User manual | c us listed - Carlton Bates

Bulletin No. PCU-F
Drawing No. LP0338
Released 08/13
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL PCU - PROCESS CONTROL UNIT

SELF-DIAGNOSTICS

FULL PID CONTROL WITH REDUCED OVERSHOOT

OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE

OPTIONAL DUAL ALARM OUTPUTS (USES OUTPUT MODULES)

OPTIONAL SECONDARY OUTPUT (USES OUTPUT MODULE)



C
UL
R
IND. CONT. EQ.
OPTIONAL TYPE 4X/IP65 SEALED FRONT BEZEL
STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES

100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY

ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS


DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
PROCESS VALUE AND SETPOINT OR SECOND ANALOG INPUT
OPTIONAL SECOND ANALOG INPUT FOR REMOTE SETPOINT
AND CASCADE CONTROL

51EB

OPTIONAL MOTORIZED VALVE POSITION CONTROL AND
VALVE FAIL ALARM


US LISTED
OPTIONAL LINEAR 4 to 20 mA OR 0 to 10 VDC OUTPUT FOR
CONTROL OR PROCESS VALUE RE-TRANSMISSION
PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED
FLEXIBILITY
MANUAL/AUTOMATIC AND LOCAL/REMOTE SETPOINT
CONTROL MODES

