United Process | Versapro | Specifications | United Process Versapro Specifications

Versapro
Temperature Controller
Installation and Operation
Handbook
Revision 1.11
VersaPro Temperature Controller
Page 2
Manual #: 022
Rev No: 1.11
Date: 30 October 2013
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United Process Controls Inc.
DISCLAIMER:
The VersaPro is to be used by the industrial operator under his/her direction. United Process Controls
Inc. is not responsible or liable for any product, process, damage or injury incurred while using the
VersaPro. United Process Controls Inc. makes no representations or warranties with respect to the
contents hereof and specifically disclaim any implied warranties or merchantability or fitness for any
particular purpose.
For assistance please contact:
United Process Controls Inc.
TEL: +1 513 772 1000 • FAX: +1 513 326 7090
Toll-Free North America +1-800-547-1055
upc.support@group-upc.com
www.group-upc.com
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VersaPro Temperature Controller
Page 3
TABLE OF CONTENTS
TABLE OF CONTENTS ..................................................................................................................................................................... 3 1. Safety and Environment Information .................................................................................................................................... 7 1.1 Service and repair ........................................................................................................................................................................ 7 2. Installation Safety Requirements .......................................................................................................................................... 7 2.1 Safety Symbol .............................................................................................................................................................................. 7 2.2 Personnel ..................................................................................................................................................................................... 7 2.3 Enclosure of live parts .................................................................................................................................................................. 8 2.4 Live sensors .................................................................................................................................................................................. 8 2.5 Wiring .......................................................................................................................................................................................... 8 2.6 Power Isolation ............................................................................................................................................................................ 8 2.7 Earth leakage current .................................................................................................................................................................. 8 2.8 Over Current protection ............................................................................................................................................................... 8 2.9 Voltage rating .............................................................................................................................................................................. 9 2.10 Conductive pollution ............................................................................................................................................................... 9 2.11 Over‐temperature protection ................................................................................................................................................. 9 2.12 Grounding of the temperature sensor shield ........................................................................................................................ 10 2.13 Installation requirements for EMC ........................................................................................................................................ 10 2.14 Routing of wires .................................................................................................................................................................... 10 3 VersaPro Features .............................................................................................................................................................. 10 4 Installation ......................................................................................................................................................................... 11 4.1 Mounting ................................................................................................................................................................................... 12 5 Process Control Options ..................................................................................................................................................... 13 6 Control Modes ................................................................................................................................................................... 13 6.1 Time Proportioning (TP) ............................................................................................................................................................. 13 6.2 Time Proportioning Dual (TD) .................................................................................................................................................... 14 6.3 Time Proportioning with Complement (TC) ............................................................................................................................... 14 6.4 Position Proportioning (PP) ....................................................................................................................................................... 14 6.5 ON/OFF (OF) ............................................................................................................................................................................. 14 6.6 ON/OFF Dual (OD) ..................................................................................................................................................................... 15 6.7 ON/OFF with Complement (OC) ................................................................................................................................................ 15 6.8 Direct Current Output ................................................................................................................................................................ 15 6.9 Direct or Reverse Control Action ................................................................................................................................................ 16 7 Alarms ............................................................................................................................................................................... 16 Copyright © 2013, United Process Controls Inc.
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7.1 Process Alarms ........................................................................................................................................................................... 17 OFF ................................................................................................................................................................................................. 17 Full Scale HI .................................................................................................................................................................................... 17 Full Scale LO .................................................................................................................................................................................... 17 Deviation Band ............................................................................................................................................................................... 17 Deviation High ................................................................................................................................................................................ 17 Deviation Low ................................................................................................................................................................................. 17 Output High .................................................................................................................................................................................... 17 Output Low ..................................................................................................................................................................................... 18 Fault ................................................................................................................................................................................................ 18 Time ................................................................................................................................................................................................ 18 Start ................................................................................................................................................................................................ 18 Soak ................................................................................................................................................................................................ 18 7.2 Alarm Action .............................................................................................................................................................................. 18 7.3 Alarm Delay Times ..................................................................................................................................................................... 19 7.4 Diagnostic Alarms ...................................................................................................................................................................... 19 8 Serial Interface ................................................................................................................................................................... 20 9 Front Panel Operation ........................................................................................................................................................ 21 9.1 Enter Key .................................................................................................................................................................................... 22 9.2 Remote Key ................................................................................................................................................................................ 22 9.3 Setup Key ................................................................................................................................................................................... 22 9.4 Dual Key Functions .................................................................................................................................................................... 31 Starting Probe Tests ....................................................................................................................................................................... 31 Start Timer ...................................................................................................................................................................................... 31 Edit Timer ....................................................................................................................................................................................... 31 Monitor Mode ................................................................................................................................................................................ 31 10 Digital Input Event .............................................................................................................................................................. 32 OFF ................................................................................................................................................................................................. 32 PROB ............................................................................................................................................................................................... 32 AUTO (controller only) .................................................................................................................................................................... 32 rEn (controller only) ....................................................................................................................................................................... 32 ACK ................................................................................................................................................................................................. 32 PrOC (controller only) ..................................................................................................................................................................... 32 Strt (controller only) ....................................................................................................................................................................... 33 HOLd (controller only) .................................................................................................................................................................... 33 End (controller only) ....................................................................................................................................................................... 33 11 Timer Function ................................................................................................................................................................... 34 11.1 Setting the Timer .................................................................................................................................................................. 34 11.2 Time ...................................................................................................................................................................................... 35 11.3 Guaranteed Start Timer ........................................................................................................................................................ 35 11.4 Guaranteed Soak Timer ........................................................................................................................................................ 36 11.5 Timer Alarm Behavior ........................................................................................................................................................... 36 11.6 Timer State Diagram ............................................................................................................................................................. 36 12 Timer SIO Operations ......................................................................................................................................................... 38 Copyright © 2013, United Process Controls Inc.
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VersaPro Temperature Controller
12.1 13 Controlling the Timer Remotely ............................................................................................................................................ 39 Tuning ................................................................................................................................................................................ 40 13.1 14 Page 5
What is tuning? ..................................................................................................................................................................... 40 Scaling Analog Inputs ......................................................................................................................................................... 43 14.1 Linear Example ...................................................................................................................................................................... 43 14.2 Keyboard Function during Input Slope .................................................................................................................................. 43 15 Scaling Analog Outputs ....................................................................................................................................................... 44 16 Calibration ......................................................................................................................................................................... 44 16.1 Calibration Displays and Keyboard Operation ...................................................................................................................... 45 16.2 Preparing for Input Calibration ............................................................................................................................................. 45 Calibration of the Thermocouple Input .......................................................................................................................................... 46 Calibration of the Cold Junction Temperature ............................................................................................................................... 46 Calibration of the Analog Output Channels ................................................................................................................................... 47 17 Communications ................................................................................................................................................................ 48 17.1 Modbus ................................................................................................................................................................................. 48 RTU Framing ................................................................................................................................................................................... 48 Address Field .................................................................................................................................................................................. 48 Function Field ................................................................................................................................................................................. 48 Data Field ....................................................................................................................................................................................... 49 Error Check Field (CRC) ................................................................................................................................................................... 49 17.2 MSI Message Protocol .......................................................................................................................................................... 50 17.3 Instrument Type ‘U’ Command Set ....................................................................................................................................... 52 ‘X’ Command .................................................................................................................................................................................. 52 Block Commands ............................................................................................................................................................................ 54 MSI Error Codes .............................................................................................................................................................................. 56 18 Troubleshooting Questions ................................................................................................................................................ 57 18.1 Analog Inputs ........................................................................................................................................................................ 57 18.2 Control Outputs..................................................................................................................................................................... 57 18.3 Digital Communications ........................................................................................................................................................ 58 18.4 Display Functions .................................................................................................................................................................. 58 18.5 Timer Function ...................................................................................................................................................................... 58 19 Versapro Monitor Mode ..................................................................................................................................................... 59 19.1 Prepare for Connection ......................................................................................................................................................... 59 19.2 How to Connect ..................................................................................................................................................................... 59 19.3 Start Monitor Mode .............................................................................................................................................................. 60 19.4 ‘D’ Display Command ............................................................................................................................................................ 61 19.5 ‘L’ Write FLASH to RAM Defaults .......................................................................................................................................... 61 19.6 ‘K’ Write RAM to EEPROM .................................................................................................................................................... 61 Copyright © 2013, United Process Controls Inc.
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19.7 ‘J’ Display EEPROM Values .................................................................................................................................................... 62 19.8 ‘S’ Status Display ................................................................................................................................................................... 62 19.9 ‘W’ Write RAM with EEPROM or Data Values ...................................................................................................................... 62 19.10 ‘X’ Exit Command .................................................................................................................................................................. 62 19.11 Viewing Status and Memory ................................................................................................................................................. 62 19.12 Loading Default Values ......................................................................................................................................................... 63 19.13 What if an error occurs ......................................................................................................................................................... 64 20 Technical Specification ....................................................................................................................................................... 65 20.1 Environmental ratings .......................................................................................................................................................... 65 20.2 Equipment ratings ................................................................................................................................................................. 65 20.3 General.................................................................................................................................................................................. 65 20.4 Electrical safety (pending approval) ..................................................................................................................................... 66 21 Versapro Memory Map ...................................................................................................................................................... 68 Copyright © 2013, United Process Controls Inc.
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VersaPro Temperature Controller
1.
Page 7
Safety and Environment Information
Please read this section carefully before installing the controller
This instrument is intended for industrial applications used in conjunction with Marathon Monitors zirconia
oxygen sensors and standard thermocouple types. It is assumed that any installation meets either CE
standards for industrial safety or NEC standard wiring practices. Failure to observe these standards or the
installation instructions in this manual may degrade the safety or electrical noise protection provided by this
instrument. It is the installer’s responsibility to ensure the safety and electrical noise compatibility of any
installation.
1.1
Service and repair
This controller has user replaceable fuses but no other user serviceable parts. Contact your Marathon
Monitors Service (800-547-1055) for repair.
Caution: Charged capacitors
Before removing an instrument from its case, disconnect the supply and wait at least two minutes to allow
capacitors to discharge. Failure to observe this precaution will expose capacitors that may be charged with
hazardous voltages. In any case, avoid touching the exposed electronics of an instrument when withdrawing it
from the case.
Electrostatic Discharge (ESD) Precautions
When the controller is removed from its case, some of the exposed electronic components are vulnerable to
damage by electrostatic discharge. Anyone who is not probably ground using an ESD wrist strap or in contact
with a ground while handling the controller may damage exposed electronic components.
2.
Installation Safety Requirements
2.1
Safety Symbol
Various symbols are used on the instrument, they have the following meaning:
!
Caution, (refer to the
accompanying documents)
Functional earth
(ground) terminal
The functional earth connection is required for safety ground add to ground RFI filters.
2.2
Personnel
Installation must be carried out by qualified personnel.
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VersaPro Temperature Controller
2.3
Page 8
Enclosure of live parts
To prevent hands or metal tools touching parts that may be electrically live, the controller should be installed in
an enclosure. The contacts on the rear of the instrument case or finger save but it is still possible for loose
wiring, or metal objects to come in contact with live terminal connections. It is recommended that power be
removed from the instrument connections before they are disconnected. However, instrument’s power
connector can be removed with power applied. Care should be taken that the connector does not come in
contact with any grounded object.
2.4
Live sensors
The dc inputs, dc logic, and dc outputs are all electrically isolated from chassis ground. If the temperature
sensor is connected directly to an electrical heating element then the inputs will also be live. The controller is
designed to operate under these conditions. However you must ensure that this will not damage other
equipment connected to these inputs and that service personnel do not touch connections to these terminals
while they are live. With a live sensor, all cables, connectors and switches for connecting the sensor and nonisolated inputs and outputs must be mains rated.
2.5
Wiring
It is important to connect the controller in accordance with the wiring data given in this handbook. Take
particular care not to connect AC supplies to the low voltage sensor input or other low level inputs and outputs.
Only use copper conductors for connections (except thermocouple inputs) and ensure that the wiring for
installations comply with all local wiring regulations. For example, in the UK, use the latest version of the
wiring regulations, BS7671. In the USA use NEC Class 1 wiring methods.
2.6
Power Isolation
The installation must include a power isolating switch or circuit breaker. This device should be in close
proximity to the control actuator, and within easy reach of the operator. There is no means of disconnecting
power from the instrument other than removing the connectors from the rear of the instrument. It is
recommended that additional power disconnects are provided in the installation to remove power from these
connectors as well.
2.7
Earth leakage current
Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This may affect the design of an
installation of multiple controllers protected by Residual Current Device, (RCD) or Ground Fault Detector,
(GFD) type circuit breakers.
2.8
Over Current protection
The instrument has an internal 3.15 Amp fuse (P/N MFU-3.15PCTT) for instrument power and 1 Amp fuses
(P/N MFU-1.0PCTT) for the control contacts and alarms. It is recommended that additional protection against
excess currents be used for loads exceeding this rating. Fusing and interposing relays should be added to the
control circuit if high current or large inductive loads are used.
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VersaPro Temperature Controller
2.9
Page 9
Voltage rating
The maximum continuous voltage applied between any of the following terminals must not exceed 250VAC:
 line or neutral to any other connection;
 relay output to logic, dc or sensor connections;
 any connection to ground.
The controller should not be wired to a three phase supply with an unearthed star connection. Under fault
conditions in this supply could rise above 264VAC with respect to ground and the product would not be safe.
Voltage transients across the power supply connections, and between the power supply and ground, must not
exceed 2.5kV. Where occasional voltage transients over 2.5kV are expected or measured, the power
installation to both the instrument supply and load circuits should include a transient limiting device.
These units will typically include gas discharge tubes, metal oxide varistors, and constant voltage transformers
help suppress voltage transients on the supply line due to lightning strikes or inductive load switching. Devices
are available in a range of energy ratings and should be selected to suit conditions at the installation.
2.10
Conductive pollution
Electrically conductive pollution must be excluded from the cabinet in which the controller is mounted. For
example, carbon dust is a form of electrically conductive pollution. To secure a suitable atmosphere in
conditions of conductive pollution, fit an air filter to the air intake of the cabinet. Where condensation is likely,
for example at low temperatures, include a thermostatically controlled heater in the cabinet.
2.11
Over-temperature protection
When designing any control system it is essential to consider what will happen if any part of the system should
fail. In temperature control applications the primary danger is that the heating will remain constantly on. Apart
from scrapping the product, this could damage any process machinery being controlled or even cause a fire.
Reasons why the heating might remain constantly on include:
 the temperature sensor becoming detached from the process;
 thermocouple wiring becoming a short circuit;
 the controller failing with its heating output constantly on;
 an external valve or contactor sticking in the heating condition;
 the controller setpoint set too high.
Where damage or injury is possible, we recommend fitting a separate over-temperature protection unit. Factory
Mutual requires that any over temperature device use an independent temperature sensor, which will isolate
the heating circuit.
Please note that the alarm relays within the controller will not give protection under all failure conditions. This
instrument is not suited for over temperature protection and should not be used as a safety device.
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VersaPro Temperature Controller
2.12
Page 10
Grounding of the temperature sensor shield
In some installations it is common practice to replace the temperature sensor while the controller is still
powered up. Under these conditions, as additional protection against electric shock, we recommend that the
shield of the temperature sensor be grounded at one end of the wire. Do not rely on grounding through the
framework of the machine.
2.13
Installation requirements for EMC
To ensure compliance with European EMC directives certain installation precautions are necessary as follows:
 When using relay outputs it may be necessary to fit a filter suitable for suppressing the emissions. The filter
requirements will depend on the type of load. For typical applications such as Schaffner FN321 or FN612
line filters or equivalents.
 If the unit is used in table top equipment which is plugged into a standard power socket, it is likely that
compliance to the commercial and light industrial emissions standard is required. In this case, to meet the
conducted emissions requirement, a suitable mains filter should be installed. Recommended filters would
be Schaffner types FN321 and FN612 or equivalents.
2.14
Routing of wires
To minimize the pick-up of electrical noise, the wiring for low voltage dc and particularly the sensor input
should be routed away from high-current power cables. Where it is impractical to do this, use shielded cables
with the shield grounded at one end.
3
VersaPro Features
The VersaPro is a single loop process controller / monitor has the following capabilities:








24 bit Sigma-Delta ADC for thermocouple with cold junction compensation.
Two (2) 4-20 milliamp outputs for control or chart recorder.
Sixteen character LCD with two four-digit LED segment displays.
Two (2) Form A control contacts. (controller)
Two (2) Form A alarm contacts.
PID control modes. (controller)
Serial Communication with Marathon Monitors or Modbus Protocol.
EEPROM stores setup and calibration values.
