0 Bitl tru FALSE inverts LO ALM OUT 0 Bit2 FALSE tru inverts REM AUT AUT 0 Bit3 FALSE tru inverts HO LD M AN OUT 0 PVOP1 HR out 10 00 O utput voltage high LR out 0 00 O utput voltage low 3IRM1 TimeBase Secs Control settings time base TI amp TD XP 100 00 Proportional band TI 10 00 Integral time TD 0 00 Derivative time Deadband 0 00 Hysteresis for O n O ff control TRK1 ODE AUTO O perating mode AUTO orMANUAL PV 0 00 Track setting if MANUAL HR in 10 00 Input voltage high LR in 0 00 Input voltage low MANSI HLOP 100 00 High limit on control output LL OP 0 00 Low limit on control output OP 1 HRout 10 00 O utput voltage high LR out 0 00 O utput voltage low Table 5 11 Setup sheet for Loop 1 all strategies T640 Reference M anual amp User Guide Issue 5 535 Standard strategies Setup sheets Loop 2 Block Field Subfield Default Setting Description SL662 Instr No 1 BiSynch address SWS2 W Field1 BitO FALSE Power up mode Bitl FALSE PV fail mode Bit2 FALSE tru inverse output action Bit3 FALSE tru inverse PID Bit4 FALSE tru On Off control Bit5 FALSE tru setpoint tracks PV if not AUTO Bit6 FALSE tru PV SPOut SP Bit7 FALSE tru inverse ratio setting Bit8 FALSE tru Mask R Bit9 F
240. rminals is described in Chapter 2 and Table 2 1 shows the ALIN terminals and their phases The literature accompanying the ALIN card describes how to make the con nections Connect the T640 to an appropriate power supply and power up both the PC and T640 Table 2 1 shows the power input terminals for the AC and the DC motherboard op tions Run the LINtools package on the PC and select the LINfiler option via the UTIL softkey Attach a LINfiler column to the T640 s E drive EEPROM Use the ALIN address noted in step 1 If this doesn t work the ALIN phases may be wrongly connected try swapping the terminal 21 and 22 connections Tag the T640C1 PK1 file and delete it by pressing the lt Delete gt function key T640 Reference M anual amp User Guide Issue 5 3 1 Tutorial AIMS OF THIS TUTORIAL This tutorial will give you hands on experience of the T640 and at the same time ac quaint you with the simplest of the four pre configured fixed function control strategies supplied in ROM This is 1 a single control loop The other three fixed function strate gies are all designed around this loop so what you learn here will help you configure them as well via T640 s front panel pushbuttons and displays Note that in this tutorial the T640 operates as a stand alone instrument no network or communications are involved Much of the information given here can also be found in other parts of this manual
241. rollers FPdis3 Leave as default TRUE in all but ratio controller FALSE in ratio controller FPdis4 Leave as default TRUE NoKeyPrt The default TRUE allows access to the normally settable parameters without using the security key This should normally be set to FALSE before the controller is put on to plant NoKeyFul This should be left as default FALSE Setting this TRUE allows access to all the parameters in the controller without the use of a full access key LEDtest Set TRUE all the LEDs on the front panel light It resets itself to FALSE CommsDis This is internally wired and may be used only for reading the state of the ALIN and Bisync communi cations TRUE parameter writes inhibited FALSE communications fully enabled FullSave Set TRUE the parameters in the running database are saved to file These parameters will be used on cold start This or PartSave should be used after configuration to ensure the set up is not lost It resets itself to FALSE PartSave This is the same as FullSave except local setpoints control outputs and control modes are not saved This allows tuning parameters to be set up and saved during commissioning without overwriting the start up conditions BinSpd1 i BinSpd1 FALSE FALSE TRUE TRUE Bisync baud rate BinSpd2 BinSpd2 FALSE TRUE FALSE TRUE Baud rate 9600 4800 1200 300 default Protectd Leave as default TRUE E2Form1 This and E2Form2 when used together in sequence will reformat the
242. s amp switches Four jumper links J2 J4 J5 and J6 together with switches 1 and 2 of Switchbank 1 are factory set to configure the motherboard according to what serial comms option was or dered You can check that these are set as required the jumpers and switches are lo cated on the motherboard where shown in Figure A 3 Table A 1 shows the switch set tings and jumper links for the five possible comms options Required DIL switch Jumper links comms option SW1 1 SW1 2 J2 J4 J5 J6 Binary RS422 OFF OFF N ot fitted 2 3 2 3 2 3 M odbus RS422 ON OFF N ot fitted 2 3 2 3 2 3 M odbus RS485 ON OFF 1 2 2 3 2 3 2 3 External ISB RS422 Don tcare ON N ot fitted 12 12 12 External ISB R 485 Don tcare ON 12 12 12 12 Not implemented at Issue 6 Table A 1 Comms option switch amp jumper link settings A 6 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 AppB 81 1 Appendix B MODBUS J BUS COMMUNICATIONS This chapter tells you about the implementation of the MODBUS JBUS communications in the T640 The main topics covered are Overview of the MODBUS communications 1 Principles of operation 2 Downloading the configuration 3 Using the diagnostic table 4 MODBUS diagnostic function codes 5 MODBUS exception responses 6 Notes on MODBUS JBUS implementation 7 1 OVERVIEW OF THE MODBUS COMMUNICATIONS The MODBUS JBUS communications provide a serial interface to the T640 LIN
