Red Lion PSC Instruction PID Controller Product Manual

Red Lion PSC Instruction PID Controller Product Manual
 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
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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
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STANDARD UNIT ONLY. Й
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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 [email protected]
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 | [email protected] 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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