SETPOINT RAMPING FOR PROCESS STARTUP

PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS

FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR Drive and Triac)
ACCEPTS EITHER 0 to 10 VDC OR 0 to 20 mA DC INPUTS
DESCRIPTION
The PCU Controller accepts either 0 to 10 VDC or a 0 to 20 mA DC input
signal, precisely scales the process signal according to programmable scaling
points, and provides an accurate output control signal (time proportional, linear,
or valve position) to maintain a process at the desired control point. A
comprehensive set of easy to use program instructions allows the controller to
solve various applications.
The controller can operate in the PID control mode for both the main output
and optional secondary output, with on-demand auto-tune, that establishes the
tuning constants. The PID tuning constants may be fine-tuned by the operator
at any time and then locked-out from further modification. The controller
employs a unique overshoot suppression feature, which allows the quickest
response without excessive overshoot. The unit can be transferred to operate in
the manual mode, providing the operator with direct control of the output. The
controller may also be programmed to operate in the ON/OFF control mode
with adjustable hysteresis.
DIMENSIONS In inches (mm)
Dual 4-digit displays allow viewing of the process value and setpoint
simultaneously. Front panel indicators inform the operator of the controller and
output status. Replaceable and interchangeable output modules (Relay, Logic/
SSR Drive, or Triac) can be installed for the main control output, alarm
output(s) and secondary output.
Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.
5.41
(137.4)
PANEL CUT-OUT
1.77 +.02
-.00
(45 +.6
-.0 )
%PW MAN AL1
DEV OP1 AL2
3.80
(96.5)
+.03
3.62 -.00
(92 +.8
-.0 )
3.60
(91.4)
DSP
PAR
1.95
(49.5)
.40
(10.2)
5.29
(134.4)
1.75
(44.4)
1
OPTIONS
Optional dual alarms can be configured to activate according to a variety of
actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT and Valve
Fail Detect) with adjustable hysteresis. A standby feature suppresses the output
during power-up until the process stabilizes outside the alarm region. An
optional secondary output is available (for processes that require cooling) that
provides increased control accuracy and response.
A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface
with actuators, chart recorders, indicators, or other controllers. The output signal
can be digitally scaled and selected to transmit one of the following: % output
power, measurement value, process measurement value deviation or setpoint
value. Valve Positioner and Second Analog Input Models have the adjustable
output demand dampening, output deadband and output update time parameters
to expand the versatility of the PCU to control devices.
The optional Motorized Valve Positioner directly controls the position of a
valve by the use of twin outputs (open and close) to control the direction of
motor rotation. The motor position defines the opening position of the valve.
Two control modes are possible: position control, that makes use of the
slidewire feedback signal supplied with the positioner and velocity control, in
which no slidewire feedback signal is used. Parameters are provided to adjust
the operation of the valve. These include:
-
- Appears when display values exceed - display range.
- Appears when loss of slidewire signal is detected.
- Appears when valve actuator error is detected.
2. POWER: Switch selectable 115/230 VAC (+10%, -15%) no observable line
variation effect, 48 to 62 Hz, 10 VA.
3. ANNUNCIATORS:
LED Backlight Status Indicators (Model dependent):
%PW
DEV
OP1
AL1
AL2
OP2
OPN
CLS
SEC
MAN
REM
Valve activity hysteresis
Valve update time
Variable control dampening
Slidewire signal fail action
Adjustable valve position limits
- Lower auxiliary display shows power output in (%).
- Lower auxiliary display shows deviation (error)
from process setpoint.
- Main control output is active.
- Alarm #1 is active.
- Alarm #2 is active (for Dual Alarm Option).
- Secondary output is active
(for Secondary Output Option).
- Valve positioner OPEN output is active
(for Valve Positioner Option).
- Valve positioner CLOSE output is active
(for Valve Positioner Option).
- Lower auxiliary display shows second analog input
(for Second Analog Input Option).
- Flashing: Controller is in Manual control mode.
- ON: controller is in remote setpoint mode
(Second Analog Input Option).
- OFF: controller is in local setpoint mode
(Second Analog Input Option).
- Flashing: controller is in Manual control mode
(Second Analog Input Optional).