243. s achieved Up to 250 function blocks can be configured depending on the size of the blocks and the number of connections For a list of blocks supported by the T640 and full details of how to configure them please refer to the LIN Blocks Reference Manual Part No HA 082 375 U003 which is part of the LIN Product Manual Part No HA 082 375 U999 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 11 7 Software Specifications This page intentionally blank 118 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Specifications High level I O HIGH LEVEL I O Layout The high level I O electronics resides on a main I O board mounted next to the mother board which plugs into the central rear panel 24 way terminal block I O site 1 These terminals can carry only half the available I O the second half can be accessed at the left hand rear panel 24 way terminal block I O site 2 via an expansion I O board fitted next to the main board Figure 2 10 in the Hardware configuration section of Chapter 2 shows this layout T640 rear panel customer connections Please refer to Chapter 2 under Connections amp wiring Customer terminals for details Input ranges The appropriate 0 5 V or 0 10 V range is automatically selected by the software when you configure the analogue input or output block in the control database However you can override the software and select the 0 1 25 V range spec
244. s your requirements Chapter 5 Standard strategies describes the T640 preconfigured strategies and how to load and run them POWER UP ROUTINE I O cards I O cards power up with their outputs killed i e tri stated or low depending on the par ticular card The T640 ISB internal serial bus starts before the user tasks start although initially the I O card outputs are not written to and hence remain in their killed state Database acquisition The database is acquired in a manner depending on the type of startup Wi Ifa warm start occurs the database is the one in RAM provided it is uncorrupted If it is corrupted the last loaded database file RUN stored in EEPROM overlaid with tepid data is used Please refer to the section below for more details on tepid data Wi Ifa cold start occurs the database is loaded from EEPROM W Otherwise the database is loaded from one of the standard pre configured strategies WB ifno valid source is found a null database is created T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 229 Power up routine Installation amp startup POWER UP Standard Warm Start SW1 4 ON Database in RAM GOTO Warm Start routine see Figure 2 15 Yes Yes No Yes strategy selected RUN fi selected PKn file Cold Start SW1 3 ON Standard strategy selected Scan EEPROM then ROM
245. sing the codes listed in Table 12 5 Burden resistors burden diodes and ALIN terminating resistors are available CODE DESCRIPTION High level mA kit LA 082 728 4 off double 250R burden resistor plugin modules 2 0ff burden diode plug in modules ALIN terminator kit LA 082 586 UOO1 82R terminating resistor plug in module LA 082 586 U002 100R terminating resistor plug in module Table 12 5 Rear panel plug in module kits 124 T640 Reference M anual amp User Guide Issue 5 T640 zero volts schematics Appendix A SETTING UP EARLY BOARDS This appendix describes how to set up early boards i e Issue 6 hardware status level 11 and older which used Jumpers 2 4 5 and 6 as well as DIL switch SW1 to config ure the communications options With Issue 7 boards status level 12 onwards your SW1 setting and Jumper 2 alone specify the required comms option You must read this appen dix in conjunction with Chapter 2 Installation amp Startup The main topics covered are Wi T640 zero volts schematics W Hardware configuration T640 ZERO VOLTS SCHEMATICS Communications zero volts schematic Figure A 1 shows the RS422 485 and ALIN comms connections with associated customer screw terminals The main CPU is opto isolated from the RS422 485 transmit receive ter minals Factory set jumpers J4 J5 and others not shown configure the motherboard for RS422 RS485 or external ISB Internal Serial Bus operation
