Dualpro
Dualpro
Operations Manual
(Version R906 - October 13, 2009)
COPYRIGHT © 2009
MARATHON MONITORS INC
This manual has part number F200001
Copyright ©2009 Marathon Monitors Inc.
For assistance please contact: Marathon Monitors Inc.
TEL: +1 513 772 1000 • FAX: +1 513 326 7090
Toll-Free North America +1-800-547-1055
[email protected]
www.group-upc.com
No part of this document may be stored or reproduced by
any means whatsoever without prior written permission
from Marathon Monitors Inc.
Dualpro, Carbpro, and Process Master are trademarked to
Marathon Monitors all other trademarks are duly noted and
are the sole the properties of their owners. No attempt at
trademark or copyright infringement is intended or implied.
The Dualpro is a two-channel process controller that is
meant to be used by the industrial operator at his or her
own risk. Marathon makes no warranties express or implied
beyond the written warranty presented at initial purchase.
Marathon is not responsible for any product, process
damage, or injury resulting from the use of this product and
makes no warranties with respect to the contents hereof
and specifically disclaims any warranties of merchantability
or fitness for any particular application or purpose.
Revision Date 13 Oct 2009
Revision number 9.06
This manual covers instrument revisions up to 4.130.
1
COMMONLY ASKED QUESTIONS ...................................6
DESCRIPTION .................................................................11
OPERATION ....................................................................14
HOW TO RESPOND TO ALARM MESSAGES: .............14
CHANGING THE SETPOINT AND THE REFERENCE
NUMBER .......................................................................15
SETPOINT PARAMETERS ...........................................15
PROG/AUTO/MAN ........................................................16
MANUAL MODE ............................................................17
AUTOMATIC MODE ......................................................17
RUNNING A PROGRAM................................................18
STOPPING A PROGRAM..............................................19
PLACING A PROGRAM IN HOLD..................................19
RESTARTING A PROGRAM FROM HOLD ...................20
PROBE CARE................................................................21
Probe Impedance Test................................................22
Probe Burn Off ............................................................24
TO CHANGE THE LOOP DISPLAYED ..........................24
TO PLACE A LOOP IN HOLD ........................................24
CHANGING PARAMETERS ..........................................25
VIEWING A PROGRAM WHILE IT IS RUNNING ...........26
STATUS DISPLAY OPERATIONS ..................................27
STATUS DISPLAY CHART ...................................................31
TABLE OF ABBREVIATIONS : ...............................................33
INSTALLATION ...............................................................35
PANEL MOUNTING/REMOVAL ....................................35
THERMOCOUPLES AND OTHER SIGNAL WIRES ......38
CHART RECORDERS...................................................38
ALARMS ........................................................................39
ELECTRICAL CONNECTIONS ...............................................39
AC POWER ...................................................................39
CONTROL CONTACTS.................................................39
COMMUNICATIONS .....................................................40
ANALOG INPUTS ..........................................................40
2
ANALOG OUTPUTS ......................................................40
OUTPUT CONTACT ......................................................40
LOOP 1 CONTROL MODE ..............................................41
SETUP & CONFIGURATION ...........................................42
DUALPRO IN A NETWORK ...................................................45
THE FRONT PANEL ........................................................49
THE KEYPAD...................................................................51
INSTRUMENT SETUP .....................................................57
CONTROL PARAMETERS - LOOPS 1 AND 2 ..........................57
INPUT SETUPS - INPUTS A, B, AND C..................................60
ANALOG OUTPUT SETUPS - ANALOG OUTPUTS 1 AND 2.......64
Analog Output Offset ..................................................64
CALCULATIONS SETUPS ....................................................66
ALARM SETUPS - ALARMS 1 AND 2.....................................70
PROGRAM MENU ..............................................................76
COMMUNICATIONS ............................................................80
DIGITAL EVENTS..........................................................87
ANALOG EVENTS.........................................................89
PROB MENU .................................................................91
Verification gas value ....................................................93
Verification Tolerance ...................................................93
PROCESS FACTOR ADJUSTMENT .......................................94
MAINTENANCE AND TROUBLESHOOTING .................96
PASSWORD PROTECTION BYPASS...........................96
CALIBRATION ...............................................................96
PREPARING FOR CALIBRATION.................................99
ANALOG OUTPUT CALIBRATION..............................111
PREPARING FOR CALIBRATION...............................112
CALIBRATING THE OUTPUTS ...................................112
ANALOG OPTO TWEAKING.........................................114
3
HOW TO CHANGE BOARDS FUSES AND
ELECTRONICS SAFELYHOW TO CHANGE BOARDS
FUSES AND ELECTRONICS SAFELY .........................116
NEARER VERSIONS OF THE DUALPRO HAVE ONLY A
MAIN FUSE FOR THE INSTRUMENT. EVENT, ALARMS,
AND CONTROL SOURCES SHOULD BE FUSED
EXTERNALLY IN THE CONTROL PANEL.SPARE PARTS
LIST ................................................................................117
SPARE PARTS LIST......................................................118
THEORY OF OPERATION.............................................119
CONTROL MODE DEFINITIONS...................................121
TIME PROPORTIONING (TP) ............................................121
TIME PROPORTIONING WITH COMPLEMENT (TC) ...............121
TIME PROPORTIONING DUAL (TD) ...................................121
MOTOR WITH SLIDEWIRE (MS).........................................122
POSITION PROPORTIONING (PP) .....................................122
ON/OFF (OF) ..............................................................123
ON/OFF WITH COMPLEMENT (OC) .................................124
ON/OFF DUAL (OD) .....................................................124
MULTI MODE (MM).........................................................125
RECIPE ERROR CODES:..............................................126
PROGRAMMER SYSTEM ERROR CODES:.................127
SPECIFICATIONS:.........................................................128
USING THE DUALPRO IN OXYGEN APPLICATIONS .131
INTRODUCTION ...............................................................131
INSTRUMENT SETUP ........................................................131
Dip switches..............................................................131
Analog output mode..................................................131
Display mode ............................................................132
Parameter Setups .....................................................132
4
INSTRUMENT OPERATION ................................................135
Manual sensor impedance and verification test ........135
Viewing sensor test data...........................................135
Changing the automatic test interval.........................136
CALIBRATION OF THE DUALPRO FOR OXYGEN TOOLS
REQUIRED .....................................................................136
THERMOCOUPLE INPUT A CALIBRATION ............................137
OXYGEN INPUT B CALIBRATION: ......................................138
THERMOCOUPLE INPUT C CALIBRATION: ..........................140
GLOSSARY....................................................................142
5
Commonly Asked Questions
How do I set the measurement for carbon or
dewpoint?
In the top bank of 8 switches, switch 1 ON and switch
2 OFF will store the calculated %C in CV-0 and the
dewpoint in CV-1. Use Input A for the temperature
used in calculating the dewpoint, Carbon, REDOX or
%O2. This is usually the probe thermocouple. Input B
is used for probe millivoltage. Pick the loop you want
to use to control. Set the control variable. Set to CV 1
the instrument control for dewpoint. Set to CV 0
control for Carbon. Process Factors and CO
compensation setting will also have an impact on your
setting. See Setup and Configuration for more
information.
How do I do a Probe test?
There is an automated probe test that can be
programmed in the setup menu system. Press the [Setup]
key and select the probe menu. Press [Enter] to move to
the Probe Test Interval (PT I). This sets the time between
tests. If it is set to 0 the automatic feature of the probe
testing is off. Set a time, in minutes, for the probe interval
if an automated sequence is wanted. Press [Shift] and
[Enter] together to start a probe maintenance cycle
manually.
WARNING
If you have a Piccolo probe, burn off
should be disabled.
Piccolo probes
should not be burned off.
6
If you have a Piccolo probe and do not know if burn off
is disabled, do not run a probe test. Contact MMI for
programming information regarding Piccolo probes.
In a 1,2,1 configuration, how do I set up my
thermocouple and my over temperature controller
inputs?
You should connect the thermocouple from the oxygen
probe to the input A terminals on the Dualpro. Input C
is typically used for furnace temperature control or
quench temperature control on the second control
loop. Never share the over temperature control
thermocouple with any other device. The over
temperature controllers should always have an
independent and isolated thermocouple.
Does it matter which temperature input I use?
The "1" shows a board specified to measure
temperature from a thermocouple. Usually, you want
to get a reading that will tell you something besides
temperature in your furnace or generator. If the
DUALPRO is to calculate % C, % O2, dewpoint
definite thermocouple connections are needed. The
probe thermocouple must be connected to Input A.
The millivolts, to input B (your 2 board). A reference
thermocouple or the furnace temperature t/c is usually
on Input C.
See the manual for a complete list of board numbers
and applications. The other board for reading
temperature is 6: a resistive temperature device (RTD)
board. This board is preferable if you are measuring
low temperatures because the accuracy is better in
the low ranges. However, its upper working limit
makes it impractical for most high temperature
applications.
7
Why doesn't my temperature read correctly?
Check your thermocouple setting.
Refer to the setup menu under “MENU INP.” The input A
(IN A) first setting is usually thermocouple (TC X). Does
the thermocouple type match the thermocouple you have
installed?
Is the thermocouple installed with the red wire in the
negative position?
Is the thermocouple wire run in conduit with any other
wire?
If it is not, is there any disruptive activity such as welding
going on near the panel?
Is the thermocouple input coupled to another device such
as a recorder?
Some recorders generate and offset or pulse to detect an
open thermocouple condition. It might be possible to turn
this function off at the recorder. If it is not then you will
have to isolate the controller from the recorder by using
different thermocouples or use one of the analog output
signals from the Dualpro to drive a linear input of the
recorder for an equivalent temperature signal.
As a last resort, disconnect any input sensor and drive
the input channel with a know good calibration source. If
the input does not match the input display, then the
instrument must be run through a calibration process.
Depending upon your application there may be other
factors. Tables of data are involved in some cases in
others there are setup parameters besides the input that
have an impact on the temperature reading. See setup
and Configuration for more information.
8
Is there a simple way to calibrate the instrument?
How do I reconfigure it?
There is a step by step method of Setup and
Configuration built into the DUALPRO. When you set
your instrument up the first time be sure to record all
the parameter settings for each instrument in an
installation on the SETUP SHEET at back of the
manual. Make copies if there are more than four
instruments in a setting. Keep these SETUP SHEETS
in a safe place where you can find them to recalibrate
or reset an instrument if necessary. See Setup and
Configuration for details.
If after you review the manual section on setups you still
have problems please call Marathon Monitors for help. To
get an instrument calibrated outside your installation you
may return it to Marathon for calibration service. This
requires calling, scheduling the return, shipping and being
without your DUALPRO for at least one week. You could
also schedule a paid service call.
How do I set the clock?
Check the operator’s quick reference to confirm how
to change a value with the arrow keys.
Press [Page Disp]
Select the VERSION page by pressing the [right] or
[left] arrow keys.
Press the [down] key to display the date.
Press and hold [Shift] press [Setpt] with it to get a
display that reads:
MODE This allows the clock flexibility in keeping dates
x x A B accurate. The formula for mode is based on
the “A” place being the number of years since
the last leap year. The one’s place is used for
9
a numeric value for the day of the week. The
“A’s” values are only 0 to 3; the “B’s” values
are Sunday = 1 through Saturday = 7.
Year can be from 1980 to 2079
YEAR
XXXX
MNTH
XXXX
DAY
XXXX
HOUR
XXXX
MIN
XXXX
The month can be set to
0001 through 0012
Day is set as date value
0001 through 0031
The hour is set in military time
0000 (midnight) to 23(11 P.M.)
Minutes are set from 0 to 59. If greater
accuracy is needed, set the DUALPRO to the
next minute and press the [Enter] key when
your external time reference seconds are equal
to zero.
10
DESCRIPTION
The MMI DUALPRO Controller/Programmer
represents the state of the art in microprocessor-based
process control technology. By combining the flexibility
of Proportional, Integral, Derivative (PID) control with
the features common in programmable controllers, the
DUALPRO can tackle even the most complex
systems.
The following features have been included to allow use
of the instrument in many applications:
CONTROL
Is fully site-configurable for single or dual loop
control with a variety of simple or complex control
variables.
PROGRAMMING
Offers a selectable option that allows programs to be
entered and edited in the MMI industry standard
Recipe language programmer or the Logic language
programmer. This gives the ability to let the
operators work with an easy to use procedural
program language.
A powerful process/logic programmer that can store
up to two-hundred (200) Recipe language programs,
consisting of nineteen (19) steps, each, and 200
Logic language programs consisting of twenty-four
(24) steps, each. It allows multiple tasks, foreground
and background tasks, subroutine calls,
test-and-branch capability, and full access to all
instrument parameters.
11
Onboard, MMIBASIC Interpreter can reach all
instrument parameters in a high-level language
format separate from the process/logic programmer.
ANALOG INPUTS
The DUALPRO allows for three analog inputs that
can be configured for various input types based on
the type of "daughter boards" located on the analog
input board. The standard connection, at TB D, will
have the first input as a thermocouple on TB D
positions 1 and 2. The second input is usually the
probe millivolt input at TB D positions 4 and 5. The
last input is usually another thermocouple input at
TB D positions 7 and 8.
Up to three (3) fully isolated analog inputs, each
separately configurable for thermocouple, RTD,
voltage, or current. The total number of inputs can
be expanded to 67 inputs with external analog
boards.
ANALOG OUTPUTS
Two (2) fully isolated analog output contacts, each
separately configurable for voltage or current output.
Internal outputs can be adjusted to 0 to 5 V dc or 0
to 22 mA. The standard setting for both channels is
4 to 20 mA outputs. The change from V dc to mA is
made through a DIP switch setting on the analog
output board. Calibration adjustments are made via
on-board potentiometers.
Additional external analog outputs can be added
with an external analog board.
ALARM OUTPUTS
Two (2) configurable alarm contacts, programmable
as process, deviation, program, or fault alarms.
12
CONTROL OUTPUTS
Two (2) configurable control output triacs allowing
dual control on both loops.
DISCRETE INPUTS and OUTPUTS
Four (4) programmer events. These events can be
partitioned as discrete inputs or outputs. Outputs
are always grouped as the lower set, inputs as the
upper set. The number of discrete events can be
expanded to 68 I/O with external event boards.
COMMUNICATIONS
Four communication ports are at TB C. They use
RS-422 / RS485 full or half duplex protocol for all
ports. Typically, the HOST port will connect to a host
computer; the AUXILIARY port to other slave
instruments, the EVENTS PORT to OPTOMUX I/O
devices, and the BASIC TERMINAL PORT to a
remote terminal or other programmable device.
A number of protocol selections are possible
including, Marathon Protocols for block transfer,
slaves, master, token ring, and Modbus.
PROBE CARE
Automatic probe testing is available and can be
initiated during setup by entering the time between
tests. Automatic probe burnoff can be setup by
entering the time between burnoffs and the time for
burnoff. See the specific probe’s documentation for
details.
13
OPERATION
Once installation and setup and configuration are
complete, the day to day operation needs of the
DUALPRO depend upon the application. The basics
are found in the Quick Reference Guide.
HOW TO RESPOND TO ALARM MESSAGES:
Note the alarm and determine what caused the alarm.
Press [Enter] once to deactivate (silence) alarm relay
contact and continue program execution.
After acknowledging the alarm, one of the following actions
may be appropriate:


Abort the program by pressing the
[Prog/Auto/Man] key.
In the case of a timed-out LIMIT
statement (message #93), it is normally
desirable to continue the program by
re-executing the offending LIMIT
statement to be sure it is satisfied. This
is done automatically when the [Enter]
key is pressed to acknowledge the
alarm. If you do not want to re-execute
the LIMIT statement, press the [Setpt]
key instead of the [enter] key. This will
cause the LIMIT statement to be
skipped and the program to continue to
the next STEP.
14
CHANGING THE SETPOINT AND THE REFERENCE
NUMBER
[Setpt] is used to enter the setpoints for Loop 1, Loop 2,
the Reference Number, and the Operator Inputs. The first
press of [Setpt] will allow the arrow keys to adjust the
value of the setpoint for Loop 1; pressing [Enter] allows
the setpoint of Loop 2 to be changed. Pressing [Enter]
again allows the Reference Number to be changed.
Pressing [Shift] at any time allows the operator to “back
up”to the to the step before [Enter] was pressed. Each
additional press of [Enter] allows operator Inputs 1 - 15 to
be changed. The next press of [Enter] will cycle back to
the setpoint for Loop 1. Anytime during the setting of
values [Setpt] may be pressed to save the value and exit.
All the parameters in this group have a lock level of 3.
SETPOINT PARAMETERS
Table 1 Setpoint Parameters
Parameters
SP 1
SETPOINT 1
SP 2
SETPOINT 2
Description
The set line represents
the basic parameter for
Loop 1 that the process
needs for control.
The Set line represents
the basic parameter for
Loop 2 that the process
needs for control.
15
REF
Reference Number
Nn OPERATOR INPUT
(n = 1-15)
Assigns a number to a
program for future
reference, different
applications include 1.
Part number. 2. Loop
control for the
Programmer.
Allows the operator to
enter information that may
be needed by a program.
These inputs may be used
similar to the reference
number.
PROG/AUTO/MAN
Loop operation modes and the control of both the
foreground and background programs are selected by the
[Prog/Auto/Man] key. The first selection, after pressing
[Prog/Auto/Man], allows for control of the foreground
program to be entered. The key presses that follow it
depend upon the state of the program. If a program is
running in both the foreground and background, a press of
[Enter] allows for control of the background program to be
selected.
Another press of [Enter] allows for the operation mode
(auto or manual) of loop 1 to be selected, and another
press allows for the operation mode of loop 2 to be
selected.
Any further presses of [Enter] will cycle back through these
selections. If a program is not running see Running A
Program below. Anytime during the selection process
[Prog/Auto/Man] may be pressed to exit the selection
process. All of the parameters under this key have a Lock
Level of 3. The background program is the exception with
a Lock Level of 2.
16
MANUAL MODE
In Manual mode the process variable is displayed in the
PROCESS display, the SET display shows the appropriate
control value, and no control action is computed. The arrow
keys can also be used to activate the control output.
Either the percent ON time (time-proportion) or valve
position (position proportion) is displayed in the SET
window. For single control mode operation this number is
always positive (0/50/100). The [Up Arrow] and the [Down
Arrow] keys increase or decrease the percent ON time or
the valve position toward its fully opened or closed
positions by approximately 1%. This continues for as long
as the key is pressed. The [Right Arrow] and [Left Arrow]
keys force the CONTROL OUTPUTs to increase or
decrease the percent output by approximately 10%.
AUTOMATIC MODE
In Automatic Mode the process variable is displayed in the
PROCESS display, the SETPOINT is displayed in the SET
display, and control action is computed based upon the PID
parameters and the input(s). Pressing and holding the [Left
Arrow] key will cause the SET display to show the control
action as described previously in "Manual Mode.”
17
RUNNING A PROGRAM
To run a program,

Press [Prog/Auto/Man].
Foreground program:





If FPRG STOP is displayed.
Use the arrow keys to select RUN.
Press [Enter]
Enter the program number to be run.
Press:

[Shift], to start the program at step 1,
or

[Enter], to pick the step number to start
after entering the starting step number,
press [Enter]




If FPROG RUN
Press [prog/auto/man] for FPRG CONT
Use the arrow keys to set program number.
Press either

[Shift] to start at step one or

[Enter] to pick the starting step, then
press [Enter] again.
Background program:






If FPRG STOP
Press [Enter] to get BPRG STOP
Use the arrow keys to pick RUN
Press [Enter] to get BPRG
Use the arrow keys to pick the program
number
Press either

[Shift] to start at step 1 or

[Enter] to pick the step number; press
18
[enter] again.







