Red Lion Controls T48 Temperature Controller, P48 Process Controller Instruction Manual

T48-COV-G.QXD 12/11/2007 9:51 AM Page 1

THE 1/16 DIN CONTROLLERS

TEMPERATURE/PROCESS

MODELS T48 & P48 INSTRUCTION MANUAL

T48-COV-G.QXD 12/11/2007 9:51 AM Page 2

INTRODUCTION

The Temperature Controller (T48) and Process Controller (P48) are both multipurpose series of industrial control products that are field-programmable for solving various applications. These series of products are built around the concept that the end user has the capability to program different personalities and functions into the controllers in order to adapt to different indication and control requirements.

The controller 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.

UL Recognized Component,

File # E156876

CAUTION: Risk of Danger.

Read complete instructions prior to installation and operation of the unit.

CAUTION: Risk of electric shock.

Table of Contents

GENERAL DESCRIPTION· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1

Safety Summary · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1

INSTALLATION DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2

Instructions: · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2

Multiple Unit Stacking · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

Unit Removal Procedure· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

Removing Bezel Assembly · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

Installing Bezel Assembly· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

CONNECTION DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4

EMC Installation Guidelines · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4

Wiring Connections · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5

Signal Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5

Thermocouple (T48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5

RTD (T48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5

Signal (P48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

Power Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

Control and Alarm Outputs · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

Relay Connections · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

Logic/SSR Connections (T48 only) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Triac Connections (T48 only) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Heater Current Monitor Wiring (T48 only) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Remote Setpoint Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Main Linear DC Output Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Second Linear DC Output Wiring· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

User Input Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7

Rear Terminal Assignments · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8

T48 Models Without RS-485 and Analog Output · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8

T48 Models With RS-485 or Linear DC Analog Output · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9

ALL P48 Models · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10

Serial Connections to a Host Terminal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11

Linear DC Analog Output Jumper Selection · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12

FRONT PANEL DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13

Button Functions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13

-i-

INITIAL CONFIGURATION START-UP · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Controller Power-up · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Parameter Configuration Overview · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Parameter Configuration Basic Start-up · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Parameter Configuration for Serial Start-up · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Control Start-up· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14

Valid Control Mode Combinations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15

Front Panel Programming Chart For T48 & P48 Controllers · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 16

NORMAL DISPLAY MODE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17

FRONT PANEL PROGRAM DISABLE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17

UNPROTECTED PARAMETER MODE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18

PROTECTED PARAMETER MODE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19

HIDDEN FUNCTION MODE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 20

CONFIGURATION PARAMETER MODE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 20

REFERENCE TABLES: CONFIGURATION PARAMETER MODULES· · · · · · · · · · · · · · · · · · · · · · · · 21

Configure Module 1 - Input Parameters (1-IN) T48 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 21

Configure Module 1 - Input Parameters (1-IN) P48 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22

Configure Module 2 - Output Parameters (2-OP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 23

Configure Module 3 - Lockout Parameters (3-LC) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24

Configure Module 4 - Alarm Parameters (4-AL) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 25

Configure Module 5 - Cooling Parameters (5-O2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 26

Configure Module 6 - Serial Communications (6-SC) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 27

Configure Module 7 - Remote Setpoint Parameters (7-rS or 7-n2) · · · · · · · · · · · · · · · · · · · · · · · · · 28

Configure Module 7 - Heater Current Parameters (7-HC or 7-n2) · · · · · · · · · · · · · · · · · · · · · · · · · 28

Configure Module 8 - Second Linear DC Analog Output (8-A2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 28

Configure Module 9 - Factory Service Operations (9-FS) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 28

USER PARAMETER VALUE CHART · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 29

CONFIGURATION PARAMETER EXPLANATIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Input Parameter Module (1- IN) T48 Models· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Input Type (tYPE) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Temperature Scale (SCAL) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Temperature Resolution (dCPt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Digital Input Filtering and Display Update Rate (FLtr) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

-ii-

Input Sensor Correction Constant (SHFt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Setpoint Limit Values (SPLO & SPHI) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31

Setpoint Ramp Rate (SPrP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 32

User Input (InPt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 32

Input Parameter Module (1- In) P48 models · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Input Type (tYPE) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Decimal Point Position (dCPt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Rounding Increment ( rnd) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Digital Input Filtering and Display Update Rate (FLtr) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Scaling Points · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Display Values (dSP1 & dSP2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 34

Signal Input Values (INP1 & INP2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 34

Setpoint Limit Values (SPLO & SPHI) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 34

Setpoint Ramp Rate (SPrP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 34

User Input (InPt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 35

Output Parameter Module (2-OP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

Time Proportioning Cycle Time (CYCt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

Output Control Action (OPAC) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

Output Power Limits (OPLO & OPHI) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

Sensor Fail Power Level (OPFL) T48 only · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

Output Power Dampening Filtering Time (OPdP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

ON/OFF Control Hysteresis (CHYS) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 37

Auto-Tune Code (tcod) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 37

Main Linear DC Output Range (ANtP) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 37

Main Linear DC Output Source (ANAS) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 37

Main Linear DC Update Time (ANUt) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 37

Main Linear DC Output Scaling Points (ANLO, ANHl) (Optional) · · · · · · · · · · · · · · · · · · · · · · · 37

Lockouts Parameter Module (3-LC)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38

Lower Display Lockouts (SP, OP, dEv, Hcur, UdSP and bdSP) · · · · · · · · · · · · · · · · · · · · · · · · 38

Protected Mode Lockouts (CodE, PId, and AL) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38

Hidden Mode Lockouts (ALrS, SPSL, trnF, and tUNE ) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38

Alarm Parameter Module (4-AL) (Optional)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39

Alarm Action (Act1, Act2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39

Heater Break Alarm· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39

-iii-

Alarm Action Figures· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 40

Alarm Reset (rSt1, rSt2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 42

Alarm Standby Delay (Stb1, Stb2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 42

Alarm Value (AL-1, AL-2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 42

Alarm Hysteresis (AHYS) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 42

Cooling Parameters Module (5-02) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 43

Cooling Output Cycle Time (CYC2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 43

Cooling Relative Gain (GAn2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 43

Heat and Cool Overlap/Deadband (db-2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 43

Serial Communications Module (6-SC) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Baud Rate (bAUd) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Character Frame Format (ConF) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Controller Address Number (Addr) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Abbreviated or Full Transmission (Abrv) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Print Options (PoPt) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 44

Remote Setpoint Parameters Module (7-n2 or 7-rS) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Remote Setpoint Display Values (dSP1 and dSP2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Remote Setpoint Signal Input Values (INP1 and INP2) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Remote Setpoint Filtering (Fltr and bANd) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Remote/Local Setpoint Transfer Options (trnF) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Heater Current Monitor Module (7-N2 or 7-HC) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

Second Linear DC Analog Output Module (8-A2) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

Second Linear DC Output Range (A2tP) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

Second Linear DC Output Scaling Points (A2LO, A2Hl) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

Factory Service Operations Module (9-FS)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

MANUAL CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 47

ON/OFF CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 48

AUTO-TUNE FOR PID CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 51

Initiate Auto-Tune · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 52

Auto-Tune Of Heat/Cool Systems · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 52

Auto-Tune Of Cascade Control · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 52

PID CONTROL EXPLANATIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 53

Proportional Band · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 53

Integral Time · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 53

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Derivative Time · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54

Output Power Offset (Manual Reset)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54

PID Adjustments · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54

MANUAL TUNING FOR PID CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 56

REMOTE SETPOINT OPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 57

CASCADE CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 57

SERIAL COMMUNICATIONS INTERFACE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

RS-485 Serial Communications · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Configuration Software · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Controller Configuration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Sending Commands And Data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Sending Numeric Data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Controller (Node) Address · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Commands Table · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 58

Register Identification Table· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 59

Terminator Table· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 59

Examples of Command Strings:· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 59

Command Code Explanations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 59

Controller (Node) Address: N · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 59

Read Register Command Code: T · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Write Register Command Code: V · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Reset Alarm Command Code: R · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Control Action Command Code: C · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Block Read Register Command Code: P· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Terminator : * or $ · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 60

Block Read Command Byte Table · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 61

Unique Register Explanations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Setpoint Ramp Using Automatic Setpoint Ramping Register: K · · · · · · · · · · · · · · · · · · · · · · · · 62

Setpoint Ramp Using Periodic Setpoint Write Register: B · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Periodic Setpoint Write Commands (E

2

PROM precautions) · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Heater Current Response: HC (T48 only) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Output Status: W · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Communication Format· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Command Response Time · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 63

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Full Field Controller Transmission Byte Format · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 64

Abbreviated Controller Transmission Byte Format · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 65

Troubleshooting Serial Communications· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 65

APPLICATION EXAMPLES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 66

T48 OEM Paint Sprayer Application · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 66

T48 Plastics Extruder Application · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 67

P48 Water Processing Application· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 68

CHECKS AND CALIBRATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Main Input Check · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69 mV Reading Check (T48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Thermocouple Cold Junction Temperature Check (T48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

RTD Ohms Reading Check (T48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Voltage Check (P48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Current Check (P48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Remote Setpoint Input Check (T48 and P48) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Heater Current Input Check (T48 only) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Error Flag E-CL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 70

Calibration For T48 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 70

Factory Service Operations - Calibration (9-FS)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 70

Millivolt Calibration (CAL) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 70

Thermocouple Cold Junction Calibration (CJC) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 71

RTD Ohms Calibration (rtd) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 71

Main or Second Linear DC Analog Output Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 71

Remote Setpoint Calibration· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 71

Heater Current Input Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 71

Calibration For P48 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72

Factory Service Operations (9-FS) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72

Input Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72

Main or Second Linear DC Analog Output Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72

Remote Setpoint Calibration· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72

TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 73

REPLACEABLE OUTPUT BOARD DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 75

SPECIFICATIONS AND DIMENSIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 76

ORDERING INFORMATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 81

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GENERAL DESCRIPTION

The T48 Controller accepts signals from a variety of temperature sensors

(thermocouple or RTD elements), while the P48 Controller accepts either a 0 to 10 VDC or 0/4 to 20 mA DC input signal. Both controllers precisely display the process, and provide an accurate output control signal (time proportional or linear DC) to maintain a process at the desired control point. The controllers’ comprehensive programming allows them to meet a wide variety of application requirements.

The controller can operate in the PID control mode for both heating and cooling, with on-demand Auto-Tune, which will establish the tuning constants. The PID tuning constants may be fine-tuned by the operator at any time and then locked out from further modification. The controller employs a unique overshoot suppression feature, which allows the quickest response without excessive overshoot. Operation of the controller can be transferred to manual mode, providing the operator with direct control of the output. The controller may also be programmed to operate in the ON/OFF control mode with adjustable hysteresis.

Dual 4-digit displays allow viewing of the process/temperature and setpoint simultaneously. Front panel indicators inform the operator of the controller and output status. The control output and the alarm outputs are field replaceable on select models.

Optional alarm (s) can be configured to activate according to a variety of actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT, and Heater

Current Break) with adjustable hysteresis. A standby feature suppresses the alarm during power-up until the process stabilizes outside the alarm region.

Optional Main Linear DC output (10 V and 20 mA) can be used for control or retransmission purposes. Programmable output update time reduces valve or actuator activity. The output range can be scaled independent of the input range.

Optional Second Linear DC output (10 V or 20 mA) provides an independent process retransmission, while the main Linear DC output is being used for control. The output range can be scaled independent of the input range.

The T48 optional Heater Current Monitor provides a direct readout of process heater current. An alarm can be programmed to signal when the heater has failed. This provides early warning of system failure before product quality is affected.

A Remote Setpoint input (0/4 to 20 mA) allows for cascade control loops, where tighter control quality is required; and allows for remotely driven setpoint signal from computers or other similar equipment. Straightforward end point scaling with independent filtering and local/remote transfer option expands the controller’s flexibility.

The optional RS485 serial communication interface provides two-way communication between a controller and other compatible equipment such as a printer, PLC, HMI, or a host computer. In multipoint applications (up to thirty-two), the address number of each controller on the line can be programmed from 0 to 99. Data from the controller can be interrogated or changed, and alarm output(s) may be reset by sending the proper command code via serial communications. PC software, SFCRM, allows for easy configuration of controller parameters. These settings can be saved to disk for later use or used for multi-controller down loading. On-line help is provided within the software.

The unit is constructed of a lightweight, high impact plastic case with a tinted front panel. The front panel meets NEMA 4X/IP65 specifications when properly installed. Multiple units can be stacked horizontally or vertically. Modern surface-mount technology, extensive testing, plus high immunity to noise interference makes the controller extremely reliable in industrial environments.

SAFETY SUMMARY

All safety related regulations, local codes and instructions that appear in the manual or on equipment must be observed to ensure personal safety and to prevent damage to either the instrument or equipment connected to it. If equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

Do not use the controller 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.

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INSTALLATION DESCRIPTION

The controller meets NEMA 4X/IP65 requirements for indoor use to provide a watertight seal in steel panels with a minimum thickness of 0.09 inch, or aluminum panels with a minimum thickness of 0.12 inch. The units are intended to be mounted into an enclosed panel. It is designed so that the units can be stacked horizontally or vertically (see Figure

1). The bezel assembly MUST be in place during installation of the unit.

INSTRUCTIONS:

1. Prepare the panel cutout to the dimensions shown in

Figure 1, Panel Installation.

2. Remove the panel latch from the unit. Discard the cardboard sleeve.

3. Carefully remove the center section of the panel gasket and discard. Slide the panel gasket over the unit from the rear, seating it against the lip at the front of the case.

4. Insert the unit into the panel cutout. While holding the unit in place, push the panel latch over the rear of the unit, engaging the tabs of the panel latch in the farthest forward slot possible.

5. To achieve a proper seal, tighten the panel latch screws evenly until the unit is snug in the panel, torquing the screws to approximately 7 in-lbs (79 N-cm). Over tightening can result in distortion of the panel, and reduce the effectiveness of the seal.

Note: The installation location of the controller is important.

Be sure to keep it away from heat sources (ovens, furnaces, etc.), and away from direct contact with caustic vapors, oils, steam, or any other process byproducts in which exposure may affect proper operation.

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Figure 1, Panel Installation

MULTIPLE UNIT STACKING

The controller is designed for close spacing of multiple units. Units can be stacked either horizontally or vertically. For vertical stacking, install the panel latch with the screws to the sides of the unit. For horizontal stacking, the panel latch screws should be at the top and bottom of the unit. The minimum spacing from center line to center line of units is 1.96" (49.8 mm). This spacing is the same for vertical or horizontal stacking.

Note: When stacking units, provide adequate panel ventilation to ensure that the maximum operating temperature range is not exceeded.

Figure 3, Multiple Unit Stacking Horizontal Arrangement

Caution: Disconnect power to the unit and to the output control circuits to eliminate the potential shock hazard when removing the bezel assembly.

UNIT REMOVAL PROCEDURE

To remove a unit from the panel, first loosen the panel latch screws. Insert flat blade screwdrivers between the latch and the case on either side 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 replace the output board. To remove the bezel assembly, insert a flat blade screwdriver into the pry slot on either side of the unit. Twist the screwdriver handle until the unit is ejected enough to allow removal.

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Figure 2, Bezel Assembly

Caution: The bezel assembly contains electronic circuits that can be damaged by static electricity. Before removing the assembly, discharge static charge 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.

INSTALLING BEZEL ASSEMBLY

To install the bezel assembly, insert the assembly into the case until the bezel is fully seated against the lip of the case. Properly installing the bezel assembly is necessary for watertight sealing.

CONNECTION DESCRIPTION

EMC INSTALLATION GUIDELINES

Although this unit is designed with a high degree of immunity to Electro

Magnetic Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in each application. The type of the electrical noise, source or coupling method into the unit may be different for various installations. 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 very electrically noisy 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 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

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WIRING CONNECTIONS

After the unit has been mechanically mounted, it is ready to be wired. All wiring connections are made to the rear screw terminals. When wiring the unit, use the numbers on the label and those embossed on the back of the case, to identify the position number with the proper function.

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. Strip the wire, leaving approximately 1/4" (6 mm) bare wire exposed (stranded wires should be tinned with solder). Insert the wire under the clamping washer and tighten the screw until the wire is clamped tightly.

Caution: Unused terminals are NOT to be used as tie points. Damage to the controller may result if these terminals are used.

SIGNAL WIRING

Thermocouple (T48)

When connecting the thermocouple, be certain that the connections are clean and tight, refer to Figure 4 for terminal connections. If the thermocouple probe cannot be connected directly to the controller, thermocouple wire or thermocouple extension-grade wire must be used to extend the connection points (copper wire does not work). Always refer to the thermocouple m a n u f a c t u r e r ’ s

Figure 4, Thermocouple Connection recommendations for mounting, temperature range, shielding, etc. For multi-probe temperature averaging applications, two or more thermocouple probes may be connected to the controller (always use the same type).

Paralleling a single thermocouple to more than one controller is not recommended. Generally, the red wire from the thermocouple is negative and connected to the controller’s common.

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RTD (T48)

When connecting the

RTD, be certain that the connections are clean and tight, refer to Figure 5 for terminal connections. RTD sensors have a higher degree of accuracy and stability than thermocouple sensors. Most RTD sensors available are the three wire type. The third wire is a sense lead for canceling the effects of lead resistance of the probe. Four wire RTD elements may be used by

Figure 5, RTD Connection leaving one of the sense leads disconnected. Two wire RTD sensors may be used in either of two ways:

A) Attach the RTD to terminals #8 and #10. Install a copper sense wire of the same wire gage as the RTD leads. Attach one end of the wire at the probe and the other end to terminal #9. Complete lead wire compensation is obtained. This is the preferred method.

B) Attach the RTD to terminals #8 and #10. Install a shorting wire between terminals #9 and #10, as shown in Figure 5, RTD Connection. A temperature offset error of 2.5°C/ohm of lead resistance exists. The error may be compensated by programming a temperature offset.

Note: With extended cable runs, be sure the lead resistance is less than 15 ohms/lead. For thermocouple or RTD runs longer than 100 feet, convert the signal to a current near the temperature probe. Current or 20 mA loop signals are less susceptible to noise and signal loss than long thermocouple or RTD runs. The RLC ITMA and IRMA DIN rail modules are designed for these applications. By converting the temperature signal, the P48 can be used in place of a T48.

Signal (P48)

When connecting signal leads, be certain that the connections are clean and tight. For voltage signals, use terminal #8 for common and terminal #9 for signal. For current signals, use terminal

#8 for common and terminal

#10 for signal. These connections are shown in

Figure 6. Multicontroller applications using the same signal source are possible, by connecting current signals in series, and voltage signals in parallel.

Figure 6, P48 Signal Connection

POWER WIRING

AC Power

Primary AC power is connected to terminals #11 and #12, 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 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.

DC Power

DC power (18 to 36 VDC) is connected to terminals #11 and #12 labeled

DC+ and DC- respectively.

CAUTION: Observe proper polarity when connecting DC voltages.

Damage to the unit may occur if polarity is reversed.

CONTROL AND ALARM OUTPUTS

For T48 heating, cooling, and alarms, there are up to three types of

ON/OFF outputs. These outputs can be relay, logic, or Triac for control or alarm purposes. Relay outputs can switch user applied AC or DC voltages.

Logic/SSR drive outputs supply power to external SSR power units. One

Logic/SSR Drive output can control up to four SSR power units at one time.

The Triac output supplies one Amp of AC current for control of an external

AC relay or Triac device. The P48 is only available with relay outputs.

Terminal numbers for the outputs and output types vary from model to model.

Refer to the Rear Terminal Assignment Tables or the label on the controller for the terminal numbers corresponding to the model being wired.

Relay Connections

To prolong contact life and suppress electrical noise interference due to the switching of inductive loads, it is good installation practice to install a snubber across the contactor. Follow the manufacturer’s instructions for installation.

Note: Snubber leakage current can cause some electromechanical devices to be held ON.

Relay Outputs:

Type: Form-A

Rating: 3 Amps @ 250 VAC or 30 VDC (resistive load), 1/10 HP @ 120

VAC (inductive load).

Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing load and/or increasing cycle time, increases life expectancy).

