MODEL T32 1_32 DIN PID CONTROLLER

MODEL T32 1_32 DIN PID CONTROLLER
BULLETIN NO. T32-X
DRAWING NO. LP0477
EFFECTIVE 4/99
MODEL T32 - 1/32 DIN PID CONTROLLER
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COMPACT IN SIZE
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ACCEPTS THERMOCOUPLE, RTD, 0-20 mA, 0-50 mV INPUTS
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PID CONTROL WITH OVERSHOOT SUPPRESSION
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ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
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STATUS INDICATORS FOR OUTPUTS
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REMOVABLE FRONT PANEL ASSEMBLY
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PARAMETER SECURITY
DESCRIPTION
SAFETY SUMMARY
The T32 1/32 DIN PID Controller accepts signals from a variety of
temperature sensors (thermocouple or RTD elements), 0-20 mA or 0-50 mV
process inputs. The controller will precisely display the process value and
provide an accurate control output to maintain the process at the desired
setpoint. The controller’s comprehensive programming allows it to meet a wide
variety of application requirements.
The controller operates in the PID Control mode for heating or cooling, with
on-demand auto-tune that automatically establishes the PID constants. These
PID constants may be fine tuned by the operator at any time. The controller
employs an overshoot suppression feature that allows for quick response with
minimal overshoot. The controller can also be programmed to operate in the
On/Off Control mode with adjustable hysteresis.
The 4-digit display allows viewing of the process variable. Front panel
indicators show the status of the outputs and auto-tune. The four front panel
keys are used to program the parameters, change the setpoint, or view the
configurations. A security pass code is used to lock-out configuration changes.
The alarm output can be configured to activate according to a variety of
actions. These actions include: Sensor Break, Absolute HI or LO, Deviation HI
or LO, or Band Inside or Outside. The main control output can be configured as
an alarm output for Absolute HI or LO actions.
The controller is constructed of a lightweight, high impact plastic case with
a tinted front panel. The small size allows for installation in tight areas. The
rugged design of the T32 makes it extremely reliable in industrial environments.
All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Do not use the unit 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 alarms is strongly recommended. The
indicators should have input sensors and AC power feeds independent from
other equipment.
CAUTION: Read complete
instructions prior to installation
and operation of the unit.
ORDERING INFORMATION
MODEL
T32
1/32 Din PID Controller
PART NUMBER
T3200000
SPECIFICATIONS
1. DISPLAY:
Main: Single 4-digit 0.38” (9.65 mm) green LED
Display Messages:
“----” - Appears when input is higher than range.
“----” - Appears when input is lower than range.
“ConF” - Appears with incorrect configuration code,
with this message the outputs will not work.
Status Annunciators:
1 - OP1 or AL1 is active
2 - AL2 is active
AT - Auto Tune is active
2. POWER: 85 VAC min. to 250 VAC max., 48 to 63 Hz 2 VA max.
Isolation: 2500 Vrms, 1 minute.
3. CONTROLS:
Four front panel push buttons for modification and configuration of
controller functions.
4. MEMORY: Nonvolatile memory stores all parameter values.
CAUTION: Risk of electric shock.
DIMENSIONS “In inches (mm)”
DESCRIPTION
Note: Recommended minimum clearance (behind the panel) for
mounting clip installation is 2.1” (53.4) H x 5.5” (140) W.
747
PANEL CUT-OUT
10. OUTPUTS:
The controller has one Relay output and one Logic / SSR output. Either
output type can be programmed to perform the Ouput Control 1 (Alarm 1)
function. The remaining output type then assumes the Alarm 2 function. This
is done through the Configuration Code.
Relay Output:
Type: Form A Normally Open (NO)
Contact Rating: 2 A @ 250 VAC (resistive load)
Logic / SSR Output:
Rating: 5 VDC ± 10% @ 30 mA (not isolated)
11. MAIN CONTROL:
Control: PID (Time Proportioning) or ON/OFF
Action: Reverse (heat) or Direct (cool)
Cycle time: 1 to 200 sec.
Auto-tune: When selected, sets proportional band, integral time and
derivative time values
12. ALARMS MODES:
The Main Control Output (OP1) can be configured as Alarm 1 (AL1). The
main alarm is always Alarm 2 (AL2).
Reset Action: Automatic only
Hysteresis: Programmable
Alarm #1 Modes:
Active High with sensor break on or off
Active Low with sensor break on or off
Alarm #2 Modes:
Disabled
Sensor Break (on at break)
Active High or Low
Deviation High or Low *
Band Inside or Outside *
* Only available with single alarm configurations.
13. ENVIRONMENTAL CONDITIONS:
Operating Range: 0 to 50°C
Operating Humidity: 5 to 95% max. relative humidity (non-condensing)
Altitude: up to 2000 meters
14. CERTIFICATIONS AND COMPLIANCES:
EMC Emissions:
Meets EN 50081-2: Industrial Environment
EMC Immunity:
Meets EN 50082-2: Industrial Environment
Electrical Safety:
Meets EN 61010-1: Installation Category II, Pollution Degree 2
15. CONNECTION: Wire clamping screw terminals
16. CONSTRUCTION:
IP20 terminal block
IP65 front panel
17. WEIGHT: 0.25 lb (110 g.)
5. MAIN SENSOR INPUT:
Sample Period: 500 msec.
Failed Sensor Response:
Display: “- - - -”
Control Output: programmable 0% or 100%
Alarm 2: High acting turn on, low acting turn off
Sensor Break Alarm: AL2 programmable to turn on
6. THERMOCOUPLE INPUT:
Types: L, J, T, K, S, and Linear mV, software programmable
Lead resistance effect:< 5 µV / 10 W Wire Res.
Cold junction compensation: < 2 mV / °C Env. Temp.
Resolution: 1° for all types, except linear mV.
WIRE COLOR
TC TYPE
L
J
T
K
S
mV
DISPLAY RANGE
ANSI
BS 1843
DIN47310
red (+)
blue (-)
0 to +600 °C
32 to +1112 °F
0 to +600 °C
32 to +1112 °F
-200 to +400 °C
-328 to +752 °F
0 to +1200 °C
32 to +2192 °F
0 to +1600 °C
32 to + 2912 °F
NA
NA
white (+)
red (-)
blue (+)
red (-)
yellow(+)
red (-)
black (+)
red (-)
yellow(+)
blue (-)
white (+)
blue (-)
brown (+)
blue (-)
white (+)
blue (-)
scaleable
NA
NA
NA
NA
NA
NA
NA
7. RTD INPUT: 2 or 3 wire, 100 ohm platinum, alpha =.00385
Resolution: 1° or 0.1°.