If FPRG RUN
Press [Prog/Auto/Man] to get FPRG CONT.
Press [Enter] to get BPRG STOP.
Use arrow keys to pick RUN.
Press [Enter].
Use the arrow keys to pick the step number.
Press either

[Shift] to start at step 1 or

[Enter] to pick the step, use arrow keys
to pick; press [Enter] again.
STOPPING A PROGRAM
To stop a program,




Press [Prog/Auto/Man.
Select FPRG to stop a foreground program or
BPRG to stop a background program.
Use the arrow keys to select STOP.
Press [Prog/Auto/Man] to exit the selections.
NOTE
This is different from HOLDing or pausing a program.
PLACING A PROGRAM IN HOLD
To hold or pause a program,

Press [Prog/Auto/Man.

Select FPRG to hold a foreground program or
BPRG to hold a background program.

Use the arrow keys to select HOLD.

Press [Prog/Auto/Man] to exit the selections
NOTE
19
This is different from stopping a program. Placing a
program in hold stops the program execution at the
program line that was executing. The B Prog or F Prog
LED will flash, indicating which program is in hold. The
program can be continued by selecting the CONT option
and pressing [Enter].
RESTARTING A PROGRAM FROM HOLD
To restart a program after holding or pausing,

Press [Prog/Auto/Man].

Select FPRG to continue a foreground
program or BPRG to continue a background
program.

Use the arrow keys to change the selection
from HOLD to CONT.

Press [Prog/Auto/Man] to exit the selections.
NOTE
If the selection displays CONT, then a program is currently
running. A press of either [Enter] or [Shift] will continue to
the next or previous selection without interrupting the
running program.
20
PROBE CARE
Probe Care is a combination of several functions that can
be performed on the oxygen sensor connected to the
Dualpro. These functions make determine the viability of
the probe as a sensing device and perform burn off
maintenance cycles.
Probe life can be estimated by tracking the impedance of
the probe over its operation life. A new probe will have an
impedance of around 1 Kohm. This impedance will
increase over time based on how quickly the sensor
electrodes are affected by the reducing atmosphere in the
furnace. As a probes impedance approaches 20 Kohms it
may be time to consider a replacement. These is why the
standard default test impedance value is typically set to 20.
From this point the probe will degrade more rapidly. The
probe should be replaced if it reaches 50 Kohms before
failing.
This probe impedance cannot be measured with an Ohm
meter. It is determined by calculating the internal source
impedance of the probe by shunting the output with a know
resistance. See the detail explanation in the Probe
Impedance section below.
The impedance test also measures the recovery time of the
probe signal level once the shunt resistor is removed. This
is another quality measurement. A healthy probe should
recover to full signal output in less than 45 seconds. This is
an additional limit that can be set to monitor and alarm if
the recovery time exceeds a normal recovery time.
If Probe Care is enabled in the Probe Care menu the
Dualpro will run and record the probe impedance, burn off
parameters and recovery times.
21
The Bank 1 dip switches on the Interface board must have
a process selection enabled for these functions work. See
the Setup and Configuration Section for an explanation of
these switch settings.
To manually start a probe maintenance program

Press [Shift] +[Enter]
CAUTION
IF PROBE CARE IS INHIBITED DO NOT ENABLE IT
UNLESS YOU ARE SURE THE PROBE HAS BURNOFF
CAPABILITY! SOME PROBES SUCH AS THE PICOLLO
PROBE
CAN
BE
DAMAGED
BY
BURNOFF
PROCEDURES.
CHECK WITH SUPERVISORY
PERSONNEL OR MARATHON PERSONNEL BEFORE
STARTING A DISABLED PROGRAM.
Probe Impedance Test
The probe impedance test is performed only if dip switch
bank 1 has enabled a process function. The probe
impedance test is performed by measuring the open circuit
voltage of the probe, then applying a known shunt resistor
across the probe signal and measuring the shunted value.
The value of the shunt resistor is 10kohm for carbon or
dewpoint calculations or 10 ohm for the oxygen calculation.
The impedance is calculated as:
Rx = (Eo/Es-1)*Rs
Where Rx = probe impedance, Eo = open circuit voltage,
Es = shunted voltage, and Rs = shunt resistor.
Since the voltage units drop out, the voltage could be in
volts, millivolts, or A/D counts. The units of Rx are the
same as Rs; therefore, the calculation is the same for Rs =
10 kohm or Rs = 10 ohm.
22
The following table outlines the steps taken by the
instrument during an impedance test.
Table 2 Probe Impedance Sequence
Sequence
#
1
2
3
4
5
6
Description
Inhibit process variable calculations.
Freeze alarms at last state except
clear any previous probe test failure
alarm.
Store present probe millivolt reading
Apply shunt resistor across probe
Wait for impedance test timer, fixed
time of 30 seconds
Compute impedance of probe and
remove shunt resistor.
If impedance is greater than
maximum allowed then set probe test
failure alarm.
Wait for probe to recover to >=99% of
original millivolts.
Maximum wait time for recovery is set
by operator.
If recovery time is greater than
maximum time then set probe test
failure alarm.
Store recovery time (or max value )
If burn off is to be performed then go
to step 1 of burn off sequence,
otherwise wait 30 seconds.
Resume normal operation of all
instrument functions.
23
Probe Burn Off
A probe burn off cycle consists of pumping a high flow of
reference air into the probe to cause the accumulated
carbon to ignite and ‘burn off’ the end of a carbon probe.
This is not a feature of an oxygen probe.
Table 3 Probe Burn Off Sequence
Sequence #
1
2
3
4
5
6
Description
Inhibit process variable calculations.
Freeze alarms at last state.
Turn on the output contact to start probe
burn-off.
Wait for probe burn-off timer, value set
by operator.
Store probe temperature and millivolts
at end of burn-off time.
Turn off output contact to end burn-off
Wait for probe to recover to >=99% of
original millivolts
Maximum wait time for recovery is set
by operator.
Store recovery time ( or max value).
Wait 30 seconds (final delay)
Resume normal operation of all
instrument functions.
TO CHANGE THE LOOP DISPLAYED

Press [Shift]
TO PLACE A LOOP IN HOLD

Press [Shift]+[Right Arrow]
24

Press [Page Disp] to return to scan or to shift
between scan and hold.
CHANGING PARAMETERS
All of the DUALPRO parameters, program numbers,
OPCODES, and data values can be altered using the
following procedure:

Press [setup]. The word MENU will appear in the
PROCESS window. The Parameter group will
appear in the SET window. Use the [right] arrow key
or the [left] arrow key to select the desired
parameter group. Press [Enter]. The symbol for the
parameter is displayed in the PROCESS window
while the current alterable data is shown in the SET
window. The flashing character is the one that can
be altered.

Use the [Left Arrow] or [Right Arrow] keys to select
the character to be altered.

Once the character to be changed is flashing, use
the [Up Arrow] or [Down Arrow] keys to select the
desired number or symbol.