Figure 7, Relay Output

-6-

Logic/SSR Connections (T48 only)

Logic/SSR Drive Output:

Rating: 45 mA @ 4 V min., 7 V nominal (current limited)

Figure 8, Logic/SSR Output

Triac Connections (T48 only)

Triac Outputs:

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

Offstate Leakage Current: 7 mA max. @ 60 Hz

Operating Frequency: 20 to 500 Hz

Protection: Internal transient snubber

Figure 9, Triac Output

-7-

HEATER CURRENT MONITOR WIRING (T48 ONLY)

Models with the Heater Current Monitor option have two input terminals to receive the output directly from a 100 mA current transformer.

Caution: Never connect a current transformer with a rating other than 100 mA.

These terminals are labeled #13 and #14 “2nd Input Option”. There is no polarity observation for these inputs.This input is only for single phase heaters.

REMOTE SETPOINT WIRING

Models with the Remote Setpoint option have two input terminals to receive a 0 to 20 mA signal. Connect the Remote Setpoint signal to terminals labeled #13 (+) and #14 (-), “2nd Input Option”. The common of this input is isolated from input common, but is not isolated from the Linear DC output commons. For proper operation, keep this common isolated from all other controller commons.

MAIN LINEAR DC OUTPUT WIRING

Models with the Linear DC output option provide either a linear 10 V or a linear 20 mA signal. The output range is selected by jumpers on the output board. (See Linear DC Analog Output Jumper Selection, page 12). The terminals are #1 (-) and #2 (+). The common of this output is isolated from input common, but is not isolated from other commons. For proper operation, keep this common isolated from all other controller commons.

SECOND LINEAR DC OUTPUT WIRING

Models with the Second Linear DC output option provide a conditioned and scaled retransmitted signal output. The terminals are #13 (+) and #14 (-).

The common of this output is isolated from the input common, but not from the other commons. For proper operation, keep this common isolated from all other controller commons.

USER INPUT WIRING

The use of shielded cable is recommended. Follow the EMC installation guidelines for shield connection.

Terminal #6 is the User Input, which is programmable for a variety of functions. Any form of mechanical switch may be connected to terminal #6

(USER INPUT) and terminal #8 (COMM.). Sinking open collector logic with less than 0.7 V saturation and off-state leakage current of less than 1 mA may also be used.

REAR TERMINAL ASSIGNMENTS

T48 Models Without RS-485 and Analog Output

TC RTD AC/DC Power

9

9

9

9

9

9

9

9

9

(+) (-)

9 8

8

8

8

8

8

8

8

8

8

9

9

9

9

9

9

9

9

8

8

8

8

8

8

8

8

Short

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

9 10

(C)

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

(C) is the Common Terminal.

Terminals 9 & 10 need to be shorted together.

* Remote Setpoint or Heater Current Input.

11

11

11

11

11

11

11

11

11

11

11

11

11

AC/(+) AC/(-)

11 12

11

11

11

11

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

A2 or 02 Dedicated A1 Dedicated O1

(C) (C)

1

1

1

3

3

3

1

1

1

1

2

2

2

4

4

4

2

2

2

2

3

3

3

3

3

3

3

3

3

2

2

2

2

2

2

2

2

2

4

5

5

5

4

4

5

5

5

5

5

5

5

(C)

5

5

5

5

5

5

4

4

4

5

5

4

4

4

4

4

4

4

4

4

4

4

4

User Input

8

8

8

8

8

(C)

8

8

8

8

8

8

8

8

8

8

8

8

8

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

2nd Input

Option *

(+) (-)

13

13

14

14

13

13

13

13

13

13

13

13

14

14

14

14

14

14

14

14

AC Model #

T4810000

T4810003

T4810004

T4811000

T4811100

T4811103

T4811104

T4820000

T4820003

T4820004

T4820200

T4820203

T4820204

T4821000

T4821100

T4821103

T4821104

T4832200

DC Model #

T4810010

T4810013

T4810014

T4811010

T4811110

T4811113

T4811114

T4820010

T4820013

T4820014

T4820210

T4820213

T4820214

T4821010

T4821110

T4821113

T4821114

T4832210

-8-

REAR TERMINAL ASSIGNMENTS

T48 Models With RS-485 or Linear DC Analog Output

TC RTD

AC/DC

Power

(+) (-) Short (C) AC/(+) AC/(-)

9 8 9 10 8 11 12

Analog

Main Out A2 or O2

(+) (-) (C)

9 8

9 8

9 8 9 10

9 8 9 10

9 8

9 10

9 10

9 10

9 8 9 10

8

8

8

8

8

8

11

11

11

11

11

11

12

12

12

12

12

12

2 1

2 1

2

2

1

1

2 1

3 4

3 4

3 4

3 4

3 4

3 4

3 4 9 8 9 10

9 8 9 10

9 8 9 10

8

8

8

11 12

11 12

11 12

9 8

9 8

9 8

9 10

9 10

9 10

9 8 9 10

9 8 9 10

9 8 9 10

8

8

8

8

8

8

11

11

11

11

11

11

12

12

12

12

12

12

2

2

2

1

1

1

1 2

3 4

3 4

3 4

3 4

3 4

1 2

Dedicated

A1

(C)

3

3

3

2

2

2

(C) is the Common Terminal.

Terminals 9 & 10 need to be shorted together.

* Remote Setpoint or Heater Current Input.

(C)

5 4

5 4

5 4

5 4

5 4

5 4

5 4

5 4

(C)

4 5

5

5

4

4

5

4

4

5

5

4

5 4

4 5

6 8

6 8

6 8

6 8

6 8

6 8

6 8

6 8

6 8

6 8

6 8

User

Input

RS485

Output

2nd Input

Option *

(C) A(+) B(-) (+) (-)

6 8 13 14

6 8

6 8

6 8

6 8

13 14

13 14

13 14

2 1

2 1

13 14

13 14

13 14

13 14

2 1

2 1

13 14

13 14

13 14

13 14

13 14

Analog

2nd Out AC Model # DC Model #

(+) (-)

13 14

T4810002

T481010A

T4810012

T481011A

T4810101

T4810105

T4810106

T4810107

T4810108

T4810111

T4810115

T481 0116

T4810117

T4810118

T4810109

T4811002

T4811102

T4820201

T4820205

T4820206

T4820208

T4820209

T4821102

T4810119

T4811012

T4811112

T4820211

T4820215

T4820216

T4820218

T4820219

T4821112

-9-

REAR TERMINAL ASSIGNMENTS

ALL P48 Models

0 - 10V

Input

(+) (-)

9 8

0 - 20 mA

Input

(+) (-)

10 8

AC/DC

Power

AC/(+) AC/(-)

11 12

Analog

Main Out A2 or O2

(+) (-)

2 1

(C)

9 8

9 8

9 8

9 8

9 8

9 8

9 8

9 8

10

10

10

10

10

10

8

8

8

8

8

10 8

10 8

8

11

11

11

11

11

11 12

11 12

11

12

12

12

12

12

12

2

2

2

2

1

1

1

1

3 4

3 4

3 4

3 4

1 2

1 2

Dedicated

A1

(C)

3

3

2

2

(C) is the Common Terminal.

* Remote Setpoint Input.

(C)

5 4

5 4

5 4

5 4

(C)

4 5

4 5

4

4

5

5

6 8

6 8

6 8

6 8

6 8

6 8

User

Input

RS485

Output

13 14

2nd Input

Option *

(C) A(+) B(-) (+) (-)

6 8

6 8

6 8

13 14

13 14

13 14

Analog

2nd Out AC Model # DC Model #

(+) (-)

P4800001 P4800011

13 14

P4810000

P4810002

P4810101

P4810105

P4810107

P481010A

P4811100

P4811102

P4810010

P4810012

P4810111

P4810115

P4810117

P481011A

P4811110

P4811112

-10-

SERIAL CONNECTIONS TO A HOST TERMINAL

Six controllers are used to monitor and control parts packaging machines in a plant. The controllers are located at each machine in the production area of the building. A communication line is run to an industrial computer located in the production office.

Each controller is programmed for a different address and all are programmed for the same baud rate and parity as the computer (ex. 9600 baud, parity even). An application program is written by the user to send and receive data from the units using the proper commands.

Figure 10, Connecting to a Host Terminal

-11-

LINEAR DC ANALOG OUTPUT JUMPER SELECTION

(Main & Second)

The Linear Analog DC Output ranges are selectable for either voltage

(0-10 V) or current (0/4-20 mA). The main set of jumpers must correspond with the configuration in Linear Output Range (ANAS) in the Output

Parameter Module (2-OP). The optional secondary set of jumpers must correspond with the configuration in Second Linear DC Output Range (A2tP) in the Second Linear DC Analog Output Module (8-A2). The jumpers are accessible from the rear after removing the controller from the case. Dashed lines show factory setting of 20 mA.

Figure 11, Linear Output Range Jumpers

-12-

FRONT PANEL DESCRIPTION

The front panel bezel material is flame and scratch resistant, tinted plastic that meets NEMA 4X/IP65 requirements, when properly installed.

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. There are two 4-digit LED displays, a red upper Main Display and a lower green Secondary Display.

There are up to six annunciators, with red backlighting, that illuminate to inform the operator of the controller and output status. See Figure 12, Front

Panel, for a description of the annunciators.

Four front panel buttons are used to access different modes and parameters. The following is a description of each button.

Do NOT use tools of any kind (screwdrivers, pens, pencils, etc.) to operate the keypad of this unit.

BUTTON FUNCTIONS

D - In the Normal Display Mode, the

Display (D) button is used to select one of the operational parameters in the secondary display. In other modes, pressing the D button causes the controller to exit (escape) directly to the

Normal Display Mode.

P - The Parameter (P) button is used to access programming, enter the change, and scroll through the available parameters in any mode.

UP, DN - In the Normal Display

Mode, the Up/Down (s/t) buttons can be used to directly modify the setpoint value or

% output power (manual control only), when viewed in the secondary display.

-13-

Figure 12, Front Panel

INITIAL CONFIGURATION START-UP

CONTROLLER POWER-UP

Upon applying power, the controller delays input indication and control action for five seconds to perform several self-diagnostic tests and to 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 sensor type in the main (top) display and the revision number of the controller’s operating system software in the secondary (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 displaying the input value and updating the outputs based upon the control calculation.

PARAMETER CONFIGURATION OVERVIEW

The controller is programmed with certain parameter settings from the factory. Factory settings are listed in parentheses in the various Configuration of Parameters tables. In many cases, these settings must be changed to the particulars of the application before proper operation can be started.

The controller is typically in the Normal Display Mode. When changes to parameter configurations are needed, the P button is pressed. From the factory, the controller will enter directly into the Unprotected Parameter Mode.

Continue to press the P button until CnFP appears in the bottom display. At this time, press the Up arrow button and 1-In will appear in the bottom display. This will be the Configuration Parameter Mode. This programming flow is shown in the Front Panel Programming Chart. (If at any time during front panel programming the D button is pressed, the controller will return to the Normal

Display Mode and the programming can be started over.)

In the Configuration Parameter Mode, the Up or Down arrow buttons can be pressed to move to the desired Parameter Module. The P button is then pressed to enter into that module. The main (top) display will be the parameter and the secondary (bottom) display will be the parameter value. The Up or

Down arrow buttons are used to change the desired parameter value and the P button enters the new value and moves to the next parameter.

The Setpoint value (lower display) is changed with the Up or Down arrow buttons when it is selected in the Normal Display Mode.

-14-

PARAMETER CONFIGURATION BASIC START-UP

For basic start-up, it is important to verify or change Input Parameter

Module (1-IN) parameters tYPE and SCAL, and Output Parameter Module

(2-OP) parameter OPAC. For alarm and heat/cool set-up, it is important to verify or change Alarms Parameter Module (4-AL) parameters ACt1, AL-1,

ACt2 and AL-2.

If the above Input Parameters or the input wiring connections are not correct, then the main (top) display may display an error message or incorrect value. Verify the input programming and wiring. (If incorrect display continues refer to Troubleshooting, page 73.) All other parameter configurations are important but will not prevent the controller from showing a correct display.

PARAMETER CONFIGURATION FOR SERIAL START-UP

The parameter settings can be changed by the front panel buttons or by serial communications using PC Windows based SFCRM software. The controller must have optional RS485 communications. An RS485 to RS232 converter is available from Red Lion Controls for RS232 interfaces. For serial communications set-up, it is important to check serial wiring and verify or change Serial Parameter Module (6-SC) parameters bAUd, ConF,s and

Addr. (See Serial Communications Interface, page 58, for more details.)

CONTROL START-UP

After verifying proper programming and system start-up, a controlling method needs to be configured. For Manual Control or open loop, where the control does not work from the setpoint or process feedback, see Manual

Control, page 47. For On / Off Control, set Proportional Band Prop to 0.0% and see On / Off Control, page 48. The controller comes with factory setting for PID Control. However, for optimum PID Control, several options exist for configuring Proportional Band, Integral Time, and Derivative Time parameters for specific applications.

a. Use controller’s built-in Auto-Tune feature (See Auto-Tune For PID

Control, page 51).

b. Use a manual tuning technique (See Manual Tuning For PID Control, page 56).

c. Use a third party tuning software package.

d. Use values based on control loop experience, calculated values or values from a similar process or previous controller.

VALID CONTROL MODE COMBINATIONS

ON/OFF, PID, and Manual Control can be used for O1 (heat) and O2 (cool) outputs according to the combinations below.

O1 MODE

PID

ON/OFF

(ProP = 0.0)

PID

PID

ON/OFF

(ProP=0.0)

O1 & O2 VALID CONTROL MODES

O2 MODE

MANUAL CONTROL

OUTPUT POWER

RANGE

O1 STATE O2 STATE

—

—

PID

ON/OFF

(GAN2=0.0)

ON/OFF

(GAN2=0.0)

0% to +100%

100%

Any other setting

-100% to +100%

0% to +100%

-100% to 0%

+100%

-100%

Any other setting

O1-TP

O1-ON

O1-OFF

O1-TP

O1-TP

O1-TP

O1-ON

O1-OFF

O1-OFF

—

—

—

O2-TP

O2-OFF

O2-ON

O2-OFF

O2-ON

O2-OFF

TP - Time Proportioning

-15-

FRONT PANEL PROGRAMMING CHART FOR T48 & P48 CONTROLLERS

-16-

NORMAL DISPLAY MODE

In the Normal Display Mode, the temperature or scaled process value is displayed in the main (top) display. By successively pressing the D button, the parameters listed below can be viewed in the secondary (bottom) display.

Each of these parameters can be independently locked out from appearing or from being modified through the Lockout Parameter 3-LC. If all four displays are locked out, the display blanks after pressing the D button. To gain access to the next modes, press the P button from any parameter.

To modify values in % Output Power (for Manual Control) or Setpoint, use the Up or Down arrows while the parameter is displayed and not locked. If locked, these parameters can be changed in the Protected Parameter Mode. The controller responds to the new values immediately, however, the change is not committed to permanent memory until 10 seconds after the last key press.

Normal Display Mode Reference Table

Illuminates

—-

%P

DV

Parameter

Local Setpoint

SP1 or SP2

% Output

Power

Setpoint

Deviation

Range and Units

(Factory Setting)

-999 to 9999

(0) for T48

(0.0) for P48

-99.9% to 100.0%

Read only Unless in

Manual Control

-999 to 9999

Read only

DV

—-

—-

Heater

Current

-999 to 9999

Read only

Units Symbol °F or °C

Read only

Blank Blank display

Description/Comments

Range limited by

SPLO & SPHI in 1-In.

Not limited by

OPLO & OPHI in 2-OP.

Shows difference between Temp/Process

(top display) and

Setpoint.

Heater Current models show heater current value and not process deviation.

T48 models only

P48 models only

FRONT PANEL 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

3-LC, the code number entered, and the state and/or function programmed for the User Input (Terminal #6) will all affect front panel access.

The following chart describes the possible program disable settings.

User Input State

Inactive or User

Input not programmed for

PLOC

Active with User

Input programmed for PLOC

Active with User

Input programmed for PLOC

OR

User Input not programmed for

PLOC

0

Code Number

0

Any # between

1 & 250

Description

Full access to all modes and parameter modules.

Access to protected parameter mode only. Code number does not appear.

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.

-17-

UNPROTECTED PARAMETER MODE

The Unprotected Parameter Mode is accessed by pressing the P button from the Normal Display Mode with Program Disable inactive. While in this mode, the operator has access to the most commonly modified controller parameters by pressing the P button. The temperature or scaled process value is displayed in the main (top) display. The parameter display will appear with the corresponding range and units in the secondary (bottom) display.

To modify values, use the Up or Down arrows while the parameter is displayed. The controller responds to the new values immediately, however, the change is not committed to non-volatile memory until the controller is returned to the Normal Display Mode. If power loss occurred before returning to the Normal Display Mode, the new values must be entered again.

To gain access to the Configuration Parameter Modules, continue to CnFP and press the Up arrow. These modules allow access to the fundamental set-up parameters of the controller. When the program list has been scrolled through, or the D button is pressed, 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.

Unprotected Parameter Mode Reference Table

Display Parameter

SP Local **

Setpoint

SP1 or SP2 *

OPOF %Output **

Power Offset

OP % Output **

Power

Range and Units

(Factory Setting)

-999 to 9999

(0) T48

(0.0) P48

-99.9% to 100.0%

(0.0)

-99.9% to 100.0%

(0.0)

Description/ Comments

Range limited by SPLO & SPHI.

User Input or Hidden Function

Mode selects SP1 or SP2

Appears only if Intt = 0 and unit is in Automatic Control.

Appears only if unit is in

Manual Control. This parameter is not limited to output power limits (OPLO & OPHI).

0.0% is ON/OFF control. If using ON/OFF, set control hysteresis appropriately.

ProP

Intt dErt

AL-1

AL-2

Proportional

Band

Integral

Time

Derivative

Time

Alarm 1

Value *

Alarm 2

Value *

CNFP Configuration

Access Point

End Returns to

Normal

Display Mode

0.0 to 999.9% of selected input range (4.0) T48

(100.0) P48

0 to 9999 sec.

(120) T48

(40) P48

0 to 9999 sec.

(30) T48

(4) P48

-999 to 9999,

(0) T48

(0.0) P48

-999 to 9999,

(0) T48

(0.0) P48

NO

Up Arrow

____

0 is off. This parameter does not appear if ProP = 0.0%.

0 is off. This parameter does not appear if ProP = 0.0%.

This parameter does not appear if configured for “heat”.

This parameter does not appear if configured for “cool”.

Return to Normal Display Mode.

Enter Configuration modules.

Brief display message while the unit returns to Normal Display

Mode.

* Model Number Dependent.

** Only appears if locked out from Normal Display Mode.

-18-

PROTECTED PARAMETER MODE

The Protected Parameter Mode is accessed by pressing the P button from the Normal Display Mode with Program Disable active. While in this mode, the parameters can be accessed by pressing the P button. The temperature or scaled process value (after initial setup) will be displayed in the main (top) display. The parameter display will appear with the corresponding range and units in the secondary (bottom) display. Each of these parameters can be independently locked out from appearing or from being modified through the

Lockout Parameter 3-LC.

To modify values, use the Up or Down arrows while the parameter is displayed. If locked, the parameter will not show in the Normal Display

Mode, but can be changed in the Protected Parameter Mode. The controller responds to the new values immediately, however, the change is not committed to non-volatile memory until the controller is returned to the

Normal Display Mode. If power loss occurred before returning to the Normal

Display Mode, the new values must be entered again.

To gain access to the Unprotected Parameter Mode (with User Input inactive or not programmed for PLOC), continue to CodE and press the arrow buttons until the value equals the Code as entered in parameter lockouts.

When an incorrect code value is entered, or when the D button is pressed,

“End” will momentarily appear and the controller will return to the Normal

Display Mode.

Protected Parameter Mode Reference Table

Display Parameter

ProP

Intt dErt

AL-1

AL-2

CodE

Proportional

Band

Integral

Time

Derivative

Time

Alarm 1 value *

Alarm 2 value *

Access code to

Unprotected

Parameter

Mode

Range and Units

(Factory Setting)

0.0 to 999.9% of selected input range

(4.0) T48

(100.0) P48

0 to 9999 sec.

(120) T48

(40) P48

0 to 9999 sec.

(30) T48

(4) P48

-999 to 9999

(0) T48

(0.0) P48

-999 to 9999

(0) T48

(0.0) P48

0 to 250

(0)

End Returns to

Normal

Display

Mode.

* Model Number Dependent.

—-

Description/Comments

0.0% is ON/OFF Control.