Lead resistance: 20 W max. per lead
Lead resistance effect: < 0.5 °C / 10 W Wire Res.
Temperature effect: 0.1 °C / 10 °C Env. Temp.
RTD TYPE
alpha =.00385
alpha =.00385
RANGE
-99.9 to +100.0 °C
-147.8 to +212.0 °F
-200 to +400 °C
-328 to +752 °F
8. PROCESS INPUT:
INPUT RANGE
RESOLUTION
4 - 20 mA
0 - 20 mA
0 - 50 mV
10 - 50 mV
4 mA
10 mV
Input Drift: <0.1% / 20°C
Scaleable: -999....9999 (min. range of 100 digits)
Current input: utilizes external 2.5W resistor (included)
9. INDICATION ACCURACY: 0.25% ± 1 digit for temperature input
0.1 % ± 1 digit for process input
1.0 INSTALLING THE CONTROLLER
Installation
Installation Environment
The T32 controller meets IP65 requirements for indoor
use when properly installed. The controller is
intended to be mounted into an enclosed
panel. Prepare the panel cutout.
Remove the mounting
clamps from the controller
by inserting a screwdriver
behind the clamps. Verify
that a panel gasket is in
back of the bezel. Insert
the controller into the
panel cutout. Position the
mounting clamps onto the
controller. Push the mounting clamps
tightly towards the panel surface.
The controller should be installed in a location that does not exceed the
maximum operating temperature and provides good air circulation. Placing the
controller near devices that generate excessive heat should be avoided. The
bezel should be cleaned only with a soft cloth and neutral soap product. Do not
use solvents. Continuous exposure to direct sunlight may accelerate the aging
process of the bezel. Do not use tools of any kind (screwdrivers, pens,
pencils, etc.) to operate the keypad of the controller.
748
Removing the Mounting Clips
Insert a screwdriver behind the clips as
shown. Rotate the screwdriver until the
clips release.
Controller Spacing
The design of the controller allows for close spacing of
multiple units. Units can be spaced either horizontally or
vertically. The minimum spacing from center line to center
line of units for horizontal installation is 2.56” ( 65 mm).
The spacing for vertical installationed is 1.65” (42 mm)
from center line to center line.
Note: When closely spacing multiple units, provide
adequate ventilation in the panel to ensure that the
maximum operating temperature of the controller is not
exceeded.
Removing The Front
Panel Assembly
The main assembly of the
controller is removable from the
case even after panel installation.
Push firmly on the center top of
the bezel and pull the bezel
straight out.
2.0 WIRING THE CONTROLLER
c. Connect the shield to common of the unit and leave the other end of the
shield unconnected and insulated from earth ground.
3. Never run Signal or Control cables in the same conduit or raceway with AC
power lines, conductors feeding motors, solenoids, SCR controls, and
heaters, etc. The cables should be run in metal conduit that is properly
grounded. This is especially useful in applications where cable runs are long
and portable two-way radios are used in close proximity or if the installation
is near a commercial radio transmitter.
4. Signal or Control cables within an enclosure should be routed as far away as
possible from contactors, control relays, transformers, and other noisy
components.
5. In extremely high EMI environments, the use of external EMI suppression
devices, such as ferrite suppression cores, is effective. Install them on Signal
and Control cables as close to the unit as possible. Loop the cable through the
core several times or use multiple cores on each cable for additional
protection. Install line filters on the power input cable to the unit 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 # 28B209-0A0
Line Filters for input power cables:
Schaffner # FN610-1/07 (RLC # LFIL0000)
Schaffner # FN670-1.8/07
Corcom # 1 VR3
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
WIRING OVERVIEW
Electrical connections are made via screw-clamp terminals located on the
back of the meter. All conductors should conform to the meter’s voltage and
current ratings. All cabling should conform to appropriate standards of good
installation, local codes and regulations. It is recommended that power supplied
to the meter (DC or AC) be protected by a fuse or circuit breaker.
When wiring the meter, compare the numbers embossed on the back of the
meter case against those shown in wiring drawings for proper wire position.
Strip the wire, leaving approximately 0.3” (7.5 mm) bare lead exposed (stranded
wires should be tinned with solder). Insert the lead under the correct screwclamp terminal and tighten until the wire is secure. (Pull wire to verify
tightness.) Each terminal can accept wire sizes from #22 AWG to #16 AWG
(0.5 mm to 1.5 mm).
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. Cable length, routing, and shield termination are very important
and can mean the difference between a successful or troublesome installation.
Listed below are some EMC guidelines for successful installation in an
industrial environment.
1. The controller should be mounted in a metal enclosure, that 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.
749
2.1 POWER WIRING
2.2 OUTPUT WIRING
AC Power
Relay Output
Logic/SSR Output
2.3 INPUT SIGNAL WIRING
Thermocouple
mV DC
RTD
2.4 REAR TERMINALS
mA DC
TERMINAL
LABELED
1
AC
Controller Power
2
AC
Controller Power
3
NO
Normally Open, Relay Output
4
COMM
5
TC-
(-) TC or (-) RTD or (-) mV or (-) mA*
6
TC+
(+) TC or (-) RTD or (+) mV or (+) mA*
7
N/C
No Connection
8
N/C
No Connection
9
CONNECTION
Common, Relay Output
No Connection
10
LOGIC+
(+) Logic (SSR) Output
11
LOGIC-
(-) Logic (SSR) Output
12
RTD
(+) RTD
*Using an external 2.5W resistor between 5&6
3.0 REVIEWING THE FRONT KEYS AND DISPLAY
KEY
KEY TERM
OPERATION MODE
SETPOINT MODE
VIEW MODE
“Module”
“Down”
Enters Setpoint Mode
Decreases Setpoint
-----
Decreases Parameter Values
“Up”
Enters Setpoint Mode
Increases Setpoint
-----
Increases Parameter Values
“Return”
Enters View Mode
After “Return”, steps through
Controller View
PROGRAMMING MODE
Enters Programming
Mode
-----
-----
Steps through Process View
750
Advances to next Module, Returns to
Operation Mode
Steps through Parameter Menus, Enters
Parameter Values
4.0 FIRST TIME POWER-UP
During first time power-up from the factory, ConF will immediately appear.
At this prompt, enter a four digit Configuration Code that meets the
requirements of the application. After this initial power-up, the controller’s
configuration code can only be changed in Module 3 of the Programming Mode.