4. CONTROLS: Four front panel push buttons for modifying and setup of
controller functions and one external input for parameter lockout or other
functions.
5. SIGNAL INPUT:
Sample Period: 100 msec typ.
Response Time: 300 msec typ. (to within 99% of final value w/step input)
Signal Overdrive Threshold:
10 V Range: 13 V typ.
20 mA Range: 26 mA typ.
Signal Overdrive Response:
Main Control Output: Programmable preset output
Display: “SENS”
Alarms: Upscale drive
DC Linear: Programmable preset output
Normal Mode Rejection: 40 dB typ. @ 50/60 Hz (improves with increased
digital filtering).
Common Mode Rejection: 100 dB typ., DC to 60 Hz
Protection: Input overload 120 VAC for 30 seconds.
Range And Accuracy:
The Valve Positioner PCU achieves tight process control, yet minimizes
unnecessary valve activity. An alarm event output or display alarm can be
programmed under loss of slidewire feedback or under valve fail detection.
The optional Second Analog Input (0 to 20 mA DC) can be configured as a
remote setpoint signal or as a secondary process signal. Configuration of the
second analog input as a remote setpoint signal allows ratio control, master
setpoint/multiple slave operation, and the ability to cascade the PCU with
another controller (external cascade). Configuration of the second input as a
secondary process signal allows operation as a two-process cascade controller
within a single unit (internal cascade). In either control mode, parameters are
provided to scale, configure, communicate and monitor the activity of both
analog inputs. A square law linearizer function can be used to linearize signals
derived from flow transmitters.
The optional RS485 multidrop serial communication interface provides twoway communication between a PCU 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 zero to ninety-nine. 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.
An optional Type 4X/IP65 rated bezel is available for wash down 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.
SIGNAL RANGE
ACCURACY (% OF
UNSCALED
READING)
0 to 10 VDC
±(0.15% + 3 mV)
300 VDC
1M Ω
10 mV
0 to 20 mADC
±(0.15% + 6 µA)
200 mADC
10 Ω
10 µA
MAXIMUM
INPUT
INPUT
RESOLUTION
IMPEDANCE
6. OUTPUT MODULES [Optional] (For All Output Channels):
Relay:
Type: Form-C (Form-A with some models. See Ordering Information.)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load) max.
Life Expectancy: 100,000 cycles at max. load rating. (Decreasing load
and/or increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typ.
Drive: 45 mA max.
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 Amp @ 35°C
0.75 Amp @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
7. MAIN CONTROL OUTPUT:
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Auto-tune: When selected, sets proportional band, integral time, and
derivative time values.
Signal Overdrive Action: Programmable
SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Do not use the PCU to directly command motors, valves, or other actuators
not equipped with safeguards. To do so, can be potentially harmful to persons
or equipment in the event of a fault to the unit. An independent and redundant
limit indicator with alarm outputs is strongly recommended. The indicators
should have input sensors and AC power feeds independent from other
equipment.
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Process Display: 0.4" (10.2 mm) high red LED
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED
Display Messages (Model dependent):
“OLOL”
“ULUL”
“SENS”
“....”
“-...”
“SLid”
“VALV”
- Appears when measurement exceeds +105% input range.
- Appears when measurement exceeds -5% input range.
- Appears when measurement exceeds “OLOL” & “ULUL”
range.
- Appears when display values exceed + display range.
2
SPECIFICATIONS (Cont’d)
Signal Overdrive Action: Upscale
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with secondary output or motorized valve position option.)
15. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 50°C
Storage Temperature Range: -40 to 80°C
Vibration to IEC 68-2-6: Operational 5-150 Hz, 1 g
Shock to IEC 68-2-27: Operational 5 g
Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input
Zero Drift (maximum):
4 to 20 mA DC Range: 0.5 µA/°C
0 to 10 VDC Range: 0.2 mV/°C
Second Input: 2 µA/°C
Relative Humidity: Less than 85% RH (non-condensing)
Altitude: Up to 2000 meters
16. ISOLATION BREAKDOWN RATINGS:
All inputs and outputs with respect to AC line: 2300 VMIN
Analog Outputs, Second Analog Input or Slidewire Input with respect to
main input: 500 VMIN
17. CERTIFICATIONS AND COMPLIANCES:
CE Approved
EN 61326-1 Immunity to Industrial Locations
Emission CISPR 11 Class A