246. sk 4 server Runs user task 4 loop 4 and sequencing Every MinRpt4 secs 10 Cache block server Processes connections into amp out of cached blocks Every 100ms 11 LLC onitors ALIN link low level status Applies timeouts to transmitted messages Reprograms ALIN hardware if errors are detected Every 100ms approx 12 Load Loads a database on remote request Event driven 18 NFS Network Filing System Processes ALIN filing system request Event driven 14 MODBUS MODBUS database management Periodic 15 Scan Collates alarm information Continuous 16 Bgnd Null task Provides environment for CPU s execution whilst no other tasks run Only when dbase halted Or less often subject to CPU loading Table 7 1 1640 task scheduling Frontpanel task This task is repeat driven every 80ms It is responsible for the scanning of front panel pushbuttons and the generation of front panel displays It is also responsible for generat ing the security key logfiles User task 1 server user task 4 server These servers are responsible for running the up to four user tasks They are repeat driven the rate being as requested by the user in the MinRpt fields of the T600 block sub ject to the requested repeat rates not exceeding the maximum permitted CPU loading See under User task tuning User task 1 server has the highest priority and user task 4 server the lowest Cache block server task This server is responsible for processing connections into and
247. ssages Table 9 1 1640 File types Comms ports There are three communications ports two serial and one peer to peer The two serial ports are the internal serial bus and the Bisync MODBUS port available as options at the rear panel via an isolated RS422 485 driver on the motherboard Jumpers and mother board switches select which port is connected via the driver Chapter 2 specifies these jumper and switch configurations The third port is the peer to peer ALIN channel Internal Serial Bus ISB The ISB communicates between the main CPU the I O card s and the front panel It also supports remote I O and external faceplates from the rear connections not available at this release The external link is half duplex using a 5 wire RS485 derivative physical and electrical interface to the I O cards The front panel and any internally fitted I O cards are directly coupled to the main processor at logic levels The ISB is asynchronous with 1 start bit 8 data bits 1 control bit and 1 stop bit operat ing at 78 125kbits second This speed allows messages to be transferred with negligible delay 92 T640 Reference M anual amp User Guide Issue 3 A Inside T640 LIN PC based Bridge 1a to LIN Configurator T221 LINtools ALIN Peer to Peer Comms Main CPU Internal Serial Bus i Vo O Front Panel T640 UNIT Figure 9 2 AUN commu
248. ssue of hardware This state is not flagged by the STATUS BadCal bit LIN blocks parameters not supported The LIN Blocks Reference Manual lists the LIN I O blocks supported by the T640 and de scribes in generic terms every parameter in those blocks However certain parameters are not supported or are only partially supported by the high level I O board Table 11 3 lists these board specific parameters Block type Parameter Support AN IP InType V option only CJ temp Not supported LeadRes Not supported STATUS PSUshort Not supported BrkW arn Not supported BrkDtctd Not supported when burden resistors in use AN OUT STATUS FaultC ct Voltage outputs short circuit only Current outputs not supported O verDrv Not supported Killed Not supported ALARMS CctFault Voltage outputs short circuit only Current outputs not supported O vrDrive Not supported DG IN Thresh Not supported InType Volts option only DG OUT Pullup Not supported DGPULS 4 1 Pullup Not supported 1 With high level boards in both T640 sites only site 1 can support a DGPULS_4 block Table 11 3 High level I O board LIN blocks parameter support 11 10 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications High4evel O Hardware organisation Figures 11 2 to 11 4 are block schematics outlining the organisation of the high level I O board hardware Figure 11 2 shows the non isolated analogue I O Figure 11 3 shows the d
249. strategies 32 1 0 calibration procedure 1128 Flashing bargraph sssesese 4 2 ID3COGG rs t eo ca 2 9 49 Flashing LED sse 43 Infrared LED sese 4410 Forced manual mode 10 5 In DUBIang85 c oit atit d d 11 9 Forced mode cet 4 2 INES At EA PETRUM 345 43 Foreign language support CA IN S button seee ees 44 6 1 Front panel 2 18 42 94 Inspect Mode entry sees 64 display Inspecting amp editing the database 345 alarm settings amp limits 349 Installation cccccccccccccccccccceccctecereceeececs 2 10 NMEA CE sect s oe tengas 74 Be Sta THU vases cresce ste cea iet 2 1 TASK ccena eoe ies 7 2 category voltages veces 23 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Index 3 I N Index safety requirements sssi 22 Mailiss it MM LM M ase 242 Instrument case ssseee 2 18 MAIN S option motherboard Instrument node number 5 39 terminal block ceire 2 13 Instrument supply occ eee terete 2 12 Mains safety cover 243 Integral term windup eees 521 Manual mode nnde nit 313 Inter server Connections 8 2 MASKED ics esee idees t cr sie 4 3 Internal Serial Bus ISB 92 Master controller lissee 5 27 Master MO Coie hr chelates B5 J errorcode eese emet edt B 17 BUS APRIL sce B18 Master node viernes 9 3 JBUS com
