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THE PROCESS SETPOINT CONTROLLER MODEL PSC INSTRUCTION MANUAL INTRODUCTION The Process Setpoint Controller Unit (PSC) is a multi-purpose series of industrial control products that are field-programmable for solving various applications. This series of products is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements. The PSC unit, which you have purchased, has the same high quality workmanship and advanced technological capabilities that have made Red Lion Controls the leader in today's industrial market. Red Lion Controls has a complete line of industrial indication and control equipment, and we look forward to servicing you now and in the future. 1) 1) iy IV) TABLE OF CONTENTS GENERAL DESCRIPTION INSTALLATION 8: CONNECTIONS A) Standard Unit Installation 8 Removal B) NEMA 4X/1P65 Unit Installation C) Unit Removal Procedure D) Removing Bezel Assembly E) Installing Bezel Assembly F) Output Modules 1. Output Variations without RS-485 Option 2. Output Variations with RS-485 Option 3. installing Output Modules 4. Output Module "Output On" State 5. Typical Connections G) Select AC Power (115/230) H) Wiring Connections 1. Signal Wiring 2. User Input Wiring 3. AC Power Wiring FRONT PANEL DESCRIPTION A) Button Functions OPERATION OVERVIEW A) Controller Power-up B) Controller Power-down C) Process Start-up D) Manual (User) & Automatic Operation E) Profile Operating Modes 1. Run Mode 2. Off Mode 3. Pause Mode 4. Delay Mode F) Controlling A Profile 1. Profile Start Operation a. Start Operation From The Profile Control Status Display b. Start Operation From The Hidden Mode c. Start Operation Using The User Input -7- D Lo 0 O O “4 yy 10-11 to 10 10 11 12 12-13 12 12 13 14 14 15-24 15 15 16-17 16 16 16 17 18-21 18 18 18 18 OPERATION OVERVIEW (Cont'd) F) Controlling A Profile (Cont'd) 1. Profile Start Operation (Cont'd) 2. Profile Stop Operation 3. Profile Advance Operation 4. Profile Pause Operation 5. Profile Continue Operation 6. Reset Event Outputs Operation G) Configuration Of Parameters H) Parameter Entry I) Normal Display Mode TABLE OF CONTENTS d. Start Operation On Power-Up e. Start Operation Via The RS-485 Serial Option a. Stop Operation From The Profile Control Status Display b. Stop Operation From The Hidden Mode c. Stop Operation On Power-Up d. Stop Operation Via The RS-485 Serial Option a. Advance Operation From The Profile Control Status Display b. Advance Operation From The Hidden Mode ¢. Advance Operation Via The RS-485 Serial Option a. Pause Operation From The Profile Control Status Display b. Pause Operation From The Hidden Mode c. Pause Operation Using The User Input d. Pause Operation Via The RS-485 Serial Option a. Continue Operation From The Profile Control Status Display b. Continue Operation From The Hidden Mode c. Continue Operation Using The User Input d. Continue Operation Via The RS-485 Serial Option a. Reset À Timed Event Output From The Hidden Mode b. Reset À Timed Event Output Using The User Input c. Reset À Timed Event Output Using The RS-485 Serial Option 1. Modifying À Secondary Display Parameter From The Front Panel a. Setpoint Value Display b. % Output Power Display c. Profile Control Status Display d. Profile Phase Time Remaining Display V) VI) VII) VIII) TABLE OF CONTENTS UNPROTECTED PARAMETER MODE A) Reference Table PROTECTED PARAMETER MODE A) Reference Table B) Front Panel Program Disable HIDDEN FUNCTION MODE A) Reference Table CONFIGURATION PARAMETER MODULES A) input Module 1. Input Type 2. Decimal Point Position 3. Rounding Increments 4. Input Signal Filter 5. Scaling Points a. Display Values b. Signal Input Values 6. Setpoint Limit Values 7. Auto Setpoint Ramp Rate 8. User Input B) Output Module 1. Time Proportioning Cycle Time 2. Output Control Action 3. Output Power Limits 4. Input Overdrive Preset Power 5. On/Off Control Hysteresis Band 6. Auto-Tune Damping Code 7. Linear DC Analog Output C) Lockouts Module 1. Lower Display Lockouts 2. Protected Mode Lockouts 3. Hidden Mode Lockouts D) Alarm Module 1. Alarm Action 2. Alarm Reset 3. Alarm Standby Delay 4. Alarm Value 5. Alarm Hysteresis -3- 25 26-27 28 28 29-49 29-32 “8688838388 31-32 32-34 32 32 32 32-33 65006886 Vill) CONFIGURATION PARAMETER MODULES (Cont'd) IX) TABLE OF CONTENTS E) Secondary Output Module (Optional) 1. Cycle Time 2. Relative Gain 3. Overlap/Deadband F) Serial Communications Module (Optional) 1. Baud Rate 2. Parity Bit 3. Address Number 4. Abbreviated or Full Transmission 5. Print Rate 6. Print Options G) Control Points Module 1. Setpoint Value 2. PID Values H) Profiles Module . Profile Cycle Count . Profile Linking . Profile Power Cycle Status . Profile Error Band Ramp Phase . Setpoint Value Hold Phase . Timed Event Output © 60 >41 ©) Сл &> (2 ГО = . Profile Example |) Factory Service Operations QUICK REFERENCE TABLES FOR CONFIGURATION PARAMETER MODULES RS-485 SERIAL COMMUNICATIONS INTERFACE (Optional) A) Communication Format B) Sending Commands and Data C) Receiving Data D) Terminal Emulation Program E) Serial Connections 1. Terminal Description 2. Connecting To An RLC Printer 3. Connecting To A Host Terminal F) Troubleshooting Serial Communications -4- 46-47 48-49 49 50-58 59-66 59-61 61-62 64-66 65 66 TABLE OF CONTENTS XI) PID CONTROL A) Proportional Band B) Integral Time C) Derivative Time D) Output Power Offset (Manual Reset) E) PID Adjustments XII) ON/OFF CONTROL ХИ!) АЧТО-ТОМЕ A) To Initiate Auto-Tune В) То Cancel Auto- Tune XIV) APPENDIX A - THEORY OF OPERATION AND BLOCK DIAGRAM XV) APPENDIX B - APPLICATION EXAMPLES XVI) APPENDIX C - SPECIFICATIONS & DIMENSIONS XVil) APPENDIX D - TROUBLESHOOTING & ERROR CODES XVill) APPENDIX E - MANUAL TUNING XIX) APPENDIX F - CALIBRATION XX) APPENDIX G - USER PARAMETER VALUE CHART XXI) APPENDIX H - ORDERING INFORMATION -5- 67-69 67-68 68-69 70-71 72-73 73 73 74-75 77-79 80-81 83-84 85-86 87 GENERAL DESCRIPTION The PSC is a setpoint controller suitable for time vs. process control applications. The PSC Controller accepts either a 0-10VDC or a 4-20mA DC input signal, precisely scales the process signal, according to programmable scaling points, and provides an accurate output control signal (time proportional or linear) to maintain a process at the desired control point. A comprehensive set of easy to use steps allows the controller to satisfy various applications. The user input can be programmed to perform a variety of controller functions. Dual 4-digit displays allow viewing of the measured process value and setpoint or the process and profile status simultaneously. Front panel indicators inform the operator of controller status and output states. Replaceable output modules (Relay, Logic/SSR drive or Triac) can be fitted to the main control output, alarm output(s) or timed event output(s), and secondary output. The PSC has been designed to simplify the set-up and operation of a controlled setpoint profile program. The setpoint program is easily entered and controlled through the front panel. Full display capabilities keep the operator informed of the process value, profile status, output states, and setpoint value. The controller can operate in the standard PID control mode for both Output 1 and Output 2 with on-demand auto-tune which establishes the PID gain set. The PID gain set can be fine tuned by the operator at any time or may be locked from further modification. The unit can be transferred to the manual control mode providing the operator with direct control of the output. The PSC features four programs or profile recipes, each with up to eight ramp/soak segments, which can be easily stored and executed at any time. Longer profiles can be achieved by linking one or more profiles together, creating a single profile of up to 32 ramp/soak segments. Process profile conformity is assured during either soak (hold) phases or both ramp and hold phases by an adjustable error band parameter. The program repeat function cycles the profile either continuously or a set number of times. Power-on options automatically re-start, stop, or resume a running profile. The profile can be controlled via the front panel buttons, the user input, or the optional serial communications port. Four control points, each having a setpoint and PID parameter set, are available for instant front panel implementation during batch changeover, or other process conditions. A control point may have its PID gain set values disabled when implementing the control point. The optional RS-485 multidrop serial communications interface provides the capability of two-way communication between a PSC unit and other compatible equipment such as a printer, a programmable controller, or a host computer. In multipoint applications the address number of each unit on the line can be programmed from 0-99. Up to thirty-two units can be installed on a single pair of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be interrogated or changed by sending the proper command code via serial communications. Alarm output(s) may also be reset via the serial communications interface option. Optional alarm output(s) may be configured to operate as a timed event output or as a standard alarm output. As an alarm output it may be configured to activate according to a variety of actions (Absolute HI or LO, Deviation HI or LO, or Band IN or OUT) with adjustable hysteresis. Also, a standby feature suppresses the output(s) on power-up until the process stabilizes outside the alarm region. Timed event output(s) allow the controller to activate other equipment while a programmed profile is running. Each profile can define up to 16 event states (phases), for each output. An optional secondary output is available for processes that require cooling or a comparable function which provides increased control accuracy and response. The optional linear 4-20mA output signal is available to interface with final actuators, chart recorders, indicators, or other controllers. The 4-20mA output signal can be digitally scaled and selected to transmit one of the following: 5 % Output Power Measurement Value Measurement Value Deviation Setpoint Value An optional NEMA 4X/IP65 rated bezel is available for washdown and/or dirty environments, when properly installed. Modern surface-mount technology, extensive testing, plus high immunity to noise interference, makes the controller extremely reliable in industrial environments. INSTALLATION & CONNECTIONS Standard Unit installation Prepare the panel cutout to the dimensions shown in the installation figure. Remove the panel latch and cardboard sleeve from the unit and discard the cardboard sleeve. The unit should be installed with the bezel assembly in place. Insert the unit into the panel cutout. While holding the front of the unit in place, push the panel latch over the rear of the unit so that the tabs of the panel latch engage in the slots on the case. The panel tatch should be engaged in the farthest forward slots possible. Tighten the screws evenly until the unit is snug in the panel. Nema 4X/IP65 Unit Installation The optional NEMA 4X/IP65 PSC Controller is designed to provide a watertight seal in panels with a minimum thickness of 1/8 inch. Prepare the panel cutout to the dimensions shown in the installation figure. Carefully apply the adhesive side of the panel gasket to the panel cutout. Remove the panel latch and cardboard sleeve from the unit and discard the cardboard sleeve. The unit should be installed with the bezel assembly in place and the bezel screws tightened slightly. Insert the unit into the panel cutout. While holding the front of the unit in place, push the panel latch over the rear of the unit so that the tabs of the panel latch engage in the slots on the case. The panel latch should be engaged in the farthest forward slot possible. To achieve a proper seal, tighten the latch screws evenly until the unit is snug in the panel (torque to approximately 7in-lbs [79N-cml). Do NOT over-tighten the screws. Note: The installation location of the controller is important. Be sure to keep it away from heat sources (ovens, furnaces, etc.), away from direct contact with caustic vapors, oils, steam, or any other process by-products in which exposure may effect proper operation. Note: Prior to applying power to the controller, the internal AC power selector switch must be set. Damage to the controller may occur if the switch is set incorrectly. 7- Unit Removai Procedure To remove a NEMA 4X/IP65 or standard unit from the panel, first unscrew and remove the panel latch screws. Insert flat blade screwdrivers between the latch and the case on the top and bottom of the unit so that the latches disengage from the grooves in the case. Push the unit through the panel from the rear. NEMA 4X /IPES GASKET FOR UNITS ONLY EXISTING PANEL LATCHING FEATURE LATCHING FEATURE PANEL MOUNTING SCREW PANEL LATCH PANEL INSTALLATION & REMOVAL -8- Removing Bezel Assembly The bezel assembly must be removed from the case to install or replace output modules, or to set the 115/230VAC selector switch. To remove a standard bezel assembly (without bezel securing screws) press the latch under the lower bezel lip and withdraw the bezel assembly. To remove the sealed NEMA 4X/IP65 bezel assembly, loosen the two bezel securing screws until a slight "click" is felt (the screws are retained in the bezel) and withdraw the assembly. It is recommended to disconnect power to the unit and to the output control circuits to eliminate the potential shock hazard with the bezel assembly removed. Note: The bezel assembly contains electronic circuits which are damaged by static electricity. Before removing the assembly, discharge stray static electricity on your body by touching an earth ground point. It is also important that the bezel assembly be handled only by the bezel itself. Additionally, if it is necessary to handle a circuit board, be certain that hands are free from dirt, oil, etc., to avoid circuit contamination which may lead to malfunction. Installing Bezel Assembly To install the standard bezel assembly, insert the assembly into the case until the bezel latch snaps into position. To install the NEMA 4X/IP65 bezel assembly, insert the assembly into BEZEL SCREWS (TwD (TWD) NEMA 4X/IP65 UNIT ONLY. Ys o © V the case and tighten the bezel screws uniformly until the bezel contacts the case and then turn each screw another half tum to insure a watertight seal (do not over-tighten screws). Note: When substituting or replacing a bezel assembly, be certain that it is done with the same model using the same Output Modules. Damage to the controller may result if the unit's output modules are not the same. A NEMA 4X/IP65 and a standard bezel assembly are NOT interchangeable. -9- BEZEL LATCH Y й E Г A у 4 Г) 7 Г, , Ú 7) A Г A CASE 7 A Й Й И STANDARD UNIT ONLY. Й Y, i 2227) > 7 7 L77 2722727777 75 EXISTING PANEL Output Modules The main control, optional alarm, and optional secondary output sockets must be fitted with the appropriate output module. Output modules are shipped separately and must be installed by the user. Output Variations Without RS-485 Option The Dual Alarm or the Secondary with Alarm output, without the RS-485 option, has independent outputs. Therefore, the secondary output and/or alarm output(s) can be installed with any combination of output modules. DUAL ALARM OR SECONDARY W/ALARM OPTION OUTPUT MODULES WITHOUT RS-485 OPTION A eur || | B— 1 sao z4ovac | ALARM Z OR | AL2/0P2-A 10 с Le (RESISTIVE LOAD) SECONDARY | AL2/0P2-8 20 | | OUTPUT 2 | A —[* y LOGIC/SSR DRIVE | OPTION AL2/0P2-C 30 T7 soon и | B —; «мос | “E | © — 90 nor connect ARD || —— A N/C M3 LA TRAC |! 1A © 240VAC AL1-A Ti 40 Ш — ay (1SOLATED) || ALARM 1 AL1-8 M1150 | с-—| ро кот соммест |! OPTION L - | AL1-C MsQ ———— == -10- Output Variations With RS-485 Option The Dual Alarm or the Secondary with Alarm output, with RS-485 option, does not have independent outputs. In this case, the secondary output and/or alarm output(s) must have the same type of output modules installed since they share the common terminal. мен те ны ны с | ныне = DUAL ALARM OR OUTPUT MODULES SECONDARY W/ALARM OPTION _ 1,99 | WITH RS—485 OPTION | | | RELAY | B — SA 9 Z40VAC NDA —— | | ALARM 1 AND LARM 2 AL/OP2 COMM.—A Ti | (RESISTIVE LOAD) | ALARM | WITH AL2/0?P2-8 (MTY SECONDARY OUTPUT 2 _ [ A —T*3, LOGIC/SSR DRIVE || OPTION L— AL1-B (| =V som | B Tc + 120€ | | пла тва | TX/RXC+) Г a TS | RS—485 TX/RX(—) UN] Po] 14 9 Z40vAC || OPTION TX EN. B (ISOLATED) | | RS-485 COMM. 1} _ 1 Installing Output Modules To install an output module into the controller, remove the bezel assembly from the case (see Removing Bezel Assembly). Locate the correct output module socket (OP1, ALI, or AL2/OP2, see hardware figure or label outside of case) and plug the output module into the socket. No re-programming is required. If changing an output module type, be sure the appropriate output interface wiring changes are made. Re-install the bezel assembly when complete. OUTPUT MODULE "OUTPUT ON" STATE Relay Normally open contact is dosed. Logic/SSR Drive Source is active, Triac Solid state switch is dosed. Typical Connections RELAY MODULE — — — — = ТА | 5 AMPS 8 POWER эм о 240VAC — С | Relay: Type: Form-C Rating: SAmps @ 120/240VAC or 28VDC (resistive load), 1/8 HP @ 120VAC (inductive load). Life Expectancy: 100,000 cycles at maximum load rating. LOGIC /SSR DRIVE MODULE | UNREG. 51094 SSR 1 — NN NOT A: POWER POWER | ISOLATED 3 UNT 2 > 500n | e | DO NOT convecr — | LOAD | _ Logic/SSR Drive: Type: Non-isolated switched DC, 12VDC typ. (internal 5009 resistance). Drive: 10mA max. (400ohm external load). Drives up to three SSR Power Units. Protection: Short-circuit protected. 120VAC TRIAC MODULE i d— — — | Г | ISOLATED 1 AMP RELAY OR HN TRIAC POWER AT DEVICE | 120/240vAC Po NOT connecT— —o LOAD Triac: Type: Isolated, Zero Crossing Detection. Rating: Voltage: 120/240VAC. Max. Load Current: 1Amp @ 35°C 0.75Amp @ 50°C Min. Load Current; 10mA Off State Leakage Current: 7TmA max. Operating Frequency: 20 to 500Hz. Protection: Internal Transient Snubber, Fused. LOGIC/SSR DRIVE MODULE RELAY MODULE -11- Select AC Power (115/230VAC) The AC power to the unit must be selected for either 115V AC or 230VAC. The selector switch is located inside the case near the rear of the unit on the main circuit board (see hardware figure and/or label on inside or outside of case). The unit 1s shipped from the factory with the switch in the 230V AC position. Note: Damage to the controller may occur if the AC selector switch is set incorrectly. HARDWARE FIGURE OPTIONAL ALARM 2 (ALZ) o SECONDARY QUTPUT (072) MODULE MAIN CONTROL OUTPUT MODULE OP 1 VAC POWER SELECTION SWITCH UP — T1EVAC ON — 230VAC DP TIONAL ALARM 1 OUTPUT MODULE AL1 -12- Wiring Connections After the unit has been mechanically mounted, it is ready to be wired. All wiring connections are made on a fixed terminal block. When wiring the unit, use the numbers on the label to identify the position number with the proper function. Strip the wire leaving approximately 1/4"(6mm) bare wire exposed (stranded wires should be tinned with solder). Insert the wire into the terminal and tighten the screw until the wire is clamped in tightly. Each terminal can accept up to two, 18-gauge wires. Wire each terminal block in this manner. Signal Wiring To minimize the chance of coupling noise into the signal wires, which could cause poor controller performance, certain guidelines for signal wire routing must be followed. A) Never run signal wires in the same conduit or raceway with conductors feeding motors, solenoid, SCR power units, heaters, compressors, relays, etc. Ideally, signal wires should be run in a separate conduit. B) When shielded wire 1s used, connect the shield to COMM (terminal #10) of the controller and leave the other end of the shield unconnected and insulated from machine ground. C) Longer runs stand an increased chance for noise pick-up. Plan the installation to minimize distances. D) Keep wires separated within electrical enclosures to further minimize noise pick-up. User Input Wiring The programmed User Input function is performed when terminal #7 is used in conjunction with common (terminal #10). Any form of mechanical switch may be connected to terminal #7. Sinking open collector logic with less than .7V saturation may also be used (no pull-up resistance is necessary). Note: Do not tie the commons of multiple units to a single switch. Use either a multiple pole switch for ganged operation or a single switch for each unit. 4-20mA Connection AC Power Wiring N | Primary AC power is connected to the separate two position terminal N AC POWER block labeled AC. To reduce the chance of noise spikes entering the AC - 115 or 230VAC line and affecting the controller, a separate AC feed should be used to power SWITCH SELECTABLE the controller. Be certain that the AC power to the controller is relatively (INTERNALLY) "clean" and within the -15%, +10% variation limit. Connecting power from heavily loaded circuits or circuits that also power loads that cycle on and off, (contacts, relays, motors, etc.) should be avoided. SIGNAL SOURCE 0-10VDC Connection | a AC POWER - 115 or 23@VAC SWITCH SELECTABLE (INTERNALLY) v SIGNAL SOURCE -13- FRONT PANEL DESCRIPTION The front panel bezel material is flame and scratch resistant tinted plastic. Available is an optional NEMA 4X/IP65 version