red lion PCU User manual

red lion PCU User manual
PCUCOV.QXD
12/3/2009 2:05 PM
Page 1
THE PROCESS CONTROL UNIT
MODEL PCU INSTRUCTION MANUAL
PCUCOV.QXD
12/3/2009 2:05 PM
Page 2
INTRODUCTION
The Process Control Unit (PCU) 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 PCU 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.
C
UL
R
US LISTED
IND. CONT. EQ.
51EB
CAUTION: Read complete
instructions prior to installation
and operation of the unit.
CAUTION: Risk of electric shock.
Table of Contents
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION & CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NEMA 4X/IP65 Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing Bezel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing Bezel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Output Module Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Select AC Power (115/230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EMC Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve Positioner Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Linear DC Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Second Analog Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Program Disable Or User Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AC Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT PANEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Button Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Controller Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Controller Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Process Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual (User) & Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote And Local Setpoint Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
i
Configuration Of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parameter Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Normal Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Modifying A Secondary Display Parameter From The Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UNPROTECTED PARAMETER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unprotected Parameter Mode Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PROTECTED PARAMETER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Protected Parameter Mode Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT PANEL PROGRAM DISABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Models With User Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Models With Program Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HIDDEN FUNCTION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hidden Function Mode Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CONFIGURATION PARAMETER MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input Module (1- In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input Type (tYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Square Root Linearization (root) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Decimal Point Position (dCPt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rounding Increment ( rnd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input Signal Filter and Display Update Rate (FLtr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Scaling Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Display Values (dSP1 & dSP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Signal Input Values (INP1 & INP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Key-in Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Signal Input Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setpoint Limit Values (SPLO & SPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setpoint Ramp Rate (SPrP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Output Module (2-OP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Time Proportioning Cycle Time (CYCt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Output Control Action (OPAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Output Power Limits (OPLO & OPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ii
Input Overdrive Preset Power (OPFL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Output Power Dampening (OPdP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ON/OFF Control Hysteresis Band (CHYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Auto-Tune Dampening Code (tcod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Linear DC Analog Output (ANAS, ANLO, ANHI, ANdb, ANUt) (Optional) . . . . . . . . . . . . . . . . . . . . 26
Lockouts Module (3-LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lower Display Lockouts (SP, OP, IN-2, dEv, bdSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Protected Mode Lockouts (Code, PID, PID2, rtbS & AL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hidden Mode Lockouts (ALrS, trnF, tUNE and SPSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Alarm Module (4-AL) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Alarm Action (Act1, Act2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Second Analog Input Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Valve Fail Alarm (VFAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alarm Action Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Alarm Reset (rSt1, rSt2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alarm Standby Delay (Stb1, Stb2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alarm Value (AL-1, AL-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alarm Hysteresis (AHYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Secondary Output Module (5-02) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Time Proportioning Cycle Time (CYC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Relative Gain (GAN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overlap/Deadband (db-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Serial Communications Module (6-SC) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Baud Rate (bAUd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Parity Bit (PArb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Address Number (Addr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Abbreviated or Full Transmission (Abrv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Print Rate (PrAt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Print Options (PoPt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Second Analog Input Module (7-2N) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operation mode (OPEr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Square Root Linearization (root) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
iii
Decimal Point Position (dPt2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Second Analog Input Scaling Points (dSP1, INP1, dSP2, INP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Display Values (dSP1 & dSP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Signal Input Values (INP1 & INP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Key-in Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Signal Input Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Local/Remote Setpoint Transfer Modes (SPtr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Secondary Output Power Dampening (OPd2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve Positioner Module (8-VP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve Position 1 And Valve Position 2 (VPS1, VPS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve Update Time (VUdt) (Position And Velocity Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve Position Deadband (VPdb) (Position Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve Fail Time Alarm (VFAL) (Position Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve Motor Open Time And Valve Motor Close Time (VOPt, VCLt) (Velocity mode) . . . . . . . . . . . . 38
Valve Minimum On Time (VONt)(Velocity Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Factory Service Operations Module (9-FS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reference Tables: Configuration Parameter Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Configure Module 1 - Input Parameters (1-IN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Configure Module 2 - Output Parameters (2-OP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Configure Module 3 - Lockout Parameters (3-LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Configure Module 4 - Alarms (4-AL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Configure Module 5 - Secondary Output Parameters (5-O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Configure Module 6 - Serial Communications (6-SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Configure Module 7 - Second Analog Input (7-2N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Configure Module 8 - Valve Positioner (8-VP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Configure Module 9 - Factory Service Operations (9-FS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
RS485 SERIAL COMMUNICATIONS INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Communication Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sending Commands And Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Receiving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Serial Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
iv
Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connecting To A Host Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
VALVE POSITION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Position Mode Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Velocity Mode Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECOND ANALOG INPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Remote Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flow Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Process Remote Setpoint Slave Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
External Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Internal Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
PID CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Proportional Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Integral Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Derivative Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Output Power Offset (Manual Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PID Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ON/OFF CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AUTO-TUNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Initiate Auto-Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Auto-Tune Of Secondary Output (OP2) / Main Output (OP1) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Auto-Tune Of Internal Cascade Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Auto-Tune Of External Cascade Systems (Remote Setpoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
APPENDIX “A” - APPLICATION EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Chemical Mixing Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Flow Rate Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
APPENDIX “C” - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
v
Output Leakage Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
APPENDIX “D” - MANUAL TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Open Loop Step Response Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Closed Loop Cycling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
APPENDIX “E” - CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Voltage Reading Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Current Reading Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Linear DC Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
0 to 10 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Second Input Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Second Analog Input Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Valve Positioner Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Configure Step 9 - Factory Service Operations (9-Fs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Current Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Analog Output Calibration (ANCL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4 to 20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
0 to 10 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Second Analog Input Calibration (2CAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Second Analog Input (Remote Setpoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Motorized Valve Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
APPENDIX “F”-USER PARAMETER VALUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
APPENDIX “G” ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
vi
GENERAL DESCRIPTION
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 at the valve.
Two control modes are possible: position control, which 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:
- Valve activity hysteresis
- Valve update time
- Variable control dampening
- Slidewire signal fail action
- Adjustable valve position limits
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 multi-drop serial communication interface provides
two-way communication between a PCU unit and other compatible
equipment such as a printer, a programmable controller, or a host computer.
In multi-point 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.
The PCU Controller accepts either a 0 to 10 VDC or a 4 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 positioning) to maintain a process at the desired control point.
A comprehensive set of easy to use steps allows the controller to solve various
application requirements.
The controller can operate in the PID control mode for both the main output
and optional secondary output. On-demand auto-tune establishes the tuning
constants. The PID tuning constants may be fine-tuned by the operator at any
time and locked out from further modification. The controller employs a
unique overshoot suppression feature that 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 can also be programmed to operate in the ON/OFF control mode
with adjustable hysteresis.
Dual 4-digit displays allow viewing of the measured value and setpoint
simultaneously. Front panel indicators inform the operator of the controller
and output status. Replaceable and interchangeable output modules (Relay,
SSR Drive, or Triac) can be installed for the main control output, Alarm
output(s), Secondary output, and Valve Positioner outputs.
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 requiring cooling,
pH balance, etc.) 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 type of
Linear DC output is determined by the model ordered. (See Ordering
Information, page 84, for available models.) The output signal can be
digitally scaled and selected to transmit one of the following: % output
power, measurement value deviation or setpoint value. For Linear DC control
applications, the adjustable output demand dampening, output deadband, and
output update time parameters expand the versatility of the PCU to final
control devices.
-1-
SAFETY SUMMARY
A programmable User Input is available with RS485, Valve Position, and
Second Analog Input models. The User Input can be programmed to perform
a variety of controller functions.
An optional NEMA 4X/IP65 rated bezel is available for wash down
applications and similar environments, when properly installed. Modern
surface-mount technology, in-house assembly and testing, and high
immunity to noise interference makes the controller extremely reliable in
industrial environments.
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
temperature limit indicator with alarm outputs is strongly recommended. Red
Lion Controls offers various units (such as an IMP, IMD1, or IMD2) that may
be used for this purpose. The indicators should have input sensors and AC
power feeds independent from other equipment.
-2-
INSTALLATION & CONNECTIONS
NEMA 4X/IP65 UNIT INSTALLATION
INSTALLATION ENVIRONMENT
The optional NEMA 4X/IP65 PCU Controller provides a watertight seal in
panels with a minimum thickness of 1/8 inch. The units meet NEMA 4X/IP65
requirements for indoor use, when properly installed. The units are intended
to be mounted into an enclosed panel. Prepare the panel cutout to the
dimensions shown in Figure 1, Panel Installation & Removal. Carefully apply
the adhesive side of the panel gasket to the panel cutout. Remove the panel
latch and cardboard sleeve from the unit. 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 7 in-lbs [79 N-cm]). 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 affect proper operation.
Caution: 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.
The unit should be installed in a location that does not exceed the maximum
operating temperature and provides good air circulation. Placing the unit near
devices that generate excessive heat should be avoided.
Continuous exposure to direct sunlight may accelerate the aging process of
the bezel.
The bezel should be cleaned only with a soft cloth and neutral soap product.
Do not use solvents.
Do not use tools of any kind (screwdrivers, pens, pencils, etc.) to operate
the keypad of the unit.
STANDARD UNIT INSTALLATION
Prepare the panel cutout to the dimensions shown in Figure 1, Panel
Installation & Removal. 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 latch
should be engaged in the farthest forward slots possible. Tighten the screws
evenly until the unit is snug in the panel.
-3-
Figure 1, Panel Installation & Removal
-4-
UNIT REMOVAL 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.
REMOVING BEZEL ASSEMBLY
The bezel assembly, shown in Figure 2, must be removed from the case to
install or replace output modules, or to set the 115/230 VAC selector switch.
Disconnect power to the unit and to the output control circuits to eliminate the
potential shock hazard when removing the bezel assembly. 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.
Caution: The bezel assembly contains electronic circuits that 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 that may lead to malfunction. If it
becomes necessary to ship the unit for repairs, place the unit in its case before
shipping it.
Figure 2, Bezel Assembly
INSTALLING BEZEL ASSEMBLY
OUTPUT MODULES
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 the
case and tighten the bezel screws uniformly until the bezel contacts the case
and then turn each screw another half turn to insure a watertight seal (do not
over-tighten screws).
Caution: 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.
The main control, optional Alarm, optional Secondary output and optional
Valve Position control output sockets must be fitted with the appropriate
output module. Output modules are shipped separately and must be installed
by the user.
Output Module Restrictions
With some models, the Alarm outputs and Valve Position outputs share the
same common terminal. When using these models, the same type of output
modules should be installed in these positions.
-5-
Installing Output Modules
To install an output module into the controller, remove the bezel assembly
from the case (See Removing Bezel Assembly, page 5). Locate the correct
output module socket (OP1, AL1, or AL2/OP2, see Figure 6, Hardware, 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.
Note: For Valve Positioner models, the circuit board markings have the
following meaning:
AL1 - Open Output
AL2/OP2 - Close Output
OP1 - Alarm #1 Output
Figure 4, Logic/SSR Drive Module
Logic/SSR Drive:
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA Max. Can drive multiple SSR Power Units.
OUTPUT MODULE “OUTPUT ON” STATE
Relay
Normally open contact is closed
Logic/SSR Drive
Source is active.
Triac
Solid state switch is closed.
Figure 5, Triac Module
Typical Connections
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 maximum @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused.
Figure 3, Relay Module
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).
Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing
load and/or increasing cycle time, increases life expectancy).
SELECT AC POWER (115/230 VAC)
The AC power to the unit must be selected for either 115 VAC or 230 VAC.
The selector switch is located inside the case near the rear of the unit on the
main circuit board (see Figure 6, Hardware, or label on outside of case). The
unit is shipped from the factory with the switch in the 230 VAC position.
Caution: Damage to the controller may occur if the AC selector switch is set
incorrectly.
-6-
EMC INSTALLATION GUIDELINES
Although this unit is designed with a high degree of immunity to
ElectroMagnetic Interference (EMI), proper installation and wiring methods
must be followed to ensure compatibility in each application. The type of
electrical noise, source or coupling method into the unit may be different for
various installations. In extremely high EMI environments, additional
measures may be needed. The unit becomes more immune to EMI with fewer
I/O connections. Cable length, routing and shield termination are very
important and can mean the difference between a successful or a troublesome
installation. Listed below are some EMC guidelines for successful
installation in an industrial environment.
1. The unit should be mounted in a metal enclosure, which is properly
connected to protective earth.
2. Use shielded (screened) cables for all Signal and Control inputs. The shield
(screen) pigtail connection should be made as short as possible. The
connection point for the shield depends somewhat upon the application.
Listed below are the recommended methods of connecting the shield, in
order of their effectiveness.
a. Connect the shield only at the panel where the unit is mounted to earth
ground (protective earth).
b. Connect the shield to earth ground at both ends of the cable, usually
when the noise source frequency is above 1 MHz.
c. Connect the shield to common of the unit and leave the other end of the
shield unconnected and insulated from earth ground.
3. Never run Signal or Control cables in the same conduit or raceway with AC
power lines, conductors feeding motors, solenoids, SCR controls, and
heaters, etc. The cables should be run in metal conduit that is properly
grounded. This is especially useful in applications where cable runs are
long and portable two-way radios are used in close proximity or if the
installation is near a commercial radio transmitter.
4. Signal or Control cables within an enclosure should be routed as far away as
possible from contactors, control relays, transformers, and other noisy
components.
5. In extremely high EMI environments, the use of external EMI suppression
devices, such as ferrite suppression cores, is effective. Install them on
Signal and Control cables as close to the unit as possible. Loop the cable
through the core several times or use multiple cores on each cable for
additional protection. Install line filters on the power input cable to the unit
Figure 6, Hardware
-7-
to suppress power line interference. Install them near the power entry point
of the enclosure. The following EMI suppression devices (or equivalent)
are recommended:
Ferrite Suppression Cores for signal and control cables:
Fair-Rite # 0443167251 (RLC #FCOR0000)
TDK # ZCAT3035-1330A
Steward #28B2029-0A0
Line Filters for input power cables:
Schaffner # FN610-1/07 (RLC #LFIL0000)
Schaffner # FN670-1.8/07
Corcom #1VR3
Note: Reference manufacturer’s instructions when installing a line filter.
6. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
7. Switching of inductive loads produces high EMI. Use of snubbers across
inductive loads suppresses EMI.
Snubbers:
RLC #SNUB0000
Figure 7, 4-20 mA Connection
WIRING CONNECTIONS
After the unit has been mechanically mounted, it is ready to be wired. All
conductors should meet voltage and current ratings for each terminal. Also
cabling should conform to appropriate standards of good installation, local
codes and regulations. It is recommended that power supplied to the unit (AC
or DC) be protected by a fuse or circuit breaker.
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" (6 mm) 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 tightly. Each terminal
can accept up to two, 18-gage wires. Wire each terminal block in this manner.
Figure 8, 0-10 V Connection
-8-
Valve Positioner Wiring
Units with Valve Positioner option have three output connections for
controlling the valve motor and three input connections for slidewire
feedback. The valve motor output connects to terminals labeled “Valve
Position Outputs”, terminals 1, 2 and 3. See Figure 9, Valve Positioner
Wiring for more details. Terminal 1 is the Valve motor supply common.
Terminal 2 is the Valve Close or CW output. Terminal 3 is the Valve Open or
CCW output. The valve motor must be fused with a suitable value.
The Triac Output Module also does not suffer from mechanical wear of
the contacts.
2) Use RC snubbers directly across the valve motor.
3) Use a separate AC supply for the valve motor.
Where possible, the valve motor control outputs and the slidewire
feedback input routing should be physically separated. Noise interference
from the outputs could couple into the slidewire feedback inputs, disrupting
proper operation.
The slidewire feedback inputs connect to the terminals labeled “Slidewire
Feedback Inputs”. The terminal placement varies with each model, see the
controller label for the actual terminals. For Velocity mode valve control the
slidewire feedback inputs are not necessary.
In some cases, it may be desirable to have an independent valve position
indicator. Red Lion Controls Model IMD1 can be wired in parallel with the
slidewire input’s Wiper and Comm. terminals for this purpose. The
approximate 0 to 0.9V signal can be scaled to indicate percent valve position.
Linear DC Output Wiring
Units with Linear DC output option have two terminals to output a 4 to 20
mA or 0 to 10 VDC signal. The type of Linear DC output is determined by the
model ordered. (See Ordering Information page 84, for available models.)
These terminals are labeled “4-20 mA (or 0-10 VDC) Analog Output Option,
Out+ and Out-”. The common of this output is isolated from main input
common , but is not isolated from the Second Analog Input Option common.
For proper operation always keep these commons isolated.
Second Analog Input Wiring
Units with Second Analog Input option have two input terminals to receive
a 4 to 20 mA signal. These terminals are labeled “Second Input, 4-20 mA+ and
4-20 mA-”.Terminal placement varies with model. See unit label for actual
terminals. The common of this input is isolated from main input common, but
is not isolated from the Linear DC Output common. For proper operation
always keep these commons isolated.
Figure 9, Valve Positioner Wiring
Although RC snubbers are employed inside the controller to suppress
inductive “kicks” from the motor, it may be necessary to take further action to
reduce noise effects:
1) Use Triac Output Modules wherever possible. The Triac device
significantly reduces radiated EMI (Electromagnetic Interference).