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Page 11
Installation
The VersaPro instrument is designed for up to 1/8" panel mounting in a DIN standard opening of 3.62" square
(adapter panels available by special order). Required rear clearance is 7.5” to allow for wiring.
As with all solid state equipment, the controller should be located away from excessive heat, humidity, and
vibration. Since the unit uses LED and LCD display devices, it should also be located so that direct sunlight
will not interfere with the display's visibility. The instrument requires 120/240 VAC 50/60 Hz and should not be
on the same circuit with other noise-producing equipment such as induction machines, large electrical motors,
etc. Signal wiring must be run separate from control wiring. It is suggested that signal wiring at the rear
terminals of the instrument be routed in one direction (up or down) while the AC power wires are routed in the
opposite direction.
The following figure shows the rear terminals locations on the rear of the VersaPro.
Figure 1 VersaPro Rear Panel
The following figure shows a typical wiring schematic for the Versapro temperature controller.
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Figure 2 Wiring Schematic
4.1
Mounting
To mount the instrument in a control panel, a hole must be cut 3.62" square in the necessary location on the
panel. The following procedure should be followed to mount the VersaPro in the panel.
1)
Insert the unit into previously cut out 3.62" square hole in panel.
2)
While supporting unit, insert one clamping bracket into the groove on the bottom of unit, and then install
the 6-32 set screw.
3)
Repeat step 2 for the top of the unit.
4)
With a HEX KEY wrench, alternately tighten the screw on either side of instrument to a torque of six in.lbs. Insure rigidity of mounting. DO NOT OVER TIGHTEN. This can wrap the instrument enclosure
and make removal difficult.
To remove the instrument from the panel, reverse the above procedures.
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5
Page 13
Process Control Options
The Versapro is configured to perform as a single loop PID controller for a specific process. This instrument is
setup as an oxygen controller.
Table 1 Instrument Control Options
Function
Temperature
Linear Input A
Linear Input B
6
Description
Uses the temperature signals from a thermocouple to control to
temperature setpoint.
Uses the millivolt signal from a linear sensor connected to terminals
+TC / -TC
Uses the millivolt signal from a linear sensor connected to terminals
+MV / -MV
Control Modes
The VersaPro controller provides:








Time Proportional Single (TP)
Time Proportional Dual (TD)
Time Proportional Compliment (TC)
Position Proportioning (PP)
On/Off (OF)
On/Off Dual (OD)
On/Off Compliment (OC)
Direct Signal Output (4-20mA)
The instrument controls with two control contacts or direct 4-20mA output from two analog output channels.
The control function can be set to direct acting or reverse acting.
Direct acting increases the output control signal to increase the process. Reverse acting decreases the output
control signal to increase the process.
6.1
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 trim gas or addition air to the process. The control loop percent output
is the percentage of the ON time relative to total cycle time. The cycle time is the 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
tradeoff between excess wear and tear on the solenoid valve with short cycle times or oscillation of the control
process using long cycle times. Only the first control contact is used in this mode.
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6.2
Page 14
Time Proportioning Dual (TD)
This mode is used when there are two processes to control that have complementary effects; like heat and
cool. The time proportioning dual mode uses two control outputs; one for heat and one for cool. 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 output. When negative the
proportioning action applies to the reverse output.
6.3
Time Proportioning with Complement (TC)
This mode is identical to the time proportioning mode except that both control outputs are used. The second
control output is the complement of the first. That is when the first output is ON then 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.
6.4
Position Proportioning (PP)
This mode is used with motorized valves that do not have slidewire feedback. This mode is sometimes
referred to as "bump" mode because it "bumps" the valve slightly more open or closed. This mode uses both
control outputs; one to drive the motor forward (open) and the other to drive it reverse (closed). The control
output is 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 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.
There is a built in deadband for this control based on the length of the cycle time. The comparison between
the previous and current output values are made at the end of each cycle time. Faster comparisons can be
made by shortening the cycle time assuming that a 100% command output is a continuously close control
contact.
6.5
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 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 that prevent these problems from occurring; hysteresis and
deadband. Hysteresis provides a delay between the control on point and the off point. Noise will not cause
the control output to “chatter” with this gap applied. Hysteresis is ±20% of the deadband value.
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Deadband allows the process to deviate away from the setpoint by the width of the deadband before any
control action occurs. The deadband is adjusted through the Proportional Band in units of the displayed
setpoint value. The reset and rate values have no effect in ON/OFF control.
Let’s assume the process setpoint is 1500° with a proportional band of 5. This represents a deadband of 5°,
which is a band of ±5° around setpoint. The hysteresis is 1° of the setpoint or 20% of the deadband. The
output is turned on when the process drops below 1495° and turns off then it reaches 1499°.
The deadband controls the point where the control is turned on to correct any deviation from setpoint. The
hysteresis controls the point where the control is turned off to prevent overshoot or chatter.
6.6
ON/OFF Dual (OD)
This mode is similar to the time proportioning dual mode. The forward output acts as described in the ON/OFF
description above. The reverse output responds when the process is above the setpoint.
Using the temperature example with a proportional band (deadband) of 5, the heat contact would turn on when
the process is 1495° and will turn off when it comes to 1499°. Likewise the cool contact would turn on when
the process exceeds 1505° and will turn off when it drops to 1501°.
6.7
ON/OFF with Complement (OC)
This mode is exactly like ON/OFF control with the addition of a second control output. The second control
contact is turned ON when the first is control contact is OFF and vice versa.
6.8
Direct Current Output
The Versapro has two analog output channels that provide an isolated 4 to 20mA signal proportional to
selectable process values. The analog outputs can be configured to control the process by driving actuators
with a 4-20mA signal proportional to the calculated percent output of the PID loop. One or both output
channels can be used depending on the control mode selected. POUT selection drives the output signal
based on the HIPO and LOPO settings. If a Dual Time Proportioning control mode is selected with a HIPO =
100 and a LOPO = -100 then the output will be 4mA for –100%, 12mA for 0%, and 20mA for +100% output.
This setting is helpful if one actuator is driving two valves in a split configuration where air is fully opened at –
100% and gas is fully opened at +100% or both are closed at 0%.
It is possible to drive two actuators independently by setting on output to PO1 or PO2 where PO1 is the 0 to
+100% control output and PO2 is 0 to –100%. In this configuration both outputs are at the maximum (±100%)
with an output of 20mA.
It is also possible to drive one actuator with an output channel and a solenoid with a control contact. For
example, select PO1 for one analog output channel to drive a gas actuator and connect an air solenoid to the
reverse control contact. The percent output for both functions is determined by the PID settings. The cycle
time should be set to the stroke time required to fully open the actuator from a fully closed condition. Typical
stroke times would be 30 to 45 seconds.
The control contacts will still act as described in the previous modes even if the analog output channels are
being used.
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6.9
Page 16
Direct or Reverse Control Action
Control action determines how the output of the controller will react to effect a change on the process. The
control action is considered ‘direct’ if an increase in the output produces an increase in the process value. A
‘reverse’ control action would be when an increase in the output produces a decrease in the process.
For example oxygen would require a reverse acting control if the process component the instrument is
controlling is a trim gas. Increasing the trim gas will result in a decrease in the oxygen reading. It is
considered a direct acting control if the process component under control is additional air. Either process
would use the first control contact; it would just be activated above or below the process setpoint depending on
what is being added to the process.
7
Alarms
The instrument has two types of alarms, process alarms and diagnostic alarms. If an alarm has been selected
and conditions are such that the alarm becomes active, the instrument will display this condition on the center
LCD display. The alarms a numbered as Alarm 1 and Alarm 2. The various displays for active alarm
conditions would be displayed as shown below. N indicates the position of the alarm number, 1 or 2.
ALARM DISPLAY
PROCESS HIGH
CONDITION
Process alarm, contact assignable
PROCESS LOW
Process alarm, contact assignable
PROCESS HIGH OR LOW
Process alarm, contact assignable
PROCESS HIGH
Process alarm, contact assignable
PROCESS LOW
Process alarm, contact assignable
PROCESS HIGH
Process alarm, contact assignable
PROCESS LOW
Process alarm, contact assignable
TIMER END
Alarm contact assigned to TinE,
Strt, SOAK
LLLL
Display only
HHHH
Display only
FLASH CSUM
Fault alarm, contact assignable
EEPROM CSUM
Fault alarm, contact assignable
KEYBOARD
Fault alarm, contact assignable
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ACTION
Full Scale High, Contact
automatically resets unless latched.
Full Scale Low, Contact automatically
resets unless latched.
Deviation Band,
Contact automatically resets unless
latched.
Deviation High, Contact automatically
resets unless latched.
Deviation Low, Contact automatically
resets unless latched.
Power Output High, Contact
automatically resets unless latched.
Power Output Low, Contact
automatically resets unless latched.
Timer end alarm when the timer
counts to zero for Timer, Start, or
Soak timer modes. The contact
latches until reset by pressing the
Enter key or through the Input Event.
Displays process value within display
range or exponent setting
Displays process value within display
range or exponent setting
Reset instrument power. Return to
Marathon if error does not clear.
Reset instrument power. Return to
Marathon if error does not clear.
Reset instrument power. Do not push
any keys while instrument is powered
on. Return to Marathon if error does
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Page 17
ALARM DISPLAY
CONDITION
FLASH ERASE
Fault alarm, contact assignable
FLASH / EE SIZE
Fault alarm, contact assignable
TEMP OPEN
Fault alarm, contact assignable
ACTION
not clear.
Programming error,
Reset instrument power, attempt
reload.
Programming error,
Reset instrument power, attempt
reload.
Check thermocouple for open
condition or loose connection.
7.1
Process Alarms
The process alarms can be setup to activate either or both of the two alarm contacts provide on the VersaPro.
Nine user selectable modes are available. The Full Scale HI, Full Scale LO, Fault, and Probe alarms are
available in the monitor. Of the alarms listed are available in the controller.
OFF
Disables the alarm function and the alarm contacts
Full Scale HI
An alarm is generated any time the process value goes above the Full Scale HI alarm value. This alarm is
reset if the process falls below the alarm value or acknowledgement from the front panel or through the
event input (if configured).
Full Scale LO
An alarm is generated any time the process value drops below the Full Scale LO alarm value. The alarm
will arm once the process is measured above the alarm value. This alarm is reset with an
acknowledgement from the front panel or through the event input (if configured).
Deviation Band
An alarm is generated any time the process value goes above or below the band alarm setting. The alarm
setting is  value of the band. For example, if a value of 10 is entered as the alarm value, an alarm is
generated if the process goes 10 units above or 10 units below the setpoint. Units are the process units
such percent or degrees. This alarm will not arm until the process is in-band of the setpoint.
Deviation High
An alarm is generated any time the process value goes above the band alarm setting. The alarm setting
is number of units allowed above setpoint. Units are the process units such percent or degrees. This
alarm will not arm until the process is in-band of the setpoint.
Deviation Low
An alarm is generated any time the process value goes below the band alarm setting. The alarm setting is
number of units allowed below the setpoint. Units are the process units such percent oxygen or degrees.
This alarm will not arm until the process is in-band of the setpoint.
Output High
An alarm is generated any time the control percent output exceeds the alarm value. The alarm setting is
maximum percent output allowed.
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Output Low
An alarm is generated any time the control percent output drops below the alarm value. The alarm setting
is minimum percent output allowed.
Fault
An alarm is generated any time an open input occurs on the T/C input. The input is pull up to a maximum
value if no input is connected or if the input fails in an open circuit mode. The center display will indicate
which of these conditions has caused the alarm. The alarm process will also become active if any of the
listed hardware faults occur. The center display will indicate which of these conditions has caused the
alarm.
Time
This alarm setting is necessary for the timer function to work. The timer will only run if it is enabled in the
Ctrl Setup menu and a timer setpoint value other than zero has been assigned. This alarm setting allows
the timer to start running when it is activated at the Start Timer parameter in the Setpt key menu, when the
dual key combination Left Arrow and Enter keys are pressed, or if the Input Event has been configured for
Start and a contact closure occurs. The timer will start running as soon as it starts, independent of any
process values. See the Timer section for more details.
Start
This alarm setting is necessary for the timer function to work. The timer will only run if it is enabled in the
Ctrl Setup menu and a timer setpoint value other than zero has been assigned. This alarm setting allows
the timer to be activated from the Start Timer parameter in the Setpt key menu, when the dual key
combination Left Arrow and Enter keys are pressed, or if the Input Event has been configured for Start
and a contact closure occurs. The timer will start running as soon as the process level is above the alarm
value and will continue to run once it has started. See the Timer section for more details.
Soak
This alarm setting is necessary for the timer function to work. The timer will only run if it is enabled in the
Ctrl Setup menu and a timer setpoint value other than zero has been assigned. This alarm setting allows
the timer to be activated from the Start Timer parameter in the Setpt key menu, when the dual key
combination Left Arrow and Enter keys are pressed, or if the Input Event has been configured for Start and
a contact closure occurs. The timer will start running as soon as the process level is within the band
around setpoint determined by the alarm value. The timer will stop any time the process falls outside the
band limit. See the Timer section for more details.
7.2
Alarm Action
Each alarm can be configured to operate in several different modes. Each alarm can be configured as a
reverse (normally closed) contact. This mode is usually used for failsafe alarms that will open during an alarm
condition, fault, or power failure. Each alarm can also be configured as a direct (normally open) contact that
closes when an alarm condition occurs. In both cases the alarm will automatically clear if the alarm condition
is resolved.
Each alarm can also be configured for either reverse or direct latched conditions. In this mode the alarm
contact will remain active until an acknowledgement is received through the event port or by pressing the
ENTER key.
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7.3
Page 19
Alarm Delay Times
Each alarm can have delay ON, delay OFF, or both delays applied. Delays can be applied in increments of a
second, up to a maximum of 250 seconds. ON delays are helpful if a known upset in the process can be
ignored. This avoids nuisance alarms but still maintains an active alarm if the alarm condition persists
following the delay. OFF delays will hold the alarm contact active for a determined period of time once the
alarm condition has cleared. This can be helpful as an interlock to other process functions that may have to
recover following an alarm condition.
7.4
Diagnostic Alarms
A diagnostic alarm is shown on the instrument’s center display when a fault is detected in the internal
hardware during power up. These alarms included:
FLASH CSUM
EEPROM CSUM
KEYBOARD
FLASH ERASE
FLASH / EE SIZE
A fault has been detected in the Flash memory.
A fault has been detected in the EEPROM.
A key is stuck or was held down during power up.
This error may occur during instrument programming. The Flash memory may be
faulty. Retry programming; make sure the communications link to the instrument is
working properly.
This error may occur during instrument programming. The Flash memory may be faulty.
Retry programming; make sure the communications link to the instrument is working
properly.
If either alarm contact is configured for a fault this alarm will engage if any of the above faults occur. The LCD
display will indicate the fault condition.
The front panel display will show 0000 if the process value is below the display resolution, or HHHH if the
process value is above the display resolution. It may be necessary to adjust the oxygen exponent and/or the
oxygen decimal point settings if these symbols occur.
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Page 20
Serial Interface
The VersaPro has a single RS-485 half duplex (two wire) communications port. This port can be configured
for either the Marathon protocol of Modbus RTU protocol. Baud rates and parities are selectable. The
Modbus protocol only uses a parity of none. See the section on communications for details on both of these
protocols.
The Versapro can be connected to networks with up to 128 similar devices. The differential transceiver used
in the Versapro meets or exceeds the TIA/EIA-485 and ISO/IEC 8482:1993(E) standards.
Connections for the serial interface should be connected to the following terminals:
TB-B 13
TB-B 14
RTX +
RTX –
All connections to any RS-485 bus should be made with shielded twisted pair wires using a low capacitance
cable specified for RS-485 multi-drop connections. The shield should be connected to ground on one end of
the wire run. Shield continuity should be maintained between wire segments. Each end of the network
should be terminated with a resistor that is close to the impedance of the cable. 100 to 120 ohms are typical
values. All connections to multiple instruments should be made in a daisy-chain fashion, from one instrument
to the next. A star network connection should never be used. A repeater should be considered for cable
distances beyond 3900 feet (1.2Km). Any network that is run between buildings should use repeaters with
optical fiber connections between buildings to avoid any noise spikes generated by lightning strikes.
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Page 21
Front Panel Operation
Figure 3 Versapro Front Panel
The LEDS to either side of the LED segment arrays light when the corresponding function is active.
 COMM flashes when the instrument is properly interrogated over the RS485 port.
 PWR is hard wired to the instrument 5VDC supply
 AUTO is lit when the instrument is controlling to a setpoint (controller option)
 REM is lit when the instrument is controlling to a remote setpoint (controller option)
 REM and AUTO flash together if the instrument is in manual mode.