AL2 ACTION
CONFIGURATION CODE TABLE
ConF =
0000
IN
A2
OA
OM
INPUT TYPE
INPUT DEVICE TYPE
IN
RTD Pt100
-99.9 to 100.0 °C
-147.8 to 212.0 °F
0
RTD Pt100
-200 to 400 °C
-328 to 752 °F
1
TC L
0 to 600 °C
32 to 1112 °F
2
TC J
0 to 600 °C
32 to 1112 °F
3
TC T
-200 to 400 °C
-328 to 752 °F
4
TC K
0 to 1200 °C
32 to 2192 °F
5
TC S
0 to 1600 °C
Linear scale
0 to 50 mV or 0 to 20 mA scaleable
7
Linear scale
10 to 50 mV or 4 to 20 mA scaleable
8
32 to 2912 °F
OUTPUT FUNCTION AND TYPE
ASSIGNMENT
OUTPUT ASSIGN
ALARM 2 FUNCTION (see Alarm Figures)
A2
Disable
No action
0
Sensor Break
Output is on only at Sensor Break
1
Absolute
Active High, on during Sensor Break
2
Absolute
Active Low, off during Sensor Break
3
Deviation
Active High (Available if OA = 0-3)
4
Deviation
Active Low (Available if OA = 0-3)
5
Band
Active Out (Available if OA = 0-3)
6
Band
Active In (Available if OA = 0-3)
7
Example: Configuration Code of 3002 is:
3 = (IN) Type J thermocouple input
0 = (OA) Output function is PID with OP1 as relay and AL2 as logic
0 = (OM) Reverse Acting Output
2 = (A2) Alarm 2 set as Absolute Alarm, Active High
TEMPERATURE INPUT PROGRAMMING (CONF: 0000 to 6537)
1. Hold“Down” until appropriate Configuration Code (ConF) is reached, then
press “Return”.
2. Press “Down” or “Up”to select °C or °F for Unit, then press “Return”,
3. Press “Down” or “Up” to set Pass CodE (factory setting is 33*, then
press“Return”.
6
OA
PID
OP1 Relay with AL2 Logic / SSR
0
PID
OP1 Logic / SSR with AL2 Relay
1
On - Off
OP1 Relay with AL2 Logic / SSR
2
On - Off
OP1 Logic / SSR with AL2 Relay
3
Indicator
AL1 Relay with AL2 Logic / SSR
4
Indicator
AL1 Logic / SSR with AL2 Relay
5
mA or mV INPUT PROGRAMMING (CONF: 7000 to 8537)
1. Hold“Down” until appropriate Configuration Code (ConF) is reached, then
press “Return”.
2. Press “Down” or “Up” until appropriate Engineering Unit * is reached, then
press “Return”.
3. Press “Down” or “Up” to select appropriate scaling decimal point (Sc.d.d) *,
then press “Return”.
4. Press “Down” or “Up” to select appropriate scaling value for low limit of
range (Sc.Lo) *, then press “Return”.
5. Press “Down” or “Up” to select appropriate scaling value for high limit of
range (Sc.Hi), then press“Return”.
6. Press “Down” or “Up” to set Pass CodE (factory setting is 33*), then
press“Return”.
Relay = (terminals 3 & 4), Logic / SSR = (terminals 10 & 11)
OUTPUT MODE
OP1 SENSOR BREAK/ AL1 FUNCTION
Reverse (heat)
Sensor Break = 0% (off), Active Low
OM
0
Direct (cool)
Sensor Break = 0% (off), Active High
1
Reverse (heat)
Sensor Break = 100% (on), Active Low
2
Direct (cool)
Sensor Break = 100% (on), Active High
3
Note: * For further information see Module 3 explanation.
5.0 IDENTIFYING THE MODES
The Controller View Mode is accessed from the Operation Mode by pressing
the “Return” key and then the “Module” key. In this mode, the operator can
view the Hardware Code (Hard), Configuration Code (ConF), and the Software
Revision Level (rEL.) by pressing the “Module” key. The Hardware Code and
Software Revision Level are for reference only, and can not be changed. The
Configuration Code is modified in Module 3 of the Programming Mode.
OPERATION MODE
In the Operation Mode, the controller displays the temperature or scaled
process value that corresponds to the input signal. In this mode, the outputs
control the process based on the their configuration. The controller
automatically returns to the Operation Mode from the other controller modes if
no keys are pressed for at least 30 seconds.
Some programming changes only take affect after returning to the Operation
Mode. If power is lost during programming, the controller powers up in the
Operation Mode. If this happens, review the programming to verify that the
changes were saved.
SETPOINT MODE
The Setpoint Mode is accessed by pressing the “Up” or “Down” keys from
the Operation Mode. While in this mode, the operator can make changes to the
setpoint value using the “Up” and “Down” keys. Two seconds after the last key
is pressed, the display flashes once to acknowledge the change in setpoint value
and the controller returns to the Operation Mode.
When configuring the control output (OP1) as Alarm 1, the setpoint does not
affect OP1 or AL1 trigger points, but does still affect Alarm 2 deviation or band
trigger points.
VIEW MODES
The Process View Mode is accessed from the Operation Mode by pressing
the “Return” key. In this mode, the operator can view the Engineering Units
(Unit), Setpoint Value (S.P.) and the Output % Power (Out) by pressing the
“Return” key. These values can only be modified in the Programming Mode.
The Output % Power can not be changed by the user.
751
6.0 PROGRAMMING THE CONTROLLER
PROGRAMMING MODE
KEY
The Programming Mode is accessed from the Operation Mode by pressing
the “Module” key. In this mode, the controller parameters are configured. The
parameters are organized into three modules that are selected by pressing the
“Module” key. The parameters within the modules are selected by pressing the
“Return” key. The values of the parameters are viewed and/or changed by
pressing the “Up” or “Down” keys.
Based on the Configuration Code, some modules may start with a different
parameter than those listed in the programming, and some parameters may not
be displayed. Each of the parameters listed in the programming show the
portion of the Configuration Code that is necessary for that parameter to appear
during programming. To aid in programming this controller, use the
Configuration Code Chart provided here to write down your configuration
code.
KEY TERM
“Module”
PROGRAMMING MODE
Advances to next Module, Returns to
Operation Mode
“Down”
Decreases Parameter Values
“Up”
Increases Parameter Values
“Return”
Steps through Parameter Menus, Enters
Parameter Values
CONFIGURATION CODE CHART
ConF =
IN
A2
OA
OM
6.1 MODULE 1
A1S.P
PRESS
ALARM 1 THRESHOLD
0
Range determined by Process
Display Scaling Limits
ConF
t.d.
=
IN
OA
OM
A2
W
4-5
W
W
PRESS
1.00
PRESS
ALARM 2 THRESHOLD
0
Range determined by Process
Display Scaling Limits
ConF
=
IN
OA
OM
A2
W
W
W
2-7
t.c.
The threshold value is combined with the Alarm 2 hysteresis value, based on
the Alarm 2 Action, to determine the on and off points (trigger points) of Alarm
2. This value is determined by the Process Display scaling limits.
P.b.