Adjusted by Auto-Tune.

0 is off. This parameter does not appear if ProP = 0.0%. Adjusted by Auto-Tune.

0 is off. This parameter does not appear if ProP = 0.0%. Adjusted by Auto-Tune.

This parameter does not appear if configured for “heat”.

This parameter does not appear if configured for “cool”.

To gain access to Unprotected

Parameter Mode, enter the same value for Code as used in parameter lockouts. Does not appear if zero is entered in code parameter lockout.

Brief display message while the unit returns to Normal Display

Mode.

-19-

HIDDEN FUNCTION MODE

The Hidden Function Mode is only accessible from the Normal Display

Mode by pressing and holding the P button for three seconds. These functions must first be unlocked in Configuration Module 3-LC. Factory settings for these parameters is lock. In this mode, these controller functions can be performed.

Remote/SP1/SP2 Setpoint Selection

Automatic/Manual Transfer

Initiate/Cancel Auto-tune

Reset Alarm Outputs

The P button is used to scroll to the desired function and the Up and Down buttons are used to select the operation. Pressing the P button while the function is displayed executes the function, and returns the unit to the Normal

Display Mode. Pressing the D button exits this mode with no action taken.

The unit automatically returns to the Normal Display Mode if no action is taken within a few seconds.

Hidden Function Mode Reference Table

Display Parameter

SPSL trnF tUNE

ALrS

Setpoint

Select

Transfer mode of operation

Auto-tune

Invocation

Alarm

Reset *

Range and Units

(Factory Setting Value)

SP1 - Setpoint 1

SP2 - Setpoint 2 rSP - Remote Setpoint

Auto - Automatic control

User - Manual control

(Auto)

Yes: starts the auto-tune sequence.

No: terminates the auto-tune sequence.

(NO)

UP button resets Alarm 1

DOWN button resets

Alarm 2

* Model Number Dependent

Description/ Comments

Exits to Normal Display

Mode after being executed.

Exits to Normal Display

Mode after being executed.

Exits to Normal Display

Mode after being executed.

Does not exit to Normal

Display Mode after being executed.

CONFIGURATION PARAMETER MODE

The Configuration Parameter Mode is accessed by pressing the Up button from CnFP in the Unprotected Parameter Mode. While in this mode, the various Configuration Modules can be displayed by pressing the Up or Down buttons. The process value (after initial setup) will be displayed in the main

(top) display. The Configuration Module will appear alternating with CnFP in the secondary (bottom) display.

To access a Configuration Module, press the P button when the desired

Configuration Module is displayed. The parameters of that Configuration

Module can be accessed by pressing the P button. (The module’s parameters are listed in the appropriate Configuration Module table in this section with configuration parameter explanations beginning on page 31.) To modify ranges and units, use the Up or Down arrows while the parameter is displayed.

The controller responds to the new values after the P button is pressed, however, the change is not committed to permanent memory until the controller is returned to the Normal Display Mode. If power loss occurred before returning to the Normal Display Mode, the new values must be entered again. Whenever the D button is pressed, End will momentarily appear and the controller will return to the Normal Display Mode. At the end of each module, the controller will go to CnFP no. Pressing the Up or Down arrows will continue in Configuration Parameter Mode and pressing the P will return to the Normal Display Mode.

Unless specified, the parameters, ranges, units and factory settings are the same for T48 and P48 controllers. Parameters that are model number or program dependent will only be displayed when the appropriate options are installed or programmed. Some parameters are accessible but may not be applicable for the chosen output control mode type.

-20-

REFERENCE TABLES: CONFIGURATION PARAMETER MODULES

Configure Module 1 - Input Parameters (1-IN) T48

These tables are only used for programming the T48 models. Use the tables on page 22 if you are programming a P48.

Display

tYPE

SCAL

Parameter

Input Type

Temperature

Scale

Range and Units

(Factory Setting)

tc-t - Type T TC tc-E - Type E TC tc-J - Type J TC tc-k - Type K TC tc-r - Type R TC tc-S - Type S TC tc-b - Type B TC tc-N - Type N TC

LIN - Linear mV display r385 - 385 curve RTD r392 - 392 curve RTD rLIN - Linear ohms display

(tc-J)

°F/°C

(°F) dCPt

FLtr

Temperature

Resolution

Digital Input

Filtering And

Display

Update

0 or 0.0

(0)

0 to 4

(1)

Description/

Comments

Thermocouple select

RTD select

If scale is changed, be sure to check all parameters.

If resolution changed, be sure to check all parameters.

Increase number for more filtering effect.

4 = 500 msec display update rate. Adjusted by Auto-Tune.

Display

SHFt

SPLO

Parameter

Input Signal

Shift (correction offset)

Setpoint Lower

Limit

SPHI

SPrP

InPt

Setpoint Upper

Limit

Setpoint Ramp

Rate

User Input *

Range and Units

(Factory Setting)

-999 to 9999

1 or 0.1 degree

(0)

-999 to 9999

0 or 0.1 degree

(0)

-999 to 9999

1 or 0.1 degree

(9999)

0.0 to 999.9 degrees/minute

(0.0)

PLOC - Program disable

ILOC - Integral action on/off trnF - Auto/manual select

SPrP - Setpoint ramp on/off

ALrS - Reset alarm output(s)

SP2 - Select SP1/SP2 rSP - Select

Local/Remote

PrNt - Serial block print

(PLOC)

Description/

Comments

Normally set to 0.

Set low limit below high limit.

Set high limit above low limit.

0.0 is off (no ramping)

Low = lock

Low = off

Low = manual

Low = end ramp

Low = reset

Low = SP2

Low =remote

Low =block print

* Model Number Dependent

-21-

Configure Module 1 - Input Parameters (1-IN) P48

These tables are only used for programming the P48 models. Use the tables on page 21 if you are programming a T48.

Display

tYPE dCPt rnd

FLtr

Parameter

Input Type

Decimal Point

Rounding

Increment

Digital Input

Filtering And

Display Update

Range and Units

(Factory Setting)

VOLt - Voltage

Curr - Current

(Curr)

0, 0.0, 0.00, or 0.000

(0.0)

1, 2, 5, 10, 20, 50, or

100

(0.1)

0 to 4

(1) dSP1

InP1 dSP2

Scaling Point #1

Display Value

Scaling Point #1

Input Signal

0/4-20 mA DC

0-10 VDC

-999 to 9999

(0.0)

0.00 to 20.00 mA

0.00 to 10.00 V

(4.00)

Value Key-in

Method

Signal Input

Method

Scaling Point #2

Display Value

-999 to 9999

(100.0)

Key-in input low value.

Apply input low value.

Key-in display high value.

Description/

Comments

If 0.000 is selected, scaling points must be a positive value.

Used in conjunction with filtering to stabilize the display reading.

Increase number for more filtering effect.

4 = 500 msec display update rate. Adjusted by Auto-Tune.

Key-in display low value.

Press D button to select Signal Input method.

Display

InP2

SPLO

SPHI

SPrP

InPt

Parameter

Scaling Point #2

Input Signal

0/4-20 mA DC

0-10 VDC

Range and Units

(Factory Setting)

0.00 to 20.00 mA

0.00 to 10.00 V

(20.00)

Value Key-in

Method

Signal Input

Method

Setpoint Lower

Limit

Setpoint Upper

Limit

Setpoint Ramp

Rate

User Input *

-999 to 9999

(0.0)

-999 to 9999

(999.9)

0 to 9999 units/minute

(0.0)

PLOC - Program disable

ILOC - Integral action on/off trnF - auto/manual select

SPrP - Setpoint ramp on/off

ALrS - Reset alarm output(s)

SP2 - Select SP1/SP2 rSP - Select

Local/Remote

PrNt - Serial block print

(PLOC)

Description/

Comments

Press D button to select Signal

Input method.

Key-in input low value.

Apply input low value.

Set low limit below high limit.

Set high limit above low limit.

0.0 is off (no ramping).

Low = lock

Low = off

Low = manual

Low = end ramp

Low = reset

Low = SP2

Low =remote

Low =block print

* Model Number Dependent

-22-

Configure Module 2 - Output Parameters (2-OP)

Display

CYCt

OPAC

OPLO

OPHI

OPFL

OPdP

Parameter

Time

Proportioning

Cycle Time

Output Control

Action

Output Power

Lower Limit

(Not used in

Manual Control)

Output Power

Upper Limit

(Not used in

Manual Control)

Sensor Fail

Power Level

(Not used in

Manual Control)

Output Power

Dampening

(filtering) Time

Range and Units

(Factory Setting)

0 to 250 seconds

(2)

Description/

Comments

0 turns O1 off. Set to zero for Linear DC output control. Not used for ON/OFF Control.

For both PID & ON/OFF control.

drct - cooling rEv - heating

(rEv)

0% to 100%, O1

(0)

-100% to 100%,

O1 & O2

(-100)

0% to 100%, O1

(100)

-100% to 100%

O1 & O2

(100)

0% to 100%, O1

(0)

-100% to 100%

O1 & O2

(0)

0 to 250 seconds

(3) T48

(1) P48

Set OPLO < OPHI

Negative % is only valid for O2 cooling control.

Set OPHI > OPLO

Negative % is only valid for O2 cooling control.

Select a level to safely control the process in the event of input sensor failure. T48 only.

0 = off (no dampening)

Set in range of 1/50 to

1/10 of integral time.

Adjusted by Auto-Tune.

Display

CHYS tcOd

ANtP

ANAS

ANUt

ANLO

ANHI

Parameter

ON/OFF Control

Hysteresis

Auto-tune

Dampening Code

Main Linear DC

Output Range *

Main Linear DC

Output Source *

Main Linear DC

Output Update *

Main Linear DC

Output Low Scaling

Value *

Main Linear DC

Output High

Scaling Value *

Range and Units

(Factory Setting)

1 to 250

(2) T48

(0.2) P48

0 to 2

(0)

0 to 10 V

0 to 20 mA

4 to 20 mA

(4 to 20 mA)

OP

InP

SP

(OP)

0 to 250 secs

(0)

-999 to 9999

(0.0)

-999 to 9999

(100.0)

Description/

Comments

For O1 ON/OFF

Control. Change to

Factory Setting prior to Auto-Tune.

0 = fastest response

2 = slowest response

Set linear output range jumper to match.

SP = Active Setpoint

0 = Update rate of 0.1

sec.

Value depends on

ANAS assignment.

Value depends on

ANAS assignment.

* Model Number Dependent

-23-

Configure Module 3 - Lockout Parameters (3-LC)

Display

SP

OP dEv

Hcur

UdSP bdSP

CodE

Parameter

Setpoint access

Range and Units

(Factory Setting) Description/ Comments

LOC - lockout rED - read only

Ent - enter

(Ent)

Determines access to temperature setpoint.

Output power access

Deviation display access

LOC - lockout rED - read only

Ent - enter

(Ent)

LOC - lockout rEd - read only

(rEd)

Determines direct access to output power.

%P indicator illuminates when parameter is selected in display.

Determines display of deviation. DV indicator illuminates when parameter is selected in display. (Does not appear if heater current option is installed).

Heater current display access *

T48 only

LOC - Lockout rEd - read only

(rEd)

Determines heater current readout. DV indicator Illuminates when selected.

Determines display of F or C.

Units display access

For T48

Blank display access

For P48

Access code

LOC - lockout rEd - read only

(rEd)

LOC - lockout rEd - read only

(rEd)

0 to 250

(0)

Determines blank secondary display.

Refer to front panel disable section for access levels.

Display

PId

AL

ALrS

SPSL trnF tUNE

Parameter

PID values access

Alarm values enable *

Reset alarms enable *

Range and Units

(Factory Setting) Description/ Comments

LOC - lockout rEd - read only

Ent - enter

(LOC)

Protected Mode lockout.

Protected Mode lockout.

LOC - lockout rEd - read only

Ent - enter

(LOC)

LOC - lockout

ENBL - enable

(LOC)

Hidden Mode lockout.

SP1/SP2/Remote setpoint enable *

Automatic/Manual

(user) mode select enable

LOC- lockout

ENBL - enable

(LOC)

LOC - lockout

ENBL - enable

(LOC)

Auto-tune enable LOC- lockout

ENBL - enable

(LOC)

Hidden Mode lockout.

Hidden Mode lockout.

Hidden Mode lockout.

* Model Number Dependent

-24-

Configure Module 4 - Alarm Parameters (4-AL)

Controller returns to configuration access point (CnFP NO) if alarm(s) are not installed.

Display

ACt1 rSt1

Stb1

AL-1

ACt2

Parameter

Alarm 1 action mode

Alarm 1 reset mode

Alarm 1 standby function (delay)

Alarm 1 value

Alarm 2 action mode *

Range and Units

(Factory Setting)

A-HI - absolute high

A-LO - absolute low d-HI - deviation high d-LO - deviation low b-IN - band inside b-ot - band outside

Hcur - heater current alarm *

Heat - control output *

(A-HI)(HEAt) *

Auto - automatic

LAtc - manual reset

(Auto) yes/no

(no)

-999 to 9999

(0) T48

(0.0) P48

A-HI - absolute high

A-LO - absolute low d-HI - deviation high d-LO - deviation low b-IN - band inside b-ot - band outside

CooL- cooling output

Hcur - heater current alarm *

(A-HI)

Description/

Comments

If changed, check alarm values. If heat is selected, the remaining alarm parameters do not appear. For P48, heat is main control output.

Manual reset via

Hidden Mode or user input.

Power-up standby delay.

If band alarm action, then only a positive value can be entered.

If changed, check alarm values. If cooling is selected, the remaining Alarm

2 parameters do not appear.

For P48, cool is second PID control output.

Display

rSt2

Stb2

AL-2

Parameter

Alarm 2 reset mode *

Alarm 2 standby function (delay) *

Alarm 2 value *

Range and Units

(Factory Setting)

Auto - automatic

LAtc - manual reset

(Auto) yes/no

(no)

-999 to 9999

(0) T48

(0.0) P48

AHYS Alarm Hysteresis value

1 to 250

(1) T48

(0.1) P48

Description/

Comments

Manual reset via hidden Mode or user input.

Power-up standby delay.

If band alarm action, then only a positive value can be entered.

Applies to both alarms. Set to eliminate chatter.

* Model Number or Mode Setting Dependent

-25-

Configure Module 5 - Cooling Parameters (5-O2)

Controller returns to configuration access point (CnFP NO) if Alarm 2 is not configured as cooling output in Alarm Module (4-AL). Cooling output for the P48 is referred to as the second control output.

Display

CYC2

Parameter

Description/

Comments

0 turns O2 off.

GAN2

Cooling output cycle time

Relative cooling gain

Range and Units

(Factory Setting)

0 to 250 sec

(2)

0.0 to 10.0

(1.0) db-2 Heating or cooling overlap/deadband

-999 to 9999

(0)

0.0 places cooling output into ON/OFF

Control and db-2 becomes hysteresis value.

Positive value is deadband. Negative value is overlap. If

GAN2 = 0, this parameter is cooling

ON/OFF Control hysteresis. Change to Factory Setting prior to Auto-Tune.

-26-

Configure Module 6 - Serial Communications (6-SC)

Controller returns to configuration access point (CnFP NO) if RS485 serial option is not installed.

Display

bAUd

Parameter

Baud rate

ConF

Addr

Abrv

PoPt

Character Frame format

Controller address

Abbreviated or full transmission

Print options

Range and Units

(Factory Setting)

300 to 9600

(9600)

7O1

7E1

7n2

8n1

(7O1)

0 to 99

(0) yes/no

(no) yes/no

(no)

Description/

Comments

Baud rate of unit must match connected equipment.

7 data, odd parity, 1 stop (was odd)

7 data, even parity, 1 stop (was even)

7 data, no parity, 2 stop (was none)

8 data, no parity, 1 stop

For multiple unit applications, each unit must have a unique node address.

Selecting yes, the controller does not transmit mnemonics.

Selecting yes allows print options shown below, to be programmed.

INP

SEt

OPr

Pbd

INt

Input

Setpoint yes/no

(yes) yes/no

(yes)

% Output Power yes/no

(yes)

% Proportional Band yes/no

(no)

Integral Time yes/no

(no)

-27-

Display

dEr

AL1

AL2 dEv

OFP r-P

Crg

Cdb

OSt rSP

HCr

Parameter

Derivative Time

Alarm 1 *

Alarm 2 *

Deviation From

Setpoint *

% Output Power

Offset

Setpoint Ramp Rate yes/no

(no)

Relative Gain yes/no

(no)

Deadband yes/no

(no) yes/no

(no)

Output Status yes/no

(no) yes/no

(no)

Remote Setpoint *

Heater Current *

Range and Units

(Factory Setting)

yes/no

(no) yes/no

(no) yes/no

(no) yes/no

(no) yes/no

(no)

* Model Number Dependent

Description/

Comments

Configure Module 7 - Remote Setpoint Parameters (7-rS or

7-n2)

Controller returns to configuration access point (CnFP NO) if remote setpoint option is not installed.

Display

dSP1

INP1 dSP2

INP2

FLtr

Parameter

Remote setpoint display scaling point

#1

Remote setpoint input scaling point

#1.

Range and Units

(Factory Setting)

-999 to 9999

(0) T48

(0.0) P48

0.00 to 20.00 mA

(4.00)

Remote setpoint display scaling point

#2

Remote setpoint input scaling point

#2

-999 to 9999

(1000) T48

(100.0) P48

0.00 to 20.00 mA

(20.00)

Description/

Comments

Remote setpoint display low value.

Key in input low value or Press D to select Signal Input method.

Remote setpoint display high value.

Key in input low value or Press D to select Signal Input method.

0 = off bAnd trnF

Remote setpoint filter time constant

Remote setpoint filter band

Remote/Local setpoint transfer options

0 to 25 seconds

(2)

0 to 250

(5) nor - normal

Auto - Automatic trAC - Tracking

(nor)

0 = filter always engaged.

Auto = Bumpless, other modes may bump.

Configure Module 7 - Heater Current Parameters (7-HC or

7-n2)

Controller returns to configuration access point (CnFP NO) if heater current option is not installed.

Display

Hcur

Parameter

Heater current transformer scaling

Range and Units

(Factory Setting)

0.0 to 999.9 Amps

(40.0)

Description/

Comments

Set scaling equal to primary rating of CT.

-28-

Configure Module 8 - Second Linear DC Analog Output (8-A2)

Controller returns to Configuration Access Point (CnFP-NO) if second linear DC analog option is not installed.

Display

A2tP

A2LO

A2Hl

Parameter

Second linear DC output range

Second linear DC output low scaling value

Second linear DC output high scaling value

Range and Units

(Factory Setting)

0 to 10 V

0 to 20 mA

4 to 20 mA

(4-20)

-999 to 9999

(0) T48

(0.0) P48

-999 to 9999

(1000) T48

(100.0) P48

Description/

Comments

Set Secondary

Output jumper to match.

Corresponding temp or process value for low output.

Corresponding temp

/ process value for high output.

Configure Module 9 - Factory Service Operations (9-FS)

Display

CodE

Parameter

Factory service function code.

Range and Units

(Factory Setting)

48 - Calibrate instrument

66 - Reset parameters to factory settings

77- (twice in succession) Reset controller calibration to nominal values

(Caution: This operation results in up to ±10% reading error.)

Description/

Comments

Refer to Calibration

Section for details.