 REM will flash if timer is running.
The upper display indicates the process value or the Setup Menu Heading when the SETUP key has been
pressed.
The center display indicates what the measured process calculation is and what the lower display indicates. In
figure 3 the instrument is indicating the measured temperature in the upper display. The lower display shows
the setpoint.
The center display also shows the parameter name in Setup mode or fault and alarm messages if any are
active.
The lower display shows the instrument setpoint if the controller is in automatic or remote mode. The display
will switch to control output level when the instrument is changed to manual.
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9.1
Page 22
Enter Key
If the normal process display is showing on the LED and LCD displays, then pressing the Enter key will cycle
the LCD and lower LED through various controller parameters. For the controller, the display will cycle through
the following list, the monitor will show only a partial list.
TEMP / SETPT
TEMP / %OUT
REMAINING TIME
The temperature process value will always be displayed in the top LED display.
Each time an alarm occurs the particular alarm prompt will appear in the LCD display. The process
information will continue to display normally if the Enter key is pressed. It is still possible to view any active
alarm by pressing the UP or DOWN arrow keys.
9.2
Remote Key
Pressing the REM key causes the VersaPro to cycle between Remote, Automatic, or Manual control. This key
has no function in the monitor version. When switching from Automatic to Manual or Manual to Automatic, the
control output remains at the last output value in either mode. This allows for a bumpless control transition
between manual and automatic mode.
When the controller is set to Automatic mode the “Auto” LED lights and the lower display indicates the process
setpoint (default).
When the controller is set to Remote mode the “Rem” LED lights and the VersaPro will accept a remote
setpoint from a master on the host serial interface. The lower display indicates the process setpoint (default).
The Setpt key does not work if the instrument is in remote mode.
When the controller is set to Manual mode both the “Rem” and “Auto” LED’s will flash together and the lower
display indicates the power output of the controller. This value can be manually increased or decreased in 1%
steps by pressing the UP or DOWN arrow keys. Pressing the RIGHT or LEFT arrow keys changes the output
in 10% steps. The output will remain in the last control level if the instrument is switched into manual mode
from remote or automatic or back to either setpoint control mode.
9.3
Setup Key
The instrument can be placed in setup mode by pressing and holding the SETUP key for 5 seconds. The
upper display initially shows the first setup menu while the center and lower displays are blank. At this level
you can select different menus by pressing the RIGHT or LEFT arrow keys. The upper display will change
accordingly.
You can enter a menu by pressing the ENTER key when the desired menu heading is being displayed.
Pressing the arrow keys can change menu parameters. Value changes can be saved or the next parameter
can be selected by pressing the ENTER key. The menu parameters will continue to cycle through the display
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Page 23
as long as the ENTER key is pressed. A new menu can be select only when the menu heading is displayed.
You can exit from the Setup mode by pressing the SETUP key at any time.
The following tables outline the Setup menus available in the VersaPro Controller and Monitor when the
operator presses the SETUP key.
Table 2 Setup Menus
Setup Menu Heading
CtrL
Inpt
CaLc
Aout
ALr
HOST
Info
CaL
Description
Control functions and PID
Thermocouple type and Millivolt setup
Lower Display setting
Analog output selection and parameters
Alarm contact configurations
Host Communication configuration
General information displays
Input / Output calibration
You have to press the SETUP key for five seconds to activate the setup mode. Initially when the setup mode is
activated, the LCD display will show the first menu heading, the upper and lower LED displays are blank.
Page to the next Menu heading by pressing the RIGHT or LEFT arrow keys. The menu headings will continue
to wrap around as the RIGHT or LEFT arrow keys are pressed. Pressing the SETUP key at any point while in
the Setup Menus will return the display to the normal process display. See the following figure.
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The displayed menu is selected by pressing the ENTER key. The first parameter name in the selected menu
list will appear in the center display. The upper LED group continues to display the menu name, the center
display shows the parameter name, and the lower LED group shows the parameter value. A flashing cursor in
the lower LED display indicates which digit can change if the parameter value is numeric. The UP or DOWN
arrows increase or decrease the digit value. The RIGHT or LEFT arrow keys move the cursor to the right or
left digit.
Figure 4 Control Menu Heading
No left to right or right to left wrap-around is provided for the cursor.
If the parameter has a table of choices such as thermocouple types, the various selections can be displayed by
pressing the UP or DOWN arrows. No digit flashes in parameter displays that have a list of choices. In either
case, the selection is set when the ENTER key is pressed and the display advances to the next parameter.
In the example shown above, the selected menu is Control (CtrL), the selected parameter is PROCESS
SOURCE, and the displayed parameter value is temperature (TEnP). This is one of several control types that
are available. Different control selections can be made by pressing the UP or DOWN arrow keys.
Pressing the SETUP key at any time escapes from the menu display and returns to the normal process
display. You can only select another menu heading when the display is at a menu heading.
The following figures and tables outline the menu options and parameters under the Setup key.
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ENTER
(HOLD FOR 5
SECONDS)
SETUP
TC OR MV
BREAK
TIMER
ENABLE
LOW
PERCENT
OUT
HI PERCENT
OUT
CYCLE TIME
RATE
RESET
PROPORTIONAL
BAND
DIGITAL
EVENT
MV FILTER
ALARM 2
TIME OFF
DELAY
ALARM 2
TIME ON
DELAY
ALARM 2
ACTION
FIRMWARE
REVISION
PERCENT
OUTPUT
COLD
JUNCTION
(DEG)
MILLIVOLT
PROB IN
MILLIVOLT
TEMP IN
INFO
PRESSING SETUP KEY ANYTIME
ESCAPES FROM MENU.
ALARM 2
TYPE
ANALOG 2
RANGE
TC FILTER
IN B SLOPE
DELAY
ALARM 1
TIME OFF
DELAY
ANALOG 2
OFFSET
F OR C
ALARM 2
VALUE
PARITY
ALARM 1
TIME ON
DELAY
ANALOG 2
UNIT
IN A SLOPE
IN B OFFSET
BAUD RATE
ADDRESS
ALARM 1
VALUE
ANALOG 1
OFFSET
ALARM 1
ACTION
PROTOCOL
HOST
ALARM 1
TYPE
ALR
ANALOG 1
UNIT
AOUT
ANALOG 1
RANGE
DISPLAY
DECML PT
CALC
IN A OFFSET
COLD JUNC
APPLY
CONTROL
MODE
CONTROL
ACTION
TC TYPE
INPT
PROCESS
SOURCE
CTRL
OUTPUT 2
SPAN
OUTPUT 2
MIN
OUPUT 1
SPAN
OUTPUT 1
MIN
CAL OUTPUT
CJ OFFSET
TC SPAN
TC ZERO
CAL INPUT
CAL
VersaPro Temperature Controller
Page 25
Figure 5 Setup Menu Tree
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Table 3 Control Menu (CtrL)
Parameter Name
PROCESS SOURCE
Units or Options
TEMP,
INPUT A, INPUT B
Range
Display range:
-500 to 9999 for
temp
0 to 100 or EU for
Input A
0 to 2000 or EU for
Input B
CONTROL MODE
TP, TC, TD, PP,
OF, OC, OD or
NON
CONTROL ACTION
PROPORTIONAL BAND
DIR/REV
Process Value
0 – 9999
RESET
Repeats / min
00.00 – 99.99
RATE
Repeats / min
00.00 – 9.99
CYCLE TIME
SECONDS
0 – 255
HI PERCENT OUT
0 – 100
LOW PERCENT OUT
TC OR MV BREAK
MAXIMUM
OUTPUT
MINIMUM OUTPUT
ZERO / HOLD
TIMER ENABLE
YES / NO
-100 to 100
Description
Control type only available on
instrument’s specific configuration.
This selection controls what other
parameters will be available.
See Control Modes if configured as
a controller, shows NON
(MONITOR) only if the instrument is
configured as a monitor.
Direct or Reverse control action
Proportional Band value in
displayed process units for PID
control or Deadband in ON/OFF
control
Integral control value, no effect in
ON/OFF settings
Derivative control value, no effect in
ON/OFF settings
Proportional time period (TP, TC,
TD)
Sets max. forward control. Output
Sets min. reverse control output
Sets output control to zero or holds
current output if a TC or millivolt
input open condition occurs. Input
A only checks TC input, Input B
only checks mV input.
Enables timer function
Table 4 Input Menu (InPt)
Parameter Name
TC TYPE
Units or Options
B, E, J, K, N, R, S, T
COLD JUNC APPLY
YES or NO
IN A OFFSET
Only in Linear mode
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Range
-999 – 9999
Description
See Input calibration for
thermocouple ranges.
Linear mode allows for input
scaling, see IN A OFFSET and IN
A SLOPE.
Applies the cold junction
correction or not when a
thermocouple type is selected. In
LINEAR mode the cold junction is
never applied. Default is NO.
Linear offset to scale Input A to
Engineering Units when INPUT A
is selected as the process
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Parameter Name
Units or Options
Range
IN A SLOPE
Only in Linear mode
-999 – 999
-99.9 – 99.9
-9.99 – 9.99
-.999 - .999
TEMP SCALE
TC FILTER
F OR C
SECONDS
IN B OFFSET
Works only in mV
Mode
-999 – 9999
IN B SLOPE
Works only in mV
Mode
-999 – 999
-99.9 – 99.9
-9.99 – 9.99
-.999 - .999
MV FILTER
SECONDS
0 – 450
Description
source.
Linear slope to scale Input A to
Engineering Units when INPUT A
is selected as the process
source.
This is the slope number in the
linear calculation where: EU =
SLOPE(mV) + OFFSET
See key
Sets temperature scale.
Temperature filter setting in
seconds. Filters the temperature
value with a moving average time
window.
Linear offset to scale Input B to
Engineering Units when INPUT B
is selected at the process source.
This is the offset in used in the
SLOPE(mV) + OFFSET equation.
Linear slope to scale Input B to
Engineering Units when INPUT B
is selected as the process
source.
This is the slope number in the
linear calculation where: EU =
SLOPE(mV) + OFFSET
Millivolt filter setting in seconds.
Filters the millivolt reading with a
moving average time window.
0 – 450
Table 5 Calculation Menu (CALC)
Parameter Name
DISPLAY DECML PT
Units or Options
Decimal point
Range
0-4
Description
Sets decimal pt., available for
Input A and Input B.
Table 6 Analog Output Menu (AOUt)
Parameter Name
ANALOG 1 UNIT
ANALOG 1 OFFSET
Units or Options
LIN A, LINB B,
TENP, POUT, PO1,
PO2 , PROG
Offset for selected
process value or
percent output.
Range
4 to 20mA output.
Description
-30.0 to 300.0 for O2
and LIN
This is the minimum value of the
process associated with the 4mA
output. The magnitude of this
number is based on the display
resolution.
In POUT mode the offset is fixed
to the LOPO value.
When PROG is selected the
offset is fixed at 0
-300 to 3000 for
temperature
LOPO for POUT
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Parameter Name
ANALOG 1 RANGE
Page 28
Units or Options
Span scaling for
selected process
value or percent
output.
Range
Description
0 or DAC_OFFSET
for PROG
0 to 9999 for O2,
LIN, and Temp
HIPO for POUT
4096 or DAC_SPAN
for PROG
ANALOG 2 UNIT
ANALOG 2 OFFSET
ANALOG 2 RANGE
LIN A, LINB B,
TENP, POUT, PO1,
PO2 , PROG
Offset for selected
process value or
percent output.
Span scaling for
selected process
value or percent
output.
This is the maximum value of the
process associated with the
20mA output. The magnitude of
this number is based on the
display resolution.When POUT is
selected this value is fixed to the
HIPO value.
When PROG is selected the
range is fixed at 4096
Same as Analog 1
Same as Analog 1
Same as Analog 1
Table 7 Alarm Menu (ALr)
Parameter Name
ALARM 1 TYPE
Units or Options
OFF
FSHI,
FSLO
dUbd
dbHI
dbLO
HIPO
LOPO
FALt
PROB
tinE
Strt
SOAk
Range
Description
OFF disables alarm contact.
FSHI - Full Scale HI, active when
process is above ALARM 1
VALUE.
FSLO - Full Scale LO, active
when process is below ALARM 1
VALUE.
dUbd – Deviation Band
available for the controller only,
active when process is outside of
symmetrical band around
setpoint.
dbHI – Deviation High, defines a
process band above the process
setpoint. The alarm is active if
the process moves outside this
band.
dbLO – Deviation Low, defines
a process band below the
process setpoint. The alarm is
active if the process moves
outside this band.
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Parameter Name
Page 29
Units or Options
Range
Description
HIPO – Output High, this alarm
sets the threshold for the
maximum control output allowed
which is set by ALARM 1 VALUE.
ALARM 1 VALUE
ALARM 1 ACTION
ALRM 1 TM ON DLY
ALRM 1 TMOFF DLY
ALARM 2 TYPE
ALARM 2 VALUE
ALARM 2 ACTION
ALRM 2 TM ON DLY
ALRM 2 TMOFF DLY
LOPO – Output Low, this alarm
sets the threshold for the
minimum control output allowed
which is set by ALARM 1 VALUE.
FALt – Fault, open inputs for mV,
thermocouple or hardware fault.
Prob – Probe, fault active if
impedance or verification are out
of range.
tinE – Time, establishes alarm
contact as the contact used for
the End alarm.
Strt – Start, same as Time.
SOAk – Soak, same as Time.
Trigger setpoint value
REV = Reverse (N.C.) can be
acknowledged even if the
condition still exists.
LREV = Latched Reverse (N.C.)
can not be acknowledged if the
condition still exists.
DIR = Direct (N.O.) can be
acknowledged even if the
condition still exists.
LDIR = Latched Direct (N.C.) can
not be acknowledged if the
condition still exists.
Delay ON time for ALARM1
Delay OFF time for ALARM1
Same as ALARM 1 TYPE
REV, LREV, DIR, LDIR
0 – 250 SECONDS
0 – 250 SECONDS
Same as ALARM 1
TYPE
Trigger setpoint value
Same as ALARM 1 ACTION
Delay ON time for ALARM2
Delay OFF time for ALARM2
0 – 250 SECONDS
0 – 250 SECONDS
Table 8 Communication Menu (HOST)
Parameter Name
PROTOCOL
Units or Options
PROP OR BUSS
ADDRESS
1 TO 15 (MSI)
1 TO 255 (MOD)
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Range
Description
PROP is Marathon Monitors,
Inc. protocol,
BUSS is Modbus
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Parameter Name
BAUD RATE
PARITY
DELAY
Page 30
Units or Options
Range
1200,2400,4800,9600,19.2K
None/Even/Odd
NONE / 10 / 20 / 30
Description
Default is 19.2K
Modbus is always None
NONE = 0 Delay
10 = 10 ms delay
20 = 20 ms delay
30 = 30 ms delay
Table 9 Info Menu (InFO)
Parameter Name
Units or Options
Range
Description
MILLIVOLT TEMP IN
MILLIVOLTS
-10-100
MILLIVOLT PROB IN
MILLIVOLTS
0-2000
COLD JUNCTION
DEG (F OR C)
0 – 60°C
PERCENT OUTPUT
FIRMWARE REV
% Output
Version number
LOPO to HIPO
Displays direct mV of
Temperature input also called
Input A in linear mode.
Displays direct mV reading of
probe input as called Input B in
linear mode.
Displays actual cold junction
temperature
Displays actual % output
Table 10 Calibration Menu
Parameter Name
CAL INPUT
Units or Options
NO / YES
TC ZERO
(CAL IN)
TC SPAN
(CAL IN)
PROBE mV ZERO
(CAL IN)
PROBE mV SPAN
(CAL IN)
CJ OFFSET
(CAL IN)
CAL OUTPUT
Range
0 – 60° C
0 – 140° F
NO / YES
OUTPUT 1 MIN
(CAL OUTPUT)
OUTPUT 1 SPAN
(CAL OUTPUT)
OUTPUT 2 MIN
(CAL OUTPUT)
OUTPUT 2 SPAN
(CAL OUTPUT
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Description
Default to NO, must be changed
to YES to enter input calibration
routine.
Changes calibration value for
thermocouple zero
Changes calibration value for
thermocouple span
Changes calibration value for
millivolt zero
Changes calibration value for
millivolt span
Sets the cold junction offset
depending on the temperature
range selected
Default to NO, must be changed
to YES to enter output calibration
routine.
Sets signal level for the minimum
mA output.
Sets signal level for the maximum
mA output.
Sets signal level for the minimum
mA output.
Sets signal level for the
maximum mA output.
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Page 31
Pressing the Setup key once at any point in the Setup menu will return the instrument to the normal process
display.