-9-
AC Power Wiring
Primary AC power is connected to the separate two position terminal block
labeled AC. To reduce the chance of noise spikes entering the AC line and
affecting the controller, an AC feed separate from that of the load should be
used to power the controller. Be certain that the AC power to the controller is
relatively “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.
Program Disable Or User Input Wiring
Some models have Terminal #7 as the User Input, which is programmable
for a variety of functions. Other models have Terminal #7 dedicated to the
program disable function. Any form of mechanical switch may be connected
to terminal #7. Sinking open collector logic with less than 0.7 V 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.
-10-
FRONT PANEL DESCRIPTION
The front panel bezel material is
flame and scratch resistant, tinted
plastic. An optional NEMA
4X/IP65 bezel version is available
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, that
illuminate to inform the operator
of the controller and output status.
See Figure 10, Front Panel for a
description of the available
annunciators.
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
operational parameters in the
secondary display. 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/Down buttons can be used to
directly modify the setpoint value or % output power (manual mode only),
Figure 10, Front Panel
when viewed in the secondary display. Otherwise, the parameter must be
called to alter the value.
PAR - The Parameter (PAR) button is used to access, enter the change, and
scroll through the available parameters in any mode.
-11-
OPERATION OVERVIEW
CONTROLLER POWER-UP
If the controller is a replacement, the PID settings from the unit being
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.
Upon applying power, the controller delays control action and process
indication for five seconds to perform several self-diagnostic tests and
display basic controller information. Initially, the controller illuminates both
displays and all annunciators to verify that all display elements are
functioning. The controller then 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, page 73, for further information).
Upon completion of this sequence, the controller begins control action by
displaying the process value and updating the outputs based upon the PID
control calculation.
MANUAL (USER) & AUTOMATIC OPERATION
The controller can be transferred between Automatic control (closed
loop; PID or ON/OFF control) and Manual control (open loop). 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 RS485 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 the secondary output is installed. For Valve Positioner
models with slidewire feedback, this mode allows manual valve positioning.
The MAN (REM for Remote Setpoint models) annunciator flashes to indicate
that the unit is in manual operation.
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 corrects (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.
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 and
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. Minimal tuning consists of
adjusting the Proportional Band, Integral Time, and Derivative Time
parameters to achieve the optimum response to a process disturbance. The
controller can be tuned once, but must 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, page 64).
B) Use a manual tuning technique (see Manual Tuning, page 76).
C) Use a third party tuning software package (generally expensive and not
always precise).
D) Use values based on control loop experience, calculated values or values
from a similar process.
-12-
REMOTE AND LOCAL SETPOINT OPERATION
The controller setpoint mode can be switched between Local Setpoint
operation and Remote Setpoint operation. In the Hidden Function Mode, the
“SPSL” parameter allows the operator to select the desired setpoint operating
mode. To allow front panel switching between setpoint modes, program the
setpoint select parameter (SPSL) to “Enbl” in the Lockout Module. The user
input or RS485 serial interface option may also be used to perform the
setpoint selection function, independent of the setting in the Lockout Module.
Front panel annunciator REM is on for Remote setpoint operation and is off
for Local setpoint operation. When transferring the controller mode from/to
the setpoint modes, various controller response options are available (see
SPtr parameter, page 37).
-13-
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. See
Figure 11, Operational/Programming Modes.
CONFIGURATION OF PARAMETERS
As supplied from the factory, the controller parameters have been
programmed to the values listed in the Programming Quick Reference
Tables. The user must modify the values, if necessary, to suit the application.
Figure 11, Operational/Programming Modes
-14-
PARAMETER ENTRY
NORMAL DISPLAY MODE
The PAR button is used to select the desired parameter. To modify the
parameter setting, use the UP and DOWN buttons. Press PAR to enter the new
value. The controller progresses 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 commonly modified parameters:
Setpoint
Output Power
Output Power Offset
Proportional Band
Integral Time
Derivative Time
Proportional Band #2
Integral Time #2
Derivative Time #2
Directed Setpoint (Cascade)
Ratio
Bias
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 removed from the controller. If
power is removed while modifying any parameter, be certain to check the
parameter for the proper value.
In the normal display mode, the process value is always displayed in the
main display. By successively pressing the DSP button, one of these
operational parameters can be viewed in the secondary display (model
dependent):
Setpoint
% Output Power
Second Analog Input (Remote Setpoint)
Process Setpoint Deviation
Each of these displays can be independently locked out from appearing or
from being modified by the user (see Lockouts Module, page 27). Only from
the normal display mode can access be gained to the other modes
(Unprotected, Protected, or Hidden).
MODIFYING A SECONDARY DISPLAY PARAMETER FROM
THE FRONT PANEL
The controller must be in the normal display mode to modify the secondary
display parameters. The Setpoint value and % output power (in manual mode)
are the two parameters which may be modified. The other parameters are
read-out values only.
Setpoint Value - 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 mode when “SP” is viewed, independent of viewing in the
secondary display. The setpoint value is confined to the programmable
setpoint limit values (SPLO & SPHI, Input Module 1).
% Output Power - The % Output Power can only be changed when the unit is
in the manual mode. See Manual (User) and Automatic Operations, page
12. The annunciator % PW lights, and the Manual annunciator flashes
when viewed. 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 mode when “OP” is viewed, independent of viewing in the
secondary display. The % output power is not confined to the programmable
output power limit values (OPLO & OPHI, Output Module 2).
-15-
UNPROTECTED PARAMETER MODE
UNPROTECTED PARAMETER MODE REFERENCE TABLE
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 no action is taken.
Display
SP
OPOF
OP
-16-
Range and
Units (Factory
Setting Value)
Setpoint
Confined to
range of limits
SPLO, SPHI,
(0)
%Output
-99.9% to
Power Offset 100.0%
(0.0)
Output
-99.9% to
Power
100.0%
(0.0)
Parameter
Prop
Proportional
Band
Intt
Integral
Time
dErt
Derivative
Time
Pb-2
Proportional
Band #2
(Secondary)
It-2
Integral
Time #2
(Secondary)
Description/
Comments
Appears only if setpoint value is
locked (LOC) or read only (rEd).
Appears only if integral time (Intt)
= 0 and controller is in automatic
mode.
Appears only if controller is in
user (manual) mode and % output
power is locked (LOC) or read
only (rEd). This parameter is not
limited to output power limits
(OPLO & OPHI).
0.0 to 999.9% of 0.0% is ON/OFF control. If using
ON/OFF mode, set control
scaled input
hysteresis appropriately.
range
(4.0)
0 to 9999 sec.
0 is off. This parameter does not
(120)
appear if proportional band =
0.0%.
0 to 9999 sec.
0 is off. This parameter does not
(30)
appear if proportional band =
0.0%.
0.0 to 999.9% of 0.0% is ON/OFF control. Second
Analog Input models only.
Scaled input
range
(4.0)
0 to 9999 sec
0 is off. This parameter does not
(0)
appear if proportional band #2 =
0.0%. Second Analog Input
models only.
Display
dt-2
SP-2
rtio
bIAS
AL-1
AL-2
CNFP
Parameter
Derivative
Time #2
(Secondary)
Internal
Cascade
Directed
Setpoint
Remote
Setpoint ratio
multiplier
Remote
Setpoint bias
offset
Alarm 1
Value
Alarm 2
Value
Range and
Description/
Units (Factory
Comments
Setting Value)
0 to 9999 sec
0 is off. This parameter does not
(0)
appear if proportional band #2 = 0.0%.
Second Analog Input models only.
-999 to 9999
Second Analog Input models only.
(N/A)
Read only parameter.
0.001 to 9.999
(1.000)
Second Analog Input models.
-999 to 9999
(0)
Second Analog Input models.
-999 to 9999
(0)
-999 to 9999
(0)
Alarm option models only.
Configuration
Access Point
NO
1-IN
2-OP
3-LC
4-AL
5-02
6-SC
7-2N
8-VP
9-FS
End
____
Unit returns
to Normal
Display Mode
This parameter does not appear if the
alarm option is not specified, the
secondary output option is installed,
or if locked (LOC).
Return to normal display mode.
Enter Configuration modules.
Configure input parameters.
Configure output parameters.
Configure parameter lockouts.
Configure alarm parameters (opt.)
Configure secondary output (opt.)
Configure serial communication
parameters (optional).
Configure second analog input
parameters (optional)
Configure valve positioner
parameters (optional)
Factory service operations (Qualified
technicians only)
Brief display message.
-17-
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. This mode cannot be accessed if all parameters are locked
out in Configuration Module 3.
PROTECTED PARAMETER MODE REFERENCE TABLE
Display
Prop
Range and
units (Factory
Setting Value)
Proportional 0.0 to 999.9%
Band
of scaled input
range
(4.0)
Parameter
Intt
Integral
Time
0 to 9999 sec.
(120)
dErt
Derivative
Time
0 to 9999 sec.
(30)
Pb-2
It-2
dt-2
SP-2
Proportional 0.0 to 999.9%
of scaled input
Band #2
(Secondary) range
(4.0)
0 to 9999 sec.
Integral
(0)
Time #2
(Secondary)
0 to 9999 sec.
Derivative
(0)
Time #2
(Secondary)
Internal
Cascade
Directed
Setpoint
-999 to 9999
(N/A)
Description/Comments
Display
0.0% is ON/OFF control. If using
ON/OFF mode, set control
hysteresis appropriately. This
parameter does not appear if
locked (LOC).
0 is off. This parameter does not
appear if proportional band = 0.0%
or locked (LOC).
0 is off. This parameter does not
appear if proportional band = 0.0%
or locked (LOC).
0.0% is ON/OFF control. Second
Analog Input models only.
rtio
bIAS
AL-1
AL-2
0 is off. This parameter does not
appear if proportional band #2=
0.0%, or if locked (LOC). Second
Analog Input models only.
0 is off. This parameter does not
appear if proportional band #2=
0.0%, or if locked (LOC). Second
Analog Input models only.
Second Analog Input models only.
Read only parameter.
-18-
Parameter
Remote
setpoint
ratio
multiplier
Remote
setpoint
bias offset
Alarm 1
value
Alarm 2
value
Range and
units (Factory
Description/Comments
Setting Value)
0.001 to 9.999 Second Analog Input models
(1.000)
only.
-999 to 9999
(0)
Second Analog Input models
only.
-999 to 9999
(0)
-999 to 9999
(0)
Alarm option models only.
Code
0 to 250
Access
(0)
code to
unprotected
mode
End
Unit returns
to normal
display
mode.
This parameter does not appear
if the alarm option is not
specified, the secondary output
option is installed, or if locked
(LOC).
To gain access to unprotected
mode, enter the same value for
Code as entered in parameter
lockouts. This parameter does
not appear if zero is entered in
code parameter lockout.
Brief display message display
mode.
FRONT PANEL PROGRAM DISABLE
MODELS WITH PROGRAM DISABLE
There are several ways to limit the programming of parameters from the
front panel buttons. The settings of the parameters in the Lockout Module, the
code number entered, and the state and/or function programmed for the User
Input (Terminal #7) affect front panel access.
It is possible to have the program disable function on versions with the
User Input, even if the User Input is not programmed for program disable
(PLOC), by the use of a code number. Versions that do not have the User Input
are dedicated to the program disable function.
The following charts describe the possible program disable settings
depending on your model.
Program Disable
MODELS WITH USER INPUT
User Input State
Code Number
Description
Inactive or User
Input not
programmed for
PLOC
0
Full access to all modes and
parameter modules.
Active with User
Input programmed
for PLOC
0
Access to protected parameter
mode only. Code number does not
appear.
Active with User
Input programmed
for PLOC
OR
User Input not
programmed for
PLOC
Any # between
1 & 250
Access to protected parameter
mode. Correct programmed code
number allows access to
unprotected parameter mode and
configuration modules.
Code Number
Description
Inactive
0
Full access to all modes and
parameter modules.
Active
0
Access to protected parameter
mode only. Code number does not
appear.
Active
Any # between
1 & 250
Access to protected parameter
mode. Correct programmed code
number allows access to
unprotected 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.
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.
-19-
HIDDEN FUNCTION MODE
HIDDEN FUNCTION MODE REFERENCE TABLE
The Hidden Function Mode is only accessible from the normal display
mode by pressing and holding the PAR button for three seconds. These
functions must be unlocked in Configuration Module #3. Factory settings are
locked. In this mode, these controller functions can be performed.
Local/Remote Setpoint Selection
Automatic/Manual Transfer
Initiate/Cancel Auto-tune
Reset Alarm Events
Each function may be “locked out” in the Configuration parameter
lockouts module. The PAR button is 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
no action is taken.
Range and Units
Description/Comments
(Factory Setting Value)
Appears only for models
LOC - Local Setpoint
Select
with Second Analog
rE_t - Remote Setpoint
Local or
Input. “SPtr” determines
(LOC)
Remote
nature of controller
Setpoint
response.
This step does not
Auto - Automatic control
Transfer
appear if locked (LOC).
User - Manual control
mode of
Exits to normal display
(Auto)
operation
mode if executed.
This step does not
Auto-tune
Yes: starts the
invocation
auto-tune sequence. appear if locked (LOC) or
exits to normal display
No: terminates the
auto-tune sequence. mode if executed. These
parameters appear only if
Prl - tune primary
Second Analog Input
(Cascade)
Internal Cascade is
SEC - tune secondary
selected.
(Cascade)
(NO)
This step does not
Alarm reset UP key resets Alarm 1
appear if alarm option not
DOWN key resets
installed, if locked (LOC)
Alarm 2
or previous step
performed.
Display Parameter
SPSL
trnF
tUNE
ALrS
-20-
CONFIGURATION PARAMETER MODULES
Rounding Increment ( rnd)
Rounding values other than “1” causes the scaled number to ‘round’ to the
nearest rounding increment selected (ie. rounding of ‘5’ 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.
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. At the 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. The unit returns 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 that 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.
Square Root Linearization (root) (Optional)
The main input can be linearized by use of the square root function. See
Square Root Linearization, page 35, for a complete description of the square
root function.
The “root” parameter in Program Module 1 applies to the main input, and the
“root” parameter in Program Module 7 applies to the Second Analog Input.
Decimal Point Position (dCPt)
Select the desired decimal point position for the scaled display. The
selected decimal point position appears in the following parameters; rnd,
dSP1, dSP2, SPLO, SPHI, SP, AL1, AL2, db-2, AHYS, and CHYS.
0
0.0
0.00
0.000
-21-
Input Signal Filter and Display Update Rate (FLtr)
Select the relative degree of input signal filtering and display update rate.
The filter is an adaptive digital filter that 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.
The Auto-tune procedure sets the filter value appropriate to the process
characteristics. Also see Output Power Dampening parameter (OPdP), page
25, for filtering the output.
Fltr- 0 to 4
0 = least input filtering
3 = most input filtering
4 = most input filtering and slower (2/sec) display update rate
(outputs update at 10/sec rate)
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% @ 4.00 mA
&
100.0% @ 20.00 mA
Scaling Points
Prior to installing and operating the controller, 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 controller 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.
Figure 12, Scaling Points
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 is in the key-in mode.
Key-in Method
Key-in the signal value for scaling point one and scaling point two.
INP1
-999 to 9999 (Ex. 0.00 VDC or 4.00 mA DC)
INP2
-999 to 9999 (Ex. 10.00 VDC or 20.00 mA 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-in
method by pressing the DSP button again.
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
-999 to 9999 (Ex. 0.0%)
dSP2
-999 to 9999 (Ex. 100.0%)
Signal Range
4.00 to 20.0 mA DC
0.00 to 10.00 VDC
Display Range
0.00 to 20.00
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.
-22-
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. On
models equipped with Second Analog Input, configured as a Remote
Setpoint, the Remote Setpoint reading is also restricted to these limits.
SPLO - -999 to 9999
SPHI - -999 to 9999
ramping prior to invoking Auto-Tune, the ramping is suspended during
Auto-Tune and then resumed afterward using the current display as a starting
value. Deviation and band alarms are relative to 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.
Note: Depending on the ramp rate relative to the process dynamics, the actual
scaled process value may not track the ramping setpoint value.
On models equipped with Second Analog Input, configured as Remote
Setpoint, this parameter may be used to establish a maximum rate of change
of the Remote Setpoint reading. If the controller or transmitter that supplies
the Remote Setpoint reading is swinging too wildly, or changing too fast,
resulting in control problems, the ramp rate can be used to reduce the rate of
change of the Remote Setpoint reading. When ramping in Remote Setpoint
operation, the flashing decimal point is suppressed. The units of ramping for
Remote Setpoint operation are 0.1 to 999.9 LSD/minute.
Setpoint Ramp Rate (SPrP)
The setpoint can be programmed to ramp independent of the controller’s
decimal point position and rounding increment. The setpoint ramp rate can
reduce sudden 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 optional user input is
programmed for setpoint ramp, it affects the enabling and disabling of
setpoint ramping (See User Input, page 23). 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.
User Input (InPt)
The user input may be programmed to perform a variety of controller
functions. The input must be in its active state for 100 msec minimum to
perform the function. The unit executes all functions in 100 msec, except the
print request function that requires 110 to 200 msec 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. Use either a
multiple pole switch for ganged operation or a single switch for each unit.
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.
Note: Front panel disable is possible without using this program lock
function, see Front Panel Program Disable, page 19.
ILOC - Integral Action Lock. A low level disables the integral action of the
PID computation. A high level resumes the integral action.
trnF - 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.