which has a bezel that meets NEMA 4X/IP65 requirements, when properly installed. There are two 4-digit LED displays, a red upper Main Display and a lower green Secondary Display. There are up to six annunciators depending on options installed, with red backlighting, which illuminate to inform the operator of the controller and output status. Four front panel buttons are used to access different modes and parameters. The following is a description of each button. Button Functions DSP - In the normal operating mode, the Display (DSP) button is used to select one of the four parameters in the secondary display or the display can be programmed to be blank. In the Configuration Parameter Modes, pressing this button causes the unit to exit (escape) to the normal operating mode with NO changes made to the selected parameter. UP, DN - In the normal operating mode, the up/dn buttons can be used to modify the setpoint value, % output power (manual mode only), the profile status, or the profile phase time SECONDARY DISPLAY- DISPLAYS ONE OF FIVE POSSIBLE PARAMETERS. ALSO DISPLAYS MNEMONIC OR NUMERIC VALUE WHEN MODIFYING A PARAMETER. ILLUMINATES WHEN SECONDARY DISPLAY SHOWS X OUTPUT POWER, — — ILLUMINATES WHEN SECONDARY DISPLAY SHOWS PROFILE STATUS OR PROFILE PHASE TIME REMAINING BEZEL SECURING SCREWS (2 (NEMA 4X/IP65 MODEL ONLY \!60 7. (ОР2) Ее (PAR) (Y) © P IH? ZPW MAN ALT РСМ OP1 AL2 О a N Г BEZEL RELEASE LATCH (STANDARD MODEL ONLY) MAIN DISPLAY— DISPLAYS SCALED PROCESS UNITS. ALSO DISPLAYS MNEMONIC OF SELECTED PARAMETER IN A CONFIGURATION MODULE. DECIMAL POINT FLASHES WHEN: AUTO SETPOINT RAMPING IS ACTIVE О A PROFILE IS RUNNING AND IN THE DELAY MODE. FLASHES WHEN UNIT {5 IN MANUAL MODE, ILLUMINATES WHEN OPTIONAL ALARM 1 IS "ON. ILLUMINATES WHEN OPTIONAL ALARM 2 |S "ON" OR WHEN OPTIONAL SECONDARY OUTPUT IS "ON". ILLUMINATES WHEN MAIN CONTROL QUTRUT IS "ON". remaining, when viewed in the secondary display. The variables for each parameter are selected using the up/dn buttons. In the Hidden Mode, the up/dn buttons can be used to reset alarm{s), event output(s), select auto or manual operation, invoke or cancel auto-tune, load a control point, or -14- change the status of a running profile. PAR - The Parameter (PAR) button is used to access, enter, and scroll through the available parameters in any mode. OPERATION OVERVIEW Controller Power-up Upon applying power, the controller delays control action and scaled process indication for five seconds to perform several self-diagnostic tests and displays basic controller information. Initially, the controller illuminates both displays and all annunciators to verify that all display elements are functioning. Following, the controller displays the programmed input type in the Main display. Concurrently, it displays the current revision number of the operating system software in the bottom display. The controller checks for correct internal operation and displays an error message (E-XX) if an internal fault is detected (see Troubleshooting). A profile can be programmed to Start (run mode), Stop (off mode), or Resume on power-up (see "Profile Power Cycle Status Parameter” section). Upon completion of this sequence, the controller begins control action by displaying the process value and updating the outputs based upon the PID control value. Controller Power Down At power down, the steady state control value as well as all parameters and control modes are saved, to provide a quick and predictable process response on the next power-up. When powering down the process, it is important to power down the controller at the same time. This prevents the reset action of the controller from shifting the proportional band while the process signal is dropping, which prevents excessive overshoot on the next process start-up. Process Start-up After starting the process, the controller's PID settings must be initially "tuned" to the process for optimum control. Tuning consists of adjusting the Proportional Band, Integral Time, and Derivative Time parameters to achieve the optimum response to a process disturbance. Once the controller is tuned, it may need to be re-tuned if the process has been changed significantly. Several options exist for tuning these parameters: A) Use the controller’s built-in Auto-Tune feature (see Auto-Tune). B) Use a manual tuning technique (see manual tuning). -15- C) Use a third party tuning software package (generally expensive and not always precise). D) Use values based on control loop experience or values from a similar process. If the controller is a replacement, the PID settings from the unit replaced may be used as good initial values. Be sure to consider any differences in the units and the PID settings when replacing. The PID settings may be fine tuned by using the techniques outlined in the PID Control section. After tuning the controller to the process, it is important to power the load and the controller at the same time for best start-up response. Manual (user) & Automatic Operation The controller can be transfered between Automatic control (closed loop; PID or ON/OFF control) and Manual control (open loop). Placing the controller in the Manual Mode does not impede the advancement or operation of a running profile. In the Hidden Function Mode, the "trnf" parameter allows the operator to select the desired operating mode. To allow front panel switching between control modes, program the transfer (trnf) parameter to 'Enbl” in the Lockout module. The User Input or RS-485 serial interface option may also be used to perform the auto/manual transfer function, independent of the setting in the Lockout module. Manual operation provides direct control of the output(s) from 0 to +100%, or -100% to +100% if secondary output is installed. The MAN (manual) annunciator flashes to indicate that the unit is in manual operation. In the Manual Mode, the output power can be adjusted using the front panel arrow buttons when % output power is viewed in the lower display. If the % output power is locked or read only, then the output power can be adjusted in the unprotected parameter mode when OP is viewed. With the serial option, the % output power can be modified independent of what is viewed in the display as long as the unit is in the manual mode. When transferring the controller mode from/to automatic, the control power output(s) remain constant, exercising true "bumpless” transfer. When transferring from manual to automatic, the power initially remains steady but integral action will correct (if necessary) the closed loop power demand at a rate proportional to the Integral Time. The programmable high and low power limit values are ignored when the unit is in manual operation. Profile Operating Modes Run Mode The controller is in the Run Mode when a profile is executing. While in the Run Mode, the profile can be stopped (Off Mode), paused (Pause Mode) or advanced to the next phase. A profile is started and placed into the Run Mode either manually or automatically when the controller is powered-up. The advancement of the profile can be viewed in the secondary display. Off Mode The Off Mode signifies that all profiles are dormant. The Off Mode is achieved by manually terminating a profile in progress or by allowing a profile to run to completion. When a profile ends or is terminated, the active setpoint is the last hold setpoint value. A profile terminated during a ramp or hold phase results in the active setpoint value to be the setpoint value at the instant of termination. -16- Pause Mode The Pause Mode signifies that a profile is active but the time base is stopped. The pause mode is caused only by a manual action. Pausing a profile during a ramp phase stops the ramp and the controller maintains the setpoint value at the instant of the pause action. During hold phases, the timing of the hold phase is stopped. The use of pause mode effectively lengthens the total run time of a profile. Pause mode is indicated by "PAUS" flashing in the profile control status display. A profile can be placed in the pause mode via the front panel buttons, the user input, or the serial communications option. The unit remains in the pause mode until a continue operation is performed. The continue operation places the profile into the run mode. PROCESS A PROFILE PAUSE MODE PROFILE PAUSED PROFILE PAUSED | | | | | | | | | | | | | | | | | | | | | PAUSE | un | CONTROL | ; MODE OFF RUN | | PAUSE RUN 4 â A A á B TIME PROFILE PAUSE PAUSE PAUSE PAUSE STARTEO STARTED RELEASED STARTED RELEASED Delay Mode The Delay Mode signifies that a profile is active but the time base, or profile advancement is stopped. This 1$ caused by automatic action of the controller when the scaled process signal deviates more than a specified amount from the profile setpoint. The Delay Mode is similar to the pause mode, except the delay mode is invoked automatically by the controller. The Profile Deviation Error Band programmed for a positive value, allows the Delay Mode to be invoked only during hold phases. A negative value allows the delay mode to be invoked during “both” ramp and hold phases. The profile automatically resumes when the process value is within the prescribed error band value. The Delay Mode is indicated by "dELy” flashing in the profile control status display and by a flashing decimal point in the upper main display. The Delay Mode can be terminated manually by changing the deviation error band value to a larger value or to zero for off. The new error band value takes effect immediately. PROCESS PROFILE DELAY MODE A PROCESS SIGNAL \ ERROR BAND PROFILE ONG TT I | | | | | 0° | | | | PROFILE | DELAY RAMP 1 DELAY HOLD 1 STATUS OFF RAMP 1 MODE RESUMES ~~ HOLD 1 MODE | RESUMES A ‘ > TIME START OPERATION -17- Controlling A Profile Profile Start Operation A profile always starts at the first ramp phase and the setpoint value ramps from the current process value. The profile can be programmed to ramp from a known setpoint value (see Ramp Phase section). Link-started profiles use the last target setpoint level as the starting point. A profile is started from the off mode, which places the controller into the run mode. To re-start a running profile from the beginning, it is necessary to first stop the profile. Start Operation From The Profile Control Status Display 1. Verify the profile control status display (P-CS) is enabled in lockout programming. . Profile must be in the off mode (no profiles running). . Press and hold "up" button for three seconds until "Pr-1" appears. - Select the desired profile by using the "up/down" buttons. . Press the "PAR" button to start the selected profile. The unit displays “Sut” in the secondary display and starts the profile. If the "PAR" button is not pressed within five seconds, no action is taken. Start Operation From The Hidden Mode 1. Verify profile access (PrAC) in the hidden mode is enabled in lockout programming. 2. Profile must be in the off mode (no profiles running). 3. Press and hold the "PAR" button for three seconds to enter the hidden mode. . Scroll to "Prun" (if necessary) by pressing the "PAR" button. . When "Prun" is displayed, use the "up/down" buttons to select the desired profile (Pr-1, Pr-2, Pr-3, or Pr-4). 6. Press the "PAR" bution to start the selected profile. The unit displays “End” in the secondary display and starts the profile. If a selection is not made within ten seconds, no action is taken. LA Ba D LA + -18- Start Operation Using The User Input The user input can only start profile #1. User Input Selected For Run/Stop (P1rS): A low to high transition at terminal # 7 always starts profile 1. User Input Selected For Run/Pause (P1rH): A low to high transition at terminal # 7 starts profile 1, if no profiles are in the pause mode. Note: Refer to input module 1, user input section, for more details. Start Operation On Power-Up If power is interrupted or removed from the unit, the profile can be programmed to automatically start when power is restored. In the Setpoint Profiles Module (8-Pr), a profile can be programmed to automatically re-start on power-up. The "Strt” option must be selected for each profile (see power cycle status parameter for details). Start Operation Via The RS-485 Serial Option Any profile can be started via the serial communications option. Transmit the unit address, command letter with the value identifier and the desired profile number via the serial port (see serial communication section for details). Shown below is a typical command string. Start profile 2 of PSC unit 6. N6CU2* Profile Stop Operation Stopping a profile places the controller into the off mode. When a profile is stopped, the active setpoint value is the old profile seipoint value. Stop Operation From The Profile Control Status Display 1. Verify the profile control status display (P-CS) is enabled in lockout programming. 2. Press and hold the "up/down" buttons simultaneously for three seconds. 3. "OFF" appears in the secondary display and the profile is placed in the off mode. Stop Operation From The Hidden Mode 1. Verify profile access (PrAC) in the hidden mode is enabled in lockout programming. 2. Press and hold the “PAR” button for three seconds to enter the hidden mode. 3. Scroll to "Prun” (if necessary) by pressing the "PAR" button, 4. When "Prun” is displayed, use the "up/down" buttons to select stop (OFF). 5. Press the "PAR" button to stop the profile. The unit displays "End" in the secondary display and stops the profile. If a selection is not made within ten seconds, no action is taken. Stop Operation On Power-Up If power is interrupted or removed to the unit, the profile can be programmed to automatically stop when power is restored. In the Setpoint Profiles Module (8-Pr), each profile must be selected for the "Stop" option (see power cycle status parameter for details). Stop Operation Via The RS-485 Serial Option A running profile can be stopped via the serial communications option. Transmit the unit address, command letter, with the value identifier and number via the serial port (see serial communication section for details). Shown below is a typical command string. Stop the currently running profile of PSC unit 6. N6CU5* Profile Advance Operation Advancing a profile ends the currently active phase and begins the next phase of the profile. The total run time of the profile is shortened by using the advance operation. Profiles in the pause mode must have a continue operation performed before an advance operation. The profile can be advanced from the delay mode. PROFILE ADVANCE FUNCTION PROCESS A Ру — > | | | PROFILE | STATUS OFF | RAMP | HOLD RAMP HOLD N à A A —> TIME START ADVANCE ADVANCE OPERATION OPERATION OPERATION ENDS ENDS RAMP PHASE HOLD PHASE Advance Operation From The Profile Control Status Display 1. Verify the profile control status display (P-CS) is enabled in lockout programming. 2. Press and hold the “up” button for three seconds. 3. "Adnc” appears in the secondary display and the profile advances to the next phase. Advance Operation From The Hidden Mode 1. Verify profile access (PrAC) in the hidden mode is enabled in lockout programming. 2. Press and hold the "PAR" button for three seconds to enter the hidden mode. 3. Scroll to "Prun” (if necessary) by pressing the "PAR" button. 4. When "Prun” is displayed, use the "up/down" buttons to select advance (Adnc). 5. Press the "PAR” button to advance the profile to the next phase. 6. The unit displays “End” in the secondary display and the profile advances 10 the next phase. If a selection is not made within ten seconds, no action is taken. Advance Operation Via The RS-485 Serial Option A running profile can be advaced to the next phase via the serial communications option. Transmit the unit address, command letter, the value identifier and number via the serial port (see serial communication section for details). Shown below is a typical command string. Advance the currently running profile of PSC unit 6 to the next phase. N6CU8* Profile Pause Operation The pause mode freezes the state of the profile. The controller maintains the setpoint value at the instant the profile is placed into the pause mode. The profile must have a continue operation performed to resume the profile operation. Pause Operation From The Profile Control Status Display 1. Verify the profile control status display (P-CS) is enabled in lockout programming. 2. Press and hold the “down” button for three seconds. 3. "PAUS” appears in the secondary display and the profile is placed in the pause mode. Pause Operation From The Hidden Mode 1. Verify profile access (PrAC) in the hidden mode is cnabled in lockout programming. 2. Press and hold the mode. “PAR” button for three seconds to enter the hidden -20- 3. Scroll to "Prun" (if necessary) by pressing the "PAR" button. 4. When "Prun" is displayed, use the "up/down" buttons to select pause (PAUS). 5. Press the "PAR" button to pause the profile. 6. The unit displays "End" in the secondary display and the profile is paused. If a selection is not made within ten seconds, no action is taken. Pause Operation Using The User Input The user input can pause a running profile. User Input Selected For Run/Pause (P1rH): A low level at terminal # 7 pauses a profile that is running. Note: Refer to input module 1, user input section, for more details. Pause Operation Via The RS-485 Serial Option A profile can be paused via the serial communications option. Transmit the unit address, command letter, with the value identifier and number via the serial port (see serial communication section for details). Shown below is a typical command string. Pause the currently running profile of PSC unit 6. N6CU6* Profile Continue Operation The continue operation resumes operation of a profile that is in the pause mode. The continue operation places the profile back into the run mode. The profile resumes normal execution from the point where it was paused. Continue Operation From The Profile Control Status Display 1. Verify the profile control status display (P-CS) is enabled in lockout programming. 2. Profile must be in the pause mode. 3. Press and hold the "up" button for three seconds. 4. "Cont" appears in the secondary display and the profile is placed into the run mode. Continue Operation From The Hidden Mode 1. Verify profile access (PrAC) in the hidden mode is enabled in lockout programming. 2. Unit must be in the pause mode. 3. Press and hold the "PAR" button for three seconds to enter the hidden mode. 4. Scroll to "Prun” (if necessary) by pressing the "PAR" button. 5. When "Prun” is displayed, use the "up/down" buttons to select continue (Cont). 6. Press the "PAR" button to continue the profile. 7. The unit displays "End" in the secondary display and the profile resumes to run. If a selection is not made within ten seconds, no action is taken. Continue Operation Using The User Input The user input can continue a paused profile. User Input Selected For Run/Pause (P1rH): A high level continues the profile. Note: Refer to input module 1, user input section, for more details. Continue Operation Via The RS-485 Serial Option A paused profile can be continued via the serial communications option. Transmit the unit address, command letter, with the value identifier and number via the serial port (see serial communication section, for details). Shown below is a typical command string. Continue profile 2 of PSC unit 6. N6CU7* -21- Reset Event Outputs Operation The Timed Event Output(s) may be manually reset to the "Off" state at any time during profile execution. Once reset, the outputs remain reset until the profile advances to the next phase and updates the event output states. Reset Timed Event Output(s) From The Hidden Mode 1. Verify alarm access (AL1S) in the hidden mode is enabled in lockout programming. 2. Press and hold the "PAR" button for three seconds to enter the hidden mode. 3. Scroll to "ALrS" (if necessary) by pressing the "PAR" button. 