9.4
Dual Key Functions
The VersaPro was four dual key functions as defined below:
RIGHT arrow / Enter
LEFT arrow / Enter
DOWN arrow / Enter
Rem / Enter
Start probe test sequence
Start Timer
Edit Remaining Timer
Monitor Mode
Starting Probe Tests
Pressing the RIGHT arrow / Enter keys simultaneously will start the probe tests if a probe test function has
been selected in the Probe Setup Menu, parameter Probe Test, and the probe temperature is above the
minimum probe temperature parameter in the same menu.
If there is a value other than 0 entered in the Probe Test Interval parameter the probe test will be performed
after the selected interval time has elapsed from the time the test was manually started. If the interval time is
set to 0 then no additional tests will be performed until the next manual start. Starting the test through this dual
key function is the same as if the Start Test parameter in the Probe menu had been changed from NO to YES.
Start Timer
Pressing the LEFT arrow / Enter keys simultaneously will start the timer if the timer has been enabled in the
Control Setup menu, the timer setpoint is greater than zero, and an alarm contact has been assigned a timer
function. Press both keys while the timer is running will stop the timer.
Edit Timer
Pressing the DOWN arrow / Enter keys simultaneously while the timer is running will allow the remaining time
to be changed. The remaining time can be increased or decreased. The change in time takes effect when the
Enter key is pressed and the display returns to the normal remaining time display.
Monitor Mode
Monitor Mode is used by factory personnel only. Return to operate mode by cycling power or sending the
appropriate command word to the instrument.
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10
Page 32
Digital Input Event
The VersaPro has a single digital input. This input is activated by making an isolated contact closure between
terminals TB-B 11 and 12. This input is debounced for a momentary closure of at least 0.6 seconds.
NOTE
Do not connect either terminals TB-B 11 or 12 to any AC or DC potentials.
These terminals are internally connected to an isolated 5VDC source. Use
only an isolated contact closure across these terminals.
The input event can be set to any one of the following functions: OFF, PrOb (start probe test), AUTO (set to
auto), rEn (set to remote), ACK (alarm acknowledge), PrOC (process hold), Strt (timer start), HOLd (timer
hold), End (timer end acknowledge). These settings can be selected in the Input Setup menu at the DIG
EVENT parameter. The selections can be made by pressing the up or down arrow keys and then pressing the
Enter key.
OFF
This selection disables the input event function. This is the default condition of this feature unless another
function is selected.
PROB
This selection will start the impedance (10Kohm) test and/or probe burnoff. The various probe tests will run
only if they are selected in the Probe Menu. The PrOB input event will have no effect if no probe tests are
selected.
If a probe test interval time is set to any value other than zero, activating this function will reset the interval
count down timer. If the probe test interval time is set to zero this function will operate only when the
contact closure is made across the event input terminals. The contact closure must open and close each
time to initiate another probe test.
AUTO (controller only)
This selection will force the instrument from manual mode or remote mode into local automatic mode. No
change will occur if the instrument is already in automatic mode.
rEn (controller only)
This selection will force the instrument from local setpoint mode or manual mode into remote setpoint mode.
No change will occur if the instrument is already in remote setpoint mode.
ACK
This selection will acknowledge any latched active alarm except the timer end alarm. This function will have
no effect if the alarm condition persists when the acknowledge signal is issued. This function resets a
latched alarm similar to pressing the Enter key.
PrOC (controller only)
This selection will place the process calculation in hold. The control output is also held at the
output level when the process hold event was set. This includes all analog output signals as well
as control contacts. This is similar to the state the instrument is set to when the probe tests are
running.
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Strt (controller only)
This selection will start the timer function if the timer is enabled, the setpoint is greater than 0, and one
alarm contact is assigned to a timer function.
HOLd (controller only)
This selection will place the timer in a hold state for as long as the event input is active.
End (controller only)
This selection will acknowledge the end condition of the timer, clear the end state, and reset the
timer for another start.
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11
Page 34
Timer Function
The Versapro timer function is available on all process controller options. The timer can operate independently
or it can be dependent on the process based on how either alarm contact is configured. The instrument has
three possible functions; timer, guaranteed start timer, and guaranteed soak timer. These functions are set
through the mode selection of alarm 1 or alarm 2 in the Setup menu. Only one alarm should be set to a timer
function at any time.
The timer will only work if three conditions are met; the timer function must be enabled in the Setup Control Menu,
an alarm contact must be configured for a timer function, and the timer setpoint must be greater then zero.
The timer setpoint is set in the Setpt Key menu. The remaining time is displayed in the display cycle list and can
be edited when the timer is running. The timer setpoint is entered in whole minutes. The remaining time will show
the tenths of a minute if the timer is less than 1000 and shown as whole minutes. The timer start setting follows the
remaining time display in the Setpt Menu.
11.1 Setting the Timer
The first step for using the timer is to enable the timer function in Setup Control Menu. This allows the timer to
be started in various ways and also allocates a serial port channel for the timer.
The next step is to move to the Alarm menu and select a timer function for one of the alarms. The alarm that is
selected will close its alarm contact with the timer counts to zero. Only one alarm should be selected for a
timer function and any time.
NOTE
Do not set both alarms to timer functions at the same time.
The final step is to press the Setpt key and the Enter key until the TIMER SETPT parameter appears. Enter
the desired value of the timer. This value is the only setpoint for the timer. This value will be used as the timer
setpoint if the instrument is in the local automatic or remote control mode. There is no separate remote timer
setpoint value. The local timer setpoint value will be over written by the value received from a remote device
like a computer or master instrument.
The final step is to start the timer. This can be done in the Setpt menu by pressing the Enter key until the
TIMER START parameter appears and selecting ‘YES’. The timer can also be started by pressing a dual key
sequence LEFT arrow and Enter, through the serial interface, or through the digital event input.
 + Enter
Timer Dual Key Functions
In Auto or Remote mode this two key combination will activate or deactivate the timer
function.
 + Enter
This two key combination allows the timer function remaining time to be edited.
The behavior of the timer is controlled through the selection of the alarm modes. If no timer alarm is selected
for either alarm 1 or alarm 2 then the timer will not start. The Time, Start, or Soak alarm modes must be
selected for one alarm contact before the timer will start.
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The Rem LED on the front panel will flash while the timer is active in the RUN, HOLD, or END modes. The
timer will go inactive when END is acknowledged or if the timer is disabled.
The timer can be stopped by pressing the Enter and Right arrow keys during an active RUN state, sending a
remote timer setpoint of 0 when the instrument is in remote mode, or by changing the remaining time to zero.
The Event Input can be configured to start the timer, hold the timer, or acknowledge the End state.
11.2 Time
The Time alarm mode it will run continuously once it has started and the alarm contract will close when the
remaining time reaches zero. The alarm value has no effect in the simple timer mode and the timer will not
stop or hold if the process value changes. The alarm message is ‘End’ will display on the LCD screen and the
appropriate alarm contact will activate.
11.3 Guaranteed Start Timer
The guaranteed start timer function works in conjunction with the alarm value. The timer will hold until the
process value is greater than the lower band value of the process. The alarm value is the band value. In the
figure below the alarm value is 10, which represents a band around setpoint of 10°. The timer will not HOLD
once it has met the initial starting conditions. The process can fluctuate outside of the alarm band after the
timer has started without placing the timer in a HOLD state. The following figure shows the behavior of the
guaranteed start timer.
Figure 6 Guaranteed Start
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11.4 Guaranteed Soak Timer
The guaranteed soak timer works in conjunction with the alarm process value. The alarm value is the valid
band around the process setpoint. The process must be within the band around the process setpoint to start
the timer once it has been activated. If the process passes above or below the alarm band setting, the timer
will go to a HOLD state. The timer will be allowed to continue only when the process is within the band setting.
In the following figure the alarm value is set to 10 degrees for a temperature process.
Figure 7 Guaranteed Soak
11.5 Timer Alarm Behavior
The alarm contacts do not work like normal process alarms when the timer, soak, or start timer functions are
selected. If the alarm is configured for the timer, the contact will only activate when the remaining time counts
down to zero and the timer reaches the END state. Once this occurs the END Alarm message will appear on
the LCD display. The alarm will stay latched until it is acknowledged by pressing the Enter key or closing a
contact across the Digital Event terminals if the End setting is selected as the Digital Event function. The Rem
light flashes during the END state and stops flashing when the timer is acknowledged and returns to the IDLE
state.
11.6 Timer State Diagram
The following diagram shows the conditions that control the state of the timer function.
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IDLE
Timer Enable = YES
Timer Start = NO
Remaining Time = 0
Timer Enable = NO OR
Timer Start = NO OR
Enter key OR
Remote Time Setpt = -1 OR
Event(END) = ON
END
Time Enable = YES
Timer Start = YES
Display = END Alarm
End Alarm = ON
Alarm contact = ON
Rem Light = Flash
Event(STRT) = ON OR
Remote Timer SP = -2 OR
Enter / Left arrow OR
Timer Start = YES AND
Timer SP > 0
Timer Enable = NO OR
Timer Start = NO OR
Remote Time Setpt = -1 OR
Enter/Left arrow
RUN
Timer Start = YES
Remain Timer = countdown
Time Alarm = OFF
Alarm Contact = OFF
Rem Light = Flash
Remain Time counts to 0
Event(HOLD) = OFF OR
Time Alarm = OFF
Timer Enable = NO OR
Timer Start = NO OR
Remote Time Setpt = -1 OR
Enter / Left arrow
Event(HOLD) = ON OR
Time Alarm = ON
HOLD
Timer Start = YES
Remain Time = hold
Time Alarm = ON
LCD Display = Hi/Lo Alarm
Alarm Contact = OFF
Rem Light = Flash
Figure 8 Versapro Timer State Diagram
The timer has four states. The IDLE state is the inactive condition. The RUN state is the active state when the
timer is counting down. The HOLD state is when counting is paused due to either Digital Event = HOLD or a
configured alarm is active. The END state is when the timer has timed-out but has not been acknowledged.
The configured alarm contact will activate when the END state is entered.
The following is a summary of ways to change the state of the Timer. These assume the standard setups are
in effect. It is assumed that the Timer is enabled for it to start or run.
Timer will start if:
1. Timer Enable = YES and
2. Alarm is set to timer function and
3. Timer Setpoint > 0 and
4. Digital STRT event = ON or
5. Enter/Left keys = CLOSE or
6. Timer Start = YES or
7. Remote Setpoint = -002
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Timer will hold if:
1.
2.
Digital HOLD event = ON or
Alarm Soak or Run deviation is active
Timer will run if:
1. Timer Enable = YES and
2. Timer Start = YES and
3. Timer Setpoint > 0 and
4. Digital HOLD event = OFF and
5. Remaining Time > 0
Timer will reset to IDLE without activating END if:
1. Enable = NO or
2. Timer Start = NO or
3. Remote Timer setpoint = -001 or
4. Enter/Left keys pressed
Timer goes to END state if:
1. Timer count down reaches 0
Timer returns to IDLE state from END when:
1. Enable = NO or
2. Timer Start = NO or
3. Operator presses Enter key or
4. Remote Timer setpoint = -001 or
5. Digital END input = ON
12
Timer SIO Operations
The Versapro allocates a second host address if the timer function is enabled and the host port protocol is set
to PRoP (Marathon) using the Marathon slave protocol. If the host port protocol is set to buss (Modbus) or the
Marathon block protocol is used, then the timer information is accessed directly. For the Marathon slave
protocol, the first address is the primary address set by the Address parameter setting in the Setup HOST
menu. The second address is assigned as Address +1 and will respond to 10Pro type commands. The
setpoint commands affect the timer setpoint. The initial state conditions must be met for the timer to run.
The remaining timer value will be transmitted as the process value when responding in 10Pro slave mode.
The timer values and process values are available at the host address if the instrument is responding to the
Marathon block command or Modbus. The Address + 1 address is always active while the timer is enabled
and the serial port protocol selection is MSI and inactive when Modbus is selected. It is important to consider
this extra address allocation if multiple slaves with timers are going to be connected to a master. Only eight
addresses are possible when the 10Pro command mode is used. See the section on serial communication for
details on these differences. If only the Marathon block command is going to be used then the instrument will
not respond on the second address.
In the MSI 10Pro protocol, the value returned for the percent output command is the timer control byte. The
bits in the control byte are defined in the following table.
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Timer Control Byte
Bit
0
1
2
3
4&6
7
Description
Timer Enabled
Timer Running
End
Hold
N/A
Control
Purpose
Indicates that the timer is enabled in the setup menu.
Indicates that the timer has started.
Indicates that the timer has timed out and not acknowledged.
Indicates that the timer is in hold mode.
Not used.
Set when the timer is started. Reset when timer has stopped. Is toggled by
the Enter + Left Arrow or set by the SIO sending a time setpoint.
12.1 Controlling the Timer Remotely
All timer setpoint values must be written to the host address + 1 and the timer function must be enabled in the
instrument control menu for the instrument to recognize any host address + 1 command.
Control of the timer via the serial port using the 10Pro commands has limited capabilities since the only value
that can be written is the time setpoint. There are special cases if the Versapro is connected to
Dualpro/Multipro as a slave. The master instrument must first send a valid setpoint value from 1 to 9999. The
master can then send a setpoint of –002 to start the timer assuming all other configuration requirements are
met. If the master sends a setpoint of –001 the timer is reset and stopped with no End alarm.
The master can set the timer functions, alarm values, and delay times using the Marathon Block or Modbus
protocols. The sequence of events is similar for either Marathon Block or Modbus protocol.
The timer control word is located at parameter 70, Timer Control and Event (TCE). The timer control byte is
the upper byte of this word. The input event configuration is in the lower byte of this word. Any configuration
of the input event must be added to the timer function values when this word is written to the Versapro. In this
example the event configuration is set to none (0). It is suggested that this word be read by masking the upper
byte of the word to record the input event configuration. This value can then be added to the following timer
control values to retain the input event configuration.
The timer will only work when it is enabled, the timer setpoint is greater then 0, and at least one alarm mode is
set to a timer function. The alarm mode has to be manually configured. Programming the timer involves the
following sequence:
Enable the timer by writing a value 32768 (0x8000) to TCE.
Set the timer setpoint by writing setpoint value to parameter 3 (TSETPT)
Start the timer by writing a value 33024 (0x8100) to TCE.
The timer will indicate that it has timed out when TCE changes to value 34560 (0x8300).
Acknowledge the end alarm by writing a value 0 (0x0000) to TCE.
A description the TCE word and the timer flags in the TCE word can be found in the Versapro Memory Map
table.
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13
Page 40
Tuning
Before attempting to tune the instrument make sure you understand the Operation and Setup part of the
instrument. This section applies to the controller only.
13.1
What is tuning?
Tuning the controller means that the control characteristics of the controller are matched to those of the
process in order to obtain hold the process to setpoint. Good control means:



Stable, ‘straight-line’ control of the process variable at setpoint without fluctuation
No overshoot, or undershoot, of the process variable relative to setpoint
Quick response to deviations from the setpoint caused by external disturbances, thereby rapidly restoring
the process variable to the setpoint value.
Tuning involves calculating and setting the value of the parameters listed the following table. These
parameters appear in the Control Setup menu.
Table 11
Parameter
Proportional band
Integral time
Meaning or Function
The bandwidth, in display units, over which the output power is proportioned
between minimum and maximum.
Determines the time taken by the controller to remove steady-state error signals.
(Reset)
Derivative time
(Rate)
Determines how strongly the controller will react to the rate-of-change of the
measured value.
The Versapro uses the Proportional Band as a representation of the Proportion section of PID, the Reset as a
representation of the Integral section of PID, and the Rate as a representation of the Derivative section of PID.
Thus by following a simple procedure, PID tuning can easily be implemented in any control situation. A
suggested procedure is diagramed in the next figure.
All of the PID parameters may be altered by changing these parameters in the Setup / Ctrl menu. The
following procedure assumes the initial PID values for a typical batch furnace. You may be able to start with a
proportional band setting of 10 or less for a smaller box or temper furnace.
If, after following the procedure, the process continues to oscillate, it may be necessary to change the HIPO or
LOPO parameters. Make sure that the control output is linear through the full range from LOPO to HIPO. In
situations where the system is difficult to tune, it is most likely the output is not linear or there is too much lag
time between the control command and measurable changes in the process. Test the system in manual
mode to verify the output is linear.
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A much higher proportional band may be necessary for extreme lag in the process response. In most cases,
the derivative part of the control equation is not necessary. Generally, furnace control can be maintained using
only the proportional band and the reset parameters.
Make sure you record all operating parameters and keep them in a secure place for later reference.
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START RESET
PROCEDURE HERE.
INCREASE PB BY
30%
OSCILLATING
START PROPORTIONAL
BAND PROCEDURE
HERE. THESE SETTINGS
ASSUME THE SYSTEM IS
STABLE WITH A PB OF
30. KEEP INCREASING
PB BY 50% IF
OSCILLATING.