EN 61010-1
RoHS Compliant
UL Recognized Component: File #E156876
UL Listed: File #E137808
Type 2 Enclosure rating (Face only) for PCU0
Type 4X/IP65 Enclosure rating (Face only) for PCU1
Refer to EMC Installation Guidelines section of the manual for additional
information.
18. CONNECTION: Jaw-type terminal block
Wire Range: 12-30 AWG copper wire
Torque: 5-7 inch-lbs (56-79 N-cm)
19. CONSTRUCTION:
Front Panel: Flame and scratch resistant tinted plastic
Case: High impact black plastic. (Mounting collar included)
Type 4X/IP65 model only: Sealed bezel utilizing two captive mounting
screws (panel gasket included) This unit is rated for Type 4X/IP65 indoor
use. Installation Category II, Pollution Degree 2
20. WEIGHT: 1.3 lbs (0.6 kgs)
8. SECONDARY OUTPUT (Optional):
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Proportional Gain Adjust: Programmable
Deadband Overlap: Programmable
9. LINEAR DC OUTPUT (Optional): With digital scale and offset,
programmable deadband and update time.
4 to 20 mA:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 25 µA)
Compliance: 10 V (500 Ω max. loop impedance)
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV)
Min. Load Resistance: 10 KΩ (1 mA max.)
Source: % output power, setpoint, deviation, or process value
(Available for OP1 or OP2, but not both.)
10. MOTORIZED VALVE POSITIONER (Optional):
Two Outputs: Valve open and valve close or Linear DC (optional)
Hardware: Plug-in, replaceable output modules
Three Inputs: Slidewire feedback, signal fail detect (Isolated from main
input)
Slidewire Resistance: 100 Ω to 100 KΩ
Slidewire Exciting Voltage: 0.9 VDC typ.
Slidewire Fail Action: programmable
Control Mode: Position mode (with slidewire) and velocity mode (w/o
slidewire).
Control Deadband: 1% to 25.0% (position mode)
0.1 to 25.0 seconds (velocity mode)
Update Time: 1 to 250 seconds
Motor Time (open, close): 1 to 9999 seconds
Position Limits: Adjustable 0.0 to 100.0% of valve stroke
Valve Fail Time: Off to 9999 seconds
Alarm mode: Dual acting; loss of slidewire feedback signal and valve fail
detection
11. SECOND ANALOG INPUT:
Range: 0 to 20 mA (Isolated from main input)
Overload: 100 mA MIN (steady state)
Input Resistance: 10 Ω typ.
Voltage Drop (@ 20 mA): 0.2 V typ.
Accuracy: 0.15% of reading ±10 µA ±1 LSD
Scale Range: -999 to 9999
12. SERIAL COMMUNICATION:
Type: RS485 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 to 99, max. of 32 units per line
Transmit Delay: 100 msec min., 200 msec max.
RS485 Common: Isolated from signal input common
Auto Print Time: Off to 9999 seconds between print-outs
13. USER INPUT (Optional): Internally pulled up to +5 VDC.
VIN = 5.25 VDC MAX, VIL = 0.85 VMAX; VIH = 3.0 VMIN,
Available on all second input (MVP & ANA) models, and on models with
RS485.
Response Time: 100 msec max.
Functions: Program Lock
Integral Action Lock
Auto/Manual Mode Select
Setpoint Ramp Select
Reset Alarms
Print Request
Local/Remote Setpoint Select
14. ALARMS (Optional):
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
Valve fail
Second Analog Input monitoring
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
BASIC OPERATION
The PCU controls a process by measuring the input signal and then calculating
a control output power value by use of a modified PID control algorithm. The unit
controls the system with the new output power value to keep the process at
setpoint. The PID control algorithm incorporates features that provide for high
control accuracy and low overshoot from process disturbances.
FRONT PANEL FEATURES
In the normal operating mode, the unit displays the scaled process value in the
upper display. One of four other parameters can be viewed in the lower display:
- Setpoint
- % Power Output
- Deviation
- Second Input Process Value
The parameters can be scrolled through by pressing the DSP button. If
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the PAR
button and modified by use of the UP and DOWN buttons. Parameters are then
entered by the PAR button, which advances the user to the next parameter.
Pressing the DSP button immediately returns the controller to the normal
operating mode when making a parameter change. The controller’s configuration
and parameter settings are stored in an internal E2PROM device.
3
HARDWARE FEATURES
OPTIONS
The fast 100 msec input sampling rate provides quick controller response to
a process disturbance, thus providing excellent process control. Measurement
accuracy of 0.15% or better, provides closer process control conforming to the
desired control setpoint value. The unit accepts either a 0 to 10 VDC or a 0 to
20 mA DC input signal. The AC input power is switch selectable, allowing the