PRESS
ConF
5.0
OA
OM
A2
W
0-1
W
W
PRESS
OP1 INTEGRAL TIME
5.0
OFF or 0.0 to 100.0 minutes
ConF
OA
W
0-1
OM
W
OA
OM
A2
W
0-1
W
W
ConF
1 to 200 seconds
=
IN
OA
OM
A2
W
0-1
W
W
OP1 OVERSHOOT CONTROL
PRESS
1.00
0.01 to 1.00
ConF
=
IN
OA
OM
A2
W
0-1
W
W
After auto-tune is executed, this value can be used to reduce overshoot
generated by a setpoint change. A setting of 1.00 disables overshoot control. A
value below 0.50 is not recommended.
OP. H
=
IN
20
O.C.
This band is a percent of process range that causes the output power to
change from 0% to 100%. Low proportional band settings result in quick
controller response at the expense of stability and increased overshoot. Settings
that are excessively low, result in continuous oscillations at setpoint. High
proportional band settings result in a sluggish response with long periods of
process “droop”. This parameter can be calculated by Auto-tune.
t.i.
=
IN
This value is used by the Power % to determine how long OP1 is on. It is
recommended to use a cycle time of 1/10 or less of the process time constant.
Higher cycle times could degrade control and shorter times provide little benefit
at the expense of shortened relay life.
=
IN
OP1 CYCLE TIME
PRESS
OP1 PROPORTIONAL BAND
0.5 to 999.9% of span
ConF
OFF or 0.00 to 10.00 minutes
Derivative action shortens the process response time and helps to stabilize
the process by providing an output based on the rate of change of the process.
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. This parameter can
be calculated by Auto-tune.
The threshold value is combined with the Alarm 1 hysteresis value, based on
the Alarm 1 Action, to determine the on and off points (trigger points) of Alarm
1. This value is determined by the Process Display scaling limits.
A2S.P
OP1 DERIVATIVE TIME
A2
PRESS
W
100.0
Integral action shifts the center point position of the proportional band to
eliminate error in the steady state. Integral action changes the output power to
bring the process to setpoint. Integral times that are too fast 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. Times that are too slow
cause a slow response to steady state errors. This parameter can be calculated
by Auto-tune.
OP1 % POWER HIGH LIMIT
ConF
10.0 to 100.0%
=
IN
OA
OM
A2
W
0-1
W
W
This value can be used to limit the % power that PID can calculate. A lower
value can reduce overshoots by limiting the process approach level.
hY.
PRESS
OP1 ON / OFF HYSTERESIS
0.5
0.1 to 10.0% of span
ConF
=
IN
OA
OM
A2
W
2-3
W
W
This value determines the hysteresis value by using the entered percentage of
the full scale. This hysteresis value is balanced around OP1 Setpoint to
determine the OP1 output on and off points (trigger points) per the OP1 On /
Off Action as illustrated in the Action Figures.
752
6.2 MODULE 2
tune
PRESS
StoP
S.P. H
AUTO-TUNING START / STOP
StoP
Strt
ConF
=
PRESS
IN
OA
OM
A2
W
0-1
W
W
PRESS
OFF
SETPOINT RAMP-UP
OFF or 0.1 to 999.9
digits/minute
ConF
A1hY
=
PRESS
IN
OA
OM
A2
W
0-3
W
W
-999 to 9999
ConF
=
IN
OA
OM
A2
W
0-3
W
W
This parameter specifies the high limit for the setpoint value. Set the limit
values so that the temperature setpoint value cannot be set outside the safe
operating area of the process.
Before starting Auto-tune, see the Auto-tune explanation. There are two
types of tuning algorithm, the Step Response and the Natural Frequency. These
types are explained in the OP1 Control Mode Explanations. The AT indicator
will be on during the Auto-Tune operation.
SL. u
OFF
SETPOINT HIGH LIMIT
0.5
ALARM 1 HYSTERESIS
0.1 to 10.0 % of the input
range
ConF
=
IN
OA
OM
A2
W
4-5
W
W
This value determines the hysteresis value by using the entered percentage of
the full scale. This hysteresis value is balanced around Alarm 1 threshold value
to determine the Alarm 1 output on and off points (trigger points) based on the
Alarm 1 Action, as illustrated in the Action Figures.
This parameter specifies the maximum rate of change of the setpoint value,
when going from a low value to a higher value. This is specified in digits per
minute. When the parameter is OFF, this function is disabled, allowing the
controller to stabilize as fast as possible to the new setpoint value.
A2hY
PRESS
0.5
ALARM 2 HYSTERESIS
0.1 to 10.0 % of the input
range
ConF
=
IN
OA
OM
A2
W
W
W
2-7
This value determines the hysteresis value by using the entered percentage of
the full scale. This hysteresis value is balanced around Alarm 2 threshold value
to determine the Alarm 2 output on and off points (trigger points) based on the
Alarm 2 Action, as illustrated in the Action Figures.
SL. d
PRESS
OFF
t.FiL
SETPOINT RAMP-DOWN
OFF or 0.1 to 999.9
digits/minute
ConF
IN
W
PRESS
=
OA
0-3
OM
W
A2
W
PRESS
OFF
In.Sh
PRESS
SETPOINT LOW LIMIT
-999 to 9999
ConF
=
IN
OA
OM
A2
W
0-3
W
W
ConF
OFF or 1 to 30 seconds
=
IN
OA
OM
A2
W
W
W
W
This value controls the input filter applied to the process input. If the
displayed process signal is difficult to read due to small process variations or
noise, increased levels of filtering will help to stabilize the display.
This parameter specifies the maximum rate of change to the setpoint value,
when going from a high value to a lower value. This is specified in digits per
minute. When the parameter is OFF, this function is disabled, allowing the
controller to stabilize as fast as possible to the new setpoint value.
S.P. L
OFF
INPUT FILTER TIME CONSTANT
0FF
INPUT DISPLAY SHIFT
OFF or -60 to 60 digits
ConF
=
IN
OA
OM
A2
W
W
W
W
This value is added to the measured process value. It can be used to correct
a known error, or to provide a user desired display at a specific input.
This parameter specifies the lower limit for the setpoint value. Set the limit
values so that the temperature setpoint value cannot be set outside the safe
operating area of the process.
AL2 and AL1 ALARM ACTION FIGURES
Absolute High; Direct; Active High
Absolute Low; Reverse; Active Low
753
AL2 ALARM ACTION FIGURES
The Hys value shown for the below figures, refers to Alarm 2 hysteresis.