4. Press the "up" button to reset event output 1. Press the "down" button to reset event output 2. An event output remains reset during phase transitions if the buttons are held. 5. The "up" or "down" button must be pressed within ten seconds to reset an event output. If an output is not reset within ten seconds, no action is taken. Reset A Timed Event Output Using The User Input The user input can reset the timed event outputs. Note: The reset operation via the user input resets "Both" AL] and AL2, independent of their operation as an alarm or event output. User Input Selected For Alarm Reset (ALrs): À low level resets the timed event outputs. As long as the input is held low, the output(s) remain reset. Note: Refer to input module 1, user input section, for more details. Reset A Timed Event Output Via RS-485 Serial Option A timed event output can be reset via the serial communications option. Transmit the unit address, command letter, with the value identifier via the serial port (see serial communication section, for details). Shown below is a typical command string. Reset timed event output 2 of PSC unit 6. N6RH* Configuration Of Parameters As supplied from the factory, the controller parameters have been programmed to the values listed in the Quick Reference Tables. The user must modify the values, if necessary, to suit the application. Operation and configuration of the controller is divided into five distinct operational/programming modes to simplify the operation of the controller: Normal Display Mode, Unprotected Parameter Mode, Protected Parameter Mode, Hidden Function Mode, and Configuration Parameter Modules. HIDDEN FUNCTION MODE x LOAD CONTROL POINT CONTROL PROFILE INVOKE /CANCEL AUTO- TUNE TRANSFER OPERATION AUTO/USER RESET ALARM/TIMED OUTPUT(S) pa PAR ACTIVE) (PROGRAM DISABLE PROTECTED PARAMETER MODE * PROPORTIONAL BAND INTEGRAL TIME DERIVATIVE TIME ALARM 1 ALARM 2 ENTER CODE NUMBER * PAR UNPROTECTED PARAMETER MODE PRESS de HOLD * PAR ) BUTTON — SETPOINT x PAR — OUTPUT POWER OFFSET — X OUTPUT POWER FOR J SECS — PROPORTIONAL BAND — INTEGRAL TIME (PROGRAM DISABLE — DERIVATIVE TIME INACTIVE) — ALARM | — ALARM 2 DSP NORMAL DISPLAY MODE ACCESS TO MAIN DISPLAY INDICATES : NO CONFIGURATION MODULES SCALED PROCESS VALUE SECONDARY DISPLAY Ж YES PAR INDICATES ONE OF THE FOLLOWING : SETPOINT CONFIGURATION PARAMETER MODULES PROFILE STATUS. — INPUT MODULE PHASE TIME REMAINING - OUTPUT MODULE BLANK DISPLAY — LOCKOUT MODULE — ALARM MODULE * — SECONDARY MODULE * — SERIAL COMMUNICATIONS MODULE * INVALID CODE # — CONTROL POINTS MODULE — PROFILES MODULE — FACTORY SERVICE OPERATIONS MODULE VALID CODE 4 * These parameters may not appear due to unit configuration or programming set-ups. Note: In any mode or module, DSP returns the controller to the normal display mode. -22- Parameter Entry The PAR button is used to select the desired parameter. To modify the parameter setting, use the UP and DOWN buttons, and then press PAR to enter the new value. The controller will progress to the next parameter. In a Configuration Parameter Module, pressing the DSP button causes the new value to be rejected, the controller displays "End", and returns to the Normal Display Mode. For those parameters outside the Configuration Parameter Modules, the new value takes effect and is committed into controller memory WHILE the value is keyed in. The following is a list of these commonly modified parameters: Setpoint Output Power Output Power Offset Proportional Band Integral Time Denvative Time Alarm 1 Value Alarm 2 Value Note: While in a Configuration Parameter Module, all new parameters are rejected and the old ones recalled if power is lost to the controller. If power is removed while modifying ANY parameter, be certain to check the parameter for the proper value. Normal Display Mode In the normal display mode, the scaled process value is always displayed in the main display. By successively pressing the DSP button, one of five parameters can be viewed in the secondary display: Setpoint % Output Power Profile Control Status Profile Phase Time Remaining Blank Each of these displays can be independently locked out from appearing or from being modified by the user (see parameter lockout section). -23- Modifying A Secondary Display Parameter From The Front Panel The controller must be in the normal display mode to modify any of the secondary display parameters. Four parameters can be modified when viewed in the secondary display (if not locked). The display may be programmed to be blank. Pressing the DSP button scrolls through the secondary display parameters. The following describes how these parameters can be modified when viewed in secondary display. Setpoint Value Display Use the up and down arrow buttons to modify the setpoint value when viewed (if not locked). If locked, the setpoint can be changed in the unprotected or protected mode when "SP" is viewed, independent of viewing in the secondary display. The setpoint value is constrained to the programmable setpoint limit values (SPLO & SPHI, input module 1). The profile setpoint value can be changed during profile operation to effect immediate changes to the profile. If locked, the target setpoint value can be changed when viewed in the protected mode. Permanent changes to the profile setpoint value must be done in the profiles module (8-Pr). Changing the setpoint value may cause the profile to enter the delay mode if the errror band parameter is enabled. The ramping setpoint value is displayed during ramp phases. Immediate changes made to the ramping setpoint value do not alter the ramp rate, but does change the ramp time remaining to the next target setpoint level. This action either lengthens or shortens the total time remaining. The phase time remaining is efiected the instant the setpoint value is changed. The holding setpoint value is displayed during hold phases. A change to the holding setpoint value causes the controller to immediately operate at the new setpoint level. In addition, the next ramp phase begins ramping from the modified setpoint value to the target setpoint value. % Output Power Display The % output power can only be changed when the unit is in the manual mode. The annunciator % PW lights when viewed, then use the up and down arrow buttons to modify the % output power (if not locked). If locked, the % output power can be changed in the unprotected or protected mode when “OP” 1s viewed, independent of viewing in the secondary display. The % output power is not constrained to the programmable output power limit values (OPLO & OPHI, output module 2). Profile Control Status Display The annunciator PGM lights when either the profile control status or the phase time remaining 1s displayed. The profile control status indicates the current mode of a profile. The table shows various displays for profile modes. Profile Status Description — Display OFF Profile is off. No profiles running. Piri Profile #1 is running and in ramp phase #1. P2H8 Profile #2 is running and in hold phase #8. P3r4 Profile #3 is running and in ramp phase #4. PAUS Profile is Paused (PAUS flashes). Currently running profile is in the pause mode. dELy Profile is Delayed (dELy flashes). Currently running profile is in the delay mode. The front panel buttons allow the operator to change the profile status. The operation of a profile is controlled directly from the profile control status display, if not locked (see controlling a profile section for details). -24- Profile Phase Time Remaining Display The annunciator PGM lights when either the phase time remaining or the profile control status is viewed. Use the up/down front panel buttons to change the time remaining, if not locked. The ramp or hold phase time remaining can be changed during profile operation to effect immediate changes to the profile. Permanent changes to the profile must be done in the profiles module (8-Pr). During ramp phases the display indicates the time remaining until the next hold phase. If the time remaining is changed during a ramp phase, the controller calculates a new, but temporary, ramp rate. The setpoint ramps at the new ramp rate value to the next setpoint level. The new ramp rate may be at a faster or slower rate depending on the direction that the time remaining was changed. Changing the time remaining value to zero causes an immediate advance to the next hold phase, unless the profile is in the pause mode. In this case, when the profile is placed back into the run mode, the profile immediately advances to the next hold phase. During hold phases the display indicates time remaining until the next ramp phase. Changes to the time remaining during a hold phase effect the duration of the hold phase. A value of zero causes the profile to advance to the next ramp phase unless the profile is in the pause mode. Changing the time remaining effects the total run time of the profile. When the profile 1s in the off mode, "0.0" minutes is displayed in the phase time remaining display. UNPROTECTED PARAMETER MODE The Unprotected Parameter Mode is accessed by pressing the PAR button from the normal display mode with program disable inactive. In this mode, the operator has access to the list of the most commonly modified controller parameters. At the end of the list, a configuration "access point” allows the operator to enter the configuration parameter modules. These modules allow access to the fundamental set-up parameters of the controller. When the program list has been scrolled through, the controller displays "End" and returns to the normal display mode. The unit automatically returns to the normal display mode if a button is not pressed within eight seconds. Unprotected Parameter Mode Reference Table Display Parameter Range and Units Description (F SP Setpoint Must be within range of mits Appears only i setpoint value is locked SPLO, SPHI (LOC) or read only (rEd). During a profile (0) ramp phase, indicates the target setpoint value, OPOF YOutput -99.9% to 100.0% Appears only if integral time (Intt) = 0 Р (0.0) Bi i OP Output -99.9% to 100.0% Appears only if controller is in user Power (0.0) (manual) mode and % output power s locked (LOC) or read only (rEd). This parameter is not limited to ProP Proportional 0.0 to 999.9% of selected 0.0% is ON/OFF control. If = 0.0%, Band input range set control hysteresis appropriately. (4,0) Intt Integral 0 to 9999 sec. 0 &s off. This parameter does not appear Time (120) if proportional band = 0,0%, dErt Dervative 0 to 9999 sec. 0 is off. This parameter does not appear Time (30) if proportional band = 0.0%, AL-1 Alarm 1 -999 to 9999 This parameter does not appear i the Vale (0) alarm option is not installed or is oo AL-2 Alarm2 -999 to 9999 This parameter does not appear if the Value (0) alarm option is not installed or is configur- ed as a timed event output. Also does not я | ion is installed CNFP Configuration NO Return to normal display mode. Access YES Enter Configuration modules. Point 1-iN Configure input parameters. 2-OP Configure output parameters. ЗС Configure parameter lockouts. 4-AL Configure alarms (optional) 5-02 Configure secondary output (optional) 6-SC Configure serial communications (optional) 7-CP Configure control points 8-PR Configure profiles 9-FS Factory service operations (Qualified technicians only) End Unit returns to — Brief display message. normal display mode. -25- PROTECTED PARAMETER MODE The Protected Parameter Mode is accessed from the normal display mode by pressing the PAR button with program disable active. In this mode, the operator has access to the list of the most commonly modified controller parameters that have been "unlocked" in the configuration parameter lockouts module. Depending on the code number entered in the lockout module, access to the unprotected parameter mode and hence, the configuration parameter modules, is possible. The controller returns to the normal display mode if the unprotected mode and configuration modules cannot be accessed. Protected Parameter Mode Reference Table Display Parameter Range and Units Description/ (Factory Setting Value) | ts ProP Proportional 0.0 to 999.9% 0.0% is ON/OFF control. If = 0.0%, set Band of selected input range control hysteresis appropriately. This (4.0) parameter does not appear if locked (LOC) Intt integral Time D to 9999 sec. 0 is off. This parameter does not appear (120) if proportional band = 0.0% or locked (OC). dErt Derivatve Time 0 to 9999 sec. 0 is off. This parameter does not appear (30) if proportional band = 0.0% or locked (LOC). AL-1 Alarm 1 value -999 to 9999 This parameter does not appear if the (0) alarm option is not installed, locked (LOC), aor configured as atimed event output, | AL-2 Alarm 2 value -999 to 9999 This parameter does not appear ff the (0) alarm option is not installed, the secondary option is installed, lodked (LOC), or co Code Access codeto Oto 250 To gain acoess to unprotected mode, unprotected (0) enter the same value for Code as entered mode in parameter lockouts. This parameter does not appear À zero is entered in code parameter lockout End Unt returns to Brief display message display mode normal display mode -26- Front Panel Program Disable There are several ways to limit operator access to the programming of parameters from the front panel buttons. The settings of the parameters in the parameter lockout module, the code number entered, and the state and/or function of the user input (terminal #7) affect front panel access. The following chart describes the possible program disable settings. User Input Code Programmed Number Description For PLOC Inactive 0 Full aces Active 0 Access to protected parameter mode only. Code number will NOT appear Active Any # Access to protected parameter mode. Corred pro- between grammed code number allows access to unprotect- 18250 ed parameter mode | i NOT programmed 0 Full access to all modes and parameter modules. or FLOG NOT programmed Any # Access to protected parameter mode. Correct pro- for PLOC between grammed code number alows access to unprotect- 1 & 250 ed parameter mode and configuration modules. Note: A universal code number 222 can be entered to gain access to the unprotected mode and configuration modules, independent of the programmed code number. -27- HIDDEN FUNCTION MODE The Hidden Function Mode is only accessible from the normal display mode by pressing and holding the PAR button for three seconds. In this mode, five controller functions can be performed. Automatic/Manual Transfer Initiate/Cance! Auto-tune Reset Alarm/Timed Event Output(s) Load Control Point Contro! Profile Status Each function may be “locked out” in the configuration parameter lockouts module. The PAR button 1s used to scroll to the desired function and the up and down buttons are used to select the operation. Pressing the PAR button while the function is displayed executes the function and returns the unit to the normal display mode. Pressing the DSP button exits this mode with no action taken. The unit automatically returns to the normal display mode if a function is not executed in eight seconds. Hidden Function Mode Reference Table Display Parameter Range and Units Description/Comments (Factory Setting Value) CP Load Control NO This step does not appear if locked (LOC). Point ср-1 Exits to normal display mode if executed. ср-2 Select control point to load the press cp-3 PAR to implement. cp-4 (NO) _ PruN Control Pr-1 This step does not appear if locked (LOC), profile Pr-2 or profile is running. status Pr-3 Exits to normal display mode if executed. Pr-4 Select profile to start, then press PAR OFF) button, Adnc This step does not appear § locked (LOC), Cont or profile is in OFF mode, PAUS If profile is running, select control mode, OFF then press PAR button. (Cont) trnF Transfer mode — | Auto - Automatic control This step does not appear Y locked (LOC). of operation User - Manual control Exits to normal display mode if executed. {Auto} tUNE Auto-Tune YES/NO Yes: starts /restarts auto-tune sequence. invocation (NO) No: terminates auto-tune sequence. This step does not appear E locked (LOC) or exits to normal display mode if executed, ALrS Heset alarrry UP key resets Alarm 1/event This step does not appear if alarm option timed event output 1 not installed, € locked (LOC) or previous output(s) DOWN key resets Alarm 2/event step performed. output 2 -28- CONFIGURATION PARAMETER MODULES Accessible from the unprotected parameter mode, the configuration parameter modules allow the operator access to the controller's fundamental set-up parameters. There are nine possible configuration stages that can be accessed. Atthe configuration stage access point "CNFP", the operator uses the UP & DOWN arrow buttons to select the desired configuration parameter module. Press the PAR button to enter the module where the settings can be viewed or modified. The PAR button is used to scroll through the parameters and the UP and DOWN buttons are used to modify the parameter value. The PAR button enters the desired choice, advancing to the next parameter. The operator can press the DSP button to exit (escape) without modifying the parameter, which returns the unit to the normal display mode. After the parameters in a module are viewed or modified, the unit returns to the configuration access point, allowing access to other modules. Input Module (1- IN) The controller has several input set-up parameters which must be programmed prior to setting any other controller parameters. Input Type (type) Select the signal input type Voltage (VOLT), or Current (CURR). The appropriate signal input terminal for voltage is #8 and for current is #9. Decimal Point Position (dCPt) Select the desired decimal point position for the scaled display. The selected decimal point position appears in the following parameters; setpoint md, dSP1, dSP2, SPLO, SPHI, SP, AL1, AL2,db-2, AHYS, CHYS, control point module, and profile module. 0 0.0 0.00 0.000 -29- Rounding Increment (rnd) Rounding values other than "1" causes the scaled number to ‘round’ to the nearest rounding increment selected (ie. rounding of 'S' cause '122' to round to "120 and "123 to round to '125’). If the process is inherently jittery, the display value may be rounded to a higher value than "1". If the range of the process exceeds the required resolution, (ex. 0-1000 PSI, but only 10 PSI resolution required), a rounding increment of 10 will effectively make the display more stable. This programming step is usually used in conjunction with programmable digital filtering to help stabilize display readings (If display stability appears to be a problem and the sacrifice in display resolution is unacceptable, program higher levels of digital filtering or increase the level of process dampening.) Rounding increments of 10,20,50, and 100 may also be used to add "dummy zeroes" to the scaled readings, as desired. 1 2 5 10 20 50 100 The rounding increment is for the controller's display only and does not affect (degrade) the control accuracy of the unit. Input Signal Filter (FLtr) Select the relative degree of input signal filtering. The filter is an adaptive digital filter which discriminates between measurement noise and actual process changes, therefore, the influence on step response time is minimal. If the signal is varying too greatly due to measurement noise, increase the filter value. Additionally, with large derivative times, control action may be too unstable for accurate control. Increase the filter value. Conversely, if the fastest controller response is desired, decrease the filter value. O-minimal 1-normal 2-increased 3-maximum Input Module (1- IN) (Cont'd) Scaling Points Prior to installing and operating the indicator, it may be necessary to change the scaling to suit the display units particular to the application. Although the unit has been programmed at the factory, the scaling will generally have to be changed. The indicator is unique in that two different scaling methods are available. The operator may choose the method that yields the easier or more accurate calibration. The two scaling procedures are similar in that the operator keys in the display values and either keys in or applies a signal value that corresponds to those scaling points. The location of the scaling points should be near the process end limits, for the best possible accuracy. Once these values are programmed (coordinates on a graph), the indicator calculates the slope and intercept of the signal/display graph automatically, No span/zero interaction occurs, making scaling a one-pass exercise, CISPLAY | | | ] i : —— INPUT 4.00mA 20.00mA DSP1 0.0 DSP2 oe! = 4.00 | INP2 = 20.00 Before programming the indicator, it is advised to organize all the data for the programming steps to avoid possible confusion. To scale the indicator, two signal values and two display values that correspond to the signal values must be known. These four values are used to complete the scaling operation. An example is listed below: Scaling Point #1 Scaling Point #2 0.0% @ 4.00mA AND 100.0% @ 20.00mA Reverse acting indication can be accomplished by either reversing the two signal points or the display value points, but not both. If both are reversed, then forward (normal) acting indication will occur. In either case, do not reverse the input wires to correct the action. Display Values (dSP1 & dSP2) Key-in the display value for scaling point one and scaling point two. dSP1 -99910 9999 (Ex. 0.0%) dSP2 -99910 9999 (Ex. 100.0%) Signal Input Values (INP1 & INP2) The signal input value can either be keyed in via the front panel buttons or an input signal can be applied to the appropriate signal input terminals. When entering the signal input parameter, the unit 1s in the key-in mode. Key-In Method Key-in the signal value for scaling point one and scaling point two. INP1 -999 109999 (Ex. 0.00 VDC or 4.00mA DC) INP2 -999 109999 (Ex. 10.00 VDC or 0.00mA DC) Signal Input Method To change to the apply signal method press the DSP button. Front panel annunciators PW and DEV will flash, and the display indicates the signal value applied to the input terminals. The unit can be toggled to the key-1n method by pressing the DSP button again. Signal Display Range Range 4.00 to 20.00mA DC 0.00 to 20.00 0.00 to 10.00 VDC 0.00 to 10.00 When the desired value is indicated on the display, press the PAR button to store the value and advance to the next parameter. Setpoint Limit Values (SPLO & SPHI) The controller has programmable high and low setpoint limit values to restrict the setting range of the setpoint. Set the limit values so that the setpoint value cannot be set outside the safe operating area of the process. SPLO - -999 10 9999 SPHI- -999 to 9999 Auto Setpoint Ramp Rate (SPrP) The setpoint can be programmed