USER PARAMETER VALUE CHART

CONTROLLER NUMBER

MNEMONIC

SP

OPOF

OP

ProP

Intt dErt

AL-1

AL-2

PARAMETER

Setpoint

% Output Power Offset

% Output Power

Proportional Band

Integral Time

Derivative Time

Alarm 1 Value

Alarm 2 Value

USER SETTING

T48 CONFIGURE INPUT 1-INP

MNEMONIC

tYPE

SCAL dCPt

FLtr

SHFt

SPLO

SPHI

SPrP

InPt

PARAMETER

Input Sensor Type

Temperature Scale Units

Temperature Resolution

Digital Filtering

Input Offset

Setpoint Lower Limit

Setpoint Upper Limit

Setpoint Ramp Rate

User Input

USER SETTING

-29-

P48 CONFIGURE INPUT 1-INP

MNEMONIC

tYPE dCPt rnd

FLtr dSP1

InP1 dSP2

InP2

SPLO

SPHI

SPrP

InPt

PARAMETER

Input Type

Decimal Point

Rounding Increment

Digital Filtering

Display Value #1

Signal Input Value #1

Display Value #2

Signal Input Value #2

Setpoint Lower Limit

Setpoint Upper Limit

Setpoint Ramp Rate

User Input

CONFIGURE OUTPUT 2-OP

MNEMONIC

CYCt

OPAC

OPLO

OPHI

OPFL

OPdP

CHYS tcod

ANtP

ANAS

ANUt

ANLO

ANHI

PARAMETER

Cycle Time

Output Control Action

Output Power Lower Limit

Output Power Upper Limit

Sensor Fail Power Preset

Output Power Dampening

ON/OFF Control Hysteresis

Auto-Tune Dampening Code

Linear Output Range

Linear Output Source

Linear Output Update time

Linear Output Scale Point Low

Linear Output Scale Point High

USER SETTING

USER SETTING

CONFIGURE LOCKOUTS 3-LC

MNEMONIC

SP

OP dEv

Hcur

UdSP

CodE

PId

AL

ALrS

SPSL trnF tUNE

PARAMETER

Access Setpoint

Access Output Power

Access Deviation Display

Access Heater Current

Access Display Units

Access Code Number

Access PID Values

Access Alarm(s) Values

Enable Reset Alarm(s)

Enable Remote/Local Transfer

Enable Auto/Man Transfer

Enable Auto-tune

CONFIGURE ALARMS 4-AL

MNEMONIC

Act1 rSt1

Stb1

AL-1

Act2 rSt2

Stb2

AL-2

AHYS

PARAMETER

Alarm 1 Action Mode

Alarm 1 Reset Mode

Alarm 1 Standby Enabled

Alarm 1 Value

Alarm 2 Action Mode

Alarm 2 Reset Mode

Alarm 2 Standby Enabled

Alarm 2 Value

Alarm Hysteresis Value

CONFIGURE COOLING 5-O2

MNEMONIC

CYC2

GAN2 db-2

PARAMETER

O2 Output Cycle Time

Relative Cooling Gain

Heat-Cool Overlap/Deadband

USER SETTING

USER SETTING

USER SETTING

-30-

CONFIGURE SERIAL COMMUNICATIONS 6-SC

MNEMONIC

bAUd

ConF

Addr

Abrv

PoPt

SEt

OPr

Pbd

Int dEr

AL1

PARAMETER

Baud Rate

Character Frame Format

Controller Address

Abbrev. or Full Transmission

Print Options

INP

AL2 dEv

OFP r_P

Crg

Cdb

OSt

RSP

HCr

CONFIGURE REMOTE SETPOINT 7-rS / 7-n2

MNEMONIC PARAMETER

dSP1

INP1 dSP2

INP2

FLtr bAnd trnF

Remote Setpoint Display Value #1

Remote Setpoint Input Value #1

Remote Setpoint Display Value #2

Remote Setpoint Input Value #2

Remote Setpoint Filter Time Constant

Remote Setpoint Filter Band

Local/Remote Transfer Options

USER SETTING

USER SETTING

CONFIGURE HEATER CURRENT INPUT 7-HC / 7-n2

MNEMONIC

Hcur

PARAMETER

Heater Current Readout Scaling

USER SETTING

CONFIGURE SECOND LINEAR OUTPUT 8-A2

MNEMONIC

A2tP

A2LO

A2HI

PARAMETER

Second Linear Output Range

Second Linear Output Low Value

Second Linear Output High Value

USER SETTING

CONFIGURATION PARAMETER EXPLANATIONS

Input Parameter Module (1- IN) T48 Models

The controller has several input set-up parameters that must be programmed prior to setting any other controller parameters.

Input Type (tYPE)

Select from the list of various thermocouple and RTD sensors.

The following is a list of the possible sensors: tc-t Type T TC tc-E tc-J tc-k tc-r tc-S tc-b tc-N

LIN r385 r392 rLIN

Type E TC

Type J TC

Type K TC

Type R TC

Type S TC

Type B TC

Type N TC

Linear mV display

385 curve RTD

392 curve RTD

Linear ohms display

Temperature Scale (SCAL)

Select either degrees Fahrenheit (F) or degrees Celsius (C).

If changed, be sure to check all parameters.

Temperature Resolution (dCPt)

Select either 1 or 0.1 degree resolution.

If changed, be sure to check all parameters.

Digital Input Filtering 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

-31-

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

36, for filtering the output.

Fltr- 0 to 4

0 = least input filtering

3 = most input filtering

4 = most input filtering and slower (500 msec) display update rate

(outputs update at 100 msec rate)

Input Sensor Correction Constant (SHFt)

If the controller temperature disagrees with a reference temperature instrument or if the temperature sensor has a known calibration, the controller temperature can be compensated by a correction offset (SHFt).

SHFt - -999 to 9999

The following equation expresses the relationship:

Desired Display Temp = (Controller Temp) + SHFt

Example 1: The controller reads 293°F while a reference instrument indicates

300°F. A SHFt value of +7°F corrects the controller indication to match the reference.

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 temperature setpoint value cannot be set outside the safe operating area of the process.

SPLO - -999 to 9999

SPHI - -999 to 9999

Setpoint Ramp Rate (SPrP)

The setpoint can be programmed to ramp independent of the controller’s display resolution. The setpoint ramp feature can reduce thermal shock to the process, reduce temperature overshoot on start-up or setpoint changes, or ramp the process at a controlled rate.

SPrP - 0.0 to 999.9 degrees/minute

A ramp value of zero disables setpoint ramping, allowing the controller to stabilize as fast as possible to the new setpoint. If the user input is programmed for setpoint ramp, it affects the enabling and disabling of setpoint ramping. Setpoint ramping is initiated on power-up or when the setpoint value is changed. Active setpoint ramping is indicated by the left most decimal point flashing in the main display.

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 ramping prior to invoking Auto-Tune, the ramping is suspended during

Auto-Tune and then resumed afterward using the current temperature as a starting value. Deviation and band alarms are relative to the target setpoint, not the ramping setpoint.

The Remote Setpoint input is also controlled by the setpoint ramp feature.

In situations where the remote setpoint must be rate controlled, this parameter can be used to slowly increment (or decrement) the signal to its final value.

The target value, not the instantaneous ramp value, is displayed. Setpoint ramp indication is disabled during remote setpoint ramping.

-32-

Note: Depending on the thermal characteristics of the process, the process temperature may not track the programmed setpoint rate.

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 120 msec minimum to perform the function. A function is performed when the User Input,

(Terminal 6) is pulled low to common (Terminal 8).

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.

Note: “Low Level” is switch closed.

“High Level” is switch open.

PLOC - Program Lock. A low level enables the program disable function which places the unit in the Protected Parameter Mode.

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.

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. On models with alarms, a low level resets any active alarm(s) to their inactive state as long as the user input is low.

SP2 - Setpoint 1/ Setpoint 2 Select. On models with Second Setpoint, a low level selects setpoint 2. A high level selects setpoint 1.

SPSL or RSP - Local/Remote Select. On models with Secondary Analog

Input, a negative transition engages Remote Setpoint operation and a positive transition engages Local Setpoint operation. The response of the controller to the setpoint transfer is set by the setpoint transfer parameter

“trnF”, under “7-rS” or “7-n2” module.

Prnt - Print Request. On models with Serial Communications, a low level transmits the print option selected in the Serial Communications Module

(6-SC). If the user input is held low, after the printing is complete, another request is issued.

Input Parameter Module (1- In) P48 models

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 signal input terminal for voltage is #9 and for current is #10. Common is #8.

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

Rounding Increment ( rnd)

Rounding values other than “1” causes the scaled number to ‘round’ to the nearest rounding increment selected (i.e.. rounding of ‘5’ causes ‘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 (improve or degrade) the control accuracy of the unit.

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Digital Input Filtering 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. See Output Power Dampening parameter (OPdP), page 36, 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)

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 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 14, Scaling Points

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

0.0% @ 4.00 mA &

Scaling Point #2

100.0% @ 20.00 mA

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 dSP2

-999 to 9999 (Ex.

0.0%)

-999 to 9999 (Ex. 100.0%)

Signal Input Values (INP1 & INP2)

The signal input value can either be keyed in via the front panel buttons or an input signal can be applied to the appropriate signal input terminals. When entering the signal input parameter, the unit is in the key-in mode.

Key-in Method

Key-in the signal value for scaling point one and scaling point two.

INP1

INP2

-999 to 9999 (Ex. 0.00 VDC or 4.00 mA DC)

-999 to 9999 (Ex. 10.00 VDC or 20.00 mA DC)

Signal Input Method

To change to the apply signal method press the D button. Front panel annunciators %P and DV 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 D button again.

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 P button to store the value and advance to the next parameter.

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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

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 1 to 9999 units/minute

Note: Defined here, a unit is the LSD of the display, regardless of decimal point position.

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. Setpoint ramping is initiated on power-up or when the setpoint value is changed. Active Setpoint Ramping is indicated by the left most decimal point flashing in the main display.

Figure 15, 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 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.

The Remote Setpoint input is also controlled by the setpoint ramp feature.

In situations where the remote setpoint must be rate controlled, this parameter can be used to slowly increment (or decrement) the signal to its final value.

The target value, not the instantaneous ramp value, is displayed. Setpoint ramp indication is disabled during remote setpoint ramping.

Note: Depending on the ramp rate relative to the process dynamics, the actual scaled process value may not track the ramping setpoint value.

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 120 msec minimum to perform the function. A function is performed when the User Input,

(Terminal 6) is pulled low to common (Terminal 8).

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.

Note: “Low Level” is switch closed.

“High Level” is switch open.

PLOC - Program Lock. A low level enables the program disable function which places the unit in the Protected Parameter Mode.

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.

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.

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ALrS - Alarm Reset. On models with alarms, a low level resets any active alarm(s) to their inactive state as long as the user input is low.

SP2 - Setpoint 1/ Setpoint 2 Select. On models with Second Setpoint, a low level selects setpoint 2. A high level selects setpoint 1.

SPSL or RSP - Local/Remote Select. On models with Secondary Analog

Input, a negative transition engages Remote Setpoint operation and a positive transition engages Local Setpoint operation. The response of the controller to the setpoint transfer is set by the setpoint transfer parameter

“trnF”, under “7-n2” module.

PrNt - Print Request. On models with Serial Communications, a low level transmits the print option selected in the Serial Communications Module

(6-SC). If the user input is held low, after the printing is complete, another request is issued.

Output Parameter Module (2-OP)

The controller has parameters that affect how the main control output (O1) and Main Linear DC output control signal responds to temperature changes and sensor failures.

Time Proportioning Cycle Time (CYCt)

The selection of cycle time depends on the time constant of the process and the type of output 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 temperature control, and shorter cycle times provide little benefit at the expense of shortened relay life. When using a Logic/SSR drive output 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. This is useful if using the linear DC output signal for control. On some models, output (O1) can be configured as an alarm output ACt1 under

Module “4-AL”.

Output Control Action (OPAC)

For heat and cool applications, the main output (O1) is normally used for heating (reverse acting) and the optional cooling output (O2) is normally used for cooling (direct acting).

OPAC - rEv (Reverse acting) drct (Direct acting)

If O2 (cooling) is not used, then the action can be reverse or direct acting.

When used for control output, the Main Linear DC output operation is affected by this parameter.

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 -

If the cooling output is selected, the limits range from:

OPLO & OPHI -

0 to 100%

-100 to 100%

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With Alarm 2 selected for cooling, the Lower Limit can be set to less than

0% to limit maximum cooling or set to greater than 0% to limit minimum heating. Set the High Limit to less than 0% to limit minimum cooling or greater than 0% to limit maximum heating. When controlling power in the manual control mode, the output power limits do not take effect.

Sensor Fail Power Level (OPFL) T48 only

If a failed sensor is detected, the control output(s) default to a preset power output.

OPFL - 0% (O1 output full “off”) to 100% (O1 output full “on”)

If Alarm 2 is selected for cooling , the range is extended from:

OPFL - -100% to +100%

At 0% both outputs are off, at 100% O1 is on and O2 is off, and at -100% O2 is on and O1 is off. The alarm outputs are up-scale drive (+9999) with an open sensor, and down-scale drive (-9999) with a shorted sensor (RTD only), independent of this setting. Manual Control overrides OPFL.

Output Power Dampening Filtering Time (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

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 (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 control outputs. Alarms have a separate hysteresis setting. See ON/OFF

Control, page 48, for more details.

CHYS - 1 to 250

The hysteresis band should be set to a minimum value to eliminate output chatter at the setpoint. Generally, 2 to 5 is sufficient for this purpose. Set the hysteresis band to factory setting prior to invoking Auto-Tune. After

Auto-Tune, the hysteresis band has no effect on PID Control.

Auto-Tune Code (tcod)

Prior to invoking Auto-Tune, the Auto-Tune 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 restarted. When set to 0, this yields the fastest process response with possible overshoot. A setting of 2 yields the slowest response with the least amount of overshoot.

Dampening codes of 0 or 1 are recommended for most thermal processes.

Figure 16, Auto-Tune Code

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Main Linear DC Output Range (ANtP) (Optional)

Select the type of output range:

0-10 = 0 to 10 V

0-20 = 0 to 20 mA

4-20 = 4 to 20 mA

The linear DC output range jumper must be set to match the range selected.

See Linear DC Output Jumper Selection, page 12. The linear DC output can be re-calibrated to provide up to 5% of over range operation. See Main or

Second Linear DC Analog Output Calibration, page 71.

Main Linear DC Output Source (ANAS) (Optional)

The output can be programmed to transmit one of the below variables:

OP - Output Power % control

INP - Temperature retransmission

SP - Setpoint (local or remote) retransmission

For Linear DC Output control, the main output (O1) can be disabled by setting the Cycle Time (CYCt) to 0 in Output Parameter 2-OP or configuring it as an alarm in Alarm 1 Action (ACt1) in Alarm Parameter 4-AL. For heat/cool with 4 to 20 mA control applications, the heat (0 to 100%) will be 12 to 20 mA and the cool (-100 to 0%) will be 4 to 12 mA. Notice that 0% (no heat or cool) is 12 mA.

Main Linear DC Update Time (ANUt) (Optional)

To reduce excess valve actuator, or pen recorder activity, the update time of the linear output can be set over the range of 0.1 to 250 seconds. A value of

0 seconds results in an update time of 0.1 second.

Main Linear DC Output Scaling Points (ANLO, ANHl) (Optional)

The output is scaled based on the Output Source (ANAS) display by use of low and high scaling parameters. Reverse acting output is possible by reversing the scaling points.

ANLO

ANHI

– Display value that corresponds to 0 V, 0 mA, or 4 mA as selected.

– Display value that corresponds to 10 V or 20 mA as selected.

Lockouts Parameter Module (3-LC)

The controller can be programmed to limit operator access to various parameters, control modes, and display contents. The configuration of the lockouts is grouped into three sections: Lower Display Lockouts, Protected

Mode Lockouts and Hidden Mode Lockouts.

Lower Display Lockouts (SP, OP, dEv, Hcur, UdSP and bdSP)

The contents of the secondary display can be changed in the Normal

Display Mode by successively pressing the D button. This action scrolls through the possible display parameters, when enabled. If all parameters are set to lock “LOC”, press D to blank the display.

The parameters can be set for one of the following:

LOC (Lockout) – Prevents the parameter from appearing in the secondary display.

rEd (Read only) – Parameter appears, but cannot be modified.

Ent (Entry) – Parameter appears and can be modified.

The lower display content possibilities are:

SP – Setpoint Value

OP dEv

UdSP bdSP

Hcur

– % Output Power

– Setpoint Deviation

*

– Temperature Units (T48)

– Blank Display (P48)

– Heater Current Readout*

* Models equipped with Heater Current Option replace “DEv” (Deviation) readout with “Hcur” (Heater current readout).

Note: If a parameter is active in the lower display and is then subsequently locked out, press “D” once in the Normal Display Mode to remove it from the display.

Protected Mode Lockouts (CodE, PId, and 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) – Prevents the parameter from appearing in the protected mode.

rEd (Read only) – Parameter appears, but cannot be modified.

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Ent (Entry) – 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

17, for a description of the various program access levels.

CodE

PId

AL

– 0 to 250

– Permits access to the main PID parameters.

– Permits access to the alarm value(s).

Hidden Mode Lockouts (ALrS, SPSL, trnF, and tUNE )

The hidden mode is accessible from the Normal Display Mode by pressing and holding the P button for three seconds. The parameters can be set for:

LOC (Lockout) – Prevents the parameter from appearing in the hidden mode.

ENbL (Enable) – Allows operator to perform the selected hidden mode function.

The functions available in the hidden mode are accessible independent of the status of program disable.

ALrS

SPSL trnF tUNE

– Reset (override) the alarm output(s).

– SP1/SP2/Remote setpoint selection.

**

– Select Automatic or Manual operation.

– Invoke or cancel Auto-Tune.

** Model Number Dependent.

Alarm Parameter Module (4-AL) (Optional)

The controller may be equipped with one or two optional alarms. On some models alarm output #1 is the same output as main control O1. In this case, the output is either programmed for the main output control function (O1) or as an alarm function (A1). This is set by alarm #1 action parameter (Act1).

If heat is selected, the remaining Alarm 1 parameters do not appear.

To enable the cooling output of the controller, select CooL for Alarm 2 action (Act2). The controller then utilizes the alarm 2 output as the cooling output (O2). Front panel annunciator A2 illuminates whenever the cooling output is on. See Cooling Output Module (5-O2), page 43, for configuration of the cooling output.

If cooling is selected, the remaining Alarm 2 parameters do not appear.

Alarm Action (Act1, Act2)

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”.

Caution: In applications where equipment or material damage, or risk to personnel due to controller malfunction could occur, an independent and redundant temperature limit indicator with alarm outputs is strongly recommended. The indicators should have input sensors and AC power feeds independent from the other equipment.

The configuration options of the alarm output are model dependent.

(Act1) - Alarm #1

A-HI

A-LO d-HI d-LO b-In b-Ot

Heat *

Hcur *

(Act2) Alarm #2

Absolute High Acting A-HI

Absolute Low Acting A-LO

Deviation High Acting d-HI

Deviation Low Acting d-LO

Band Inside Acting

Assigns output 01/A1 as control output

Assigns A1 as heater break alarm (T48) b-In

Band Outside Acting b-Ot

CooL *

Hcur *

Absolute High Acting

Absolute Low Acting

Deviation High Acting

Deviation Low Acting

Band Inside Acting

Band Outside Acting

Assigns 02/A2 as cooling or second output

Assigns A2 as heater break alarm (T48)

* Model Number Dependent.

Note: Deviation and band type alarms track both local and remote setpoint.

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Heater Break Alarm

T48 models equipped with the Heater Current Monitor provide an alarm output in the event of a heater or a heater control circuit failure. The alarm is dual mode and activates under either of the following two conditions:

1. Main control output (O1) is on for a minimum of 600 msec and the feedback heater current is below the alarm value.

2. Main control output (O1) is off for a minimum of 600 msec and the feedback heater current is above 10% +0.5 amp of the alarm value.

For heater ground faults, the heater power circuit fuse opens. The heater break alarm activates per condition one above. This alarm is only useful for controller output cycle times (CYCt) of 10 seconds or more, due to the minimum on and off times of alarm detection.

The heater break alarm value is usually set in the range of 50% to 80% of the nominal heater current. This usually provides sufficient margin against false alarms that may occur from line voltage drops and normal heater aging.

Set the alarm value after observing the actual heater current readout.

If the alarm is set for latching operation, the controller delays alarm action an additional 1 second (both on and off alarm detection). This suppresses false alarm outputs in the event of a brief power glitch in the heater circuit. A latched heater break alarm requires manual reset. If the alarm is set for auto reset

(non-latching), once past the 600 msec minimum dwell time the alarm triggers and releases immediately after the condition that caused the alarm clears.

Alarm Action Figures

The alarm action figures describe the status of the alarm output and the front panel indicator for various over/under temperature conditions. 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”.

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Alarm Reset (rSt1, rSt2)

Each alarm reset action may be independently configured.

LAtC - Latched

Auto - Automatic

Latched alarms require operator action to reset the alarm condition. The front panel buttons can be used to reset an alarm when the controller is in the

Hidden Function Mode (See page 20). An alarm condition may also be reset via the user input.

Automatic reset alarms are reset by the controller when the alarm condition clears. Figure 17, Alarm Reset Sequence, depicts the reset actions.