Deviation High with Positive Alarm Values
Deviation Low with Positive Alarm Values
Band Inside Acting Alarm Values
Deviation High with Negative Alarm Values
Deviation Low with Negative Alarm Values
Band Outside Acting Alarm Values
6.3 MODULE 3
PASS
PRESS
33
PASS CODE VERIFY
ConF
0 to 9999
Sc.d.d
=
IN
OA
OM
A2
W
W
W
W
PRESS
After the first start-up, a PASS CodE will be required to make changes in
Module 3. From the factory, 33 is the PASS value stored in CodE and must be
entered to make any additional changes.
ConF
PRESS
2002
CONFIGURATION CODE
0000 to 8537
ConF
PRESS
Sc.Lo
PRESS
=
IN
OA
OM
A2
W
W
W
W
°F
°C
°F
none
nU
U
nA
A
b8r
PSI
rh
Ph
Description
Centigrade
Fahrenheit
None (blank)
Millivolts
Voltage
Milliamps
Ampere
Bar
PSI
Rh
pH
ConF: IN
0-8
0-8
7-8
7-8
7-8
7-8
7-8
7-8
7-8
7-8
7-8
0
0.0
0.00
0.000
ConF
=
IN
OA
OM
A2
7-8
W
W
W
SCALING VALUE FOR LOW LIMIT
ConF
0
-999 to 9999
=
IN
OA
OM
A2
7-8
W
W
W
Determines Process Display scaling value for low end of selected Linear
Scale Range.
Sc.Hi
ENGINEERING UNITS
Selection
0
0
1
2
3
Determines decimal point location for Process Display.
Enter a four digit Configuration Code that meets the requirements of the
application (see Configuration Code Table). The controller will not allow an
invalid Configuration Code.
Unit
DECIMAL POINT
PRESS
W The remaining
ConF values have
no effect on this
selection.
SCALING VALUE FOR HIGH LIMIT
ConF
0
-999 to 9999
=
IN
OA
OM
A2
7-8
W
W
W
Determines Process Display scaling value for high end of selected Linear
Scale Range.
Code
PRESS
33
PASS CODE SETUP
0 to 9999
ConF
=
IN
OA
OM
A2
W
W
W
W
Determines the value to be entered at PASS, to allow access to programming.
A value between 0 and 9998 restricts access to Module 3 only. A value of 9999
restricts access to all of the Programming Modes. If parameter security is not
needed, it is strongly recommended that a value of 0 be entered here. There is
no universal PASS value that will override the CodE value. If the CodE value
is forgotten, then every number combination must be tried until the match is
found. It is highly recommended to write down the CodE value.
Only Centigrade and Fahrenheit affect the scaling of the Process Display.
The other selections are for Units View purposes only.
754
7.0 ON/OFF CONTROL EXPLANATION
Single Output
The controller operates in On/Off Control when
Configuration Code OA is set for 2 or 3. In this
control action OP1 operates without PID control. The
setpoint and OP1 hysteresis values determine the on
and off trigger points of the OP1 output.
In this control, the process will oscillate around
the setpoint value. The OP1 On/Off Hysteresis value,
together with the process characteristics, determine
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 output mode OM (third digit of the
Configuration Code) can be set to reverse for heating
(output on when below the setpoint) or direct for
cooling (output on when above the setpoint)
applications.
ON/OFF, Reverse Acting (Heat)
ON/OFF, Direct Acting (Cool)
8.0 PID CONTROL EXPLANATIONS
Proportional Band
Derivative Time
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.
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.
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.
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”.
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 overcompensation 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 (initially set to zero) to eliminate steady state errors.
755
9.0 AUTO-TUNE EXPLANATION
Auto-Tune is a user initiated function during which the controller
automatically determines the PID settings based upon the process
characteristics. During Auto-Tune, the controller oscillates the output and
monitors the input response. The AT indicator will be on during the Auto-Tune
operation. At the end of this operation, the calculated PID values are stored in
memory and the controller returns to the Operation Mode.
Prior to initiating Auto-Tune, it is essential that the controller Cycle Time
parameter and the Setpoint value be configured for the application. Auto-Tune
is started or stopped using the tunE parameter in Module 2. The Overshoot
Control parameter in Module 1 should be set to 1.00 before initiating Auto-tune.
The controller automatically selects (based on the process conditions) one of
two types of tuning algorithm. The length and number of cycles required to
calculate Proportional, Integral, and Derivative (PID) values are application
dependent. (When Integral and Derivative parameters are configured for OFF,
they are not included in the control algorithm.)
Manual 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.
The Overshoot Control parameter can also be adjusted for tighter control
after Auto-Tune.
TYPICAL RESPONSE CURVE
Step Response
This type of tuning algorithm is automatically selected when the process
value is more than 5% span from the Setpoint at the start of Auto-Tune. This
method has the advantage of faster calculation, with a reasonable accuracy in
the results.
OVERSHOOT AND OSCILLATIONS
To Dampen Response:
- Increase Proportional Band
- Increase Integral Time
- Use Setpoint Ramping
- Increase Derivative Time
- Check Cycle Time
Natural Frequency
This type of tuning algorithm is automatically selected when the process
value is close to the Setpoint. This method has the advantage of higher accuracy
in the results, with a reasonable speed calculation.
SLOW RESPONSE
To Quicken Response:
- Decrease Proportional Band
- Decrease Integral Time
- Increase or Defeat Setpoint
Ramping
- Decrease Derivative Time
756
10.0 CALIBRATION
The controller has been fully calibrated at the factory. Display offset and
scaling in Module 3 converts the input signal to a desired process value. If the
controller appears to be indicating incorrectly or inaccurately, these parameters
should be checked first.
When recalibration is required (generally every 2 years), it should only be
performed by qualified technicians using appropriate, highly accurate
equipment. The equipment must remain switched on for a minimum of one hour
at a maintained environmental condition. Calibration may be aborted by
disconnecting power to the controller before pressing the “Return” key. No
controller parameter changes are necessary to perform calibration.
Input Calibration
For thermocouple, mV and mA input calibration, connect a 50.000 mV input
to terminals 5 (-mV) and 6 (+mV). For RTD input calibration, place a 313.594
ohm resister between terminals 6 and 12 and connect terminals 6 and 5 together.
(If both types of input are being calibrated, then connect only one input, perform
the complete calibration and repeat the procedure with the other input.)
Now perform the following:
PRESS KEY(S)
“Return”, “Module”, “Module”, “Module”
“Down” & “Up” together
Enter programmed Pass Code, “Return”
“Down” (If calibrating for RTD, do not wait.)
DISPLAY RESULT
reL
PASS
CAL.1
Wait for stable display *
“Return”
CAL.2
“Down” (If not calibrating for RTD, do not wait.)