to ramp independent of the controller's display resolution. The setpoint ramp rate can reduce shock to the process, reduce overshoot on start-up or setpoint changes, or ramp the process at a controlled rate SPrP - 0.1 to 999.9 units/minute A ramp value of zero disables setpoint ramping. If the user input 15 programmed for setpoint ramp, it affects the enabling and disabling of setpoint ramping (refer to user input section). Setpoint ramping is initiated on power-up or when the setpoint value is changed and is indicated by a decimal point flashing in the far right corner of the main display. Note: The auto setpoint ramp rate is independent from the operation of a profile. Once the ramping setpoint reaches the target setpoint, the setpoint ramp rate is disengaged until the setpoint is changed again. If the ramp value is changed during ramping, the new ramp rate takes effect. If the setpoint is ramping prior to invoking Auto-Tune, the ramping is suspended during Auto-Tune and then resumed afterward using the current main display value as the starting value. Deviation and band alarms are relative 10 the target setpoint, not the ramping setpoint. If the analog output is programmed to transmit the setpoint value, the instantaneous ramping setpoint value is transmitted. SETPOINT | TARGET 500 pr TN SEE o ~— RAMP TERMINATED INITIAL 200 RAMP INITIATED wm TIME | | | SETPONT ZO | CHANGED La " 10 MINUTES Note: Depending on the ramp rate relative to the process dynamics, the actual scaled process value may not track the ramping setpoint value. -31- User Input (InPt) The User Input requires the input to be in its active state for 100msec minimum to perform the function. The unit will execute all functions in 100msec, except the print request function which requires 110 10 200msec for a response. A function is performed when the User Input (terminal 7), is used in conjunction with common (terminal 10). Note: Do not tie the commons of multiple units to a single switch. Either use a multiple pole switch for ganged operation or a single switch for each unit. Transition activated functions do not occur on controller power-up. Below is a list of the available functions. PLOC - Program Lock. A low level enables the program disable function which places the unit in the Protected Parameter Mode. A high level disables the program disable function. Note: Front panel disable is possible without using this program lock function, refer to front panel program disable section. ILOC - Integral Action Lock. A low level disables the integral action of the PID computation. A high level resumes the integral action. tmF - Auto/Manual Transfer. A negative transition places the unit in the manual (user) mode and a positive transition places the unit in the automatic operating mode. The output is "bumpless” when transferring to either operating mode. SPrP - Setpoint Ramp. A low level terminates auto setpoint ramping and the controller operates at the target setpoint. Terminating auto setpoint ramping is the same as setting the ramp rate to zero (SPrP = 0.0). A high level enables the auto setpoint ramp rate. Note: This does not operate with a profile. ALrS - Alarm/Timed Event Output Reset. If the alarm option is installed, a low level resets the alarm/timed event output(s) to their inactive state as long as the user input is low. Pmt - Print Request. A low level transmits the print options selected in the serial communications module (6-SC). If the user input 1s held low, after the printing is complete a second print request is issued. User Input (InPt) (Cont'd) CP - Control Point Select. A high to low transition loads Control Point 2 into the memory of the controller. The controller now operates with data of Control Point 2. A low to high transition loads Control Point 1 into the memory of the controller. The controller now operates with data of Control Point 1. Note: Control Point data loaded into memory overwrites the existing data setpoint and optionally the PID gain set. Control Points may be loaded during profile operation. P1rH - Profile Run/Pause. A low level pauses any running profile. A high level allows a paused profile to resume. A low to high transition starts Profile 1, if no other profile was running. P1rS - Profile Run/Stop. Á low level stops any running profile. A high level allows any profile to run. A low to high transition always starts profile 1. Output Module (2-OP) The controller has parameters which affect how the control output responds to process changes and signal overdrive actions. Time Proportioning Cycle Time (CYC1) The selection of cycle time depends on the time constant of the process and the type of output module used. For best control, a cycle time equal to 1/10 of the process time constant is recommended; longer cycle times could degrade process control, and shorter cycle times will provide little benefit at the expense of shortened relay life. When using a Triac module or when using the Logic/SSR drive output module with the SSR Power Unit, a relatively short cycle time may be selected. A setting of zero keeps the main control output and front panel indicator off. Therefore, if using the 4-20mA analog output for control, the main output and indicator can be disabled. CYCt Oto 120 seconds Output Control Action (OPAC) The main control output (OP1) channel is programmable for reverse acting or direct acting. Most control applications use reverse acting (see ON/OFF Control section). OPAC - rev (Reverse acting) dret (Direct acung) -32- The 4-20mA linear DC analog output, when assigned to output power (OP) for control purposes, will always follow the controller output power demand. A direct acting linear output signal can be implemented in two ways: 1. Use "direct” for output control action (OPAC). 2. Interchange the two analog output scaling points ANLO & ANHI (see Linear DC analog output in the output parameter module section). Note: When using a relay output module, the control action may also be reversed by using the normally closed contacts. Output Power Limits (OPLO 8 OPHI) Enter the safe output power limits for the process. These parameters may also be used to limit the minimum and maximum controller power due to process disturbances or setpoint changes to reduce overshoots by limiting the process approach level, OPLO & OPHI - 0 to 100% If the secondary output option is installed, the limits range from: OPLO & OPHI - -100to 100% With the secondary output option installed, the Lower Limit can be set to less than 0% to limit maximum secondary output power or set to greater than 0% lo limit minimum main control output power. Set the High Limit to less than 0% to limit minimum secondary output power or greater than 0% to limit maximum main control output power. When controlling power in the manual mode, the output power limits do not take affect. Input Overdrive Preset Power (OPFL) If input overdrive signal is detected, the control output (OP1) will default lo a preset power output settings. Note: The controller does not detect an open or short sensor. OPEL - 0% to 100% 0 = OP1 output full "off" 100 = OP1 output full "on" If the secondary output option is installed, the range is extended from: OPFL - -100% to +100% At 0% both outputs will be off, at 100% OP1 is on and OP2 is off, and at -100% OP2 is on and OP1 is off. The alarm outputs always have an up-scale drive (+9999), independent of this setting, for an input overdrive signal. The following table shows the relationship between the signal input, display indication, and the output status. NOTE: Display will flash between scaled process value and "OLOL", or "ULUL". 4 - 20mA Range Input Signal Display OP1/0P2 Outputs 26.00mA SENS Input overdrive preset power (OPFL) setting 21.00mA OLOL Normal Output Operation + Scaled Value Normal Output Operation -1.00mA ULUL Normal Output Operation -2.00mA SENS Input overdrive preset power setting 0 - 10V Range 13.00V SENS Input overdrive preset power setting 10.50V OLOL Normal Output Operation 7 Scaled Value Normal Qutput Operation -0.50V ULUL Normal Output Operation -1.00V SENS Input overdrive preset power (OPFL) setting On/oftf Control Hysteresis Band (CHYS) The controller can be placed in the ON/OFF control mode by setting the proportional band to 0.0%. The control hysteresis value affects only the main control output (OP1). The hysteresis band should be set to a minimum value to eliminate output chatter at the setpoint. Set the hysteresis band to a sufficient level prior to invoking auto-tune. CHYS 1to 250 units -33. Auto-Tune Damping Code (tcod) Prior to invoking Auto-tune, the damping code should be set to achieve the desired damping level under PID control. When set to 0, this yields the fastest process response with some overshoot. A setting of 4 yields the slowest response with the least amount of overshoot. Damping codes of 0 or 1 are recommended for most processes. PROCESS | DAMPING CODE FIGURE SP TYPICAL RESPONSE CURVES WITH AUTOTUNE DAMPING COCES 8 TO 4. Note: Actual responses may vary depending on the process, step changes, etc. — TIME Linear DC Analog Output (ANAS, ANLO, & ANHI) (Optional) The 4-20mA Linear DC output can be programmed to transmit one of four controller parameters: ASSIGN DC OUTPUT (ANAS): INP - Scaled input process value OP - Percent output power dEV - Process setpoint deviation SP - Process setpoint value With high and low digital scaling points, the range of the Linear DC output can be set independent of the controller's range. ANLO (4mA)- -999 to 9999 ANHI (20mA) - -999 to 9999 This allows interfacing directly with chart recorders, remote indicators, slave controllers, or linear power control units. The output is isolated from input common and located on rear terminals #11 (QUT+) & #12 (OUT-). When using the linear DC analog output for main control by assigning the DC output for percent output power, the front panel indicator OP1 can be disabled by setting the time proportioning cycle time equal to zero. This also disables the main control output, OPI. If transmitting the setpoint value, (for cascaded control with additional controllers), the controller will transmit the instantaneous ramping setpoint, not the target value, when the controller is actively ramping the setpoint. -34- EX1.} Chart Record Process Display Value: The process range is 300-700. Programming 300 for ANLO (4mA value) and 700 for ANHI (20mA value) yields full scale deflection for a chart recorder (4-20mA). The 4-20mA output is assigned to transmit the input process (ANAS = INP). EX2.) Linear Control Output: A linear DC input power control unit is used for process control. Programming 0.0% for ANLO (4mA value ) and +100.0% for ANHI (20mA value) configures the output. The 4-20mA output is assigned to transmit percent output power (ANAS = OP). ANALOG OUTPUT (mA) __o DISPLAY UNITS ANLO АМН! Lockouts Module (3-LC) The controller can be programmed to limit operator access to various parameters, control modes, and display contents. The configuration of the lockouts is grouped into three sections: Lower Display Lockouts, Protected Mode Lockouts and Hidden Mode Lockouts. Lower Display Lockouts (SP, OP, P-cs, P-tr, UdSP) The contents of the secondary display can be changed in the normal display mode by successively pressing the DSP button. This scrolls through the four possible display parameters, if enabled. Each parameter can be set for one of the following: LOC (Lockout) - Prevents the parameter from appearing in the secondary display. rEd (Read only) - Parameter appears, but cannot be modified. Ent (Entry) - Parameter appears and can be modified. The five lower display content possibilities are: SP - Setpoint Value OP - % Output Power P-CS - Profile Control Status P-tr - Profile Phase Tıme Remaining bdSP - Blank Display If a parameter is active in the lower display and then subsequently locked out, press "DSP" once in the normal display mode to remove it from the display. If all parameters are set to lock "LOC", the display will remain on the last parameter that was viewed. -35- Protected Mode Lockouts (Code, PID, & AL) The protected mode is active when program disable is active. The PID and Alarm parameters can be set for one of the following: LOC (Lockout) - Prevents the parameter from appearing in the display rEd (Read only) - Parameter appears, but cannot be modified. Ent (Entry) - Parameter appears and can be modified. The PID setting allows access to Proportional Band (ProP), Integral Time (Intt), and Derivative Time (dErt) parameters. Alarm 1 and 2 values (AL1 & AL2) may also be locked out if installed. A code number to enter the unprotected mode can be programmed into the controiler. To enter the unprotected mode from the protected mode, the code number must match the code number entered. Refer to front panel program disable section for access levels. Code - O to 250 Hidden Mode Lockouts (ALrS, CPAC, PrAC, trnF, & tUNE) The hidden mode 1s accessible from the normal display mode by pressing and holding the PAR button for three seconds. The parameters can be set for: LOC (Lockout) - Prevents the parameter from appearing in the display. ENbL (Enable) - Allows operator to perform function. The five controller functions are executed in hidden mode and are accessible independent of the status of program disable. ALrs - Reset (override) an alarm/timed event output(s). tmF - Transfer controller from or to automatic to manual operation. CPAC - Load 1 of the 4 control points (CP). PrAC - Allows the operator to start one of the 4 profiles. If a profile is running, the status (Adnc, Cont, PAUS, or OFF) can be changed. tUNE - Invoke or cancel Auto-Tune. Alarm Module (4-AL) (Optional) The controller may be optionally fitted with the dual alarm option (AL1 and AL2), or a single alarm with the secondary output option (AL 1 and OP2). One of three types of output modules (Relay, Logic/SSR Drive or Triac) must be ordered separately and installed into the alarm channel socket. Note: Units with RS-485 serial option must have the same type of modules installed for the Dual Alarms setup. The output modules may be replaced or interchanged (with appropriate wiring considerations) at any time without re-programming the controller. A front panel annunciator illuminates to indicate that the alarm output is on (AL1 for alarm 1 and AL2 for alarm 2). Note: When deviation low-acting with positive alarm value (d-L0), deviation high-acting with negative value (d-Hi}, or Band inside-acting (b-IN) is selected for the alarm action, the indicator is "OFF" when the alarm output is "ON", The alarm values can be accessed in configuration module (4-AL), the unprotected mode, and in the protected mode, if not locked. CAUTION: In applications where equipment or material damage, or risk to personnel due to controller malfunction could occur, an independent and redundant process limit indicator with alarm outputs is strongly recommended. Red Lion Controls offers various units, such as an IMP, IMD1, or IMD?, that may be used for this purpose. The indicators should have independent input sensors and AC power feeds from the other equipment. Alarm Action (Act1, Act2) The alarm(s) may be independently configured for one of six possible alarm modes or configured to operate as a timed event output(s). The timed event output(s) are programmed in profiles module 8 (8-Pr). Absolute High Acting (A-HI) Absolute Low Acting (A-LO) Deviation High Acting (d-HI) - Tracks Setpoint Value Deviation Low Acting (d-LO) - Tracks Setpoint Value Band Inside Acting — (bin) - Tracks Setpoint Value Band Outside Acting (b-Ot) - Tracks Setpoint Value Timed Event Output — (P-Ev) Note: If an alarm is programmed for Timed Event Output (P-Ev), the remaining alarm parameters are not applicable. -36- ABSOLUTE HIGH-ACTING ALARM (A—HIJ PROCESS AL 7 7 4 NA \ A L y Hs 7 vu | | | | | | | | | | | | Ÿ | | OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON ABSOLUTE LOW-ACTING ALARM (A-LO) PROCESS А ALN OS 4 У NE, T \/ \/ | | | | | Y i 1 ! OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON Alarms configured for deviation or band action, track the setpoint during ramp and hold phases of a profile. Deviation and band alarms trigger from the target setpoint when the auto setpoint ramp rate (SPrP) feature is enabled. The alarm action figures describe the status of the alarm output and the front panel indicator for various over/under process conditions. (See output module "OUTPUT ON" state table for definitions, under installing output modules section.) The alarm output waveform is shown with the output in the automatic reset mode. Note: Select the alarm action with care. In some configurations, the front panel indicator (LED) might be "OFF" while the output is "ON". DEVIATION HIGH—ACTING WITH POSITIVE ALARM VALUE — (d—HI) PROCESS A SP + AL /\ ZN ZN _ / NA Zi 4" / | NT ZU | | | | | | | | У | | | QUTPUT OFF QUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON DEVIATION HIGH~ACTING WITH NEGATIVE ALARM VALUE (d-—HI) PROCESS A SP SP + (-AUL) \ /N Nu ZA A NEE У | | | OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF LED OFF LED ON LED OFF LED ON -37- DEVIATION LOW-ACTING WITH POSITIVE ALARM VALUE (d-LO) PROCESS A AY NA Zi 1 SP + AL i V | / | N | | | sp | | | | | | | | | \\%ЬС | | | CUTPUT ON QUTPUT OFF QUTPUT ON OUTPUT OFF LED OFF LED ON LED OFF LED ON DEVIATION LOW-ACTING WITH NEGATIVE ALARM VALUE (d-LO) PROCESS A SP \ fT NN Iw SP + (-AL) 7 | NN ни NS | | | | | v | | | OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON PROCESS A IN BAND INSIDE ACTING (b-IN) —7 AN | AN | | | | | | | | | | Im | | ) | pra | | SP | —7 | , | | | | | | | | SP | || | | | 7 T 1 I | | \, ANA y ws | | | | [ST | | | v | | | | | | OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF LED OFF LED ON LED OFF LED ON LED OFF LED ON PROCESS BAND OUTSIDE ACTING (b—0t) SP + AL DN AN fi \ & Hrs iN | | / | | | DS | | ; | | | A | | | |} рец | | | | | | | | | | | | | | | Ï | | SP — AL | | N их Ts | | | | (ST | | | V | | | | | OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON LED OFF LED ON LED OFF LED ON LED OFF LED ON -38- Alarm Reset (rSt1, rS12) Each alarm reset action may be independently configured. LAtC - Latching Auto - Automatic Latched alarms require operator acknowledgment to reset the alarm condition. The front panel buttons can be used to reset an alarm when the controller is in the hidden mode (see hidden function mode). An Alarm condition may also be reset via the RS-485 serial interface or by the user input. Automatic (Auto) reset alarms are reset by the controller when the alarm condition clears. The alarm reset figure depicts the reset types. ALARM RESET SEQUENCE PROCE 55 ALARM MODE | (ABSOLUTE LOW ACTING SHOWN) CN ~~ / NT NA | | | | | | ALARM VALUE | | | | | TIME | | | | | | | | | | | | | | AUTOMATIC ON ON ESET OFF OFF OFF MANUAL RESET OFF | ON OFF ON MANUAL RESET PERFORMED BY OPERATOR -39- Alarm Standby Delay (Stb1, Stb2) The alarm(s) may be independently configured to exhibit a power-on, standby delay which suppresses the alarm output from tuming "ON" until the process first stabilizes outside the alarm region. After this condition is satisfied, the alarm standby delay is canceled and the alarm triggers nomally, until the next controller power-on. The alarm standby delay figure depicts a typical operation sequence. ALARM STANDBY DELAY SEQUENCE Р “ ALARM MODE (ABSOLUTE LOW ACTING W/AUTO-RESET SHOWN) ALARM VALUE UNIT - TIME POWER —ON I —] — — === ——— STANDBY ENABLED —+ — — — ha A — — STANDBY ON DISABLED | ON [OFF ON Alarm Value (AL-1, AL-2) The alarm values are either absolute (absolute alarms) or relative to the setpoint value (deviation and band alarms). An absolute alarm value is the value that is entered. A relative alarm value is offset from the process setpoint value by the amount entered and tracks the setpoint value as it changes. AL-1 and AL-2 - -999 to 9999 OFF If the alarm action is set as a Band Alarm, then only a positive value can be entered. AL-1 and AL-2 - Oto 9999 Alarm Hysteresis (AHYS) The alarm(s) values have a programmable hysteresis band to prevent alarm output chatter near the alarm trigger setpoint. The hysteresis value should be set to eliminate this effect. A value of 2 to 5 is usually sufficient for most applications. A single alarm hysteresis value applies to both alarms. Refer to the alarm action figures for the effect of hysteresis on the various larm types. Alarm types AHYS - 1to 250 Secondary Output Module (5-02) (Optional) The optional secondary output (OP2) operates as an independent output for systems that use heat/cool, PH balance, etc. One of the three types of output modules (Relay, Logic/SSR Drive or Triac) must be ordered separately and installed into the cooling channel socket. Note: Units with the RS-485 serial communications option must have the same type of modules installed for the secondary output and alarm output. The output modules may be replaced or interchanged (with appropriate wiring considerations) at any time without re-programming the controller. The front panel indicator OP2 illuminates when the secondary output is on. (See Output Module "OUTPUT ON" State Table for definition, under installing output modules section). Secondary output power is defined as ranging from -100% (full ON) to 0% (OFF, unless a deadband overlap is used). Cycle Time (CYC2) A value of 0 turns off the secondary output, independent of the power demand. CYC2- Oto 120 seconds Relative Gain (GAN2) This parameter defines the gain of the secondary band relative to the main output band. A value of 0.0 places the secondary output into ON/OFF control mode with the parameter (db-2) becoming the secondary output hysteresis. This may be done independent of the main output control mode (PID or ON/OFF). Relative gain is generally set to balance the effects of OP? to that of OP1 for best control. GAN2 - 0.0to 10.0 Overlap/Deadband (db-2) This parameter defines the area in which both main control output and secondary output are active (negative value) or the deadband area between the bands (positive value). If an overlap is specified, the displayed percent output power is the sum of the main power (OP1) and the secondary power (OP2). db-2 - -999 10 9999 If relative gain is zero, the secondary output operates in the ON/OFF mode, with this parameter becoming the secondary output hysteresis (positive value only). This parameter should be set prior to invoking Auto-Tune. The operation figures illustrate the effects of different deadbands. 