Figure 13, Setpoint Ramp Rate
Once the ramping setpoint reaches the target setpoint, the setpoint ramp
rate disengages until the setpoint is changed again. If the ramp value is
changed during ramping, the new ramp rate takes effect. If the setpoint is
-23-
User Input (InPt) (Cont’d)
SPrP - Setpoint Ramp. A low level terminates setpoint ramping and the
controller operates at the target setpoint. Terminating setpoint ramping is
the same as setting the ramp rate to zero (SPrP = 0.0). A high level enables
the programmed setpoint ramp rate.
ALrS - Alarm Reset. If the alarm option is installed, a low level resets the
alarm(s) to their inactive state as long as the user input is low.
Prnt - Print Request. A low level transmits the print options selected in the
serial communications module (6-SC). If the user input is held low, after
the printing is complete a second print request is issued.
SPSL - Select Local or Remote Setpoint. On models equipped with Second
Analog Input, configured as Remote Setpoint, a negative transition
engages Remote Setpoint operation and a positive transition engages Local
Setpoint operation. Select the controller output response to the
Local/Remote transfer operation (bumpless, tracking, etc) by the setpoint
transfer parameter (SPtr).
OUTPUT MODULE (2-OP)
The controller has parameters that affect how the main control output
(OP1) responds to process changes and signal overdrive actions.
Time Proportioning Cycle Time (CYCt)
The selection of cycle time depends on the time constant of the process and
the type of output module used.
CYCt - 0 to 250 seconds
For best control, a cycle time equal to 1/10 of the process time constant, or
less is recommended; longer cycle times could degrade process control, and
shorter cycle times provide little benefit at the expense of shortened relay life.
When using a Triac module or a 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 analog output for control, the main output and indicator
can be disabled. This parameter is skipped for Valve Positioner models.
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, page 62).
OPAC - rEv (Reverse acting)
drct (Direct acting)
If drct (direct acting) is selected, the main output (OP1) is direct acting and
the secondary output (OP2) is reverse acting. The secondary output always
maintains the opposite setting of the main output.
Note: When using a relay output module, the control action may also be reversed
by using the normally closed contacts.
The linear DC analog output, when assigned to output power (OP) for
control purposes, tracks 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, page 26).
-24-
Output Power Limits (OPLO & 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 -100 to 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% to 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 effect.
The dampening parameter is expressed as a time constant in seconds.
Increasing the value increases the dampening or filtering effect. A value of
zero disables output power dampening. The amount of dampening to be used
depends primarily on the response time of the process and the amount of final
actuator activity desired. Generally, dampening times in the range of 1/20 to
1/50 of the controller’s integral time (or process time constant) prove to be
effective. Dampening times longer than these may cause controller instability
due to the added lag effect of too much filtering.
In the case where a relatively high dampening time is desired, the
controller’s proportional band may be increased to restore an adequate
stability margin. The Auto-tune procedure of the controller sets the
dampening value appropriate to the characteristics of the process.
ON/OFF 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).
CHYS - 1 to 250 units
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. Internal cascade controllers, secondary loop, have a
fixed hysteresis of 1.5% of scaled range.
Input Overdrive Preset Power (OPFL)
If an input overdrive signal is detected, the control output(s) default to a
preset power output.
OPFL - 0% (OP1 output full “off”) to 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 are 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.
For position mode valve controllers, the valve is positioned according to
the setting of this parameter.
For velocity mode valve controllers, the following actions occur:
Velocity mode: OPFL = 0%, valve CLOSE output activates
OPFL = 100%, valve OPEN output activates
OPFL = any other setting, both valve outputs disable
Output Power Dampening (OPdP)
The output power calculated by the PID controller can be dampened
(filtered) to reduce the controller output activity. Those processes with high
gain and/or derivative times or those processes with a relatively high noise
content can benefit from the dampening action.
OPdP - 0 to 250 seconds
-25-
Auto-Tune Dampening Code (tcod)
Prior to invoking Auto-Tune, the dampening code should be set to achieve
the desired dampening level under PID control. After Auto-tune is complete,
changes to “tcod” parameter have no effect until Auto-tune is re-started.
When set to 0, this yields the fastest process response with possible
overshoot. A setting of 4 yields the slowest response with the least amount of
overshoot. Dampening codes of 0 or 1 are recommended for most processes.
Linear DC Analog Output (ANAS, ANLO, ANHI, ANdb, ANUt)
(Optional)
The Linear DC output can be programmed to transmit one of the following
controller parameters:
ASSIGN DC OUTPUT (ANAS):
OP
– Percent output power
INP
– Scaled input process value
dEV
– Process setpoint deviation
SP
– Process setpoint value
dE-2
– Process deviation of secondary loop (Internal Cascade only)
SP-2
– Process setpoint of secondary loop (Internal Cascade only)
With high and low digital scaling points, the range of the Linear DC output
can be set independent of the controller’s range. This allows interfacing
directly with chart recorders, remote indicators, slave controllers, or linear
power control units.
ANLO (4 mA or 0 VDC)
ANHI (20 mA or 10 VDC)
–
–
-999 to 9999
-999 to 9999
Linear DC output deadband (ANdb) and linear DC output update time
(ANUt) parameters are additional parameters used for control purposes
(ANAS=OP). The deadband parameter requires that the output power, in
percent, must change more than the deadband amount in order for the output
to update. A value of 0.0 disables the deadband action. The linear output
update time updates the output at the time interval specified. A value of 0
seconds updates the output at the controller’s scan rate (10/sec). In the manual
mode of operation both parameters are overridden. The front panel indicator
OP1 and main output can be disabled by setting the time proportioning cycle
time equal to zero (CYCt = 0).
Note: Valve Position controllers disable the “OPEN” and “CLOSE” outputs
when the linear DC output is assigned to output power. In this case, the
slidewire feedback signal may be used to verify valve position.
Figure 14, Dampening Code
ANdb
ANUt
–
–
0.0 to 25.0%
0 to 250 seconds
For setpoint transmission, (external cascade control used with another
controller), the controller transmits the instantaneous ramping setpoint, not
the target value, when the controller is ramping the setpoint. For models
with Remote Setpoint, the linear output transmits the active setpoint (local
or remote).
-26-
LOCKOUTS MODULE (3-LC)
Example: Chart Record Process Display Value (0 to 10 VDC):
The process range is 300-700. Programming 300 for ANLO (0 VDC
value) and 700 for ANHI (10 VDC value) yields full scale deflection for a
chart recorder (0 to 10 VDC). The 0 to 10 VDC output is assigned to
transmit the input reading (ANAS = INP).
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.
Example: Linear Control Output (4 to 20 mA):
A linear DC input power control unit is used for process control. An
output control deadband of ±2.0% and an output update time of 10 seconds
is desired. The following set-up values illustrate the configuration:
ANAS
ANLO
ANHI
ANdb
ANUt
=
=
=
=
=
Lower Display Lockouts (SP, OP, IN-2, dEv, bdSP)
The contents of the secondary display can be changed in the normal display
mode by successively pressing the DSP button. This action scrolls through
the possible display parameters, when enabled.
The parameters can be set for one of the following:
OP
0.0%
100.0%
2.0%
10 seconds
LOC (Lockout)
–
rEd (Read only) –
Ent (Entry)
–
Prevents the parameter from appearing in the
secondary display.
Parameter appears, but cannot be modified.
Parameter appears and can be modified.
The lower display content possibilities are:
SP
OP*
IN-2*
dEv*
bdSP
–
–
–
–
–
Setpoint Value
% Output Power
Second analog input (Remote setpoint)
Setpoint Deviation
Blank Display
If all parameters are set to lock “LOC”, the display remains on the last
parameter that was viewed.
*Note: These parameters are model specific and may not appear in the
programming sequence.
Note: If a parameter is active in the lower display and is then subsequently locked
out, press “DSP” once in the normal display mode to remove it from the display.
Figure 15, Linear DC Output
-27-
Protected Mode Lockouts (Code, PID, PID2, rtbS & AL)
The protected mode is active when program disable is active. The
parameters in the protected mode can be set for one of the following modes:
LOC (Lockout)
–
rEd (Read only)
Ent (Entry)
–
–
ALARM MODULE (4-AL) (OPTIONAL)
The controller may be optionally fitted with the dual alarm option (AL1
and AL2). Some models are equipped only with a single alarm (AL1). One of
three types of output modules (Relay, Logic/SSR Drive or Triac) must be
ordered separately and installed into the appropriate alarm channel socket.
The output modules may be replaced or interchanged (with appropriate
wiring considerations) at any time without re-programming the controller.
The alarm values can be accessed in configuration module (4-AL), the
unprotected mode, and in the protected mode, if not locked.
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-LO), 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”. These alarm modes latch the outputs when the output is “ON”, when
selected for latched operation.
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 IMD2) that may be used for this purpose. The indicators should have input
and AC power feeds independent from the other equipment.
Prevents the parameter from appearing in the
protected mode.
Parameter appears, but cannot be modified.
Parameter appears and can be modified.
The code number allows access to the unprotected mode. To enter the
unprotected mode from the protected mode, the code number entered must
match the code number entered here. See Front Panel Program Disable, page
19, for a description of the various program access levels.
Code
PID
PID2S
rtbSS
–
–
–
–
ALS
–
0 to 250
Permits access
Permits access
Permits access
parameters
Permits access
to the main PID parameters
to the secondary PID parameters
to Remote Setpoint ratio and bias
to the alarm value(s).
Hidden Mode Lockouts (ALrS, trnF, tUNE and SPSL)
The hidden mode is accessible from the normal display mode by pressing
and holding the PAR button for three seconds. The parameters can be set for:
LOC (Lockout)
–
ENbL (Enable)
–
Prevents the parameter from appearing in the
hidden mode.
Allows operator to perform the selected hidden
mode function.
Alarm Action (Act1, Act2)
The alarm(s) may be independently configured for one of the following
modes:
Absolute High Acting
Absolute Low Acting
Deviation High Acting
Deviation Low Acting
Band Inside Acting
Band Outside Acting
The functions available in the hidden mode are accessible independent of
the status of program disable.
ALrSS
SPSLS
trnf
tUNE
S
–
–
–
–
Reset (override) the alarm output(s).
Select Local or Remote Setpoint operation.
Select Automatic or Manual operation.
Invoke or cancel Auto-Tune.
Note: These parameters are model specific and may not appear in the
programming sequence.
-28-
(A-Hi)
(A-LO)
(d-Hi)
(d-LO)
(b-in)
(b-Ot)
ü
ý
þ
Relative to Setpoint
(Local or Remote)
Second Analog Input Alarm
On models equipped with the Second Analog Input, the alarm(s) may be
configured to monitor the second input reading in addition to the main input.
Refer to the corresponding alarm operation figures for operation modes.
Note that deviation and band alarm modes are only valid for Internal
Cascade operation.
Absolute High Acting -2
Absolute Low Acting -2
Deviation High Acting -2
Deviation Low Acting -2
Band Inside Acting -2
Band Outside Acting -2
(A2HI)
(A2LO)
(d2HI)
(d2LO)
(b2IN)
(b2Ot)
ü
ý
þ
Valve Fail Alarm (VFAL)
On models equipped with Valve Positioner (Position mode control only),
Alarm #1 may be configured as a valve fail alarm (Act1 = valv). This alarm
mode is useful to provide early detection of valve failure before significant
process errors occur. In this mode, the usual alarm function is disabled.
The alarm triggers under the two following conditions:
1. The valve slidewire feedback position does not match the controller output
power (within the valve position deadband) after the valve fail time has
expired. The alarm indicates that the valve cannot be properly positioned
due to a malfunction of the valve or valve positioner.
2. The slidewire feedback signal is broken or out of range. In this case, the
valve position controller cannot position the valve.
Relative to SP-2, Second
Input (Internal Cascade)
Message display alarms “valv” and “slid” appear when conditions 1 and 2
occur, respectively, whether or not the alarm is configured as a valve fail
alarm. This alarm mode also applies to linear DC output used for valve
positioning. In this case, a slidewire signal must be supplied to the controller
for valve fail detection. To silence a triggered Valve Fail alarm, see Valve
Fail Time Alarm (VFAL) parameter, page 38.
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, page 6, for definitions, under installing
output modules section.) The alarm output wave form 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”.
-29-
Alarm Action Figures
-30-
-31-
Alarm Reset (rSt1, rSt2)
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, page 20). An
Alarm condition may also be reset via the RS485 serial interface or by the user
input. Automatic (Auto) reset alarms are reset by the controller when the alarm
condition clears. Figure 16, Alarm Reset Sequence, depicts the reset types.
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 turning “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 normally,
until the next controller power-on. Figure17, Alarm Standby Delay Sequence
depicts a typical operation sequence.
Figure 17, Alarm Standby Delay Sequence
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 is changed.
AL-1 and AL-2 - -999 to 9999
If the alarm action is set as a Band Alarm, then only a positive value can be
entered.
AL-1 and AL-2 - 0 to 9999
Figure 16, Alarm Reset Sequence
-32-
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. See the
Alarm Action Figures, page 30, for the effect of hysteresis on the various
alarm types.
AHYS - 1 to 250
Overlap/Deadband (db-2)
This parameter defines the area in which both the 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 to 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). The Operation Figures illustrate the effects of different deadbands.
SECONDARY OUTPUT MODULE (5-02) (OPTIONAL)
The optional secondary output (OP2) operates as an independent output for
systems that require a second output. One of the three types of output modules
(Relay, Logic/SSR Drive or Triac) must be ordered separately and installed
into the OP2 channel socket. 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, page 6, for definition).
Secondary output power is defined as ranging from -100% (full on) to 0%
(off, unless a deadband overlap is used).
Time Proportioning Cycle Time (CYC2)
A value of 0 turns off the secondary output, independent of power demand.
CYC2 - 0 to 250 seconds
Figure 18, Operation (db=0)
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 OP2 to that
of OP1 for best control.
GAN2 - 0.0 to 10.0
Figure 19, Operation (db>0)
-33-
Overlap/Deadband (db-2) (Cont’d)
SERIAL COMMUNICATIONS MODULE (6-SC) (OPTIONAL)
When communicating with a PCU 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
RS485 Serial Communications Interface, page 47.
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 RS485 interface line must each have
a different address number. A value of 0 does not require the address specifier
command, when communicating with the PCU. The address numbers range
from 0 to 99.
Abbreviated or Full Transmission (Abrv)
When transmitting data, the PCU 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 - 6 SET 123.8F<CR> <LF>
Full Transmission
YES - 123.8<CR> <LF>
Abbreviated Transmission
Figure 20, Operation (db<0)
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 is
observed during band transition.
Print Rate (PrAt)
The PCU can be programmed to automatically transmit the selected print
options at the programmed print rate. Selecting 0 (zero) disables the
automatic print rate feature.
PrAt - 0 to 9999 seconds
-34-
Print Options (PoPt)
Selecting YES for the print options allows 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
SEt
OPr
Pbd
INt
dEr
AL1
AL2
dEv
OFP
r-P
Crg
Cdb
OSt
rAt
bIA
rSP
IN2
Pb2
It2
dt2
SP2
-
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
Print
SECOND ANALOG INPUT MODULE (7-2N) (OPTIONAL)
The Second Analog Input can be configured as a Remote Setpoint Input or
as a Secondary Input for Internal Cascade control. As a Remote Setpoint, the
controller can operate as an External Cascade controller, Setpoint Slave
controller and as a Ratio controller. See Cascade Control, page 56, for an
overview of cascade control.
Input Process Value
Setpoint Value
% Output Power Value
% Proportional Band Value
Integral Time Value
Derivative Time Value
Alarm 1 Value
Alarm 2 Value
Deviation From Setpoint Value
% Output Power Offset Value
Setpoint Ramp Rate Value
Relative Gain Value
Deadband Value
Output Status
Remote Setpoint Ratio
Remote Setpoint Bias
Remote Setpoint Reading
Second Input Reading
Proportional Band #2
Integral Time #2
Derivative Time #2
Internal Cascade Directed Setpoint
Operation mode (OPEr)
The Second Analog Input must be configured for either Remote Setpoint
Operation or Internal Cascade Operation (single controller cascade).
rSP
- Remote Setpoint
CSCd - Internal Cascade
Square Root Linearization (root)
In some cases it may be necessary to linearize the Second Analog input by
use of the square root function.
Selection of ‘yES’ results in the square root linearization of the Second
Analog Input(only). Selection of ‘NO’, results in linear scaling. The square
root linearization exhibits a 3% low cut point (17% of scaled reading) to
eliminate reading jitter at low flow rates. The following example illustrates
the scaling of the Second Analog Input with square root linearization.
Example: It is necessary to square root linearize the output of a differential
pressure transmitter to indicate and control flow. The defining equation is
F = 278 D p, where D P = 0 - 500 PSI, transmitted linearly by a 4 - 20 mA
transducer. At full flow rate ( D P = 500 PSI), the flow is 6216 ft3/hr. The
following scaling information is used with the controller:
dPt2
root
dSP1
INP1
dSP2
INP2
-35-
=
=
=
=
=
=
0
yES
0 Ft 3/hr
4.00 mA
6216 Ft3/hr
20.00 mA
Square Root Linearization (root) (Cont’d)
As a result of the scaling and square root linearization, the following
represents the readings at various inputs:
Delta P
(PSI)
0.00
15.63
31.25
62.50
125.00
187.50
250.00
312.50
375.00
437.50
500.00
Before programming the indicator, organize all the data for the
programming steps to avoid 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.