Wait for stable display *
“Return”
“Return”
“Return”
CAL.3
CAL.4
Process Display
* Display may not vary more than ± 1 digit. If not stable after a few seconds, then
press “Down” or “Up” and wait again. Continue this action until a stable display is
shown.
TROUBLESHOOTING
PROBLEM
REMEDIES
NO DISPLAY
CHECK: Power level, power connections
CAN NOT ENTER MODULE 3 or PROGRAMMING MODE
PRESS: The “Module” key until PASS appears then enter the correct pass code
and press the “Return” key
CAN NOT REMEMBER PASS CODE
ENTER: Other pass code combinations and press the “Return” key
CAN NOT CHANGE CONF CODE
VERIFY: The controller is in Programming Module 3 Mode and code value is valid
INCORRECT DISPLAY VALUE
CHECK: Configuration Code, Input Display Shift, Scaling Low, Scaling High
“- - - -” in DISPLAY
CHECK: Signal wiring, Configuration Code
“_ _ _ _” in DISPLAY
CHECK: Signal wiring, Configuration Code
“ConF” in DISPLAY
CHECK: Configuration Code
OUTPUT DOES NOT WORK
CHECK: Output wiring, output power, Configuration Code, setpoint or alarm
threshold value, hysteresis value
CONTROLLER OVERSHOOTS or
DOES NOT GET TO SETPOINT
CHECK: Overshoot Control, PID values, Setpoint Slopes
PERFORM: Auto-tune
SOME PARAMETERS DO NOT APPEAR
CHECK: Configuration Code
SETPOINT ENTRY STOPS AT A VALUE
CHECK: Setpoint High Limit
For further technical assistance, contact technical support.
757
PARAMETER VALUE CHART
T32 1/32 DIN PID Controller
Programmer ________________ Date ________
Meter# _____________ Pass Code __________
Module 2
Based on the Configuration Code of the controller, some parameters
may not be available.
DISPLAY
SL. u
SL. d
S.P. L
S.P. H
A1hY
A2hY
t.FiL
In.Sh
Module 1
DISPLAY
A1S.P
A2S.P
hY.
P.b.
t.i.
t.d.
t.c.
O.C.
OP. H
PARAMETER
USER SETTING
AL1 THRESHOLD
AL2 THRESHOLD
OP1 HYSTERESIS
OP1 PROPORTIONAL BAND
PARAMETER
USER SETTING
SETPOINT SLOPE-UP
SETPOINT SLOPE-DOWN
SETPOINT LOW LIMIT
SETPOINT HIGH LIMIT
AL1 HYSTERESIS
AL2 HYSTERESIS
FILTER TIME CONSTANT
INPUT DISPLAY SHIFT
OP1 INTEGRAL TIME
OP DERIVATIVE TIME
Module 3
OP1 CYCLE TIME
DISPLAY
ConF
Unit
Sc.d.d
Sc.Lo
Sc.Hi
Code
OP1 OVERSHOOT CONTROL
OP1 % POWER HIGH LIMIT
PARAMETER
CONFIGURATION CODE
ENGINEERING UNIT
DECIMAL POINT
SCALING LOW
SCALING HIGH
PASS CODE SETUP
PROGRAMMING MODE CHART
758
USER SETTING
Bulletin No. T48-E
Drawing No. LP0332
Revised 2/01
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL T48 - 1/16 DIN TEMPERATURE CONTROLLER
!
PID CONTROL WITH REDUCED OVERSHOOT
!
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
!
NEMA 4X/IP65 BEZEL
!
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
TEMPERATURE AND SETPOINT
!
STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES
!
ACCEPTS 10 TYPES OF SENSOR INPUTS (Thermocouple or RTD)
!
OPTIONAL HEATER CURRENT MONITOR AND HEATER BREAK
ALARM
!
OPTIONAL DUAL ALARM OUTPUTS
!
OPTIONAL TWO LINEAR DC OUTPUTS (0 to 10 V, 0/4 to 20 mA)
!
MANUAL/AUTOMATIC CONTROL MODES
!
SETPOINT RAMPING FOR PROCESS STARTUP
!
OPTIONAL TRIAC OUTPUT
!
PROGRAMMABLE USER INPUT (Digital) FOR ADDED FLEXIBILITY
!
SECOND SETPOINT SETTING
!
SENSOR ERROR COMPENSATION (Offset) AND BREAK
DETECTION
!
OPTIONAL REMOTE SETPOINT INPUT (0/4 to 20 mA)
!
OPTIONAL RS-485 SERIAL COMMUNICATIONS
!
PC SOFTWARE AVAILABLE FOR CONTROLLER CONFIGURATION
!
HEATING AND OPTIONAL COOLING OUTPUTS
!
PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS
!
FIELD REPLACEABLE OUTPUT BOARD
(Relay or Logic/SSR Drive)
UL Recognized Component,
File # E156876 (M)
DESCRIPTION
The T48 Controller accepts signals from a variety of temperature sensors
(thermocouple or RTD elements), precisely displays the process temperature,
and provides an accurate output control signal (time proportional or linear DC)
to maintain the process at the desired temperature. The controller’s
comprehensive yet simple programming allows it to meet a wide variety of
application requirements.
The controller operates 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. The unit can be transferred to operate in the manual mode, providing
the operator with direct control of the output. The controller may also be
programmed to operate in the ON/OFF control mode with adjustable hysteresis.
CAUTION: Read complete
instructions prior to installation
and operation of the unit.
A second setpoint is available on select models to allow quick selection of a
different setpoint setting.
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. On many models the main control output and the alarm outputs
are field replaceable.
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 temperature stabilizes outside the alarm region.
The second alarm can be configured as a secondary PID output (heat/cool
applications).
Optional Main Linear DC output (10 V or 20 mA) can be used for control or
temperature re-transmission 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
temperature re-transmission, while the main Linear DC output is being used for
control. The output range can be scaled independent of the input range.
CAUTION: Risk of electric shock.
DIMENSIONS “In inches (mm)”
PANEL CUT-OUT
1
6. THERMOCOUPLE INPUT:
Types: T, E, J, K, R, S, B, N, Linear mV, software selectable
Input Impedance: 20 MΩ all types
Lead resistance effect: 0.25 µV/Ω
Cold junction compensation: Less than ±1°C typ., (±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.
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.
Optional Remote Setpoint input (0/4 to 20 mA) allows for multiple ganged
controller operation for large oven and extruder applications; allows for cascade
control loops, where tighter control 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 expand
the controller’s flexibility.
The optional RS-485 serial communication interface provides two-way
communication between a T48 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 T48 on the line can be programmed
from 0 to 99. Data from the T48 can be interrogated or changed, and alarm
output(s) may be reset by sending the proper command code via serial
communications. PC software, SFT48, 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.