After all characters are as wanted, press the [Setup]
key to place the value in memory and exit,
or
press [Enter] to save the value and continue
(forward) editing other parameters,
or
[Shift] to save the value and continue (back) editing
other parameters.
NOTE
If an entered number value is not within the acceptable
data range, the maximum/minimum value will flash in the
SET display. Repeat the above procedure until an
acceptable value has been entered.
25
VIEWING A PROGRAM WHILE IT IS RUNNING
To view any part of the program while its running press
[Page Disp.] this will open the Status Display Page. To
navigate the indexing of the Status Display, think of the
items that show up in the Process and Set displays of the
instrument as paragraphs of various pages. As a page is
reached, the first paragraph identifies the page.
•
To travel through a page the [up arrow] or [down
arrow] keys will move the display from paragraph to
paragraph.
•
To “turn pages” the [left arrow] or [right arrow] keys
will move the display from page to page.
The last paragraph viewed on a page is stored in memory.
When returning to a page to see the last viewed paragraph
press the [Setpt] key. To stop viewing any time press the
[Page Disp] key. This will return the display to operating
mode. The following items are intended to provide a
complete definition and layout of the status display.
26
Status Display Operations
The Status Display consists of eleven (11) pages
containing between three (3) and 255 paragraphs
each. Pages with repetitive or sequential paragraphs
are generally shown as having the beginning and
ending paragraphs separated by three dots
(indicative of missing paragraphs). The eleven
pages will be defined as shown below:
PAGE
TITLE
DESCRIPTION
0
4.0 d
Displays the Version number of the
installed unit and the current date
and time.
1
BAS
Displays the line being executed
and the two user- created
messages
2
PROG
Displays the STEP/PROGRAM of
the current, calling, and
background programs; the
executing OPCODE and any
alarms that are present.
3
EVNT
Contains "tick mark" indicators of
the Digital Events Setpoint, Actual
States, and OPTOMUX Port
communication status.
Continued on next page
27
4
DATA
Contains the process variables
including thermocouple, cold
junction, and calculated values.
5
EXT
ALOG
6
SET
UP
Displays the values for the
Setpoints, the Process Factors, and
the Reference Number, and the
operator inputs.
7
CONT
Displays various control
parameters such as: Proportional
Band, Reset, Rate, Cycle Time,
Process Factor, and Percent
Output.
8
SLAVE
INST
Displays the slave instrument's
setpoint and actual data for
instrument 1 through 8 and
communications status of each
instrument..
9
TMRS
Displays the data of the external
Analog channels 0 through 15,
and the Analog Communications
Status.
Displays current displacement of
timers 0 through F (15 in decimal).
Continued on next page
28
10
00=0
Displays the parameters and
their present values (in hex).
11
PROB
CARE
Displays the data associated
with the last probe maintenance
cycle.
NOTES to the following Status Display table
EVNT DISPLAY
? = 0 through 4: This is a repetitive screen sequence of
SP (setpoint) and ACT (actual) followed by PAR
(parameter) each being a number 0 through 4.
It is possible to manual turn on or off individual events by
selecting the set point (SP ?) display where ? is the
event board to change. SP 0 indicates the instrument’s
internal events. SP 1 through SP 4 indicates external
OPTO event boards. To turn an event on/off while SP ?
is shown, press the [Shift] + [Setpt] keys at the same
time. The display will change to ESP? 0oF. Press the
[Right] or [Left] keys to turn the event on/off. Press the
[Up] or [Down] keys to select another event. Only events
0 through 3 are valid for the internal events (SP 0).
EXT ALOG DISPLAY
? = 0 through 15 EA (external analog) events 0 - 15 are
displayed here.
SETUP DISPLAY
? = 1 THROUGH 15: This is a repetitive screen showing
the 16 “N” numbers or program registers that can be
used at operator inputs to control instrument programs.
CONTROL DISPLAY
? = 1 OR 2. The control menu cycles through the shown
29
set of screens to indicate either Loop 1 or Loop 2 control
parameters.
SLAVE DISPLAY
? = Slave instrument number. Slave instrument screens
cycle through as a set from 1 to 8. SSP (slave setpoint),
SAC (slave actual), and SPO (slave percent out) are the
first set of screens.
TIMERS DISPLAY
? = Timer number
Timers are numbered in hex from 1 through F (15) and
the screens repeat accordingly.
GENERIC DISPLAY
The instrument's parameter tables are shown in this
display. This page should be avoided by operators.
The upper display XX = Y indicates the parameter
number and table where XX is the parameter
number in hexadecimal and Y is the table. The
instrument has 31 tables number 0 through V. It is
possible to advance through these tables by
pressing the [Setup] key. Each table has 256
parameters number from 00 to FF. It is possible to
advance through these parameters ten at a time by
pressing the [Enter] key. Pressing the [Up] or
[Down] keys allows you to move up or down through
the table parameters.
30
Status Display chart
4.0 d
r138
2002
0324
1000
54
BAS
INT
Line
0000
PROG
EVNT
DATA
R 0
F000
G 0
F000
0000
R 0
B000
G 0
B000
------PAL
SP ?
‘’’’
ACT ?
‘’’’
PAR?
‘’’’
ST ?
G 00
LSP?
CJ
93.00
IN A
3500
IN B
2504
IN C
2410
CV 0
2.550
CV 1
-100
CV 2
.000
CV 3
.000
LAC?
EMAP
OFF
RT
.00
MT
.00
31
EXT
ALOG
EA ?
000
ST ?
B 10
Status Display cont.
SET
UP
SP 1
1000.
SP 2
2000.
REF
100.0
N?
1.000
PF 1
150.0
PF 2
150.0
CONT
PO ?
0.0
PB ?
20.0
RES?
.200
RAT?
.000
CYC?
10.00
LPO?
.000
HPO?
100.0
LDL?
.000
SW
250.4
SLVE
INST
SSP?
.000
SAC?
.000
SPO?
.000
ST ?
B 25
DPST
'
TMRS
TMR?
9999
00=0
C03C
PROB
CARE
DATE
11.23
TIME
6.00
IMP
2.5
I RT
.000
BOMV
1130
BOTC
1672
BORT
.000
VGAS
.0
VTOL
,0
VRES
.0
32
Table of abbreviations :
abbreviation
definition
ac
Alternating current
ao
analog output location also called analog
outputs
C
centigrade
CV
calculated value or control variable *
dc
direct current
Dim
F
dimensioning statement
Fahrenheit
Hz
Hertz
I/O
input or output
mA
milliampere(s) also called milliamps
mV dc
millivolt direct current
PF
Process Factor
Rev
Revision
RTD
Resistive Temperature Device
SCSP
Supervisory Computer Software system
33
abbreviation
TB
T/C
V
definition
Terminal Block
Thermocouple
volts
V ac
Volts alternating current
V dc
Volts direct current
v
version
#
number
"
inches
* This is situation dependant. CV is used in display space
to indicate a value to be entered in a program slot.
34
INSTALLATION
The DUALPRO instrument is designed for .125" thick panel
mounting in a quarter DIN standard opening of 5.43"
square (adapter panels available by special order).
Required rear clearance is 10.5" to allow for wiring.
As with all solid state equipment, the controller should be
away from excessive heat, humidity, and vibration. Since
the unit uses red LED display devices, it should also be so
that direct sunlight will not interfere with the display's
visibility. The instrument requires 100/120/200/240 V ac
(jumper selectable on power interconnect board inside the
REAR PANEL) 50/60 Hz and should not be on the same
circuit with other electrical noise producing equipment such
as induction machines, large electrical motors, etc. All
instrument wiring must be run separate from all control
wiring. Noise suppression must be employed. Commercial
noise suppression equipment is available. MMI can provide
recommended parts or numbers for transient noise
suppression from solenoid valves or similar equipment.
PANEL MOUNTING/REMOVAL
Because the instrument uses a ventilated enclosure, it is
not dust tight. It should always be mounted in a sealed
control panel.
To mount the instrument in a control panel, cut a 5.43"
square hole in the necessary location on the panel. The
following procedure should be followed to mount the
DUALPRO in the panel.
1. INSERT the unit into 5.43" square cut out in the panel.
2. While supporting the unit, insert one, slotted, clamping
bracket into the small rectangular cutout on the side of the
unit.
35
3. Repeat step 2 for the opposite side of the unit.
4. With a 7/16" socket or wrench, alternately tighten bolts
on either side of the instrument until the springs are
compressed halfway to ensure rigidity of mounting.
CAUTION
To prevent damage or warping of the unit's case, do not
over tighten the clamp bolts.
36
To remove the unit, loosen the side clamping brackets and
reverse steps 1 through 3 above.
On subsequent removals and installations the rear panel
can be removed (4 screws) and the wiring does not have to
be disturbed.
WARNING
ALL CONNECTIONS, REAR PANEL INSTALLATIONS
AND REMOVALS; AS WELL AS TRIAC BOARD
INSTALLATIONS AND REMOVALS MUST BE DONE
WITH POWER REMOVED FROM TERMINAL BLOCK A
(TBA) AND TERMINAL BLOCK B (TBB). ALL OTHER
(PC) BOARDS SHOULD ONLY BE REMOVED OR
INSTALLED WHEN INSTRUMENT POWER IS TURNED
OFF VIA THE TOGGLE SWITCH ON THE TRIAC
BOARD. OTHERWISE, SERIOUS PERSONAL AND/OR
EQUIPMENT DAMAGE CAN OCCUR.
37
THERMOCOUPLES AND OTHER SIGNAL WIRES
The wiring used to connect the signal wires to the
instrument should be run in conduit, separate from any AC
lines in the area. This provides noise immunity and physical
protection. Thermocouples should be wired with the
appropriate alloy extension wire with no termination other
than at the instrument. As with all cold junction
compensating instruments, EXTREME CARE should be
used when an existing thermocouple is to be used for both
the Controller and another instrument at the same time.
CHART RECORDERS
If a chart recorder is to be used, it must have input
specifications within 0 to 5 V dc, and 4 to 20 mA. The ideal
location of the recorder is adjacent to the instrument but it
may be located remotely if the connecting wires are
properly shielded. Long wiring runs from the chart recorder
outputs may require resistive termination (2 K ohms or so)
at the remote end to decrease the effects of electrical
noise. For best results, the chart recorder input(s) should
be isolated from ground. Another possible configuration is
to calibrate the Analog output to 0-20 mA and use a
terminating resistor to get the required voltage at the chart
recorder. This setup will help reduce noise at the chart
recorder.
38
ALARMS
Two user programmable alarm contacts are available for
connection at the DUALPRO rear panel. The system
design for alarm usage will determine the alarm wiring and
configuration.
Electrical connections
Connections to the unit are made via four terminal blocks,
located on the REAR PANEL, labeled TBA, TBB, TBC, and
TBD. Positions are numbered from top to bottom. AC
power, event, control, and alarm connections are made on
TBA and TBB. All communications are located on TBC and
all analog I/O signals are located on TBD. Refer to your
installation drawings for a complete layout of the electrical
connections.
AC POWER
The DUALPRO requires 100/120/200/240 V ac at ¼ AMP.
Be sure the jumpers on the power connection are correct
for the voltage supplied.
CONTROL CONTACTS
Eight control contacts are located on TBA and TBB. Be
certain to isolate the instrument with a relay (MMI part
39
number F921702).
COMMUNICATIONS
Four communication busses are located at TBC and use
RS-422 full or half duplex protocol for all ports. Typically,
the HOST port will connect to a host computer; the
AUXILIARY BUSS to other instruments (including those in
the PRO series); the EVENTS PORT to OPTOMUX I/O
devices; and the BASIC TERMINAL PORT to a remote
terminal or other programmable devices
ANALOG INPUTS
The DUALPRO allows for three analog inputs with their
individual functions determined by "daughter boards"
located on the analog input board inside the unit. The
standard connection, located at TBD, will have the first
input as a thermocouple. The other two inputs are used
optionally to input voltage or milliamp signals with resistor .
ANALOG OUTPUTS
Two separate and isolated analog outputs are provided on
TBD and can be adjusted to any upper and lower limit
within the ranges given: 0 to 5 Vdc or 0 to 20 mA to include
the standard settings of 4 to 20 mA or 0 to 5 Vdc output.
The change from V dc to mA is made through a DIP switch
setting on the analog output board. Adjustments are made
via on board potentiometers. See Maintenance and
Troubleshooting for details of settings.
OUTPUT CONTACT
To allow for full dual loop control, with two control contacts
available for each loop, an “as needed” scheme is used.
This calls for event contacts 2 and 3 to be attached as third
and fourth control contacts when the setup requires it. If
they are not needed they remain as events. See THEORY
40
of OPERATION for complete definitions of the control
modes indicated below.
LOOP 1 CONTROL MODE
LOOP 2
CONTROL
MODE
Control
Function
TP/OF
TC/OC
TD/O
D
MS/PP
TP/OF
Lp 1 fwd
Lp 1 rev
Lp 2 fwd
Lp 2 rev
Ctrl 1
---Ctrl 2
----
Ctrl 1
Evt 3
Ctrl 2
----
Ctrl 1
Ctrl 2
Evt 3
----
Ctrl 1
Ctrl 2
Evt 3
----
TC/OC
Lp 1 fwd
Lp 1 rev
Lp 2 fwd
Lp 2 rev
CTRL 1
----Ctrl 2
Evt 3
Ctrl 1
Evt 3
Ctrl 2
Evt 2
Ctrl 1
Ctrl 2
Evt 3
Evt 2
Ctrl 1
Ctrl 2
Evt 3
Evt 2
TD/OD
Lp 1 fwd
Lp 1 rev
Lp 2 fwd
Lp 2 rev
Ctrl 1
----Ctrl 2
Evt 3
Ctrl 1
Evt 3
Ctrl 2
----
Ctrl 1
Ctrl 2
Evt 3
Evt 2
Ctrl 1
Ctrl 2
Evt 3
Evt 2
MM (note
1)
Lp 1 fwd
Lp 1 rev
Lp 2 fwd
Lp 2 rev
Ctrl 1
----Note 2
Ctrl 2
Ctrl 1
Ctrl 2
Evt 3
note 3
Ctrl 1
Ctrl 2
------
Ctrl 1
Ctrl 2
------
PP
Lp 1 fwd
Lp 1 rev
Lp 2 fwd
Lp 2 rev
Ctrl 1
---Ctrl 2
Evt 3
Ctrl 1
Evt 3
Ctrl 2
Evt 2
Ctrl 1
Ctrl 2
Evt 3
Evt 2
Ctrl 1
Ctrl 2
Evt 3
Evt 2
41
NOTES:
Continued on next page
1. MM (Multi Mode) for loop 2 is dual mode (-100% to
100%) when loop 1 is in TP, OF or OC. Otherwise it is a
single mode (0 to 100 %)
2. ANALOG OUTPUT 1, if set to PO2, will be zero to full
scale for 0 to 100% if loop 2 is in MM and loop 1 is in TP,
OF, TC or OC.
3. ANALOG OUTPUT 2 if set to PO2 will be zero to full
scale for 0 to -100% if loop 2 is in MM and loop 1 is in
TP, OF, TC or OC.
4. Only one analog output needs to be set to PO 2 for
notes 2 and 3 to apply.
SETUP & CONFIGURATION
DIP SWITCH SETTINGS
The user has a number of options that can be specified
using the Dual Inline Packaging (DIP) switches located on
the INTERFACE BOARD inside the DUALPRO.
To gain access to the DIP switches, loosen the black
knurled knob on the FRONT PANEL by turning in a
42
counter-clockwise direction. Carefully remove the FRONT
PANEL, but DO NOT remove the ribbon cable connecting
the FRONT PANEL to the INTERFACE BOARD. Safely
support the FRONT PANEL near the instrument. Adjust
DIP switches for the desired operating mode. When switch
adjustments are complete, replace FRONT PANEL to
prevent contamination.
Locate the appropriate switches as shown in the figure
below. Switches pushed to the left are ON pushed to the
right are OFF.
SW1
DIP Switch Bank 1
SWITCH
1
2
3
4
FUNCTION
Switch 1 & 2 select the
calculation mode. If both are off
then no calculation is preformed.
If sw1 is on and sw2 is off then
%C is calculated and stored in cv0 and dewpoint is calculated and
stored in cv-1. If sw1 is off and
sw2 is on then %O is calculated
and stored in both cv-0 and cv-1.
If both are on and the REDOX
value is calculated and stored in
cv-0
5
Slidewire deadband values
assigned as follows:
5
4
3 Dead band value
OFF OFF OFF
0.2
OFF OFF ON
0.4
OFF ON
OFF
1.0
43
OFF
ON
ON
ON
ON
6
7
8
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
2.0
3.4
5.2
7.4
10.0
Not Assigned.
Service 1
Service 2
Each DUALPRO connected to a master instrument or
supervisory Computer system must have a unique address
for proper communications, use the table below to select
the address setting for an individual instrument. The Host
Address is the address that identifies the DUALPRO and
makes it unique . 0 is rarely used in computer supervisory
control systems for instruments. 0 is assumed to be the
Master Address, a role the supervisory computer takes in a
networked system.
44
Dualpro in a network
Find the DIP switch bank 2, with 4 switches in it, to set the
host address. This bank resembles the figure below. Use
the following table to set the switches for the correct
address.
Switches pushed to the left are ON, to the right are OFF.
45
HOST address settings
DEC
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
HEX
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
1
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
2
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
3
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
4
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ANALOG OUTPUT MODE
Analog output selector switches are located on the analog
output board. The selection choices are between Voltage
and current. The DIP switch pointing up is Voltage mode
and pointing down is current mode. If the instrument is
switched from one mode to the other, the analog output
must be recalibrated. See Maintenance and
Troubleshooting for how to calibrate.
46
THERMOCOUPLE BURNOUT SELECTION.
The thermocouple jumper selects either a full upscale or a
full down scale reaction to take place when a thermocouple
fails or becomes open. The thermocouple daughter board
has a default setting of full upscale reaction to take place
when a thermocouple fails or opens. If full scale
downwards is desired cut the solder track from the + to the
C and then jumper from the - to the C.
Connector
Standoff
DAUGHTER BOARD TYPES
The user can specify at purchase several different daughter
47
board configurations.
Options include
• 1 = thermocouple (T/C) MMI Part # A810077
• 2 = auxiliary or O2 Mv
MMI Part # A810076
• 3 = slidewire feedback MMI Part # A810095
• 4 = 0 - 10 V linear
MMI Part # A810147
• 5 = 4 - 20 m A
MMI Part # A810168
• 6 = RTD *
MMI Part # A810115
• 7 = combustion O probe
MMI Part #
A810190
• 8 = pulse input
MMI Part # A810145
*(Resistive Temperature Device)
The standard factory setup is a 1, 2, 1.
If a daughter board is changed even with the same type,
that input must be recalibrated.
48
THE FRONT PANEL
The DUALPRO can be set to do specific jobs by entering
information through the front panel keyboard. Information
entered is stored in non-volatile memory. All the setups are
entered using the [Setup] key. Some of the parameters
opened by the [Setup] key require a password for entry, in
order to be sure that unauthorized or accidental changes
are not made. The DUALPRO is shipped from the factory
without a password; so, pressing [Enter] will by-pass the
password.
The DUALPRO front panel consists of an upper and lower
segment Light Emitting Diode (LED) display, twelve LED
indicators, and ten membrane keypads (keys). The upper
segmented display shows the process value in normal
operation and is referred to as the PROCESS window.
When entering parameters, this display will show a
message identifying the parameter being entered.
The lower display in normal operation will show the process
49
setpoint when in auto and the control percent output when
in manual. It is referred to as the SET window. When
entering parameters, this display will show the value of the
parameter being entered. This display will temporarily show
other data dependent on certain keys being held down as
described in the keypad section.
The twelve LED indicators provide information on the
operation of the DUALPRO as follows:
50
The keypad
The functions of the ten membrane keys may change when
the DUALPRO is placed into different modes. This
describes the keys if activated from the normal mode of
operation. The descriptions of the various modes will
describe how the keys are used in that mode.
This key displays messages concerning
the operation of the foreground program,
background program, Loop 1, and Loop
2. The foreground and background
programs may separately be stopped,