2X PROPORTICNAL OPI BAND ОР? ‘100% | "| 00% OUTPUT | | | POWER (%) | | | | | | | = UNITS MAIN SECONDARY | OUTPUT OUTPUT | SETPOINT DEADBAND POSITIVE VALUE OP1 | r= RELATIVE GAIN +100% | | | OUTPUT | | | / POWER (%) | | | | | | | La MAN _ | RELATIVE GAN = .5 OUTPUT La SECONDARY J SETPOINT OUTPUT -41- DEADBAND NEGATIVE VALUE —] = ОР! | | RELATIVE GAIN ОР2 +100% Na 1 > 100% OUTPUT | И | | POWER (%) | | | | | | | | | = UNITS | | RELATIVE GAIN = .5 | — SECONDARY MAIN —— OUTPUT OUTPUT SETPOINT In practice with the secondary output, observe the controlled process characteristics and if the process remains above setpoint with a sluggish return, increase the relative gain. Similarly, if the process drops too sharply with an overall saw-tooth pattern, decrease the relative gain. Alter the deadband overlap until a smooth response in the controlled process 1s observed during band transition. Serial Communications Module (6-SC) (Optional) When communicating with a PSC unit via the serial port, the data formats of both units must be identical. A print operation occurs when the user input, programmed for the print request function is activated, when a "P" command is sent via the serial communications port, or after the time expires for the automatic print rate,if enabled. Serial communication is covered in detail in the RS-485 SERIAL COMMUNICATIONS SECTION. Baud Rate (bAUd) The available baud rates are: 300, 600, 1200, 2400, 4800, or 9600 Parity Bit (PArb) Parity can be odd, even, or no parity. Address Number (Addr) Multiple units connected on the same RS-485 interface line must each have a different address number. A value of 0 does not require the address specifier command, when communicating with the PSC. The address numbers range from 0 to 99. Abbreviated or Full Transmission (Abrv) When transmitting data, the PSC can be programmed to suppress the address number, mnemonics, units, and some spaces by selecting YES. An example of abbreviated and full transmission are shown below: NO - 6SET 123.8F<CR> <LF> Full Transmission YES - 123.8<CR> <LF> Abbreviated Transmission Print Rate (PrAt) The PSC can be programmed to automatically transmit the selected print options at the programmed print rate. Selecting 0 disables the automatic print rate feature. PrÂt - Oto 9999 seconds -49- Print Options (PoPt) Selecting YES for the print options will allow the operator to scroll through the available options using the PAR button. The up and down arrow keys toggle between "yes" and "no" with "yes" enabling the option to be printed when a print function occurs. INP Print Input Process Value SEt Print Setpoint Value OPr Print % Output Power Value Pbd Print % Proportional Band Value INt Print Integral Time Value dEr Print Derivative Time Value AL1 Print Alarm 1 Value AL2 Print Alarm 2 Valué dEv Print Deviation From Setpoint Value OFP Print % Output Power Offset Value r-P Print Setpoint Ramp Rate Value CrG Print Relative Gain Value Cdb Print Deadband Value P-t Print Profile Phase Time Remaining P-S Print Profile Operation Status Control Points Module (7-CP) There are four Control Points, each having a setpoint value and an associated PID gain set value. A control point can be implemented at any time to accommodate changing process requirements due to batch changeover, level changes, etc. The PID gain set values (ProP, Int, & Dert) may be optionally implemented with the setpoint value. A Control Point can be loaded from the hidden mode or by the user input (control points | and 2 only, see user input control point (CP) function). The control point overwrites the previous setpoint and optionally the PID values. The unit begins controlling based on these new values. When a control point is loaded, the controller suppresses the output 'bump’ usually associated with PID gain changes. Control points must be manually loaded and may be used in conjunction with a running profile. Control Point Set-up (CSEt) Select the control point to be configured. NO CP-1 CP-2 CP-3 CP-4 Selecting NO returns the unit to the configuration access point. Setpoint Value (SP-n) Enter the process setpoint value for the selected control point. This value is constrained to the setpoint low (SPLO) and setpoint high (SPHI) range limits (see inputs configuration module). SP-n - -999 to 9999 PID Values(PId) Choose the option of loading the PID gain set values with setpoint value when implementing a Control Point. NO - Disables PID entries and returns to control point set-up (CSEt). YES - PID gain set is implemented when control point is loaded. Enter the desired PID gain set values. Pb-n - Proportional Band 0.0 to 999.9% It-n - Integral Time 0 to 9999 secs dt-n - Derivative Time 0 to 9999 secs Profiles Module (8-Pr) Prior to programming a profile, it is recommended to configure the basic controller operation. A profile is a series of one or more programmable ramp and hold phases. A minimum of three parameters are required for a profile: Ramp Rate (Pn) Target Setpoint (PnLn) Hold Time (PnHn) Each profile can be programmed with up to eight ramp and hold phases. Associated with each profile is a timed event output set that updates as the profile advances. Additional parameters are provided which enhance the controller and profile capabilities. Profile Set-Up Select which profile or timed event output to program. PSEt - Pr-1 Profile 1 Profile 2 Profile 3 Profile 4 Timed event output for profile 1 Timed event output for profile 2 Timed event output for profile 3 Timed event output for profile 4 Pr-2 Pr-3 Pr4 PE-1 PE-2 PE-3 PE-4 The programming parameters for each profile are the same. The operator programs each phase and continues until all eight phases are programmed or a ramp rate of -0.1 is entered. Shown below are the parameters for profile 1. Pr-1 - PICC PILI P1St PIEb Plr! PILI P1H1 P1r2 PIL2 P1H2 P1r3 P1L3 P1H3 P1r4 Cycle count PIL4 Setpoint level 4 Linking P1H4 Hold time 4 Power cycle status P1r5 RampmtesS Error band PILS Setpoint level 5 Ramp rate 1 P1HS Hold time5 Setpoint level 1 Pl Ramp rate 6 Hold time 1 PIL6 Setpoint level 6 Ramp rate 2 P1H6 Hold time 6 Setpoint level 2 P1r7 Ramprate7 Hold time 2 P1L7 Setpoint level 7 Ramp rate 3 P1H7 Hold time 7 Setpoint level 3 P18 Ramprate8 Hold time 3 PIL8 Setpoint level 8 Ramp rate 4 P1H8 Hold time 8 Profiles Module (8-Pr) (Cont'd) PROCESS A PROFILE LEVEL 2 | | | | Ру — > | | | | | | | RAMP 1 ! $ PROFILE START HOLD 1 | RAMP 2 PHASE RAMP 7 | | | | HOLD 7 | | | | | LEVEL B | | f PROFILE END — TIME Changes can be made to any profile parameter while the profile is running. Ramp rate, hold time, and setpoint level changes take effect as the profile advances. If a change is made to a phase that is active, the change is not recognized until the next time the profile is run. From the normal display mode, the phase time remaining and target setpoint value allow temporary changes to a running profile. These changes take effect immediately. Profile Cycle Count (PnCC) Once a profile 1s started, it runs the programmed number of cycles and then automatically defaults to the off mode. If this parameter is changed while the profile is running, the new value does not take effect until the profile is stopped (off mode). It is not possible to examine the number of profile cycle counts that a profile has completed. A cycle count value of O prevents the profile from operating. A cycle count value of 250 allows continuous profile cycling. Profile Linking (PnLn) Each profile can have up to eight ramp and eight hold phases programmed. If more than eight phases are required, profiles may be linked together. Linking allows the next profile to automatically start when the current profile has completed its cycle count. A single profile can be expanded up to 32 ramp and hold phases of execution by linking. P1Ll.n - Selecting YES links profile 1 to profile 2. P2Ln - Selecting YES links profile 2 to profile 3. P3Ln - Selecting YES links profile 3 to profile 4. P4Ln - Selecting YES links profile 4 to profile 1. Profiles execute the prescribed number of cycle counts prior to linking to the next profile. A linked profile uses the last setpoint value of the previous profile as its starting point. The linking parameter can be changed during profile operation. PROFILE CYCLE COUNT & LINK FEATURES PROFILE y 1 4 CYCLE COUNT LINK 4 TO | PROFILE y 2 PROFILE # 3 PROFILE # 4 LINK LINK LINK 2703 3 TD 4 1 TO 2 CYCLE COUNT CYCLE COUNT CYCLE COUNT -44- Profile Power Cycle Status (PnSt) Upon controller power-on, several profile operating modes exist. Each profile has an independent power cycle status. StOP - Stop places a profile into the Off mode, regardless of the mode prior to power down. CONt - Continue resumes the operation of a running profile (including event output states) at the point where power was removed to the controller, Strt - Start automatically re-starts a profile. This is useful for automatic execution, soft-start profile at power-up, or automatic execution of a standard profile. Power cycle status may be changed while a profile is running. The options of the power cycle status may create conflicts between one or more profiles. The priority structure for the power cycle status is: Priority #1 - The profile that was running and programmed for continue resumes operation when power is restored. Priority #2 - If the profile that was running prior to power down is not programmed for continue, any profile programmed for start will re-start. Profile 1 has the highest priority. Profile Error Band (PnEDb) The Profile process value can be assured by using the profile Error Band parameter. If the process value deviates outside the error band value while a profile is running, the controller enters the delay mode. Inthe delay mode, the time base of the profile is held (delayed) until the process value is within the deviation error band. At this time, the profile continues running unless the process value again deviates. These actions assure that the actual process value conforms to the profile. The error band can be programmed for a positive or negative value which is expressed in units. PnEb - -999 to 9999 units A Positive Error Band value operates on hold phases only. This is useful when the soak time must be assured without affecting ramp phase time. A Negative Error Band value allows a profile to enter the delay mode on both ramp AND hold phases. This parameter may be altered during profile operation and the new values takes effect immediately. À value of 0 disables Error Band detection. Ramp Phase (Pnrn) The ramp phase is defined as automatic changing (ramping) of the setpoint value over a discrete time period at a predefined rate. The ramp rate is expressed in tenths of units per minute. Pnm - 0.1 to 999.9 units/minute The slope of the ramp phase (up or down) is automatically determined by the controller using the current setpoint value and target setpoint value. Upon starting a profile, the setpoint value begins ramping from the measured input process value to the target setpoint value. A profile can begin ramping from a defined setpoint level by entering 0.0 for the first ramp phase and 0.0 for the first hold phase. Entering 0.0 causes the profile to advance directly to the target setpoint value and begin the hold phase. This is known as a Step Ramp Phase. Timed Event outputs update at a Step Ramp Phase. The next ramp phase starts after the hold phase times-out. A “staged” ramp approach is possible by using hold phase times of 0.0 minutes and redefining the new ramp rate(s). PROFILE STATUS PROCESS STAGED RAMP & STEP RAMP PROFILE A LEVEL 3 LEVEL 4 | | | RAMP 2 RAMP 3 HOLD 3 | HOLD 4 | | | | | 1 1 1 1 START STAGED RAMP STAGED RAMP STEP RAMP OPERATION PnHY = 2.8 PnH2 = 3.8 Pará = 8.8 | OFF | RAMP 1 > TIME Setpoint Value (PnLn) The controller ramps to the Target Setpoint Value and then maintains the Target Setpoint Value over the hold phase time. The setpoint value is constrained to the setpoint limit values (SPLO & SPHI). PnLn - -999 10 9999 Hold Phase (PnHn) The controller maintains the target setpoint value constant during a hold phase for a fixed period of time. The hold phase is expressed in tenths of minutes. 0.1 to 999.9 minutes Hold times longer than 999.9 minutes are possible by joining two or more hold phases. Hold phases are joined by setting the in-between ramp rate to 0.0, which skips the ramp phase. A hold phase time value of 0.0 minutes skips the hold phase. Although Event Outputs assigned to that phase are updated. Two or more ramp phases (staged ramps) may be joined together by setting the in-between hold phase time to 0.0 minutes, Timed Event Output(s) (Pn 1 to Pn 16) The alarm channels can be independently configured to operate as an Alarm Output or a Timed Event Output. The alarm(s) must be configured in the Alarm Module (4-AL). If configured as an alarm, the output state assignments are ignored. Timed Event Outputs use ALI and/or AL2 to signal or activate other equipment during execution of a profile. The Timed Event Outputs are updated at the start of each ramp and hold phase and remain defined for the duration of that phase. Front panel annunciators ALI or AL2 light, if the Timed Event Output phase is programmed to activate the corresponding alarm output. The table lists the four assignment choices for each phase: Mnemonic Description 1F2F Alam 1 off, Alarm 2 off 1F2N Alarm 1 off, Alarm 2 on 1N2F Alarm 1 on, Alarm 2 off 1N2N Alam + on, Alarm 2 on -46- Each phase of the profile corresponds to an Event Output number. One of the output state assignments is programmed to each profile phase. The table lists the correspondence. Timed Event Output Profile Phase Number Mnemonic Deecsiption _ | Pn 1 Par1 Ramp Rate 1 Pn2 PnH1 Hold Time 1 Pn3 Pnr2 Rarrp Rate 2 Pn 4 PnH2 Hold Time 2 Pns Pnr3 Ramp Rate 3 Pn6 PnH3 Hold Time 3 Pn 7 Pnr4 Rarmp Rate 4 Png PnH4 Hold Time 4 Pn9 Рлг5 Ramp Rate 5 Pn10 PnH5 Hold Time 5 Pritt Pnr6 Ramp Rate 6 Pni2 PnH6 Hold Time 6 Pn13 Рог? Ramp Rate 7 Pn14 PnH7 Hold Time 7 Pn15 Pnr8 Ramp Rate 8 Pnt6 PnHB Hold Time 8 Note: Each Timed Event Output number can be programmed to one of the output states (1F2F, 1F2N, IN2F, or INZN). Timed Event Output(s) (Pn 1 to Pn 16) (Cont'd) It is possible to have the Event Outputs operate during profile phases by creating phantom’ phases, whose sole function is to allow a new state of Event Qutputs. Each profile corresponds to a Timed Event Output. The Event Output(s) may be manually reset to the off state at any time during profile execution. A timed event output may be reset via the user input (if programmed), the front panel buttons (in the hidden mode), or the RS-485 serial communication option. Once reset they remain in that state until the profile advances to the next phase and the event output updates. PROCESS | PHASE START PROGRAM TIMED EVENT OUTPUT(S) Timed Event Output Phase Number | State Pnr1 Pn 1 1N2F PnH1 Pn 2 1N2N Pnr2 Pn 3 1F2N PnH2 Pn 4 1F2F Pnr3 Pn5 1F2F PnH3 Pn 6 1N2F EVENT NUMBER ALARM OUTPUT 1 ee ON ALARM OUTPUT 2 | | 1 Î MANUAL RESET OF ALARM EVENT #2 | | RAMP 4 HOLD 1 RAMP 2 | HOLD 2 | RAMP 3 , HOLD 3 ] E. >| Ps | —t> TIME | Pn 1 Pn 2 | Pn 3 Pn 4 Рп 5 | Pa 6 | | | OFF OFF OFF | ON | | | | | | | | | | | OFF ON OFE | ON OFF | OFF | OFF -47- Profile Example The following example shows the set-up of a profile that executes one time and uses the timed event outputs. General Requirements: 1. Program data into profile |. 2. Delay profile if process value is not within 8 units, only during hold phases. 3. Continue profile if power is removed to the controller. 4. Implement User Input for profile 1 run/pause operation. Profile Requirements: A. Ramp up from idle process value of 85 to 350 at 4.0/minute (ramp time = 66.3 minutes). Hoid at 350 for 20.0 minutes. B. Ramp up from 350 to 500 at 3.0/minute (ramp time = 50.0 minutes). Hold at 500 for 60.0 minutes. . Step ramp up from 500 to 750. No hold phase at 750. . Ramp up from 750 to 875 at 7.5/minute (ramp time = 16.7 minutes). Hold at 875 for 2.5 hours (150 minutes). . Ramp down from 875 to 250 at 10.0/minute (ramp time = 62.5 minutes). Engage auxiliary pump during this ramp (Event output 1). . No hold phase at 250. Tum off auxiliary pump. . Ramp down from 250 to 100 at 3.75/minute (ramp time = 40.0 minutes). No hold phase at 100. Turn on end of program signal (Event output #2). H. End program at 100. ti Dn CT PROFILE EXAMPLE PROCESS (Units) 4 ses — 85e 808 - 750 - 700 - 656 - 608 + 558 - A HOLD 4 RAMP 4 RAMP 3 RAMP 5 | a —" Tr |. i + 1 + Т Т T 1 Ц I I 20 47 58 80 170177 148 160 188 208 227 247 267 28% 308 320 340 369 470 422 448 CFF | ON | OFF J RESET OFF | ON | | À | J A 1 À | | 1 1 | |. Д. | q 1 1 I I T I I I I TIME {Minutes) ALARM OUTPUT 1 (AL1), AUXILIARY PUMP ALARM OUTPUT 2 (AL2), END OF PROLFILE SIGNAL The Programming Data For The Exampie: Input Module 1 (1-IN) Mnemonic Value InPt Р1Н Alarm Module 4 (4-AL) Mnemonic Value Act 1 P-Ev Act 2 P-Ev Profile Module 8 (8-Pr) Mnemonic Value P1CC 1 Pitn no P1St Cont PIED 8 P1r1 4.0 P1L1 350 Р1Н1 20.0 P1r2 3.0 P1L2 500 P1H2 60.0 P1r3 0.0 P1L3 750 P1H3 0.0 Pira 7.5 P1L4 875 P1H4 150.0 P4r5 10.0 P4L5 250 PIHS 0.0 P16 3.8 P1L6 100 P1H6 0.0 P1r7 -0.1 Description User input is programmed for run/pause operation Description Program alarm 1 for timed event output Program alarm 2 for timed event output Description Cycle profile once after started Do not link to profile 2 when done Continue profile operation when power is restored Delay mode if process value deviates + 8 units Ramp rate 1 is 4.0/minute Setpoint level 1 is 350 Hold time 1 is 20.0 minutes Ramp rate 2 is 3.0/minute Setpoint level 2 is 500 Hold time 2 is 60.0 minutes Ramp rate 3 is step ramp Setpoint level 3 is 750 Hold time 3 is skipped Ramp rate 4 is 7.5/minute Setpoint Level 4 is 875 Hold time 4 is 150.0 minutes Ramp rate 5 is 10.0/minute Setpoint level 5 is 250 Hold time 5 is skipped Ramp rate 6 Is 3.8/minute Setpoint level 6 is 100 Hold time 6 is skipped Ramp rate 7 ends profile -49- Profile Module 8 (8-Pr) (Cont'd) Mnemonic P11 P12 P13 P14 P15 P16 P17 P18 P19 P110 P111 P112 Value 1F2F 1F2F 1F2F 1F2F 1F2F 1F2F 1F2F 1F2F 1N2F 1F2F 1F2F 1F2N Description Keep both outputs off Keep both outputs off Keep both outputs off Keep both outputs off Keep both outputs off Keep both outputs off Keep both outputs off Keep both outputs off Turn on auxiliary pump Turn oft auxiliary pump Keep both outputs off Turn on end of profile signal Factory Service Operations Module (9-FS) The Factory Service Operations are programming functions which are performed on an infrequent basis. They include: controller calibration, and reset programming to factory configuration setting. Given the ramifications of these operations, access to each is protected by an access code number. Entering code 66 will restore all parameters to factory settings, the unit will indicate the operation after the PAR button is pressed, by displaying "rSEt" in the lower display momentarily. The calibration operations are detailed in Appendix "F". Note: Entering code 66 will reset all programming parameters to the factory settings. Quick Reference Table: Contiguration Input Module 1 (1-IN) Display Parameter Range and Units Description/ (Faciory Setting Value) | tYPE Input type VOL! - Vokage Curr - Current {Curd JCPt Decimal Point 0, 0.0, 0.00, or 0.000 If 0.000 is selected scaling points {0.0} must be a posit] rnd Rounding 1, 2, 5, 10, 50, or 100 Used in conjunction with filtering to Increments {0.1} stahl; i } FLtr Digtal titering 0103 Increase number for mare fikering for input signal (1) affect, dSP1 Scaling Point -999 to 9999 Normaily, key-in display low value. #1 Display Value | (0.0) INP1 Scaling Pont Normally, key-in input low value. #1 Input Press DSP button to select Signal value -999 to 9999 signal nput method. Key-In Method (4.00) Signal input Normaly, apply input low value. Method 4 - 20mADC | 0.00 to 20.00 —_0-10VDC 0.00 to 10.00 dSP2 Scaling Point -999 to 9999 Normally, key-in display high vale. #2 Display Value | (0.0) INP2 Scaling Point Normally, key-in input high value. #2 Input Press DSP button to select Signal value -999 to 9999 signal input method. . Key-in Method (20.00) Signal Input Normally, apply input high vale. Method 4 - 20mADC | 0.00 to 20.00 Q-10VDC _0.00 to 10,00 