Figure 17, Alarm Reset Sequence

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 temperature 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. This feature also works for deviation and band alarms when the setpoint is changed via keypad. This action suppresses

“nuisance” alarms. Figure 18, Alarm Standby Delay Sequence, depicts a typical operation sequence.

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Figure 18, 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 temperature 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.

Alarm Hysteresis (AHYS)

The alarm value(s) have a programmable hysteresis band to prevent alarm output chatter near the alarm trigger point. 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 40, for the effect of hysteresis on the various alarm types.

AHYS - 1 to 250

Cooling Parameters Module (5-02) (Optional)

The cooling output (O2) is software selectable with dual alarm models (For the P48, this is referred to as the Second Control Output). This output operates as an independent cooling output for systems that use heating and cooling. To enter the Cooling Output Module, the cooling output of the controller must first be selected in Alarm Module (4-AL). When cooling is selected, alarm 2 is used for the cooling output.

The front panel indicator A2 illuminates when the cooling output (O2) is on. Cooling output power is defined as ranging from -100% (full cooling) to

0% (no cooling, unless a heat-cool band overlap is used). See Output Power

Limits in Module 2 for maximum and minimum settings. The same PID values control both heat and cool.

Cooling Output Cycle Time (CYC2)

A value of 0 turns off the cooling output, independent of cooling power demand.

CYC2 - 0 to 250 seconds

Cooling Relative Gain (GAn2)

This parameter defines the gain of the cooling band relative to the heating band. A value of 0.0 places the cooling output into ON/OFF Control mode with the ON/OFF Control Hysteresis (CHYS) in Output Parameter Module

(2-OP) becoming the cooling 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 cooling to that of heating for best control. Figures 19, 20, & 21, Heat/Cool Operation, illustrate the effect of different gains.

GAN2 - 0.0 to 10.0

Heat and Cool Overlap/Deadband (db-2)

This parameter defines the area in which both heating and cooling are active (negative value) or the deadband area between the bands (positive value). The parameter units are degrees or tenth’s of degrees (depending on system resolution). If a heat/cool overlap is specified, the displayed percent output power is the sum of the heat power (O1) and the cool power (O2).

db-2 - -999 to 9999

When the Cooling Relative Gain is set to zero for ON/OFF Control mode, this parameter should only be set to a positive value or zero. The Heat/Cool

Operation Figures illustrate the effects of different deadbands.

Figure 19, Heat/Cool Operation (db=0)

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Figure 20, Heat/Cool Operation (db>0)

When using the cooling output, observe the controlled temperature characteristics. If the temperature remains above setpoint with a sluggish return, increase the cooling gain. Similarly, if the temperature drops too

sharply with an overall saw-tooth pattern, decrease the cooling gain. Alter the heat-cool overlap until a smooth response in the controlled temperature is observed during band transition.

Figure 21, Heat/Cool Operation (db<0)

Serial Communications Module (6-SC) (Optional)

Unless controller serial configurations match those of the host communicating device, front panel serial parameter changing is needed for communication. Baud rate and character frame must be the same as the other communicating device. The controller address is the unique node address for multiple controllers applications. (See Serial Communications Interface, page 58, for further explanations.)

Baud Rate (bAUd)

The available baud rates are:

300, 600, 1200, 2400, 4800, or 9600

Character Frame Format (ConF)

The character frame can be 7O1, 7E1, 7n2, or 8n1..

Controller Address Number (Addr)

Multiple controllers 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 controller. The address numbers range from 0 to 99.

Abbreviated or Full Transmission (Abrv)

When transmitting data, the controller 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

Print Options (PoPt)

Selecting YES for the print options allows the operator to scroll through the available options using the P button. The up and down arrow keys toggle between “yes” and “no”. “yes” enables the option to be printed when a print function occurs.

INP - Print Input Process Value

SEt - Print Setpoint Value

OPr - Print % Output Power Value

Pbd - Print % Proportional Band Value

INt - Print Integral Time Value dEr - Print Derivative Time Value

AL1 - Print Alarm 1 Value

AL2 - Print Alarm 2 Value dEv - Print Deviation From Setpoint Value

OFP - Print % Output Power Offset Value r_P - Print Ramp Rate

Crg - Print Relative Gain Value

Cdb - Print Deadband Value

OSt - Print Output Status rSP - Print Remote Setpoint Reading

HCr - Print Heater Current Reading

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Remote Setpoint Parameters Module (7-n2 or 7-rS) (Optional)

Configuration of the Remote Setpoint involves scaling the input to the desired setpoint range, selecting filter characteristics, and setting remote/local setpoint transfer response.

Remote Setpoint Display Values (dSP1 and dSP2)

Key-in the display value for Scaling Point 1 and Scaling Point 2.

dSP1 -999 to 9999 (Ex. 0) dSP2 -999 to 9999 (Ex. 500)

Remote Setpoint Signal Input Values (INP1 and 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.

Initially, the unit is in the key-in method.

Key-in Method

Key-in the display value for Scaling Point 1 and Scaling Point 2.

INP1 0.00 to 20.00 (Ex. 4.00 mA DC)

INP2 0.00 to 20.00 (Ex. 20.00 mA DC)

Signal Input Method

To change to the apply signal input method, press the D button while InP1 or InP2 is displayed. Front panel annunciators %P and DV flash and the display indicates the signal value applied to the input terminals. The controller can be toggled to the key-in method by pressing the D button again.

In this case, the previously accepted value is recalled.

When the desired value is indicated on the display, press the P button to store the value and advance to the next parameter.

Remote Setpoint Filtering (Fltr and bANd)

The remote setpoint signals can be filtered with a time constraint from 1 to

25 seconds; or the filter can be disabled. The filter is an adaptive, first-order, low pass type. As long as the difference between the current reading and the previous reading is less than the filter band value (band), the filter remains in effect. When the difference exceeds the filter band, the filter disengages until the difference is less than the filter band value. This action allows quick filter response to large setpoint changes, while retaining filtering action under normal process conditions.

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Normally the filter band value is set slightly larger than the noise level of the remote input. The time constant of the filter is set consistent with the amount of filtering desired. Increased filter time constant values are effective for smoothing remote setpoint readings. This may be beneficial for cascade operation and other “live” signal applications.

Alternatively, the remote setpoint can be ramped at a controlled velocity to limit controller response to large setpoint changes.

Remote/Local Setpoint Transfer Options (trnF)

When switching between Local or Remote Setpoint, the response of the controller can be programmed in a variety of ways.

These responses apply to changes in setpoint mode from the controller’s front panel and User Input. The table summarizes the responses for Setpoint transfer operations:

SPtr Parameter nor

Auto

Local to Remote

– Output may bump.

– No output bump. Process error eliminated at rate of integral action

Remote to Local

Output may bump

No output bump. Process error eliminated at rate of integral action trAC – Output may bump.

Note: In situations where an output bump may occur, the setpoint ramp function

(SPrP) can be used to reduce or eliminate bumping when switching between setpoints.

Local setpoint assumes value of Remote setpoint

(tracks). No Output bump.

Heater Current Monitor Module (7-N2 or 7-HC) (Optional)

Enter the full scale rating of the current transformers used with the T48 controllers. This scales the Heater Current Monitor of the controller to indicate directly in amperes of heater current.

Hcur - 0.0 to 999.9 amperes

Alternatively, the Heater Current Monitor may be scaled to indicate in percent of nominal heater current (0.0 to 100.0%). This may be useful in applications employing several controllers, each with nominal heater current readings that are different from each other. In this case, each controller can be scaled to indicate the same reading (100.0%), independent of each controller’s actual heater current. For example, if using a 50 ampere current transformer and the actual maximum heater current is 38 amperes, the Heater

Current Monitor scaling value is:

Hcur =

50.0 Amperes

Amperes

x

100.0% = 131.6

This scaling value results in a Heater Current Monitor indication of

100.0% at an actual heater current of 38 amperes.

See Alarm Action, page 39, to program a heater break alarm.

Second Linear DC Analog Output Module (8-A2) (Optional)

The Second Linear DC Analog Output provides retransmission of the conditioned and scaled input signal independent of the Main Linear DC Output.

Second Linear DC Output Range (A2tP)

Select the type of output range:

0-10 = 0 to 10 V

0-20 = 0 to 20 mA

0-40 = 4 to 20 mA

The linear DC output range jumper must be set to match the range selected.

See Linear DC Output Jumper Selection, page 12. The linear DC output can be re-calibrated to provide up to 5% of over range operation. See Linear DC

Output Calibration, page 71, for more details.

Second Linear DC Output Scaling Points (A2LO, A2Hl)

The output can be scaled based on the controller’s input display by use of low and high scaling parameters. Reverse acting output is possible by reversing the scaling points.

Factory Service Operations Module (9-FS)

The Factory Service Operations include: controller calibration, and reset programming to factory configuration setting. Access to each operation is protected by an access code number. Entering code 66 restores all parameters to factory settings, the unit indicates the operation after the P button is pressed, by displaying “rSEt” in the lower display momentarily.

Caution: Entering code 77, twice in succession, erases the controller calibration values and defaults the values to nominal settings. Reading errors of ±10% may result. Do not perform this operation unless the controller has lost calibration. Loss of calibration is signaled by an “E-CL” error flag at power-up. To clear this flag, perform calibration procedure as noted in

Factory Service Operations - Calibration (9-FS), page 70. Alternatively,

“stepping” through one of the calibration procedures clears the error flag, but does NOT validate the calibration accuracy in any manner.

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MANUAL CONTROL

The controller can be transferred between Automatic Control (closed loop;

On/Off or PID control) and Manual Control (open loop; where the control does not work from the setpoint or process feedback.)

Manual operation provides percentage of control of the main output (per the direct or reverse action configured in Output Parameter 2-OP OPAC) from 0 to +100% power. When A2 is configured for cooling (O2), Manual operation still provides 0 to 100% power to the main (O1) output and provides percentage of control to cooling (O2) output from -100% to 0% power.

(Negative percent power is positive cooling (O2) percent power.)

To allow front panel switching between control modes, the Transfer

Parameter (trnF) must be enabled (Enbl) in Lockout Module (3-LC). The user can then select Manual Control from the Hidden Function Mode using

Transfer Parameter (trnF). The percent output power is then adjusted with the

Up and Down arrow buttons in the Normal Display Mode with the %P and

MN annunciators illuminated.

In Time Proportional output control (relay, logic, or triac) the percent output power is converted into output on time using Time Proportioning

Cycle Time (CYCt) value in Output Parameter Module (2-OP). For example with 4 cycle time and 75% power, the output will be on (4 x.75) for 3 seconds and off for 1 second.

In Linear DC output control (0-10 VDC or 0/4-20 mA), the percent output power is converted into a linear value per the Linear output low scaling value

(AnLO) and Linear output high scaling value (AnHI) in Output Parameter

Module (2-OP). For example with 0 VDC (scaled 0.0%) to 10 VDC (scaled

100%) and 75% power, the linear DC output will be 7.5 VDC.

When transferring the controller mode from or to Automatic Control, the controlling outputs remain constant, exercising true “bumpless” transfer.

When transferring from Manual to Automatic, the power initially remains steady but integral actions corrects (if necessary) the closed loop power demand at a rate proportional to the Integral Time. The low (OPLO) and high

(OPHI) output power limits in Output Parameter (2-OP) are ignored when the controller is in Manual Control.

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ON/OFF CONTROL

Single Output

The controller operates in

ON/OFF Control when the

Proportional Band is set to 0.0%. In this control, the process will constantly oscillate about the setpoint value. The amount of

ON/OFF Control Hysteresis

(CHYS) in Output Parameter

Module (2-OP), together with the process characteristics determines the period and amplitude of the oscillations. Larger values of hysteresis increase both the amplitude and period of oscillations but also reduce the number of output switching cycles.

The Control Action (OPAC) in

Output Parameter Module (2-OP) can be set to reverse (rEv) for heating (output on when below the setpoint) or direct (drct) for cooling

(output on when above the setpoint) applications.

In controllers with operating system software revision earlier than V4.x, the ON/OFF Control

Hysteresis value is not balanced around the setpoint value. In these controllers, the Hysteresis is totally added to the setpoint in reverse action and totally subtracted from the setpoint in direct action. The revision number of the controller’s operating system software is shown in the secondary (bottom) display during controller power up.

Figure 22, Output 1 (O1) ON/OFF Control

Software Revision V4.0 or Later

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Figure 23, Output 1 (O1) ON/OFF Control

Software Revision V3.x or Earlier

Dual Output

For heat and cool systems, the heat (O1) and cool (O2) outputs can be used together in the ON/OFF control. For this operation, set the Cooling Relative

Gain (GAN2) in Cooling Parameter Module (5-02) to 0.0. This places O2 into

ON/OFF Control. In this mode, the ON/OFF Control Hysteresis (CHYS) in

Output Parameter Module (2-OP) applies to both O1 and O2. The Heat/Cool

Deadband (db-2) in Cooling Parameter Module (5-02) sets the amount of operational deadband or overlap between the outputs.

For these applications, the Control Action (OPAC) in Output Parameter

Module (2-OP) is normally set to reverse (rEv). This sets O1 into reverse

(heat) with O2 always in direct (cool). Cooling output for the P48 is referred to as the second control output.

In controllers with operating system software revision lower than 4.0, the

ON/OFF Control Hysteresis value is not balanced. In these controllers, the

Hysteresis is totally added or subtracted from the setpoint. The revision number of the controller’s operating system software is shown in the secondary (bottom) display during controller power up.

Figure 24, O1/O2 ON/OFF Control

Software Revision V4.0 or Later

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Figure 25, O1/O2 ON/OFF Control

Software Revisions V3.x or Earlier

Figure 26, O1/O2 ON/OFF Control

Software Revision V4.0 or Later

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Figure 27, O1/O2 ON/OFF Control

Software Revisions V3.x or Earlier

AUTO-TUNE FOR PID CONTROL

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.

Auto-Tune Code. A code setting of zero gives the fastest response with possible overshoot, and a code of two gives the slowest response with minimum overshoot.

Figure 28, Auto-Tune Code

Note: If the induced oscillations caused by Auto-Tune can cause system problems or are otherwise unacceptable, the 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 code (tcod) must be set in the Output Parameters section.

Auto-Tune requires the hysteresis setting to be above the process noise floor; generally, 2 - 5 degrees or 1-2% of range is adequate. For most applications, the control hysteresis should be set at 2 (factory setting). The Auto-Tune code may be set to yield the response characteristics shown in Figure 28,

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Figure 29, Auto-Tune Operation

The following controller parameters are automatically adjusted 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)

As shown in Auto-Tune Operation, Figure 29, Auto-Tune Operation cycles the process at a control point 3/4 of the distance between the current process value (at the instant Auto-Tune is started) and the setpoint. The 3/4 control

point was selected to reduce the chance of overshoot at setpoint when

Auto-Tuning at start-up. If Auto-Tuning from setpoint and 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.

Initiate Auto-Tune

Auto-Tune may be initiated at start-up, from setpoint, or at any other process point.

To Initiate Auto-Tune:

1. Make sure that Auto-Tuning is enabled in Lockouts Parameter Module

(3-LC).

2. Place the controller into the Normal Display Mode.

3. Press P for 3 seconds from Normal Display Mode.

4. Scroll to “tUNE” by use of P, if necessary.

5. Select “YES” and press P.

Auto-Tune is initiated.

To Cancel Auto-Tune: (Old PID settings remain in effect).

A) Make sure that Auto-Tuning is enabled in parameter lockouts module.

1. Place the controller into the normal display mode.

2. Press P for 3 seconds from normal display mode.

3. Scroll to “tUNE” by use of P, if necessary.

4. Select “NO” and press P.

5. Auto-Tune canceled.

B) Or reset the controller by disconnecting power.

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Auto-Tune Of Heat/Cool Systems

During Auto-Tune of heat/cool systems, the controller switches the cooling output (O2) on and off in addition to the heat output (O1). The heat/cool overlap deadband parameter (db-2) determines the amount of overlap or deadband between the two outputs during Auto-Tune. For most applications, set this parameter to 0.0 prior to starting Auto-Tune. 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 Cooling Relative Gain parameter (GAN2) for heat/cool systems.

Some water cooled processes exhibit an extreme non-linear gain characteristic. That is, the process cooling gain starts very high and flattens out deeper into the cooling region. This effect may result in regular oscillations at setpoint as the controller applies heat to counteract the effect. These processes may benefit from a lower cooling fan setting and/or reduced water flow in the jacket or manifold. The process heat and cool gains should be balanced as much as possible, and the controller gains adjusted to the process.

Auto-Tune Of Cascade Control

The following procedure may be used to tune cascaded controllers:

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 (5% 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 from the Local

Setpoint when in Local Setpoint mode.

PID CONTROL EXPLANATIONS

Proportional Band

Proportional band is defined as the “band” (range) 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 input sensor range.

For T48, the ranges are fixed for the thermocouple and RTD types.

For P48, the range is set by the difference between “dSP2 and dSP1”.

Figure 30, Proportional Band

Example: Thermocouple type T with a temperature range of 600°C is used and is indicated in degrees Celsius with a proportional band of 5%. This yields a band of 600°C X 5% = 30°C.

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 48, for more information).

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Integral Time

Integral time is defined as the time, in seconds, in which the output due to integral action alone equals the output due to proportional action with a constant process error. As long as a constant error exists, integral action repeats the proportional action each 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 the 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 31, Integral Time

Derivative Time

Derivative time is defined as the time, in seconds, in which the output due to proportional action alone equals the output due to derivative action with a ramping process error. As long as 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.

Output Power Offset (Manual Reset)

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 32, Derivative Time

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Figure 33, Typical Response Curve

PID Adjustments (Cont’d)

Figure 34, Process Response Extremes

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MANUAL TUNING FOR PID CONTROL

In some unusual cases, the Auto-Tune function may not yield acceptable control results. In this case, the controller can be manually tuned to optimize the PID setting according to the process and the desired control requirements.

Manual Tuning Procedure

A chart recorder or data logging device is necessary to measure the time between process cycles.

1. Set the Proportional Band (ProP) from the Unprotected Parameter Mode to

10.0% for T48 models and 100.0% for P48 models.

2. Set the Integral Time (Intt) and Derivative Time (dErt) to 0 seconds.

3. Set Output Power Dampening Time (OPdP) in Output Parameter Module

(2-OP) to 0 seconds.

4. Set Output Cycle Time (CYCt) in Output Parameter Module (2-OP) to no higher than 1/10 of the process time constant (when applicable).

5. Place controller in Manual Control and set % Power from the Normal

Display Mode to drive the process value to the desired value. Make certain that the controller can drive the process to the setpoint. Allow the process to stabilize after setting the % Power.

6. Place controller into Automatic Control. If the process will not stabilize and starts to oscillate, set the Proportional Band 2x higher and go back to step 5.

7. If the process is stable, decrease Proportional Band setting by 2x and change the setpoint value a small amount to excite the process. Continue with this step until the process oscillates in a continuous nature.

8. Fix the Proportional Band to 3x the setting that just caused the oscillations.

9. Set the Integral Time to 2x the period of the oscillations.

10. Set the Derivative Time to 1/8 (0.125) the Integral Time.

11. Set Output Power Dampening Time to 1/40 (0.025) the period of the oscillation.

Note: This procedure is an alternate to the controller’s Auto-tune function. It will not provide acceptable results if system problems exist.

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REMOTE SETPOINT OPTION

A remote 0/4 to 20 mA analog input signal can be used to change the setpoint value. This input can be scaled over a process range independent of that of the system range. In operation, the front panel “MN” indicator illuminates for local setpoint operation and is off for remote setpoint operation. In either mode, the indicator flashes during Manual Mode.

Filtering, ramp rate (velocity limiting), and local/remote transfer response options can be configured to suit the application. Local/Remote transfer operations are performed either externally (user input) or at the keypad.

If large changes in the remote setpoint signal result in undesirable controller performance, the remote setpoint can be velocity limited (ramped) by the setpoint ramp parameter (SPrP).

Similarly, if fluctuation in the remote setpoint signal also results in poor performance, the programmable filter can be used to provide a steady setpoint to the controller. A unique feature of the filter is the filter band. Fluctuations that occur that are less than the filter band value keep the filter engaged, while fluctuations outside the filter band disable the filter. This action allows the controller to respond rapidly to large changes of the remote setpoint signal.

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 output.

The secondary controller has a Remote Setpoint option in order to receive the directed setpoint. See Figure 35, Cascade Control, for more details.