viewed, run, continued, or placed in hold.
Loop 1 and Loop 2 may be separately placed in
either manual or automatic mode.
Pressing this key allows the user to
edit the setpoint (SP1, SP2), reference
number (RN), and operator-input
numbers (N1 – N15)
51
This key allows the status display page to be
viewed, and allows a limited number of
features to be edited.
Pressing this key places the
DUALPRO into parameter entry
mode for all setup parameters.
Pressing this key shifts the
display representation from one
loop to the other as indicated by
the loop LED’s. It also performs
as the second key for most dual
key operations. The [Shift] key also can be
used to cycle through the parameters of other
keys in a reverse direction. In multi-key
operations, always press and hold the [Shift]
key then press the other keys.
This key has no function by itself under normal
operation. However, it is used to cycle through,
in a forward direction, the parameters of the
other keys.
The [Right Arrow] is only
used when in manual mode
or parameter entry mode.
Each press of the [Right
Arrow] key will cause the
percent output of the displayed loop to
increase by approximately 10% when the
loop is in Manual mode.
52
The [Up Arrow] is used to increase
the edited digit in parameter entry
mode and to manually adjust the
percent output in the manual
control mode. Each press of the
[Up Arrow] key causes the percent output of the
displayed loop to increase by 1%.
The [Down Arrow] is used to
decrease the edited digit in
parameter entry mode and to
manually adjust the percent output
in the manual control mode. Each press of the
[Down Arrow] key causes the percent output of
the displayed loop to decrease by 1%
The [Left Arrow] is only used when in
manual mode or parameter entry mode.
Each press of the [Left Arrow] key will
cause the percent output of the
displayed loop to decrease by
approximately 10%.
++ ++
This two key combination performs an LED
test whereby every segment and decimal
point of the fourteen segment displays and
every LED is illuminated. Should an LED not light up, it is
defective. If any part of the display does not light during this
test, it is defective.
53
This two key combination determines how the two control
loops will be displayed. Pressing [Page Disp] key in this
mode allows the display to either scan between Loop 1 and
Loop 2, or to display only the loop placed in hold. The loop
to be placed in hold may be determined by pressing the
[Shift] key.
+++++
This two key combination sets up the cold junction trim.
+++
This two key combination opens the program editor option.
This two key combination sets up the password. Any order
of keys except for [shift] or [Enter] can be used as
passwords. Up to nine key presses can be used. Press
[Enter] to save a newly set password. The number in the
SET display will count the number of keys entered.
Pressing [Enter] without pressing any other key (i.e.: SET
54
display = 0) will enter "no" password. Whether or not a
password is needed on each parameter is determined by
the lock level setting and the lock level required for each
parameter. The lock level which affects each parameter will
be listed at the end of each parameter description as LL-X
(X=0 to 3).
These two key combinations will start the probe
maintenance routine, if it is enabled.
This is a four-key sequence that will set up the memory
of the instrument. If the lock level is less then 3, a
password will be required to execute this function.
This is a four-key sequence will test the memory. If the
lock level is less than 3, a password will be required to
execute this function.
55
This is a four-key sequence will place the Dualpro in
INPUT CALIBRATION MODE. If the lock level is less
than 3, a password will be required to execute this
function.
56
INSTRUMENT SETUP
The [Setup] key allows for setup parameter options to be
changed/set. These options exist in "groups". They are
displayed as "menu" choices after [Setup] is pressed. Press
[Enter] to step forward in any option, or [Shift] to back up to
a previous option. The arrow keys are used to change the
option within its limits. Pressing [Setup] at any time will exit
from this option setup sequence.
Options are saved as they are changed. To move from
menu column to menu column press
or
when menu
is displayed. To move from selection to selection in a
column press [Enter] to go forward and [Shift] to go
backward.
Control Parameters - Loops 1 and 2
Proportional Band
The proportional Band range is 0001 to 9999.
If the proportional band is set at 10% and the
error is 100 (10% of the total range) then the
output would be 100% presuming a reset of 0
The n = 1 for loop 1 or 2 for loop 2. With Simple ON/OFF
control Proportional Band is used to set the dead-band.
Lock Level (LL)=2.
PBn
XXXX
Reset 1
RESn
XX.XX
The Reset setting is in repeats per minute.
The range is 00.00-99.99 (=XXXX) resets per
minute in .01 increments. The n=1 (for Loop
1) or 2 (for Loop 2). LL=2
Rate
RATn
XX.XX
The Rate setting is in minutes and can range
57
from 00.00-09.99 (=XX.XX) minutes in .01 increments. The
n=1 (for Loop 1) or 2 (for Loop 2). Refer to Appendix on
PID control for more information on Setting up the PB, rate,
and reset. LL=2.
Cycle Time
CYCn
XXXX
The cycle time is in seconds. The range is
0001 - 0250 (=XXXX). The n=1 (for Loop 1)
or 2 (for Loop 2). LL=2.
Maximum %
HPOn
XXXX
Maximum percent output loop 1 (set > LPO1)
Minimum %
LPOn
XXXX
Minimum percent output loop 1 (set < HPO1)
CAUTION:
Unknown results can occur if LPO is set
above HPO.
Load Line
Is a manual offset to the control output
(manual reset). The LOAD LINE can be set
from (-100) to 0100 (=XX- XX). LOAD LINE
must be set to zero when using ON/OFF
control. The n=1 (for Loop 1) or 2 (for Loop 2). LL=2
LDLn
XXXX
Control Variable
CV n
XXXX
n = 1 (for Loop 1) or 2 (for Loop 2).
XXXX = inputs A (IN A),B (IN B), or C (IN C)
and Calc Value 0 (CV 0),1 (CV 1),2 (CV 2), 3
58
(CV 3) or Not Applied (N/A). The input type selected by this
parameter determines the process variable to be controlled
by the respective loop. The setpoint units and control
calculation are also based on this selection. LL=1
Control Mode
n = 1 for (Loop 1) or 2 (for Loop 2).
The control mode setting determines the
type of control action that will occur when the
difference between the actual process
variable value and the setpoint that value becomes great
enough to warrant corrective action by the control loop. i.e.:
with temperature as the process variable and a setpoint of
1600¦. When the actual temperature drops below 1600 the
control loop should respond by applying heat. The control
mode setting determines what form that application will
take. (i.e.: a control contact turning on, or an increase in a
0- 5 V dc signal.) The left most X (of XXXX) represents
direct (D) or reverse (R), and the remaining X's =:
CM n
XXXX
TP = TIME PROPORTIONING
TC = TIME PROPORTIONING WITH COMPLEMENT
TD = TIME PROPORTIONING DUAL
MS = MOTOR WITH SLIDEWIRE FEEDBACK ( Loop 1
only)
OF = OFF / ON CONTROL OC = OFF/ON CONTROL
WITH COMPLIMENT
OD = OFF / ON CONTROL DUAL
PP = POSITIONING PROPORTIONING
MM = MULTIMODE (loop 2 only) (See theory of operation
for definitions of these terms)
LL = 1
Use Events for Control
uSEV
XXXX
xxxx = yes or no
use events for control. This selection
59
determines if event outputs 2 and 3 would be used for
control based on the output contact selection chart (page
34). yes = use events, no = don’t LL=1
Input Setups - Inputs A, B, and C
Input Selection
n = A (for input A), B (for input B), or C (for
input C). XXXX = LINear; thermocouple
(TC): B, C, E, J, K, N, NM, R, S, or T; U1 for
user defined linearization curves.
PUL – For pulse input.
OFF - Turns input off and stops update of corresponding
input parameters.
PROGram - Linear inputs can be scale the displayed
engineering units using the offset and span values.
RTD - For RTD connection. LL=1
IN n
XXXX
Cold Junction
CJC n
XXXX
n = A (for input A), B (for input B), or C (for
input C). COMPENSATION XXX = YES, to
select cold junction compensation, or NO to
not select cold junction compensation. LL=1
Input Offset
n = A (for input A), B (for input B) or C (for
input C). Selects the amount of offset for the
InOF
programmable input function. (See Setup
XXXX and Calibration for more details.) XXXX =
(-999) to 0999. With farthest left digit flashing
the [Up Arrow] key selects the decimal position and the
[Down Arrow] key selects positive or negative. LL=2
Input Span
60
n = A (for input A), B (for input B) or C (for
input C). Selects the amount of span for the
programmable input function. (See Setup
and Calibration for more details.) XXXX =
(-999) to 0999. With farthest left digit flashing the [Up
Arrow] key selects the decimal position and the [Down
Arrow] key selects positive or negative. LL=2
InSP
XXXX
Input Decimal Point
InDP
XXXX
X = 0-3. Selects the number of decimal
places displayed in programmed input
display. LL=2
User Active
user offset and multiplier active where n = a,
b, or c. (x= y (yes) or x= n(no)) LL=2
These selection enables (yes) or disables the
user offset and user multiplier for the
selected input (a, b , or c). This allows the
input calibration to be trimmed without changing the actual
calibration release.
USRn
XXXX
61
User Offset
UnOF
XXXX
user offset where n = a, b, or c (xxxx = -500
to 500) LL= 2
If user active (yes), then this offset value is
added to the linear input value
User Multiplier
UnSP
XXXX
User Multiplier where n = a, b, or c (xxxx =
0.9000 to 1.100) LL=2
if active is yes, then this multiplier is used to
scale the input value after the user offset is
added.
Pulse Factor
FACn
XXXX
Pulse Factor where n = 1, 2, or 3 (xxxx =
0.200 to 9.999) LL=2
When the input type is pulse, then the factor
is a multiplier to compute the input value.
Pulse Power
Pulse Power of 10 where n = 1,2or3 (xx=-3 to
10Pn
4) LL=2.
XXXX When the input type is pulse, the power of
ten is used with the factor to compute the
input value. A power of ten value of 2
multiplier by 100.
Pulse Decimal Place
DPPn
XXXX
Pulse decimal place where n = 1,2,3 (xxxx
include decimal location)LL=2.
Determines the decimal place in the input
value when pulse type is selected.
62
Pulse Units
Pulse Units where n = 1,2, or 3 (xxxx = time
or 1/TI) LL=2 When pulse input type is
selected, the units of the input value is time
or per time. Time units can be seconds,
minutes, or hours. Units per time can be
revolutions per minute (RPM), feet per second, or
whatever.
UN n
XXXX
Thermocouple Display
TC
XX
XX = ºF or ºC. Selects the units in which the
thermocouple temperatures are displayed
and stored: degrees in Fahrenheit or degrees
Celsius,. LL=2
63
Analog Output Setups - Analog Outputs 1 and 2
Analog Output
n = 1 (for analog output 1) or 2 (for analog
output 2). XXXX = Calculated Value 0, or 1;
Percent Out 1, or 2; Programmed; or INput A,
B, or C. This selection is used to determine
which of the above variables the Analog Output will
represent. The minimum (offset) and maximum (range)
values are set for the input variable so that it can be scaled
to the output based on its' minimum and maximum. i.e.: if
the input is "IN A" and the analog output is set for 0-5 V dc;
with the offset at "0000" and the range at "1000" (for a total
of 1000¦ {0-1000}). If input A were at 500¦ the output would
be 2.5 V dc. With the offset at "1000" and the range at
"1000" (for a total of 1000¦ {1000-2000}). If input A was
1500 the output would be 2.5 V dc.
AO n
XXXX
Program mode allows the analog output value to be
assigned directly from the program. LL=1
Analog Output Offset
n = 1 (for analog output 1) or 2 (for analog
output 2). offset The analog output zero
starting value can be a value from -999 to
4000. This is used to scale the process
variable output range. This value is not used
when either control percent output or program outputs is
selected as the Analog output variable. LL=2
AOnO
XXXX
64
Analog Output Range
n = 1 (for analog output 1) or 2 (for analog
output 2). range The analog output range is
AO n
by this parameter from 0 to 4000. This
XXXX set
value is not used when either control percent
output or program output is selected as the
Analog output variable. LL=2
65
Calculations Setups
Process Factor (1 or 2)
XXXX = 0000-0999. Process factors 1 and
2 are independent of the loops and are used
in the calculation of percent Carbon and
dewpoint. PF1 is used when percent carbon
is calculated and PF2 is used when dewpoint
is calculated. If Piccolo (PIC) dewpoint mode
is selected, the PF1 and PF2 are both used to calculate
dewpoint and percent carbon is not computed.
PF n
XXXX
CO Compensation
COmP
XXXX
XXX = YES OR NO. If Yes, then CV3 is
interpreted as % CO from an IR analyzer.
The value is used in calculating % Carbon by
effectively modifying the process factor. An
input of 0-2000mV is scaled as 0-30% CO.
LL=1
Dewpoint Type
Std/PIC standard or piccolo probe
based.LL=1
The piccolo option is used when a non air
reference gas is used. The %C is not
calculated and CV0 is not changed. PF1 is use to input the
equivalent mV.
dPC
XXXX
66
Dewpoint
dP
XX
° F or °C Choice of dewpoint calculations
done in Centigrade or Fahrenheit. LL=2
Oxygen Millivoltage Offset
O2oF
XXXX
This offset is added to the probe millivoltage
reading (input B) before it is used in
calculating percent Carbon or dewpoint. LL=2
Filter Carbon
% carbon filter; no = off, yes = on LL=2
If no, then the display and datalogged %
carbon values are instantaneous. If yes then
the display and datalogged % carbon values
are an average over the specified filter time. The
instantaneous values are always used for control.
FILC
XXX
Carbon filter Time
CFTI
XXX.X
% carbon filter time in minutes ; 0 to 60.0
A sliding window average of the % values is
computed over the specified time.
LL=2
Filter Dewpoint
Dewpoint filter: no = off, yes = on. If no,
then the display and datalogged dewpoint
values are instantaneous. If yes then the
display and datalogged dewpoint values are
an average over the specified filter time. The
instantaneous values are always used for control.
FILD
XX
67
Dewpoint Filter Time
DFTI
XXX.X
Dewpoint filter time in minutes 0 to 60.0.
A sliding window average of the dewpoint
values is computed over the specified time.
LL=2
Oxygen exponent
Oxygen exponent (xx = 0 to 31) LL=2. When
the oxygen calculation is selected this setup
determines the units. A value of 2 represents
10″ therefore the units are percent . A value
of 6 would have units of PPm (parts per million) but most
sensors are only able to measure ppm to about 100ppm.
Lower oxygen levels are subject to other reducing forces
besides oxygen partial pressure
O2Ex
XX
Oxygen Decimal Place
Oxygen Decimal Place (where xxxx = where
the decimal place is). LL=2. When the
Oxygen calculation is selected this value
determines the resolution to which the
calculated value is displayed. For example
by changing the decimal place the %O in the atmosphere
could be displayed as 21, 20.9 , or 20.95. The setting
effects the O2 display if oxygen is set to CV0 via the DIP
switch settings.
O2dP
XXXX
Redox Metal
68
MET
XX
REACTION
(xx = 0 to 29) LL=2
This value selects the metal contents for the
redox calculation. The default metals loaded
into the Dualpro are shown below.
MET # REF
4/3Al+O2=2/3Al2O3 0
2Ca+O2=2CaO
1
2Co+O2=2CoO
2
4/3Cr+O2=2/3CrO3
3
4Cu+O2=2Cu2O
4
2Fe+O2=2FeO
5
4Fe3O4+O2=6Fe2O3 6
6FeO+O2=2Fe3O4
7
2Mg+O2=2MgO
8
2Mn+O2=2MnO
9
2Ni+O2=2NiO
10
2Si+O2=2SiO
11
2Ti+O2=2TiO
12
2V+O2=2VO
13
2Zn+O2=2ZnO
14
AL
Ca
Co
Cr
Cu
Fe
Fe23
Fe34
Mg
Mn
Ni
Si
Ti
V
Zn
A
-.0026
-.00278
-.00104
-.00168
-.00089
-.00075
-.00101
-.00101
-.00316
-.00169
-.00106
-.00024
-.0043
-.00279
-.0128
B
C
5.214588
5.837392
2.008383
3.405068
1.451836
1.787298
1.637716
2.016779
5.887252
3.502102
1.957724
1.117118
10.50107
5.24182
9.626133
MET # is the metal selection number used in the AACC
2300, Dualpro, and Multipro.
REF is the 4-character metal selection message for the
Multipro Redox Metals Page.
69
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Alarm Setups - Alarms 1 and 2
Alarm Mode
AL1m
XXXX
The far left X = R (for Reverse operation of actuation), or
D (for Direct operation). These operations work as follows:
R - REVERSE operation (opposite of NORMAL) for
ALARM actuation (i.e.: the ALARM contact is normally
closed until it reaches the trigger limit specified by the
Alarm Value, then the contact opens).
D - This is DIRECT operation for ALARM actuation (i.e.:
the contact is normally open until it reaches the trigger limit
specified by the Alarm Value, then the contact closes).
The XXX located to the right of the decimal point
indicates the variable upon which actuation is based.
These variables are as follows:
PVn - PROCESS control mode. Alarm actuation is
based on the PROCESS VARIABLE exceeding the limit
set in the alarm values. n = 1 for Loop 1 or 2 for Loop 2.
BNn - ALARM actuation uses BAND WIDTH control
above and Alarm Mode (cont.) below the loop SETPOINT.
I E: If the band set by the alarm value is 100° and the
SETPOINT is at 1000°, the alarm will trigger at 1100° and
900°). n = 1 for Loop 1 or 2 for loop 2.
70
DEn - Alarm actuation uses DEVIATION BAND control
above or below the loop SETPOINT. The + and - symbols
determine if the deviation is allowed above (+) the
SETPOINT or below (-) it. (i.e.: If a deviation of 100° is set
in the alarm values and 1000° is the SETPOINT the alarm
will trigger at 1100° or 900°, for -100°). n = 1 for Loop 1 or
2 for Loop 2.
POn - Alarm actuation is based on the PERCENT
OUTPUT exceeding the limit as set in the alarm values. n
= 1 for Loop 1 or 2 for Loop 2.
INB - ALARM actuation is based on the analog signal at
Input B input exceeding the limit set by the alarm values.
Input B input is physically located at Terminal Board D-4,
D-5, and D-6 on the unit's rear connectors.
INC - ALARM actuation is based on the analog signal
at Input C exceeding the limit set by the alarm values.
Input C is physically located at TBD-7, TBD-8 and
TBD-9 on the unit's rear connectors.
PRG - An INTERNAL program will actuate the
ALARM. The alarm value setting is ignored.
FLT - An input FAULT, or an internal program is to be
used as basis for the actuation. The alarm value setting is
ignored.
Cvn - Alarm actuation is based upon one of the
calculated values (n = 0, 1, 2, or 3) exceeding the limit set
by the alarm values..
AAL - Alarm actuation is based upon an alarm set in
one of the active alarm words.
71
Alarm Value 1
AL1V
XXXX
-999 to 9999. Sets the alarm trip point. LL=2
Alarm Turn On Delay 1
A1TN
XXXX
0000 to 0250 seconds. Sets a delay period between
alarm condition and alarm activation. LL=2
Alarm Turn Off Delay 1
A1TF
XXXX
0000 to 0250 seconds. Sets a delay period between
alarm condition and alarm deactivation. LL=2
Alarm Mode
AL2M
XXXX
The far left X = R (for Reverse operation of
actuation), or D (for Direct operation). These operations
work as follows:
R - REVERSE operation (opposite of NORMAL) for
ALARM actuation (i.e.: the ALARM contact is normally
closed until it reaches the trigger limit specified by the
Alarm Value, then the contact opens).
D - This is DIRECT operation for ALARM actuation
(i.e.: the contact is normally open until it reaches the
trigger limit specified by the Alarm Value, then the contact
closes).
72
The to XXX located to the right of the decimal point
indicates the variable upon which actuation is based.
These variables are as follows:
PVn - PROCESS control mode. Alarm actuation is
based on the PROCESS VARIABLE exceeding the limit
set in the alarm values. n = 1 for Loop 1 or 2 for Loop 2.
BNn - ALARM actuation uses BAND WIDTH control
above and below the loop SETPOINT. I E: If the band
set by the alarm value is 100° and the SETPOINT is at
1000°, the alarm will trigger at 1100° and 900°). n = 1 for
Loop 1 or 2 for loop 2.