A
CHANGE SETPOINT
BY 5%
RESET X 2
CHANGE SETPOINT
BY 5%
DECREASE PB BY
10%
STABLE
IS CONTROL
STABLE?
ALLOW PROCESS TO
STABILIZE
SET PB = 30
RESET = .01
RATE = .01
SETPT = TYPICAL
TUNING FINISHED
RECORD PID
VALUES
OSCILLATING
YES
RESET / 2
B
STABLE
B
RATE X 2
OVERSHOOT TOO HIGH
OVERSHOOT
ACCEPTABLE AND
STABLE?
CHANGE SETPOINT
BY 5% AND ALLOW
STABILIZATION
RESET X 2
BELOW SETPOINT
HOW IS SYSTEM
REACTING?
ALLOW SYSTEM TO
STABILIZE
A
OSCILLATING
RATE / 2
START RATE
PROCEDURE HERE.
VersaPro Temperature Controller
Page 42
Figure 9 PID Tuning Procedure
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14
Page 43
Scaling Analog Inputs
If either input is set to Linear mode the displayed value for that input can be scaled any desired engineering
unit. This is helpful if the measured linear value has to be scaled and re-transmitted on one of two analog
output channels.
Using the equation y = mx + b, where
Y is the desired engineering unit to be displayed
X is the linear millivolt value
M is the Slope of the y/x relationship
B is the y intercept
14.1
Linear Example
Let us use Input A as an input for an oxygen transmitter that linearizes the percent oxygen to a 0mV to 53.2mV
signal for a 0% to 100% oxygen range. Since both the signal output and the process minimum are both 0, the
Input A offset will be 0.
The slope can be calculated by dividing the maximum process value (100) by the maximum input level
(53.2mV). This gives a slope value of 1.879. This number can be entered as the Input A slope. The decimal
point can be shifted by placing the flashing cursor on the most significant digit and pressing the Left arrow key
until decimal point shifts to the required position.
These scaling values will produce a process value of 100.0160% oxygen for a maximum sensor input of
53.2mV. The process display can be configured to display either 100 or 100.0. This process value can then
be retransmitted to other control devices are a recorder. The control model of the Versapro will be able to
control to a setpoint for the new process value.
14.2
Keyboard Function during Input Slope
The four digits in the slope display can be change from 0 to 9 or the left digit and change to the negative sign.
This most significant digit position also allows you to shift the decimal point by pressing the LEFT arrow key.
The decimal point will shift from first digit to the third digit as the LEFT arrow key is pressed. Pressing the
RIGHT arrow key when the cursor is on the least significant digit will shift the decimal point to the right.
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Scaling Analog Outputs
The analog outputs are scaled to simple offset and span values. For example if analog output 1 were to be
scaled for a 0 to 2000° value, the offset value would be 0 and the span value would be 2000.
It is possible to narrow the response to the process even if the instrument can measure a larger process range.
If a smaller range of temperature is to be retransmitted it would be necessary to change the offset value to the
lowest value to be retransmitted. The span would be set to the highest value. For example if a temperature
span of 1000° to 1500° was to be recorded then the offset would be 1000, the span would be 1500 and the full
4mA to 20mA range would respond to this range of temperature.
The same rules apply to analog output 2. The range of the offset and span numbers depends on the range of
the process value that has been selected for either analog output.
Additional selections for Power Output and Program mode have fixed offset and span values. The power
output offset and span values are fixed to the LOPO and HIPO values selected for the control outputs under
the Setup Control menu.
The Program mode selection has a fixed offset of 0 and a fixed span of 4096. When this output mode is
selected the analog output can only be changed by writing a value to either the DACV1 or DACV2 registers.
16
Calibration
There are two analog inputs, a cold junction compensation sensor, and two analog outputs on the VersaPro.
The input level is determined by which terminals are used for the input signal. There are two pairs of input
terminals: TB-B 1, 2 for the thermocouple (T/C) input and TB-B 3, 4 for the probe millivolt input.
The 4 – 20mA analog outputs are at TB-B 5, 6 and TB-B 7, 8.
The following is a brief description of input/output and its specifications.
a)
T/C Input
Input range
TC burnout
b)
c)
d)
Probe mV Input
Input range
Input impedance
Open input
-10 to +70 millivolts  2 V
>full scale
-50 to +2000 millivolts  .1 mV, linear
40 megohm
>full scale
Output 1
Output range
Max. Load
0 to 20 milliamps
650 ohms
Output range
Max. Load
0 to 20 milliamps
650 ohms
Output 2
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16.1
Page 45
Calibration Displays and Keyboard Operation
When entering the Calibration Menu, the operator has to answer one of two questions depending on which I/O
functions have to be calibrated. If the CALIBRATION IN prompt is answered with a YES, then the parameters
related to the thermocouple input, millivolt input, and cold junction can be changed. If this prompt is skipped by
pressing the Enter key, then a second prompt, CALIBRATION OUT is displayed. If this prompt is answered
with a YES, then the zero and span values for both analog outputs can be changed.
In the Calibration Menu the displays and front panel keys take on special assignments. The LCD display
shows the input and calibration point being calibrated. The upper LED display indicates that the instrument is
in CAL mode. The lower LED display indicates the actual input level for the input channels or the calibration
factor for the output channels.
It is very important that the display is indicating the proper I/O parameter before making an adjustment or the
wrong value will be changed.
For the CAL INPUT calibration mode, the following keys perform the described functions:
Key
Function
UP ARROW
Increases the displayed value.
DOWN ARROW
Decreases the displayed value.
RIGHT ARROW
Shifts the flashing digit to the right and decreases the amount of adjustment or sensitivity
of the adjustment.
LEFT ARROW
Shifts the flashing digit to the left and increases the amount of adjustment or sensitivity
of the adjustment.
ENTER
Advances to next input value and saves the calibration changes.
SETUP
Exits the calibration mode.
16.2
Preparing for Input Calibration
The following is required to calibrate thermocouple and millivolt inputs:
Calibrated millivolt source, 0 – 2000mV with a 0.1 mV resolution
Calibrated microvolt source, -10mV to 50mV with a 0.1 uV resolution.
Copper wire to connect the millivolt source to the instrument.
Calibrated thermocouple simulator with internal cold junction compensation
Thermocouple extension wire for the type of thermocouple to be used.
In the Input Setup menu, select the thermocouple type to be used in the process. Enable Cold Junction
Compensation.
The first part of the calibration is in linear mode first. The thermocouple setting has no effect on the millivolt
readings in the first part of the input calibration but will effect the reading during the cold junction adjustment.
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Calibration of the Thermocouple Input
Calibration procedure:
1. Connect terminals TB-B 1, 2 to an isolated, stable millivolt source calibrator using standard copper wire, 20
AWG is sufficient.
2. Set the calibrator output to 0.00 mV.
3. Activate the calibration mode by entering the SETUP menus, selecting the Calibration menu and changing
Calibration IN - NO to YES.
4. Use the Enter key to select the TC ZERO mode.
5. Using the arrow keys, adjust the displayed value to equal the calibrator input.
6. Press the Enter key to select the TC SPAN mode.
7. Set the calibrator output to 50.0mV (70mV maximum).
8. Using the arrow keys, adjust the displayed value to equal the calibrator output.
Calibration of the Cold Junction Temperature
Calibration procedure:
1. Change the millivolt source calibrator to thermocouple mode with internal cold junction compensation.
Change the copper wire with the correct thermocouple extension wire
2. Set the calibrator to a typical temperature level.
3. Use the Versapro Enter key to advance to the CJ Adjustment display.
4. Using the arrow keys, adjust the displayed value to equal the calibrator input.
Ref to the following tables for the valid range of thermocouple inputs that can be used to calibrate the cold
junction compensation.
Table 12 Thermocouple Calibration Values
T/C type
B
E
J
K
N
R
S
T
Minimum
Value °F (°C)
800 (426)
-454 (-270)
32 (0)
32 (0)
32 (0)
300 (150)
300 (150)
32 (0)
Maximum Value
°F (°C)
3000 (1800)
1832 (1000)
1300 (900)
2300 (1200)
2300 (1200)
3000 (1800)
3000 (1800)
700 (350)
The usable ranges for the thermocouple types are shown in the following table. If it is desirable to have a
higher accuracy over a specific operating range then the input should be calibrated over that range.
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Table 13 Usable Thermocouple Range (°F)
T/C type
B
E
J
K
N
R
S
T
Minimum
Value (°F)
800
-440
-335
-340
-325
300 *
300 *
-380
Maximum
Value (°F)
3270
1830
1400
2505
2395
3210
3210
755
* Due to the extreme non-linearity of low level signals, using type R and S below 300° F is not recommended.
Calibration of the Analog Output Channels
The same calibration procedure can be used for either output channel.
Calibration procedure:
1. Connect terminals TB-B 5, 6 (or 7, 8) to a multimeter such as a Fluke 77. Select the milliamp
measurement range and verify that the test leads are plugged into the milliamp jack and common on the
multimeter.
2. Activate the calibration mode by entering the SETUP menu, selecting the Calibration menu, press the
ENTER key until CAL OUTPUT - NO is displayed.
3. Change the NO prompt to YES using the UP arrow key.
4. Press the ENTER key to select the OUTPUT 1 MIN mode. If OUTPUT 2 is required, continue pressing the
ENTER key until OUT 2 MIN is displayed.
5. Using the UP or DOWN arrow keys, adjust the displayed number from 0 to 9. Press the RIGHT or LEFT
arrow keys to select the adjustment sensitivity. Adjust the displayed value until the multimeter indicates the
desired minimum output. This is typically set for 4 mA (cal factor ~ 800), but this level can be adjusted to
0mA (cal factor ~ 0).
6. Press the ENTER key to select the OUTPUT 1 SPAN mode. If OUTPUT 2 is required, continue pressing
the ENTER key until OUTPUT 2 SPAN is displayed.
7. Using the arrow keys as explained in step 5, adjust the output to read 20mA on the multimeter. A typical
cal factor for 20mA is 3150. The maximum cal factor is 4095.
8. Press the SETUP key to save the calibration values and exit the calibration routine.
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VersaPro Temperature Controller
17
Communications
17.1
Modbus
Page 48
The MODBUS protocol describes an industrial communications and distributed control system (DCS) that
integrates PLCs computers, terminals, and other monitoring, sensing, and control devices. MODBUS is a
Master/Slave communications protocol, whereby one device, (the Master), controls all serial activity by
selectively polling one or more slave devices. The protocol provides for one master device and up to 247
slave devices on a half duplex twisted pair line. Each device is assigned an address to distinguish it from all
other connected devices.
The VersaPro recognizes three Modbus RTU (Remote Terminal Unit) commands. These are: read single I
registers (command 4), read a single H register (command 3), and preset a single H register (command 6)
In the RTU protocol sends data in 8-bit binary characters. Message characters are transmitted in a continuous
stream. The message stream is setup based on the following structure:
Number of bits per character:
Start bits
1
Data bits (least significant first)
8
Parity
0 (no bits for no parity)
Stop bits
1 or 2
Error Checking
CRC (Cyclical Redundancy Check)
In Modbus mode, the VersaPro can be only be configured for the ‘none’ parity option.
The instrument never initiate communications and is always in the receive mode unless responding to a query.
RTU Framing
Frame synchronization can be maintained in RTU transmission mode only by simulating a synchronous
message. The instrument monitors the elapsed time between receipt of characters. If three and one-half
character times elapse without a new character or completion of the frame, then the instrument flushes the
frame and assumes that the next byte received will be an address. The follow command message structure is
used, where T is the required character delay. Response from the instrument is based on the command.
T1,T2,T3
ADDRESS
8-BITS
FUNCTION
8-BITS
DATA
N X 8-BITS
CHECKSUM
16-BITS
T1,T2,T3
Address Field
The address field immediately follows the beginning of the frame and consists of 8-bits. These bits indicate
the user assigned address of the slave device that is to receive the message sent by the attached master.
Each slave must be assigned a unique address and only the addressed slave will respond to a query that
contains its address. When the slave sends a response, the slave address informs the master which slave is
communicating.
Function Field
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The Function Code field tells the addressed slave what function to perform. MODBUS function codes are
specifically designed for interacting with a PLC on the MODBUS industrial communications system. Command
codes were established to manipulate PLC registers and coils. As far as the VersaPro is concerned, they are
all just memory locations, but the response to each command is consistent with Modbus specifications.
The high order bit in this field is set by the slave device to indicate an exception condition in the response
message. If no exceptions exist, the high-order bit is maintained as zero in the response message.
Data Field
The data field contains information needed by the slave to perform the specific function or it contains data
collected by the slave in response to a query. This information may be values, address references, or limits.
For example, the function code tells the slave to read a holding register, and the data field is needed to
indicate which register to start at and how many to read.
Error Check Field (CRC)
This field allows the master and slave devices to check a message for errors in transmission. Sometimes,
because of electrical noise or other interference, a message may be changed slightly while it is on its way from
one device to another. The error checking assures that the slave or master does not react to messages that
have changed during transmission. This increases the safety and the efficiency of the MODBUS system.
The error check field uses a CRC-16 check in the RTU mode.
The following is an example of a function 03 call for timer setpoint value (TSETPT) at memory location 03. The
value returned by the instrument is the hex value 1E (30 seconds).
Transmit from Host or Master
Address
01
Cmd
03
Reg HI
00
Reg LO
03
Count HI
00
Count LO
01
CRC HI
74
CRC LO
0A
Response from Versapro
Address
01
Cmd
03
Byte
Count HI
00
Byte Count LO
Data HI
02
00
Data LO
1E
CRC
HI
38
CRC Lo
4C
Note that all the values are interpreted as hexadecimal values. The CRC calculation is based on the A001
polynomial for RTU Modbus. The function 04 command structure is similar to the 03 structure.
The following is an example of a function 06 call to change the remote setpoint (RSETPT) to 200 (2.00%). The
response from the instrument confirms the new value as being set.
Transmit from Host or Master
Address
01
Cmd
Address
01
Cmd
06
Reg HI
00
06
Reg HI
00
Reg LO
01
Data HI
00
Data LO
C8
CRC HI
D9
CRC LO
9C
Data LO
C8
CRC HI
D9
CRC LO
9C
Response from Versapro
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Reg LO
01
Data HI
00
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The Versapro will respond to several error conditions. The three exception codes that will generate a
response from the instrument are:
01 – Illegal Function
02 - Illegal Data Address
03 – Illegal Data Value
04 – Slave Device Failure
The response from the Versapro with an exception code will have the most significant bit of the requested
function set followed by the exception code and the high and low CRC bytes.
17.2
MSI Message Protocol
The basic Marathon Monitors message protocol format is shown below.
As indicated, the MSI or proprietary mode allows communication using the 10PRO ‘A’ command protocol or
the ‘U’ block protocol.
The following command set applies to the ‘A’ command and is used for the Versapro and other 10PRO type
instruments such as temperature controller slaves. The command set is sent by a master to a 10PRO slave
instrument. These commands can also be used by any device such as a computer communicating with
instruments via an instrument network. The commands that are supported are shown in the following table.
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Table 14 10Pro / 10Pro-T Command Set
COMMAND LETTER
p (low case)
o (low case)
i (low case)
h (low case)
I (upper case as in
Instrument)
J (upper case)
l (lower case as in
limits)
m (low case)
P (upper case)
Process ( temperature)
Read Auto / Manual mode
Read Remote / Local
Read Remote Process Setpoint
Read Auto Process Setpoint
Update Process Setpoint
Temporarily
Update Process Setpoint
Permanently
Read Actual Process
Timer
Same
Same
Read Remote Time Setpoint
Read Auto Time Setpoint
Update Time Setpoint
Temporarily
Update Time setpoint
Permanently
Read Remaining Time
Returned Value
A = auto, B = manual
A = local, B = remote
integer decimal number
integer decimal number
integer decimal number
Read % Output
Update Auto/Manual mode
Read Time control byte
Same
integer decimal number
A = auto, B = manual
integer decimal number
integer decimal number
The following are examples of commands and responses using the 10Pro type command set. The first row in
each table shows the ASCII characters of the command as they would appear if monitored on the serial port.
The second row in each table is the hexadecimal translation of the characters transmitted on the serial port.
These values must be known to calculate the checksum.
This is the command and response for reading the actual process value of a 10Pro type slave instrument. In
this example the 10Pro instrument address is 2 and the return value is 0071. This could be 71 degrees. 0.71%
carbon, 7.1 degrees dewpoint, or 0.71% oxygen depending on the process and the instrument settings. Other
parameters and scaling are available if the linear inputs are selected. In general the number that is returned is
the number displayed on the instrument. Decimal point information is assumed.