unit to operate from either 115 VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the output modules may be easily
changed or replaced without disturbing the wiring behind the panel. No
re-programming is required when changing or replacing modules.
The optional Type 4X/IP65 rated model utilizes two bezel securing screws
and a neoprene gasket to guarantee a water tight seal, when properly installed.
The standard model simply requires pressing a latch to remove the unit.
Low-drift, highly stable circuitry ensures years of reliable and accurate
process control. The recommended two-year re-calibration interval is easily
accomplished via the programming menu.
RATIO CONTROL
SECOND INPUT
FLOW A
UNCONTROLLED
FLOW
FLOW C = FLOW A + FLOW B
%PW REM AL1
SEC OP1 AL2
DSP
PAR
LINEAR DC
OUTPUT
MAIN INPUT
CONTROLLED
FLOW
FLOW B = [RATIO * FLOW A] + BIAS
SETPOINT FEATURES
The PCU configured for ratio operation controls a process as a ratio of
another process or to another variable. Ratio control is commonly used for flow
applications, however, any two process variables can be controlled in a
ratio mode.
Ratio Control Configuration Parameters
The controller setpoint can be protected from out of range values by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can be programmed.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate. This feature reduces
shock to the process and helps to minimize overshoot. The setpoint may also be
transmitted by the optional linear DC output for slave control loops.
The second analog input may be configured as a remote setpoint. As such, the
controller is easily switched from local/remote setpoint operation via the front
panel or user input. Ratio and bias parameters provide on-line scaling of the
remote setpoint. Absolute limit values and maximum rate of change of the
remote setpoint further enhance controller flexibility.
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
“InPt”
INPUT FEATURES
Select ratio mode
Select second input square root linearization
Select second input decimal point
Enter scaling units of second input
Local/Remote Select options
Program User Input for Local/Remote
Setpoint selection
Ratio Control Operational Parameters
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating characteristics, helping to provide better process
control. Programmable scaling points allow the controller to display in any
engineering unit; flow, level, pressure, etc. Scaling points are used in
conjunction with the programmable rounding increment to stabilize a jittery or
otherwise hard to read process signal for better indication.
The programmable User Input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), etc.
The second analog input has independent scaling parameters to match the
units of other processes or transmitters, or to match the controller’s range.
“rtio”
“bIAS”
- Remote setpoint ratio
- Remote setpoint bias
MOTORIZED VALVE POSITIONER
AL1 OUTPUT
VALVE FAIL
ALARM
STEAM FLOW
OUTPUT FEATURES
%PW MAN OPN
DEV AL1 CLS
Programmable output power limits provide protection for processes where
excessive power can cause damage. Automatic signal overdrive detection, for
fail-safe operation, causes the controller to default to a programmed output
power (upscale or downscale burnout). With adjustable time proportioning
cycle time, and programmable DC linear output, the controller can satisfy a
wide variety of output requirements.
Programmable dampening output hysteresis and output update time parameters
can dramatically reduce actuator activity without degrading control accuracy.
The RS485 Communication option allows the user to access various
controller parameters such as the setpoint, % output power, % proportional
band, etc. The controller may be set up to transmit various parameters at a
programmable automatic print rate.
DSP
PAR
VALVE OPEN OUTPUT
VALVE CLOSE OUTPUT
SECOND INPUT
VALVE POSITION
MAIN INPUT
PROCESS
The motorized valve positioner controls the position of a valve directly, by
use of “open” and “close” control outputs. The slidewire feedback signals of
the valve may optionally be connected to the controller. Alternatively, the
controller may be configured for linear input valve control using the 4 to 20 mA
DC output.
AUTO-TUNE
The PCU has an auto-tune feature that, on demand, automatically determines
the PID control parameters for a particular process. After completion of autotune, the PID parameters are automatically optimized for that process and
loaded into nonvolatile memory. The operator may view and modify the
parameters as desired.
Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