SPLO Lower mit set- | -999 to 9999 Set low limit below high limit. point range SPH] Upper imit set- | -999 to 9999 Set high limit above low limit. point range (999.9) SPrP Setpoint ramp 0.0 to 999.9 0.0 is off (no ramping) rate unts/minute {0.0} ЮР: User PLOC - Programdisable Available with RS-485 option only. input ILOC - Integral action on/off trnF - Auto/manual transfer SPrP - Ramp rate on/off ALtS - Reset alarm output(s) Prnt - Print request CP - Control pont load PirH - Runpause a profile or start profile 1 P1rS - Profile 1 stop/restart (PLOC) -50- Quick Reference Table: Contiguration Output Module 2 (2-OP) scaling value Display Parameter Range and Units Description/ (E CYCt Cycle time 0 to 120 seconds 0 turns OP1 off. (2) OPAC Control action rEv For both PID & ON/OFF control. dret (rEv) OPLO Output power 0% to 100%, OP1 Set OPLO < OPHI. lower limit -100% to 100%, OP1 & OP2 If secondary option is installed. range (0, no secondary) {-100, secondary). OPHI Output power 0% to 100% , OP1 Set OPHI > OPLO. upper limit -100% to 100%, OP1 & OP2 If secondary option is installed. range. (100) OPFL Input overdrive | 0% to 100%, OP1 Set to a value to safely control power preset -100% to 100%, OP1 8 OP? the process in the event of an (O) input overdrive condition. CHYS ON/OFF control | 1 to 250 Main control output (OP1) only. hysteresis (1) tood Auto-Tune Oto4 0 = fastest response i (O) 4 = $ ANAS Linear DC OP - % output power This parameter does not appear 4-20mA INP - process value if analog option is not installed. output SP - setpoint value assignment dEv - deviation (OP) ANLO Linear DC out- | -999 to 9999 Units depend on ANAS selec- put low. 4mA (0.0) tion. This parameter does not sca , . ANHI Linear DC out- | -999 to 9999 Units depend on ANAS selec- put high. 20mA | (100.0) tion. This parameter does not appear if analog option is not installed. -51- Quick Reference Table: Configuration Lockout Module 3 (3-LC) Display Parameter Range and Units Description/ (E | Comments | SP Setpoint acoess | LOC - lockout Allows access to process setpoint. rEd - read only Ent - enter (Ent) OP Output power LOC - lockout Alows direct access to out- access rEd - readony put power. %PW ndicator Ent - enter iluminates when parameter (Ent) a selected in di P-CS Profile status LOC - lockout Alows acosss to profile status. display rEd . - readony PGM indicator iluminates when Ent - enter parameter is selected in display. (Ea) P-tr Profie time LOC - lockout Allows acoess to phase time remaining. remaining rEd _ - read only PGM indicator ifluminates when Ent - enter parameter is selected in display. Ed) bdSP Blank display LOC - lockout Blanks secondary display. red readony (rEd) Code Access code Oto 250 Refer to front panel disable Pid PID values LOC - lockout Protected mode lockout enable rEd - readony Ent - enter (LOC) AL Alarm values LOC - lockout Protected mode lockout enable rEd - readony ENt - enter (LOC) ALrS Reset alarm LOC - lockout Hidden mode lockout timed event ENBL - enable outputs enable | (LOC) CPAC Control point LOC - lockout Hidden mode lockout access ENBL - enable (LOC) PrAC Ramp/hold LOC - lockout Hidden mode lockout profile ENBL - enable access (LOC) trnF Automatic LOC - lockout Hidden mode lockout Manual (user) ENBL - enable transfer enable | (LOC) {UNE Auto-tune LOC - lockout Hidden mode lockout enable ENBL - enable (LOC) -52- Quick Reference Table: Configuration Alarms Module 4 (4-AL) Unit returns to configuration access point if alarm(s) are not installed. Display Parameter Range and Units Description/ AF Acti Alarm 1 A-Hi absolute high it changed, check alarm values. If P-Ev operation A-LO absolute low is selected, remaining parameters for mode d-Hl deviation high Alarm 1 does not appear. d-LO deviation low b-IN band inside b-ot band outside P-Ev timed event output (A-H1) rSt1 Alarm 1 Auto - automatic Manual reset via hidden mode. reset LAte - manual reset mo (Auta) Stb1 Alarm 1 yes/no Power-up standby delay. standby (NO) function (delay) AL-1 Alarm 1 value -999 to 9999 if band alarm action, positive values only. (0) Acto Alarm 2 A-HI absolute high If changed, check alarm value. li P-Ev operation A-LO absolute iow is selected, remaining parameters for mode d-HI deviation high Alarm 2 does not appear. d-LO deviation low b-IN band inside b-ot band outside P-Ev timed event output (A-HI) rSt2 Alarm 2 reset Auto - automatic Manual reset via hidden mode. mode LAtc - manual reset (Auto) Stb2 Alam 2 yes/no P ower-up standby delay. standby (NO) function {delay) AL-2 Alarm 2 value -999 10 9999 if band alarm action, postive values only. (Q) AHYS Alarm 1 10 250 Applies to both alarms, Hysteresis (1) Set to eliminate chatter. value -53- Quick Reference Table: Configuration Secondary Module 5 (5-02) Unit returns to configuration access point if secondary option not installed. Display Parameter Range and Units Description/ (Fa CYC? cycle tme 0 to 120 sec O turns OP2 off. GANZ Relative gain 0.0 to 10.0 0.0 places cooling output into ON/OFF (1.0) control mode and db-2 becomes hysieresis value, db-2 overlap- -999 to 9999 Positive value is deadband. Negative deadband (O) value is overlap. it GAN2 =D, this parameter ss OP? ON/OFF control hysteresis. -54- Reference Table: Configuration Serial Communications Module 6 (6-SC) Unit returns to configuration access point if RS-485 serial option is not installed. INt - Integral Time dEr - Dervative Time AL1 - Alarm 1 AL2 - Alarm 2 dEv - Deviation From Setpoint OFP - % Output Power Offset r-P - Setpoint Ramp Rate Crg - Relative Gain Cdb - Deadband P-t - Profile Phase Time Remaining P-S - Profie Operation Status {INP, SEt, OPr) Display Parameter Range and Units Description/ (Е bAUd Baud rate 300 to 9600 Baud rate of uni must match other (1200) equipment, PArb Party bit odd, even, or no parity Parity of unit must match other (odd) equipment. Ador Unit address Oto 99 For multiple units, each unit must have (0) a unique address Abrv Abbreviated or | yes/no Selecting yes, the controller does NOT ful transmission |. (NO) transmit mnemenics. Prat Auto print rate 0 to 9999 0 disables auto print function. (0) PoPt Print options yes/no Selecting yes allows print options to be (NO} programmed. INP - Input Process Value SEt - Setpoint OPr - % Output Power Pbd - % Proportional Band -55- Quick Reference Table: Configuration Control Point Module 7 (7-CP) Display Parameter Range and Units Description/ (Factory Setting Value) | CSEt Control Point NO NO - Return to CONF set-up CP-1 Control Point 1 CP-2 Control Point 2 CP-3 Controi Paint 3 CP4 Control Point 4 (NO) The parameters for the four Control Points are the same. (n = control point 1, 2, 3, or 4.) SP-n Setpoint value | SPLO to SPHI Limited to setpoint limit values. for Control (0) Pointn Pid PiD gain set for | NO - disable PID, return to CSE! PID values to be loaded with setpont Control Point n ¡ yES - continue with entry of PID entry, when implemented. (NO) Pb-n Proportional 0.0 to 999,9% 0.0% = ON/OFF control band for Control Pointn ¡ (4.0) КП integral time O to 9999 seconds 0 is off. Does not appear if Pb-n = 0.0%, for Control Pointn (120) di-n Dervatve time | O to 9999 seconds D is off. Does not appear if Pb-n = 0.0%. for Control Point n (30) Retum to "CSet” to program other Control Points if desired. -56- Quick Reference Table: Configuration Profile Module 8 (8-Pr) Protie returns to "PSE!" stage. Display Parameter Range and Units Description/ (F с PSEt Setpoint Profile | No NO - Return to CNFP Pr-1 Profile 1 Pr-2 Profile 2 Pr-3 Profile 3 Pr-4 Profile 4 PE-1 Time event output for profile 1 PE-2 Time event output for profile 2 PE-3 Time event output for profile 3 PE-4 Time event output for profile 4 (NO) The parameters for the four profies are the same. (Pn = profile 1, 2, 3, or 4) PnCC Profilen 0-250 Qu off cycle count (O) 250= continuous PnLn Profile n YES/NO Link à more than 8 ramp/hokd phases link option (NO) are required, PnSt Profie n Stop- Stop profile Continue has priority. power-on status | CONt- Continue profile Strt- Start profile (Stop) PnEb Profie n -999 to 9999 O= off. (+) values hold phases only error band (0) (-) y: Pnr1 Profile n 0.0 to 999.9 0.0 = step (instant ramp) -0.1 ends the ramp rate 1 units/minute profile. (0.0) PnL1 Profilen SPLO to SPHI Constrained to setpoint mt values. setpoint level 1 | (0) PnH1 Profile n 0.0 to 999.9 0.0 = no hold phase. hold time 1 minutes (0.0) Program up to 8 ramypvhold phases. Profle ends when ramp = -0.1 or PnH8 & programmed. Pnr8 Profile n 0.0 to 999.9 Same as ramp 1. ramp rate 8 unts/minute (0.0) PnL8 Profilen SPLO to SPHI Same as setpoint 1. setpoint leve! 8 : (O) PnH8 Profile n 0.0 to 999.9 Same as hold 1. hold time 8 minutes (0.0) -57- Quick Reference Table: Configuration Profile Module 8 (8-Pr) (Cont'd) Display | Parameter | Range and Units Description/ (Factory The parameters for the four timed event outputs are the same. (Pn = Timed Event Output for profile 1, 2, 3, or 4. } Pn 1 Event output 1F2F Assign alarms to timed event output in number 1, for 1F2N alarm action. profile n 1N2F Fa OFF № = ОМ 1N2N 1 = AL1;2=AL2 {(1Е2Е). Each event output has the same programmable options. Event updates end when profile ends. Pn 16 Event output 1F2F Assign alarms to timed event output in number 16, for 1F2N alarm action. profie n 1N2F Е = OFF; N=ON 1N2N 1 =AL1;2= AL2 LFF) Event Outpur step returns to "PSEr stage. Quick Reference Table: Contiguration Factory Service Operations Module 9 (9-FS) Dispiay Parameter Range and Units Description/ (Factory Setting Value) Code Enter factory 48 - Calbrate instrument Reter to Appendix F for details service function 66 - Reset parameters to factory settings -58- RS-485 SERIAL COMMUNICATIONS INTERFACE RS-485 communications allows for transmitting and receiving of data over a single pair of wires. This optional feature can be used for monitoring various values, resetting output(s), and changing values, all from a remote location. Typical devices that are connected to a PSC unit are a printer, a terminal, a programmable controller, or a host computer. The RS-485 differential (balanced) design has good noise immunity and allows for communication distances of up to 4000 feet. Up to 32 units can be connected on a pair of wires and a common. The RS-485 common is isolated from the controller input signal common to eliminate ground loop problems associated with the input probe. The unit's address can be programmed from 0 to 99. An Optional RLC Serial Converter Module (RS-422 to 20mA current loop) can be installed to expand the unit’s flexibility. Communication Format The half-duplex communication operation sends data by switching voltage levels on the common pair of wires. Data is received by monitoring the levels and interpreting the codes that were transmitted. In order for data to be interpreted correctly, there must be identical formats and baud rates between the communicating devices. The formats available for the PSC unit are 1 start bit, 7 data bits, No parity or 1 parity bit (odd or even) and 1 stop bit. The programmable baud rates are; 300, 600, 1200, 2400, 4800, or 9600 baud. 10 BIT DATA FORMAT 7 DATA BITS E LE ob E TO T1 T2 T3 T4 15 T6 17 18 T9 TIO START BIT i. PARITY BIT ODD 1 STOP BIT 1 -59- 9 BIT DATA FORMAT 7 DATA BITS | | | | | | | LK pi 11111110 TO T1 T2 T3 14 15 T6 T7 18 19 1 STOP BIT START BIT 1 Before serial communication can take place, the unit must be programmed to the same baud rate and parity as the connected equipment. In addition, the loop address number and print options should be known. When used with a terminal or host computer and only one unit is employed, an address of zero (0) may be used to eliminate the requirement for the address specifier when sending a command. If more than one unit is on the line, each unit should be assigned a different address number. Sending Commands And Data When sending commands to a PSC unit, a command string must be constructed. The command string may consist of command codes, value identifiers, and numerical data. Below is a list of commands and value identifiers that are used when communicating with the PSC unit. COMMAND | DESCRIPTION N (4EH) Address command; Followed by a one or two digit address nurrber 0-93. P (50H) Transmit print options command; Transmits the options selected in the Program Options (PoPt) section. R (52H) Reset command; Folowed by one df the Value Identifiers (Gor H). T (54H) Trans mit value command; Followed by one of the Value Identifiers (A-M,O,O)- C (43H) Control action command; Followed by the Value Identifier (S or U) and number. V (56H) Change value command; Followed by one Value Identifier (B-H & J-M,0), then the proper numerical data. Sending Commands And Data (Cont'd) VALUE SERIAL DESCRIPTION UNITS Control Mode 1- Automatic Program 1 = Start Profile 1 Operation 2 = Start Profile 2 Operation 3 = Start Profile 3 Operation 4 = Start Profile 4 Operation 5 = Stop Profile Operation 6 ~ Pause Profile Operation 7 = Continue Profile Operation 8 « Advance Profie to Next Phase Note: The % output power can be changed only if the controller is in the manual mode of operation. Profile data cannot be configured via the serial interface. changes can be made to a running profile. * The Auto Setpoint Ramp Rate is not associated with a profile. This parameter 15 programmed in the Input Parameter Module (1-IN) (see Setpoint Ramp Rate for details). A command string is constructed by using a command, a value identifier, and a data value if required. The Data value need not contain the decimal point since it is fixed within the unit, when programmed at the front panel. The PSC will accept the decimal point, however it does not interpret them in any way. Leading zeros can be eliminated, but all trailing zeros must be present. Example: If an alarm value of 750.0 is 10 be sent, the data value can be transmitted as 750.0 or 7500. If a 750 is transmitted, the alarm value is changed to 75.0 in the unit. PEt rtrd I RS Only status -60- The address command allows a transmission string to be directed to a specific unit on the serial communications line. When the unit address is zero, transmission of the address command is not required. For applications that require several units, it is recommended that each unit on the line be assigned a specific address. If they are assigned the same address, a Transmit Value Command, will cause all the units to respond simultaneously, resulting in a communication collision. The command string is constructed in a specific logical sequence. The PSC does not accept command strings that do not follow this sequence. Only one operation can be performed per command string. The following procedure should be used when constructing a command string. 1. The first two to three characters of the command string must consist of the Address Command (N) and the address number of the unit (0-99). If the unit address is zero, the address command and number need NOT be sent. 2. The next character in the command string is the command that the unit is to perform (P,R,T,C, or V). 3. A Value Identifier is next if it pertains to the command. The command P (print) does not require a Value Identifier. 4. The numerical data will be next in the command string if the "Change Value" or "Control Action" command is used. 5. All command strings must be terminated with an asterisk » (2AH). This character indicates to the unit that the command string is complete and begins processing the command. Below are typical examples of command strings. Ex. 1 Change Proportional Band Value to 13.0% on the unit with an address of 2. Command String: N2VD130* Ex. 2 Transmit the Process Display Value of the unit with an address of 3. Command String: N3TA =» Ex. 3 Reset Alarm Output 1 of the unit with an address of 0. Command String: RGx Ex. 4 Start profile 1 of the unit with an address of 13. Command String: №3С01ж If illegal commands or characters are sent to the PSC, the string must be re-transmitted. When writing application programs in Basic, the transmission of spaces or carriage return and line feed should be inhibited by using the semicolon delimiter with the "PRINT" statement. The unit does not accept a carriage return or line feed as valid characters. See "Terminal Emulation Program” section for a listing of an IBM* PC Basic terminal emulation program. It is recommended that a "Transmit Value” command follow a "Change Value” Command. If this is done, the reception of the data can provide a timing reference for sending another command and insures that the change has occurred. When a "Change Value or Reset” command is sent to the unit, there is time required for the unit to process the command string. The diagrams show the timing considerations that need to be made. TIMING DIAGRAMS PRINT REQUEST COMMAND | BAUD RATE 1 28dmsec Vox, i AT SELECTED ¡ 188Bmaec vw PSC BEGINS PROCESSING AFTER * IS RECEIVED DAUD RATE AT 2 THE BAUD RATE WITH A 100 TO 200msec DELAY COMMAND | — PSC CHANGE VALUE, STRING | PROCESSES CONTROL VALUE TRANSMITTED | COMMAND | § > PSC OR > £ =| IN RECEIVE RESET AT SELECTED | 1p@msec Mox |S 5 | MODE COMMAND BAUD RATE |! I 1 COMMAND | PSC PSC ANY ADDITIONAL DATA STRING | PROCESSES TRANSMITS STRINGS OR BLOCKS TRANSMIT VALUE TRANSMITTED | COMMAND | DATA STRING| ARE TRANSMITTED AT SC IN RECEIVE * IBM is a registered trademark of International Business Machines. -61- Receiving Data Data is transmitted from the PSC when a "T” Transmit Value or a "P" Transmit Print Options command is sent to the unit via the serial port. Also, when the User Input, programmed for the Print Request function, 1s activated. The print rate features allows the selected print options to be transmitted at a programmable automatic rate via the serial port. The format for a typical transmission string with mnemonics is shown below: 1 2 3 4 5 6 7 8 9 10 41 12 13 14 15 16 17 1B BEEBE ERE REE Je | UNIT MNEMONICS Z E “FOUR Dies DIGITS Y =D nobis Y SE z 52359 EL Sa É Y LAST LINE > = 5 ы = OF < £5 Z TRANSMISSION = u x o q LY LO The first two digits transmitted are the unit address followed by one blank space. If the unit address is O, the first locations are blank. The next three characters are the mnemonics followed by one or more blank spaces. The numerical data value is transmitted next followed by the identifying units. Negative values are indicated by a "-" sign. The decimal point position “floats” within the data field depending on the actual value it represents. The numeric data is right justified without leading Zeros. When a "T” command or print request is issued, the above character siring is sent for each line of a block transmission. An extra <SP><CR><LF> is transmitted following the last line of transmission from a print request, to provide separation between print outs. If abbreviated transmission is selected, just numeric data is sent. If abbreviated transmission is NOT selected, the unit transmits Mnemonics and the units. Receiving Data (Cont'd) A print-out from a PSC unit with an address of 1 and all print options If more than one string is transmitted, there is a 100msec minimum to selected is shown below: 200msec maximum built-in time delay after each transmission string and 1 INP 500U after each block of transmission. When interfacing to a printer, sending 1 SET 525U mnemonics are usually desirable. Examples of transmissions are shown 1 PWR 20.0% below: 1 PBD 4.0% 1 INP 500U<CR><LF>100 - 200msec Mnemonics Sent 1 INT 1205 1 SET 525U<CR><LF>100 - 200msec 1 DER 305 I PWR 20%<CR><LF><SP><CR><LF>100 - 200msec 1 ALI 6000) -673,5<CR><LF>100 - 200msec NO Mnemonics Sent ou ty The Print Options provide a choice of which PSC data values are to be 1 OFP 0.0% transmitted. The PSC will transmit the Print Options when either the User 1 RMP 0.0R Input, programmed for the print request function is activated, a "P" 1 CRG 1.0G (Transmit Print Options) command is sent to the PSC via the serial port, or 1 CDB 10U the Automatic Print Rate is set for a specific time. The Print Options are 1 TIM 1.6M programmed in the Serial Communications Module (6-SC) with the 1 STS P2H3 available options: 1. Print Display Process Value. Note: If the secondary option is installed, AL2 is not printed or functional. 2. Print Setpoint Value, 3. Print % Output Power Value. 4. Print % Proportional Band Value. 5. Print Integral Time Value. 6. Print Derivative Time Value. 7. Print Alarm 1 Value. 8. Print Alarm 2 Value. 9. Print Deviation From Setpoint Value. 10. Print % Output Power Offset Value. 11. Print Setpoint Ramp Rate Value. 12. Print Relative Gain Value. 13. Print Deadband Value. 14. Print Profile Phase Time Remaining. 