Note: 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. Normally, the secondary controller is a faster control loop.

It is able to respond quickly to disturbances before they affect the primary loop. Therefore, the control quality of the primary loop under cascade control is superior to that of a single loop controller.

Figure 35, Cascade Control

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SERIAL COMMUNICATIONS INTERFACE

RS-485 Serial Communications

The optional RS-485 serial communication interface provides two-way communication between the controller and other compatible equipment such as a printer, PLC, HMI, or a host computer. In multipoint applications, each controller can be configured with a unique node address ranging from 0-99.

Through this serial interface, data from the controller can be interrogated or changed, alarm output(s) reset and Auto-tune invoked.

Since the same pair of wires are used for both transmit and receive, only one-way communication is possible at a time. The controller has a variable response time, to allow the host device adequate time to release the communication line after issuing a command to the controller.

Configuration Software

The Serial communications option is necessary to work with Red Lion

Control’s Windows based SFCRM software. This software allows for easy controller parameter configuration by computer. These settings can be saved to a disk file for later use or used for multi-controller down loading. On-line help is provided within the software.

Controller Configuration

The controller’s serial communication format is configured in Serial

Communication Program Module 6-SC using the front panel. Baud rate and character frame must be matched to the other communicating device. The node address parameter is a unique address number assigned to each slave unit on the bus.

Sending Commands And Data

When sending commands to the controller, a command string of ASCII characters must be constructed. The string varies in length depending on the nature of the command. At most, a command string consists of a Controller

(Node) Address number (not required for address of 0), a Command Code character, a Register Identification character (for most commands),

Numerical Data (if writing data to the controller) and ending with a string

Terminator of “*” or “$”. The controller will not respond with an error message to invalid commands.

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Sending Numeric Data

Data written to individual registers must be limited to the registers numerical data range (See Register Identification Table). If more digits are sent, the controller only accepts the last four digits of the numeric data.

Negative numbers must have a minus sign. The controller ignores any decimal point and conforms the number to the register identification resolution. (Example: “25” is written to the proportional band register. The value recorded by the register is now 2.5. If a value of 25% is intended, write a value of 25.0 or 250.

Controller (Node) Address

Code Description

N Controller Node

Address Specifier

Comments

Target a specific controller with the next

Command. Must be followed by a one or two digit (0-99) controller node address number. Not required for a node address of 0.

Commands Table

Code

T

V

Description

Read Value

(Transmit)

Write Value

(Change)

R Reset Alarm

C Control Action

P Print Block

Request

Comments

Read value register command. Must be followed by Register ID character A-M, BB, HC, or W.

Write value register command. Must be followed by Register ID character B-H or J-M and appropriate Numeric Data.

Write alarm register command. Must be followed by Register ID character G or H.

Write control register command. Must be followed by Register ID character S-U with

Numeric Data of 1 or 2.

Read block register command. Allows multiple reads with one command.

Register Identification Table

Register

ID

A

Register

(Parameter)

Input

B

C

F

G

D

E

H

J

I

K

L

M

BB

HC

S

T

U

W

Setpoint

Alarm 2

Deviation

T

Applicable

Command

T, V

Output power

T, V (manual mode only)

Proportional T, V

Integral T, V

Derivative

Alarm 1

T, V

T, V, R

T, V, R

T

Power Offset T, V (auto mode only)

Setpoint

Ramp

T, V

Cooling Gain T, V

Cooling

Offset

T, V

T Remote

Setpoint

Heater

Current

T

Auto /

Manual

Auto-tune

C

C

Local /

Remote

Output

Status

C

T

Abbreviation

(Mnemonic)

T48: TMP

P48: INP

SET

PWR

Numeric Data

Range

Engineering

Units

-999 to 9999 T48: F or C

P48: Blank

-999 to 9999 T48: F or C

P48: Blank

-99.9 to 100.0 %

PBD

INT

DER

AL1

AL2

DEV

OFP

RMP

CRG

CDB

—-

—-

—-

OST

0.0 to 999.9

0 to 9999

0 to 9999

%

S

S

-999 to 9999 T48: F or C

P48: Blank

-999 to 9999 T48: F or C

P48: Blank

-999 to 9999 T48: F or C

P48: Blank

-99.9 to 999.9 T48: F or C

P48: Blank

0 to 9999 R

0.0 to 10.0

G

-999 to 9999 T48: F or C

P48: Blank

RSP -999 to 9999 T48: F or C

P48: Blank

HCF or HCN 0.0 to 999.9

A

1 (Auto),

2 (Manual)

1 (Start),

2 (Stop)

Blank

Blank

1 (Local),

2 (Remote)

Blank

0000 to 1111 Blank

Terminator Table

Character

*

$

Description

Command Terminator

Command Terminator

Comments

Slow response (100 to 200 msec) setpoint saved to E

2

PROM

Fast response (2 to 100 msec) setpoint not saved to E PROM

Examples of Command Strings:

Example: Write 10.0 to Setpoint register with a controller address of 2.

Command String: N2VB100*

Explanation: Address = 2, Command =V, Register ID = B, Numeric Data =

100, Terminator = * (with $ setpoint will not be saved to E

2

PROM)

Example: Read input register of controller with an address of 3.

Command String: N3TA*

Explanation: Address = 3, Command =T, Register ID = A, Terminator = *

Example: Reset Alarm Output 1 of controller with an address of 0.

Command String: RG*

Explanation: Address = not used for address 0, Command =R, Register ID

= G, Terminator = *

Example: Write to Auto-Tune control register (start Auto-Tune) on controller with an address of 5.

Command String: N05CT1$

Explanation: Address = 5, Command = C, Register ID = T, Numeric Data =

1 (start), Terminator = $

Command Code Explanations

Controller (Node) Address: N

When more than one controller is on the serial communication bus, a unique controller (node) address must be assigned to each unit. The address range extends from 0 to 99. This is defined in the controller configurations.

To communicate with a specific controller, the address code N followed by the controller’s address value must start a command string. A controller with an address of 0 does not require the node address command. Controllers with an address greater than 0 will respond to transmit commands by sending their address followed by the requested data.

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Read Register Command Code: T

The Read Register command is used to read data from a register. This command must be followed by a Register ID character. In full response mode, the controller responds to this command by transmitting its Address (if greater than 0), corresponding register mnemonic and register data. In abbreviated response mode, the controller transmits data only. The response time to this command is controlled by the type of termination character. This is a single register response.

Write Register Command Code: V

The Write Register command is used to write data to a register. This command must be followed by a Register ID character and Numeric Data. A unique command line is required for each register write operation. No response occurs for invalid write operations. The Read Register command

(T) can be used for readback verification.

Reset Alarm Command Code: R

The Reset Alarm command resets the alarm outputs. This command must be followed by a Register ID character (G for Alarm 1, and H for Alarm 2).

This command does not alter the actual alarm mode or value setting.

Control Action Command Code: C

The Control Action command is used to affect certain controller operating modes.The registers used with this command are: Auto/Manual mode select,

Auto-Tune mode select, and Remote Setpoint mode select. After the Register

ID character, either a “1” or “2” is sent to set a specific controller mode.

Block Read Register Command Code: P

The Block Read Register command is used to read data from multiple registers with a single command. With this command, if no register ID characters follow, the controller responds with register data that is preset by the Print Options parameter (Module 6-SC). This mode is useful for print ticket applications. However, if Register ID characters follow this command, the controller responds with register data indicated by the ID character field.

This character ID field does not follow the normal Register ID format, but instead is a field composed of ASCII encoded bit mapped bytes. (See Block

Read Command Register ID Table.)

-60-

Four of these field bytes are used in this format:

P<Byte1><Byte2><Byte3><Byte4>

Each byte represents a code that selects a register(s) for transmission. The

Block Read Command Byte Table relates specific registers for reads to the field bytes.

Examples:

Print: Alarm 1 and Alarm 2 values (both are in Byte2 table)

Explanation: Byte1 = 0, Byte2 = 3, Byte3 & Byte4 are not needed

ASCII String : P03* (Either the “*” or “$” terminator could be used.)

For those programming in HEX: P = <50>, 0 = <30>, * = <2A>, $ = <24>

HEX String : <50><30><33><2A>

Print: Input, Cooling Deadband and Output Status (Input is in Byte1 table and the other two are in Byte4 table)

Explanation: Byte1 = 8, Byte2 = 0, Byte3 = 0, Byte4 = C

ASCII String : P800C$ (Either the “*” or “$” terminator could be used.)

HEX String : <50><38><30><30><43><24>

Terminator : * or $

After a Read Register command is sent, the response time of the controller is determined by the type of command terminator character. The “$” terminator causes a response time of 2 msec to 100 msec and the “*” terminator causes a response time of 100 msec to 200 msec. (The 2 msec delay allows for a two character transmission time at 9600 baud. ) The controller does not begin processing the command string until the “$” or “*” is received.

The Carriage Return <CR> and the Line Feed <LF> cause the controller to ignore the command string. When writing setpoint values, only values using the “*” terminator are saved to E

2

PROM memory.

Block Read Command Byte Table

Locate the desired register combination for each Byte.

X=register to be printed. Use ASCII 0 for blank trailing byte locations.

For those programming in HEX: P = <50>, 0 = <30>, * = <2A>, $ = <24>

Byte1

Input Setpoint

Output

Power

P Band ASCII HEX

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

D

E

F

9

A

B

C

7

8

5

6

3

4

1

2

<39>

<41>

<42>

<43>

<44>

<45>

<46>

<31>

<32>

<33>

<34>

<35>

<36>

<37>

<38>

Byte2

Integral

Time

Derivative

Time

Alarm 1 Alarm 2

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

ASCII

D

E

F

9

A

B

C

7

8

5

6

3

4

1

2

HEX

<39>

<41>

<42>

<43>

<44>

<45>

<46>

<31>

<32>

<33>

<34>

<35>

<36>

<37>

<38>

-61-

Byte3

Deviation

Offset

Power

X

X

X

X

X

X

X

X

Byte4

Cooling

Deadband

X

X

X

X

X

X

X

X

Output

Status

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Setpoint

Ramp

X

X

X

X

X

X

X

X

Cooling

Gain

X

X

X

X

X

X

X

X

Remote

Setpoint

X

X

X

X

X

X

X

X

X

X

X

X

Heater

Current

X

X

X

X

ASCII

D

E

F

9

A

B

C

7

8

5

6

3

4

1

2

ASCII

D

E

F

9

A

B

C

7

8

5

6

3

4

1

2

HEX

<39>

<41>

<42>

<43>

<44>

<45>

<46>

<31>

<32>

<33>

<34>

<35>

<36>

<37>

<38>

HEX

<39>

<41>

<42>

<43>

<44>

<45>

<46>

<31>

<32>

<33>

<34>

<35>

<36>

<37>

<38>

Unique Register Explanations

Setpoint Ramp Using Automatic Setpoint Ramping Register: K

The controller’s Setpoint Ramp parameter provides a controlled ramp when the setpoint value is changed. (The Setpoint Ramp value can be changed by using VK command.) When the setpoint value is changed, the controller begins to ramp from the existing value to the new target setpoint, at a rate set by this register. A value of zero in the Setpoint Ramp register disables ramping.

During the controlled ramp phase, the Integral Action is automatically disabled. This tends to reduce overshoot due to excessive integral build-up. The

Integral Action automatically resumes at the end of the controlled ramp phase.

To terminate a ramp in progress, write 0 (zero) to the Setpoint Ramp register. This results in immediate control to the target setpoint.

Setpoint Ramp Using Periodic Setpoint Write Register: B

A host computer can command the setpoint value of the controller by writing new setpoint values based on clock ticks. In this manner, the host has explicit control over setpoint values, ramp and hold phases.

During ramp phases, the Integral Action may lead to overshoot problems.

In this case, the integral action may be slowed or completely disabled by setting the integral time register.

Periodic Setpoint Write Commands (E

2

PROM precautions)

In the case of periodically writing setpoint values to the controller (host is running a temperature/process profile), terminate the write command with the “$” terminator character. This instructs the controller to accept the setpoint value, but not to write the value to E

2

PROM memory. This eliminates cycling of the internal memory chip, which has a finite life-cycle rating (1 million typical). This rating should not be exceeded.

After power loss, the setpoint value written will be lost when using “$”.

Termination of the setpoint write command with the “*” character instructs the controller to save the value to E

2

PROM memory. In this case, the setpoint value will be recalled after a power loss.

Heater Current Response: HC (T48 only)

The Heater Current register identifies whether the output is on or off at the time it is read. This is indicated by the three letter mnemonic HCN or HCF

(N=on, F=off). For example, when a read occurs while the output is off, this response occurs: “HCF x.x”. This indicates that the heater current reading is with the main output switched off. If the controller responds with “HCN x.x”, the reading is with the main output switched on. The output status register is not synchronous in time with heater current register.

Output Status: W

The Output Status register indicates the present status of the controller’s discrete alarm outputs (coils). This is a read only register. The controller responds with OST followed by a field consisting of 4 bytes. The bytes represent the status of the outputs in the following order: main output O1, cooling/ secondary output (O2), alarm 2 output (A2), alarm 1 output (A1).

When the output is on, the corresponding byte is “1.” When the output is off, the corresponding byte is “0”.

Communication Format

Data is transferred from the controller over a serial communication channel. In serial communications, the voltage is switched between a high and low level at a predetermined rate (baud rate) using ASCII encoding. The receiving device reads the voltage levels at the same intervals and then converts the number back to a character.

The table lists the required voltage levels at the receiver for RS485 interface.

Logic

1

0

RS485

a-b <-200 mV a-b >+200 mV

Interface State

mark (idle) space (active)

Data is transmitted one byte at a time. Each ASCII character is “framed” with a beginning start bit, an optional error detection parity bit and one or more ending stop bits.

-62-

Stop Bit

The last character transmitted is the stop bit. The stop bit provides a single bit period pause to allow the receiver to prepare to re-synchronize to the start of new transmission (start bit of next byte). After the stop bit, the receiver continuously looks for the occurrence of the next start bit.

Command Response Time

The controller can only receive or transmit data at any one time (half-duplex operation). If bus activity, such as another command, occurs before the controller has ended its transmission, garbled data will result. When sending commands and data to the controller, timing restrictions are imposed when sending another command afterwards. This allows enough time for the controller to process the command and prepare for the next command. If the timing requirements are not obeyed, lost transmissions may result.

Figure 36, Character Frame

To allow the host adequate time to release the bus after a transmission, the response time of the controller is programmable. The controller utilizes a receiver design that interprets a mark condition for open connections.

Start Bit and Data Bits

Data transmission always begins with the start bit. The start bit signals the receiving device to prepare for reception of data. One bit period later, the least significant bit of the ASCII encoded character is transmitted, followed by the remaining data bits. The receiving device then reads each bit position as it is transmitted. Since the sending and receiving devices operate at the same transmission speed (baud rate), the data is read without timing errors.

Parity Bit

After the data bits, the parity bit is sent. The transmitter sets the parity bit to a zero or a one, so that the total number of ones contained in the transmission

(including the parity bit itself) is either even or odd. This bit is used by the receiver to detect one bit errors occurring in the transmission. Given this limitation, the parity bit is often ignored by the receiving device. The controller ignores the parity bit of incoming data and sets the parity bit to odd, even or none (mark parity) for outgoing data.

-63-

Figure 37, Timing Diagram

At the start of the time interval t

1

, the computer program prints or writes the string to the com port, thus initiating a transmission. During t

1

, the command characters are transmitting and at the end of this period, the command terminating character (*) is received by the controller. The time duration of t

1 is dependent on the number of characters and baud rate of the channel.

t

1

= (10 X # of characters) / baud rate

At the start of time interval t

2

, the controller starts the interpretation of the command and when complete, performs the command function. This time interval varies from 2 msec to 100 msec. If no response from the controller is expected, the controller is ready to accept another command at the end of t

2

. A must be observed before sending minimum delay of 100 msec for period t

2 another command to the same controller.

If the controller is to reply with data, the time interval t

2 is controlled by the use of the command terminating character. The standard command line terminating character is ‘*’. This terminating character results in a response time window of 100 msec minimum and 200 msec maximum. This allows sufficient time for the release of the bus by the transmitter. Terminating the command line with ‘$’ results in a response time window (t

2

) of 2 msec minimum and 100 msec maximum. The faster response time of this terminating character requires that the transmitter release within 2 msec after the terminating character is received.

At the beginning of time interval t

3

, the controller responds with the first is dependent on the character of the reply. As with t

1

, the time duration of t number of characters and baud rate of the channel.

3 t

3

= (10 X # of characters) / baud rate.

The number of response characters varies depending on the setting of the

3

, the controller is full / abbreviated transmissions parameter. At the end of t ready to receive the next command.

The maximum serial throughput of the controller is limited to the sum of: t

1

, t

2 and t

3

.

Full Field Controller Transmission Byte Format

The first two characters transmitted are the node address, unless the node address assigned = 0, in which case spaces are substituted. A space follows the node address field. The next three characters are the register ID. The numeric data is transmitted next. The numeric field is 5-6 characters long. If the decimal point is present, the field is 6 characters. Negative values have a leading minus sign. The data field is right justified with leading spaces.

Engineering Units byte is next. The end of the response string is terminated with a carriage return <CR> and line feed<LF>. When print block transmission is finished, an extra <SP><CR><LF> is used to provide separation between the blocks.

Byte

1-2

3

4-6

7-12

13

14

15

16

17

18

Description

2 byte Node Address field [00-99]

<SP> (Space)

3 byte Register ID field

6 byte data field, 4 bytes for number, one byte for sign, one byte for decimal point

1 byte Engineering Units

<CR>

<LF>

<SP>(Space). This character only appears in the last line of a print

block.

<CR> This character only appears in the last line of a print block.

<LF> This character only appears in the last line of a print block.

-64-

Abbreviated Controller Transmission Byte Format

The abbreviated response suppresses the node address and register ID characters, leaving only the numeric part of the response. The numeric field is

5-6 characters long. If the decimal point is present, the field is 6 characters.

Negative values have a leading minus sign. The data field is right justified with leading spaces.The end of the response string is terminated with a carriage return <CR> and line feed <LF>. When print block transmission is finished, an extra <SP><CR><LF> is used to provide separation between the blocks.

Byte

1-6

10

11

7

8

9

Description

6 byte data field, 4 bytes for number, one byte for sign, one byte for decimal point

<CR>

<LF>

<SP>(Space). This character only appears in the last line of a print

block.

<CR> This character only appears in the last line of a print block.

<LF> This character only appears in the last line of a print block.

Example of Full Field Printout of Factory Settings

P48

INP 25.0

SET 0.0

PWR 47.8%

PBD 100.0%

INT 40S

DER 4S

AL1 0.0

AL2 0.0

DEV 25.0

OFP 0.0%

RMP 0.0R

CRG 1.0G

CDB 0.0

OST 0000

T48

TMP 87F

SET 0F

PWR 0.0%

PBD 4.0%

INT 120S

DER 30S

AL1 0F

AL2 0F

DEV 87F

OFP 0.0%

RMP 0.0R

CRG 1.0G

CDB 0F

RSP 0F

HCF 0.0A

OST 0101

-65-

Troubleshooting Serial Communications

If problems are encountered when interfacing the controller(s) and host device or printer, the following check list can be used to help find a solution.

1. Check all wiring. Proper polarity of all devices on the serial loop must be observed. Refer to previous application examples.

2. Check the controller’s communication format in module 6-SC. Make sure all devices on the serial loop are configured with the same communication format.

3. Check the requesting device constructed command string format.

4. When sending commands to the controller, an asterisk “*” or dollar sign

“$” must terminate the command. Make sure a carriage return or line feed does not follow the command terminator.

5. Check the controller’s unit address in module 6-SC. It should be zero if the address command is not used in the command string for single controller configurations. In multiple controller configurations, make sure each controller has a unique unit address.

6. Initiate transmissions from the controller by programming the User Input for PrNt in module 1-IN for print and programming module 6-SC at PoPt set INP (input) to YES. As long as the user input is connected to common, controller data will be sent.

7. With two-way communications or multiple controller configurations, make sure only one device is communicating at a time.

8. If all of the above has been done, try reversing the polarity of the serial wires at host device or printer. Some devices have reversed polarity.