TC TYPE
T
E
J
K
R
S
B
N
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 T48 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 controller. An independent and
redundant temperature limit indicator with alarm outputs is strongly
recommended.
mV
RTD TYPE
385
392
OHMS
1. DISPLAY: Dual 4-digit
Upper Temperature Display: 0.4" (10.2 mm) high red LED
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED
Display Messages:
-
Appears
Appears
Appears
Appears
Appears
Appears
when
when
when
when
when
when
DV
O1
A1
A2
BS 1843
blue (+)
red (-)
violet (+)
red (-)
white (+)
red (-)
yellow (+)
red (-)
black (+)
red (-)
black (+)
red (-)
grey (+)
red (-)
orange (+)
red (-)
no standard
white (+)
blue (-)
brown (+)
blue (-)
yellow (+)
blue (-)
brown (+)
blue (-)
white (+)
blue (-)
white (+)
blue (-)
no standard
orange (+)
blue (-)
no standard
RANGE
-200 to +600°C
-328 to +1100°F
-200 to +600°C
-328 to +1100°F
1.0 to 320.0
8. 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.)
9. USER INPUT: Internally pulled up to +5 VDC (1 MΩ).
VIN MAX = 5.25 VDC, VIL = 0.85 V max., VIH = 3.65 V min.,
IOFF = 1µA max.
Response Time: 120 msec max.
Functions: Program Lock
Integral Action Lock
Auto/Manual Mode Select
Setpoint Ramp Enable
Reset Alarms
Setpoint 1/Setpoint 2 Select
Local/Remote Setpoint Select Serial block point
measurement exceeds + sensor range.
measurement exceeds - sensor range.
open sensor is detected.
shorted sensor is detected (RTD only)
display values exceed + display range.
display values exceed - display range.
LED Status Annunciators:
%P
MN
-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
7. RTD INPUT: 2 or 3 wire, 100 Ω platinum, alpha = 0.00385 (DIN 43760),
alpha = 0.0039162
Excitation: 150 µA typical
Resolution: 1 or 0.1 degree
Lead Resistance: 15 Ω max. per input lead
SPECIFICATIONS
“OLOL”
“ULUL”
“OPEN”
“SHrt”
“...”
“-..”
RANGE
- Lower auxiliary display shows power output in (%).
- Flashing: Controller is in manual mode.
On: Local Setpoint (Remote Setpoint option)
Off: Remote Setpoint
- Lower auxiliary display shows deviation (error) from
temperature setpoint or shows heater current.
- Main control output is active.
- Alarm #1 is active (for A1 option.).
- Alarm #2 is active OR
- Cooling output (O2) is active
10. 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:
Rating: 45 mA @ 4 V min., 7 V nominal
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
11. 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: Programmable
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 input user for parameter lockout or
other functions.
4. MEMORY: Nonvolatile E2 PROM retains all programmable parameters and
values.
5. MAIN SENSOR INPUT:
Sample Period: 100 msec
Response Time: Less than 300 msec typ., 400 msec max. (to within 99% of
final value w/step input; typically, response is limited to response time of
probe)
Failed Sensor Response:
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.)
Common Mode Rejection: Greater than 120 dB, DC to 60 Hz
Protection: Input overload 120 VAC max. for 15 seconds max.
2
12. ALARMS: 1 or 2 alarms (optional)
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Heater break alarm
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Probe Break Action: Upscale
Annunciator: LED backlight for “A1”, “A2”
13. COOLING: 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
14. 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
ACCURACY *
(18 to 28°C)
ACCURACY *
(0 to 50°C)
COMPLIANCE
RESOLUTION
0 to 10 V
0.10% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
10k ohm min.
1/3500
0 to 20 mA
0.10% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
500 ohm max.
1/3500
4 to 20 mA
0.10% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
500 ohm max.
1/2800
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 (ie. earth ground).
18. ENVIRONMENTAL CONDITIONS:
Operating Range: 0 to 50°C
Storage Range: -40 to 80°C
Span Drift (max.): 130 ppm/°C, main input
Zero Drift (max.): 1µV/°C, main input
Operating and Storage Humidity:
85% max. relative humidity (non-condensing) from 0°C to 50°C.
Altitude: Up to 2000 meters
19. ISOLATION BREAKDOWN RATINGS:
AC line with respect to all inputs and outputs: 2000 Volts
Main input with respect to Analog Output, Remote Setpoint Input,
Heater Current Input: 500 Volts for 60 sec min.
All other inputs and outputs with respect to relay contacts: 2000 VAC
20. CERTIFICATIONS AND COMPLIANCES:
UL Recognized Component: File #E156876 (M)
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 2; 4 Kv contact
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3 Level 3; 10 V/m 1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 Kv I/O
Level 3; 2 Kv power
RF conducted interference
EN 61000-4-6 Level 3; 10 V/rms 2
150 KHz - 80 MHz
Simulation of cordless telephones ENV50204 Level 3; 10 V/m
900 MHz ± 5 MHz
200 Hz, 50% duty cycle
Emissions to EN 50081-2
RF interference
EN 55011 Enclosure class A
Power mains class A
* Accuracies are expressed as ± percentages after 20 minutes 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 temperature
range reflects the temperature coeffecient 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 approximately 10% overrange
and a small underrange (negative) signal.
15. REMOTE SETPOINT INPUT: (optional)
Input type:
0/4 to 20 mA
Input Resistance: 10 Ω
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 +½ LSD)
Over 0 to 50°C range: ±(0.2% of full scale +½ LSD)
Reading Rate: 10/sec.
Setpoint Filtering: Programmable Digital
Setpoint Ramping: Programmable, 0.1 to 999.9 degrees/minute.
16. HEATER CURRENT MONITOR INPUT: (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 Ω
Accuracy:
At 25° C: ±(0.5 % of full scale +½ LSD), (5 to 100% of Range)
Over 0 to 50°C range: ±(1.0% of full scale +½ LSD), (5 to 100% of
Range)
Frequency: 50 to 400 Hz.
Alarm Mode: Dual acting; heater element fail detect and control device fail
detect.
Overrange: 105% Capacity
Overload: 200 mA (continuous).
17. SERIAL COMMUNICATIONS: (optional)
Type: RS485 multipoint, balanced interface
Baud Rate: 300 to 9600
Data Format: 7 data bits, odd, even or no parity, 1 stop bit
Node Address: 0-99, max of 32 units per line
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.
I/O cables routed in metal conduit connected to earth ground.
Install power line filter, RLC #LFIL0000 or equivalent.
2. Permissible loss of performance during EMI disturbance at 10 Vrms:
Process signal deviation less than 3% of full scale.