various levels of process control and response characteristics.
Motorized Valve Positioner Configuration Parameters
Position mode: “VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
“Act1”
Velocity mode: “VUdt”
“VOPt”
“VCLt”
“VOnt”
4
-
Enter or measure valve closed position
Enter or measure valve open position
Enter Valve update time
Enter valve control deadband
Enter valve fail detect time
Program alarm as valve fail output
Enter Valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
INTERNAL CASCADE
EXTERNAL CASCADE
SECONDARY
CONTROLLER
PRIMARY
CONTROLLER
STEAM
FLOW
LINEAR DC
LINEAR DC OUTPUT
SECOND INPUT
(PRIMARY OUTPUT)
REMOTE SETPOINT
STEAM
%PW REM AL1
SEC OP1 AL2
SECOND INPUT
DSP
MAIN INPUT
(PRIMARY VARIABLE)
PAR
%PW MAN AL1
DEV OP1 AL2
STEAM PRESSURE
(SECONDARY VARIABLE)
LINEAR DC
%PW REM AL1
SEC OP1 AL2
OUTPUT
DSP
DSP
PROCESS
MAIN INPUT
STEAM PRESSURE
(SECONDARY VARIABLE)
PAR
PAR
TCU
Cascade control allows the process to be divided into two control loops: the
primary control loop and the secondary control loop. The secondary loop receives
its setpoint from the primary loop to control an intermediate variable (steam
pressure). The control level of the intermediate variable is the input to the primary
process. The primary loop (main input) controller maintains loop regulation by
manipulating the setpoint of the secondary controller. The setpoint of the
secondary controller, in turn, changes the intermediate variable. The secondary
loop can react faster to disturbances of the intermediate variable, thereby
minimizing the effects to the primary control loop. Control loops cascaded in such
a manner provide greater control quality than would be possible with single loop
control. A single PCU can accomplish two-process cascade control.
Similar to internal cascade control, external cascade control differs by the
employment of two controllers, one of which is equipped with a second analog
input configured as a remote setpoint. A PCU controls the secondary loop, while
a TCU controls the primary loop.
External Cascade Configuration Parameters
Internal Cascade Configuration Parameters
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“OPd2”
-
PCU
PROCESS
MAIN INPUT
PROCESS TEMPERATURE
(PRIMARY VARIABLE)
Select cascade mode
Select second input square root linearization
Select second input decimal point
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
-
Select ratio mode
Select second input square root linearization
Select second input decimal point
Enter scaling units of second input
Local/Remote select options
External Cascade Operational Parameters
Enter scaling units of second input
“rtio”
“bIAS”
- Remote setpoint ratio
- Remote setpoint bias
Output dampening of secondary
Internal Cascade Operational Parameters
“SP-2”
“Pb-2”
“It-2”
“dt-2”
-
View secondary setpoint value
Enter secondary proportional band
Enter secondary integral time
Enter secondary derivative time
LINEAR DC OUTPUT SETPOINT RE-TRANSMISSION
SETPOINT MASTER CONTROL
Setpoint Master Control allows automatic setpoint changes to
slave controller units (up to 50 units total) from a master PCU
controller. The linear DC output of the master is looped with the
second analog input of the slave PCU controllers. Each slave unit
can have unique remote setpoint ratio and bias values.
Setpoint Slave Configuration Parameters
“OPEr” - Select remote setpoint mode
“root”
- Select second input square root
linearization
“dPt2”
- Select second input decimal point
“dSP1”
“INP1”
- Enter scaling units of second input
“dSP2”
“INP2”
“SPLO”
- Limit range of remote setpoint
“SPHI”
“SPrP” - Limit rate of change of remote
setpoint
SECOND INPUT
MASTER
UNIT
SLAVE
UNIT #1
REMOTE SETPOINT
%PW MAN AL1
DEV OP1 AL2
%PW REM AL1
SEC OP1 AL2
SLAVE
UNIT `N'
(UP TO 50)
SECOND INPUT
REMOTE SETPOINT
%PW REM AL1
SEC OP1 AL2
DSP
DSP
DSP
PAR
PAR
PAR
Setpoint Slave Operational Parameters
“rtio”
“bIAS”
- Second input ratio
- Second input bias
MAIN
INPUT
PROCESS #1
5
MAIN
INPUT
PROCESS #2
MAIN
INPUT
PROCESS "N"
CONTROLLER PROGRAMMING
Configuration 3, Parameter lock-outs
The PCU has been designed to reduce the operator interaction with the
controller while still maintaining a high degree of control accuracy and user
flexibility. Front Panel Program Disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial parameter set-up.
The programming of the controller is divided into four sections:
Unprotected Parameter Mode
Configuration Parameter Mode
Protected Parameter Mode
Hidden Function Mode
These four programming modes allow the controller to adapt to any required
user-interface level.
Configuration 4, Alarms
UNPROTECTED PARAMETER MODE *
The unprotected parameter mode is accessible when program disable is