15. Print Profile Status. -62- Terminal Emulation Program For IBM* PC Utilizing the Serial communications capability of the PSC requires the use of an RS-485 serial card in the computer. If an IBM* PC compatible computer is used, this card is installed in an expansion slot on the mother-board. The RS-485 card should be configured for "2-wire half-duplex" operation. For this mode of operation, each piece of equipment must be able to switch from receive mode to transmit mode and vice-versa. The controller is normally in the receive mode. It will automatically switch to the transmit mode when a Transmit Value Command is issued or a Print Request is issued. For the computer to switch from receive to transmit mode, the controlling software must be written to perform this task. On most RS-485 serial cards, the RTS (Request-to-Send) signal can be configured to be used as the direction (transmit/receive) control signal. The controlling software must switch the state of the RTS line when the computer is to switch from transmitting to receiving data. The controller allows 100msec minimum for the computer to switch from transmit to receive mode. If an RS-485 card cannot be obtained, and only an RS232 port is available, the Red Lion Controls GCM232 & GCM422 converter modules can be used. The GCM232 converts from RS232 10 20mA current loop. The GCM422 converts the 20mA current loop to RS422/RS485. A male 25 pin D connector is required to interface the GCM422 to the unit. TO COMPUTER RS—232 1/2 WATT 680 Ohm 6 x MODEL APS a 3 POWER SUPPLY + о D-CONNECTOR РМ #5 11130) x/RX(+) Pl Les Le loa les le 711 6/2|Rs-485 COMM. R5- 48% GCM232 GCM422 INTERFACE CONVERTER CONVERTER MODULE MODULE -63- Listed below is a basic program that emulates a terminal. It is written using IBM* PC Basic. The program may need to be modified if using a different basic interpreter. Set up the PSC for a baud rate of 9600. When the program is running, commands can be typed in from the keyboard as shown in the previous examples. An asterisk (*) is used to end all commands, Do NOT use the carriage retum to end a command. 1 REM "FOR THIS PROGRAM TO WORK THE "RS-485" CARD SHOULD BE SET-UP AS COM?" 2 REM "ALSO THE CARD SHOULD USE "RTS" FOR HANDSHAKING" 3 REM "THE PSC UNIT SHOULD BE SET-UP FOR 9600 BAUD, AND ODD PARITY" 4 TXEMPTY = &H60 5 LSR = &H2FD: REM "COMM2 LINE STATUS REGISTER" 6 MCR = &H2FC: REM "COMM2 MODEM CONTROL REGISTER" 10 CLS : CLOSE : 20 OPEN "COM2:9600,0,7,1* FOR RANDOM AS #1 30 ON TIMER(1) GOSUB 300 40 AS = INKEYS: IF AS < >" ” THEN GOTO 1000: REM "CHECK FOR KEYBOARD INPUT" 50 {F LOC(1) = 0 THEN 40 ELSE 80: REM CHECK FOR INPUT 60 IF LOC(1) = 0 THEN 80: REM "SKIP CLEARING OF BUFFER" 70 B$ = INPUTS(LOC(1), 41): REM "CLEAR BUFFER" 80 Е = INP (MCR) AND 253: OUT MCR, F: REM "SET FOR RECEIVE MODE” 90 IF INP(LSR} < > TXEMPTY THEN 90: REM "WAIT UNTIL. DONE TRANSMITTING" 100 TIMER ON 110 IF LOC(1) = 0 THEN 110 120 B$ = INPUTS(1, 41) 130 IF B$ = CHR$(10) THEN 160" REM "TQ PREVENT DOUBLE SPACING ON PRINT" 140 PRINT BS; 160 IF NOT B$ = " * THEN GOTO 90 170 TIMER OFF 200 GOTO 40 300 TIMER OFF: RETURN 40 1000 D = INP(MCR) OR 2: OUT MCR, D: REM "SET FOR TRANSMIT MODE" 1010 PRINT #1, A$; : PRINT A$; : REM "PRINT KEYSTROKE* 1020 IF AS = “%" THEN PRINT 1030 IF A$ = "*“ THEN !F INP(LSA) < > TXEMPTY THEN 1030 ELSE GOTO 60 1040 A$ = INKEY$: IF A$ < >" " THEN GOTO 1000 1050 GOTO 1010 x [BM is a registered trademark of International Business Machines. Serial Connections When wiring the terminal block at the rear of the unit, refer to the label with the terminal description for installing each wire in its proper location. Only two transceiver wires and a common are needed. The two data (transceiver) wires connect to the TX/RX (+) and TX/RX(-) terminals, appropriately. The cable should consist of a shielded twisted pair and in some applications a signal ground may be required to establish a ground reference. The signal ground is required if the equipment does not have internal bias resistors connected to the RS-485 transceiver lines. The signal ground is connected at the RS-485 common of only one PSC unit to the RS-485 equipment. If necessary, the shield can be used as the signal ground. The signal input common is isolated from the RS-485 common and the 4-20mA analog output "-" terminal. Note: Do NOT connect any of the commons to the 4-20mA output "-" terminal. Terminal Descriptions RS-485 COMM. - Common may be required for communication hook-up. TX/RX (+) & TX/RX (-) - The PSC transmits and receives on these two terminals which are connected to the external device. TX EN. - Used with a Red Lion Controls (RLC) GCM422 Serial Converter Module (RS422 to 20mA Loop). Otherwise not normally used. -64- MODEL APS POWER SUPPLY Connecting To An RLC Printer 1/2 WATT B80 Oh GCM422 RS—-485 COMM. (§)]16 [I] D-CONNECTOR PIN #°5 | RX+ PIN(25) RED MODEL Ly TK+ PIN(17) GRN RX— PIN(Z3) WMT 680 Ohm > 2 TT 14 > de D-CONNECTOR PIN 45 _ RX+ PIN(25) RED TX+ PIN(17) GRN RX~ PIN(23) WHT TX- PIN(24) BLK GCM422 + ля One or several PSC units can be connected to an RLC model DMPC printer using an Optional RLC GCM422 converter module. The two applications show the wiring for a single and a multiple hook-up to the printer. The TX EN (Transmit Enable) terminal is connected to the transmit disable pin on the GCM422 module. The printer receives data when the User Input, programmed for the print request function, is activated. The GCM422 module must have the internal jumper placed in the 485 position. The 25 pin connector on the GCM422 module must have pins 2 & 3 and 14 & 16 jumpered. The PSC must be programmed for the same baud rate as the printer. When more than one controller is on the line, each TX EN terminal is connected to the transmit disable pin of the GCM422 module. Only one PSC can have the print function activated at a time, otherwise line collision occurs resulting in a garbled print-out. Connecting To A Host Terminal Six PSC units are used to control a process in a plant. The PSC units are located at the proper location to optimize the process. A communication line 1s run to an industrial computer located in the production office. The drawing shows the line connection. Each PSC is programmed for a different address and are all programmed for the same baud rate and parity as the computer (ex 9600 baud, parity even). OFFICE COMPUTER (WITH RS485 INTERFACE CARD INSTALLED) DON a A L Li 11 TO SERIAL PORT ON COMPUTER SHIELD 7 E —| = a or & Ohh 8 < TX EN. IÓN 5! < @ | 65-8 сомы. $)! 6 8 m A+) O › ‹ 113 @) тхуяжс+) + 3 x/Rx(-} 8) Fi14iQ) Tx/axc-) 5 7X Ex. IQ 154) ™ ex. À | rs-485 coun. |§ 11 8 ) 35-483 сомы. ) & o xx) SI 130 TX /RX{+) 5 ™/RX{-) В 4, + ; TX/RX(-) 8 TX EN. SUSE SOX En. Я \ 65-485 co. Qi 8i I 150 85-485 соум. | 3 -66- An application program is written to send and receive data from the units using the proper commands. Troubleshooting Serial Communications If problems are encountered when interfacing the PSC(s) and host device or printer, the following check list can be used to help find a solution. 1. Check all wiring. Refer to the previous application examples and use them as a guide to check your serial communication wiring. Proper polarity of ail units and other peripherals must be observed. 2. If the PSC is connected to a "host computer", device or printer (other than the RLLC DMPC), check to make sure that the computer or device is configured with the same baud rate and communication format as the PSC. The communication format the PSC will accept is; 1 start bit, 7 data bits, no parity or 1 parity bit (odd or even), and 1 stop bit. 3. Check the PSC's unit address. If the Address command is not used when transmitting a command to the PSC, the PSC’s address must be set to 0. See "Sending Commands & Data” section for command structure. 4. If two-way communications are to be established between the PSC and a computer, have the computer receive transmissions from the PSC first. Activating the User Input, programmed for the print request function, will initiate transmissions from the PSC. 5. When sending commands to the PSC, an asterisk * (2Ah) must terminate the command. After system power-up an asterisk must first be sent to clear the PSC input buffer. 6. In multiple unit configurations, make sure each unit has a different address other than zero. 7. If all of the above has been done, try reversing the polarity of the transceiver wires between the PSC(s) and the RS-485 interface card. Some cards have the polarity reversed. PID CONTROL Proportional Band Proportional band is defined as the "band” of units the process changes to cause the percent output power to change from 0% to 100%. The band may or may not be centered about the setpoint value depending upon the steady state requirements of the process. The band is shifted by manual offset or integral action (automatic reset) to maintain zero error. Proportional band is expressed as percent of the scaled display range. QUTPUT | REVERSE DIRECT i POWER (%) ACTING | ACTING | | P-BAND | P—BAND | | | | | | | | | 0 | | = SIGNAL Les - SETPOINT The proportional band should be set to obtain the best response to a disturbance while minimizing overshoot. Low proportional band settings (high gain) result in quick controller response at expense of stability and increased overshoot. Settings that are excessively low will produce continuous oscillations at setpoint. High proportional band settings (low gain) results in a sluggish response with long periods of process "droop”. A proportional band of 0.0% forces the controller into ON/OFF control mode with its characteristic cycling at setpoint (see ON/OFF Control). integral Time Integral time is defined as the time, in seconds, in which the output due to integral action alone equals the output due to proportional action with a constant process error. As long as a constant error exists, integral action WIl] “repeat” the proportional action every integral time. Integral action shifts the center point position of the proportional band to eliminate error in the steady state. The units of integral time are seconds per repeat. DEVIATION | - TIME OUTPUT INTEGRAL OUTPUT POWER (%) | -67- ET -— TIME PROPORTIONAL OUTPUT L- INTEGRAL | | TIME | _ Eo Integral action (also known as "automatic reset”) changes the output power to bring the process to setpoint. Integral times that are too fast (small times) do not allow the process to respond to the new output value and, in effect, "over compensate" which leads to an unstable process with excessive overshoot. Integral times that are too slow (large times) produce a response which is sluggish to eliminate steady state errors. Integral action may be disabled by setting the time to 0. If done so, the previous integral output power value is maintained. NOTE: TOTAL OUTPUT POWER IS THE SUM OF THE THREE PID SETTINGS. Integral Time (Cont'd) If integral action is disabled (Automatic Reset), manual reset is available by modifying the output power offset ("OPOF" initially set to zero) to eliminate steady state errors. This parameter appears in unprotected parameter mode when integral time is set to zero. The controller has the feature to prevent integral action when operating outside the proportional band. This prevents "reset wind-up”. Note: The Proportional band shift due 10 integral action may itself be "reset" by temporarily setting the controller into the ON/OFF control mode (proportional band =0). Derivative Time Derivative time is defined as the time, in seconds, in which the output due to proportional action alone equals the output due to derivative action with a ramping process error. As long as ramping error exists, the derivative action will be “repeated” by proportional action every derivative time. The units of derivative time are seconds per repeat. DEVIATION - TIME | OUTPUT | PROPORTIONAL OUTPUT POWER (%) | ——— DERIVATIVE OUTPUT a TIME NOTE: TOTAL OUTPUT POWER IS THE | DERIVATIVE | TIME | Derivative action is used to shorten the process response time and helps 10 stabilize the process by providing an output based on the rate of change of the process. In effect, derivative action anticipates where the process is headed and changes the output before it actually “arrives”. Increasing the derivative time helps to stabilize the response, but too much derivative time I | | | | | SUM OF THE THREE PID SETTINGS. -68- coupled with noisy signal processes, may cause the output to fluctuate too greatly, yielding poor control. None or too little derivative action usually results in decreased stability with higher overshoots. No derivative action usually requires a wider proportional and slower integral times to maintain the same degree of stability as with derivative action. Derivative action is disabled by setting the time to zero. Output Power Offset (Manual Reset) If the integral time is set to Ô (automatic reset is off), it may be necessary to modify the output power to eliminate errors in the steady state. The Output Power Offset (OPOF) is used to shift the proportional band to compensate for errors in the steady state. The output power offset (OPOF) parameter will appear in the unprotected mode, if the integral time = 0. If integral action (automatic reset) is later invoked, the controller continues from the previous output power offset and updates accordingly. Pid Adjustments To aid in the adjustment of the PID parameters for improved process control, a chart recorder is necessary to provide a visual means of analyzing the process. Compare the actual process response to the PID response figures with a step change to the process. Make changes to the PID parameters in no more than 20% increments from the starting value and allow the process sufficient time to stabilize before evaluating the effects of the new parameter settings. TYPICAL RESPONSE OF VARIOUS CONTROL MODES P&I PROCESS P&I &D | SP P xD P only æ- TIME PROCESS RESPONSE EXTREMES OVERSHOOT AND OSCILLATIONS SLOW RESPONSE PROCESS PROCESS À | SP A. — SP —æ TIME — TIME TO DAMPEN RESPONSE: TO QUICKEN RESPONSE: — INCREASE INTEGRAL TIME. — DECREASE PROPORTIONAL BAND. — USE SETPOINT RAMPING. — INCREASE OR DEFEAT SETPOINT RAMPING, — USE OUTPUT POWER LIMITS. — EXTEND OUTPUT POWER LIMITS. — RE—INVOKE AUTO—TUNE WITH А — RE-INVOKE AUTO—TUNE WITH A HIGHER DAMPING CODE. LOWER DAMPING CODE. — INCREASE PROPORTIONAL BAND. — DECREASE INTEGRAL TIME. — INCREASE DERIVATIVE TIME. — DECREASE DERIVATIVE TIME. — CHECK CYCLE TIME. -69- ON/OFF CONTROL The controller can operate in the ON/OFF control mode by setting the proportional band = 0.0 The ON/OFF control hysteresis band (CHYS) parameter can be used to eliminate output chatter around setpoint. The secondary output can also be used in the ON/OFF control by setting the relative gain = 0.0 The phase of the control action can be reversed by the output control action parameter. ON/OFF control is usually characterized by significant temperature oscillations about the setpoint value. Large control hysteresis values makes the oscillations larger. ON/OFF control should only be used where the constant oscillations have little effect on the process. MAIN CONTROL OUTPUT (OP1) SECONDARY OUTPUT (OP2) process REVERSE ACTING Le —^ LS Tt | | | | OUTPUT OFF OUTPUT OFF LED OFF OUTIL LED OFF FORWARD ACTING PROCESS | y $ HYS PS | | OUTPUT OFF OUTPUT OFF LED OFF TN LED OFF | | | | REVERSE ACTING PROCESS | oN. SP y > HYS | | | | | ss | i OUTPUT OFF OUTPUT OFF | OUTPUT ON LED OFF LED ON LED OFF process FORWARD ACTING | N. alii wl) Tee | | | OUTPUT OFF OUTPUT OFF LED OFF ÓN | LED OFF -70- ON/OFF CONTROL ON/OFF and PID control can be used for the main output (OP1) and the secondary output (OP2) in several combinations. The following lists the valid control modes: OP1 MODE | OP2 MODE MANUAL MODE OP1STATE | OP2STATE ON/OFF PID ON/OFF ON/OFF ON/OFF (PrOP=0.0) | (GAN2=0.0) TP - Time Proportioning Note: in manual mode, the % output power is not limited to the output power limits (OPLO & OPHI). -71- AUTO-TUNE Auto-Tune is a user initiated function in which the controller automatically determines the optimum PID settings based upon the process characteristics. The PROCESS desired process setpoint should be entered first. AUTO-TUNE OPERATION FIGURE Auto-Tune may then be initiated at start-up, from i setpoint, or at any other process value point. After Auto-Tune is complete, the PID settings SETPOINT remain constant until user modified. As shown in the Auto-Tune Operation figure, Auto-Tune cycles the process at a control point 3/4 of the distance between AUTOTUNE 7 /N the current process signal value where Auto-Tune CONTROL was initiated and the setpoint. The 3/4 control point N | NN | | was selected to reduce the chance of signal overshoot | | | | | at setpoint when Auto-Tuning al start-up. If | | | | | AUTOTUNE COMPLETE. PID Auto- Tuning from setpoint and signal overshoot is А ОКЕ = | | | | | SETTINGS ARE CALCULATED unacceptable, place the controller in the user | | | | | AND LOADED INTO MEMORY (manual) mode and reduce the power to lower the process signal value. Allow the process to stabilize | | | | | | mo TIME and execute Auto-Tune from the lower process value. PHASE | Aut? | Aut2 | Aut3 | Auté | AutS | After starting Auto-Tune, the secondary display DISPLAY MODES | | | | indicates the current phase (Autl, Aut2, Aut3, Aut4, & Aut5). If the controller remains in an Auto-Tune hase unusually long, the process or connections ma OUTPUT CONTROL ACTION OP1—ON pas OP1-ON 254 DP1-ON be faulty. Auto-Tune may be terminated at any time (REVERSE) peor 2700 |OP2-0FF| DP2-ON jOP2-OFF without disturbing the previous PID constants. As an alternative to Auto-Tuning, the manual tuning procedure can be used to give satisfactory results. Prior to initiating Auto-Tune, it is essential that the controller be configured to the application. In particular, control hysteresis (CHYS) and Auto-Tune damping code (icod) must be set in the Output Parameters section. Generally, control hysteresis of 2-5 units is adequate. The damping code may be set to yield the response characteristics shown in the damping code figure. A damping code setting of 0 gives the fastest response with some overshoot, and a code of 4 gives the slowest response with minimum overshoot. -72- For systems using the secondary output, use a damping code of 1 or 2. The relative gain (Gan2) and deadband overlap (db-2) must be set by the user (the controller will not alter these parameters). (See Secondary section for adjustment of these parameters). During Auto-Tune, it is important that external load disturbances be minimized, and if present, other zone controllers idled as these will have an effect on the PID constant determination. Keep in mind for large systems with long time constants, Auto-Tune may take hours to complete. PROCESS | DAMPING CODE FIGURE TYPICAL RESPONSE CURVES WITH AUTOTUNE DAMPING CODES @ TO 4. Note: Actual responses may vary depending on the process, step changes, etc. — «= TIME .73- To Initiate Auto-Tune: Make sure that Auto-Tuning is enabled in parameter lockouts module. Place the controller into the normal display mode. Press PAR for 3 seconds from normal display mode. Scroll to "tUNE" by use of PAR, if necessary. Select "YES" and press PAR. Auto-Tune is initiated. To Cancel Auto-Tune: (Old PID settings remain in effect). A) Make sure that Auto-Tuning is enabled in parameter lockouts module. Place the controller into the normal display mode. Press PAR for 3 seconds from normal display mode. Scroll to "UNE" by use of PAR, if necessary. Select "NO" and press PAR. Auto-Tune canceled. B) Or reset the controller by disconnecting AC power. Note: If using the linear DC output (4-20mA) for control, full power will be applied (+100% OP1 or -100% OP2) regardless of the output power limit settings. APPENDIX "A" - THEORY OF OPERATION The PSC reads the input signal from the transducer and scales the signal for the main display. The PSC controls a profile by comparing the scaled process value to the setpoint profile in progress, and calculates the output power value by use of a modified PID control algorithm. The unit then outputs the new control value to the system under control to conform the process to the profile. The PID control algorithm incorporates features which provide good process control and reduced overshoot to minimize process errors. The input signal is filtered by a low-pass filter to increase stability and then is converted to a digital code by a precise analog to digital conversion process. The 4-20mA linear DC current output option features digital scaling and is isolated from controller common. All controller parameters are permanently stored in non-volatile E2PROM. An AC power selector switch permits operation from 115 or 230VAC supplies. BLOCK DIAGRAM ch SWITCH SELECTABLE 250 5 5 ac] NOTES: A.C. POWER SELECTOR SWITCH MUST BE SET INTERNALLY. MAIN CONTROL QUTPUT MAY HAVE ANY TYPE MODULE INSTALLED, +5v x OPTION VARIATIONS DETERMINE TERMINAL DESCRIPTIONS, REFER TO FIGURE 1 FOR DESCRIPTIONS. OP1—A OP1—B 3 POWER SUPPLY +5V —5v +12V +22V (ISOLATED) —3.5V (ISOLATED) +5V (ISOLATED) > DISPLAYS PROCESS CIRCUITRY —k—| kevpaD | USER INPUT [=] SELF CALIBRATIN A/D CONVERTER > E? MEMORY -74- PSC W/O RS-485 OPTION PSC W/ RS-485 OPTION ANY OUTPUT MODULE (RELAY, LOGIC/SSR DRIVE, OR TRIAC) ANY TYPE OUTPUT MODULE (RELAY, LOGIC/SSR DRIVE, OR TRIAC) MAY BE USED IN ANY OUTPUT SOCKET MAY BE INSTALLED INOUTPUT OP1 (OP1, AL1, OR AL2/OP2). THE DUAL ALARM OR SECONDARY WALARM OPTION MUST HAVE THE SAME TYPE MODULE INSTALLED, SINCE THEY SHARE THE SAME COMMON TERMINAL. — LOGIC/SSR | | TRIAC MODULE | | LOGIC/SSR | | DRIVE MODULE | | ISOLATED ВИ DRIVE MODULE | | (NOT ISOLATED) | | Ly аВУАС 55 | er ISOLATED) | | | | + | | RS-485 | | | | +12V = | Sop +12, | Bl | sem CIRCUITRY Г С А в С A B < m O O $ E E ad sue ое © | | + | 3 3 N N N = o 2 x > X — — — = D < > Q < < < 8 NV ~ < un ео a < & = Note: The serial communications option and the an abog output option < must NOT be connected to the same common. [Improper opera- tion of the analog output may result it connected. Figure 1 -75- APPENDIX "B" - APPLICATION EXAMPLE pH LAST PROFILE PROFILE PHASE COMPLETE 16 9 8 7 8 | PH DEVIATION 5 | ALARM 4 | 3 | HORN 2 | + TIME | | ] | { | pin | Pin | P1r2 | PIHZ | Pez | PH | PROFILE м o | a os PHASE | JE ax a 1 | | | | | гов | PM 2 | е! 3 | Pi 4 1 MS Г EVENT ON OUTPUT 1 PSC Chemical Treatment Process Application A chemical treatment process requires the pH of a solution be ramped at staged levels over specific time periods during start-up. The PSC unit is installed to meet this requirement. After the tank is filled, the PSC's user input is inggered to run profile 1 to start the process. Alarm output 2 signals the operator if the PH level deviates outside the running profile. The error band (profile conformance) 1s programmed to the desired value to prevent the pH from deviating from the programmed setpoint profile. Timed event output 1 signals that the profile has reached the last phase of the process. 