DEn - Alarm actuation uses DEVIATION BAND control
above or below the loop SETPOINT. The + and - symbols
determine if the deviation is allowed above (+) the
SETPOINT or below (-) it. (i.e.: If a deviation of 100° is set
in the alarm values and 1000° is the SETPOINT the alarm
will trigger at 1100° or 900°, for -100°). n = 1 for Loop 1
or 2 for Loop 2.
POn - Alarm actuation is based on the PERCENT
OUTPUT exceeding the limit as set in the alarm values. n
= 1 for Loop 1 or 2 for Loop 2.
The XXX located to the right of the decimal point
indicates the variable upon which actuation is based.
These variables are as follows:
INB - ALARM actuation is based on the analog signal at
Input B input exceeding the limit set by the alarm values.
Input B input is physically located at Terminal Board D-4,
D-5, and D-6 on the unit's rear connectors.
INC - ALARM actuation is based on the analog signal
at Input C exceeding the limit set by the alarm values.
Input C is physically located at TBD-7, TBD-8 and
73
TBD-9 on the unit's rear connectors.
PRG - An INTERNAL program will actuate the
ALARM.The alarm value setting is ignored.
FLT - An input FAULT, or an internal program is to be
used as basis for the actuation. The alarm value setting is
ignored.
Cvn - Alarm actuation is based upon one of the
calculated values (n = 0, 1, 2, or 3) exceeding the limit set
by the alarm values. LL=1
AAL - Alarm actuation is based upon an alarm set in
one of the active alarm words.
Alarm Value
AL2V
XXXX
alarm value 2
-999 to 9999. Sets the alarm trip point. LL=2
Alarm Turn On Delay
A2TN
XXXX
Alarm 2 on delay
0000 - 0250 seconds. Sets a delay period between alarm
condition and alarm activation. LL=2
Alarm Turn Off Delay
A2TF
XXXX
0000 to 0250 seconds. Sets a delay period between end of
74
alarm condition and alarm deactivation. LL=2
75
Program Menu
Program Partition
PRGP
XXXX
If XXX = 0 the feature is deactivated. If XXX = 1 to
200 the number set will represent the partition between
background and foreground programs. Programs whose
numbers are above the partition may only be run in the
foreground and programs whose numbers are below the
partition may only be run in the background. LL=1
Foreground
FPRG
XXXX
If XXXX = VER4 then the foreground programmer
uses a standard LOGIC language program. (The same as
the background program.) If XXXX = v3.5 then the
foreground program is a RECIPE language program. LL=1
Program Alarm Hold Time
PAHT
XXXX
Selects the "Hold Time" to latch a PAL (Program
Alarm) for HOLD TIME Datalogging purposes. An alarm will
be held in the internal alarm stack for the time specified,
after which the oldest PAL will be cleared. The delay time
set should be based on the scan time of Process Master for
this instrument. This setting will have no visual effect on
front panel operations. XXX = 0, 10, 30, 60, 90, 120, 180
sec. LL=1
Thermocouple Offset
76
TCO
XXXX
Alarm 85 function. Sets the allowed temperature
deviation between the probe thermocouple (input A) and
the temperature control thermocouple (input C) when Alarm
85 is activated in a recipe. (See programming section for
alarm codes and details) LL=2
Auto Continue
AUTO
XXXX
XXX = YES OR NO. Yes allows for the automatic
continuation of a program that was running when the
instrument lost power for a period of more than 10
seconds. No does not continue the program when power is
reapplied. Note: Program will auto start regardless of
selection if power loss is less than 10 seconds. LL=1
Auto Program Start
APS
XXXX
X = YES OR NO. Yes forces the background
program No. 1 to start at step No. 1, whether it was running
or not, when power is reapplied after a power loss. No does
not force the background program to start when power is
reapplied. LL=1
ABS
XXXX
Auto background start. Where x = yes or no. If yes the
background (logic) program is started at program 1 step 1 if
stopped for more than 5 seconds. LL=1.
77
Lock Level
LOCK
X
Requires PasSWorD entry for access. X = 0-3
where 3 is unlocked.
0
1
2
3
LOCK LEVEL DEGREE OF ACCESS
NO ACCESS (lowest level)
LIMITED ACCESS
SOME RESTRAINTS / RECIPE EDIT
FULL ACCESS (highest level)
To unlock a locked keyboard the password must be
entered when requested. Requests are made on a
parameter to parameter basis. Once a password is used to
unlock a parameter, full access is given to any parameter
(under the same function key) with a Lock Level equal to or
higher than the parameter just unlocked. If a parameter
with a lower Lock Level is encountered, the password must
be entered for access, or pressing the [Enter] key will
proceed to the next parameter. (Likewise the [Shift] key will
proceed to the next parameter in reverse order.) i.e.: the
lock level parameter has LL=0, if the password is used to
unlock this parameter, all other parameters are open while
still operating in the [Setup] key function. If the password is
used to unlock the Proportional Band parameter (LL=2),
only parameters of Lock Levels 2 and 3 may be accessed
without password entry (while still under the same function
key). LL = 0
78
H OPCODE Redirection
HOP
XXXX
Selection is whether or not to activate the
redirection. The lower display can be toggled between
'NORM' and 'DIR '. These messages refer to normal or
directed mode. (See programming section for details.)
LL=1
H OPCODE Channel
HCH
XX
0 to 15: selection is the channel number where 0
refers to the master DUALPRO and numbers 1 through 15
its slave Dualpros. (See programming section for details.)
LL = 1
HSL
XXX
The selection is the slave temperature controller of
the selected channel. Since the slave DUALPRO may be a
Protocol Converter, the selection allows for sixteen
temperature slaves. (See programming section for details.)
LL = 1
79
Communications
Host Port
HOST
XX
HE = Half Duplex Even Parity
HN = Half Duplex No Parity
FE = Full Duplex Even Parity
FN = Full Duplex No Parity
LL=1
Host Baud
HOST
XXX
1200
2400
4800
9600
19.2K
38.4K
76.8K
LL=1
Host Protocol
HPRO
MMI = Marathon Proprietary Protocol
MOD = MODBUS RTU Protocol
80
Host Modbus Address
HMAD
XXXX
XXXX = 0 to 247
Address used if Modbus protocol selected. If set to 0 then
dipswitch. Host address value is used.
Version 3 Address
V3AD
XXX
Setting 0 uses the DIP switch settings.
Settings 1 through 15 respond to the numbered address.
The version 3 address is used when a Dualpro is replacing
a version 3 Carbpro connected to a Process Master 5.x
system. The Dualpro will evaluate a version 3 Carbpro at
the specified address and still respond to version 4
requests at the DIV switch address.
Version 3 conversion
V3CV
XXX
YES translates the version 3 programs in version 3
mode. NO passes the program through without conversion
utilities. If a dualpro replaces a version 3 instrument, the
programs must be converted. LL = 1
81
Secondary Port Address
SPAD
XXX
xx = 0 to 15; if 0 secondary port is inactive. This
feature sets an second address at which the instrument will
respond on the host port. The secondary port table
parameter selects which parameter table will be set for
block reads. LL=1
Secondary Port Table
STBL
XX
xx = table # 0 to 31 which is used with the secondary
port address. LL=1
Aux
Port Mode
AUXM
XXX
Selects the auxiliary ports mode of operation. XXX =
BRoaDcast, TEMperature buss, network MASter, OFF,
LISten, UDC, or TOKen. LL=1
Broadcast: continuously sends setpoint 1 in 10 pro
mode using the broadcast address character “?”.
Temperature: sequentially accesses addresses 1
through 8 in 10pro mode requesting the setpoint, process
variable , percent output, and operating mode. Also sends
the setpoint if requested.
Network Master: sequentially accesses addresses 1
through 15 in block mode and string the information in
tables 1 through 15 respectively.
82
Off: No active requests, but will respond as a
MODBUS slave.
List: drivers are off, but all valid block responses on
the buss are stored in their respective tables.
UDC: same as temperature mode except uses
Honeywell UDC 3000 communications.
Token: A combustion of Master and Listen mode.
The instrument remains in listen mode until receiving the
token. Then it is the Master for one cycle though all 15
addresses. The token is then sent to the instrument.
MODBUS: MODBUS RTU Protocol Master.
Auxiliary Port Communications
aux
XXX
Selects the auxiliary ports communications
information as follows:
HE = Half Duplex Even Parity
HN = Half Duplex No Parity
FE = Full Duplex Even Parity
FN = Full Duplex No Parity
LL=1
Auxiliary Baud
aux
XXX
1200
2400
4800
9600
LL=1
19.2K
38.4K
76.8K
83
Token Address
TADR
XX
This parameter determines which token address the
instrument used when the aux port is in token mode. Set to
0 the instrument responds to the DIP switch settings. Set
to 1 through 15 the instrument responds to the number’s
address. LL=1
Aux Port MODBUS Address
AMAD
XXXX
XXXX = 0 to 247; if the Aux Port Mode is 'MOD,' this
parameter determines the Modbus slave address to which
it will respond. If this value is 0 then the host dipswitch
address will be used.
Master Buss Time Out Partition
MBTP
XXX
XX = 0-15. Used only when the AUX port is in
master or token mode. Selects the channel number at and
above which the MBTO value is used instead of the normal
time out value. IF XX=0 this feature is disabled. This
feature is used when a device (such as a PLC) is
connected to the MMI network emulating a MMI instrument.
LL=1
Master Buss Time Out Value
MBT0
XXXX
84
XX.XX = 00.10 to 02.55 seconds. When the MBTP is
non-zero, this value is used as the BUSS time out value
when attempting to communicate with channels equal to
MBTP and above. LL=1
Master Buss Write Partition
MBWP
XX
XX = 0-15. Used to define unused slave channels so
that the memory space can be used by the programmer.
Indirect writes to channel numbers equal to or above the
MBTP (if active) will be stored into memory allocated for
these channels. These values can later be read by indirect
reads.
If XX=0, then this feature is inactive. The MBTP
takes precedence over MBWP; therefore, if MBWP is set
equal to or greater than the MBTP (except if 0), the MBWP
is effectively MBTP - 1. LL=1
Remote Local Bit For Slave
RBIT
XXX
Selects whether the local mode indicator of the
slave temperature controller should use BIT 12 of the
actual setpoint. Use YES for compatibility with old
applications. Select NO for most new ones. LL = 1
85
Basic Port
BASP
XXXX
XXX = BAS, TEMP or HOST
BAS = Basic programs may be run and the basic port is
used only for BASIC communications.
TEMP = Basic programs may not be run and the
port is then used as a temp buss at 4800 BAUD. This
occurs if the Aux port is not set to UDC or TEM. This allows
an instrument to have a Master Network (see AUXM
description) and a temp instrument network at the same
time.
HOST = Basic programs may not be run and the
port is then used as a second host buss at 4800 BAUD. LL
=1
86
DIGITAL EVENTS
Events Partition Internal
EPI
X
X = 0-4, where 0 is all inputs and 4 is all outputs. A 1
will represent 1 output and 3 inputs, and so on until when
at 4 all outputs are set. LL=1
Number Of External Events
BXEV
X
X = 0-4 representing the number of digital, event
boards. LL=1
Events Baud Rate
EVBD
XXXX
XXXX = 1200 (for 1200 BAUD) or 4800 (for 4800 BAUD)
LL=1
Dual Buss Mode
DUAL
XXXX
xxx = yes or no. If yes and the basic port is not temp
and the aux buss is not temp or UDC, the events buss is
used for both events boards and temperature controller.
LL=1
87
UDC Partition
UDCP
X
x = 0 to 8, set the number of UDC instruments that
are installed on the events buss in dual buss mode. The
UDC’s use the high address numbers in the range 1-8.
LL=1
Events Partition
EPXn
XX
X = 0-15, and n is the external board number (1-4).
X = 0 implies all inputs, and X = 15 implies 15 outputs and
1 input.
X = 5 implies 5 outputs and 11 inputs; and so
on. The partition should be selected for each external
board. LL=1)
Events Mapping
EMAP
XXX
YES / NO , yes activates logical events mapping.
Refer to the programmers manual for complete information
on logical event mapping. LL=1
88
ANALOG EVENTS
AEVT
External Analog Address Offset
XAAO
X
X = 0-3.
Normally X is set to 0 and the Analog OPTOMUX
board connected to the instrument has an address of FC
hex. When X=1, then the Analog OPTOMUX used by the
instrument is at address FD hex. Likewise, when X=2, the
address is FE hex, and X=3 produces an address of FF
hex. This is used when more than one Analog OPTOMUX
is connected to the instrument. LL=1
Events Partition Analog
EPXA
XX
n = X.
XX = 0-15 which selects the partitioning of the
events on the external analog board. Partitioning described
in the events partition. X=0 implies all inputs, and X=15
implies 15 outputs and 1 input. X=5 implies 5 outputs and
11 inputs; and so on. LL=1
Analog Opto Tweaking
AOTW
XXX
YES / NO This is a way of calibrating the OPTO
board reading for DUALPRO use. LL=1
89
Analog Output Offset
AFOn
XXXX
0 to F used in Tweaking operation. Range: +/- 999
LL=1
Analog Output Span
ASPn
XXXX
0 - F used in Tweaking operation. Range from .900
to 1.1 LL=1
Ext Analog Tc Types
EALn
XXXX
n = 0-9, and A-F, the external inputs.
XXXX = J, K, R, S, T, N/A, LINEARIZATION or
PROG the thermocouple types. The thermocouple type
should be selected for each external input.
When PROG is selected, N3 determines which
standard curve will be used and which analog input is used
as cold junction compensation. N3's usage is divided as
follows: The high byte is used to determine which module
of the available 16 is used as the Cold Junction module.
The low byte is used to determine which thermocouple type
is used for the remaining 15 modules: linear, prog, J = 5,
K= 8, R=17, S=17, T=18, N/A. LL=1
90
PROB MENU
Prob
Probe test Interval
PTI
XXXX
Probe test Interval (time in minutes, between
automatic test). LL=1
xxxx = 0 to 9999
Probe Impedance
PIMP
XXXX
Max Probe Impedance allowed for no probe fault.
xxxx = 000.0 to 999.9 LL=2
Probe Test Recovery
PTRT
XXXX
Max Probe Test Recovery in seconds
xxxx = 0 to 999 LL=2
Burn Off Timer
BOT
XXXX
length of burn off time in seconds
xxxx = 0 to 999.LL=2
91
Burn Off Timer Recovery
BORT
XXXX
Max Burn Off Timer Recovery in seconds
xxxx = 0 to 3600. LL=2
Final Delay
FDE
XXXX
Final Delay time in seconds.
Xxxx = 0 to 999. LL=2
Time average 1
TA1
XXXX
Time average 1 for O2 probe verification.
Xxxx= 0 to 255 minutes. LL=2
Time average 2
TA2
XXXX
Time average 2 for O2 probe verification.
Xxxx= 0 to 255 minutes. LL=2
Time Delay 1
TD1
XXXX
Time average 1 for O2 probe verification.
Xxxx= 0 to 255 seconds. LL=2
Time Delay 2
92
TD2
XXXX
Time average 2 for O2 probe verification.
Xxxx= 0 to 255 seconds. LL=2
Verification gas value
VGAS
XXXX
Verification gas value for O2 probe verification.
Xxxx = 0 to 100.0. LL=2
Verification Tolerance
VTOL
XXXX
Verification tolerance for O2 probe verification.
Xxxx = 0 to 10.0. LL=2
Inhibit
INHB
XXXX
Inhibit probe maintenance yes/no. if yes then no
maintenance cycle (impedance test or burn off) can be
started or run. LL=1
93
Process Factor Adjustment
Process Factor IR
Millivolts Low
Millivolts High
TC Low
TC High
CO Low
CO High
CO2 Low
CO2 High
CH4 Low
CH4 High
PF Low
PF High
94
Maximum Adjustment
TC Source
95
Maintenance and Troubleshooting
PASSWORD PROTECTION BYPASS
To bypass the password, press [Enter]. If you are
locked out because you forgot the password, you will have
to remove the front panel. Find DIP switch 8 in the top
bank. Turn it to ON.. Press [Shift][Page Disp] and
[Enter][Enter] to create "enter" as a new password. Turn
switch 8 in the top bank OFF. Replace the front panel. The
new password is in effect. See Setup and Configuration for
more details.
CALIBRATION
The DUALPRO instrument is shipped completely
pre-calibrated. The drift characteristics of the input circuits
are excellent but from time to time adjustment may be
necessary to maintain a high degree of accuracy.
ANALOG INPUT CALIBRATION.
There are three analog inputs and a cold junction
compensation sensor on the DUALPRO. The input level
and input features for each input are determined by
changeable daughter boards that are mounted piggy back
on the analog input board. There are several types of input
daughter boards: thermocouple input, auxiliary input, 4 to
20 mA input, 0 to 10 V linear, RTD, and slide wire input.
The standard factory configuration is for input A to
be a thermocouple input, input B to be an Oxygen probe
input(auxiliary input) board, and input C to be another
thermocouple input. If the instrument to be calibrated does
not have the standard factory configuration, then identifying
the configuration is necessary so that the proper procedure
for each input board can be followed. For daughter board
96
types see the SETUP & CONFIGURATION section.
CALIBRATION DISPLAYS AND KEYBOARD
When operating in the calibration mode, the
displays and front panel keys take on special assignments.
The PROCESS display shows the value of the input being
calibrated with a flashing digit. This flashing digit shows the
relative sensitivity of the arrow keys, as described following
the key descriptions. The SET display shows which input is
being calibrated and whether the zero value or the span
value is being modified.
The SET display messages are shown below:
Message
Description
Z-A
Zero input A
Z-B
Zero input B
Z-C
Zero input C
Z-SW
Zero slide wire (from input C)
S-A
Span input A
S-B
Span input B
S-C
Span input C
S-SW
Span slide wire (from input C)
NOTE
It is very important to be sure the SET display is showing
the proper mode before making an adjustment or the wrong
value will be changed.
97
ADJUSTMENT SENSITIVITY
The adjustment sensitivity works in the following manner. If
the digit farthest right in the process display is flashing,
then each press of the [Up Arrow] or [Down Arrow] key will
change the calibration value shown by one unit. This is the
least sensitive position. If the digit farthest left is flashing,
then each press of the [Up Arrow] or [Down Arrow] key will
change the calibration value by a thousand units. The
middle digits will show sensitivities of a hundred and ten
units respectively. It is not important to know the relative
worth of one calibration unit. Understanding that the
location of the flashing digit affects change that one key
press will make on the calibration value is necessary. By
observing the degree of sensitivity one key press makes at
each flashing digit location, you can quickly see how to use
this feature. Enter calibration mode by using the 4 key
sequence or jumper terminals 17 & 18.
98
PREPARING FOR CALIBRATION
THERMOCOUPLE DAUGHTER BOARD CALIBRATION
PARTS REQUIRED
1. 1 - 0-50 milivolt dc power supply. (for input voltage
simulation )
2. 1- set of twisted pair copper wire. ( for input voltage
simulation )
3. 1- jumper ( to short out the input )
4. 1- digital volt meter. ( to determine the amount of input
voltage )
5. 1- piece of thermocouple extension wire same as being
used on instrument.
( to calibrate the cold junction
compensation )
6. 1- thermocouple input simulator. ( to simulate the
thermocouple input readings )
SETUP FOR LINEAR CALIBRATION NOTE : for simplicity
the following procedure will be referring to input 1, this may
not apply to all instrument configuration. (please substitute
the appropriate input for this procedure )
1. determine which inputs are thermocouple inputs, the
part number should let you know. ( example a fdp1214.0 has a thermocouple input on input 1 and input 3. )
2. set the thermocouple input type to linear for all
thermocouple board(s).
LINEAR CALIBRATION PROCEDURE
1. place the jumper from pins 1 and 2 on t.b. d. ( shorting
out input 1 )
2. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
3. verify z-a is displayed in the set window. ( if a is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
99
4. adjust the value in the process window to read zero ( 0