APPLICATION EXAMPLES

T48 OEM Paint Sprayer Application

An OEM manufacturing spray painting equipment utilizes the T48 to maintain optimum paint temperature. In addition to the low cost, the 1/16 DIN package size permits the OEM to design temperature control into various sized painting equipment, from small hand sprayers to large paint booths. The heating element used to heat the paint, is connected to the Main Control

Output (OP1) programmed for On/Off control. Alarm 1 is programmed as

Band Inside Acting, so that as long as the paint temperature is within manufacturer’s specifications for temperature, the “GO” light is on. Alarm 2 is programmed as Band Outside acting so that the “NO GO” light is lit when the paint temperature is more than 12°outside the manufacturer’s specifications of 140 to 150°F.

Figure 38, OEM Paint Sprayer Application

-66-

Process Requirements

Unprotected Parameters

PrOP

AL-1

AL-2

0

12

12

On/Off control

GO light on within setpoint ±12

NO GO light on outside setpoint ±12

SCAL dCPt

FLtr

SHFt

SPLO

SPHI

SPrP

InPt

1 - In Configure Input Parameters tYPE tc-J *

F *

0 *

1 *

0 *

140

150

0.0 *

Thermocouple type “J”

Control and indicate in °F

One degree display resolution

Nominal input signal digital filtering

No shift correction necessary

Limit min. setpoint temperature to 140 °F

Limit max. setpoint temperature to 150 °F

No setpoint ramping

PLOC * User Input program lock

2 - OP Configure Output Parameters

CYCt

OPAC rEv *

OPLO

OPHI

OPFL

OPdP

2 *

0 *

100 *

0 *

CHYS 2 * tcod

3 *

0 *

Not used for On/Off control

Use reverse acting for heating

For on/off, leave at 0%

For on/off, leave at 100%

Turn off if sensor fails

Output power dampening = 3 seconds

2 degree on/off band

Not used for On/Off control rSt1

Stb1

AL-1

Act2 rSt2

Stb2

AL-2

AHYS

4 - AL Configure Alarm Parameters

Act1 b-IN

Auto * no *

12 b-ot

Auto * no *

12

1 *

Band Inside

Automatic light on/off

Power-up standby

Go light on within setpoint ±12

Band outside

Automatic light on/off

Power-up standby

No Go light on outside setpoint ±12

1° alarm activation hysteresis

* Factory Settings

T48 Plastics Extruder Application

Several T48 controllers are employed to control the temperature of a plastics extruder. Each T48 controls a heating element and a cooling water solenoid to maintain each extruder zone at the desired temperature. The Heater Current

Monitor option is used for early detection of heater element failure.

The multi-function User Input can be programmed to allow selection of manual operation when connected to common. This allows the user to hold the control output of the controller during abnormal process conditions.

Figure 39, Plastics Extruder Application, shows one such zone.

Figure 39, Plastics Extruder Application

-67-

P48 Water Processing Application

A city water company needs to maintain a steady flow of water for their customer needs. They have an existing 0 to 10 VDC flow transmitter to measure the water flow. They need to control the water flow, have a high and low alarm, and keep a recorded chart of the flow for later reference. The Main

Linear DC output of the P48 is used to control the position of water value to maintain the desired flow setpoint value. The P48 relay outputs are programmed to give a high flow alarm and a low flow alarm. With the Second

Linear DC output model, the flow measurement to the P48 can be retransmitted to a chart recorder.

ALARM

POWER

+ -

CHART

RECORDER

HIGH

ALARM

LOW

ALARM

CONTROL

VALVE

UNIT POWER

FLOW

SENSOR

WATER FLOW

Figure 40, Water Processing Application

-68-

Process Requirements

Unprotected Parameters

ProP

Intt dErt

AL-1

AL-2

XX

XX

XX

90.0

20.0

Calculated by Auto-Tune

Calculated by Auto-Tune

Calculated by Auto-Tune

High alarm

Low alarm

1-IN Configure Input Parameters tYPE dCPt

FLtr dSP1

INP1 dSP2

INP2

SPLO

SPHI

SPrP

INPt

VOLt

0.0 *

XX

0.0

0.00

10.0

150.00

40.0

80.0

0.0 *

Voltage Input

Resolution

Calculated by Auto-Tune

Input low value

Low display value

Input high value

High display value

Setpoint low limit

Setpoint high limit

No ramping

PLOC * User input program lock

2-OP Configure Output Parameters

CYCt 0 Disable O1 output

The remaining parameters in this module are set to factory settings.

rSt1

Stb1

AL-1

Act2 rSt2

Stb2

AL-2

AHYS

4-AL Configure Alarm Parameters

Act1 A-HI

LAtC yes

90.0

A-LO

LAtC yes

20.0

5.0

Set 01/A1 for control output

Manual reset

Disable alarm during power-up

Set 90.0 gal/min high alarm value

Set alarm #2 for deviation band from setpoint

Manual reset

Disable alarm during power-up

Set 20.0 gal/min low alarm value

Alarm activation hysteresis

8-A2 Configure Second Analog Parameter

A2tP

A2LO

A2HI

4-20

0.0

150.0

4-20 mA retransmitted

Display low value

Display high value

* Factory Settings

CHECKS AND CALIBRATION

The instrument has been fully calibrated at the factory for all input types. 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 following procedures may be used for this purpose.

Note: Allow 1/2 hour warm-up before checking these parameters.

MAIN INPUT CHECK mV Reading Check (T48)

1. Connect a DC mV source with an accuracy of 0.03% or better to terminal #8

(-) & #9 (+).

2. Configure Input Parameters Module 1 for linear mV (lin) input, under tYPE.

3. Compare the controller read-out to the standard at various points over the range (-5.00 mV to 56.00 mV). The tolerance is ±(0.15% of reading +1

LSD).

4. Calibrate the controller if the readings are out of tolerance.

Thermocouple Cold Junction Temperature Check (T48)

1. Connect a thermocouple probe of known accuracy (Types T, E, J, K, N only) to controller. Select the probe used in Configure Module 1.

2. Connect a reference temperature probe to measuring end of thermocouple to monitor temperature. Allow sufficient time for temperatures to equalize.

3. Compare controller display with reference temperature probe. The controller display should equal the calibrated probe temperature.

(Tolerance is ±1°C).

4. Calibrate the cold junction temperature if out of tolerance.

RTD Ohms Reading Check (T48)

1. Connect RTD simulator (with an accuracy of 0.1 ohm or better) capable of operating with less than 150 mA to terminals #8, #9, & #10.

2. Configure Input Parameters Module 1 for linear ohms (rLIn) input, under tYPE.

3. Compare the controller read-out with the RTD simulator at various points over the range 1.0 to 300.0 ohms. The tolerance is ±(0.3% of span ±1LSD).

4. Calibrate the controller RTD ohms if out of tolerance.

-69-

Voltage Check (P48)

1. Connect a DC voltage source with an accuracy of 0.1% or better. Apply a 0 to 10 V signal to terminals #8 (-) & #9 (+).

2. In Input Module 1, configure input signal InP1 and display value dSP1 to

0.00. Configure input signal InP2 and display value dSP2 to 10.00.

3. Compare the controller readout to the voltage source over the range (0-10 V).

The tolerance is ±(0.3% of reading +0.03 V).

4. Calibrate the controller if the readings are out of tolerance.

Current Check (P48)

1. Connect a DC current source with an accuracy of 0.1% or better. Apply a 0 to 20 mA signal to terminals #8 (-) & #10 (+).

2. In Input Module 1, configure input signal InP1 and display value dSP1 to

0.00. Configure input signal InP2 and display value dSP2 to 20.00.

3. Compare the controller readout to the current source over the range (0-20 mA). The tolerance is ±(0.3% of reading +0.04 mA).

4. Calibrate the controller if the readings are out of tolerance.

Remote Setpoint Input Check (T48 and P48)

1. Connect a DC current source with an accuracy of 0.03% or better. Apply a 0 to 20 mA signal to terminals 13 (+) and 14 (-).

2. In Remote Setpoint Input Module 7, configure input signal InP1 and display value dSP1 to 0.00. Configure input signal InP2 and display value dSP2 to 20.00.

3. Compare the readout in the secondary main display to the current source over the range (0-20 mA). The tolerance is ±(0.2% of full scale +½ LSD).

4. Calibrate Remote Setpoint Input if readings are out of tolerance.

Heater Current Input Check (T48 only)

1. Connect an AC current source with an accuracy of 0.1% or better. Apply a

100 mA signal to terminals 13 (+) and 14 (-).

2. In Heater Current Input Module 7-HC. Configure HCur for 100.0.

3. The readout in the secondary main display should be 100.0. The tolerance is ±(1.0% of full scale +½ LSD).

4. Calibrate Heater Current Input if readings are out of tolerance.

Error Flag E-CL

If error flag “E-CL” appears at power-up, a loss of calibration parameters due to noise spikes has occurred. Entering code 77 twice in Factory Service

Operations Module (9-FS) erases the controller calibration values and defaults the values to nominal settings. Reading errors of ±10% may result. It is recommended that the controller be fully re-calibrated. If using thermocouple only, the RTD calibration need not be performed.

Note: The “E-CL” flag may be cleared by “stepping” through cold junction or linear output calibration procedures without the need to change any calibration values. A ±10% reading error will still exist.

Calibration For T48

When re-calibration is required (generally every two years), this procedure should be performed by qualified technicians using appropriate equipment.

Equipment source accuracy of 0.03% or better is required.

The procedure consists of: applying accurate mV signals, setting the thermocouple cold junction temperature, and applying precision resistance, among others. Allow a 30 minute warm-up period before starting this procedure.

Do not use thermocouple wire for the Millivolt or RTD ohms Calibration.

This procedure may be aborted by disconnecting power to the controller before exiting the configuration mode. The existing calibration settings remain in affect.

Note: After completing any of the calibration sequences, the controller defaults the input sensor type to thermocouple type “J” (tc-j). Be sure to set input sensor for proper type.

Note: The controller must be restored to normal display mode before any data is stored.

-70-

Factory Service Operations - Calibration (9-FS)

Display

CodE

CAL

CJC rtd

A1CL

A2CL

2CAL or

N2CL

Parameter

Enter function code

Millivolt Calibration

Thermocouple cold junction temperature calibration

RTD Resistance

Calibration

Main Linear DC

Output Calibration

Second Linear DC

Output Calibration

Remote Setpoint or

Heater Current Input

Calibration

Range

48 yes/no yes/no yes/no yes/no yes/no yes/no

Description/Comments

Calibrate instrument

Calibration required for both

RTD and TC input. If this procedure is performed, the cold junction temp or RTD ohms calibration procedures in turn must be completed.

Not required if only using RTD input. This procedure can only be performed AFTER an accurate mV calibration.

Not required if only using TC input. This procedure can only be performed AFTER an accurate mV calibration.

Model number dependent.

Calibrate either 10 V or 20 mA

Range

Model number dependent.

Calibrate either 10 V or 20 mA

Range

Model number dependent

Millivolt Calibration (CAL)

Connect precision millivolt source with an accuracy of 0.03% to terminals

(-) #8 and (+) #9. Cold Junction or RTD Ohms calibration MUST be performed after millivolt calibration.

Display

StP1

StP2

StP3

StP4

StP5

Action

Apply 0.0 mV

Apply 14.0 mV

Apply 28.0 mV

Apply 42.0 mV

Apply 56.0 mV

Description/Comments

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Thermocouple Cold Junction Calibration (CJC)

This procedure must be performed AFTER an accurate mV calibration.

1. Exit Factory Service Operations (press D) and return to Normal Display

Mode.

2. Connect a thermocouple probe of known accuracy to the controller (Types

T, E, J, K, and N only). Select the probe type used in Configure Module 1.

3. Connect a reference temperature probe to the measuring end of the T48 thermocouple probe. The two probes should be shielded from air movement and allowed sufficient time to equalize in temperature. (As an alternative, the T48 thermocouple probe may be placed in a calibration bath of known temperature.)

4. Compare controller display with reference temperature probe (or calibration bath). If the displayed controller temperature does not equal the reference probe temperature, calculate the CJ Error as follows:

CJ Error

= reference probe temperature

displayed controller temperature

5. Enter Factory Service Operations Module (9-FS).

Display

CJC

Parameter

Cold Junction

Temperature

Description/Comments

Observe the indicated cold junction temperature. Add the calculated CJ Error to the displayed value. Enter the sum as the new value for CJC. Exit 9-FS and repeat step 4.

Note: If the initial value for CJC is not within the range 15.0°C to 40.0°C, enter 25.0°C for

CJC and repeat the Cold Junction Calibration procedure.

RTD Ohms Calibration (rtd)

This procedure must be performed AFTER an accurate mV calibration.

Connect one leg of precision resistance (accuracy of 0.1 ohm) to terminals #9 and #10 together, and the other leg to #8.

Display

Rtd1

Rtd2

Action Description/Comments

Connect 0.0 ohm (jumper wire) Wait 10 seconds, press P.

Connect 277.0 ohm Wait 10 seconds, press P.

Main or Second Linear DC Analog Output Calibration

1. Set the Linear DC Output jumper for the range to be calibrated. (See Linear

DC Analog Output Jumper Selection, page 12).

2. Connect a meter with an accuracy of 0.05% or better to the output.

3. For each step, use the controller arrow keys to adjust the external meter display to match the parameter being calibrated. Press P when the output is correct, or if the parameter is not being calibrated.

Display

C 0V

Parameter

0 V Calibration

C 10V 10 V Calibration

C 0c 0 mA Calibration

C 20c 20 mA Calibration

External Meter

0.00

10.00

0.00

20.00

Action

Adjust if necessary, press P.

Adjust if necessary, press P.

Adjust if necessary, press P.

Adjust if necessary, press P.

Remote Setpoint Calibration

Connect DC mA source with an accuracy of 0.03% or better.

Display

StP1

StP2

StP3

StP4

StP5

Action

Apply 0 mA

Apply 5 mA

Apply 10 mA

Apply 15 mA

Apply 20 mA

Description/Comments

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Heater Current Input Calibration

Connect AC mA source with an accuracy of 0.1% or better.

Display

StP1

StP2

StP3

StP4

StP5

Action

Apply 0 mA AC

Apply 5 mA AC

Apply 50 mA AC

Apply 75 mA AC

Apply 100 mA AC

Description/Comments

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

-71-

Calibration For P48

When re-calibration is required (generally every two years), this procedure should be performed by qualified technicians using appropriate equipment.

Equipment source accuracy of 0.03% or better is required.

The procedure consists of applying accurate voltage and current signals.

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 effect.

Factory Service Operations (9-FS)

Display

CodE

CAL

Parameter

Enter factory service function code

Input calibration

Range

48

A1CL

A2CL n2CL

Main Linear DC Output calibration

Second Linear DC

Output calibration

Remote Setpoint

Calibration

Description/Comments

Calibrate Instrument yes/no Calibration for both voltage and current.

yes/no Model number dependent.

Calibrate either 10 V or 20 mA.

yes/no Model number dependent.

Calibrate either 10 V or 20 mA.

yes/no Model number dependent

Input Calibration

Connect voltage calibration source with an accuracy of 0.1% or better.

Display

StP1

StP2

StP3

Action

Apply 0.0 V

Apply 2.5 V

Apply 5.0 V

Description/ Comments

Wait 10 seconds press P.

Wait 10 seconds press P.

Wait 10 seconds press P.

StP4

StP5

Apply 7.5 V

Apply 10 V

Wait 10 seconds press P.

Wait 10 seconds press P.

Connect current calibration source with an accuracy of 0.1% or better.

StPA Apply 0 mA Wait 10 seconds press P.

StPB Apply 20 mA Wait 10 seconds press P.

Main or Second Linear DC Analog Output Calibration

1. Set the Linear DC Output jumper for the range to be calibrated. (See Linear

DC Analog Output Jumper Selection, page 12).

2. Connect a meter with an accuracy of 0.05% or better to output.

3. For each step, use the controller arrow keys to adjust the external meter display to match the parameter being calibrated. Press P when the output is correct, or if the parameter is not being calibrated.

Display

C 0V

Parameter

0 V Calibration

C 10V 10 V Calibration

C 0c 0 mA Calibration

C 20c 20 mA Calibration

External Meter

0.00

10.00

0.00

20.00

Action

Adjust if necessary, press P.

Adjust if necessary, press P.

Adjust if necessary, press P.

Adjust if necessary, press P.

Remote Setpoint Calibration

Connect DC mA source with an accuracy of 0.03% or better.

Display

StP1

StP2

StP3

StP4

StP5

Action

Apply 0 mA

Apply 5 mA

Apply 10 mA

Apply 15 mA

Apply 20 mA

Description/Comments

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

Wait 10 seconds, press P.

-72-

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 board is fitted, and that the set-up parameters are correct. For further technical assistance, contact technical support at the appropriate company numbers listed.

PROBLEMS

NO DISPLAY

CONTROLLER

NOT WORKING

“E-FP” IN DISPLAY

POSSIBLE CAUSE

1. Power off

2. Brown out condition.

3. Loose connection or improperly wired.

4. Bezel assembly not fully seated into rear of unit.

1. Incorrect parameter set-up.

REMEDIES

1. Check power.

2. Verify power reading.

3. Check connections.

4. Check installation.

1. Check set-up parameters.

“E-UP” IN DISPLAY

“E-E2” IN DISPLAY

“E-CL” IN DISPLAY

“...” OR “-..” IN DISPLAY

“OPEN” IN DISPLAY

(T48)

1. Defective front panel button.

1. Internal problem with controller.

1. Loss of set-up parameters due to noise spike.

2. Defective or mis-calibrated cold junction circuit.

3. Loss of set-up parameters.

4. Internal malfunction.

1. Press D to escape, then check all buttons for proper operation.

2. Replace unit.

1. Replace unit.

1. Press D to clear, then check all set-up parameters.

a. Check sensor input and AC line for excessive noise.

b. If fault persists, replace unit.

1. Loss of calibration parameters due to noise spike.

1. Press D to clear, then check accuracy of controller.

a. Recalibrate controller.

b. Reset calibration parameters to nominal values

(See Factory Service Operations Module).

1. Display value exceeds display range.

1. Change resolution to display whole number.

a. Verify reading.

2. Check cold junction calibration.

3. Check set-up parameters.

4. Check calibration.

1. Probe disconnected.

2. Broken or burned out probe.

3. Corroded or broken terminations.

4. Excessive process temperature.

1. Connect probe. (Connection must remain intact for 3 sec.

to clear “OPEN” condition.)

2. Replace probe.

3. Check connections.

4. Check process parameters.

-73-

TROUBLESHOOTING (Cont’d)

PROBLEMS

“SENS” IN DISPLAY

(P48)

“OLOL” IN UPPER DISPLAY

POSSIBLE CAUSE

1. Input exceeds range of controller.

2. Incorrect input wiring.

3. Defective transmitter

4. Internal malfunction.

1. Input exceeds range of controller.

2. Temperature exceeds range of input probe.

3. Excessive positive probe temperature.

4. Loss of set-up parameters.

“ULUL” IN UPPER DISPLAY 1. Input is below range of controller.

2. Temperature below range of input probe.

3. Excessive negative probe temperature.

4. Loss of set-up parameters.

1. RTD probe shorted.

“SHrt” IN DISPLAY

(T48)

CONTROL SLUGGISH OR NOT

STABLE

1. Incorrect PID values.

2. Improper probe location.

“OLOL” OR “ULUL” IN LOWER

DISPLAY

1. Signal input exceeds allowable range by 5%.

REMEDIES

1. Check input signal level.

2. Check input wiring.

3. Check signal calibration.

4. Check calibration.

1. Check sensor or input signal level.

2. Change to input sensor with a higher temperature range.

3. Reduce temperature.

4. Check set-up parameters.

1. Check sensor or input signal level.

2. Change to input sensor with a lower bottom range.

3. Increase temperature.

4. Check set-up parameters.

1. Check wiring.

2. Replace RTD probe.

1. See PID Control.

2. Evaluate probe location.

1. Check Remote Signal Source.

-74-

REPLACEABLE OUTPUT BOARD DESCRIPTION

Output Board

The controller is supplied with an output board (relay, logic/SSR or triac) installed. The output board is configured for the type of Main Control and

Alarm Output based upon the model number ordered. The output board is field replaceable in many models. (For models where the output board is not replaceable, the controller must be returned to the factory for output board repair.) See Ordering Information, page 81, for available models.

Replacing Output Board

1. Remove the bezel assembly. (See Removing Bezel Assembly, page 3).

2. Lift up on the top bezel board latch while gently pulling out on the bezel/display board assembly. Do NOT remove the display board from the bezel.