Example:
Transmitter Flow
(mA)
(ft3/hr)
4.00
0
4.50
1099
5.00
1554
6.00
2198
8.00
3108
10.00
3807
12.00
4396
14.00
4914
16.00
5383
18.00
5815
20.00
6216
Scaling Point #1
0.0% @ 4.00 mA
Scaling Point #2
AND
100.0% @20.00 mA
Display Values (dSP1 & dSP2)
Key-in the display value for Scaling Point 1 and Scaling Point 2.
dSP1 -999 to 9999 (Ex. 0.0%)
dSP2 -999 to 9999 (Ex. 100.0%)
Signal Input Values (INP1 & INP2)
The signal input value can either be keyed via the front panel buttons or an
input signal can be applied to the appropriate signal input terminals. Initially,
the unit is in the key-in mode.
Key-in Method
Key-in the signal value for Scaling Point 1 and Scaling Point 2.
INP1
-999 to 9999 (Ex. 4.00 mA DC)
INP2
-999 to 9999 (Ex. 20.00 mA DC)
Signal Input Method
To change to the signal input method press the DSP button. Front panel
annunciators %PW and SEC flash and the display indicates the signal value
applied to the input terminals. The unit can be toggled to the key-in method by
pressing the DSP button again.
When the desired value is indicated on the display, press the PAR button to
store the value and advance to the next parameter.
The scaling of the Remote Setpoint and Internal Cascade units are
normally made equal to the physical range of the system.
Decimal Point Position (dPt2)
For Remote Setpoint operation, the decimal point position is normally
programmed to be the same as the main input. For Internal Cascade operation,
the decimal point may be different from the main input.
Example:
If main input = 500 degrees FS, Second Input = 15.00 PSI FS, then dCPt = 0
and dPt2 = 0.00.
Second Analog Input Scaling Points (dSP1, INP1, dSP2, INP2)
Prior to installing and operating the indicator, it may be necessary to
change the scaling to suit the display units particular to the application.
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 display value points. The location of the scaling points should be near
the process end limits, for the best possible accuracy.
Once these values are programmed, the indicator calculates the slope and
intercept of the signal/display graph automatically. No span/zero interaction
occurs, making scaling a one-pass exercise.
Example: If the control range of the process is 100 to 400 units, the Remote
Setpoint is normally scaled to 100 and 400.
Example: The Secondary variable under internal cascade control is steam
pressure over the range of 0.00 to 60.00 PSI. The Second Analog input is
normally scaled to 0.00 and 60.00 units.
-36-
Local/Remote Setpoint Transfer Modes (SPtr)
When switching from/to Local or Remote Setpoint, the response of the
controller can be programmed to act in a variety of ways.
These responses apply to changes in setpoint mode from the controller’s
front panel, User Input or Serial communications. The table summarizes the
responses for Setpoint transfer operation:
SPtr parameter
nor
Local to Remote
VALVE POSITIONER MODULE (8-VP)
The Valve Positioner controller must be configured to operate in either
Position Mode or Velocity Mode. Position Mode requires a slidewire
feedback signal from the valve or valve positioner. Velocity Mode does not
require a slidewire feedback signal. See Valve Position Option, page 54, for
an overview of valve position control.
Remote to Local
– Output may bump.
Output may bump.
Auto
– No output bump. Process
error eliminated at rate of
integral action.
No output bump. Process
error eliminated at rate of
integral action.
trAC
– Output may bump.
Local setpoint assumes
value of Remote setpoint
(tracks). No output bump.
Valve Position 1 And Valve Position 2 (VPS1, VPS2)
The full closed valve position and the full open valve position are
represented by parameters VPS1 and VPS2, respectively. These values are
expressed as a percentage of the valve open position. They do not represent
slidewire resistance. Normally, for position mode control, VPS1 = 0.0% and
VPS2 = 100.0%. In some processes, it may be necessary to limit the range
over which the controller positions the valve. In such a case, VPS1 defines the
minimum open position and VPS2 defines the maximum open position. The
controller then scales the valve position values to represent 0 and 100%
output power. In this way the valve is confined to work over a smaller portion
of its total range.
Setting both parameters to 0.0% engages velocity mode control. Slidewire
feedback is not required for velocity mode. Additionally, slightly different
controller parameters are required for this mode.
VPS1 & VPS2 –
-99.9% to 999.9%
For position mode control, there are several ways to determine the valve
position values:
1) Position the valve to the closed or open positions (by use of the controller or
manually) and have the controller measure and record these positions. To
engage this mode, press the DSP button while either VPS1 or VPS2
parameters are called. %PW and DEV annunciators flash to indicate this
mode. The valve may then be positioned directly through the use of the
front panel UP and DOWN buttons. The UP button causes the valve to
move open and the DOWN button causes the valve to move closed.
Simultaneously, the controller indicates the slidewire position. After the
valve has been moved to the desired position (by use of the button and
observing the display), press PAR to record the position. This technique is
preferred because it compensates for leadwire resistance errors.
Note: In situations where an output bump may occur, the setpoint ramp function
(SPrP) can be used to reduce or eliminate bumping when switching setpoint
modes. The setpoint ramp feature ramps the setpoint from the old setpoint
mode to the new setpoint mode. After the initial ramp has been completed, the
active setpoint (Local or Remote) remains in the setpoint ramp mode.
Secondary Output Power Dampening (OPd2)
The output power of the secondary loop (Internal Cascade) can be
dampened (filtered) independent of the primary loop. The secondary output
power is the actual output of the controller. The primary output power
(setpoint to the secondary) is dampened by the OPdP parameter. The
secondary output power is dampened by the OPd2 parameter.
-37-
Valve Position 1 And Valve Position 2 (VPS1, VPS2) (Cont’d)
2) Use the specifications provided by the valve manufacturer. Divide the
closed and open position resistance values by the total slidewire resistance
to yield percentage values. Directly key-in the values as a percentage.
3) Measure the resistance of the open and closed positions and divide by the
total slidewire resistance to yield percentage values. Directly key-in the
percentage values.
An active valve fail alarm is silenced in these ways:
1) Set the valve fail time to 0
2) The output power and slidewire signals subsequently agree.
3) Cycle power to the controller.
VFAL - 0 to 9999
Valve Motor Open Time And Valve Motor Close Time (VOPt, VCLt)
(Velocity mode)
For velocity mode control, the valve motor open transit time (VOPt) and
valve motor close transit time (VCLt) must be known. In many cases, these
transit times differ from the valve specification. The actual transmit times
under load are normally measured for best results. In some cases, the open and
close times may be different. The transit time range is 1 to 9999 seconds.
Valve Update Time (VUdt) (Position And Velocity Mode)
The valve update time is the time interval in which the valve position
outputs are updated. The update time may be increased to reduce valve
activity. Valve update times up to 1/10 of the integral time (or process time
constant) may be used with good results. Longer update times may adversely
affect control quality. The update time is variable from 0 to 250 seconds. A
value of zero causes the valve position to be updated at the controller’s scan
rate (10/sec).
Valve Minimum On Time (VONt)(Velocity Mode)
As a result of the pulsed-type algorithm used in velocity mode control, a
minimum on-time pulse threshold is required for proper valve control. The
control does not update the outputs until the calculated on-time pulse exceeds
this value. Normally, set this value to the minimum on-time of the valve
motor. If not given, or otherwise unsuitable, set this value approximately
equal to 2.0 to 5.0% of valve open or valve close time. The minimum on-time
range is 0.1 to 25.0 seconds.
Valve Position Deadband (VPdb) (Position Mode)
The difference between the power output and the slidewire valve position
must exceed the deadband in order for the controller to update the valve
position. Normally, the deadband is set to a minimum to compensate for valve
motor overrun and gearing backlash to eliminate hunting. Deadband values
that are too large may result in excessive errors. Values that are too small may
result in excessive hunting. The Output Power Dampening (OPdP) parameter
can also be used to reduce valve activity. Typically set in the range of 1 to 3%.
VPdb - 0.0% to 25.0%
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 restores all parameters to factory settings, the unit indicates
the operation after the PAR button is pressed, by displaying “rSEt” in the
lower display momentarily. The calibration operations are detailed in
Calibration, page 78.
Valve Fail Time Alarm (VFAL) (Position Mode)
The valve fail time is the maximum time allowed in which the slidewire
feedback signal must match the output power before an error message
appears. If this condition is not met, a valve sentry alarm message appears
(“VALV” in display), indicating a failed valve or failed valve positioner.
Optionally, an alarm can be configured to provide an output event (see Alarm
Action, page 28). This feature also applies to valve positioning with linear DC
output. The fail time must be set, at a minimum, larger than the Valve Update
Time together with the valve motor transit time. A value of zero disables the
valve fail feature.
-38-
REFERENCE TABLES: CONFIGURATION PARAMETER
MODULES
Configure Module 1 - Input Parameters (1-IN)
Display
Parameter
tYPE
Input type
root
Square root
linearization
Decimal
point
dCPt
rnd
Rounding
increments
FLtr
Digital
filtering for
input signal
dSP1
Scaling point
#1 Display
Value
Scaling point
#1 input
signal value
key-in method
Signal input
method
4 to 20 mA
0-10 VDC
Scaling point
#2 display
value
INP1
dSP2
Range and Units
(Factory Setting
Value)
VOLt - Voltage
Curr - Current
(Curr)
Yes/no
(no)
0, 0.0, 0.00, or 0.000
(0.0)
Description/
Comments
Display
INP2
Second Analog Input
Models only.
If 0.000 is selected,
scaling points must
be a positive value.
1, 2, 5, 10, 50, or 100 Used in conjunction
(0.1)
with filtering to
stabilize the display
reading.
0 to 4
Increase number for
(1)
more filtering effect.
4 = 2/sec display
update rate.
-999 to 9999
Normally, key-in
(0.0)
display low value.
-999 to 9999
(4.00)
0.00 to 20.00
0.00 to 10.00
-999 to 9999
(100.0)
SPLO
SPHI
SPrP
InPt
Normally, key-in input
low value. Press DSP
button to select signal
input method.
Normally, apply input
low value.
Normally, key-in
display high value.
-39-
Parameter
Scaling point
#2 input
signal value
key-in method
Signal input
method
4 to 20 mA
0-10 VDC
Lower limit
setpoint range
Upper limit
setpoint range
Setpoint ramp
rate
User input
Range and Units
(Factory Setting
Value)
-999 to 9999
(20.00)
0.00 to 20.00
0.00 to 10.00
-999 to 9999
(0.0)
-999 to 9999
(999.9)
0.0 to 999.9
units/minute
(0.0)
PLOC - Program
disable
ILOC - Integral action
on/off
trnf - auto/manual
select
SPrP - Setpoint ramp
rate on/off
ALrS - Reset alarm
output(s)
Prnt - print request
SPSL - Remote/Local
Setpoint select
(PLOC)
Description/
Comments
Normally, key-in input
high value. Press
DSP button to select
signal input method.
Normally, apply input
high value.
Set low limit below
high limit.
Set high limit above
low limit.
0.0 is off (no ramping)
This parameter also
ramps Remote
Setpoint.
Available on all
second input ( MVP
and ANA) models and
on models with
RS485.
Configure Module 2 - Output Parameters (2-OP)
Display
CYCt
OPAC
OPLO
OPHI
OPFL
OPdP
CHYS
tcod
Range and Units
Description/
(Factory Setting
Comments
Value)
Cycle time
0 to 250 seconds
0 turns OP1 off. This
(2)
parameter does not
appear if Valve
Positioner option is
installed.
For both PID &
Control Action
drct
ON/OFF control.
rEv
(rev)
Output power lower 0% to 100%, OP1 Set OPLO < OPHI
limit range
(0)
If secondary output is
-100% to 100%,
installed.
OP1 & OP2
(-100)
Output power
0% to 100%, OP1 Set OPHI > OPLO
upper limit range
(100)
If secondary output is
-100% to
100%OP1 & OP2 installed.
(100)
Input overdrive
0% to 100%, OP1 Set to a value to
power preset
safely control the
-100% to 100%,
process in the event
OP1 & OP2
of input overdrive
(0)
condition.
0 to 250 seconds
0 = off (no
Output power
(3)
dampening) Set in
dampening
range of 150 to 110 of
(filtering) time
integral time.
ON/OFF control
1 to 250
Hysteresis for OP1.
hysteresis
(1.0)
Auto-tune
0 to 4
0 = fastest response
dampening mode
(0)
4 = slowest response
Parameter
Display
Range and Units
(Factory Setting
Value)
OP -% output power
INP - scaled
display value
SP - setpoint value
dEv - deviation
dE-2 - Internal
Cascade Secondary
deviation
SP-2 - Internal
Cascade, Directed
Setpoint
(OP)
-999 to 9999
(0.0)
ANAS
Linear DC
output
assignment
ANLO
Linear DC
output low
scaling value
ANHI
Linear DC
output high
scaling value
-999 to 9999
(100.0)
ANdb
Linear DC
output
deadband
Linear DC
update time
0.0 to 25.0%
(0.0)
ANUt
-40-
Parameter
0 to 250 seconds
(0)
Description/
Comments
This parameter
appears if analog
option is installed.
Units depend on
ANAS selection. This
parameter appears if
analog option is
installed.
Units depend on
ANAS selection. This
parameter appears if
analog option is
installed.
Only used when
ANAS=OP. 0.0%= no
deadband
Only used when
ANAS=OP. 0 seconds
updates output at a
rate of 10/sec.
Configure Module 3 - Lockout Parameters (3-LC)
Display
Parameter
SP
Setpoint
access
OP
Output power
access
dEv
Deviation
Range and Units
(Factory Setting
Value)
LOC - lockout
rED - read only
Ent - enter
(Ent)
LOC - lockout
rED - read only
Ent - enter
(Ent)
LOC - lockout
rEd - read only
(rEd)
IN-2
Second Analog LOC - lockout
input
rEd - read only
(rEd)
bdSP
Blank display
Code
Access code
PId
PID values
enable
PId2
LOC - lockout
rEd - read only
(rEd)
0 to 250
(0)
LOC - lockout
rEd - read only
Ent - enter
(LOC)
Secondary PID LOC - lockout
values enable rEd - read only
Ent - enter
(LOC)
Description/Comments
Display
Determines access to
process setpoint.
rtbS
Determines direct access
to output power. %PW
indicator illuminates when
parameter is selected in
display.
Determines display of
deviation. DEV indicator
illuminates when
parameter is selected in
display.
Determines display of
Second Analog input
(Remote Setpoint)
(SEC) illuminates)
Blanks secondary display.
AL
ALrS
SPSL
trnF
tUNE
Refer to front panel
disable section for access
levels.
Protected mode lockout.
Protected mode lockout.
Cascade only.
-41-
Range and Units
(Factory Setting
Value)
Remote Setpoint LOC - lockout
Ratio & Bias
rEd - read only
Ent - enter
(LOC)
Alarm values
LOC - lockout
enable
rEd - read only
Ent - enter
(LOC)
Reset alarms
LOC - lockout
enable
ENBL - enable
(LOC)
LOC- lockout
Remote/Local
ENBL - enable
setpoint select
(LOC)
enable
Automatic/Manual LOC - lockout
ENBL - enable
(user) mode
(LOC)
select enable
Auto-tune enable LOC- lockout
ENBL - enable
(LOC)
Parameter
Description/Comments
Remote Setpoint Ratio
and Bias values enable
Protected mode lockout
Hidden mode lockout
Hidden mode lockout
Hidden mode lockout
Hidden mode lockout
Configure Module 4 - Alarms (4-AL)
Unit returns to configuration access point if alarm(s) are not
installed.
Display
Act1
rSt1
Stb1
AL-1
Range and Units
(Factory Setting Value)
Alarm 1 operation A-HI - absolute high
mode
A-LO - absolute low
d-HI - deviation high
d-LO - deviation low
b-IN - band inside
b-ot - band outside
Valv - valve fail alarm
A2HI - absolute high,
second input
A2LO - absolute low,
second input
d2HI - deviation high,
second input, cascade
d2LO - deviation low,
second input, cascade
b2IN - band in, second
input, cascade
b2Ot - band out, second
input, cascade
(A-HI)
Alarm 1 reset
Auto - automatic
mode
LAtc - manual reset
(Auto)
Alarm 1 standby
yes/no
function (delay)
(no)
Alarm 1 value
-999 to 9999
(0.0)
Parameter
Description/
Comments
If changed, check
alarm values.
Display
Act2
Alarm 2
operation mode
rSt2
Alarm 2 reset
mode
Stb2
Alarm 2 standby
function (delay)
Alarm 2 value
Manual reset via
hidden mode
Power-up
standby delay.
If band alarm
action, then only
a positive value
can be entered.
AL-2
AHYS
-42-
Parameter
Range and Units
(Factory Setting Value)
A-HI - absolute high
A-LO - absolute low
d-HI - deviation high
d-LO - deviation low
b-IN - band inside
b-ot - band outside
A2HI - absolute high,
second input
A2LO - absolute low,
second input
d2HI - deviation high,
second input, cascade
d2LO - deviation low,
second input, cascade
b2IN - band in, second
input, cascade
b2Ot - band out, second
input, cascade
(A-HI)
Auto - automatic
LAtc - manual reset
(Auto)
yes/no
(no)
-999 to 9999
(0.0)
Alarm Hysteresis 1 to 250
value
(0.1)
Description/
Comments
If changed, check
alarm values.
Manual reset via
hidden mode.
Power-up standby
delay.
