N1040 Controller TEMPERATURE CONTROLLER – INSTRUCTIONS MANUAL – V1.1x A SAFETY ALERTS

N1040 Controller
TEMPERATURE CONTROLLER – INSTRUCTIONS MANUAL – V1.1x A
RECOMMENDATIONS FOR THE INSTALLATION
SAFETY ALERTS
The symbols below are used on the equipment and throughout this
document to draw the user’s attention to important operational and
safety information.
CAUTION:
Read the manual thoroughly
before installing and operating
the equipment.
CAUTION OR DANGER:
Electrical shock hazard
All safety related instructions that appear in the manual must be
observed to ensure personal safety and to prevent damage to either the
instrument or the system. If the instrument is used in a manner not
specified by the manufacturer, the protection provided by the equipment
may be impaired.
INSTALLATION / CONECTIONS
The controller must be fastened on a panel, following the sequence
of steps described below:
• Prepare a panel cut-out of 46 x 46 mm;
• Remove the mounting clamps from the controller;
• Insert the controller into the panel cut-out;
• Slide the mounting clamp from the rear to a firm grip at the panel.
ELECTRICAL CONNECTIONS
• All electrical connections are made to the screw terminals at the
rear of the controller.
• To minimize the pick-up of electrical noise, the low voltage DC
connections and the sensor input wiring should be routed away
from high-current power conductors. If this is impractical, use
shielded cables. In general, keep cable lengths to a minimum.
• All electronic instruments must be powered by a clean mains
supply, proper for instrumentation.
• It is strongly recommended to apply RC'S FILTERS (noise
suppressor) to contactor coils, solenoids, etc. In any application it
is essential to consider what can happen when any part of the
system fails. The controller features by themselves can not assure
total protection.
FEATURES
INPUT TYPE SELECTION
Table 01 shows the sensor types accepted and their respective
codes and ranges. Access the parameter TYPE in the INPUT cycle
to select the appropriate sensor.
TYPE
CODE
Thermocouple J
Tc j
Range: -110 to 950 ºC (-166 to 1742 ºF)
RANGE OF MEASUREMENT
Thermocouple K
Tc k
Range: -150 to 1370 ºC (-238 to 2498 ºF)
Thermocouple T
Tc t
Range: -160 to 400 ºC (-256 to 752 ºF)
Pt100
Pt
Range: -200 to 850 ºC (-328 to 1562 ºF)
Table 01 – Input types
Figure 01 below shows the electrical terminals of the controller:
OUTPUTS
The controller offers two, three or four output channels, depending on
the loaded optional features. The output channels are user
configurable as Control Output, Alarm 1 Output, Alarm 2 Output,
Alarm 1 OR Alarm 2 Output and LBD (Loop Break Detect)
Output.
OUT1 - Logical pulse, 5 Vdc / 20 mA, available at terminals 4 and 5.
OUT2 - Relay SPST-NA, 3 A / 250 Vac, available at terminals 6 and 7.
OUT3 - Relay SPST-NA, 3 A / 240 Vac, available at terminals 13
and 14.
OUT4 - Relay SPDT, available at terminals 10, 11 and 12.
CONTROL OUTPUT
Figure 01 - Connections of the back panel
NOVUS AUTOMATION
The control strategy can be ON/OFF (when PB = 0.0) or PID. The
PID parameters can be automatically determined enabling the autotuning function (ATvN
ATvN).
ATvN
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N1040 Controller
ALARM OUTPUT
The controller contains 2 alarms that can be directed (assigned) to any
output channel. The alarm functions are described in Table 02.
off
Output is not used as alarm.
lo
Alarm of Absolute Minimum
Value. Triggers when the
value of measured PV is
below the value defined for
alarm Setpoint.
ki
Alarm of Absolute Maximum
Value. Triggers when the
value of measured PV is
above the value defined for
alarm Setpoint.
PV
SPA1
PV
SPA1
Alarm of Differential Value. In this function the
parameters SPA1 and SPA2 represent the deviation
of PV in relation to the SP of CONTROL.
dif
PV
PV
SP – SPA1
SP
SP + SPA1
SV + SPA1
alarme
Positive SPA1
SP
SV – SPA1
SAFE OUTPUT VALUE WITH SENSOR FAILURE
This function defines an output value (user defined) to be assigned to
the control output in the event of a sensor failure.