inactive or when the proper access code number from the protected mode is
entered. The configuration parameter modes can be accessed only from this mode.
“SP”
“OP”
“Prop”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
“Pb-2”
“It-2”
“dt-2”
“AL-1”
“AL-2”
“CNFP”
“End”
-
Enter Setpoint
Enter output power
Enter proportional band
Enter integral time
Enter derivative time
Enter Remote Setpoint ratio value
Enter Remote Setpoint bias value
View internal cascade secondary setpoint
demand
Enter internal cascade, secondary
proportional band
Enter internal cascade, secondary integral
time
Enter internal cascade, secondary derivative
time
Enter value for alarm #1
Enter value for alarm #2
Select basic configuration mode
Return to normal display mode
“tYPE”
“root”
“dCPt”
“rnd”
“FLtr”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPLO”
“SPHI”
“SPrP”
“InPt”
-
Configuration 2, Outputs
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“OPdP”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
“ANdb”
“ANUt”
-
*
“Act1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
-
Select degree of setpoint access
Select degree of power access
Enable deviation display *
Enable second input display *
Enable blank display
Enter parameter access code
Select degree of PID access
Select degree of secondary PID access *
Select degree of ratio/bias access *
Select degree of alarm access *
Enable alarm reset access *
Enable local/remote setpoint selection *
Enable auto/manual mode selection
Enable auto-tune invocation
-
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
Configuration 5, Secondary Output
“CYC2”
“GAN2”
“db-2”
*
- Enter time proportioning cycle time
- Enter relative gain
- Enter deadband or overlap
Configuration 6, Serial Communications
“bAUd”
“PArb”
“Addr”
“Abrv”
“PrAt”
“PoPt”
-
*
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic
transmissions
- Enter automatic print rate
- Select parameters to be included in print-out
Configuration 7, Second Input
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
“OPd2”
-
CONFIGURATION PARAMETER MODE
The configuration parameter mode allows the operator to set up the basic
requirements of the controller. It is divided into sections which group together
related programming steps, such as inputs, outputs, alarms, etc. Upon completion
of each section, the program returns to the configuration selection stage
allowing the user to return to the normal display mode.
Configuration 1, Inputs
“SP”
“OP”
“dEv”
“IN-2”
“bdSP”
“CodE”
“PId”
“PId2”
“rtbS”
“AL”
“ALrS”
“SPSL”
“trnF”
“tUNE”
*
Select remote setpoint or internal cascade
mode
Select second input square root linearization
Select second input decimal point
Entering scaling parameters of second input
Enter local/remote select options
Enter Secondary output control dampening
Configuration 8, Motorized Valve Positioner
Select input signal type
Select square root linearization of main
input *
Select scaled display decimal point position
Enter rounding increment and trailing zeroes
for scaled display
Select level of input filtering
Position mode: “VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
Velocity mode: “VUdt”
“VOPt”
“VCLt”
“VOnt”
Scale main input
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function *
-
*
Enter or measure valve closed position
Enter or measure valve open position
Enter valve update time
Enter valve control deadband
Enter valve fail detect time
Enter valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
HIDDEN FUNCTION MODE *
The hidden function mode is accessible from the normal operating mode. The
four functions in this mode may be locked-out individually in configuration 3
parameter lock-out section.
Enter time proportioning cycle time Select control action
Enter output power low limit
Enter output power high limit
Enter signal overdrive power preset
Enter output control dampening
Enter ON/OFF control hysteresis
Select auto-tuning dampening
Select linear DC output assignment *
Enter linear DC output low scaling value *
Enter linear DC output high scaling value *
Enter linear DC output control deadband *
Enter linear DC output update time *
“SPSL”
“trnF”
“tUNE”
“ALrS”
*
6
- Select Local/Remote Setpoint
- Transfer between automatic (PID) control
and manual control
- Invoke/cancel PID Auto-tune
- Reset latched alarms
These parameters may not appear due to option configuration or other
programming.
PROTECTED PARAMETERS MODE *
The protected parameters mode is enabled when program disable is active.
This mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are selected in the configuration 3
parameter lock-out section can be accessed.