Transmit from Host or Master
Add
2
0x32
Prefix
A
0x41
Cmd
l
0x6C
Delim
<NULL>
0x00
LRC
<HEX 1F >
0x1F
<EOT>
0x04
Response from 10Pro
<ACK>
0x06
Add
2
0x32
Prefix
A
0x41
Cmd
l
0x6C
D1
0
0x30
D2
0
0x30
D3
7
0x37
D4
1
0x31
Delim
<NULL>
0x00
LRC
<HEX 1F >
0x1F
<EOT>
0x04
Here is an example of a request and response for the local setpoint of the instrument in Automatic mode. The
response indicates that the instrument’s address is 2 and the local setpoint is 1500.
Transmit from Host or Master
Add
2
0x32
Prefix
A
0x41
Cmd
h
0x68
Delim
<NULL>
0x00
LRC
<HEX 1B >
0x1B
<EOT>
0x04
Response from 10Pro
<ACK>
0x06
Add
2
0x32
Prefix
A
0x41
Cmd
h
0x68
D1
1
0x31
D2
5
0x35
D3
0
0x30
D4
0
0x30
Delim
<NULL>
0x00
LRC
<HEX 19 >
0x19
<EOT>
0x04
Here is an example that shows how the HOST changes the instrument’s remote setpoint. The instrument’s
address is 15. The HOST has sent a command to update the remote setpoint with 1450. The instrument
responds by echoing the command.
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Transmit from Host or Master
Add
F
0x46
Prefix
A
0x41
Cmd
I
0x49
D1
1
0x31
D2
4
0x34
D3
5
0x35
D4
0
0x30
Delim
<NULL>
0x00
LRC
N
0x4E
<EOT>
0x04
Response from 10Pro
<ACK>
0x06
17.3
Add
F
0x46
Prefix
A
0x41
Cmd
I
0x49
D1
1
0x31
D2
4
0x34
D3
5
0x35
D4
0
0x30
Delim
<NULL>
0x00
LRC
H
0x48
<EOT>
0x04
Instrument Type ‘U’ Command Set
The MSI (Marathon Monitors Inc.) command set supports the extensive capabilities of the Dualpro the 10Pro-E and the
Versapro. The command set consists of the characters shown in the following table.
Table 15 MSI Command Set
Update
Read
Description
X
x
Read / Writer Table Parameters
Not Allowed
*
Read Block Transfer
‘X’ Command
The ‘X’ command allows almost unlimited access to all the instrument parameters. The ‘X” command accesses the
various parameter tables in the instrument. A typical parameter table for most Marathon instruments has 240 parameters
numbered consecutively from 0 to 239 (0 – 0xEF). Instruments such as the Dualpro have many tables (0 – 31), where
each table has 11 blocks or more.
The Versapro, 10Pro-E, and Version 3.5 Carbpro have only table 0. The table value is assumed to be 0 and the
parameter is addressed directly with the possible range of 0 to 71. These number correspond with the decimal numbers
in the Versapro Memory Map table.
To READ a data value from a table / parameter number in the instrument, use the following format:
AUx (Table # Parameter #) <delimiter> <checksum> <EOT>
Here is an example of a request and response for the instrument’s proportional band setting in table 0, parameter 10
(0x0A). The instrument address is 1. The data value that is returned by the instrument is hexadecimal 0014 or 20.
Transmit from Host or Master
Add
1
0x31
Prefix
U
0x55
Cmd
x
0x78
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Table #
00
0x30 0x30
Par #
0A
0x30 0x41
Delim
NULL
0x00
LRC
<HEX 6D >
0x6D
EOT
0x04
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Instrument Response
<ACK>
0x06
Add
Prefix
Cmd
2
0x32
U
0x55
x
0x78
Table
#
00
0x30
0x30
Par
#
0A
0x30
0x41
Data
Delim
$
0x24
D1
D2
D3
D4
Delim
LRC
0
0x30
0
0x30
1
0x31
4
0x34
<NULL>
0x00
J
0x4A
<EOT>
0x04
The response from the instrument includes the ‘$’ character. This characters acts as the data delimiter, which separates
the parameter data from the parameter address.
Here is an example of a request and response for the instrument’s Alarm 1 value in table 00 (0x00) parameter 06 (0x06).
The instrument address is 1. The data value that is returned by the instrument is 50 (0x32). The actual value is 0.50
where the decimal point is implied by the process.
Transmit from Host or Master
Add
1
0x31
Prefix
U
0x55
Cmd
Table #
00
0x31 0x30
x
0x78
Par #
06
0x31 0x33
Delim
NULL
0x00
LRC
1A
0x1A
EOT
0x04
Response from Instrument
<ACK>
0x06
Add
Prefix
Cmd
1
0x31
U
0x55
x
0x78
Table
#
00
0x30
0x30
Par
#
06
0x30
0x36
Data
Delim
$
0x24
D1
D2
D3
D4
Delim
LRC
0
0x30
0
0x30
3
0x33
2
0x32
<NULL>
0x00
9
0x39
<EOT>
0x04
The parameter write command uses the following format:
AUX (Table # Parameter #) $ data <delimiter> <LRC> <EOT>
To write a value to the instrument for a specific parameter use the uppercase X. To read a specific parameter from the
instrument, use the lowercase x.
Here is an example of a parameter write command and response for data in table 00 (0x00) parameter 06 (0x06). The
instrument address is 1. The data value that is written to the instrument is 0000 (0x0000).
Transmit from Host or Master
Add
Prefix
Cmd
1
0x31
U
0x55
X
0x58
Table
#
00
0x30
0x30
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Par
#
06
0x30
0x36
Data
Delim
$
0x24
D1
D2
D3
D4
Delim
LRC
0
0x30
0
0x30
0
0x30
0
0x30
NULL
0x00
1E
0x1E
EOT
0x04
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Response from Instrument
ACK
0x06
Add
Prefix
Cmd
1
0x31
U
0x55
X
0x58
Table
#
00
0x30
0x30
Par
#
06
0x30
0x36
Data
Delim
$
0x24
D1
D2
D3
D4
Delim
LRC
0
0x30
0
0x30
0
0x30
0
0x30
NULL
0x00
18
0x18
EOT
0x04
The parameters for the Versapro are listed in the manual appendix. This listing includes the parameter name, number,
and a short description that includes bit and byte mapping information.
Block Commands
Block transfer commands are used to read and write data in a group of 24 words. The Versapro has only three blocks in
table zero. The block transfer command has to identify the table as well as the block.
A block read command format is shown below.
A U * tt bb D L E
(E)End of Transmission (EOT) HEX(04)
(L) LRC is the result of an XOR function performed
on all previous character in the messeage.
(D) Delimter marks the end of DATA and signals the
up coming EOT character.
NUL HEX(00) or Backspace HEX(08)*
*If LRC was going to be an EOT HEX(04) then D =
HEX(08).
(bb) Block number 0 - 2
(tt) Table number (HEX)
(*) Block Read command character
(I) Instruement Prefix: U = Dualpro/10Pro-E/V3.5/
Versapro.
(A) Address of instrument.
Figure 10 Block Read Command Format
The reply to a Block read request follows.
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A U * tt bb $ ddd-------ddd CC D L E
(E)End of Transmission (EOT) HEX(04)
(L) LRC is the result of an XOR function performed
on all previous character in the messeage.
(D) Delimter marks the end of DATA and signals the
up coming EOT character.
NUL HEX(00) or Backspace HEX(08)*
*If LRC was going to be an EOT HEX(04) then D =
HEX(08).
(CC) MOD 256 checksum of data characters ASCII
values in two (2) HEX digits.
Ninety-six (96) HEX digits of data, four (4) digits, (2)
bytes, (24) parameters
($) Data separator
(bb) Block number (HEX)
(tt) Table number (HEX)
(*) Block Read command character
(I) Instruement Prefix: U = Versapro instrument prefix.
(A) Address of instrument.
Figure 11 Block Read Response Format
The following is an example is for a block request from the Host and a reply from the instrument. The Host
sends the command:
1U*0000<00>N<04><06>
Where the instrument address is ‘1’, the instrument type is ‘U’, the table and block are both zero (TTBB), and
the delimiter, LRC and EOT follow.
The instrument responds with the string shown in the following table.
Table 16 Sample Block Response
Address
Type
Command
Register
Delimiter
Parameter 1
Parameter 2
Parameter 3
Parameter 4
Parameter 5
Parameter 6
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Hex
1
U
*
0000
$
C11C
00E5
8112
0096
0096
00C8
ASCII
31
55
2A
30 30 30 30
24
43 31 31 43
30 30 45 35
38 31 31 32
30 30 39 36
30 30 39 36
30 30 43 38
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Parameter 7
Parameter 8
Parameter 9
Parameter 10
Parameter 11
Parameter 12
Parameter 13
Parameter 14
Parameter 15
Parameter 16
Parameter 17
Parameter 18
Parameter 19
Parameter 20
Parameter 21
Parameter 22
Parameter 23
Parameter 24
MOD 256
Delimiter
LRC
EOT
03B6
07D0
0000
0C00
03E8
03E8
0000
0000
0000
0000
0060
1C25
00F3
3C69
0001
03E8
0000
3D62
BF
00
1B
04
30 33 42 36
30 37 44 30
30 30 30 30
30 43 30 30
30 33 45 38
30 33 45 38
30 30 30 30
30 30 30 30
30 30 30 30
30 30 30 30
30 30 36 30
31 43 32 35
30 30 46 33
33 43 46 39
30 30 30 31
30 33 45 38
30 30 30 30
33 44 36 32
42 46
00
1B
04
Note that the MOD 256 is the 256 modulus of the sum of the ASCII values of the parameters. The delimeter
and LRC are calculated as described in a previous section.
MSI Error Codes
The Marathon protocol for the Versapro has three error codes that can be generated by the instrument: E1 = Incorrect
LRC detected on received message, E2 = Invalid command detected, and E3 = Invalid table or parameter address.
The format for the error message is
<NAK> Error Code DEL LRC <EOT>
Where <NAK> is the hexadecimal value 15 followed by the ASCII characters for the appropriate error code.
The delimiter and LRC are calculated the same as for a normal message. The EOT (hexadecimal 04) end
every message in the MSI protocol.
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Page 57
Troubleshooting Questions
This section is organized alphabetically by the functional name of various instrument operations and features.
Some explanations may be listed in more than one category since the problem can be approached from
several different points of view. Each problem is presented as a question for typical problems that may be
encountered. In most cases the problem can be resolved by changing a setup parameter in the instrument.
18.1
Analog Inputs
How come the display flashes HHHH or LLLL when I try to read a signal at input A or input B in linear
mode?
There are possibly two reasons; the decimal point setting in the Calc menu has to be adjusted for the
maximum signal level to be read or the signal level has exceeded the range of the input channel. Channel A is
set up primarily for thermocouple levels from –10mV to 70mV. Channel B is set up for oxygen sensor millivolt
ranges of 0 to 2000 mV. The display decimal point setting will not truncate the input value, it just increases the
resolution of the input signal. If the value is within the input range of the channel but greater than or less than
the possible display setting then the limit warnings will flash on the display.
How come I can’t see the linear reading on my controller / monitor?
It is necessary to change the decimal point in the Calc setup menu.
I am trying to offset the temperature using the offset and scaling number in the Input menu but the
temperature does not change.
The input offset and scaling numbers for inputs A and B only work if either Linear A or Linear B are selected as
the process source in the Control Menu. If it is necessary to offset the temperature slightly it is possible to do
this by changing the cold junction trim adjustment in the Input Calibration menu. It is not recommended that
the actual linear calibration values for input A are changed.
18.2
Control Outputs
I have a dual contact control mode selected but my second contact does not work.
When a dual control mode is selected it is necessary to also set the high percent output (HIPO) and low
percent output (LOPO). In single time proportioning, the default mode, the HIPO is 100 and the LOPO is 0.
When a dual mode is selected it is necessary to change the LOPO to –100. In the case of carbon control it is
typically required to control gas and air. The first control contact would be connected to the gas solenoid and
the second control contact would be connected to the air solenoid. The gas solenoid would be turn on all the
time when the control output goes to 100%. Likewise the air solenoid would be on all the time if the control
output was –100%.
When would I change my HIPO or LOPO settings to something other then the 100% or –100%?
These values rarely have to be changed but one case that requires it is when the control actuator is not acting
an expected linear fashion. An example would be an SCR driving a heater. If the SCR is not actually turning
on until the control signal is at 20% and stops increasing at 80% then the linear response of the actuator is
only between 20% and 80%. If the controller assumes the full output range of 0 to 100% then a large delay in
process reaction will drive the reset function in the PID control calculation into oscillation. It would be
necessary to set the LOPO to 20% and the HIPO to 100% to achieve stable control.
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18.3
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Digital Communications
How come I have communications problems with an instrument address following a Versapro address
setting.
If the timer function has been enabled and the Versapro host protocol is set to ‘Prop’ for the Marathon protocol,
the instrument will take the next host address setting to respond with the timer parameters. The problem can
be corrected by turning of the timer function in the Control menu or setting to next instrument address to
Versapro host address + 2.
18.4
Display Functions
How come the display flashes HHHH or LLLL when I try to read a signal at input A or input B in linear
mode?
There are possibly two reasons; the decimal point setting in the Calc menu has to be adjusted for the
maximum signal level to be read or the signal level has exceeded the range of the input channel. Channel A is
set up primarily for thermocouple levels from –10mV to 70mV. Channel B is set up for oxygen sensor millivolt
ranges of 0 to 2000 mV. The display decimal point setting will not truncate the input value. If the value is
within the input range of the channel but greater than or less than the possible display setting then the limit
warnings will flash on the display.
How come I can’t see the linear reading on my controller / monitor?
It is necessary to change the decimal point in the Calc setup menu.
How come the process values will not cycle on the display when I press the Enter key?
The display will not cycle through the process values if there is an active alarm. Press the Enter key to see
any active alarms. If multiple alarms are active it will be necessary to press the UP or DOWN keys until all of
the alarms have been displayed. It is necessary to clear these alarms before the display will cycle by pressing
the Enter key.
18.5
Timer Function
How come I cannot enter a timer setpoint.
Two things have to be set for the timer to work; the timer has to be enabled in the Control Menu, and a timer
alarm function has to be selected for alarm 1 or alarm 2 but not both alarms at the same time. Only when
these conditions have been met will the instrument accept a timer setpoint.
How come I cannot start a timer function when the Input Event is set to Start and activated?
Make sure all of the conditions explained in the first question of this time section have been met.
Why is there a delay between the Timer display changing to zero and the End alarm coming on?
The timer is counting in milliseconds but only displays whole seconds. When the display first changes from 1
to 0 it actually changes to 0.99. It continues to count down for the remaining milliseconds until the timer
reaches zero at which point it turns on the End alarm.
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Versapro Monitor Mode
The Versapro’s internal EEPROM can be reprogrammed when placed in Monitor Mode. This mode allows the
user to perform checks and set default conditions in the instrument by using a RS232 to RS485 converter and
the popular Windows program HyperTerminal. It is necessary to enter this mode when a CPU has been reprogrammed or if a checksum fault has occurred in EEPROM.
The user can also use advanced features of Monitor Mode such as status check, read RAM and FLASH
memory, write to RAM memory, load FLASH defaults to RAM, load EEPROM defaults from RAM to EEPROM,
or write from EEPROM into RAM.
19.1
Prepare for Connection
Make sure you have recorded all the operational parameters of the instrument before you change the
EEPROM values. These parameters will include the thermocouple type, alarm functions, and probe care
settings. For the controller version of the Versapro this will also include control and PID settings as well. Note
the instrument calibration settings for the two analog output channels by going into the SETUP mode, selecting
CAL OUT – Yes and recording the offset and span values shown for each channel. Advance to the each
parameter by pressing the <Enter> key. Press <Setup> to return to the process mode.
19.2
How to Connect
The Versapro has a RS485 half-duplex port located on terminals TB-B 13 and 14, where 13 is the +RS485
connection and 14 is the –RS485 connection.
Insure your converter is plugged into the serial port of your computer. Insure that your converter is configured
as a half-duplex (two wire) output and not as a full-duplex (four wire) output.
Apply power to the instrument and observe that it is operating in normal process mode where the process
name is displayed in the center LCD display.
NOTE
Your version of HyperTerminal may be different then the steps outlined in this procedure. The basic
information provide here will apply to any configuration. Accept the setup defaults if you are not sure about a
specific feature that is not addressed here.
When HyperTerminal starts up it asks for a name of a new connection. Enter a name that you can associate
with the Versapro setup.
The ‘Connect To’ window will then appear.
Make the following selections in the Connect To window;
Connect using: (select the comm port the RS485 is connected to)
Press the ‘OK’ button.