When the input sensor is identified as broken, the controller switches
the control mode to MANUAL while forcing MV to assume the user
configured value in the 1E.ov parameter. This function requires that one
of the alarms be configured as 1Err and the 1E.ov parameter (control
output percentage) programmed with a value other then 0 (zero).
Once this function is triggered, the controller remains in SAFE mode
(MANUAL control output) even after the sensor failure appears to be
fixed. The operator intervention is required for switching back to
AUTO mode.
1E.ov values are only 0 and 100 % when in ON/OFF control mode.
For PID control mode any value in the range from 0 to 100 % is
accepted.
Negative SPA1
Alarm of Minimum Differential Value. It triggers when
the value of PV is below the defined point by (using
the Alarm 1 as example).
difl
A LBD event may be sent to any output channel. Simply configure the
LDB function to the desired output channel (OUT1 or OUT2): the
selected output will be activated when a LDB condition is detected.
When the Lbd.t parameter is programmed with 0 (zero), the LDB
function is disabled.
The LBD is useful in detecting system failures, such us defective
sensors or actuators, loads and power supply, among others.
The controller’s front panel, with its parts, can be seen in the Figure 02:
PV
PV
SP – SPA1
OPERATION
SP
SP
Positive SPA1
SP – SPA1
Negative SPA1
Alarm of Valor Maximum Differential Value. Triggers
when the value of PV is above the defined point by
(using Alarm 1 as example):
difk
PV
PV
SP
SP + SPA1
SP + SPA1
Positive SPA1
ierr
SP
Negative SPA1
Sensor Break Alarm. Activated when the input signal
of PV is interrupted, out of the range limits or Pt100 in
short-circuit.
Table 02 – Alarm functions
Figure 02 - Identification of the parts referring to the front panel
Display of PV / Programming (top display, red color): Displays the
current value of PV (Process Variable). When in configuration mode,
it shows the parameters names.
Display of SP / Parameters (bottom display, green color): Displays
the value of SP (Setpoint). When in configuration mode, it shows the
parameters values.
TUNE Indicator: Stays ON while the controller is in tuning process.
Note: Alarm functions on Table 02 are also valid for Alarm 2 (SPA2).
OUT Indicator: For relay or pulse control output; it reflects the actual
state of the output.
INITIAL BLOCKING OF ALARM
A1 and A2 Indicators: signalize the occurrence of alarm situation.
The initial blocking option inhibits the alarm from being recognized if
an alarm condition is present when the controller is first energized (or
after a transition from run YES NO). The alarm will be enabled
only after the occurrence of a non alarm condition followed by a new
occurrence for the alarm.
The initial blocking is useful, for instance, when one of the alarms is
configured as a minimum value alarm, causing the activation of the
alarm soon upon the process start-up, an occurrence that may be
undesirable.
The initial blocking is disabled for the sensor break alarm function.
P Key: used to walk through the menu parameters.
OFFSET
Allows fine adjustments to the PV reading for compensation of sensor
error.
FUNÇÃO LBD – LOOP BREAK DETECTION
The parameter defines a time interval, in minutes, within which the
PV is expect to react to a control output signal. If the PV does not
react properly within the time interval configured in lbd.t, the
controller interprets this as a control loop break and signals this
occurrence in the display.
NOVUS AUTOMATION
Increment key and
values of the parameters.
- Decrement key: allow altering the
Back key: used to retrocede parameters.
OPERATION
When the controller is powered up, it displays its firmware version for
3 seconds, after which the controller starts normal operation. The
value of PV and SP is then displayed and the outputs are enabled.
In order for the controller to operate properly in a process, its
parameters need to be configured first, such that it can perform
accordingly to the system requirements. The user must be aware of
the importance of each parameter and for each one determine a valid
condition.
The parameters are grouped in levels according to their functionality
and operation easiness. The 5 levels of parameters are:
1 – Operation / 2 – Tuning / 3 – Alarms / 4 – Input / 5 – Calibration
The “P” key is used for accessing the parameters within a level.