“ProP”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
“Pb-2”
“It-2”
“dt-2”
-
Enter Proportional band
Enter integral time
Enter derivative time
Enter remote setpoint ratio value
Enter remote setpoint bias value
Enter internal cascade, secondary setpoint
Enter internal cascade, secondary
proportional band
- Enter internal cascade, secondary integral
time
- Enter internal cascade, secondary derivative
time
“AL-1”
“AL-2”
“CodE”
*
- Enter value for alarm #1
- Enter value for alarm #2
- Enter access value to unprotected
parameters & configuration parameters
These parameters may not appear due to option configuration or other
programming.
OUTPUT MODULES
TYPICAL CONNECTIONS
RELAY
MODULE
A
C
ISOLATED
1 AMP
AT
120/240VAC
POWER
B
5 AMPS
AT
240VAC
LOAD
DO NOT CONNECT
Relay:
Type: Form-C (Form-A with some models. See ordering information.)
Rating: 5 amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120
VAC (inductive) maximum.
Life Expectancy: 100,000 cycles at maximum load rating.
(Decreasing load and/or increasing cycle time, increases life expectancy).
LOGIC/SSR DRIVE
MODULE
+12VDC
UNREG.
NOT
ISOLATED
DO NOT CONNECT
+
C
SSR 1
POWER
3 UNIT 2
4
A
B
C
RELAY OR
TRIAC
DEVICE
POWER
LOAD
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 ampere @ 35°C
0.75 ampere @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
A
B
120VAC
TRIAC MODULE
POWER
LOAD
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA maximum.
APPLICATION
A chemical company would like to
maintain the level of an acid solution tank to
insure constant availability for their process.
They have chosen a PCU controller which
has a continuous level probe with a 4 to 20
mA output proportional to tank level,
connected to the input terminals. The tank is
filled by controlling the position of a
proportional control valve. The control valve
is controlled by a 3 to 15 PSI air signal.
The PCU uses the level control input as its
feedback. The 4 to 20 mA input signal is
scaled so that 4 mA equals 0% and 20 mA
equals 100%.
The 4 to 20 mA output of the PCU is taken
to an I/P converter to convert the 4 to 20 mA
output to a 3 to 15 PSI signal for the control
valve. The relay outputs of the PCU are used
for high and low level alarms.
7
ORDERING INFORMATION
MODELS WITHOUT SECOND INPUT OPTIONS
Type 4X/IP65
BEZEL
4 to 20 mA
ANALOG OUTPUT
0 to 10 VDC
ANALOG OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
NO
YES
NO
NO
NO
NO
PCU01000
NO
YES
NO
2
NO
NO
PCU01001
YES
NO
NO
NO
NO
NO
PCU10000
YES
NO
NO
2
NO
NO
PCU10001
YES
NO
NO
1
YES
NO
PCU10002
YES
YES
NO
NO
NO
NO
PCU11000
YES
YES
NO
2
NO
NO
PCU11001
YES
YES
NO
1
YES
NO
PCU11002
YES
YES
NO
2
NO
YES
PCU11004
YES
YES
NO
1
YES
YES
PCU11005
YES
NO
YES
2
NO
NO
PCU12001
YES
NO
YES
2
NO
YES
PCU12004
YES
NO
YES
1
YES
YES
PCU12005
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common terminals (Form A Type). As a result,
these outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.
SECOND ANALOG INPUT MODELS (RSP)
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
NO
NO
2
NO
YES
PCU10104
YES
YES
NO
2
NO
NO
PCU11108
YES
NO
YES
2
NO
NO
PCU12108
Type 4X/IP65
BEZEL
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common
terminals (Form A Type). As a result, these outputs should be fitted with the same type of output module.
The main output (OP1) may be fitted with any type of output module.
MOTORIZED VALVE POSITIONER MODELS (MVP)
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
NO
NO
1
NO
YES
PCU10307
YES
YES
NO
1
NO
NO
PCU11306
YES
NO
YES
1
NO
NO
PCU12306
Type 4X/IP65
BEZEL
ACCESSORIES
DESCRIPTION
PART NUMBER
Relay Module
OMD00000
Triac Module
OMD00001
Logic/SSR Drive Module
OMD00003
45 A Single Phase Panel Mount SSR
RLY50000
25 A Single Phase DIN Rail Mount SSR
RLY60000
40 A Single Phase DIN Rail Mount SSR
RLY6A000
25 A Three Phase DIN Rail Mount SSR
RLY70000
Note: Output 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),
the secondary output, and valve positioner outputs.
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 line voltage.
All modules are packaged separately and must be installed by the user.
Red Lion Controls
Headquarters
20 Willow Springs Circle
York PA 17406
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
Red Lion Controls
Europe
Softwareweg 9
NL - 3821 BN Amersfoort
Tel +31 (0) 334 723 225
Fax +31 (0) 334 893 793
Red Lion Controls
India
201-B, 2nd Floor, Park Centra
Opp 32 Mile Stone, Sector-30
Gurgaon-122002 Haryana, India
Tel +91 984 487 0503
Red Lion Controls
China
Unit 302, XinAn Plaza
Building 13, No.99 Tianzhou Road
ShangHai, P.R. China 200223
Tel +86 21 6113 3688
Fax +86 21 6113 3683

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