In the ‘Port Settings’ window that appears next, make the following selections;
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Page 60
Bits per second: 19200
Data bits: 7
Parity: EVEN
Stop bits: 1
Flow control: None
Select the File \ Properties \ Settings tabs and make the following selections;
Select the ‘Terminal Keys’ button
Select the ‘Ctrl+H’ button
Set ‘Emulation’ to ANSI
Set ‘Telnet terminal ID’ to ANSI
Set ‘Backscroll buffer lines’ to 500
Click on the ASCII Setup… button;
Set ‘Line delay’ to 25 msec
Set ‘Character delay’ to 0 msec
Click on the ‘OK’ button to escape the Connections window.
HyperTerminal will now be connected to the comms port waiting for serial data from the Versapro.
19.3
Start Monitor Mode
At the Versapro press and hold the <REM> and <Enter> keys. Hold these keys until the center display
changes to "MONITOR MODE”, (about 5 seconds). The instrument will send a prompt to the HyperTerminal
screen that should look like figure 1. If the Versapro is already in Monitor Mode it may only have the Power
light on with no other display. Cycle power on the instrument while connected to see the “Marathon Monitors,
Inc.” prompt.
Figure 12 Initial Prompt Screen
The following table lists the commands that are available in Monitor mode.
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VersaPro Temperature Controller
Command
D
J
K
L
S
W
X
Z
Page 61
Command Description
Displays 16 rows by 16 bytes of memory
Displays all values in EEPROM
Programs EEPROM for RAM values
Loads RAM EEPROM area with FLASH defaults
Displays status of processor
Writes a byte from EEPROM to RAM EEPROM mirror or writes data to RAM.
Exits Monitor mode
Resets processor idle counter
The Versapro is placed into Monitor mode when the <Enter> and <Rem> keys on the instrument are pressed
simultaneously and held for about 5 seconds. The LCD display will display the prompt ‘MONITOR MODE’ and
the LED display will be blank. The instrument also sends banner and prompt character to the HyperTerminal
screen. The following figure shows this display.
At the ‘>’ prompt type any of the above commands.
At this point the instrument is not performing any process or control functions but is only waiting for Monitor
mode commands.
19.4
‘D’ Display Command
The ‘D’ command is a multiple character command that displays a block of memory. The command format is
D xxxx <Enter>. The xxxx is any memory location in four character hexadecimal format. The <Enter> is
pressing the computer keyboard <Enter> key.
If no memory starting address is entered the Monitor assumes a starting location of 0000. Each line of the
display starts with the first memory address followed by 16 bytes of data stored in the following 16 memory
locations. 16 lines are displays, showing 255 bytes of data.
The range of memory must be between 0000 and FFFF. The display will wrap to the beginning of the memory
if it exceeds the limit of the FFFF location. Some of the zero page memory values will change when the
Monitor mode is started. This command is useful for looking at data in upper memory that stays relatively
static.
19.5
‘L’ Write FLASH to RAM Defaults
The ‘L’ command is the first command used to program the EEPROM with default values in FLASH. The
EEPROM is written for a RAM area that mirrors the structure of the EEPROM. To initialize the EEPROM it is
first necessary to write the default values from FLASH into the RAM mirror.
This is a single character command that is sent to the instrument when the character is typed at the
HyperTerminal display and the keyboard <Enter> key is pressed. The computer will display all the values that
have been written into the RAM area. See the ‘K’ command for the next step in programming the EEPROM.
19.6
‘K’ Write RAM to EEPROM
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VersaPro Temperature Controller
Page 62
The ‘K’ command is a single character command that copies the values in the RAM mirror into the EEPROM.
The EEPROM is completely erased before any values are written. There is no display that is generated while
this function is executed. It is necessary to wait about 5 seconds for the display prompt (>) to return before
another command is issued.
19.7
‘J’ Display EEPROM Values
This is a single character command that displays all of the EEPROM values in the same format as the ‘D’
command.
19.8
‘S’ Status Display
This is a single character command that displays the status of the processor. This command is helpful when
trying to determine what fault may have caused a reset. The display will show any fault codes and a thumb
twiddler value. This value is an idle counter for the processor and should be greater than zero for normal
operation.
19.9
‘W’ Write RAM with EEPROM or Data Values
The ‘W’ command is a multiple character command that writes a byte from EEPROM to RAM memory if the
RAM address is within the range of the EEPROM - RAM image. Otherwise if the RAM address is an address
is outside the EEPROM image address it will write input data to a RAM address. The formate is W <addr> for
the first condition and W <addr> <data> for the second condition where both the address and data are four
character hexadecimal values.
19.10 ‘X’ Exit Command
This is a single character command the turns off the Monitor mode, resets the processor, and returns the
processor to normal process mode. If the processor does not return to normal mode following this command,
check the status for any fault conditions.
19.11 Viewing Status and Memory
The next figure shows the displays for the status command and the memory display command. The status
command will show any faults or resets that have occurred in the instrument. The Thumb Twiddler number is
a count of idle time for the processor. The reset number for this is 3000 (‘Z’ command). This number should
never reach zero.
The ‘D’ command is followed by the start of the memory locations to be displayed. In this case the EEPROM
memory block is being displayed starting at hexadecimal address 0800.
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VersaPro Temperature Controller
Page 63
Figure 13 ‘S’ and ‘D’ Commands
19.12 Loading Default Values
The most common use of the Monitor Mode is to re-set or load the processor’s internal EEPROM with default
values and re-calculate the EEPROM checksum. This is done with a series of commands starting with the ‘L’
command.
The instrument holds default operational parameters in FLASH. This area of memory is mapped the same way
the EEPROM memory is. The instrument also uses a pre-defined area in RAM to change and then copy data
into EEPROM. This RAM area is also mapped the same as the EEPROM. It is necessary to copy the FLASH
values to the RAM area first using the ‘L’ command.
At the > prompt, type in the character ‘L’ and press the Enter key. This command will tell the instrument to
load the RAM area with default values from the FLASH memory.
A series of character lines will print down the screen followed by another prompt. At the prompt, type in the
character ‘K’ and press Enter. This command will tell the instrument to load the EEPROM from the RAM
image that has just been programmed.
The screen will advance one line and display the prompt. At the prompt, type in the character ‘X’ and press
Enter. The ‘X’ command causes the instrument to exit monitor mode, resets the processor, and returns to
operation mode. This sequence is shown in the following figure.
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VersaPro Temperature Controller
Page 64
Figure 14 ‘L’ and ‘K’ Commands
At the prompt, type in the character ‘X’ and press Enter. The ‘X’ command causes the instrument to exit the
Monitor Mode, reset, and return to operation mode. Check the instrument parameter settings and verify the
input and output calibration settings.
19.13 What if an error occurs
If you receive check sum errors following the ‘L’ or ‘K’ commands, retry these commands. If this does not
resolve errors during the RAM or EPROM procedures then the instrument memory maybe damaged. The
instrument should be returned to Marathon Monitors, Inc. for testing and possible repair.
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VersaPro Temperature Controller
20
Page 65
Technical Specification
20.1 Environmental ratings
Panel sealing:
Instruments are intended to be panel mounted. The rating of panel sealing is
IP64.
Operating temperature:
0 to 55oC. Ensure the enclosure provides adequate ventilation.
Relative humidity:
5 to 95%, non-condensing.
Atmosphere:
The instrument is not suitable for use above 2000m or in explosive or corrosive
atmospheres.
20.2 Equipment ratings
Supply voltage:
Supply frequency:
Power consumption:
Relay 2-pin (isolated):
Relay changeover (isolated):
Over current protection:
Relay outputs:
Low level I/O:
DC output (Isolated):
Fixed digital inputs:
DC or PV input:
Transmitter supply:
Digital Comms:
20.3 General
Thermocouple input:
Millivolt input :
Cold junction compensation:
Calibration accuracy:
Isolation:
100 to 240Vac -15%, +10%, or optionally:
48 to 62Hz.
15 Watts maximum.
Maximum: 264Vac, 2A resistive. Minimum: 12Vdc, 100mA.
Maximum: 264Vac, 2A resistive. Minimum: 6Vdc, 1mA.
External over current protection devices are required that match the wiring of the
installation. A minimum of 0.5mm2 or 16awg wire is recommended. Use
independent fuses for the instrument supply and each relay output. Instrument
supply: 85 to 264Vac, 2A.
Triac outputs: 1A.
All analog input and output connections are intended for low level signals less
than 24VDC.
0 to 20mA (650 max), 0 to 10V (using a 500 dropping resistor).
Contact closure. (common to internal 5VDC source.)
As main input plus 0-1.6Vdc, Impedance, >100M. (isolated.)
30Vdc at 20mA. (isolated.)
EIA-485 half duplex. (isolated).
Type B, K, R, and S accuracy after linearization +/- 1 deg F
0 to 2000 millivolts +/- 0.1 millivolt
0 to 60°C +/- 1 deg F
The greater of +0.2% of reading, +1 LSD or +1oC.
1000V DC/AC
Power input to signal inputs
Power input to communications
Calculations:
Percent carbon 0 – 2.55% (no CO compensation)
Dewpoint -99 – 212 °F (no hydrogen compensation)
Percent oxygen. 0 – 20.9%
(Small oxygen concentrations can be measured by changing the exponent
setting.)
Accuracy:
Probe Care:
+/- 1 of LSD of process value.
Probe verification and impedance for oxygen probes.
Communications port:
Protocol:
Baud rates:
RS-485 Half Duplex Only
10Pro, MMI block transfer, or Modbus RTU
1200, 2400, 4800, 9600, 19.2K
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VersaPro Temperature Controller
Parity:
Page 66
Even, odd, or None
Control Mode
Time Proportioning Single Contact Direct
Time Proportioning Single Contact Reverse
Time Proportioning Dual Contact Direct
Time Proportioning Dual Contact Reverse
Time Proportioning Complement Contact Direct
Time Proportioning Complement Contact Reverse
Position Proportioning Direct
Position Proportioning Reverse
On / Off Direct
On / Off Reverse
On / Off Dual Direct
On / Off Dual Reverse
On / Off Complement Direct
On / Off Complement Reverse
Alarm Type (both Alarm 1 and 2)
High Limit Temp
Low Limit Temp
Process Deviation Band
Process Deviation High
Process Deviation Low
Control Percent Out
Input Fault (mV or Thermocouple)
Time (start timer no conditions)
Start (guaranteed timer at setpoint)
Soak (guaranteed timer run in band)
Digital Event Input (isolated contact closure)
Probe Burnoff
Manual/Auto
Local/Remote
Alarm Acknowledgement
Freeze Process
Start Timer
Hold Timer
Acknowledged Timer End
20.4
Electrical safety (pending approval)
Standards:
Installation category II:
Pollution degree 2:
EN 61010, Installation category II, pollution degree 2.
Voltage transients on any mains power connected to the instrument must not
exceed 2.0 kV.
Conductive pollution must be excluded from the cabinet in which the instrument
is mounted.
Environmental Conditions
Operating Temperature
Copyright © 2013, United Process Controls Inc.
-20 °C to 65 °C (-4 to 176 F)
All rights to copy, reproduce and transmit are reserved
VersaPro Temperature Controller
Storage Temperature
Operating and Storage Humidity
Page 67
-40 °C to 85 °C (-40 to 185 F)
85% max relative humidity, noncondensing, from –20 to 65°C
Note: Specifications may change without notification.
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VersaPro Temperature Controller
21
Page 68
Versapro Memory Map
NOTE: Modbus refers to the hexadecimal address location. These parameters are formatted as unsigned 16
bit integers. Any real number such as temperature can be evaluated as a signed number, other parameters
are bit mapped words that must be evaluated as single bits are bit groups.
HEX
00
DEC
0
PARAMETER
IDLE
01
1
RSETPT
02
2
LSETPT
03
3
TSETPT
04
4
PROC
05
5
TIME
06
6
ALARM1
07
7
ALARM2
Copyright © 2013, United Process Controls Inc.
BLOCK 0
DESCRIPTION
READ/WRITE
Idle processor count. This number should never READ ONLY
be 0.
READ/WRITE
Remote setpoint sent to the instrument from the
Host port. This number has to be scaled to the
range of the displayed process value based on the
decimal point and exponent settings of the
instrument.
Range = -999 to 9999
Default = 0.000
For example: If the process = oxygen, display
decimal point = 2, and exponent = 6, as remote
setpoint of 1234 would be interpreted and
displayed as 12.34 ppm.
READ ONLY
Process setpoint set by the operator through the
Setpoint menu. This number is scaled to the range
of the displayed process value based on the
decimal point and exponent settings of the
instrument.
Range = -999 to 9999
Default = 0.000
READ/WRITE
Timer setpoint set via the Host port or locally.
Range = 0 to 999 minutes
Default = 0
This value is the calculated process value shown READ ONLY
as an integer. The decimal point and exponent
values are required to determine the actual scaled
value.
Range = -999 to 9999.
For example: If the process = oxygen, display
decimal point = 2, and exponent = 6, and PROC =
1234, then the actual value and displayed as 12.34
ppm.
This is the remaining time on the timer as it counts READ ONLY
down from Time Setpoint. Zero indicates timer has
stopped.
Range = 0 to 999 minutes
Default = 0
READ ONLY
Alarm value is based on process value display
decimal point and exponent. Both are required to
determine the real alarm value.
Range = -999 to 9999.
Default = 0000
Alarm value is based on process value display
READ ONLY
decimal point and exponent. Both are required to
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VersaPro Temperature Controller
HEX
DEC
08
8
PARAMETER
ALRMMD1
Page 69
BLOCK 0
DESCRIPTION
determine the real alarm value.
Range = -999 to 9999.
Default = 0000
Alarm 1 configuration
BITS 0 – 3
0000 = OFF (DEFAULT)
0001 = DEVIATION BAND
0010 = BAND LOW
0011 = BAND HIGH
0100 = PERCENT OUT LOW
0101 = PERCENT OUT HIGH
0110 = FULL SCALE LOW
0111 = FULL SCALE HIGH
1000 = PROBE IMPEDANCE / VERIFY
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = START
1101 = SOAK
1110 = TIMER
1111 = FAULT
READ/WRITE
READ ONLY
BIT 4 ACTION CONTROL
0 = DIRECT
1 = REVERSE
BIT 5 NO LATCH = 0, LATCHED = 1
BIT 6 – 15 SPARE
09
9
ALRMMD2
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Alarm 2 configuration
BITS 0 – 3
0000 = OFF (DEFAULT)
0001 = DEVIATION BAND
0010 = BAND LOW
0011 = BAND HIGH
0100 = PERCENT OUT LOW
0101 = PERCENT OUT HIGH
0110 = FULL SCALE LOW
0111 = FULL SCALE HIGH
1000 = PROBE IMPEDANCE / VERIFY
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = START
1101 = SOAK
1110 = TIMER
1111 = FAULT
READ ONLY
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
Page 70
BLOCK 0
DESCRIPTION
BIT 4 ACTION CONTROL
0 = DIRECT
1 = REVERSE
READ/WRITE
BIT 5 NO LATCH = 0 LATCHED = 1
0A
10
PB
0B
11
RESET
0C
12
RATE
0D
13
CYCTIM
0E
14
RSTC
0F
15
HIPO
10
16
LOPO
11
17
CONMD
BIT 6 – 15 SPARE
Proportional Band – Based on display units
Range = 1 to 9999
Default = 20
Reset – Based on seconds
Range = OFF to 9999
Where 0020 is assumed to be 00.20 seconds
Default = OFF (reset value = 0)
Rate – Based on seconds
Range = OFF to 9999
Where 0020 is assumed to be 00.20 seconds
Default = OFF (rate value = 0)
Cycle Time – Based on seconds
Range = 0.2 to 9999
Where 0002 is assumed to be 0002 seconds
Default = 30
TruCarb Sensor real time resistance not corrected
for resistance due to temperature. The value is an
integer with an implied milliohm resolution.
Control Output High Limit
Range = -100 to 100 where HIPO is always
greater than LOPO.
Default = 100
Control Output Low Limit
Range = -100 to 100 where LOPO is always less
than HIPO.