250. t function shows Error 64K RAM 128K St Level lt 4 All features function All features function except sequencing 256K St Level 25 All features function Configuration should notexist All features function Main fuse See Figure 2 11 The motherboard carries the T640 power supply fuseholder The fuse is a 20 x 5 mm 250Vac antisurge cartridge fuse rated at 500mA AC option or 2A DC op tion Unscrew the fuse cap anticlockwise to remove The fuse should be replaced by au thorised personnel only Note that a fuse may fail owing to ageing but if it fails because of a fault with the unit please refer to your nearest Eurotherm Process Automation agent T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 2 23 Switchbank 1 Installation amp startup Daughter board where fitted J2 is on daughter board where fitted otherwise J2 is on motherboard Power supply fuseholder Figure 2 11 T640 motherboard showing fuse amp jumper locations Switchbank 1 Figure 2 12 shows the location and functions of the eight switches in DIL switchbank 1 M Switches 1 and 2 together with one jumper link configure the type of communica tions used by the T640 via its serial port See Table 2 4 below in the section Serial communications jumper link amp switches These switches and the link are set at the factory according to the comms option ordered and should generally be left as sup plied
251. t in engineering units HL SP This sets a high limit for the setpoint including any trim whether the setpoint is local or remote LL SP This sets a low limit for the setpoint including any trim whether the setpoint is local or remote HL SL This sets a high limit for the local setpoint LL SL This sets a low limit for the local setpoint Alarms These are the process alarms of the control loop N ote Priority 0 disables the alarm completely An alarm with 0 priority no longer affects the digital output HI ALM OUT 0 or LO ALM OUT Q Priority 6 15 need to be acknowledged Priority 11 15 open the Alarm relay Alarms of priority equal to USR_ALM Priority will open the W atchdog relay HighAbs PVexceedsHAA lowAbs PV is less than LAA HighDev PV SP exceeds HDA lowDev SP PV exceeds LDA HAA High absolute alarm setting LAA Low absolute alarm setting HDA High deviation alarm setting LDA Low deviation alarm setting Dis_DP Sets the number of digits displayed to the right of the decimal point This parameter is for display purposes only and has no effect on the ranging continued T640 Reference M anual amp User Guide Issue 5 Standard strategies Strategy 2 continued Block Field Subfield Description DOP 2 This block processes the digital outputs The default values in this block need not normally be al ered Invert This field inverts the sense of the digital outputs on a bit by bit basis Bit4 to Bit are not
252. task vto den eno 7 3 LEo dtask e eniti o OR 7 3 I SAE E et E E RE ele 7 3 Sean task soa d RE ER ERE RO E 7 3 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Contents 7 Contents Band task nisi EE 7 3 User tasks dene a eai trt eed cett ea a c aaa 7 3 Server Interactions ae ee aee d deeds 7 4 Front panel interface sss 7 5 User task server operation sessseeeeeee 7 6 User task TIMING eite te RO en ee eene 7 1 Repeat times amp execution times sess 7 1 Automatic dynamic tuning eeeeeeeeeeeeeeeeenneeen nennen 7 1 Manual t ning Pa eee Ines E e AE 7 1 Chapter 8 DATA COHERENCE Data flow between tasks ssesseseseeeeeeen nnne 8 1 1 Connections into this task from other tasks in the same instrument node sss 8 1 2 Connections into this task from other tasks in other physical instruments eese 8 2 3 Connections out of this task to another node 8 2 Chapter 9 INSIDE T640 Internal layo t eerte tenete nnne hereto Functional blocks ee et ere he eek edhe Motherbo rd 2 ad Re eR erbe aus Comms ports Power supplies oL n Ranae DII switchbanks eiie oon cire 9 3 Front panel T O sub assemblies Customer Screw terminals 9 4 Chapter 10 ERROR CONDITIONS amp DIAGNOSTICS Power up displays eec tpi e ne dept
253. tches need only be set to the required standard strategy number the first time that strategy is run Once the correct strat egy has been run a filename RUN file and a filename DBF file exist in EEPROM These files ensure that the same database runs on powerup provided that the se lection switches are still set to either the correct strategy number or to no new strategy selected all off The drawback with simply leaving the switches set is that should the filename PKn file get deleted or replaced with one having a differ ent filename the T640 will next powerup in the idle state or run the wrong strat egy respectively To avoid these possibilities you are recommended to set the standard strategy se lection switches the first time a new standard strategy is run to generate the cor rect DBF and RUN files then power down the T640 and turn the switches off Subsequently the T640 will make its warm cold start decision based on the RUN file independently of the possibly missing or corrupted PKn file T640 Reference M anual amp User Guide Issue 5 5 5 Customer terminals Standard strategies FIXED FUNCTION STRATEGY DESIGN PRINCIPLES The four fixed function strategies have been designed to be as straightforward to config ure and use as possible HM All the control loops follow the same design with the same function blocks and the same I O allocations on each I O site see Table 5 2 The variations are kept to a minim