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N1040 Controller
Keeping the “P” key pressed, at every 2 seconds the controller jumps
to the next level of parameters, showing the first parameter of each
level:
PV >> atvn >> fva1 >> type >> pass >> PV …
To enter a particular level, simply release the “P” key when the first
parameter in that level is displayed. To walk through the parameters
in a level, press the “P” key with short strokes. To go back to the
previous parameter in a cycle, press :
Each parameter is displayed with its prompt in the upper display and
value/condition in the lower display. Depending on the level of
parameter protection adopted, the parameter PASS precedes the first
parameter in the level where the protection becomes active. See
section CONFIGURATION PROTECTION.
sfst
SoftStart function – Time in seconds during which the
controller limits the MV value progressively from 0 to
100 %. It is enabled at power up or when the control
output is activated. If in doubt set sfst = 0 (the zero
value disables the Soft start function).
0vt1
0vt2
0vt3
0vt4
Assign functions to the Output channels OUT1, OUT2,
OUT3 e OUT4:
Off - Not used.
(trl(trl control output.
A1
- alarm 1 output.
A2
- alarm 2 output.
A1a2 - Alarm 1 + Alarm2 (OR logic).
Lbd - Loop Break Detect Alarm.
DESCRIPTION OF THE PARAMETERS
OPERATION CYCLE
PV + SP PV and SP indication – The upper display shows the
current value of PV. The lower display shows the
control SP value.
Sp.a1
Sp.a2
ALARM SETPOINT: Tripping point for alarm 1 and 2.
Value that defines the point of activation for the
programmed alarms with the functions Lo or ki.
ki
For the alarms configured with Differential type
functions, this parameter defines deviation (band).
Not used for the other alarm functions.
pb
Fva1
Fva2
Functions of Alarms. Defines the functions for the
alarms among the options of the Table 02.
Sp.a1
Sp.a2
ALARM SETPOINT: Tripping point for alarm 1 and 2.
Value that defines the point of activation for the
programmed alarms with the functions Lo or ki.
ki
For the alarms configured with Differential type
functions, this parameter defines deviation (band).
Not used for the other alarm functions.
Sp1.e
sp2.e
TUNING CYCLE
Atvn
ALARMS CYCLE
AUTO-TUNE: enables the auto-tuning function for the
PID parameters (pb
pb,ir
pb ir,
ir dt).
dt Defines the control
strategy to be taken:
off – Turned off. (no PID tuning)
Fast – Fast automatic tuning.
Full – More accurate automatic tuning.
bla1
bla2
Blocking Alarms.
YES - enables initial blocking
NO
- inhibits initial blocking
Refer to the section DETERMINATION OF PID
PARAMETERS for more details.
xya1
xya2
Proportional Band - Value of the term P of the control
mode PID, in percentage of the maximum span of the
input type. Adjust of between 0 and 500.0 %.
Alarm Hysteresis. Defines the difference between the
value of PV at witch the alarm is triggered and the
value at witch it is turned off.
flsh
Allows visual signalization of an alarm occurrence by
flashing the indication of PV in the operation level.
YES - enables alarm signaling flashing PV
NO
- disables alarm signaling flashing PV
When set to zero (0), control action is ON/OFF.
ir
Configures display of SPA1 and SPA2 also in the
Operation Cycle.
YES - SPA1/SPA2 are displayed in the Operation
Cycle
NO - SPA1/SPA2 are not displayed in the Operation
Cycle
Integral Rate - Value of the term I of the PID algorithm,
in repetitions per minute (Reset). Adjustable between 0
and 99.99. Displayed only if proportional band ≠ 0.
INPUT CYCLE
dt
Derivative Time - Value of the term D of the control mode
PID, in seconds. Adjustable between 0 and 300.0
seconds. Displayed only if proportional band ≠ 0.
Type
INPUT TYPE: Selects the input signal type to be
connected to the process variable input. Refer to Table
01 for the available options.
(t
CYCLE TIME: Pulse Width Modulation (PWM) period
in seconds. This term is not used when controller is set
to ON/OFF action (Pb=0).
fltr
Kyst
yst
CONTROL HYSTERESIS: Is the hysteresis for
ON/OFF control (set in temperature units). This
parameter is only used when the controller is in
ON/OFF mode (Pb=0).