If band alarm
action, then only a
positive value can
be entered.
Applies to both
alarms. Set to
eliminate chatter.
Configure Module 5 - Secondary Output Parameters (5-O2)
Unit returns to configuration access point if secondary output option is
not installed.
Display
CYC2
Parameter
GAN2
Secondary output
cycle time
Relative gain
db-2
Overlap-deadband
Range and Units
(Factory Setting
Value)
0 to 250 sec
(2)
0.0 to 10.0
(1.0)
-999 to 9999
(0.0)
Description/
Comments
0 turns OP2 off.
0.0 places
secondary output
into ON/OFF control
mode and db-2
becomes hysteresis
value.
Positive value is
deadband. Negative
value is overlap. If
GAN2 = 0, this
parameter is OP2
ON/OFF control
hysteresis.
-43-
Configure Module 6 - Serial Communications (6-SC)
Unit returns to configuration access point if RS485 serial option is not
installed.
Display
Parameter
bAUd
Baud rate
PArb
Parity bit
Add
Unit address
Range and Units
(Factory Setting
Value)
300 to 9600
(1200)
odd, even, no parity
(odd)
0 to 99
(0)
Abr
Abbreviated or
full transmission
yes/no
(no)
PrAt
Auto print rate
PoPt
Print options
0 to 9999
(0)
yes/no
(no)
INP
SEt
Input Process
Value
Setpoint
OPr
% Output Power
Pbd
INt
% Proportional
Band
Integral Time
dEr
Derivative Time
AL1
Alarm 1
Display
Description/
Comments
Baud rate of unit must
match connected
equipment.
Parity of unit must
match other equipment.
For multiple units, each
unit must have a unique
address.
Selecting yes, the
controller does not
transmit mnemonics.
0 disables auto print
function
Selecting yes allows
print options shown
below, to be
programmed.
yes/no
(yes)
yes/no
(yes)
yes/no
(yes)
yes/no
(no)
yes/no
(no)
yes/no
(no)
yes/no
(no)
-44-
Parameter
Range and Units
(Factory Setting
Value)
AL2
Alarm 2
yes/no
(no)
dEv
Deviation From
Setpoint
yes/no
(no)
OFP
% Output Power Offset
yes/no
(no)
r_P
Setpoint Ramp Rate
yes/no
(no)
Crg
Relative Gain
yes/no
(no)
Cdb
Deadband
yes/no
(no)
OSt
Output Status
yes/no
(no)
rAt
Remote Setpoint Ratio
yes/no
(no)
bIA
Remote Setpoint Bias
yes/no
(no)
Pb2
Secondary Proportional yes/no
Band
(no)
It2
Secondary Integral
Time
yes/no
(no)
dt2
Secondary Derivative
Time
yes/no
(no)
rSP
Remote Setpoint
yes/no
(no)
SP2
Secondary Directed
Setpoint
yes/no
(no)
IN2
Second Analog Input
yes/no
(no)
Description/
Comments
Configure Module 7 - Second Analog Input (7-2N)
Unit returns to configuration access point if Second Analog Input option
is not installed.
Display
Parameter
OPEr
Second Analog
Input operation
mode
root
Square root
linearization
Second Input
decimal point
position
dPt2
dSP1
INP1
dSP2
INP2
SPtr
OPd2
Range and Units
(Factory Setting
Value)
CSCd - Internal
Cascade mode
rSP - Remote
Setpoint mode
(rSP)
yes/no
(no)
0, 0.0, 0.00
or 0.000
(0.0)
Second Input
scaling point #1
display value
Second input
scaling point #1
input value
-999 to 9999
(0.0)
Second Input
scaling point #2
display value
Second input
scaling point #2
input value
-999 to 9999
(100.0)
Local/Remote
Setpoint transfer
action
nor - normal
Auto - automatic
trAC - track
(nor)
0 to 250 seconds
(2)
Secondary output
power dampening
-9.99 to 99.99
(4.00)
-9.99 to 99.99
(20.00)
Configure Module 8 - Valve Positioner (8-VP)
Unit returns to configuration access point if Valve Positioner option is
not installed.
Description/
Comments
Display
Parameter
Remote Setpoint
mode also for
External Cascade
VPS1
Valve position #1
Linearization applies
to the Second Input
Normally same
position as main
input for Remote
Setpoint
Normally key-in
process low value
VPS2
Valve position #2
VUdt
Valve update time
VPdb
Valve position
deadband
VFAL
Valve fail time
alarm
VOPt
Valve motor open
time
VCLt
Valve motor close
time
VOnt
Valve minimum on
time
Either key-in value
or press DSP for
measure/record
mode
Normally key-in
process high value
Either key-in value
or press DSP for
measure/record
mode
Applies only to
Remote Setpoint
mode.
0=off
-45-
Range and Units
(Factory Setting
Value)
-99.9 to 999.9%
(0.0)
Description/
Comments
Normally full closed
valve position.
Either key-in value or
press DSP for
measure/record mode
-99.9 to 999.9%
Normally full open
(100.0)
valve position.
Either key-in value or
press DSP for
measure/record mode
0 to 250 seconds
0 = update at a rate of
(10)
10/sec.
0.1 to 25.0%
Adjust to reduce
(2.5)
hunting and valve
activity (Position
mode only)
0 to 9999 seconds 0=off, set value larger
(0)
than update time plus
motor transit time
(Position mode only)
1 to 9999 seconds Measure actual valve
(30)
motor open time
(Velocity mode only)
1 to 9999 seconds Measure actual valve
(30)
motor close time
(Velocity mode only)
0.1 to 25.0 seconds Adjust to reduce
(1.0)
hunting and valve
activity (Velocity
mode only)
Configure Module 9 - Factory Service Operations (9-FS)
Display
Code
Parameter
Range and Units
(Factory Setting
Value)
Enter factory service 48 - Calibrate
function code.
instrument
Description/
Comments
Refer to Calibration
Section for details.
66 - Reset
parameters to
factory settings
-46-
RS485 SERIAL COMMUNICATIONS INTERFACE
RS485 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 PCU unit are a printer, a terminal, a
programmable controller, or a host computer.
The RS485 differential (balanced) design has good noise immunity and
allows for communication distances up to 4,000 feet. Up to thirty-two units can
be connected on a pair of wires and a common. The RS485 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 GCM422 (RS-422 to 20 mA
current loop) can be installed to expand the unit’s flexibility.
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
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 PCU 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 PCU unit.
COMMUNICATION FORMAT
Command
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 are 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 PCU unit are 1 start
bit, 7 data bits, No parity (parity equals extra stop bit) or 1 parity bit (odd or
even) and 1 stop bit. The programmable baud rates are; 300, 600, 1200, 2400,
4800, or 9600 baud.
Figure 21, 10 Bit Data Format,
-47-
Description
N (4EH)
Address command: Followed by a one or two digit
address number 0-99.
P (50H)
Transmit print options command; Transmits the options
selected in the Program Options (PoPt) section.
R (52H)
Reset command; Followed by one of the Value Identifiers
(G or H).
T (54H)
Transmit value command; Followed by one of the Value
Identifiers (A-M, O, Q, W-Z, AA, or BB).
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, O, Q, or X-Z), then the proper numerical data.
* The output status indicates the status of the controller’s outputs. The status can
only be read (see the following table). The alarms outputs may be reset by the
reset operator(R).
SENDING COMMANDS AND DATA (Cont’d)
VALUE
DESCRIPTION
IDENTIFIER
A
Input Display Value
SERIAL
MNEMONIC
INP
U
B
Setpoint
SET
U
C
Output Power
PWR
%
D
Proportional Band
PBD
%
E
Integral Time
INT
S
F
Derivative Time
DER
S
G
Alarm 1
AL1
U
H
Alarm 2
AL2
U
I
Deviation
DEV
U
J
Output Power Offset
OFP
%
K
Setpoint Ramp Rate
RMP
R
L
Relative Gain
CRG
G
M
Deadband
CDB
U
O
Remote Setpoint Ratio
RAT
R
Q
Remote Setpoint Bias
BIA
U
S
Controller Mode
1 -Automatic
2 - Manual
(User)
U
Setpoint Mode
1 – Local
2 - Remote
W
Output status*
OST
U
X
Secondary Proportional Band
PB2
%
Y
Secondary Integral Time
IT2
S
Z
Secondary Derivative Time
DT2
S
AA
Second Input Reading
IN2
U
BB
Remote Setpoint Reading or
Secondary Directed Setpoint
RSP or
SP2
U
UNITS
Output Status
NON-VALVE POSITIONER MODELS
VALVE POSITIONER MODELS
A = Main output (OP1)
A
=
Alarm 1 output(AL1)
B = Secondary output (OP2)
B
=
0
C = Alarm 2 output (AL2)
C
=
Motor close output(CLS)
D = Alarm 1 output (AL1)
D
=
Motor open output(OPN)
Example:
OP1 = ON, OP2 = OFF, AL2 = OFF, AL1 = ON
Transmission = “ OST 1001”
Note: The % output power can be changed only if the controller is in the
manual mode of operation.
The 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 PCU accepts 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 to be sent, the data value can be
transmitted as 750.0 or 7500. If a 750 is transmitted, the alarm value
changes to 75.0 in the unit.
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 causes
all the units to respond simultaneously, resulting in a communication
collision. The command string is constructed in a specific logical
sequence. The PCU does not accept command strings that do not follow
this sequence. Only one operation can be performed per command string.
Output status transmission format = ABCD (0 = output off, 1 = output on)
Note: The % output power can be changed only if the controller is in the manual
mode of operation.
-48-
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 is 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 the
unit begins processing the command.
Below are typical examples of command strings.
Example: Change Proportional Band Value to 13.0% on the unit with an
address of 2.
Command String: N2VD130*
Figure 22, Timing Diagrams
Example: Transmit the Input Display Value of the unit with an address of 3.
Command String: N3TA*
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.
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. Figure 22,
Timing Diagrams, shows the timing considerations that need to be made.
Example: Reset Alarm Output 1 of the unit with an address of 0.
Command String: RG*
If illegal commands or characters are sent to the PCU, the string must be
re-transmitted.
-49-
RECEIVING DATA
Examples of transmissions are shown below:
1 INP 500U<CR><LF>100 - 200 msec
Mnemonics Sent
1 SET 525U<CR><LF>100 - 200 msec
1 PWR 20%<SP><CR><LF><SP><CR><LF>100 - 200 msec
Data is transmitted from the PCU when a “T” Transmit Value or a “P”
Transmit Print Options command is sent to the unit via the serial port. Data is
also transmitted when the User Input, programmed for the Print Request
function, is activated. The print rate feature allows the selected print options
to be transmitted at a programmable rate over the serial port. The format for a
typical transmission string with mnemonics is shown in Figure 23, Typical
Transmission String:
-673.5<CR><LF>100 - 200 msec
No Mnemonics Sent
The Print Options provide a choice of which PCU data values are to be
transmitted. The PCU transmits the Print Options when either the User Input,
programmed for the print request function is activated, a “P” (Transmit Print
Options) command is sent to the PCU via the serial port, or the Automatic
Print Rate is set for a specific time. The Print Options are programmed in the
Serial Communications Module (6-SC) with the available options:
1. Print Input Display Value.
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 Output Status
15. Print Remote Setpoint Ratio
16. Print Remote Setpoint Bias
17. Print Proportional Band #2
18. Print Integral Time #2
19. Print Derivative Time #2
20. Print Second Input Reading
21. Print Remote Setpoint Reading
22. Print Secondary Setpoint Value
Figure 23, Typical Transmission String
The first two digits transmitted are the unit address. If the unit address is 0,
the first two digits are blank. A space follows the unit address digits. 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 string
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, only numeric data is sent. If
abbreviated transmission is not selected, the unit transmits mnemonics and
the numeric data.
If more than one string is transmitted there is a 100 msec minimum to 200
msec maximum built-in time delay after each transmission string and after
each block of transmission. When interfacing to a printer, sending
mnemonics are usually desirable.
-50-
A print-out from a PCU unit with an address of 1 and all print options
selected is shown below:
1 INP 500U
1 SET 525U
1 PWR 20.0%
1 PBD 4.0%
1 INT 120S
1 DER 30S
1 AL1 600U
1 AL2 475U
1 DEV -25U
1 OFP 0.0%
1 RMP 0.0R
1 CRG 1.0G
1 CDB OU
1 OSt 1001
1 RAt 1.000R
1 BIAS 0U
1 Pb2 4.0%
1 It2 120S
1 dt2 30S
1 IN2 100.0U
1 RSP 0U
1 SP2 0.0U
Note: If the secondary output option is installed, AL2 is not printed or functional.
-51-
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. It is
recommended that shielded (screened) cable be used for serial
communications. This unit meets the EMC specifications using Alpha #2404
cable or equivalent. There are higher grades of shielded cable, such as four
conductor twisted pair, that offer an even higher degree of noise immunity.
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 RS485 transceiver lines. The signal ground is connected at
the RS485 common of only one PCU unit to the RS485 equipment. If
necessary, the shield can be used as the signal ground.
The signal input common is isolated from the RS485 common and the
analog output “-” terminal.
Note: Do not connect any of the commons to the analog output “-” terminal.
Terminal Descriptions
RS485 COMM. - Common may be required for communication hook-up.
TX/RX(+) & TX/RX(-) - The PCU 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 20 mA Loop). Otherwise not normally used.
Note: Some models do not have TX EN. This is an output used in conjunction with
interface converter Model GCM422, to convert RS485 to 20 mA current loop.
-52-
Connecting To A Host Terminal
Six PCU units are used to control a process in a plant. The PCU units are
located at the proper location to optimize the process. A communication line
is run to an industrial computer located in the production office. Figure 24,
Connecting To A Host Terminal, shows the line connection. Each PCU is
programmed for a different address and all are programmed for the same baud
rate and parity as the computer. 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 PCU(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 all
units and other peripherals must be observed.
2. If the PCU is connected to a host computer, device or printer, make sure that
the computer or device is configured with the same baud rate and
communication format as the PCU. The communication format the PCU
accepts is; 1 start bit, 7 data bits, no parity or 1 parity bit (odd or even), and
1 stop bit.
3. Check the PCU’s unit address. If the Address command is not used when
transmitting a command to the PCU, the PCU’s address must be set to 0.
See Sending Commands & Data, page 47, for command structure.
4. If two-way communications are to be established between the PCU and a
computer, the computer must receive a transmission from the PCU first.
Activating the User Input, programmed for the print request function,
initiates transmissions from the PCU.
5. When sending commands to the PCU, an asterisk (2Ah) must terminate the
command. After system power-up an asterisk must be sent to clear the PCU
input buffer.
6. In multiple unit configurations, each unit must have 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 PCU(s) and the RS485 interface card. Some
cards have the polarity reversed.
Figure 24, Connecting To A Host Terminal
-53-
VALVE POSITION OPTION
constant of the process is 60 seconds, the Valve Update Time (VUdt) of the
controller is set at five seconds to reduce valve activity. Adding Valve
Update Time to the valve motor transit time (20 seconds), the valve fail
time is set at 50 seconds [2 * (20+5)] to alert for a valve fail condition. The
valve position hysteresis is set at 2.0% to allow for valve motor overrun and
backlash, and also to provide a control deadband to reduce valve activity. A
minimum valve position is set to 20% to allow a minimum amount of steam
flow into the heat exchanger. The maximum valve position is set at 100%.
The following data is used to configure the Position mode valve control
parameters of the PCU:
The Valve Position option of the PCU directly controls the position of a
valve. The Valve Motor Open and Valve Motor Close outputs independently
activate the valve motor to position the valve for closed loop control. The PCU
is capable of two Valve Position control modes: Position mode, in which valve
position slidewire feedback is used by the controller, and Velocity mode, a
special positioning algorithm in which no slidewire signal is required.
POSITION MODE VALVE CONTROL
In Position mode valve control, the slidewire resistance, representing the
valve position, is measured by the PCU and scaled internally to equal 0% to
100%. The scaled valve position is compared with the output power to
determine if the valve needs to be repositioned. Since the output power and
valve position both range from 0% to 100%, and normally equal each other,
the output power display (%PW) represents valve position. Based on this
information, the valve can be positioned manually from the Manual (USEr)
mode of the controller. The output power can be manually ranged from 0% to
100% to position the valve.
In the event that the valve position feedback and the output power do not
agree, due to a faulty valve motor, binding valve or defective slidewire, a
valve fail alarm occurs, if desired. The valve fail alarm is based on a timer in
which the output power and valve feedback positions must match within a
preset time. A display message of “VALV” occurs in this event. Optionally,
an alarm event output can be programmed to signal the event to other
equipment. Once the alarm triggers, the output power and feedback positions
must match to silence the alarm. Setting the valve fail time parameter to zero
disables this feature and also silences a triggered alarm.
The controller also senses loss of slidewire feedback signal and can
activate the open or close outputs in such an event. See Input Overdrive
Preset Power (OPFL), page 25, for a description of this operation.
VPS1
VPS2
VUdt
VPdb
VFAL
Example:
Steam is used to heat water by passing it through a heat exchanger.
Variations in inlet water temperature, steam pressure, hot water demand,
etc., all contribute to the need for closed loop control. The steam pressure is
controlled by a PCU with Valve Positioner option. A valve positioner with
1,000 ohm slidewire feedback is used. The PCU maintains constant hot
water temperature by controlling the position of the valve. Given the time
20.0
100.0
5
2.0
50
Scale minimum valve position to 20.0%
Scale maximum valve position to 100.0%
Update valve position, at most, once every 5 seconds
Set valve position deadband to 2.0%
Set valve fail timer to 50 seconds
Figure 25, Motorized Valve Positioner
-54-
VELOCITY MODE VALVE CONTROL
Example:
Steam is used to heat water by passing it through a heat exchanger.