254. the alarm as fol lows Figure 3 8 shows these how the ALM button works 1 Press ALM briefly The tag display shows LOOP 1 and LOOP appears in the green units display This tells you that the alarm is in Loop 1 2 Press ALM again The tag display shows SETP1 and BLOCK appears in the green units display This localises the alarm condition to a specific area of the control data base called a function block the name of the block in this case being SETP1 Function blocks are explained in more detail below 3 To see if there are any other Loop 1 blocks in alarm press the raise A button The tag display now shows PV 1 indicating that a block called PV__1 is also in alarm 4 Investigate the PV 1 block s alarm by pressing ALM again The tag display shows Hardware with SubFd showing in the units display This tells you that the particular type of alarm involves the T640 hardware in some way Hardware being the name of the Alarm subfield within the affected block Subfields are explained in the Func tion blocks section below 5 To see if there are any other alarms in the PV 1 block press the lower W button This changes the tag display to OCctdel which indicates that an open circuit has been detected on the PV input This is not surprising since you have not connected any thing to the input terminals other than the power supply Note that the hardware alarm you just saw is itself due to the open cir
255. the issue number of the whole section as listed in the above table is always the issue number of the most recently up is sued page s in that section All registered and unregistered trademarks are properties of their respective holders T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 al EUROTHERM Declaration of Conformity Manufacturer s name Eurotherm Limited Manufacturer s address Dominion Way Worthing West Sussex BN14 8QL United Kingdom Product type Integrated Loop Processor and ancillary parts Model s T640 Loop Processor Status level A4 or higher T640C Loop Processor Status level 110 or higher T710 Sleeve Status level A2 or higher T901 Memory Module All status levels T950 Security Key All status levels Safety specification EN61010 1 1993 A2 1995 EMC emissions specification ENS0081 2 Group 1 Class A EMC immunity specification EN50082 2 Eurotherm Limited hereby declares that the above products conform to the safety and EMC specifications listed Eurotherm Limited further declares that the above products comply with the EMC Directive 89 336 EEC amended by 93 68 EEC and also with the Low Voltage Directive 73 23 EEC Signed Pel oly lo N pow Dated CX D 06 2000 Signed for and on behalfofEurotherm Limited Peter de la ger de Technical Director Certificate Part No IA 249 986 U170 Issue 3 June 2000 C
256. thin 1 sample period with options to go high scale low scale or retain last good value 60dB SMR 120dB CMR software selectable between 50Hz and 60Hz Low level mV input mode Input ranges Absolute max input 14 2 to 77mV 7 1 to 38 5mV 3 5 to 19 2mV and 1 8 to 9 6mV software selectable 24V Thermocouple input mode Input ranges CJC accuracy 25 C CJC ambient rejection 210 to 1200 C 270 to 1372 C 270 to 400 C 50 to 1767 C 50 to 1767 C 270 to 1000 C 0 to 1820 C 0 to 1300 C 1000 to 2300 C 0 to 2490 C 0 to 2320 C MoRe 0 to 1990 C 0 25 C to 1 1 C 30 1 typically Z z Z Z wm wu Ww UA T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Thermocouple I O Specifications THERMOCOUPLE INPUTS 250V Isolation e 5V e 45V nD High resolution gt cr nE 2 e integrating gt A to D Y d e CJC High resolution Data ov oV integratin m Senso AoD J encoder e 5V p ov yak e ov ET Isolated power supplies 250V 1 O card Isolation PSU Isolated power supplies e 5V e 45V nH High resolution n integrat
257. to completion The blocks and their associated intra task connections are then executed in order All connections sourced from this user task are then copied into their destination blocks in all higher priority user tasks as a single indivisible operation Again as was noted above all higher priority tasks must have run to completion Any pending queued writes generated in step 2 are then performed Finally the task busy flag is removed Note that this structure results in the least work being carried out by the highest priority task Note also that tasks may be suspended under the control of the strategy via the T600 block s UsrTaskn parameters thereby allowing them to be event driven CONNECTIONS CONNECTIONS Sieh Input Output ves SABENS Mene Eeh connects from PLP PUM connects to mpy Mark task upto date updated us goner prodi Execute the blocks pion enpagi queue UNBUSY COHERENT TASK BODY Database WRITES in this period are directed to QUEUE Figure 7 3 User task server operation 7 6 T640 Reference M anual amp User Guide Issue 3 A Task organisation USER TASK TUNING Repeattimes amp ex ecution times The T600 block s four parameters MinRpt to MinRpt4 let you specify the minimum re peat time for each user task When these are set to zero the T640 takes this t