Digital Input Filter - Used to improve the stability of the
measured signal (PV). Adjustable between 0 and 20. In
0 (zero) it means filter turned off and 20 means
maximum filter. The higher the filter value, the slower is
the response of the measured value.
Dp.po
Selects the decimal point position to be viewed in both
PV and SP.
Action Control:
vni
vni t Selects display indication for degrees Celsius or
A(t
re
Fahrenheit:
( - Indication in Celsius.
f - Indication in Fahrenheit.
Control with Reverse Action. Appropriate for
heating. Turns control output on when PV is
below SP.
dir Control with Direct Action. Appropriate for
cooling. Turns control output on when PV is
above SP.
0ffs
SENSOR OFFSET: Offset value to be added to the PV
reading to compensate sensor error. Default value: zero.
Spll
Defines the SP lower limit of.
To 50 mV input type sets the lower range for SP and
PV indication.
NOVUS AUTOMATION
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N1040 Controller
Spxl
Defines the upper limit for adjustment of SP.
To 50 mV input type sets the upper range for SP and
PV indication.
The Access Password is defined by the user in the parameter
Password Change (PAS
PAS.
PAS.(), present in the Calibration Level. The
factory default for the password code is 1111.
Lbd.t
Time interval for the LBD function. Defines the
maximum interval of time for the PV to react to a
control command. In minutes.
1e.ov
Percentage output value that will be transfer to MV
when the SAFE output function is enabled. If 1eov =
0, the SAFE output function is disabled and the outputs
are turned off in the occurrence of a sensor fail.
PROTECTION ACCESS PASSWORD
The protection system built into the controller blocks for 10 minutes
the access to protected parameters after 5 consecutive frustrated
attempts of guessing the correct password.
CALIBRATION CYCLE
All of the input and output types are calibrated in the factory. If a
recalibration is required, this should be carried out by a
experienced personnel. If this cycle is accidentally accessed, pass
or
keys.
through all the parameters without pressing the
pass
Password. This parameter is presented before the
protected cycles. See item Protection of Configuration.
(alib Enables or disables instrument calibration by the user,
YES:
YES shows calibration parameters
No:
No Hides the calibration parameters.
inL(
Input Low Calibration. Enter the value corresponding to
the low scale signal applied to the analog input.
ink(
Input High Calibration. Enter the value corresponding
to the full scale signal applied to the analog input.
rstr
Restore. Restores the factory calibration for all inputs
and outputs, disregarding modifications carried out by
the user.
(j
Cold Junction. This screen is for information purpose
only.
Pas.(
Password Change. Allows defining a new access
password, always different from zero.
Prot
Protection. Sets up the Level of Protection. See Table
05.
Freq
Mains frequency. This parameter is important for
proper noise filtering.
CONFIGURATION PROTECTION
The controller provides means for protecting the parameters
configurations, not allowing modifications to the parameters values,
avoiding tampering or improper manipulation. The parameter
Protection (PROt
PROt),
PROt in the Calibration level, determines the
protection strategy, limiting the access to particular levels, as shown
by the Table 04.
Protection Level
1
2
3
4
5
6
Protection Levels
Only the Calibration level is protected.
Calibration and Input levels.
Calibration, Input and Alarms levels.
Calibration, Input, Alarms and Tuning levels.
All levels are protected, but the SP screen in
the operation level.
All levels are protected, including SP.
MASTER PASSWORD
The Master Password is intended for allowing the user to define a
new password in the event of it being forgotten. The Master
Password doesn’t grant access to all parameters, only to the
Password Change parameter (PAS(
PAS().
PAS( After defining the new
password, the protected parameters may be accessed (and modified)
using this new password.
The master password is made up by the last three digits of the serial
number of the controller added to the number 9000. As an example,
for the equipment with serial number 07154321, the master password
is 9 3 2 1.
Controller serial number is displayed by pressing
for 3 seconds.
DETERMINATION OF PID PARAMETERS
During the process of determining automatically the PID parameters,
the system is controlled in ON/OFF in the programmed Setpoint. The
auto-tuning process may take several minutes to be completed,
depending on the system. The steps for executing the PID autotuning are:
•
Select the process Setpoint.
•
Enable auto-tuning at the parameter “Atvn
Atvn”,
Atvn selecting FAST
FAST
or FULL.