Variations in inlet water temperature, steam pressure, hot water demand,
etc., all contribute to the need for closed loop control. The steam pressure is
controlled by a PCU with Valve Positioner option. The PCU maintains
constant hot water temperature by controlling the position of the valve. No
slidewire feedback is used. Given the time constant of the process is 60
seconds, the Valve Update Time (VUdt) of the controller is set at five
seconds to reduce valve activity. The valve motor open and close transit
times were measured at 20 and 25 seconds respectively. The minimum on
time pulse is set at 0.5 seconds to allow for valve motor overrun and
backlash, and also to provide for a control deadband. The effective control
deadband expressed in percent of controller output is:
The Velocity mode of the Valve Positioner option is a special valve control
algorithm that does not use a slidewire feedback signal. In this control mode,
the controller responds with changes in output power instead of responding to
the output power directly, as in Position mode. Subsequently, as long as there
is process error, the controller activates the motor control outputs
periodically to eliminate the error.
The valve motor open and close transit time and minimum motor on-time
are required parameters for Velocity mode. The valve motor transit times
should be measured in actual use as they frequently differ from the nominal
valve motor times. The minimum on-time is another Velocity mode
parameter. It establishes the control deadband of the controller. Minimum on
times that are too short could cause excessive valve activity. Minimum
on-times that are too long may cause too much error. Velocity mode of the
controller is engaged by setting both Valve Position parameters to 0.0%.
Effective deadband (in percent ) =
=
Vont
0.5* (Vopt + VCLt )
0.5
0.5* (20 + 25)
= 2.2%
The following data is used to configure the Velocity mode valve control
parameters of the PCU:
VPS1
VPS2
VUdt
VOPt
VCLt
Vont
-55-
0.0
0.0
5
20
25
0.5
Set valve position #1 to 0.0 to engage Velocity mode
Set valve position #2 to 0.0 to engage Velocity mode
Update valve position, at most, once every 5 seconds
Set valve motor open time to 20 seconds
Set valve motor close time to 25 seconds
Set valve motor minimum on time (deadband) to 0.5 seconds
SECOND ANALOG INPUT OPTION
Process Remote Setpoint Slave Control
Example: Multiple PCUs are used to regulate the temperature zones of a
continuous drying oven. To reduce thermal shock to the product, the
setpoint levels of incoming zone controllers are low, while the other
controllers have setpoints that are increasingly ramped up to the ideal
drying temperature. The PCUs are slave controllers that have Remote
Setpoint with unique bias values to implement the ramp in setpoint values
of the drying oven. One PCU is the master controller. The master controller
re-transmits the setpoint value via the linear DC output (4 to 20 mA) to the
slave zone controllers. The slave zone controllers receive the 4 to 20 mA
signal as a Remote Setpoint.
The Second Analog Input option is an additional analog input used for
Remote Setpoint or Internal Cascade operation. The mode of operation is
selected by programming. The Second Analog Input reading can be viewed in
the secondary display. Front panel annunciator SEC illuminates to indicate
this display mode.
REMOTE SETPOINT
The PCU with Second Analog Input can be configured as a Remote
Setpoint. This mode of operation enables Cascade control (external), Ratio
control and Process Setpoint Slave control, among others.
The Remote Setpoint value used internally by the controller is:
Remote Setpoint = (Scaled Second Analog Input * rtio) + bIAS
where rtio = 0.000 to 9.999
bIAS = -999 to 9999
The rtio and bIAS parameters offer on-line scaling of the Remote Setpoint
to adjust control ratios or biases among related processes.
In Remote Setpoint mode, the front panel annunciator REM is illuminated.
When in Local Setpoint mode, this annunciator is off. In either Local or
Remote Setpoint mode, the Manual (USEr) mode is indicated by the REM
annunciator flashing.
The Remote Setpoint is restricted to the setpoint limit values SPLO and
SPHI. These parameters may be used to limit the range of the Remote Setpoint
to a safe or more stable control range. For Remote Setpoint signal sources that
change wildly or are too sensitive to process upsets, the Setpoint Ramp
parameter (SPrP) can be used to ramp (rate limit) the Remote Setpoint reading.
This can subsequently reduce the fluctuations of the Secondary control loop.
CASCADE CONTROL
Cascade control involves the separation of a process into two control
loops: the Primary and the Secondary.
The Secondary control loop is designed to regulate the manipulated
variable which is normally the faster responding variable. The Primary loop
controller establishes this setpoint to the Secondary to maintain Primary loop
regulation. Disturbances occurring to the Secondary control loop are quickly
compensated for, before the effect appears in the Primary loop output. This
early loop compensation or “feed forward” action of Cascade control can
improve control quality compared with standard single loop control. Since
the Primary and Secondary “see” different processes, they normally have
different tuning values, with the Secondary normally faster responding.
The PCU is capable of two modes of Cascade control: External Cascade and
Internal Cascade. External cascade involves the use of two controller units, one
of which is a Remote Setpoint controller. Internal Cascade has both the Primary
and Secondary control loops implemented within one controller unit.
Flow Ratio Control
Example: For processing purposes, it is necessary to control the flow of one
process with respect to the flow rate of another. The PCU is to control the
flow at a ratio of 1.5x that of the uncontrolled flow. The PCU with Remote
Setpoint programmed for a ratio value of 1.500 (rtio) and a bias value of 0
(bias) suits this application.
-56-
External Cascade Control
External Cascade Control involves the use of two controllers, one of which
has a Remote Setpoint Input.
The outer loop controller (Primary controller) directs the setpoint of the
inner loop controller (Secondary controller) through the linear DC 4 to 20 mA
output. The Secondary controller has a Second Analog Input option
configured as a Remote Setpoint (RSP) in order to receive the directed
setpoint. See Figure 26, for more details.
The Remote Setpoint of the Secondary controller must be scaled prior to
tuning the controllers. Normally, the Remote Setpoint is scaled to equal the
actual process range of the secondary. Scaled in this way, the Primary
controller can direct the setpoint of the Secondary controller over its
operating range. The internal Remote Setpoint value is as follows:
Remote Setpoint = (Scaled Second Analog Input * Ratio Parameter) + Bias
Parameter
The following data configures the Remote Setpoint of the PCU:
OPEr
root
dPt2
dSP1
INP1
dSP2
INP2
SPtr
-
rSP
NO
0.0
0.0
4.00
200.0
20.00
Auto
Select Remote Setpoint mode
No square root linearization necessary
Select decimal point position to match that of main input
Scale Remote Setpoint to match main input range of PCU
Scale input range to match 4 to 20 mA output of TCU
Scale Remote Setpoint to match main input range of PCU
Scale input range to match 4 to 20 mA output of TCU
Select bumpless Local/Remote setpoint transfer
In some cases the Remote Setpoint signal may change too rapidly or have
excessive process noise. This may lead to instability or even oscillation of the
Secondary controller. The Setpoint Ramp parameter (SPrP) is effective in
limiting the amount of change of the Remote Setpoint. The Setpoint Ramp
parameter should be set to a minimum ramp value consistent with the
response time of the Primary process. Additionally, Setpoint Limit Low and
Setpoint Limit High parameters (SPLO, SPHI) may be used to constrain the
Remote Setpoint value to safe limits or narrow the operating range for
stability purposes.
See Auto-Tune, page 64, for tuning procedure of External Cascade
controllers.
Example: A TCU (temperature input) and PCU (process input) are used in an
External Cascade arrangement to regulate the temperature of a large dye vat.
The PCU is the Secondary controller with Remote Setpoint to regulate steam
pressure. The TCU is the primary controller with linear DC output which
directs the setpoint of the Secondary controller in order to maintain vat
temperature. The range of the secondary steam process is 0.0 to 200.0 PSI.
Figure 26, External Cascade
-57-
Internal Cascade Control
The Internal Cascade control mode of the PCU embodies the function of two
Cascade controllers into a single unit. In all other respects, Internal Cascade
yields the same control flexibility and control quality as External Cascade.
In Internal Cascade, the Primary loop provides an internal setpoint for the
Secondary loop. The Primary loop output power (0-100%) is scaled internally
by the “DSP1” and “DSP2” scaling parameters to yield the Secondary
(directed) setpoint. This setpoint is used by the secondary loop to calculate
the actual output (physical output). The setpoint can be viewed during
operation by the SP-2 parameter. See Figure 27, for more details.
For proper Auto-Tuning of the Primary loop, it it necessary that “DSP1”
and “DSP2” represent the actual process low and process high values,
respectively, of the Secondary process. The tuning parameters (Prop, Intt,
dErt, OPdP) pertain to the primary loop and the tuning parameters (Pb-2, It-2,
dt-2, OPd2) pertain to the secondary loop.
Example: A PCU with Second Analog Input is used in an Internal Cascade
arrangement to regulate the temperature of a large dye vat. The Second
Analog Input is the input to the Secondary loop. This loop regulates steam
pressure. The Primary loop (temperature) directs the setpoint of the
Secondary to maintain vat temperature. The range of the Secondary steam
process is 0.0 to 200.0 PSI transmitted by a 4 to 20 mA transducer. The
following data configures the Internal Cascade controller:
OPEr
root
dPt2
dSP1
INP1
dSP2
INP2
OPd2
-
CSCd
NO
0.0
0.0
4.00
200.0
20.00
2
Select Internal Cascade mode
No square root linearization necessary
Select decimal point position for 0.0 PSI
Secondary process display low value (0.0 PSI)
Secondary process transmitter low value (4 mA)
Secondary process display high value 200.0 PSI)
Secondary process transmitter high value (20 mA)
Secondary output power (physical output) dampening
The Secondary process value can be monitored during operation in the
secondary display.
See Auto-Tune, page 64, for tuning procedure of Internal Cascade controllers.
Figure 27, Internal Cascade
-58-
PID CONTROL
PROPORTIONAL BAND
INTEGRAL TIME
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 scaled display range.
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
repeats 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.
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. This causes over
compensation and leads to an unstable process with excessive overshoot.
Integral times that are too slow (large times) cause a slow response to steady
state errors. Integral action may be disabled by setting the time to zero. If time
is set to zero, the previous integral output power value is maintained.
If integral action is disabled, 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 this feature to prevent integral action
when operating outside the proportional band. This prevents “reset wind-up”.
Note: The Proportional band shift due to integral action may itself be
“reset” by temporarily setting the controller into the ON/OFF control
mode (proportional band=0)
Figure 28, Proportional Band
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 produce continuous oscillations at
setpoint. High proportional band settings (low gain) result 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, page 62, for more information).
Figure 29, Integral Time
-59-
DERIVATIVE TIME
OUTPUT POWER OFFSET (MANUAL RESET)
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 a ramping error exists, the derivative action
is “repeated” by proportional action every derivative time. The units of
derivative time are seconds per repeat.
Derivative action is used to shorten the process response time and helps to
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 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.
If the integral time is set to zero (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 appears
in the unprotected mode, if the integral time equals zero. 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.
Figure 31, Typical Response Curve
Figure 30, Derivative Time
-60-
PID ADJUSTMENTS (Cont’d)
Figure 32, Process Response Extremes
-61-
ON/OFF CONTROL
The controller operates in the ON/OFF
control mode by setting the proportional
band = 0.0%. The ON/OFF control hysteresis
band (CHYS) parameter eliminates output
chatter around setpoint. The Secondary output
can also be used in the ON/OFF control by
setting the relative gain = 0.0 (GAN2).
Additionally, the deadband parameter (db-2)
determines the amount of operational deadband
or overlap between the two outputs.
The phase of the control action can be
reversed by the output control action parameter.
ON/OFF control is usually characterized by
signal oscillations about the setpoint value.
Large hysteresis values make the oscillations
larger. ON/OFF control should only be used
where the constant oscillations are acceptable.
Figure 33, OP1 On/Off Action
-62-
Figure 34, OP2 On/Off Action
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 & OP2 VALID CONTROL MODES
OP1
MODE
OP2
MODE
MANUAL MODE
OUTPUT POWER
RANGE
OP1
STATE
OP2
STATE
PID
—
0% to +100%
OP1-TP
—
ON/OFF
PrOP = 0.0
—
100
OP1-ON
—
Any other setting
OP1-OFF
-100% to +100%
OP1-TP
OP2-TP
OP1-TP
OP2-OFF
PID
PID
PID
ON/OFF
0% to +100%
(GAN2=0.0)
-100% to 0%
ON/OFF
ON/OFF
+100%
(PrOP=0.0) (GAN2=0.0)
-100%
Any other setting
—
OP1-TP
OP2-ON
OP1-ON
OP2-OFF
OP1-OFF
OP2-ON
OP1-OFF
OP2-OFF
TP - Time Proportioning
Note: In manual mode, the % output power is not limited to the output
power limits (OPLO & OPHI).
Figure 35, OP1/OP2 On/Off Action
-63-
AUTO-TUNE
Auto-Tune is a user initiated function in which the controller automatically
determines the PID settings based upon the process characteristics. During
Auto-Tune, the controller temporarily causes the system to oscillate by
cycling the output power from 0 to 100%. The nature of these oscillations
determines the settings of the controller’s parameters.
Figure 37, Auto-Tune Operation
dampening code may be set to yield the response characteristics shown in
Figure 36, Dampening Code. A dampening code setting of zero gives the
fastest response with possible overshoot, and a code of four gives the slowest
response with minimum overshoot.
The following controller parameters are set by Auto-tune according to the
characteristics of the process:
Proportional Band (ProP)
Integral Time (Intt)
Derivative Time (dErt)
Input Filter (Fltr)
Output Power Dampening (OPdP)
Figure 36, Dampening Code
Note: If the induced oscillations caused by Auto-Tune can cause system problems
or are otherwise unacceptable, the Step Response Manual Tuning Procedure
can be used as a tuning alternative.
Prior to initiating Auto-Tune, it is essential that the controller be
configured to the application. In particular, control hysteresis (CHYS) and
Auto-Tune dampening code (tcod) must be set in the Output Parameters
section. Generally, control hysteresis of 2 to 5 units is adequate. The
-64-
AUTO-TUNE OF SECONDARY OUTPUT (OP2) / MAIN
OUTPUT (OP1) SYSTEMS
As shown in Figure 37, Auto-Tune Operation, Auto-Tune cycles the
process at a control point 3/4 of the distance between the current process
signal value (at the instant Auto-Tune is started) and the setpoint. The 3/4
control point was selected to reduce the chance of signal overshoot at setpoint
when Auto-Tuning at start-up. If Auto-Tuning from setpoint and signal
overshoot is unacceptable, temporarily lower the setpoint by an amount of the
oscillation and then Auto-Tune. Reset the setpoint to the original value when
Auto-Tune is complete. After starting Auto-Tune, the secondary display
indicates the current phase (Aut1, Aut2, Aut3 & Aut4). If the controller
remains in an Auto-Tune phase unusually long, the process or connections
may be faulty. Additionally, during Auto-Tune it is important that
disturbances to the system be minimized, as these may have an effect on the
parameter determination.
During Auto-Tune of OP2/OP1 systems, the controller switches the
secondary output (OP2) on and off in addition to the main output (OP1). The
deadband parameter (db-2) determines the amount of overlap or deadband
between the two outputs during Auto-Tune. Refer to ON/OFF CONTROL ,
page 62, for the operation of this parameter. The deadband parameter remains
unchanged after Auto-Tune is complete. Therefore, when proportional
control is started after the completion of Auto-Tune, this parameter may need
to be reset.
It is important that external load disturbances be minimized, and if present,
other zone controllers idled as these may have an effect on the PID constant
determination. The controller additionally sets the Relative Gain parameter
(GAN2) for OP2/OP1 systems.
INITIATE AUTO-TUNE
Auto-Tune may be initiated at start-up, from setpoint, or at any other
process signal point.
To Initiate Auto-Tune:
1. Make sure that Auto-Tuning is enabled in parameter lockouts module.
2. Place the controller into the normal display mode.
3. Press PAR for 3 seconds from normal display mode.
4. Scroll to “tUNE” by use of PAR, if necessary.
5. Select “YES” and press PAR.
Auto-Tune is initiated.
AUTO-TUNE OF INTERNAL CASCADE CONTROLLERS
Auto-Tune of Internal Cascade controllers involves tuning of the Primary
PID and Secondary PID parameters. Each set of parameters is tuned
individually with the secondary parameters normally tuned first. For
Internal Cascade controllers, Auto-Tune offers the option of tuning the
Primary or Secondary:
tunE
To Cancel Auto-Tune: (Old PID settings remain in effect).
A) Make sure that Auto-Tuning is enabled in parameter lockouts module.
1. Place the controller into the normal display mode.
2. Press PAR for 3 seconds from normal display mode.
3. Scroll to “tUNE” by use of PAR, if necessary.
4. Select “NO” and press PAR.
5. Auto-Tune canceled.
B) Or reset the controller by disconnecting AC power.
no
Pri
–
–
SEC
–
No Auto-Tune or abort Auto-Tune
Start Auto-Tune of primary or Auto-Tune of primary in
progress
Start Auto-Tune of secondary or Auto-Tune of
secondary in progress
The Auto-Tune status display indicates the set of parameters actively
Auto-Tuned:
TunePhase
1
2
3
4
Note: If using the linear DC output for control, full power is applied (+100% OP1
or -100% OP2) regardless of the output power limit settings. Set the Linear DC
Output scaling points to limit the magnitude of the output, if desired.