115 VAC {MAIN POWER) 115 VAC O “1 AA A AN 0-10v 4~20mA 1/P CONVERTER CHEMICAL TO BE ADDED TO END OF PROCESS INDICATOR a PH SENSOR | | out SNL © 3 T | USER INPUT ALARM 2 OPTION (RELAY MODULE INSTALLED) MAIN CONTROL OUTPUT for — DC INPUTS 4—-20mÁA ANALOG OUTPUT OPTION (RETRANSMIT X OUTPUT POWER) ALARM 1 OPTION (RELAY MODULE INSTALLED) -76- APPENDIX "C" - SPECIFICATIONS AND DIMENSIONS AL? - Alarm #2 is active (For dual alarm option). ОР2 - Secondary output is active (For secondary option). 1. DISPLAY: Dual 4-digit 3. CONTROLS: Four front panel push buttons for modifying and setup of Upper Process Display: 0.4" (10.2mm) High Red LED controller functions and one external input. Lower Auxiliary Display: 0.3" (7.6mm) High Green LED 4. SETPOINT PROFILE: Display Messages: Profiles: 4 hore = Appears when measurement e ao of input range. Segments Per Profile: 8 ramp/hold segments (linkable to 32 segments). ue ppears when measurement exceeds -5% of input range. Ramp Rate: 0.1 to 999.9 units/minute or no ramp. "SENS" - Appears when measurement exceeds "OLOL" and “ULUL" range. ng " . "о - Appears when display value exceeds + display range. Hold es by Taking, from 0.1 to 999.9 minutes, can be extended to 500 Hn - hen display value exceeds - displ . 2. ANNUNCI ATORS. ro when ClepRy vale of рву 9 Error Band Conformity: Off or from 1 to 9999 units deviation, 6 LED Backlight Status Indicators: + value for hold phases, - value for both ramp and hold phases. %PW Lower auxiliary display shows power output in (%). Power-On Modes: Stop, auto-start, or profile resume. PGM - Lower auxiliary display shows profile status or profile time remaining. Start Mode: Ramps from process value. MAN - Controller is in manual mode. Program Auto Cycle: 1 to 249, or continuous. OPI - Mai control output is active. Event Outputs: 2, time activated with profile [uses Alarm output(s)]. АН - Alarm#1 is active. Control: Front panel buttons, user input, or RS-485 communications. DIMENSIONS In inches (mm) Note: Recommended minimum clearance (behind the panel) for panel latch installation is 5.5" (140)H x 2.1" (53.4)W. - 5.41 я | (137.4) Panel Cut-out — 7 ——— E — $ 180 7 | q | e — 1.771 8|— . . (45 8) P IHC O XPW MAN AL! 3.80 q 3.62283 PGM OP1 AL2 (86.5) С (82 15) es | , HEE ml |) 4D - 5,29 (49.5) {10.2} (134.4) -77- APPENDIX “C* - SPECIFICATIONS & DIMENSIONS (Cont'd) Logic/SSR Drive: Can drive up to three SSR Power Units. Type: Non-isolated switched DC, 12VDC typ 5. CONTROL POINTS: (internal 5000 resistance). Setpoints: 4 Drive: 10mA max. (4002 external load). PID gain sets: 4 Protection: Short-circuit protected. Control: Front panel buttons or user input. Triac: 6. SIGNAL INPUT: Type: Isolated, Zero Crossing Detection. Sample Period: 100mS Ratings: Response Time: 300mS (to within 99% of final value wistep input). Voltage: 120/240VAC Signal Overdrive Threshold: Max Load Current: 1 AMP @ 35°C 10V Range: 13V 0.75 AMP @ 50°C 20mA Range: 26mA Min Load Current: 10mA Signal Overdrive Response: Off State Leakage Current: 7mA MAX. Main Control Output: Programmable preset output. Operating Frequency: 20 to 500Hz Display: "SENS". Protection: Internal Transient Snubber, Fused. DC Linear: Programmable preset output. 9. MAIN CONTROL OUTPUT: Normal Mode Rejection: 40db @ 50/60Hz Control: PID or ON/OFF. (improves with increased digital filtering). Output: Time proportioning or linear DC, Common Mode Rejection: 100db, DC to 50/60 Hz. Hardware: Plug-in, replaceable output modules. 7. RANGE AND ACCURACY: Cycle time: Programmable. Signal Accuracy (% of Maximum Input Resolutlon Auto-Tune: When performed, sets proportional band, integral time, and derivative time values. 0-10VDC +/-(0.15% + 3mV) 300VDC 1MQ 10mV Signal Overdrive Action: Programmable. 0-20MADC +/-(0.15% + GuA) 200MADC 100 10hA 10. SECONDARY OUTPUT (Optional): 8. OUTPUT MODULES (For All Output Channels): Control: PID or ON/OFF. (Optional - Must be ordered separately) Output: Time proportioning or linear DC. Relay: Hardware: Plug-in, replaceable output modules. Type: Forn-C (Form-A with RS-485 option) Cycle time: Programmable. Rating: 5 Amps @ 120/240V AC or 28V DC (resistive load), Proportional Gain Adjust: Programmable. 1/8 HP @ 120VAC (inductive load). DeadBand Overlap: Programmable. Life Expectancy: 100,000 cycles at maximum rating. 11. LINEAR DC DRIVE (Optional): (Decreasing load and/or increasing cycle time, Type: Linear 4-20mA with digital scale and offset. increases life expectancy). Compliance: 10V (50082 max. loop impedance). Resolution: 11 bits. Accuracy: +(0.1% of reading + 25 A). Source: % output power, setpoint, deviation, or process value. (Available for OP1 or OP2, but not both.) -78- 12. ALARMS (Optional): 13. 14. Hardware: Plug-in, replaceable output module. Modes: Absolute high acting Absolute low acting Deviation high acting Deviation low acting Inside band acting Outside band acting Timed event output(s) Reset Action: Programmable; automatic or latched. Delay: Programmable; enable or disable. Hysteresis: Programmable. Annunciator: LED backlight for "AL1", "AL2", (Alarm #2 not available with secondary output). SERIAL COMMUNICATIONS (Optional): Type: RS-485 Multi-point, Balanced Interface. Communication Format: Baud Rate: Programmable from 300 to 9600. Parity: Programmable for odd, even, or no parity. Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit. Unit Address: Programmable from 0-99, maximum of 32 units per line. Transmit Delay: 100msec Minimum, 200msec Maximum. RS-485 Common: Isolated from signal input common. Auto Print Time: Off to 9999 seconds between print-outs, USER INPUT: Viy Max = 5.25VDC, ViL = .85VMax; Vii = 2.0VMIN. Response time: 100msec maximum. Functions: Program Lock Print Request Integral Action Lock Load Contro! Point Auto/Manual Transfer Run/Hold Profile 1 Setpoint Ramp Select Run/Stop Profile 1 Reset Alarms -79- 15. 16. 17. 18. 19 POWER: 115/230 VAC (+10%, -15%) no observable line variation effect, 48-62 Hz, 10V A, switch selectable. TEMPERATURE EFFECTS: Operating Range: 0° to 50°C Storage Range: -40° to 80°C Span Drift: 90 ppm/°C Zero Drift: 6-10VDC Range - 0.2mV/°C 4-20mA DC Range - 0.5uA/°C Relative Humidity: Less than 85% RH CONNECTION: Jaw-type terminal block. CONSTRUCTION: Front Panel: Flame and scratch resistant tinted plastic. Case: High impact black plastic. (Mounting collar included). NEMA 4X/IP65 model only: Sealed bezel utilizing 2 captive mounting screws (panel gasket included). . WEIGHT: 1.3 Ibs. (.6 kgs) Accessory: External SSR Power Unit: Switched Voltage Range: 50 to 280VAC (Nominal: 240VAC) Load Current: 45 Amps @ 25°C ambient temperature 35 Amps @ 50°C ambient temperature On State Input: 3 to 32VDC @ 15002 impedance. (isolated) (Use Logic/SSR drive output module) Off State Input: 0.0 to 1.0 VDC Size: 5.5" (14cm)L x 4.75" (12cm)W x 2.62" (6.6cm)H APPENDIX "D" - TROUBLESHOOTING The majority of problems can be traced to improper connections or incorrect set-up parameters. Be sure all connections are clean and tight, that the correct output module is fitted, and that the set-up parameters are correct. Problems Possible Cause Remedies NO DISPLAY 1. Power off 1. Check power. 2. Voltage selector switch in the wrong position. 2. Check selector switch position. 3. Brown out condition 3. Verify power reading. 4. Loose connection or improperly wired. 4, Check connections. 5. Bezel assembly not fully seated into rear of unit. 5. Check installation. INDICA TOR 1. Incorrect parameter set-up 1. Check set-up parameters. NOT WORKING a. Power-up unit for self-test. "E-FP" IN DISPLAY 1. Defective front panel button. 1. Press DSP to escape, then check all buttons for proper operation. 2. Replace unit. "E- UP” IN DISPLA Y 1. Internal problem with controller. 1. Replace unit. "E-E2" IN DISPLAY 1. Loss of set-up parameters due to noise spike. 1. Press DSP to clear then check ALL set-up parameters. a. Check sensor input & AC line for excessive noise. b. If fault persists, replace unit. e... OF"... IN DISPLAY 1. Input display out of range. 2. Loss of set-up parameters. 1. Check unit scaling. 2. Check set-up parameters. "OLOL” IN DISPLAY I. Input signal overload. 2. Loss of set-up parameters. 1. Check input signal level. 2. Check set-up. "ULUL" IN DISPLAY 1. Input signal underload. 2. Loss of set-up parameters. 1. Check input signal level. 2. Check set-up parameters. -80- APPENDIX "D" - TROUBLESHOOTING (Cont'd) 3. Controller needs calibration. 3. Problems Possible Cause Remedies DISPLAY INCORRECT 1. Lose or corroded connections. 1. Check connections. OR DISPLAY WANDERS 2. Signal source in noisy environment. 2. Evaluate signal source location. a. Increase digital input filtering. Check calibration. (See Appendix "F" Calibration Accuracy) 2. Incorrect programming or scaling. 3. Connections reversed. 4. DC voltage source in loop. RUN PROCESS NOT STABLE OR SLUGGISH 1. Incorrect PID values. 1. See PID CONTROL. OUTPUTS NOT WORKING 1. Improperly wired. 1. Check wiring. 2. Incorrect output module. 2. Check output module. 3. Defective output module. 3. Check or replace output module. LINEAR DC OUTPUT 1. Too high load resistance. 1. Check that maximum load resistance is NOT WORKING < 500Q (10V). Check programming. . Check connections. . This is an active loop. Remove all DC voltage sources. CONTROLLER LOCKS UP OR RESETS 1. Noise spikes entering controller due to load switching transients. 2. Defective controller. 1. a. Use Triac output module, if possible. 2. b. Use RC snubbers or similar noise suppressors at load point. (Do NOT use at the controller.) c. Use separate AC feed line to controller. d. Locate controller € signal lines away from noise producing mechanisms (solenoids, transformers, relays, etc.). e. See "Installation Considerations Of Electronic Instruments Controls In Industrial Environments” in RLC catalog. Replace unit. -81- APPENDIX "E" - MANUAL TUNING An alternative to Auto-Tuning is manual tuning. The following is a manual tuning procedure for determination of the PID control constants. The method described here is an adaptation of the Ziegler-Nichols Closed Loop Cycling procedure first presented in 1942. This method induces process oscillations, therefore, exercise caution for sensitive systems. 1) Connect a chart recorder to log the process value and set chart speed appropriate for the process. 2) Set proportional band (ProP) to 20.0%. 3) Set integral time (Intt) and derivative time (dErt) 10 0. 4) Slowly decrease proportional band (increase controller gain) until process Just BEGINS 10 oscillate. Allow adequate time for the process to respond. If oscillations appear to grow, increase proportional band. Adjust the proportional band until steady oscillations appear. 5) Note the peak-to-peak amplitude of the cycle (A) and multiply it by the desired response, then divide by the full range of the sensor, to obtain the Proportional Band value. The period of oscillation (T) is multiplied by the desired response to obtain the desired Integral Time and Derivative Time values. -82- PROCESS 7] A, A » TIME APPENDIX "F"'- CALIBRATION Calibration Check The instrument has been fully calibrated at the factory for the voltage and current inputs. If the unit appears to be indicating or controlling incorrectly, refer to the troubleshooting section before attempting this procedure. If the controller is suspected of reading incorrectly, the instrument may be checked for indication accuracy without disturbing the factory calibration. The three parameters to be checked are: voltage reading, mA reading, and the 4-20 linear mA output. The following procedures may be used for this purpose. NOTE: Allow 1/2 hour warm-up before checking these parameters. Voltage Reading Check 1) Connect a DC volt source with an accuracy of 0.01% or better to terminal #8 (+) and terminal #10 (-). 2) Advance to the configuration parameter modules from the normal display mode. 3) Select the controller to indicate voltage (VOL), in the input parameter module. 4) Press the "PAR" key until "INP 1" appears in the main display. 5) Press the "DSP" key, once, the "%PW" & "DEV" annunciators will flash. 6) The secondary display will indicate the voltage applied at Terminals 8 & 10. 7) Compare the controller readout to the standard at various points over the range (0-10V). The tolerance is 0.15% of reading +/- 1LSD. 8) Calibrate the controller if the readings are out of tolerance. -83- Current Reading Check 1) Connect a current source with an accuracy of 0.01% or better to terminal #9 (+) and terminal #10 (-). 2) Advance to the configuration parameter modules from the normal display mode. 3) Select the controller to indicate current (Curr), in the input parameter module. 4) Press the "PAR" key until "INP 1" appears in the main display. 5) Press the "DSP" key, once, the "%PW" & "DEV" annuniciators will flash. 6) The secondary display will indicate the current applied at Terminals 9 & 10. 7) Compare the controller readout to the standard at various points over the range (4-20mA). The tolerance is 0.15% of reading +/- 1LSD. 8) Calibrate the controller if the readings are out of tolerance. Linear mA Output Check 1) Connect an ammeter to the linear output (#11 & #12) with an accuracy of 0.1% or better 2) Set "ANAS" (analog assignment) to "INP", in configure input parameters. 3) Drive the input signal level below the programmed "ANLO" value. Check for 4mA (+/- .02mA). 4) Drive the input signal level above the programmed "ANHI" value. Check for 20mA (+/- .03mA). 5) Calibrate the controller linear mA output if out of tolerance. Calibration When re-calibration is required (generally every two years), this procedure should only be performed by qualified technicians using appropriate equipment. Equipment source accuracies of 0.01% or better are required. The procedure consists of three parts: applying accurate voltage signals, applying precision mA currents and measuring accurate mA currents. Allow a 30 minute warm-up period before starting this procedure. This procedure may be aborted by disconnecting power to the controller before exiting the configuration mode. The existing calibration will remain in affect. Configure Step 9 - Factory Service Operations (9-FS) | Display | Parameter | Deascription/Comments Code Enter factory service 48 Calbrate instrument function code CAL Voltage & current {| yes/no Calibration of vokage input is done first. calbration Voltage And Current Calibration Connect precision voltage source with an accuracy of 0.01% to terminals (+) #8 and (-) #10 for voltage calibration. Stp- Pause controller wil impose a 5 sec. . the Connect a precision current source with an accuracy of 0.01% to terminals (+) #9 and (-) #10, for current calibration when step A appears. unit automatically advances to analog output calibration # the option is installed. Analog Output Calibration (ANCL) Connect precision ammeter (0.1% accuracy) to rear terminals (+) #11 and {-) #12. | Display | Parameter | Description/Comments ANCL 4-20mA analog | yes/no This parameter will not appear if analog output option is not installed. Quinut calibration ANCA Analog output Observe current reading. НА, 00, mé, press. PAR. i not equal, modty existing 4mA code value | achieve A, Pres ANC2 Analog output Observe current reading. I 20. 00 mA, press PAR. 20mA code If not equal, modify existing code value using up & down buttons to achieve value 20.00 mA. Press PAR. -84- APPENDIX "G" - USER PARAMETER VALUE CHART Unit Number ANLO 4mA Value Configure Serial Communications Mnemonic Parameter User Setting ANHI 20mA Value Mnemonic Parameter User Setting SP Setpoint - , bAUd Baud Rate OPOF Output Power Offset _ Configure Lockouts PAD Parity Bit ОР Output Power _ Mnemonic Parameter User Setting Addr Unit Address ProP Proportional Band - SP Access Setpoint — —— Abrv Abbrev. or Full Transmission Intt Integral Time op Access Output Power — PrAt Automatic Print Rate dErt Derivative Time Pros Access Profile Status — PoPt Print Options AL-1 Alarm 1 P-tr Acoess Time Remaining —_— INP AL-2 Alarm 2 UdSP Access Display Units — SEt Code Access Code Nurrber SL OPr Configure input PID Access PID Values — Pbd tYPE Input Type - AL Access Aarmís) Values INt dCPt Decimal Point - ALIS Enable Reset Alarms) dEr rnd Rounding Increment _ CPAC Enable Control Points _ AL1 FLtr Digital Filtering _ PrAC Enable Profile Status AL2 dSP1 Display Value 1 - en trnF Enable Auto/Man Transfer dEv INP1 Signal Input Value 1 о tUNE Enable Auto-Tune OFP dSP2 Display Value 2 —— . _ INP2 Signal Input Value 2 ——. Configure Alarms с SPLO Setpoint Lower Limit Act Alarm 1 Operation Mode Cab SPHI Setpoint Upper Limit rSt1 Alarm 1 Reset Mode р SPP Ramp Rate Stb1 Alarm 1 Standby Enabled Pas InPt User Input AL-1 Alarm 1 Value Act2 Alarm 2 Operation Mode Configure Output rSt2 Alarm 2 Reset Mode CYCt Cycle Time - Sth2 Alarm 2 Standby Enabled OPAC Control Action - AL-1 Alarm 2 Value OPLO Output Power Lower AHYS Alarm Hysteresis Value Limit Range - OPHI iret Rane! Upper Configure Secondary Output OPFL Sensor Fail Power Preset —-_ CYce OP2 Cycle Time CHYS ON/OFF Control Hysteresis _____ GANZ Relative Gain tcod Auto-Tune Damping Code db-2 Overlap/Deadband ANAS 4-20mA Output Assignment -85- APPENDIX "G" - USER PARAMETER VALUE CHART (Cont'd) Configure Control Points Mnemonic Parameter SP Setpoint Value PID YES/NO Load With Setpoint Value Pb Proportional Band ft Integral Time dt Derivative Time Configure Profiles Mnemonic PnCC Pnin PnSt PnEb Pnr1 Pnl1 PnH1 Pnr2 Pal? PnH2 Pnr3 Pni3 PnH3 Pnr4 Pni4 PnH4 Pnr5 Pni5 PnH5 Pnr6 Pnl6 Parameter Profile Cycle Count Profile Link Profile Status Profie Error Band Profile Ramp Rate 1 Profie Setpoint Level 1 Protie Hold Time 1 Profile Ramp Rate 2 Protfie Setpoint Level 2 Profie Hold Time 2 Profile Ramp Rate 3 Profile Setpoint Level 3 Profie Hold Time 3 Profile Ramp Rate 4 Profile Setpoint Level 4 Profile Hold Time 4 Profile Ramp Rate 5 Profile Setpoint Level 5 Profile Hold Time 5 Profile Ramp Rate 6 Profile Setpoint Level 6 User Setting CP-t CP-2 CP-3 CP4 Pr-2 Pr-3 Pr-4 И an HT an -86- Mnemonic Parameter PnH6 Profie Hold Time 6 Рпг7 Profile Ramp Rate 7 Pnl7 Profile Setpoint Level 7 PnH7 Profie Hold Time 7 Pnr8 Profile Ramp Rate 8 Pnl8 Profile Setpoint Level 8 PnH8 Profile Hold Time 8 Configure Timed Event Outputs Pn 1 Event 1 Рп2 Event 2 Pn3 Event 3 Pn4 Event 4 Pn5 Event 5 Pn6 Event 6 Pn? Event 7 Pn8 Event 8 Png Event 9 Pn 10 Event 10 Рп 11 Event 11 Pn12 Event 12 Рп 13 Event 13 Pn 14 Event 14 Pn 15 Event 15 Pn 16 Event 16 Controller Operating Mode Automatic or Manual Auto-Tune Invoked at PE- User Setting Pr-1 Pr-2 Pr-3 Pr4 PE-2 PE-3 — PE-4 APPENDIX "H" - ORDERING INFORMATION NEMA SECONDARY RS-485 PART DESCRIPTION 4X1P65 OUTPUT COMM. W/ NUMBERS Process Setpoint Controller Note: Quiput Modules are NOT supplied with the controller… When specifying the controller, be sure to purchase the appropriate output module for the Main Control Output and if necessary, the alarm output(s) and secondary output. The controller can be fitted with any combination of output modules that do not have the RS-485 option. The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an SSR power unit. It should never be connected to a line voltage. * Units equipped with the RS-485 must have the Dual Alarm or Secondary w/Alarm options fitted with the same type output modules (the Main Output OP1 may be fitted with any type of output module). All modules are shipped separately and must be installed by the user. -87- LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company's liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company's option. The Company disclaims all liability for any affirmation, promise or representation with respect to the products. The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries, deaths, property damage, lost profits, and other matiers which Buyer, its employees, or sub-contractors are or may be to any extent liable, including without limitation penalties imposed by the Consumer Product Safety Act (PL. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter. No warranties expressed or implied are created with respect to The Company’ s products except those expressly contained herein. The Customer acknowledges the disclaimers and limitations contained and relies on no other warranties or affirmations. PSC/IM-1 4/93 RED LI ON INTERNATIONAL HEADQUARTERS CONTROLS 20 Willow Springs Circle, York, Pa. 17402 (717) 767-6511 FAX: (717) 764-0839 EUROPEAN HEADQUARTERS 892 Plymouth Road, Slough, Berkshire SL1 4LP ENGLAND 753-696888 FAX: 753-696339
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