258. ton and putting the master Loop 2 into Auto mode press A NOTE If these conditions are not true Loop 1 will be in the mode selected and Loop 2 will be tracking it The sequence in which the modes are selected does not matter as the interlocking signals ensure no illegal modes occur W If Loop 1 s R button is pressed before Loop 2 s A button Loop 1 s A indicator will flash indicating the mode Primed In operation Primed is identical to Auto except that as soon as Loop 2 is put into Auto Loop 1 goes into Remote E If Loop 2 s A button is pressed before Loop 1 s R button Loop 2 s A indicator will light but the T indicator will remain lit indicating that Track is overriding Auto When Loop 1 s R button is pressed Loop 2 is no longer forced to track and cascade control begins T640 Reference M anual amp User Guide Issue 5 5 27 Strategy 3 Standard strategies Strategy 3 I O customer terminals Strategy 3 uses a pair of I O boards located in sites 1 and 2 of the T640 accessible via customer terminals 1A to 1Z site 1 and 2A to 2Z site 2 These terminations and their functions are almost the same as those for strategy 2 given in Tables 5 4 and 5 7 The exceptions are that the following terminals have no function in the strategy B Pin 1F REM SP Pin 1Q REM SP EN 1 Pin 2J TRACK Pin 2R TRACK EN 1 Pin 2P COMP EN 0 Strategy 3 function blocks and parameters This strategy has three
259. trol Reset Bitl to FALSE return to auto mode then repeat the PV fail simulation This time the control output holds at its current value despite the loss of PV and adoption of forced manual mode Finally reconnect PV press A and allow equilibrium to return On off control 1 Use the INS button to access Bit4 of the SWS 1 block This bit selects on off control action TRUE or normal continuous control action FALSE With on off action the control output is either at 0 or 100 of range with nothing in between Set Bit4 to tru and watch the chaos on the front panel as the simulated PV oscillates above and below the setpoint trying to attain equilibrium Restore Bit4 to FALSE NOTE With a suitable Deadband value selected via the 3TRM1 block on off control can be applied successfully in appropriate plant situations Tracking of PV by the setpoint 1 Access Bit5 of the SWS 1 block When TRUE this bit forces the local setpoint to track i e follow the process variable PV whenever the controller is not in automatic mode It may be safer for SL to keep equal to PV in the event of a loss of control so that when control is eventually restored and auto mode resumed there will not be a sudden and possibly damaging change in control output value T640 Reference M anual amp User Guide Issue 5 323 Tutorial 2 Set Bit5 to tru and return to the normal display in auto mode press A 3 Now select manual mode by pressin
260. um and are clearly identified FIXED FUNCTION STRATEGIES MOTHERBOARD CUSTOMER TERMIN ALS Table 5 3 lists the fixed function strategy motherboard terminal functions for both the MAINS and the DC options Where relevant the table also indicates the names of func tion blocks having parameters that affect the operation of the corresponding I O The number of parameters that must be set up is minimal All settable parameters have usable default values Partial access is available without a security key by default The only connections required to get something happening are the PV and the 3T OUT terminals Pin Assignment Description Blocks 1 internal earth Do not connect these terminals externally 2 internal earth L ains live live amp neutral mains input terminals N ains neutral MAINS option motherboard only blank in DC option 7 DC source 1 ve DC option power input terminals PRIMARY supply 8 DC source 1 ve DC option motherboard only blank in MAINS option 9 DC source 2 ve DC option power input terminals BACKUP supply 10 DC source 2 ve DC option motherboard only blank in MAINS option 11 RS422 TX Serial communication connections SL661 12 RS422 TX f R5485 is selected pins 11 and 12 are unused amp pins 14 and 15 13 RS422 RS485 Gnd become RS485 and RS485 respectively 14 RS422 RX RS485 See 7640 User Guide for details on setting serial comms switches