3. Remove the output board by pulling it away from the other boards. Replace the output board by aligning the board to board connector. Be certain the connector is fully mated.

4. Connect the bezel/display board assembly by guiding the board ends into the bezel latches. Slide the assembly on evenly until the display board connector is completely engaged and bezel latches are fully seated onto the boards.

Figure 41, Output Boards

Figure 42, Output Board Replacement

-75-

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:

“OLOL”

“ULUL”

“OPEN”

“SHrt”

“SENS”

“...”

“-..”

¾ Measurement exceeds + input range.

¾ Measurement exceeds - input range.

¾ Open sensor is detected. (T48 only)

¾ Shorted sensor is detected (RTD only)

¾ Measurement exceeds controller limits. (P48 only)

¾ Display values exceed + display range.

¾ Display values exceed - display range.

LED Status Annunciators:

%P

MN

DV

O1

A1

A2

¾ Lower auxiliary display shows power output in (%).

¾ Flashing: Controller is in manual mode.

ON: Local Setpoint (Remote Setpoint option)

OFF: Remote Setpoint

¾ Lower auxiliary display shows deviation (error) from process setpoint or shows heater current.

¾ Main control output is active.

¾ Alarm #1 is active. (for AL1 Option)

¾ Alarm #2 is active OR

Cooling (Second) output (O2) is active.

DIMENSIONS In inches (mm)

2. POWER:

AC Versions: 85 VAC min. to 250 VAC max., 50 to 60 Hz, 8 VA max.

DC Versions:

DC Power: 18 to 36 VDC; 7 W

AC Power: 24 VAC ±10%; 50 to 60 Hz, 9 VA

3. CONTROLS: Four front panel push buttons for modification and setup of controller functions and one external user input for parameter lockout or other functions.

PROM retains all programmable parameters 4. MEMORY: Nonvolatile E

2 and values.

5. MAIN SIGNAL INPUT:

Sample Period: 100 msec

Response Time: Less than 300 msec typical, 400 msec max. (to within 99% of final value w/step input; typically, response is limited to response time of probe)

Failed Sensor Response (T48 only):

Main Control Output(s): Programmable preset output

Display: “OPEN”

Alarms: Upscale drive

Normal Mode Rejection: 40 dB @ 50/60 Hz

(improves with increased digital filtering).

PANEL CUT-OUT

Figure 43, Dimensions

-76-

Common Mode Rejection: Greater than 120 dB, DC to 60 Hz

Protection: Input overload 120 VAC max. for 15 sec. max.

6. T48 INDICATION ACCURACY: ±(0.3% of Span +1°C) Includes NIST conformity, cold junction effect and A/D conversion errors at 23°C after

20 min. warm-up.

7. THERMOCOUPLE INPUT (T48 only):

Types: T, E, J, K, R, S, B, N, Linear mV, Software selectable

Input Impedance: 20 MW, all types

Lead resistance effect: 0.25 mV/W

Cold junction compensation: Less than ±1°C (±1.5°C max.) error over 0 to

50°C max. ambient temperature range. Defeated for Linear mV indication mode.

Resolution: 1° for all types, or 0.1° for T, E, J, K and N only.

TC TYPE

T

E

J

K

R

S

B

N mV

RANGE

-200 to +400°C

-328 to +752°F

-200 to +750°C

-328 to +1382°F

-200 to +760°C

-328 to +1400°F

-200 to +1250°C

-328 to +2282°F

0 to +1768°C

+32 to +3214°F

0 to +1768°C

+32 to +3214°F

+149 to +1820°C

+300 to +3308°F

-200 to +1300°C

-328 to +2372°F

-5.00 to +56.00

WIRE COLOR

ANSI BS 1843

(+) blue

(-) red

(+) white

(-) blue

(+) violet

(-) red

(+) white

(-) red

(+) yellow

(-) red

(+) black

(-) red

(+) brown

(-) blue

(+) yellow

(-) blue

(+) brown

(-) blue

(+) white

(-) blue

(+) black

(-) red

(+) grey

(-) red

(+) white

(-) blue

(+) none

(-) blue

(+) orange

(-) red

(+) orange

(-) blue no standard no standard

8. RTD INPUT (T48 only): 2 or 3 wire, 100 W platinum, alpha = 0.00385

(DIN 43760), alpha = 0.0039162

Excitation: 150 mA typical

Resolution: 1 or 0.1 degree

Lead Resistance: 15W max. per input lead.

-77-

RTD TYPE

385

392

OHMS

RANGE

-200 to +600°C

-328 to +1100°F

-200 to +600°C

-328 to +1100°F

1.0 to 320.0

9. P48 RANGE AND ACCURACY:

Input

Range

10 VDC

(-1 to 11)

20 mA DC

(-2 to 22)

Accuracy*

(18 to 28°C)

0.10% of reading

+0.02 V

0.10% of reading

+0.03 mA

Accuracy*

(0 to 50°C) Impedance

Max.

Continuous

Overload

0.30% of reading

+0.03 V

1M ohm 300 V

0.30% of reading

+0.04 mA

10 ohm 100 mA

Resolution

10 mV

10 uA

* Accuracies are expressed as ± percentages after 20 minute warm-up. The controller’s accuracy is specified in two ways: Accuracy over an 18 to

28°C range at 10 to 75% RH environment; and accuracy over a 0 to 50°C range at 0 to 85% RH (non-condensing) environment. Accuracy over the wide sensor range reflects the coefficient of the internal circuitry.

10. USER INPUT: Internally pulled up to +5 VDC (1 MW). V

IN

MAX = 5.25

OFF

= 1 mA max.

VDC; V

IL

= 0.85 V max; V

IH

= 3.65 V min; I

Response time: 120 msec max

Functions: Program Lock

Integral Action Lock

Auto/Manual Mode Select

Setpoint Ramp Enable

Reset Alarms

Local/Remote Setpoint Select

Setpoint 1/Setpoint 2 Select

Serial Block Print

11. CONTROL AND ALARM OUTPUTS (Heating, Cooling or Alarm):

Relay outputs with Form A contacts

Contact Rating: 3 A @ 250 VAC or 30 VDC (resistive load) 1/10 HP @

120 VAC (inductive load)

Life Expectancy: 100,000 cycles at max. load rating.

(Decreasing load and/or increasing cycle time, increases life expectancy.)

Logic/SSR Drive Outputs (T48 only):

Rating: 45 mA @ 4 V min., 7 V nominal

Triac Outputs (T48 only):

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

Offstate Leakage Current: 7 mA max. @ 60 Hz

Operating Frequency: 20 to 400 Hz

Protection: Internal transient snubber

12. MAIN CONTROL:

Control: PID or ON/OFF

Output: Time proportioning or linear DC

Cycle time: Programmable

Auto-tune: When selected, sets proportional band, integral time, and derivative time values.

Probe Break Action (T48 only): Programmable

13. ALARM: 1 or 2 alarms (model dependent)(optional)

Modes:

Absolute high acting

Deviation high acting

Inside band acting

Heater break alarm

Absolute low acting

Deviation low acting

Outside band acting

Reset Action: Programmable; automatic or latched

Standby Mode: Programmable; enable or disable

Hysteresis: Programmable

Probe Break Action (T48 only): Upscale

Annunciator: LED backlight for “A1”, “A2”

-78-

14. COOLING/SECOND: Software selectable (overrides alarm 2).

Control: PID or ON/OFF

Output: Time proportioning

Cycle time: Programmable

Proportional Gain Adjust: Programmable

Heat/Cool Deadband Overlap: Programmable

15. MAIN AND SECOND LINEAR DC OUTPUT: (optional)

Main: Control or Re-transmission, programmable update rate from 0.1 sec to 250 sec

Second: Re-transmission only, fixed update rate of 0.1 sec

Output **

Range

0 to 10 V

0 to 20 mA

4 to 20 mA

Accuracy *

(18 to 28°C)

0.10% of FS

+ 1/2 LSD

0.10% of FS

+ 1/2 LSD

0.10% of FS

+ 1/2 LSD

Accuracy *

(0 to 50°C)

0.30% of FS

+ 1/2 LSD

0.30% of FS

+ 1/2 LSD

0.30% of FS

+ 1/2 LSD

Compliance

10k ohm min.

500 ohm max.

500 ohm max.

Resolution

1/3500

1/3500

1/2800

* Accuracies are expressed as ± percentages after 20 minute warm-up. Output accuracy is specified in two ways: Accuracy over an 18 to 28°C range at 10 to 75% RH environment; and accuracy over a 0 to 50°C range at 0 to 85%

RH (non-condensing) environment. Accuracy over the wide signal range reflects the coefficient of the internal circuitry.

** Outputs are independently jumper selectable for either 10 V or 20 mA. The output range may be field calibrated to yield approximate 10% overrange and a small underrange (negative) signal.

16. REMOTE SETPOINT INPUT: (optional)

Input type: 0/4 to 20 mA

Input Resistance: 10 ohms.

Overrange: -5% to 105%

Overload: 100 mA (continuous)

Scale Range: -999 to 9999 degrees or -99.9 to 999.9 degrees

Resolution: 1 part in 10,000

Accuracy:

At 25°C: ±(0.1 % of full scale +1/2 LSD)

Over 0 to 50°C range: ±(0.2% of full scale +1/2 LSD)

Reading Rate: 10/sec

Setpoint Filtering: Programmable Digital

Setpoint Ramping: Programmable, 0.1 to 999.9 degrees/minute.

17. HEATER CURRENT MONITOR INPUT (T48 only): (optional)

Type: Single phase, full wave monitoring of load currents controlled by main output (01)

Input: 100 mA AC output from current transformer (RLC #CT004001) or any CT with 100 mA AC output.

Display Scale Range: 1.0 to 999.9 Amps or 0.0 to 100.0%

Input Resistance: 5 W

Accuracy:

At 25°C range: +(0.5% of full scale + 1/2 LSD), (5 to 100% of range)

Over 0 to 50°C range: ±(1.0% of full scale +1/2 LSD), (5 to 100% of range)

Frequency: 50 to 400 Hz

Alarm Mode: Dual acting: heater element fail detect and control device fail detect

Overange: 105% Capacity

Overload: 200 mA (Continuous)

18. SERIAL COMMUNICATIONS: (optional)

Type: RS485 multipoint, balanced interface

Baud Rate: 300 to 9600

Data Format: 7O1, 7E1, 7N2, 8N1

Node Address: 0-99, max of 32 units per line

Transmit Delay: 2-100 msec or 100-200 msec

Data Encoding: ASCII

Isolation w.r.t Main Input Common: 500 Vrms for 1 min. (50 V working)

Not isolated w.r.t. Remote Setpoint or Heater Current inputs, or Analog

Output common

Note: RS485 and the Analog Output commons are not internally isolated within the controller. The terminating equipment of these outputs must not share the same common (i.e.. earth ground).

19. ISOLATION BREAKDOWN RATINGS:

AC line with respect to all Inputs and outputs: 250 V working (2300 V for 1 minute).

Main input with respect to Analog Outputs, Remote Setpoint Input, Heater

Current Input: 50 V working (2300 V for 1 minute).

All other inputs and outputs with respect to relay contacts: 2000 VAC

Not isolated between Analog Outputs, Remote Setpoint and Heater

Current commons.

-79-

20. CERTIFICATIONS AND COMPLIANCES:

SAFETY

UL Recognized Component, File #E156876, UL873, CSA 22.2 No. 24

Recognized to U.S. and Canadian requirements under the Component

Recognition Program of Underwriters Laboratories, Inc.

Type 4X Enclosure rating (Face only), UL50

IECEE CB Scheme Test Certificate # UL1369-156876/USA,

CB Scheme Test Report # 96ME50224-040396 (T48 only)

Issued by Underwriters Laboratories, Inc.

IEC 61010-1, 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

Electromagnetic RF fields

Fast transients (burst)

Emissions to EN 50081-2

RF interference

EN 61000-4-2 Level 2; 4 kV contact

Level 3; 8 kV air

1

EN 61000-4-3 Level 3; 10 V/m

80 MHz - 1 GHz

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/rms

150 KHz - 80 MHz

Power frequency magnetic fields EN 61000-4-8 Level 4; 30 A/m

Simulation of cordless telephones ENV 50204 Level 3; 10 V/m

900 MHz ± 5 MHz

200 Hz; 50% duty cycle

EN 55011 Enclosure class A

Power mains class A

Notes:

1. No loss of performance during EMI disturbance at 10 V/m.

Unit is panel mounted in a metal enclosure (Buckeye SM7013-0 or equivalent) that provides at least 20 dB shielding effectiveness. Metal panel is connected to earth ground.

Power Line and I/O cables routed in metal conduit connected to earth ground.

2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:

Analog output may deviate during EMI disturbance.

For operation without loss of performance:

Install power line filter, RLC#LFIL0000 or equivalent.

OR

Install 2 ferrite cores, RLC#FCOR0000 or equivalent, to AC lines at unit for frequencies above 5 MHz.

I/O cables routed in metal conduit connected to earth ground.

Refer to the EMC Installation Guidelines section of the manual for additional information.

21. ENVIRONMENTAL CONDITIONS:

Operating Range: 0 to 50°C

Storage Range: -40 to 80°C

T48 Span Drift (maximum): 130 ppm/°C, main input

T48 Zero Drift (maximum): 1 mV/°C, main input

Operating and Storage Humidity:

85% max. relative humidity (non-condensing) from 0°C to 50°C.

Vibration according to IEC 68-2-6: 5 to 150 Hz, in X, Y, Z direction for 1.5

hours, 2gs.

Shock according to IEC 68-2-27: Operational 20 g (10 g relay), 11 msec in

3 directions.

Altitude: Up to 2000 meters

22. CONNECTION: Wire clamping screw terminals

23. CONSTRUCTION: Black plastic alloy case and collar style panel latch.

Panel latch can be installed for vertical or horizontal instrument stacking.

One piece tinted plastic bezel. Bezel assembly with circuit boards can be removed from the case to change the output board without removing the case from the panel or disconnecting wiring. Unit meets NEMA 4X/IP65 requirements for indoor use when properly installed. Installation Category

II, Pollution Degree 2.

24. WEIGHT: 0.38 lbs (0.17 kgs)

-80-

T48 TEMPERATURE CONTROLLER ORDERING INFORMATION

Options and Output Boards are factory configured per the part number specified. Part numbers without replacement output boards listed must be returned to the factory for output board replacement.

MODELS WITHOUT RS485 AND LINEAR DC ANALOG OUTPUT

DEDICATED

MAIN CONTROL

O1 OUTPUT

Relay

Relay

Relay

Relay

Relay

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Triac

DEDICATED

ALARM 1

A1 OUTPUT

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Logic/SSR

A2 (ALARM 2)

OR

02 (COOL) *

Relay

Relay

Relay

Relay

Relay

Relay

Logic/SSR

REMOTE

SETPOINT

INPUT@

YES

YES

* - This output is programmable as either Control (PID) or as an Alarm.

@ - These part numbers are equipped with a second setpoint.

HEATER

CURRENT

INPUT@

YES

YES

PART NUMBERS

18 to 36 VDC/24 VAC 85 to 250 VAC

T4810010

NA

T4811110

T4811113

T4811114

T4820010

NA

T4821110

T4821113

T4821114

T4832210

T4810000

T4811000

T4811100

T4811103

T4811104

T4820000

T4821000

T4821100

T4821103

T4821104

T4832200

REPLACEMENT

OUTPUT BOARD

RBD48100

RBD48111

RBD48111

RBD48111

RBD48111

RBD48200

RBD48211

RBD48211

RBD48211

RBD48211

N/A

-81-

MODELS WITH RS485 OR LINEAR DC ANALOG OUTPUT

DEDICATED

MAIN CONTROL

O1 OUTPUT

Relay

MAIN CONTROL

O1 OR A1 *

(ALARM 1)

Relay

Relay

Relay

Relay

Relay

DEDICATED

ALARM 1

A1 OUTPUT

(ALARM 2)

A2 OR 02

(COOL) *

REMOTE

SETPOINT

INPUT@

HEATER

CURRENT

INPUT@

RS485

@

Relay

Relay

Relay

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Logic/SSR

Relay

YES

YES

YES

YES

YES

YES

YES

YES

YES

1

YES

YES

YES

YES

YES

YES

YES

2

* - This output is programmable as either Control (PID) or as an Alarm.

** - This output is jumper and program selectable for either a current or voltage Linear DC output.

@ - These part numbers are equipped with a second setpoint.

2

1

- Replacement Output Board RBD48100 may be used.

- Replacement Output Board RBD48111 may be used.

MAIN ANALOG

OUTPUT**

@

YES

YES

YES

YES

YES

YES

YES

YES

T48 ACCESSORIES

MODEL DESCRIPTION

External SSR Power Unit (for Logic/SSR output models)

Single Phase 25 A DIN Rail Mount Solid State Relay

RLY

CT

Single Phase 40 A DIN Rail Mount Solid State Relay

Three Phase DIN Rail Mount SSR

40 Ampere Current Transformer (for Heater Current Input models)

50 Ampere Current Transformer (for Heater Current Input models)

SFCRM PC Configuration Software for Windows 98, ME, 2000 and XP (for RS485 models)

ICM4

ICM5

RS232/RS485 Serial Converter Module

Three Way Isolated RS232/RS485 Serial Converter

SECOND

ANALOG

OUTPUT**@

YES

PART NUMBERS

RLY50000

RLY60000

RLY6A000

RLY70000

CT004001

CT005001

SFCRM

ICM40030

ICM50000

PART NUMBERS

18 to 36 VDC/

24 VAC

NA

T481011A

T4810111

T4810115

T4810116

T4810117

T4810118

T4810119

T4811112

T4820211

T4820215

T4820216

T4820218

T4820219

T4821112

85 to 250 VA

C

T4810002

T481010A

T4810101

T4810105

T4810106

T4810107

T4810108

T4810109

T4811102

T4820201

T4820205

T4820206

T4820208

T4820209

T4821102

-82-

P48 PROCESS CONTROLLER ORDERING INFORMATION

Options and Output Boards are factory configured per the part number specified. Part numbers without replacement output boards listed must be returned to the factory for output board replacement.

All part numbers are software version V4.0 or greater. Models with Remote Setpoint Input, RS485, Main Analog Output or Second

Analog Output include a second setpoint.

DEDICATED

MAIN

CONTROL

O1 OUTPUT

MAIN

CONTROL

O1 OR A1

(ALARM 1)*

DEDICATED

ALARM 1

A1 OUTPUT

A2 (ALARM 2)

A2 OR 02

(SECOND) *

REMOTE

SETPOINT

INPUT@

RS485

@

MAIN

ANALOG

OUTPUT**@

SECOND

ANALOG

OUTPUT**

@

YES

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

Relay

YES

YES

YES

YES

YES

YES

YES YES

* - This output is programmable as either Control (PID) or as an Alarm.

** - These part numbers are jumper and program selectable for either a current or voltage Linear DC output.

@ - These part numbers are equipped with a second setpoint.

PART NUMBERS

18 to 36 VDC/

24 VAC

P4800011

P4810010

P4810111

P4810115

P4810117

P481011A

P4811110

P4811112

85 to 250

VAC

P4800001

P4810000

P4810101

P4810105

P4810107

P481010A

P4811100

P4811102

REPLACEMENT

OUTPUT BOARD

N/A

RBD48100

N/A

N/A

N/A

N/A

RBD48111

RBD48111

P48 ACCESSORIES

MODEL DESCRIPTION

SFCRM PC Configuration Software for Windows 98, ME, 2000 and XP (for RS485 models)

ICM4 RS232/RS485 Serial Converter Module

ICM5 Three Way Isolated RS232/RS485 Serial Converter

PART NUMBERS

SFCRM

ICM40030

ICM50000

-83-

T48-COV-G.QXD 12/11/2007 9:51 AM 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.

T48-COV-G.QXD 12/11/2007 9:51 AM Page 4

T-P48/IM - G 8/07

DRAWING NO. LP0466

Red Lion Controls

20 Willow Springs Circle

York PA 17406

Tel +1 (717) 767-6511

Fax +1 (717) 764-0839

Red Lion Controls BV

Printerweg 10

NL - 3821 AD Amersfoort

Tel +31 (0) 334 723 225

Fax +31 (0) 334 893 793

Red Lion Controls AP

31, Kaki Bukit Road 3,

#06-04/05 TechLink

Singapore 417818

Tel +65 6744-6613

Fax +65 6743-3360