) , by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
5. once zero ( 0 ) is achieved press the enter key once to
store the value, and go to s-a.
6. remove the jumper, connect the twisted pair copper wire
to the voltage simulator and connect to the instrument
where the jumper was.
7. set the simulator to 50 milivolts.
8. adjust the value in the process window to read 2500 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 2500 is achieved press the enter key once to
store the value, and go to z-a.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
SETUP FOR COLD JUNCTION COPMENSATION
CALIBRATION
1. determine which inputs are thermocouple inputs, the
part number should let you know. ( example a fdp1214.0 has a thermocouple input on input 1 and input 3. )
2. set the input to the correct thermocouple type(s) for the
specific board(s).
3. turn on the cold junction compensation for the input(s).
COLD JUNCTION COMPENSATION CALIBRATION
PROCEDURE
1. connect the correct thermocouple extension wire to the
thermocouple input simulator and the dualpro. ( t.b. d
pins 1 and 2 )
2. set the simulator for a zero value. ( see table in manual
)
100
3. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
4. verify z-a is displayed in the set window. ( ifa is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
5. adjust the value in the process window to read the
zero value , by using the up and down, left and right
arrow keys. ( the flashing digit determine the amount of
adjustment. the right most digit is the least coarse, and
the farther left the digit is the more coarse the
adjustment will get. )
6. once the zero value is achieved press the enter key
once to store the value, and go to s-z.
7. set the simulator for a span value ( see table in manual
)
8. adjust the value in the process window to read the
span value selected, by using the up and down, left and
right arrow keys. ( the flashing digit determine the
amount of adjustment. the right most digit is the least
coarse, and the farther left the digit is the more coarse
the adjustment will get. )
9. once the span value is achieved press the enter key
once to store the value, and go to z-a.
10. follow this procedure until the input reads correctlyand
for any other inputs.
11. exit calibration mode by pressing the setup key.
Thermocouple type
B
C
E
J
K
N
NNM
R
Zero ºF
200
32
32
32
32
32
32
300
101
SpanºF
3000
3000
1300
1300
2300
2300
2000
3000
Thermocouple type
S
T
Zero ºF
300
32
SpanºF
3000
700
The usable ranges of the thermocouple types are
shown in The table above. If having a high accuracy over a
specific operating range is desirable then the input should
be calibrated over that range. Follow the calibration
procedure for normal calibration with the following changes.
Use the low end of the desired range as the zero value and
the high end as the span value. There will be more
interaction between zero and span with this method. The
desired operating range must fit with the limits of the table.
O2 AUXILLARY INPUT DAUGHTER BOARD
CALIBRATION
PARTS REQUIRED
1. 1 - 0-2volt dc power supply. (for input voltage
simulation )
2. 1- set of twisted pair copper wire. ( for input voltage
simulation )
3. 1- jumper ( to short out the input )
4. 1- digital volt meter. ( to determine the amount of input
voltage )
setup for calibration
note : for simplicity the following procedure will be referring
to input 2, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are auxiliary inputs, the part
number should let you know. ( example a fdp121-4.0
has an auxiliary input on input 2. )
2. set the input type to linear for the board(s).
CALIBRATION PROCEDURE
1. place the jumper from pins 4 and 5 on t.b. d. ( shorting
out input 2 )
102
2. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
3. verify z-b is displayed in the set window. ( if b is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
4. adjust the value in the process window to read zero ( 0
) , by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
5. once zero ( 0 ) is achieved press the enter key once to
store the value, and go to s-b.
6. remove the jumper, connect the twisted pair copper wire
to the voltage simulator and connect to the instrument
where the jumper was.
7. set the simulator to 1.5volts dc.
8. adjust the value in the process window to read 1500 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 1500 is achieved press the enter key once to
store the value, and go to z-a.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
SLIDEWIRE FEEDBACK INPUT DAUGHTER BOARD
CALIBRATION
PARTS REQUIRED
1. 1 - 0-2volt dc power supply. (for input voltage
simulation )
2. 1- set of twisted pair copper wire. ( for input voltage
simulation )
3. 1- jumper ( to short out the input )
103
4. 1- digital volt meter. ( to determine the amount of input
voltage )
SETUP FOR CALIBRATION
note : for simplicity the following procedure will be referring
to input 3, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are slidewire feedback input(s),
the part number should let you know. ( example a
fdp123-4.0 has a slidewire feedback input on input 3. )
2. set the input type to linear for the board(s).
CALIBRATION PROCEDURE
1. place the jumper from pins 7 and 8 on t.b. d. ( shorting
out input 3 )
2. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
3. verify z-c is displayed in the set window. ( if c is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
4. adjust the value in the process window to read zero ( 0
) , by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
5. once zero ( 0 ) is achieved press the enter key once to
store the value, and go to s-c.
6. remove the jumper, connect the twisted pair copper wire
to the voltage simulator and connect to the instrument
where the jumper was.
7. set the simulator to 1.5volts dc.
8. adjust the value in the process window to read 1500 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
104
9. once 1500 is achieved press the enter key once to
store the value, and go to z-c.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
0-10 VOLT LINEAR DC INPUT DAUGHTER BOARD
CALIBRATION
PARTS REQUIRED
1. 1 - 0-10volt dc power supply. (for input voltage
simulation )
2. 1- set of twisted pair copper wire. ( for input voltage
simulation )
3. 1- jumper ( to short out the input )
4. 1- digital volt meter. ( to determine the amount of input
voltage )
SETUP FOR CALIBRATION
note : for simplicity the following procedure will be referring
to input 3, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are 0-10 volt dc linear input(s),
the part number should let you know. ( example a
fdp124-4.0 has a 0-10 volt dc linear input on input 3. )
2. press the setup key once.
3. use the up or down arrow keys to display inp in the set
window
4. press the enter key until in c is displayed in the process
window
5. set in c to prog. by using the up or down arrow keys.
6. press the enter key until cjcc is displayed in the
process window
7. set cjcc to no.
8. press the enter key until icof is displayed in the process
window
9. set icof to 0000.
105
10. press the enter key until icsp is displayed in the
process window
11. set icsp to 01.00
12. press the enter key until icdp is displayed in the
process window
13. set icdp to 2
CALIBRATION PROCEDURE
1. place the jumper from pins 7 and 8 on t.b. d. ( shorting
out input 3 )
2. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
3. verify z-c is displayed in the set window. ( if c is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
4. adjust the value in the process window to read zero (
00.00 ) , by using the up and down, left and right arrow
keys. ( the flashing digit determine the amount of
adjustment. the right most digit is the least coarse, and
the farther left the digit is the more coarse the
adjustment will get. )
5. once zero ( 00.00 ) is achieved press the enter key
once to store the value, and go to s-c.
6. remove the jumper, connect the twisted pair copper wire
to the voltage simulator and connect to the instrument
where the jumper was.
7. set the simulator to 10 volts dc.
8. adjust the value in the process window to read 10.00 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 10.00 is achieved press the enter key once to
store the value, and go to z-c.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
106
4-20 MILIAMP DC INPUT DAUGHTER BOARD
CALIBRATION
PARTS REQUIRED
1. 1 - 4-20 miliamp dc power supply. (for input current
simulation )
2. 1- set of twisted pair copper wire. ( for input current
simulation )
3. 1- digital volt meter. ( to determine the amount of input
current )
SETUP FOR CALIBRATION
note : for simplicity the following procedure will be referring
to input 3, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are 4-20 miliamp dc input(s), the
part number should let you know. ( example a fdp1254.0 has a 4-20 miliamp dc input on input 3. )
2. set the input type to linear for the board(s).
CALIBRATION PROCEDURE
1. connect the twisted pair copper wire to the current
simulator and connect to t.b. d pins 7 and 8 of the
dualpro.
2. set the simulator to 4.0 miliamps dc.
3. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
4. verify z-c is displayed in the set window. ( if c is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
5. adjust the value in the process window to read zero ( 0
) , by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
107
6. once zero ( 0 ) is achieved press the enter key once to
store the value, and go to s-c.
7. set the simulator to 20 miliamps dc.
8. adjust the value in the process window to read 2000 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 2000 is achieved press the enter key once to
store the value, and go to z-c.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
RTD DC INPUT DAUGHTER BOARD CALIBRATION
PARTS REQUIRED
1. 1 - rtd simulator. (for input simulation )
2. 1- set of twisted copper wire, 3 conductor. ( for input
simulation )
SETUP FOR CALIBRATION
note : for simplicity the following procedure will be referring
to input 1, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are rtd input(s), the part number
should let you know. ( example a fdp623-4.0 has a rtd
input on input 1. )
2. set the input type to rtd for the board(s).
CALIBRATION PROCEDURE
1. connect the twisted copper wire 3 conductor to the rtd
simulator and connect to t.b. d pins 1, 2 and 3 of the
dualpro.
2. set the simulator to -100 degrees
108
3. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
4. verify z-a is displayed in the set window. ( if a is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
5. adjust the value in the process window to read -100,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
6. once -100 is achieved press the enter key once to store
the value, and go to s-a.
7. set the simulator to 100.
8. adjust the value in the process window to read 100 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 100 is achieved press the enter key once to store
the value, and go to z-a.
10. follow this procedure until the input reads correctly and
for any other inputs.
11. exit calibration mode by pressing the setup key.
O2 FOR OXYGEN INPUT DAUGHTER BOARD
CALIBRATION
PARTS REQUIRED
1. 1 - 0-100 milivolt dc power supply. (for input voltage
simulation )
2. 1- set of twisted pair copper wire. ( for input voltage
simulation )
3. 1- jumper ( to short out the input )
4. 1- digital volt meter. ( to determine the amount of input
voltage )
109
SETUP FOR CALIBRATION
note : for simplicity the following procedure will be referring
to input 2, this may not apply to all instrument configuration.
(please substitute the appropriate input for this procedure )
1. determine which inputs are auxiliary inputs, the part
number should let you know. ( example a fdp171-4.0
has an o2 for oxygen input on input 2. )
2. set the input type to linear for the board(s).
CALIBRATION PROCEDURE
1. place the jumper from pins 4 and 5 on t.b. d. ( shorting
out input 2 )
2. place the dualpro in calibration mode, by using the
following key sequence: shift, enter, setpt, and page
disp.
3. verify z-b is displayed in the set window. ( if b is not
displayed press the shift key until it is displayed, if z is
not displayed press the enter key until it is displayed. )
4. adjust the value in the process window to read zero ( 0
) , by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
5. once zero ( 0 ) is achieved press the enter key once to
store the value, and go to s-b.
6. remove the jumper, connect the twisted pair copper wire
to the voltage simulator and connect to the instrument
where the jumper was.
7. set the simulator to 100milivolts dc.
8. adjust the value in the process window to read 100 ,
by using the up and down, left and right arrow keys. (
the flashing digit determine the amount of adjustment.
the right most digit is the least coarse, and the farther
left the digit is the more coarse the adjustment will get. )
9. once 100 is achieved press the enter key once to store
the value, and go to z-a.
10. follow this procedure until the input reads correctly and
for any other inputs.
110
11.
exit calibration mode by pressing the setup key.
ANALOG OUTPUT CALIBRATION
The two Analog Output signals can be configured for the
following ranges: 0 to 5 V or 4 to 20 mA. The output mode
for each of the Analog Outputs are determined by the two
separate Dip switches on the ANALOG OUTPUT board.
Any time the mode of operation is switched between
current and voltage, the outputs must be recalibrated. The
outputs do not have to be recalibrated when switching
between signal types i.e.: if the output is calibrated for 0 to
5 volts, and it is needed to change from Process Variable
to Proportional Output 1, no recalibration is necessary (5
volts will be equal to 100%).
111
PREPARING FOR CALIBRATION
To set the desired mode, find the proper switch that
corresponds to the output to be used. Select the voltage
mode by pushing the rocker switch down at the bottom
edge of the switch. Select the current mode by pushing the
rocker switch down at the top of the switch. Repeat
procedure for the other output.
CALIBRATING THE OUTPUTS
To calibrate the Analog Outputs:
• Consideration must be made at this time about
which type output, current or voltage, is to be used. Check
the two rocker switches on the Analog Output board to
confirm that the desired mode is selected for each output.
112
The easiest way to adjust the current output for 4 mA, is to
put the instrument in Manual Mode by using the
[Prog/Auto/Man] key.
• next, remove the FRONT PANEL by loosening the
black knurled knob in the counterclockwise direction.
Remove the panel from the chassis and support it near the
instrument.
• To calibrate the outputs using the following
method, both Analog Outputs must be set to the
Proportional Output (PO1) control mode. This is done by:
i.
Pressing [Setup] and selecting AOUT from
the menu. Press [Enter] to move forward
through the menu.
ii.
At the AO 1 display, change the control mode
in the lower window to PO 1.
iii.
Press [Enter] repeatedly.
iv.
At the AO 2 display, change the control mode
in the lower window to PO 1.
v.
Press [Setup] to exit the menu.
*•Remove any wires at the Analog Output terminals
(TBD-13, TBD-14, TBD-15 and TBD-16).
*• Attach the leads of a digital multi-meter(DMM) to
the terminals that correspond to the output to be calibrated
(TBD-13(+) and TBD-14(-) for Analog Output #1. TBD-15
(+) and TBD-16(-) for Analog Output #2).
*• Set the Percent Output to 0% using the [Left
Arrow] key.
*• Find the OFFSET POT for the output to be
adjusted. Adjust the pot until the DMM reads 4 mA current
output or 0 V.
• Repeat * steps for the other output.
• To get the full SPAN output value, press the [right
arrow] until 100 is displayed in the PROCESS Window
indicating 100 percent is being applied.
• With the DMM connected at the proper output
terminal connection, adjust the GAIN pot of the
corresponding output until the DMM reads the required
113
output (5 V max) or 20 mA).
• Move the meter leads to the other Analog Output
and repeat the previous step for the SPAN output.
• Repeat the Zero and Span process until no further
adjustment is required.
• Reset PO1 to its original setting, if it was changed
in the *l offset pot step above, to their desired values.
Reattach any wires removed from the Analog Output
terminals.
• Reattach the units FRONT PANEL to the chassis.
The Analog Output Calibration procedure is now complete.
Analog OPTO Tweaking
The analog OPTO tweaking feature of the DUALPRO
allows the operator to adjust the zero and span of each
module on the analog OPTO rack. This is similar to
calibration except that the operation is done in the
DUALPRO after the digital data is received from the OPTO
rack. The purpose of the tweaking feature is to provide a
means of fine tuning the readings from the OPTO board.
For example, if a thermocouple attached to the appropriate
module is reading a few degrees high or low the tweaking
feature can be used to adjust for this error.
To use the analog OPTO tweaking feature it must be
activated. This is done under the Setup key 'AEVT' menu.
When the process display shows 'AOTW', the tweaking
feature is activated by selecting yes in the set display. The
tweaking feature applies to all sixteen modules on the rack.
Be sure that the offset is set to 0000 and the span to 1.000
on any modules you do not wish to adjust. The offset and
span effect the digital data received from the OPTO rack
before any linearization is applied. The range of the offset
number is + or - 999 counts. The full scale range of the
data from the OPTO module is 4095 counts regardless of
the type of module. For example a 0 to 5 volt module full
scale is 4095 counts therefore each counts is 1.22 millivolts.
114
The tweaking offset can therefore adjust the offset (zero) of
the approximately 24%.The range of the span adjustment
is 0.900 to 1.100. This allows a + or - 10% adjust to the
gain. Since the span multiplier occurs on the nonlinearized data, an error of 2% may need a slightly higher
or lower multiplier than 2%.
The best way to use the tweaking feature is the same way
a calibration would be done. First apply a zero or near zero
signal, and adjust the offset for a correct reading. then
apply a full scale signal and adjust the span for a correct
reading. Repeat the zero and span processes until there is
no interaction. For greater accuracy over a know operating
range, use the low end of the range for the zero and the
high end of the range for the span. The disadvantage of
this technique is that there will be more interaction between
the zero and the span.
The sophisticated DUALPRO user might be using the
analog OPTO address offset feature to have more than one
analog OPTO rack on the DUALPRO. The tweaking
feature can not distinguish which board is active and would
apply the tweaking factors to all the data. Since the logic
programmer is probably being used to switch between the
boards, the logic programmer could also turn on the
tweaking feature for the desired board and turn it off when
selecting the other board(s). This would allow the tweaking
feature to be used on a critical board without affecting the
data from the other boards.
115
HOW TO CHANGE BOARDS FUSES AND
ELECTRONICS SAFELYHOW TO CHANGE BOARDS
FUSES AND ELECTRONICS SAFELY
Boards
Observe all electrical safety standards when handling the
DUALPRO. Turn off or remove the power connection
before handling any of the boards and work on a grounded
surface with electrostatic defusion equipment. Use the
following chart to identify the location of your boards. To
troubleshoot a malfunction it is often necessary to
exchange (swap) boards. Using proper grounding
precautions, open the front panel using the knob at the
bottom. Turn off the power. Turn off the triac board switch.