-65-
Display
(Primary)
APr1
APr2
APr3
APr4
Display
(Secondary)
ASC1
ASC2
ASC3
ASC4
AUTO-TUNE OF EXTERNAL CASCADE SYSTEMS (REMOTE
SETPOINT)
The following additional parameters are calculated and set as a result of
Auto-Tuning of the secondary:
Secondary Proportional Band (Pb-2)
Secondary Integral Time (It-2)
Secondary Derivative Time (dt-2)
Secondary Output Power Dampening (OPd2)
Auto-Tuning of the secondary presents two different control points at
which the controller cycles power. In Automatic mode of operation, the
secondary control point is the setpoint directed by the primary at the instant
Auto-Tune is started. In Manual mode of operation, the secondary control
point is the secondary process value reading at the instant Auto-Tune is
started. The secondary is normally Auto-Tuned with the controller in the
Manual mode of operation unless the process is reasonably under control.
Prior to tuning the Secondary, it is essential that it is scaled to match the actual
secondary process range. This is important for proper Auto-Tuning of the
primary. Subsequent changes made to scaling values may require re-tuning.
The following procedure may be used to initially tune an Internal Cascade
controller:
1) Place the controller into Manual (USEr) mode of operation.
2) Adjust output power level until primary variable is close to primary
setpoint. (±10% of range)
3) Auto-Tune the secondary.
4) Auto-Tune the primary.
5) Place controller into Automatic (Auto) mode of operation.
6) Initial tuning is complete.
After the process has stabilized, the primary and secondary may be
re-tuned in Automatic mode of operation. Normally, the primary requires
re-tuning whenever the secondary PID constants are changed.
External Cascade systems involve the use of two controllers, the Primary
and the Secondary, that have a Remote Setpoint Input. In such a system, the
Secondary controller is normally tuned first followed by tuning of the primary
controller. Prior to tuning the Secondary controller, it is essential that the
Remote Setpoint is scaled to match the actual secondary process range. This is
important for proper Auto-Tuning of the primary controller. Subsequent
changes made to scaling values may require re-tuning. The following
procedure may be used to initially tune an External Cascade controller:
1) Place the Secondary controller into Local Setpoint mode and Manual
(USEr) mode of operation.
2) Adjust output power level of the secondary until primary variable is close
to primary setpoint. (±10% of range)
3) Key-in secondary setpoint value equal to secondary process value.
4) Auto-Tune the secondary controller while in Local Setpoint mode.
5) Place the secondary controller into Remote Setpoint mode and Automatic
(Auto) mode of operation.
6) Auto-tune the primary controller while the primary is in Automatic mode
of operation.
7) Initial tuning of system is complete.
After the process has stabilized, the primary and secondary may be
re-tuned in Automatic mode of operation. Normally, the primary requires
re-tuning whenever the secondary PID constants are changed.
Note: For Remote Setpoint controllers, the Auto-tune control point is derived
from the Remote Setpoint when in Remote Setpoint mode and it is derived from
the Local Setpoint when in Local Setpoint mode.
-66-
APPENDIX “A” - APPLICATION EXAMPLES
CHEMICAL MIXING APPLICATION
A customer wants to control the ratio of one liquid flow to the other in a
chemical mixing application. Each flow is monitored with a flow transducer
that provides a 4 to 20 mA output signal. The PCU monitors the flow of
liquid “A” via the optional Remote Setpoint Input. Liquid “B” is monitored
by the main input. Both inputs are scaled independently during initial setup
and programming. The only task left to the operator is to enter the desired
ratio of B to A.
The 4 to 20 mA output of the PCU controls the position of a proportional
valve. Thus controlling the flow of B. As disturbances cause the flow of A to
vary, the PCU ensures that the proper ratio is always maintained. The flow of
“A” is shown in the secondary display simultaneously with the flow of
“B”(main display).
Figure 38, Chemical Mixing, Flow Ratio Application
-67-
FLOW RATE PROGRAMMING EXAMPLE
A plastics manufacturer needs to maintain a constant flow rate on a feed
stock pipeline to insure their product stays within specification. A PCU is
installed to maintain the flow by controlling a proportional control valve.
The output of the flow meter is 0 to 10 VDC. The control valve is positioned
by an electric actuator that requires a 4 to 20 mA control signal.
The following is a list of the parameter values keyed-in to the controller.
Configure Alarm Parameters
Configure Input Parameters
tYPE
dCPt
rnd
FLtr
dSP1
INP1
dSP2
INP2
SPLO
SPHI
SPrP
INPt
VOLT
0.0
0.1
1
0.0
0.00
100.0
10.00
0.0
110.0
0.1
trnF
Act1
rSt1
Stb1
AL-1
Act2
rSt2
Stb2
AL-2
AHYS
Set input signal for voltage
Scaled display to indicate in tenths
No rounding of the display
Normal input signal filtering
Display value for scaling point 1 is 0.0
Signal value for scaling point 1 is 0.00
Display value for scaling point 2 is 100.0
Signal value for scaling point 2 is 10.00
Limit min. setpoint value to 0.0 units
Limit max. setpoint value to 110.0 units
Setpoint ramp rate = 0.1 units/minute
Allow remote switching of auto/manual mode
Configure Output Parameters
CYCt
OPAC
OPLO
OPHI
OPFL
0
rEV
0
100
0
OPdP
CHYS
tcod
ANAS
ANLO
ANHI
Andb
ANut
2.0
0.1
0
OP
0.0
100.0
2.5
2
}
Main control output and indicator off
Main control output is reverse acting
Limit min. controller power to 0%
Limit max. controller power to 100%
Controller output power to 0 if input overdrive
signal is detected
Output power dampening = 2.0
Control hysteresis set for 0.1
Select fastest response
Linear DC output used for control
Control valve provides full deflection for 4 to
20 mA signal range
Impose 2.5% deadband on Linear DC output
Update output once every 2 seconds
-68-
A-HI
LAtC
YES
90.0
A-LO
LAtC
YES
20.0
0.1
Set alarm #1 for absolute high acting
Alarm set for latching
Disable alarm during power-up
Set alarm value for 90.0
Set alarm #2 for absolute low acting
Alarm set for latching
Disable alarm during power-up
Set alarm value for 20.0
Alarm activation hysteresis set for 0.1
APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS
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”
–
–
–
–
–
–
–
3. ANNUNCIATORS:
LED Backlight Status Indicators (Model dependent):
%PW
DEV
OP1
AL1
AL2
OP2
OPN
CLS
SEC
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.
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, 48-62 Hz, 10 VA.
DIMENSIONS In inches (mm)
–
–
–
–
–
–
–
–
–
MAN –
REM –
–
–
Lower auxiliary display shows power output in (%).
Lower auxiliary display shows deviation (error) from 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).
Note: Recommended minimum clearance (behind the panel) for panel latch installation is 5.5" (140)H x 2.1" (53.4)W.
Figure 39, Dimensions
-69-
Max. Load Current: 1 Amp @ 35°C
0.75 Amp @ 50°C
Min. Load Current: 10 mA
Offstate 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
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 mA)
Compliance: 10 V (500 W max. loop impedance)
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV)
Min. Load Resistance: 10 KW (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 W to 100 KW
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: 13.00 V typ.
20 mA Range: 26.00 mA typ.
Signal Overdrive Response:
Main Control Output(s): 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:
Signal
Accuracy (% of
Maximum
Input
Resolution
Range
Unscaled Reading)
Input
Impedance
0-10 VDC ±(0.15% + 3 mV + 1 LSD) 300 VDC
1 MW
10 mV
0-20 mA DC ±(0.15% + 6 mA + 1 LSD) 200 mA DC
10 W
10 mA
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 max. (inductive load)
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 typical
Drive: 45 mA maximum
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120 to 240 VAC
-70-
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: 0.1% 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: 0-20 mA (Isolated from main input)
Overload: 100 mA MIN (steady state)
Input Resistance: 10 W typ. Voltage drop (@ 20 mA); 0.2 V typ.
Accuracy: 0.15% of reading ±10 mA ± 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 and ANA) models and on models with
RS485.
Response time: 100 msec max.
Functions:
Program Lock
Auto/Manual Mode Select
Setpoint Ramp Select
Print Request
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
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 Range: 0 to 50°C
Storage Range: -40 to 80°C
Vibration According to IEC 68-2-6: Operational 5 to 150 Hz, in X, Y, Z
direction for 1.5 hours, 1 g.
Shock According to IEC 68-2-27: Operational 5 g's, 11 msec in 3
directions.
Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input
Zero Drift (maximum):
4 to 20 mA DC Range: 0.5 mA/°C
0-10 VDC Range: 0.2 mV/°C
Second Input: 2 mA/°C
Relative Humidity: Less than 85% RH (non-condensing) from 0°C to 50°C.
Altitude: Up to 2000 meters
16. ISOLATION BREAKDOWN RATINGS:
All inputs and outputs with respect to AC line: 2300 VMIN
Analog Output, Second Analog Input, or Slidewire Input with respect
to Main Input: 500VMIN
Integral Action Lock
Reset Alarms
Local/Remote Setpoint Select
-71-
2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
Measurement input and/or analog output signal may deviate during
EMI disturbance.
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent.
Refer to the 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: NEMA 2 for standard models.
Front Panel: Flame and scratch resistant tinted plastic
Case: High impact black plastic. (Mounting collar included)
NEMA 4X/IP65 model only: Sealed bezel utilizing two captive mounting
screws (panel gasket included) This unit is rated for NEMA 4X/IP65
indoor use. Installation Category II, Pollution Degree 2.
20. WEIGHT: 1.3 lbs (0.6 kgs)
17. CERTIFICATIONS AND COMPLIANCES:
SAFETY
UL Listed, File #E137808, UL508, CSA C22.2 No. 14-M95
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
UL Recognized Component, File # E156876, UL873, CSA C22.2 No. 24
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
Type 2 or 4X Enclosure rating (Face only), UL50
IECEE CB Scheme Test Certificate #UL1239-156876/USA,
CB Scheme Test Report #96ME50279-070794
Issued by Underwriters Laboratories, Inc.
IEC 1010-1, EN 61010-1: Safety requirements for electrical
equipment for measurement, control, and laboratory use, Part 1.
IP65 Enclosure rating (Face only), IEC 529
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2
Level 2; 4 Kv contact
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3
Level 3; 10 V/m1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4
Level 4; 2 Kv I/O
Level 3; 2 Kv power
RF conducted interference
EN 61000-4-6
Level 3; 10 V/rms2
150 KHz - 80 MHz
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
Notes:
1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:
Measurement input and/or analog output signal may deviate during
EMI disturbance.
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent.
-72-
APPENDIX “C” - 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. For further technical
assistance, contact technical support at the numbers listed on the back cover of the instruction manual.
PROBLEMS
NO DISPLAY
INDICATOR
NOT WORKING
“E-FP” IN DISPLAY
1.
2.
3.
4.
5.
1.
POSSIBLE CAUSE
Power off
Voltage selector switch in the wrong position.
Brown out condition.
Loose connection or improperly wired.
Bezel assembly not fully seated into rear of unit.
Incorrect parameter set-up.
1.
2.
3.
4.
5.
1.
1. Defective front panel button.
1.
“E-UP” IN DISPLAY
“E-E2” IN DISPLAY
1. Internal problem with controller.
1. Loss of set-up parameters due to noise spike.
2.
1.
1.
“....” OR “-...” IN DISPLAY
1.
2.
3.
1.
2.
3.
1.
2.
1.
2.
1.
2.
3.
1.
2.
3.
1.
2.
1.
2.
“SENS” IN DISPLAY
“OLOL” IN DISPLAY
“ULUL” IN DISPLAY
Input display out of range.
Loss of set-up parameters.
Internal malfunction.
Incorrect input wiring.
Defective transmitter.
Internal malfunction.
Input signal overload.
Loss of set-up parameters.
Input signal overload.
Loss of set-up parameters.
-73-
REMEDIES
Check power.
Check selector switch position.
Verify power reading.
Check connections.
Check installation.
Check set-up parameters.
a. Power-up unit for self-test.
Press DSP to escape, then check all buttons for proper
operation.
Replace unit
Replace unit
Press DSP to clear, then check all set-up parameters.
a. Check input and AC line for excessive noise.
b. If fault persists, replace unit.
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
unit scaling.
set-up parameters.
calibration.
input wiring.
signal calibration.
calibration.
input signal set-up.
set-up parameters.
input signal set-up.
set-up parameters.
APPENDIX “C” - TROUBLESHOOTING (Cont’d)
PROBLEMS
POSSIBLE CAUSE
REMEDIES
“VALV” IN DISPLAY
Valve Fail Alarm
1. Valve or valve motor jammed.
2. Loss of power to valve motor.
3. Slidewire feedback signal lost.
1. Check valve or valve motor for operation.
2. Check power to valve motor.
3. Increase valve fail time.
“SLId” IN DISPLAY
1. Slidewire feedback signal lost.
1. Check slidewire feedback signal.
DISPLAY INCORRECT OR
DISPLAY WANDERS
1. Loose or corroded connections.
2. Signal source in noisy environment.
3. Controller needs calibration.
1. Check connections.
2. Evaluate signal source location.
a. Increase digital input filtering.
3. Check calibration.
PROCESS SLUGGISH OR
NOT STABLE
1. Incorrect PID values.
1. See PID Control.
EXCESSIVE VALVE
ACTIVITY OR HUNTING
1.
2.
3.
4.
Insufficient valve control deadband.
Insufficient output dampening.
Incorrect PID values.
Valve update time too short.
1.
2.
3.
4.
Increase valve deadband.
Increase output dampening.
See PID Control.
Increase valve update time.
OUTPUTS NOT WORKING
1.
2.
3.
4.
Output module not installed.
Improperly wired.
Incorrect output module.
Defective output module.
1.
2.
3.
4.
Install
Check
Check
Check
LINEAR DC OUTPUT
NOT WORKING
1.
2.
3.
4.
Improper load resistance.
Incorrect programming or scaling.
Connections reversed.
DC voltage source in loop (4 to 20 mA only).
1.
2.
3.
4.
Check load resistance.
Check programming.
Check connections.
This is an active loop. Remove all DC voltage sources
(4 to 20 mA only).
CONTROLLER LOCKS UP
OR RESETS
1. Noise spikes entering controller due to load
switching transients.
2. Defective controller.
-74-
output module.
wiring.
output module.
or replace output module.
1. Use RC snubber across the load.
a. Use Triac output modules whenever possible.
b.Use separate AC feed line to controller.
c. Locate controller & signal lines away from noise
producing mechanisms (solenoids, transformers,etc).
2. Replace Unit.
OUTPUT LEAKAGE CURRENT
The AL1 and AL2/OP2 outputs of the PCU have an RC Network (Snubber)
on the Normally Open contacts. High energy noise spikes are generated
whenever current through an inductive load (such as motors, solenoids or
relay coils) is interrupted. This noise may interfere with the unit doing the
switching and other nearby equipment causing erratic operation and
accelerate relay contact wear.
The Snubber Network is specifically designed with a capacitor and resistor
connected in series and installed across relay contacts. The network will have
a small amount of AC leakage current even when the PCU’s Relay Module is
“off”. The leakage current is 2.1 mA nominal at a line voltage of 120 VAC,
and 4.3 mA nominal at 240 VAC respectively. Leakage current may cause
some loads to stay on or to turn on when the Relay Module is turned off. This
would only occur in unusual applications (such as with a relay with unusually
low holding current or an LED). The leakage current may be eliminated by
disabling the snubber, however, doing so will degrade the EMC performance
of the unit.
First determine which output is associated with the leakage current: either
AL1 or AL2/OP2. Remove the Bezel Assembly from the case (see Removing
Bezel Assembly, page 5). The snubbers are located on the Option PCB (on the
right side of the unit when viewed from the front). The snubbers consist of a
capacitor and a resistor. The two resistors are located along the upper rear
edge of the Option PCB. They are green in color and have color code stripes of
yellow, violet, black and gold. There will be markings on the PCB close to the
resistors that say “SNUB1” and “SNUB2” for AL1 and AL2/OP2
respectively. Using a pair of diagonal cutters, cut both leads of the
appropriate resistor and remove it from the unit. Be sure to remove the resistor
for only the problem alarm channel; leave the other channel’s snubber
functional in case it is needed.
The above stated leakage currents are valid when using the Relay Module
(OMD00000). The Triac Module (OMD00001) has it’s own built in snubber
and will introduce additional leakage current into the circuit. The Triac
Module has leakage current of 2.1 mA nominal at a line voltage of 120 VAC,
and 4.3 mA nominal at 240 VAC.
Note: The Snubber Network will be in one of the two configurations shown at
right, depending on model ordered.
Figure 40, Snubber Locations
-75-
APPENDIX “D” - MANUAL TUNING
OPEN LOOP STEP RESPONSE METHOD
The Open Loop Step Response Method is a tuning procedure that does not
induce process oscillations. This method involves making a step change to
the process and observing the process reaction. A strip paper recorder or other
high resolution data logging equipment is required for this procedure. This
procedure requires that all disturbances to the process are minimized because
the data is influenced by these disturbances.