FULL
The option FAST performs the tuning in the minimum possible time,
while the option FULL gives priority to accuracy over the speed.
The sign TUNE remains lit during the whole tuning phase. The user
must wait for the tuning to be completed before using the controller.
During auto tuning period the controller will impose oscillations to the
process. PV will oscillate around the programmed set point and
controller output will switch on and off many times.
If the tuning does not result in a satisfactory control, refer to Table 05
for guidelines on how to correct the behavior of the process.
PARAMETER
Band Proportional
Rate Integration
Derivative Time
VERIFIED PROBLEM
SOLUTION
Slow answer
Decrease
Great oscillation
Increase
Slow answer
Increase
Great oscillation
Decrease
Slow answer or instability
Decrease
Great oscillation
Increase
Table 05 - Guidance for manual adjustment of the PID parameters
For further details
on PID tuning, visit our web site:
Table 04 – Levels of Protection for the Configuration
ACESS PASSWORD
The protected levels, when accessed, request the user to provide the
Access Password for granting permission to change the
configuration of the parameters on these levels.
The prompt PASS precedes the parameters on the protected levels.
If no password is entered, the parameters of the protected levels can
only be visualized.
NOVUS AUTOMATION
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N1040 Controller
MAINTENANCE
WARRANTY
PROBLEMS WITH THE CONTROLLER
Connection errors and inadequate programming are the most
common errors found during the controller operation. A final revision
may avoid loss of time and damages.
The controller displays some messages to help the user identify
problems.
MESSAGE
Warranty
conditions
are
available
on
our
web
site .
DESCRIPTION OF THE PROBLEM
----
Open input. No sensor or signal.
Err1
Err6
Connection and/or configuration problems.
Check the wiring and the configuration.
Other error messages may indicate hardware problems requiring
maintenance service. When contacting the manufacturer, inform the
for more
instrument serial number, obtained by pressing the key
than 3 seconds.
PROCESS VARIABLE INPUT CALIBRATION
Visit our web site for further information .
PART NUMBER FORMATION
N1040 – PR
Basic version; two outputs: OUT1= logical
pulse / OUT2= relay
N1040 – PRR
Three outputs: OUT1= logical pulse / OUT2
and OUT3 = relay
N1040 – PRRR
Four outputs: OUT1= logical pulse / OUT2,
OUT3 and OUT4= relay
SPECIFICATIONS
DIMENSIONS:............................................................48 x 48 x 80 mm
Approximate:............................................................................75 g
POWER SUPPLY:..........................100 to 240 Vac (±10 %), 50/60 Hz
................................................................... 24 to 300 Vdc (±10 %)
Maximum consumption:......................................................... 5 VA
ENVIRONMENTAL CONDITIONS:
Operation Temperature: ................................................ 0 to 60 ºC
Relative Humidity:....................................................80 % @ 30 ºC
................ For temperatures above 30 ºC, reduce 3 % for each ºC
.......Internal use; Category of installation II, Degree of pollution 2;
altitude < 2000 meters
INPUT.......Thermocouples J; K; T and Pt100 (according of Table 01)
Internal Resolution:...................................... 32767 levels (15 bits)
Resolution of Display:..........12000 levels (from -1999 up to 9999)
Rate of input reading: .........................................up 55 per second
Precision: ........Thermocouples J, K, T: 0.25 % of the span ±1 ºC
................................................................ Pt100: 0.2 % of the span
Input Impedance:..................Pt100 and thermocouples: > 10 MΩ
Measurement of Pt100: ..........................3-wire type, (α=0.00385)
With compensation for cable length, excitation current of 0.170 mA.
OUT1: .........................................................Voltage pulse, 5 V / 25 mA
OUT2: ..................................................... Relay SPST; 1.5 A / 240 Vac
OUT3: ..................................................... Relay SPST; 1.5 A / 240 Vac
OUT4: ........................................................ Relay SPDT; 3 A / 240 Vac
CASE: ..........................................IP65, Polycarbonate (PC) UL94 V-2
STARTS UP OPERATION AFTER 3 SECONDS CONNECTED TO
THE POWER SUPPLY;
CERTIFICATION:
NOVUS AUTOMATION
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