Remove the board that may be causing the problem
and exchange it for a new one. Note : If removing or
116
replacing the triac board , be sure all power connected
to the back of the instrument is off.
FUSES
If the problem involves an event, alarm, control or power to
the instrument itself, first check that the instrument is
connected to the power source correctly. If that is not the
problem, then check the fuses on the Triac board. The
figure below will help identify the possible fuse causing the
problem with older versions of the Dualpro Triac board.
WARNING
Remove all AC Power (Instrument, Alarms, Events)
from the rear of the instrument before removing the
Triac board.
Nearer versions of the Dualpro have only a main fuse for
the instrument. Event, Alarms, and Control sources should
be fused externally in the control panel.
117
SPARE PARTS LIST
Marathon recommends that customer's purchase a second
unit as a back up so that service remains uninterrupted. If
that is not possible then at least purchase the following
items:
• MFU-1.0GMA 1 AMPERE FUSES
• A810151 - fast analog output board
• A810071 - analog output board
• A810070 - communications board
• A810153 - Turbo CPU board
• A810073 - interface board
• A810074 - Triac board
• A810052 - display board
• K810122 - DUALPRO faceplate
and the corresponding daughter boards for your
configuration from the following list
• A810076 Auxiliary / O2 mV
• A810077 Thermocouple
• A810095 Slidewire Feedback
• A810115 Resistive Temperature Device
• A810147 0 to 10 V Linear
• A810168 4 to 20 mA
• A810190 combustion O probe
118
Theory of Operation
The Proportional Integral and Derivative (PID) control in the
DualPro is based on the theories first developed by Ziegler
and Nichols in 1942. For a detailed explanation of these
theories see: David W. St. Clair Controller Tuning and
Control Loop Performance; 1990: Straight Line Control
Company, 3 Bridlebrook Lane, Newark, De 19711.
The DUALPRO has two distinct programming languages:
the logic language called version 4 language and the recipe
language called version 3.5 language. Originally, the
DUALPRO did not have recipe language. It was added to
the DUALPRO because of customer requests. The recipe
language is a derivative of the version 3 UNIPRO
/CARBPRO language. Consequently, it looks like version 3
UNIPRO / CARBPRO, version 3.5 CARBPRO and
MULTICARB languages to the user with a few minor
exceptions.
The background "logic" language has four purposes:
• to allow the same instrument to be used for several
specific applications that require custom operation
codes
• to be able to move and manipulate data for scaling,
data logging, alarm testing
• to handle bit logic and sequencing operations
• to communicate with and concentrate data from
many sources
The foreground "recipe" language has two purposes:
• to give the user a familiar framework to run their
recipes for heat treating
• to provide a method by which the logic language
can work with these programs to add increased
flexibility with the use of flags and waits
119
Note that the logic language can operate either in the
background or the foreground but the recipe language can
only operate in the foreground. When the instrument is set
up, the installer has the option of setting the foreground
language to Ver4 or Ver3.5. Thus, no version 4
programming capabilities are lost! The DUALPRO can run
version 3.5 programs without any logic program running but
this reduces the DUALPRO to a version 3.5 CARBPRO.
The programming languages of this instrument are meant
to work seamlessly with each other. While the foreground
program is accessible to the metallurgist or the highly
skilled floor operator for the entry of recipes, the
background language is intended to remain invisible after
installation
The Dual loop control allows greater flexibility in
programming and upward expandability of a system
controlled by the DualPro. This same dual loop control
allows simultaneous control of two process variables.
DualPro is one of the few if not the only instrument with
four communications ports. The four communications ports
allow varied communication between the DualPro and other
instruments. This allows the use of simultaneous control
and communications features.
120
Control Mode Definitions
Time Proportioning (TP)
Time proportioning adjusts the duty cycle of the control
device to maintain control. This is usually done with
solenoid valves controlling the flow of a critical material to
the process. The control loop percent output is the ON
time percentage of the value. The cycle time parameter
determines the total cycle time, ON time plus OFF time.
For example if the control loop percent output is 34% and
the cycle time is 10 seconds, then the ON time would be
3.4 seconds and the OFF time would be 6.6 seconds. The
selection of the proper cycle time is a trade off between
excess wear and tear on the solenoid valve with short cycle
times and rough (pulsing) flow of the control material with
long cycle times. Only one control output triac is used in
this mode.
Time Proportioning with Complement (TC)
This mode is identical to the time proportioning mode
except that two control output triacs are used. The second
control output is the complement of the first, that is when
the first output is ON the second is OFF and vice versa.
This mode is used with single action motorized valves that
open quickly when a voltage is applied to one terminal and
close quickly when voltage is applied to the other terminal.
Time Proportioning Dual (TD)
This mode is used when there is two process materials to
control which have complementary effects; like gas and air
in a heat treating furnace. If the carbon potential is too low
then more gas is required. If the carbon potential is too high
then once the gas flow has been shut off air is required.
The time proportioning dual mode uses two control output
121
triacs; one for gas and one for air. There is never a time
when both outputs are on simultaneously. The control loop
computes a percent output from -100 to +100%. When
positive, the proportioning action applies to the forward
(gas) output. When negative the proportioning action
applies to the reverse (air) output.
Motor with slidewire (MS)
This mode is used for motorized valves that have a
slidewire feedback. This mode requires a slidewire board
for input C of the DUALPRO. MS mode can only be
selected for loop 1 of the DUALPRO. The motor slidewire
is then wired to this input. This mode uses two control
output triacs; one to drive the motor forward (open) and the
other to drive it reverse (closed). This mode is effectively a
control loop within a control loop. The main control loop
computes a desired output percentage. The secondary
loop then drives the motor (forward or reverse) until the
slidewire indicates that the valve is open the proper
percentage. To prevent the motor from "hunting" a
deadband can be set using the DIP switches. This value
can be set from .2 % to 10%. In most applications the
motor with slidewire does not provide any better control
than position proportioning (see below).
Position Proportioning (PP)
This mode is used with motorized valves that do not have
slidewire feedback. This mode is sometimes referred to as
the "bump" mode because it "bumps" the valve slightly
more open or closed. This mode uses two control output
triacs; one to drive the motor forward (open) and the other
to drive it reverse (closed). For each computation of the
control this mode computes the difference between the
new percent output and the last percent output. If the
difference is positive than the valve motor is driven open for
that percentage of the cycle. If negative it is driven closed
122
by that percentage of the cycle time. For example if the
new percent out is 60% and the old was 45% then the
motor is driven open for 15% of the cycle time. If the cycle
time is set to the time that the motor takes to move from
fully closed to fully open, then the flow is theoretically
increased by 15%. Two special cases exist. If the control
output is computed at 100% then the motor is driven
continuously in the open direction. Likewise if the control
output is computed as 0% then the motor is driven
continuously closed.
ON/OFF (OF)
ON/OFF control is exactly what it implies, the control action
is either ON or OFF. With true ON/OFF control the control
output triac is ON whenever the process is below the
setpoint value and OFF when the process is at or above
the process value. In many real world applications this
simple control method will cause "contact chatter" because
of noisy signals which will switch the ON and OFF states
rapidly. Also since the control action does not turn OFF
until the setpoint is reached, the process will overshoot due
to lags in the control action. Marathon controllers
incorporate two features which prevent this problems from
occurring; hysterisis and deadband. Hysterisis provide a
gap between the process turn on point and the turn off
point. With this gap noise will not cause the control output
to "chatter". Deadband allows the process to deviate away
from the setpoint by the width of the deadband before any
control action occurs. The deadband on the DUALPRO is
adjusted with the proportion band setup (the reset and rate
must be set to 0 for ON/OFF control). For temperature
control a proportional band of 10 would represent a
deadband of 10 degrees. A proportional band of 5 would
represent 5 degrees of deadband, etc. This is
accomplished by allowing the PID control loop to calculate
in a normal fashion. The percent output is then used to
determine when the output should be turned on or off. The
output is turned on when the percent output reaches 10%.
123
Hysterisis is added by not turning off the output until the
percent output drops to 2%. With the temperature control
example where the proportion band is set at 10, the output
would turn on when the process dropped to 10 degrees
below the setpoint and turn off when the temperature
reached 2 degrees below the setpoint. With a proportional
band of 1 these points would be 1 degree and 0.2 degrees
respectively.
ON/OFF with Complement (OC)
This mode is exactly like ON/OFF control with the addition
of a second control output triac. The second triac would be
ON when the first is OFF and vice versa.
ON/OFF Dual (OD)
This mode is similar to time proportioning dual in that two
control output triac are used such as in a heat/cool
application. The forward (heat) output would act as
described in the ON/OFF description above. The reverse
(cool) output would respond when the process is above the
setpoint. To facilitate this process the PID control loop
computes a percent output from -100 to +100%. The plus
values mean the process is below setpoint and the minus
values mean the process is above setpoint. The forward
contact would turn on when the percent output reaches
10% or above. It would not turn off until the percent output
dropped to 2% or below. In a similar fashion, the reverse
contact would turn on when the percent output dropped to 10% or lower (more negative). It would turn off when the
percent output rose to -2% or higher (more positive). For
the temperature example with a proportional band of 10,
the heat contact would turn on when the temperature was
10 degree or more below the setpoint and would turn off
when it came within 2 degrees of the setpoint. Likewise the
cool contact would turn on when the temperature rose 10
124
degrees above the setpoint and would turn off when it
dropped to within 2 degrees of the setpoint.
Multi Mode (MM)
Multi Mode is a control mode on the DUALPRO that deals
with output resource assignment. Multi Mode can only be
selected for loop 2 of the DUALPRO. Multi Mode is either
time proportioning single or dual depending on the setup of
the DUALPRO. The simplest form of Multi Mode occurs
when loop 1 is set for TD, OD, MS, or PP. In this case
Multi Mode is time proportioning single and has no output
triacs. Therefore one of the analog outputs must be
assigned to PO2 (loop 2, percent output) for loop 2 to have
any output resource. For other assignments of loop 1,
Multi Mode makes loop 2 a dual time proportion loop.
However, loop 2 only has one output triac assigned to it. If
loop 1 is set for TP or OF, the control output 2 is assigned
to loop 2. This triac will be the reverse output of the dual
loop. If loop 1 is set for TC or OC, the event output 3 is
assigned to loop 2. This triac will be the forward output of
loop 2. The two analog outputs have special functions if
assigned to PO2 when loop 2 is in MM and loop 1 is either
TP, OF, TC, or OC. If analog output 1 is assigned to PO2,
it will be zero to full scale for 0 to +100% output of loop 2.
If analog output 2 is assigned to PO2, it will be zero to full
scale for 0 to -100% output of loop 2. Only one of the
analog outputs need be assigned to PO2 for this to occur.
125
Recipe Error Codes:
01…79
80
81
82
83
84
85
86…90
91
92
93
94
95
96
97
98
99
Programmed alarm
Turns off 81
Temperature deviation band alarm
Turns off 83
%C (dewpoint or mV) deviation band alarm.
not assigned
Deviation alarm between probe TC and
temperature controller.
not assigned
Temperature buss error
OPTOMUX buss error
LIMIT statement time-out
not assigned
Illegal RAMP
Auto restart after power failure
Illegal subroutine call
Illegal JUMP attempted
not assigned
126
Programmer System Error codes:
Note : * = Program Halt
Foreground Background
Program
Program
*100
101
*104
105
*106
107
*110
111
*112
113
*114
115
*116
117
*118
119
*120
121
*124
125
*126
127
130
132
131
133
134
136
135
137
138
139
140
142
144
146
148
141
143
145
147
149
*252
253
*254
255
Description
Bad load on executing jump
Step too big in jump
Program number too big in jump
Bad load in executing gosub
Gosub too deep
Step too big in gosub
Program # too big in gosub
Bad load on return from gosub
Bad load running background
Step too big running
background
Program number too big running
background
Read indirect too big
Write indirect too big or requests
que full
Sync out but not master unit
Send program to slave but not
master unit
Start program in slave but not
master unit
Program send value not valid
Data stack pushed too deep
Data stack empty on pop
Block specification incorrect
Block send but not master or
que full
Bad load when restoring a
program on a power fail restore
Bad load of prog 1 on auto prog
start
127
Specifications:
Alarm output 2 user selectable Triac outputs for process
alarms.
Ambient temperature
Analog output
0 to 130 ° F
adjustable Voltage (0 to 10 V dc or
milliamperage (2 to 22) based on
various selectable sources.
Auxiliary and Slide Wire input impedance
Auxiliary and Slidewire input range
Control Outputs
44 M ohm
-50 to 2000 mV dc
2 configurable output Triacs allowing
dual control on both loops for ON /
OFF, Time-proportioning or positionproportioning control.
Serial interface:
Host
RS-422 1200/4800/ 9600 / 19200 /
38.4K / 76.8K BAUD Full / Half duplex,
Even / no
parity, MMI protocol
Auxiliary
RS-422 1200 /4800 / 9600 / 19200
BAUD, Full /Half duplex, Even No/
Parity, 1 stop bit, Multiple modes.
OPTOMUX RS-422 1200 / 4800 BAUD, 8 Bit, no
parity, 1 stop Bit Full Duplex, 2 pass
OPTOMUX protocol.
BASIC terminal Port RS-422 4800 BAUD, Full duplex, for
BASIC interpreter
Dimensions
Event Output
5.75" height, 5.75" width, 10.5" length
4 events configured for in or out.
Control/alarms
4 Triac contact closure combination for
output and or input available to
128
process programmer. 1 amp rating
Inputs
3 inputs
Humidity
0 to 85% noncondensing
Input linear
10 thermocouple types ( See the list
under thermocouple)
2 user definable curves
1 programmable offset and span
1 RTD, 10 ohm platinum, Alpha =
.00385 (DIN 43 760)
Line voltage
85 to 140 V ac, 50 / 60 Hz. 190 to
250 V ac, 50 /60 Hz
Output
Triacs fused at 1 Amp 125/240
maximum.
Panel cut out
5.43" X 5.43" square
Programs
logic = 200, 24 steps each. Recipe =
200 , 19 steps each. 55 on internal
ROM.
Proportional Band 1 to 9999
Reset 0 to 99.99 RPM
Rate 0 to 9.99 minutes
Cycle Time 0 to 250 seconds
Load Line -100 to 100 %
High limit 0 to 100 %
Low limit -100 to 100 %
PID Constants
Setpoints
-999 to 9999
Signal display
range
- 300 to 3500 (+4) Depending upon
thermocouple type. - 999 to 9999 for
programmed values
Thermocouple board
129
Signal input range -10 to +64 mV
Thermocouple
Weight
B: Platinum 30% Rhodium vs. Platinum
6% Rhodium
C: Tungsten 5% Rhenium vs.
Tungsten 26% Rhenium
E: Chromel-Constantan
J: Iron-Constantan
K: Chromel-Alumel
N: Nickel 14.2% Chromium 1.4%
Silicon vs. Nickel 4.4% Silicon 0.1%
Magnesium
NNM: Nickel vs. Nickel 18%
Molybdenum
R: Platinum vs Platinum 13% Rhodium
S: Platinum vs Platinum 10% Rhodium
T: Copper-Constantan
Approximately 11 pounds
130
USING THE DUALPRO IN OXYGEN APPLICATIONS
Versions 4.124 and up.
Introduction
This application note will describe the setups needed to use
the Dualpro in per cent oxygen applications. The Process
display will show the percent oxygen (and the temperature
if SCAN mode is used). Page display will show the oxygen
sensor temperature, recent sensor tests, etc. Also, the
analog output 2 will retransmit percent oxygen as a 4 to 20
mA signal equal to 0 to 25% O2. Analog output 1 will
retransmit temperature as a 4 to 20 mA signal equal to 0 to
3000 oF (or 0 to 1500 o C).
Instrument setup
Dip switches
Set Bank 1 (top) dip switch #2 to ON and dip switch
#1 to OFF. This will enable the percent oxygen
calculation
Analog output mode
Verify that the Analog Output board is in current
mode for both channels. If not, then switch to current
mode and recalibrate the analog outputs. (See
section 9-1 of the main Dualpro manual for help)
131
Display mode
The display mode must be placed into either HOLD
or SCAN. To do this, press the Shift + right arrow
together. The Process display will show either HOLD
or SCAN.
Parameter Setups
Press Setup to display the setup menu. The chart
below shows which parameters under each menu
heading must be setup.
Menu Heading
Parameter
(Process Window)
Setup
(Set
Window)
CON
CV 1
CV 2
CV 2
IN A
INP
IN A
CJCA
IN B
CJCB
TC
T/C B
YES
LIN
NO
Deg F (or
Deg C)
AOUT
AO 1
AO1O
AO1R
IN A
0
3000 (or
1500 for
deg C)
CV 0
0000
25.00
AO 2
AO2O
AO2R
132
PROB
PT I
480(Note:
minutes)
020.0
30 (Note:
seconds)
0000
PIMP
Ptrt
BO T
(Note: No probe burnoff)
BorT
(Note: No recovery time)
F dE
seconds)
TA1
TA2
TD1
TD2
VGAS
0000
30 (Note:
0003
0003
0120
0090
Set to value
of reference
gas
002.0
NO
VTOL
Inhb
(Yes=NO probe tests)
CALC
O2EX
O2DP
2
1
133
Wiring
Connect the probe thermocouple to TBD-1 (+) and
TBD-2 (-).
Connect the probe mv output to TBD-4 (+) and TBD5 (-).
Connect the temperature recorder to TBD-13 (+) and
TBD-14 (-).
Connect the percent oxygen recorder to TBD-15 (+)
and TBD-16 (-).
Connect the verification 3-way solenoid to TBA-5
and TBB-2.
Connect a jumper from TBA-2 to TBA-4.
Connect a jumper from TBB-2 to TBB-4.
Connect 115 VAC 60 Hz power to TBA-1 (Line),
TBB-1 (Neutral), and TBA-3 (Ground).
134
Instrument Operation
Manual sensor impedance and verification test
A sensor impedance and verification test may be manually
started by pressing the Shift + Enter keys simultaneously.
Display will show test in progress. Please wait until test is
completed to view date from the sensor test using next
section (Viewing sensor test date).
Viewing sensor test data
The data from the most recent sensor test can be viewed
on the instrument page display. Press the Page Disp key.
Use the left arrow key or right arrow key to find the
message PROB CARE. Use the down arrow or up arrow
key to display the test data described in the table.
Process display
Description of data
DATE
(mm.dd)
TIME
(hh.mm)
IMP
IRT
seconds
BOMV & BORT
BOTC
VGAS
The month and day of the last test
VTOL