261. umber and may differ from 00 Ignore this in the tuto rial This block contains a field called Options Within Options is a subfield called FullSave You set this TRUE to activate the save to EEPROM 1 Press INS to access loop inspect mode 2 Press A or V to move to LOOP 4 which is the user task containing the T60_00 block 3 Press INS again to inspect the blocks in Loop 4 The first one is USR_ALM which stores the alarm priority needed to trip the watchdog alarm relay currently set at 2 4 Move to the next block T60 00 and press INS to see the Options field which is the only accessible field in this block 5 Press INS again to see the Options subfields and move down the list until you reach FullSave 6 Press INS and set the value to tru by pressing A The message SAVING appears in the tag display as the save is executed and the value of the subfield automatically returns to FALSE After a few moments the tag display reports Save OK Press A to return to normal mode Saved databases Your customised database is now safely stored in EEPROM under the same filename that the original default database had But note that the original fixed function default strategies will always reside in ROM and could be made to overwrite your customised strategy To avoid this if you intend to keep a customised strategy in EEPROM do not reset the SWI strategy select switches switches 6 7 and 8 in Figure 3 4 If you do t
262. upplied in the T640 s ROM are described in some detail but the seven more advanced strategies stored in EEPROM are only summa rised You are referred to where more comprehensive information can be obtained on all strategies PURPOSE OF THE STANDARD STRATEGIES In general control strategies are created on a PC within the LINtools package then down loaded to the T640 across the LIN or ALIN As an alternative however you can load and run one of the pre configured standard strategies supplied inside each T640 instead of creating your own strategies from scratch Once a standard strategy is loaded you can di rectly via the front panel alter any default parameter values to suit your plant require ments then save the customised database for future use via the T600 block s FullSave or PartSave parameters see the LIN Blocks Reference Manual Accessing the database is described in Chapter 4 User interface The tutorial in Chapter 3 also gives you some practice at editing the parameter values of a standard strategy via the front panel Another approach is to use one of the standard strategies as a starting point for more ex tensive editing in LINtools control configurator By adding and removing blocks and connections you create a new strategy that more exactly meets your requirements You can also create your own entirely new standard strategies loadable via the mother board DIL switches in the same way as the regular st
263. uring power up and should be read in conjunction with Figure 2 14 As there is no hardware realtime clock in the T640 it must derive elapsed time since power down needed in the warm start routine from a clock it main tains over the peer to peer communications If this is not possible power up follows the alternative route shown in Figure 2 15 After loading the entire database is subjected to a sumcheck test User task startup Chapter 7 7640 Task organisation gives information on user tasks etc Before user tasks start the output blocks execute their power up defaults as defined by their OPTIONS PwrFlLo parameters or in the case of a cold start as specified at strategy configuration time This is needed to ensure that the JnitDmnd value in the MAN STAT block is itself initialised and causes the real plant outputs to attain their power up states Output blocks with sumcheck errors do not execute at all hence their outputs remain killed User tasks now start executing The MODE block selects manual mode if ManPwrUp is TRUE and the manual station initialises the Demand parameter Tepid data At the end of each task iteration a package of data is assembled in a TPD file in RAM ready to be written to EEPROM should a power down occur This data tepid data includes each loop s local setpoint SL output OP and operating mode MODE In the event of a power down there is enough time for the tepid data
264. user task in the main display has halted B Err hhhh flashing brightly in alternation with the normal tag display means a filing system or database system error e g coldstart file access failure identified by a 4 digit hex code hhhh Filing system alarms override database alarms on the front panel To clear them press the A and W keys simultaneously Table 10 1 lists all the hex code error numbers and their meanings T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 10 1 Error conditions amp diagnostics B Database alarms Unacknowledged alarms in the loop occupying the main dis play cause the tag display to bright flash the highest priority alarm name in alternation with the standard message Unacknowledged alarms elsewhere display LP n ALM where n is the relevant loop number Please refer to Chapter 4 Alarm display amp in spection section for further details on alarm display inspection and acknowledge ment Error Meaning 6001 Failure to load M O DBUS database 6002 Failure to start M O DBUS database 8201 Device not mounted compatible not formatted or corrupt 8202 Invalid device specified 8203 Error performing I O to device write read protected by wrong switch settings 8204 Feature not implemented 8205 Formatting error 8206 Physical device not present 8207 Device full 8208 File not found 8209 No handles for file not enough memory to open file and note its state 820A Bad filename 8