1) Connect a chart recorder to log the process value and set the paper speed
appropriate for the process.
2) Set the controller to manual (user) control mode.
3) Allow the process to stabilize (line out).
4) Make a step change of 10% or more in the controller output. It may be
necessary to increase the size of the step to yield a sufficient process
reaction curve.
5) Record the response of the process. Use the information from the table to
calculate the controller tuning values. The PID tuning parameters are
determined graphically from Figure 41, Process Reaction Curve. Draw a
vertical line at the moment the step change was made. Draw a line (labeled
tangent) through the process reaction curve at its maximum upward slope.
Extend this line to intersect the vertical line.
Parameter
Proportional Band (%)
Integral Time (Sec)
Fast
Response
Damped
Response
Slow
Response
20000a
Range ´ Step%
40000a
Range ´ Step%
60000a
Range ´ Step%
3t
4t
5t
Derivative Time (Sec)
0.4t
0.4t
0.4t
Output Power
Dampening (Sec)
t/20
t/15
t/10
Example: From the Process reaction Curve
a = 30, t = 300 sec, step = 10%, display range = 0 to 1000.
For fast response:
Prop
Intt
dert
OPdP
=
=
=
=
60.0%
900 sec
120 sec
15
Figure 41, Process Reaction Curve
-76-
CLOSED LOOP CYCLING METHOD
An alternative to auto-tuning is manual tuning. This tuning method induces
oscillations into the process in the same way as the controller’s auto-tune
function. If oscillations are not acceptable, the open-loop tuning method can
be used.
The following is a manual tuning procedure for determination of the PID
control constants.
1. Connect a chart recorder to log process value and set the paper speed
appropriate for the process.
2. Set the controller to automatic (auto) control mode.
3. Set proportional band to 999.9%. (maximum setting)
4. Set integral time and derivative time to 0 seconds.
5. Decrease proportional band (increase controller gain) by factors of two
until process just begins to oscillate and the oscillations are sustained.
Make a small change in setpoint to provide a stimulus for oscillations.
Allow adequate time for the process to respond. If oscillations appear to
grow, increase proportional band. Adjust the proportional band until
steady oscillations appear.
6. Note the peak-to-peak amplitude of the cycle (a) in degrees and the period
of oscillation (t) in seconds.
Parameter
Fast Response
Proportional Band (%)
Integral Time (sec)
Derivative Time (sec)
Output Power
Dampening (sec)
200a/range
1t
0.2t
t/40
Damped
Response
400a/range
2t
0.25t
t/30
Figure 42, Closed Loop Tuning
Slow
Response
600a/range
3t
0.25t
t/20
-77-
APPENDIX “E” - CALIBRATION
CALIBRATION CHECK
LINEAR DC OUTPUT 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,
see Troubleshooting, page 73, 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 parameters to be checked are: voltage reading, mA reading, linear DC
output, Second Input, and Valve Position Feedback. The following
procedures may be used for this purpose.
Note: Allow 1/2 hour warm-up with the controller in an upright position to allow
adequate ventilation to the case before checking these parameters.
4 to 20 mA
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 4 mA (±0.02 mA).
4. Drive the input signal level above the programmed “ANHI” value. Check
for 20 mA (±0.03 mA).
5. Calibrate the controller linear DC output if out of tolerance.
VOLTAGE READING CHECK
0 to 10 VDC
1. Connect a voltmeter to the linear output (#11 & #12).
2. Set “ANAS” (Analog Assignment) to “INP”, in Configure Input
Parameters.
3. Drive the input signal level below the programmed “ANLO” value. Check
for 0 VDC (±20 mV).
4. Drive the input signal level above the programmed “ANHI” value. Check
for 10 VDC (±30 mV).
5. Calibrate the controller linear DC output if out of tolerance.
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. Set the controller to indicate voltage (VOLt), 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 voltage applied at Terminals 8 & 10.
7. Compare the controller read-out to the standard at various points over the
range (0-10 V). The tolerance is 0.15% of reading ± 1 LSD.
8. Calibrate the controller if the readings are out of tolerance.
SECOND INPUT CHECK
The Second Input Check applies to those models that have the Second
Analog Input (Remote Setpoint) and Valve Positioner options. Different
signals are required for each option.
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. Set 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” annunciators will flash.
6. The secondary display will indicate the current applied at Terminals 9 & 10.
7. Compare the controller read-out to the standard at various points over the
range (4 to 20 mA). The tolerance is 0.15% of reading ± 1 LSD.
8. Calibrate the controller if the readings are out of tolerance.
Second Analog Input Check
1. Apply signals over the range of 0 to 20 mA DC to the terminals labeled
Second Input, 4-20 mA+ and 4-20 mA-. The tolerance is 0.2% of full scale
± 1 LSD.
2. Calibrate the Second Analog Input if out of tolerance.
Valve Positioner Check
1. Apply signals derived from the resistor string as described in Valve
Positioner Calibration. The tolerance is 0.2% of full scale ± 1 LSD.
2. Calibrate the Second Analog Input if out of tolerance.
-78-
CALIBRATION
Current Calibration
Connect a precision current source with an accuracy of 0.01% to terminals
(+) #9 and (-) #10 for current calibration when step A appears.
When re-calibration is required (generally every two years), this procedure
should be performed by qualified technicians using appropriate equipment.
Equipment source accuracy of 0.01% or better is required.
The procedure consists of: applying accurate voltage signals, applying
precision mA current and measuring accurate mA currents, among others.
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 settings
remain in affect.
Display
48
Parameter
0.000 V step
1.667 V step
3.333 V step
5.000 V step
6.667 V step
8.333 V step
10.000 V step
Pause
StPB
20.000 mA
Description/Comments
Apply 0.000 mA, wait 10 seconds, press PAR.
Apply 20.000 mA, wait 10 seconds, press PAR.
Analog Output Calibration (ANCL)
4 to 20 mA
Press PAR until “ANCL” appears in the display. Connect precision
ammeter (0.1% accuracy) to rear terminals (+) #11 and (-) #12.
Description/Comments
Calibrate instrument
yes/no Calibration of voltage input is done
first.
yes/no This parameter will not appear if
analog output option is not installed.
yes/no This parameter will not appear if
second analog input is not installed.
Voltage Calibration
Connect precision voltage source with an accuracy of 0.01% to terminals
(+) #8 and (-) #10 for voltage calibration.
Display
StP1
StP2
StP3
StP4
StP5
StP6
StP7
StP-
0.000 mA
The unit automatically advances to analog
output calibration if the option is installed.
Configure Step 9 - Factory Service Operations (9-Fs)
Display
Parameter
Code
Enter factory service
function code
CAL
Voltage and Current
Calibration
ANCL
Analog Output
Calibration
2CAL
Second Analog
Input Calibration
Parameter
StPA
Display
ANC1
Parameter
Analog output
4 mA code
value
ANC2
Analog output
20 mA code
value
Description/Comments
Observe current reading. If 4.00 mA, press
PAR. If not equal, modify existing code value
using up and down buttons to achieve 4.00
mA. Press PAR.
Observe current reading. If 20.00 mA, Press
PAR. If not equal, modify existing code value
using up and down buttons to achieve 20.00
mA. Press PAR.
0 to 10 VDC
Press PAR until “ANCL” appears in the display. Connect a precision
voltmeter (0.1% accuracy) to rear terminals (+) #11 and (-) #12.
Description/Comments
Apply 0.000 V, wait 10 seconds, press PAR.
Apply 1.667 V, wait 10 seconds, press PAR.
Apply 3.333 V, wait 10 seconds, press PAR.
Apply 5.000 V, wait 10 seconds, press PAR.
Apply 6.667 V, wait 10 seconds, press PAR.
Apply 8.333 V, Wait 10 seconds, press PAR.
Apply 10.000 V, wait 10 seconds, press PAR.
The controller imposes a 5 sec. delay (Keep
the 10.000 V signal applied). The unit
automatically advances to StPA.
-79-
Display
ANC1
Parameter
Analog output
0 VDC code
value
ANC2
Analog output
10 VDC code
value
Description/Comments
Observe voltage reading. If 0.00 VDC, press
PAR. If not equal, modify existing code value
using up and down buttons to achieve 0.00
VDC. Press PAR.
Observe voltage reading. If 10.00 VDC, Press
PAR. If not equal, modify existing code value
using up and down buttons to achieve 10.00
VDC. Press PAR.
Second Analog Input Calibration (2CAL)
The signals applied to the Second Analog Input for calibration depend on
the type of model. Second Analog Input and Motorized Valve Positioner
represent the models for which unique calibration signals are required.
Motorized Valve Positioner
Construct a precision resistor
divider network consisting of
four 250W 0.1% tolerance
resistors connected in series as
shown in Figure 43, Resistor
Divider. Connect one end of the
resistor string to the rear
terminal labeled Slidewire
Feedback Inputs, Comm. and the
other end to Excitation. The
connection to the Wiper terminal
comes from different points of
the resistor string.
Second Analog Input (Remote Setpoint)
Connect precision DC milliampere source (0.01% accuracy) to rear
terminals labeled Second Analog Input, 4 to 20 mA+ and 4 to 20 mA-.
Display
StP1
Parameter
Description/Comments
0.00 mA step
Apply 0.00 mA DC, press PAR.
StP2
5.00 mA step
Apply 5.00 mA DC, press PAR.
StP3
10.00 mA step
Apply 10.00 mA DC, press PAR.
StP4
15.00 mA step
Apply 15.00 mA DC, press PAR.
StP5
20.00 mA step
Apply 20.00 mA DC, press PAR.
Figure 43, Resistor Divider
Display
-80-
Parameter
Description/Comments
StP1
0.0% step
Connect wiper input to 0% point of divider
(Comm.), wait 10 seconds, press PAR.
StP2
25.0% step
Connect wiper input to 25% point of divider, wait
10 seconds, press PAR.
StP3
50.0% step
Connect wiper input to 50% point of divider, wait
10 seconds, press PAR.
StP4
75.0% step
Connect wiper input to 75% point of divider, wait
10 seconds, press PAR.
StP5
100.0% step
Connect wiper input to 100% point of divider
(Excitation), wait 10 seconds press PAR.
APPENDIX “F”-USER PARAMETER VALUE CHART
UNIT NUMBER
MNEMONIC
SP
OPOF
OP
ProP
Intt
dErt
SP-2
Pb-2
It-2
dt-2
rtio
bIAS
AL-1
AL-2
PARAMETER
Setpoint
Output Power Offset
Output Power
Proportional Band
Integral Time
Derivative Time
Internal Cascade Directed Setpoint
Proportional Band #2 (secondary)
Integral Time #2 (secondary)
Derivative Time #2 (secondary)
Remote Setpoint Ratio
Remote Setpoint Bias
Alarm 1
Alarm 2
USER SETTING
CONFIGURE OUTPUT
MNEMONIC
CYCt
OPAC
OPLO
OPHI
OPFL
OPdP
CHYS
tcod
ANAS
ANLO
ANHI
ANdb
ANut
CONFIGURE INPUT
MNEMONIC
tYPE
dCPt
root
rnd
FLtr
dSP1
INP1
dSP2
INP2
SPLO
SPHI
SPrP
InPt
PARAMETER
Input Type
Decimal Point
Square Root Linearizing
Rounding Increment
Digital Filtering
Display Value 1
Signal Input Value 1
Display Value 2
Signal Input Value 2
Setpoint Lower Limit
Setpoint Upper Limit
Ramp Rate
User Input
USER SETTING
-81-
PARAMETER
Cycle Time
Control Action
Output Power Lower Limit Range
Output Power Upper Limit Range
Input Overdrive Power Preset
Output Power Dampening
ON/OFF Control Hysteresis
Auto-Tune Dampening Code
Linear Output Assignment
Linear Output Scale Value
Linear Output Scale Value
Linear Output Deadband
Linear Output Update Time
USER SETTING
CONFIGURE SERIAL COMMUNICATIONS
CONFIGURE LOCKOUTS
MNEMONIC
SP
OP
dEv
IN-2
bdSP
Code
PID
PID2
rtbs
AL
ALrS
SPSL
trnF
tUNE
PARAMETER
Access Setpoint
Access Output Power
Access Deviation Display
Access Second Analog Input Display
Access Blank Display
Access Code Number
Access Primary PID Values
Access Secondary PID Values
Access Ratio and Bias Values
Access Alarm(s) Values
Enable Reset Alarm(s)
Enable Local/Remote Setpoint Selection
Enable Auto/Man Transfer
Enable Auto-tune
MNEMONIC
bAUd
PArb
Addr
Abrv
PrAt
PoPt
USER SETTING
CONFIGURE ALARMS
MNEMONIC
Act1
rSt1
Stb1
AL-1
Act2
rSt2
Stb2
AL-2
AHYS
PARAMETER
Alarm 1 Operation Mode
Alarm 1 Reset Mode
Alarm 1 Standby Enabled
Alarm 1 Value
Alarm 2 Operation Mode
Alarm 2 Reset Mode
Alarm 2 Standby Enabled
Alarm 2 Value
Alarm Hysteresis Value
USER SETTING
CONFIGURE SECONDARY OUTPUT
MNEMONIC
CYC2
GAN2
db-2
PARAMETER
OP2 Output Cycle Time
Relative Gain
Overlap/Deadband
USER SETTING
-82-
PARAMETER
Baud Rate
Parity Bit
Unit Address
Abbrev. or Full Transmission
Automatic Print Rate
Print Options
INP
SEt
OPr
Pbd
INt
dEr
AL1
AL2
dEv
OFP
r_P
Crg
Cdb
OSt
rAt
bIA
RSP
IN2
Pb2
It2
dt2
SP2
USER SETTING
CONFIGURE SECOND ANALOG INPUT
MNEMONIC
PARAMETER
OPEr
Second Input Operating Mode
USER SETTING
root
Second Input Square Root Linearization
dPt2
Second Input Decimal Point Position
dSP1
Second Input, Display Scale Point 1
INP1
Second Input, Input Scale Point 1
dSP2
Second Input, Display Scale Point 2
INP2
Second Input, Input Scale Point 2
SPtr
Local/Remote Setpoint Select Action
OPd2
Secondary PID Output Power Dampening
CONFIGURE VALVE POSITIONER
MNEMONIC
PARAMETER
VPS1
Valve Positioner Scale Point 1
USER SETTING
VPS2
Valve Positioner Scale Point 2
VUdt
Valve Positioner Update Time
VPdb
Valve Positioner Deadband
VFAL
Valve Positioner Fail Time Alarm
VOPt
Valve Positioner Motor Open Transit Time
VCLt
Valve Positioner Motor Close Transit Time
VONt
Valve Positioner Minimum On Time
CONTROLLER OPERATING MODE
Local or Remote Setpoint
Automatic or Manual
Auto-tune Invoked at
____________________________
____________________________
____________________________
-83-
APPENDIX “G” ORDERING INFORMATION
MODELS WITHOUT SECOND INPUT OPTIONS
PART
0 to 10 VDC
4 to 20 mA
ALARM
SECONDARY
RS485
NUMBER
ANALOG
ANALOG
OUTPUTS
OUTPUT
115/230 VAC
OUTPUT
OUTPUT
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.
NEMA 4X/IP65
BEZEL
SECOND ANALOG INPUT MODELS (ANA)
PART
0 to 10 VDC
4 to 20 mA
NEMA
ALARM
SECONDARY
NUMBER
ANALOG
ANALOG
4X/IP65
OUTPUTS
OUTPUT
RS485
115/230 VAC
OUTPUT
OUTPUT
BEZEL
YES
NO
NO
2
NO
YES
PCU10104
YES
YES
NO
2
NO
NO
PCU11108
YES
NO
YES
2
NO
NO
PCU12108
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.
-84-
MOTORIZED VALVE POSITIONER MODELS (MVP)
NEMA
4X/IP65
BEZEL
YES
YES
YES
4 to 20 mA
ANALOG
OUTPUT
NO
YES
NO
0 to 10 VDC
ANALOG
OUTPUT
NO
NO
YES
ALARM
OUTPUTS
SECONDARY
OUTPUT
RS485
1
1
1
NO
NO
NO
YES
NO
NO
PART
NUMBER
115/230 VAC
PCU10307
PCU11306
PCU12306
ACCESSORIES
DESCRIPTION
Relay Module
Triac Module
Logic/SSR Drive Module
SSR Power Unit
Single Phase 25 A DIN Rail Mount Solid State Relay
Single Phase 40 A DIN Rail Mount Solid State Relay
Three Phase DIN Rail Mount Solid State Relay
PART NUMBER
OMD00000
OMD00001
OMD00003
RLY50000
RLY60000
RLY6A000
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.
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-86-
PCUCOV.QXD
12/3/2009 2:05 PM
Page 3
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and
workmanship for a period limited to two years 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 matters which Buyer, its employees, or subcontractors are or may be to any extent liable, including without limitation penalties imposed by
the Consumer Product Safety Act (P.L. 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.
PCUCOV.QXD
12/3/2009 2:05 PM
Page 4
PCU/IM - K 11/09
DRAWING NO. LP0265
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
Printerweg 10
NL - 3821 AD Amersfoort
Tel +31 (0) 334 723 225
Fax +31 (0) 334 893 793
Red Lion Controls
India
54, Vishvas Tenement
GST Road, New Ranip,
Ahmedabad-382480 Gujarat, India
Tel +91 987 954 0503
Fax +91 79 275 31 350
Red Lion Controls
China
Unit 101, 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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