Default = 0
Control Type setting
BITS 0 – 3= CONTROL PARAMETER
0000 = SPARE
0001 = Temperature
0010 = Millivolt INPUT B
0011 = Carbon
0100 = Dewpoint
0101 = Oxygen
0110 = Redox
0111 = Millivolt INPUT A
1000 = GC Carbon
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
BIT 4 = NORMAL (0) FREEZE CONTROL
OUTPUT (1)
BITS 5 – 7 = MODE
000 = TIME PROPORTIONING
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
Page 71
BLOCK 0
DESCRIPTION
001 = TIME PROP W/ COMPLEMENT
010 = TIME PROP, DUAL
011 = SPARE
100 = ON/OFF
101 = ON/OFF W/ COMPLEMENT
110 = ON/OFF, DUAL
111 = VALVE POSITIONING W/ FEEDBACK
READ/WRITE
BIT 8 = DIRECT (0) OR REVERSE (1)
ACTING
BIT 9 = MANUAL (0) OR AUTO (1)
BIT 10 = SETPT LOCAL (0) OR SETPT REMOTE
(1)
BIT 11 = MONITOR (0), CONTROLLER (1)
BITS 12 = SENSOR BREAK OUTPUT 0 (0),
OUTPUT HOLD (1)
12
18
CONFIG0
13
19
CTRLOUT
Copyright © 2013, United Process Controls Inc.
BITS 13 – 15 NOT USED
Input Configuration
BITS 0-3 TC Input TYPE
0000 = B (DEFAULT)
0001 = E
0010 = J
0011 = K
0100 = N
0101 = R
0110 = S
0111 = T
1000 = SPARE
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = SPARE
1101 = SPARE
1110 = SPARE
1111 = SPARE
BIT 4 = SPARE
BIT 5 0 = NO CJ APPLIED, 1 = CJ APPLIED
BIT 6 0 = °F, 1 = °C
BIT 7 0 = 60HZ FILTER
BIT 8 – 11 Millivolt Input TYPE
0000 = LINEAR (DEFAULT)
All other bit combinations are spare
BITS 12 – 15 are spare
Control Output, unsigned integer
Actual control output where:
READ ONLY
READ ONLY
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VersaPro Temperature Controller
HEX
DEC
14
20
ALRMT1
15
21
ALRMT2
16
22
FAULT
17
23
CJTRM
HEX
18
DEC
24
PARAMETER
PARAMETER
ASRC
Copyright © 2013, United Process Controls Inc.
Page 72
BLOCK 0
DESCRIPTION
1000 = 100.0% and 64536 = -100.0%
ALARM 1 ON/OFF TIMES
RANGE = 0 – 255 SECONDS
DEFAULTS = 0
BIT 0-7 = ON TIME
BIT 8-15 = OFF TIME
ALARM 2 ON/OFF TIMES
RANGE = 0 – 255 SECONDS
DEFAULTS = 0
BIT 0-7 = ON TIME
BIT 8-15 = OFF TIME
FAULT BIT MAP
BIT 0 = Temperature Input Open
BIT 1 = MV Input Open
BIT 2 = Range of input is low
BIT 3 = Range of input is high
BIT 4 = Timer End
BIT 5 = Probe Care Fault
BITS 6 – 7 = SPARE
BIT 8 = CPU Fault
BIT 9 = Min Idle counter = 0
BIT 10 = Keyboard failure, stuck key or a key was
pressed during power up.
BIT 11 = Flash Erase Failed
BIT 12 = Flash Checksum Failed
BIT 13 = EEPROM Checksum Failed
BIT 14 = Flash/EEPROM Size Fault
BIT 15 = ADC Fault
COLD JUNCTION TRIM
RANGE = –128 TO +127 WHERE
1 COUNT = 1 DEG (C or F) and –128 = 65408
BLOCK 1
DESCRIPTION
ANALOG OUT SOURCES
LOW BYTE, ANALOG OUTPUT 1
BITS 0 – 3
0000 = N/A
0001 = Temperature
0010 = Linear Input A
0011 = Carbon value
0100 = Dewpoint value
0101 = Oxygen value
0110 = Redox value
0111 = Output Power
1000 = Control Output 1
1001 = Control Output 2
1010 = Linear Input B
1011 = Programmable*
READ/WRITE
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ/WRITE
READ ONLY
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
Page 73
BLOCK 1
DESCRIPTION
READ/WRITE
*For Programmable, write required output value
into DACV1, where DACV1 = 0 is minimum output
and
DACV1 = 4096 is maximum output.
BITS 4 – 7 SPARE
HIGH BYTE, ANALOG OUTPUT 2
BITS 8 – 12
0000 = N/A
0001 = Temperature
0010 = Linear Input A
0011 = Carbon value
0100 = Dewpoint value
0101 = Oxygen value
0110 = Redox value
0111 = Output Power
1000 = Control Output 1
1001 = Control Output 2
1010 = Linear Input B
1011 = Programmable*
*For Reference Number and Programmable , write
required output value into DACV2, where DACV2
= 0 is minimum output and
DACV2 = 4096 is maximum output.
BITS 13 – 15 SPARE
19
25
AOUTOF1
1A
26
AOUTRN1
1B
27
AOUTOF2
1C
28
AOUTRN2
Copyright © 2013, United Process Controls Inc.
Special case: If Analog Output 1 = CONTROL
OUTPUT 1 and Analog Output 2 = CONTROL
OUTPUT 2 and the Control Mode is dual, then
Analog Output 1 is 4-20ma for 0 to +100% PO and
Analog Output 2 is 4-20ma for 0 to -100% PO.
READ ONLY
ANALOG OUTPUT 1 OFFSET
Minimum source value that correlates to minimum
Analog Output of 4 mA. The source value is
based on the selection in ASRC lower byte
READ ONLY
ANALOG OUTPUT 1 RANGE
Maximum source value that correlates to maximum
Analog Output of 20 mA. The source value is
based on the selection in ASRC lower byte where
READ ONLY
ANALOG OUTPUT 2 OFFSET
Minimum source value that correlates to minimum
Analog Output of 4 mA. The source value is
based on the selection in ASRC upper byte
ANALOG OUTPUT 2 RANGE
READ ONLY
Maximum source value that correlates to maximum
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
1D
29
TEMPFIL
1E
30
MVFIL
1F
31
CONFIG2
20
32
COLDJCT
21
33
TEMP
22
34
MV
23
35
HADR AND
SIOSET
Page 74
BLOCK 1
DESCRIPTION
READ/WRITE
Analog Output of 20 mA. The source value is
based on the selection in ASRC upper byte where
Temperature Input Filter in seconds
Range = 0 to 3276. The higher the number the
faster the reading update.
DEFAULT = 1000
Millivolt Input Filter in seconds
Range = 0 to 3276. The higher the number the
faster the reading update.
DEFAULT = 1000
SETUP VALUES
BITS 0 - 4 OXYGEN EXPONENT
RANGE = 0 to 31, where 2 = % and 6 = ppm
DEFAULT = 2
BITS 5 - 6 DISPLAY DECIMAL PLACE where:
0 = no decimal point in display
1 = Display XXX.X
2 = Display XX.XX
3 = Display X.XXX
DEFAULT = 0
BITS 8 – 12 REDOX METAL NUMBER
RANGE = 0 – 14
DEFAULT = 0
BITS 13 – 15 SPARE
COLD JUNCTION
Where 1 COUNT = 1°F (°C), RANGE = -99 TO
255°F (°C). Note this parameter is an unsigned
integer.
MEASURED TEMPERATURE
Where temperature is presented in degrees C or
F, based on the C/F setting. Note this parameter
is an unsigned integer of temperature -2721 =
62815
Range = max / min range of selected
thermocouple.
MEASURED MILLIVOLT
Where this value is scaled in 0.1 mV increments,
i.e. 10001 = 1000.1.
Range = 0 to 2000 mV.
LOW BYTE – HOST ADDRESS
BITS 0-7
RANGE = 0 – 255
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
READ ONLY
HIGH BYTE – SIO SETUP
BITS 8 – 9 PARITY SETTING
00 = Even Parity, 7 bits, 1 Stop bit
01 = No Parity, 8 bits, 1 Stop bit
10 = Odd Parity, 7 bits, 1 Stop bit
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
Page 75
BLOCK 1
DESCRIPTION
BITS 10 – 11 RESPONSE DELAY
0 = No delay applied to response
1 = 10ms delay applied to response
2 = 20ms delay applied to response
3 = 30ms delay applied to response
READ/WRITE
BITS 12 – 14 BAUD SELECT
000 = 76.8K
001 = 38.4K
010 = 19.2K (DEFAULT)
011 = 9600
100 = 4800
101 = 2400
110 = 1200
111 = 600
24
36
PF
25
37
DACV1
26
38
DACV2
27
39
LOCK AND PLIM
28
40
PIMP
29
41
PRTM
Copyright © 2013, United Process Controls Inc.
BIT 15 HOST FORMAT
0 = MMI (PROP)
1 = MODBUS (DEFAULT)
PROCESS FACTOR FOR CARBON OR
DEWPOINT
RANGE = 0 to 4095
DEFAULT = 150
For TruCarb this is the RS00 cal, the value
ANALOG OUTPUT 1
0 to 4095 is 4 to 20 mA In dual mode 4mA = -100,
12mA = 0, 20mA = +100
ANALOG OUTPUT 2
0 to 4095 is 4 to 20 ma In dual mode 4mA = -100,
12mA = 0, 20mA = +100
LOW BYTE – LOCK LEVEL
BITS 0 – 2
LOCK LEVEL; 0-3 0 is full lock, 3 is wide open
BITS 3 – 7 SPARE
READ ONLY
READ ONLY
READ ONLY
READ ONLY
HIGH BYTE – PROBE IMPEDANCE LIMIT
0 – 255 KOHMS, DEFAULT VALUE = 20K
For TruCarb this limit has a default of 1.14 ohms
with a limit of 2.55 ohms.
READ ONLY
LAST PROBE IMPEDANCE VALUE
For oxygen, carbon, and dew point this is the
impedance of an oxygen sensor (KOHMS X 10)
i.e. 25 = 2.5 KOHMS
For TruCarb this is the RSTC cal. The final
(lowest) resistance value of the sensor resistance
during a decarb cycle. i.e. 2109 = 2.109 ohms.
READ ONLY
LAST PROBE RECOVERY TIME FROM
IMPEDANCE TEST (SECONDS)
RANGE = 0 to 255
Available for Redox, Carbon, and Dewpoint. Not
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
2A
42
PBOMV
2B
43
PBOTC
2C
44
PBORT
2D
45
PREMT
2E
46
VGAS
2F
47
PMC
HEX
30
DEC
48
PARAMETER
PTINT
31
49
PTRECT
32
50
BOTM
33
51
BOREC
Copyright © 2013, United Process Controls Inc.
Page 76
BLOCK 1
DESCRIPTION
available for TruCarb.
LAST MILLIVOLTS DURING PROBE BURN OFF
RANGE = -99 TO 2048
i.e. 1018 = 1018 mV
Available for Redox, Carbon, Dewpoint, and
TruCarb.
LAST TEMPERATURE DURING PROBE
BURNOFF RANGE = 0 to 3000
i.e. 1715 = 1715° (F or C based on CONFIG0 BIT
6)
Available for Redox, Carbon, Dewpoint, and
TruCarb.
LAST PROBE BURNOFF RECOVERY TIME
RANGE = 0 – 255 SECONDS
Available for Redox, Carbon, and Dewpoint.
REMAINING TIME TO NEXT PROBE TEST
RANGE = 0 – 999
Where 999 = 99.9 hours
For Oxygen Controller: Measured Verification gas.
Value = Actual measured oxygen (0.1%)
PROBE MAINTENANCE CONTROL WORD
BITS 0 – 1
00 = START FULL MAINTENANCE
01 = START BURNOFF (VERIFY) ONLY
10 = START PROBE IMP ONLY
11 = NONE
BITS 2 – 6 UNDEFINED
BIT 7 = NORMAL (0), CANCEL (1)
BITS 8 – 15 = PROBE MAINTENANCE
SEQUENCE NUMBER
BLOCK 2
DESCRIPTION
PROBE TEST INTERVAL SETTING (HRS)
Operator input for interval setting
RANGE = 0 – 999
Where 999 = 99.9 hours
DEFAULT = 0 (Disable Probe test)
PROBE TEST RECOVERY TIME SETTING
(SECONDS)
RANGE = 0 to 999
DEFAULT = 30
BURN OFF TIME SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Burnoff function available for Redox, Carbon, and
Dewpoint.
BURN OFF RECOVERY TIME SETTING
(SECONDS)
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VersaPro Temperature Controller
HEX
DEC
PARAMETER
34
52
VSTD
35
53
VTOL
36
54
TAVE
37
55
TDEL1
38
56
TDEL2
39
57
TMIN
3A
3B
3C
3D
3E
58
59
60
61
62
TC_ZERO
TC_SPAN
MV_ZERO
MV_SPAN
DAC_OFFSET_1
Copyright © 2013, United Process Controls Inc.
Page 77
BLOCK 2
DESCRIPTION
RANGE = 0 to 999
DEFAULT = 30
Burnoff function available for Redox, Carbon, and
Dewpoint.
VERIFY TEST GAS STANDARD
For oxygen process this is the test standard value
used to verify the probe.
RANGE = 0 to 999
Where the value 999 = 99.9% oxygen
DEFAULT = 30 (3.0%)
For TruCarb this is the FTCS calibration value.
This is the temperature correction factor in
milliohms to compensate the wire resistance
during decarb for the temperature measured
during the decarb process.
VERIFY TEST TOLERANCE SETTING
This setting establishes the limit as VSTD  VTOL
when comparing to the measured value VGAS
Range = 0 to 999
Where 0005 = 00.5%
DEFAULT = 0005
Verify function available for Oxygen.
VERIFICATION SAMPLE AVERAGING SETTING
(SECONDS)
RANGE = 0 to 999
DEFAULT = 2
Verify function available for Oxygen.
VERIFY DELAY 1 SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Verify function available for Oxygen.
VERIFY DELAY 2 SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Verify function available for Oxygen.
MINIMUM TEMPERATURE FOR PROBE CARE
TEST
This setting establishes the lowest process
temperature allowed for a probe test or TruCarb
decarburization process to proceed.
RANGE = 500°F to 2000°F (260°C to 1090°C)
DEFAULT = 1400°F (760°C)
NOTE: This value must be checked in the SETUP
menu when the temperature scales have been
changed.
TC ZERO CALIBRATION NUMBER
TC SPAN CALIBRATION NUMBER
MV ZERO CALIBRATION NUMBER
MV SPAN CALIBRATION NUMBER
DAC 1 OFFSET CALIBRATION
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VersaPro Temperature Controller
HEX
3F
40
41
42
DEC
63
64
65
66
43
44
67
68
ANUM
BZERO
45
46
69
70
BNUM
TIME CONTROL
AND EVNT
47
71
PARAMETER
DAC_SPAN_1
DAC_OFFSET_2
DAC_SPAN_2
AZERO
COMP
Copyright © 2013, United Process Controls Inc.
Page 78
BLOCK 2
DESCRIPTION
DAC 1 SPAN CALIBRATION
DAC2 OFFSET CALIBRATION
DAC2 SPAN CALIBRATION
LINEAR OFFSET, Y INTERCEPT LINEAR
SCALING FOR INPUT A
LINEAR SPAN VALUE FOR INPUT A
LINEAR OFFSET, Y INTERCEPT LINEAR
SCALING FOR INPUT B
LINEAR SPAN VALUE FOR INPUT B
LOW BYTE – INPUT EVENT CONFIGURATION
Bits 0 – 3
0000 = None
0001 = Auto Mode Selected
0010 = Remote Setpoint Selected
0011 = Acknowledge alarms
0100 = Timer Hold
0101 = Timer End
0110 = Timer Start
0111 = Start probe test
1000 = Process hold
Bits 4 – 7 not used.
HIGH BYTE - TIMER CONTROL
BIT 0 – SPARE
BIT 1 – Timer stop(0), Timer start(1)
BIT 2 – Timer running(1)
BIT 3 – Timer End Active(1)
BIT 4 – Timer Hold Active(1)
BIT 5 – 6 SPARE
BIT 7 = Timer Disabled (0), Timer Enabled (1)
CO / H COMPENSATION for carbon or dewpoint
RANGE 0 – 255
DEFAULT = 20 (% CO FOR CARBON)
DEFAULT = 40 (% H2 FOR DEWPOINT)
For TruCarb this value is the shim stock offset in
% carbon, i.e. 0145 = 1.45%
READ/WRITE
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VersaPro Temperature Controller
Page 79
Reach us at www.group-upc.com
United Process Controls brings together leading brands
to the heat treating industry including Waukee
Engineering, Furnace Control, Marathon Monitors and
Process-Electronic.
We provide prime control solutions through our
worldwide sales and services network with easy-toaccess local support.
UNITED PROCESS CONTROLS INC.
MMI PRODUCTS PLANT
3100 East Kemper Road, Cincinnati, Ohio 45241, U.S.A.
Phone: +1-513-772-1000 Fax: +1-513-326-7090
Toll-Free North America +1-800-547-1055
E-mail: waukee.sales@group-upc.com
Copyright © 2013, United Process Controls Inc.
All rights to copy, reproduce and transmit are reserved
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