VRES
The hour and minute of the last test
The sensor impedance in kilo-ohms
Impedance test recovery time in
Ignore, not used in %O2 applications
Ignore, not used in %O2 applications
Reference gas
Value for verification
Verification tolerance
Verification result
135
Changing the automatic test interval
The automatic sensor test interval may be set to any value
from 0 to 9999 minutes. Setting the value to 0 disables the
automatic test feature. Values less than 60 minutes are not
recommended. The parameter to change for the automatic
sensor test interval is PT I. This is accessed by the Setup
key under the PROB menu.
Calibration of the Dualpro for Oxygen Tools Required
1 - Small flat blade screwdriver
1 - Temperature source (to emulate oxygen
sensor
thermocouple)
1 - Piece of thermocouple extension wire
1 - MilliVolt source (To emulate oxygen
sensor)
1 - Twisted pair of copper wire
NOTE
Both a millivolt and temperature source is required.
RONAN Engineering, Model X-88 Calibrator or similar is
required (800-327-6626).
136
Thermocouple Input A Calibration
1. Place the Dualpro into calibration mode by
pressing the following keys (SHIFT, ENTER, SETPT, AND
PAGE DISP.) or by placing a jumper between Terminal
block “D” # 17 & # 18
2. Connect the thermocouple extension wire to the
temperature source and to the Dualpro terminal block “D”
# 1 & # 2.
3. Using the temperature source, “ENTER” the
correct “zero” value indicated for the thermocouple wire
selected (Generally a “B” type T/C) (refer to the Dualpro
manual for proper zero values for the thermocouple wire
selected).
4. Verify that the Dualpro display has Z-A in the SET
(Lower Window of the Dualpro) WINDOW, and a value in
the PROCESS (Upper Window of the DualPro) WINDOW
with one of the digits flashing. ( the flashing digit represents
the sensitivity of the adjustment needed. The right most
digit is the finest adjustment and the left most digit is the
most coarse adjustment. The middle two digits are between
the fine and coarse adjustments).
5. If the Dualpro is not displaying Z-A in the SET
(Lower Window of the Dualpro) WINDOW press the
“ENTER” key to change the first letter, or press the shift
key to change the second letter.
6. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys to
change the sensitivity of the adjustment.
7. Change the value on the Dualpro to match the
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value on the calibrator.
8. Once the correct zero value is displayed press the
enter key. (This will save the zero calibration value and also
prepare the instrument for the span calibration)
9. “ENTER” a span value (refer to the Dualpro
manual for proper zero and span values for the t/c wire
selected).
10. Verify that the Dualpro display has S-A in the
SET (Lower Window of the Dualpro) WINDOW.
11. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys to
change the sensitivity of the adjustment.
12. Once the correct span value is displayed press
the enter key. (This will save the span calibration value)
13. Repeat steps 3-12 until the calibration values are
correct.
Oxygen Input B Calibration:
1. Place the Dualpro into calibration mode by
pressing the following keys (SHIFT, ENTER, SETPT, AND
PAGE DISP.) or by placing a jumper on Terminal block “D”
# 17 & # 18
2. Connect the twisted pair of copper wires to the
calibrator and to the Dualpro terminal block “D”,
# 4 & # 5.
3. “ENTER” a zero value, 0 (zero) mV.
4. Verify that the Dualpro display has Z-B in the SET
138
(Lower Window of the Dualpro) WINDOW, and a value in
the PROCESS (Upper Window of the DualPro) WINDOW
with one of the digits flashing. ( the
flashing digit
represents the sensitivity of the adjustment needed. The
right most digit is the finest adjustment and the left most
digit is the most coarse adjustment. The middle two digits
are between the fine and coarse adjustments).
5. If the Dualpro is not displaying Z-B in the SET
(Lower Window of the Dualpro) WINDOW press the enter
key to change the first letter, or press the shift key to
change the second letter.
6. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys to
change the sensitivity of the adjustment.
7. Change the value on the Dualpro to match the
value on the calibrator.
8. Once the correct zero value is displayed press the
enter key. (This will save the zero calibration value and also
prepare the instrument for the span calibration)
9. “ENTER” a span value, 300 mV
10. Verify that the Dualpro display has S-B in the
SET (Lower Window of the Dualpro) WINDOW.
11. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys
to change the sensitivity of the adjustment.
12. Once the correct span value is displayed press
the enter key. (This will save the span calibration value).
13. Repeat steps 3-12 until the calibration values are
correct.
139
Thermocouple Input C Calibration:
1. Place the Dualpro into calibration mode by
pressing the following keys (SHIFT, ENTER, SETPT, AND
PAGE DISP.) or by placing a jumper on Terminal block “D”
# 17 & # 18
2. Connect the thermocouple extension wire to the
temperature calibrator and to the Dualpro Terminal block
“D” # 7 & # 8
3. “ENTER” a zero value (refer to the Dualpro
manual for proper zero values for the thermocouple wire
selected).
4. Verify that the Dualpro display has Z-C in the SET
(Lower Window of the Dualpro) WINDOW, and a value in
the PROCESS (Upper Window of the DualPro) WINDOW
with one of the digits flashing. ( the flashing digit represents
the sensitivity of the adjustment needed. The right most
digit is the finest adjustment and the left most digit is the
most coarse adjustment. The middle two digits are between
the fine and coarse adjustments).
5. If the Dualpro is not displaying Z-C in the SET
(Lower Window of the Dualpro) WINDOW press the enter
key to change the first letter, or press the shift key to
change the second letter.
6. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys to
change the sensitivity of the adjustment.
7. Change the value on the Dualpro to match the
value on the calibrator.
140
8. Once the correct zero value is displayed press the
enter key. (This will save the zero calibration value and also
prepare the instrument for the span calibration)
9. “ENTER” a span value (refer to the Dualpro
manual for proper zero and span values for the t/c wire
selected).
10. Verify that the Dualpro display has S-C in the
SET (Lower Window of the Dualpro) WINDOW.
11. Use the up and down arrow keys to make any
changes to the value and the left and right arrow keys to
change the sensitivity of the adjustment.
12. Once the correct span value is displayed press
the enter key. (This will save the span calibration value).
13. Repeat steps 3-12 until the calibration values are
correct.
141
Glossary
Anything in block capitals (ANSI, BYTE, BAUD) is an
acronym or abbreviation.
Manufactured terms: Technical Jargon for which there is no
satisfactory substitute term in common English as spoken
in the United States of America.
The definitions provided here are those in common usage
at Marathon Monitors. While some may be industry
standard others are specialized to Marathon usage.
Glossary:
ANSI (acronym): American National Standard Institute.
Organization for setting standards of performance,
hardness, safety or other measurable feature. Their
standards are used in laws and codes for product safety
and reliability.
ASCII (acronym): American Standard Code for Information
Interchange. Its use here usually refers to the standard
code for serial communications of alphanumeric and control
characters.
Asynchronous a communication method where data is sent
when it is ready without reference to a timing clock or
waiting until the receiver signals it is ready to receive it.
BASIC (n): Beginners All-purpose Symbolic Instruction
Code. A programming language developed at Dartmouth
College as a learning tool.
BAUD rate (n): standard information exchange speeds that
are used by telephone data exchange equipment (modem,
fax = facsimile, two-way video conferencing and the like)
142
equal to number of signal events or BITS per second used.
Binary (n): The basic coding system of all computer
languages consisting of 1's and 0's indicating either an off
or on position for a switch.
BIT (n): a single minute piece of binary data represented by
either a 1 or a 0. A 1 = on, a 0 = off. These on or off
positions are grouped into a block of 8 BITS to make up the
basic building blocks of data processing memory storage
and retrieval.
Block diagram (n): a shortened, graphical representation of
the cause and effect relationship between the input and
output of the physical system.
Block mapping (g): a method of moving and retrieving
stored data that resides in specific memory locations called
blocks.
BYTE (N): an eight BIT piece of memory storage and
retrieval data.
Buss (n): paralell lines for transfer signals between devices
or components.
Character (n): a letter, digit, or other symbol used as a
representation of data.
______String (n): a connected sequence of characters.
Control_______ (n): a character whose appearance in a
particular context starts, stops, or modifies an operation
that effects the recording, transmission, interpretation or
processing of data.
Closed loop (n): a control system in which the control action
is dependant on the output in some way.
Control loop (n): The continuous comparison of a process
143
output to its setpoint ; adjusting the inputs to the process to
achieve and maintain that setpoint.
Controlled output (n): The quantity or condition of the item
which is controlled.
Controller (n): A device with a transfer function especially
tailored to improve the dynamics of a system. In practice,
it is a mechanism, with adjustable parameters, designed to
receive a setpoint and feedback signals and to send an
output signal to activate a final control element such as a
valve.
Control system (n): an arrangement of Physical
components organized in a way that allows it to command,
direct, regulate itself or another system.
Control signal(n): the quantity or condition which is applied
to the item being controlled.
Datalogging (v): recording of historical data about a furnace
operation on a computer; to record process parameters.
Decimal (n): base ten number system using the characters
0 through 9 to represent values.
Derivative (n): A function within the a P. I. D. controller
which produces an output proportional to the rate of
change of the input variable.
Digital Control System (n): a system in which the
components are discrete time devices and are exposed to
pulsed rather than continuous signals.
DIP switch (acronym) "dual inline package" switch: pre
formed micro switch packets which allow the operator to
"permanently" preset a single programmable item such as
144
the address of an instrument in a daisy chain. DIP
switches produce a rudimentary binary message
dependant upon the wiring formation and if they are "read"
by some computer based communications system.
DIN (acronym): an abbreviation for the German national
standards organization, sets exacting standards for
industrial openings in cabinet faces, camera lenses, etc.
Also sets sizes for laboratory glassware, film speeds. used
here in relation to size of opening standard.
Disturbance (n): an undesired input signal which affects the
value of the controlled output. If this is an electronic signal
it is also referred to as "Noise".
DPR = digital process recorder: Honeywell trademarked
name portion as in DPR100, DPR3000 for a chart recorder.
These recorders range from single pen strip recorders to
multipen circular ones.
Error (n) : the difference between the setpoint of a
controller and its measured variable
Event (n): a binary input or output bit (of data) usually
switch or contact data.
Event mapping (g): the ability of a programmer to place a
bit of information in a specific location where it can then be
retrieved by a program for use.
Feedback (n): the property of a closed loop system which
permits a control variable to be compared with the input so
that the appropriate control action may be formed as a
function of the output and input.
Filter (n): a transducer whose frequency response
characteristics are chosen so that signals within a certain
145
frequency range are faithfully transmitted with little of other
frequencies passing through.
Frequency (n): the number of complete cycles per unit of
time that a sinusoidal ( or any regular) oscillation occurs.
Gain (n): a number which represents the ratio of the output
device to its input.
Gap (n): the space in the flow of processing between
groups of parts. In most recipes gaps are expressed as
time measurements.
Half duplex (n): a one way at a time data communication;
both devices can send and receive data only one at a time.
Handshake (n): An interface procedure that is based on
status/data signals; that assures an orderly data transfer as
opposed to an asynchronous exchange.
Hertz (n): An electrical term; a unit of frequency equal to
one cycle pre second.
Hexadecimal (n): A base sixteen number system using the
characters 0 through 9 and A through F to represent the
values. Often abbreviated as HEX.
Host (n): the primary or controlling instrument in a multipart
system.
Hystersis (n): The difference in output when a setpoint is
first approached with increasing and then decreasing value.
Expressed in terms of percent full scale during any one
calibration cycle, similar to back-lash in a gear train cycle.
Input (n): a signal or other excitation applied to a control
146
system from an external source to produce a specific
response from the control system.
Integral (adj): the I in P. I. D. control, a function which
produces an output which is proportional to the integral of
the error signal. When the error is zero the integral is a
constant; when the error is a constant, the integral is a
ramp function.
Interface (n): the means by which two systems or devices
are connected and communicate with each other.
Interpreter (n): a system program that converts and
executes each instruction of a high level language program
into machine code as it runs before going on to the next
instruction.
Interrupt (n): a program device which stops a process or
program in such a way that it can be resumed.
Load tracking (n): the record of a group of parts through the
processing set for them.
Leading edge (n): the first part of group of parts going
through processing.
LED = light emitting diode (n) : abbreviation for a diode
functioning as a lamp usually in a digital data display.
Linearize (a verb manufactured from a noun): with a
particular, limited range of variables; substitution of a linear
function for a non linear one. This linear function gives
approximately the same relationships.
Loop (n) a closed path in a feedback control system.
Manipulated variable (n) the process variable that is
147
changed by the controller in order to effect corrections, the
control signal.
Measured variable (n): the process parameter which is
being controlled.
Menuing (manufactured verb from the noun menu) options
(g) a term adopted by Marathon engineers to name the
process of reading menu selections from the screen of a
DUALPROÔ or other Marathon instrument with that option
in its program.
Noise(n): electronic interference that conceals or causes
unwanted fluctuations in the variable or the signal it is
supposed to represent. See also Disturbance.
Nominal part density (n) : a predetermined or premeasured
quantity of parts concentrated on a given location of a belt
in a belt furnace.
Octal (n): a base eight number system using the characters
0 through 7 to represent values.
Offset (n): the steady state error in a control loop stemming
from proportional only control action.
ON/OFF control, also called binary or logic control (n) : the
control system in which the final control device has only two
possible positions or states.
Open loop system: one in which the control is independent
of the output.
Operator Interface: (n) the point at which human beings
and system instruments connect. This can be a faceplate
keyboard, a computer touch screen, or a computer
keyboard and monitor. Other "interfaces" include switches,
controlling leavers, Non system faceplates, buttons,
148
monitors and keyboards.
Output: the actual response from the control system.
Overshoot: the difference between the final steady state
value and the value of the first reading. Often expressed
as a fraction of the difference between the initial and final
values.
Parameter: Marathon Monitors uses the term to define a
value that occupies a 16 bit binary word. This can consist
of signed or unsigned values and the location can be used
for one or more values depending on the size of the code
required to store the value.
Parameter table: a group of 240 of these data.
PI (acronym) : the Marathon Monitors Inc. version of the
predefined constant p.
PLC (abbreviation) = programmable logic controller: a
sophisticated piece of equipment capable of
communicating with a programming unit--(DUALPRO,
Process Master, 10PULSE) and equipment --( solenoid
valves, drive belts) with the ability to get work done by the
equipment that the programming unit calls for, such as,
increasing gas flow to the furnace, moving parts through
the furnace, or opening or closing the furnace door. A PLC
can store programs and do its own programs as well as
those of the control unit. It's response time is shorter than
most programming units when relating to switches and
controls of the solenoid type.
Proportional (adj): the P in P. I. D.; in a PID controller, the
function which produces an output in proportion to the error
signal.
149
Realrun* screens (n) a display on a computer monitor
usually the Process Master file server computer monitor or
a node (OVERVIEW 8600) at an operator work station.
These screens are used to show current Data in the
master DUALPRO* in organized, easy to see format.
Realrun* can be used to display limited amounts of
computer Data information such as an in process part or
job number.
Recipe, (n) a sequential list of setpoints, event action and
soak times to be used for every control loop in a system.
Setpoints for every control loop in the line of a Beltpro*
system.
Reference input (n) :an external signal applied to a
feedback control system in order to command a specified
action; often representative of ideal behavior.
Regulator (n) : a controller with the primary objective of
maintaining an output constant in spite of load variations.
Setpoint (n): The desired value of a measured variable ; the
controller acts to make the measured variable match the
setpoint.
Settling time (n) : amount of time required to reach 2 to 5 %
of the final value.
Stable (n): a state of being, a system that will stay at rest
unless excited by an external source and will return to rest
in external excitements are removed.
Three mode controller (n) : a P. I. D. controller.
Time constant (n) : the time needed for the output to
change from a given value to within 63% of the total
change when a step input is made. The Greek letter tau or t
in formulas represents this.
150
Toggle (v) from the noun toggle switch: to move between
two preset states -- "to toggle between off and on" for
example.
Trailing edge (n) the last of a group of parts going through
processing.
Transducer (n) a device that converts one energy form into
another.
UDC (abbreviation) = universal digital controller:
HoneywellÔ trademarked temperature control devices as in
UDC2000, UDC3000 etc.
WORD(n): a two BYTE piece of binary memory storage
and retrieval data.
For assistance please contact:
Marathon Monitors Inc.
TEL: +1 513 772 1000 • FAX: +1 513 326 7090
Toll-Free North America +1-800-547-1055
[email protected]
www.group-upc.com
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