265. values that are to be displayed on T640 s front panel represented in Figure 7 1 as outputs lt User task 1 repeat time User task 1 MEE HEN O Output User task 2 2 2 eee eee eee eee eee eee o DEED Output o 7 Usertask3 EN TREE n Output User task 4 5555555500 MM N Ww eod MEE o o EE E E gt Output Cached block server MERERI Time Figure 7 1 User task server interactions 74 T640 Reference M anual amp User Guide Issue 3 A Task organisation Front panel interface Please refer to the schematic in Figure 7 2 Each user task has a logical front panel asso ciated with it and maintained by it where its outputs destined for display are held The front panel task see Table 7 1 generates front panel displays from the data held in these logical front panels The summary display area of each logical front panel is always connected via the front panel task to the corresponding summary display area of the physical real front panel But the detailed display area of only one logical front panel can be connected to the physi cal front panel at any one time to produce the main loop display This is determined by the position of the front panel loop select switch set by pressing the raise lower pushbut tons described in the User Guide Logical front panels Physical front pa
266. which therefore do not have to be re calibrated For example if you re calibrate one analogue input channel only the set of analogue input channels will be automatically re calibrated after powering down and up I O circuits Figures 11 5 to 11 7 show schematically some ways to use the high level I O 1T Site 1 1U Plant digital logic outputs 1V 2 1WQ Pullup input serves both sites 4 inputs 1X Q Customer s PSU Digital f 1Y 15 5V 28V ground 12 i Plant logic OV 2T Site 2 2U Plant digital logic outputs 2v 2 gt iius 2W Digital f 2Y ground 22 2 JE Plant logic OV Figure 11 5 Digital outputs driving plant logic using customer s PSU 11 16 T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 Specifications High level I O Customer s 24V PSU NOTES Wi Each digital input can sink up to 25mA atlogic 0 When output HIGH relay O FF Wi If customer PSU disconnected blocking diodes B stop current flowing from high off outputs via protective diodes D and common supply wiring through on relays which could hold them on 1T e O Yo Z RL ON
267. work 6000 distributed control system where its full versatility and power can be realised See Figure 1 1 For small yet complex applications T640 s comprehensive front panel displays and push buttons mean that it can also work perfectly well on its own as a totally independent con troller NETWORK 6000 PROCESS AUTOMATION SYSTEM OPERATOR COMMAND CONSOLES DistRIBUTED REMOTE MULTIPLE WORKSTATIONS PRINTERS WORKSTATIONS NETWORKS PRINTERS OTHER VENDORS COMPUTERS BRIDGES COMPUTING NETWORK RUGGEDISED H DATABASE OPERATOR STATIONS SERVERS CONTROL NETWORK TO OTHER VENDORS EQUIPMENT LOCAL UNIT CONTROLLER T600 INTEGRATED LOOP PROCESSOR HEEXINENSENINO DISCRETE DCS INTELLIGENT INSTRUMENTATION CONTROL UNIT Figure 1 1 Network 6000 distributed control system T640 Reference M anual amp User Guide HA 082 468 U003 Issue 5 1 1 Introduction Summary of T640 s main features Block structured configuration up to four PID loops in separate tasks Large library of LIN blocks supported Strategies downloadable from the PC based LINtools configurator Internal switch selectable pre configured strategies supplied in the instrument Clear front panel text numeric and bargraph displays and controller pushbuttons Fro
268. zero volts schematics eese A 1 Communications zero volts schematic sess A 1 Hardware configuration sess A 3 Internal layouts eterne iret A 3 Memory module removal sese A 3 Maii f Se aaa D RR RE Te aces A 4 Switchbank dss ane etes A 5 Serial communications jumper links amp switches A 6 Appendix B MODBUS JBUS COMMUNICATIONS Overview of the MODBUS communications B 1 Tl Main features once tee eed B 1 1 2 T640 software structure esee B 2 1 3 MODBUS JBUS function codes supported B 2 2 Principles of operation sse B 3 2 Slayemqnode c o aeneis eter ete er B 4 2 2 Master Mode iate err DS B 5 2 3 Master mode polling sequence sse B 6 2 3 1 Read operations esses B 6 2 3 2 Write operations sess B 7 2 4 Refresh rates and timing information B 7 2 4 1 T640 slave mode timing sese B 7 T640 Reference Manual amp User Guide HA 082 468 U003 Issue 5 Contents 11 Contents Appendix C 2 4 0 T640 master mode timing sse B 8 2 5 Memory use and requirements sess B 10 2 5 1 Current configuration sizes and limits B 10 2 5 20 Memory requirements for the tables B 10 2 6 Data CONVERSIO

T640 Integrated loop processor Reference manual & User guide

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T640 Integrated loop processor Reference manual &amp; User guide

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T640 Integrated loop processor Reference manual & User guide