Analog output deviation less than 1% of full scale.
RSP and HCM signal deviation less than 0.5% of full scale.
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. CONNECTION: Wire clamping screw terminals
22. 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.
23. WEIGHT: 0.38 lbs (0.17 kgs)
3
A Second Linear DC output is dedicated for retransmission of input
temperature. The output can be scaled and converted independent of the input
and Main Linear DC output. This output is isolated from the input.
BASIC OPERATION
The T48 controls a process temperature by measuring the temperature via an
input probe, then calculating a control output power value by use of a modified
PID control algorithm. The unit controls the system with the new output power
value to keep the process temperature at setpoint. The PID control algorithm
incorporates features which provide for high control accuracy and low
temperature overshoot from process disturbances.
SETPOINT FEATURES
The controller setpoint can be protected from out of range values by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can be programmed.
A second setpoint value can be programmed which can be made active by a
user input and/or through the front panel on selected models.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate. This feature reduces
thermal shock to the process and helps to minimize temperature overshoot.
FRONT PANEL FEATURES
In the normal operating mode, the unit displays the process temperature in the
upper display. One of the following parameters can be viewed in the lower
display:
- Setpoint
- % Power Output
- Temperature Deviation
- Heater Current
- Temperature symbol (F or C)
- Blank Display
The user scrolls through these parameters by pressing the D button. If
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the P button
and modified by use of the UP and DOWN buttons. Parameters are then entered
by the P button, which advances the user to the next parameter. Pressing the D
button immediately returns the controller to the normal operating mode without
changing the currently selected parameter.
INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating temperature characteristics, helping to provide better
temperature control. A programmable temperature shift function can be used to
compensate for probe errors or to have multiple T48 units indicate the same
nominal temperature.
The programmable User Input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), transfer to
second setpoint, etc.
OUTPUT FEATURES
Programmable output power limits provide protection for processes where
excessive power can cause damage. Automatic sensor probe break detection, for
fail-safe operation, causes the controller to default to a programmed output
power (upscale or downscale burnout). Programmable output cycle time, output
hysteresis and dampening can reduce output activity without degrading control
accuracy. The main outputs can operate in PID, ON/OFF, or manual control
modes.
HARDWARE FEATURES
A fast 100 msec input sampling rate provides quick controller response to a
process disturbance, thus providing excellent temperature control. Measurement
accuracy of 0.3% of span ±1°C or better, provides close process control
conforming to the desired control setpoint value. The T48 accepts a variety of
both thermocouple and RTD temperature probes. An output board contains the
Main Control output, Alarm 1 output, Alarm 2/Cooling output, and/or Linear
DC output. Since the controller is serviceable from the front of the panel, the
output board (on some models) may be easily changed or replaced without
disturbing the wiring behind the panel. No re-programming is required when
changing or replacing the output board for units without the Linear DC output
option. Units with the linear output option require calibration procedure for the
new linear output.
Low-drift, highly stable circuitry ensures years of reliable and accurate
temperature control. The recommended two year re-calibration interval is easily
accomplished via the programming menu.
CONTROL AND ALARM OUTPUTS
In addition to the Linear DC outputs, 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, that can switch up to 45
Amps. 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.
AUTO-TUNE
The T48 has an auto-tune feature which, on demand, automatically
determines the PID control parameters for a particular thermal process. After
completion of auto-tune, the PID parameters are automatically optimized for
that process and loaded into non-volatile memory. The operator may view and
modify the parameters as desired.
Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
various levels of process control and response characteristics.
REMOTE SETPOINT INPUT
The remote setpoint input facilitates the use of a remote signal to drive the
controller’s setpoint. The remote signal can be scaled independent to that of the
controller’s range. The controller’s response to local/remote setpoint transfers
can be programmed. Also, the remote signal is filtered by use of an adaptive
filter. With this filter, relatively large filtering time constants can be used
without suffering from long settling times. The time constant and filter disable
band are programmable. Additionally, the remote signal can also be velocity
limited (or ramped) to slow the controller’s response to changes in setpoint.
This results in a steady control response with no overshoot.
RS-485 Communications
The RS-485 communications option allows the connection of up to 32
devices on a single pair of wires with a distance of up to 4,000 feet and a
maximum baud rate of 9600. Since the same pair of wires are used for both
transmit and receive, only one way communication is possible at any given
time. The controller has a programmable response time to allow the host device
adequate time to release the communication line for a transmission.
Selected parameters from the T48 can be interrogated or changed, and alarm
output(s) may be reset by sending the proper command code via serial
communications. It is also possible to invoke Auto-tune through the serial port.
Serial communications used with SFT48 software allows for easy controller
parameter configuration by computer.
HEATER CURRENT MONITOR
The T48 provides a direct readout of process heater current. This provides
valuable information regarding single phase heater system integrity. It is
especially useful on extruder and large oven applications where adjacent
controllers mask the effect of a failed heater. The heater break alarm senses two
types of heater system faults:
1) Main control output is “on” and heater current is below alarm value. This
indicates failed heater or failed parts of heater, breaker trip, failed power
control device, etc.
2) Main control output is “off” and heater current is above 10% of alarm value.
This indicates a failed power control device, wiring fault, etc.
HEATING AND COOLING SYSTEMS
The T48 is available with dual outputs to provide heating and cooling to
those processes that require them. For example, many extruder applications
require both heating and cooling to maintain accurate extruder barrel and die
temperatures. The T48 is easily configured for these types of applications.
LINEAR DC ANALOG OUTPUTS
The Main Linear DC output has independent scaling, programmable output
update time and filter (damping) time. These parameters permit flexibility in
process configuration. The output can be set for 0 to 10V, 0 to 20 mA or 4 to 20
mA ranges, and can be configured for control or for transmission of temperature
or setpoint values.
4
Configuration 2, Outputs (2-OP) *
CONTROLLER PROGRAMMING
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“OPdP”
“CHYS”
“tcod”
“AntP”
“ANAS”
“ANut”
“ANLO”
“ANHI”
Front Panel Program Disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial set-up.
The following four programming modes allow the controller to adapt to any
required user-interface level:
Unprotected Parameter Mode
Protected Parameter Mode
Hidden Function Mode
Configuration Parameter Mode
UNPROTECTED PARAMETERS MODE *
The Unprotected Parameters Mode is accessible from the Normal Display
Mode when program disable is inactive or when the proper access code number
from the Protected Parameter Mode is entered. The Configuration Parameter
Modes can be accessed only from this mode.
“SP”
“OP”
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CNFP”
“End”
-
“SP”
“OP”
“dEv”
“Hcur”
“UdSP”
“CodE”
“PId”
“AL”
“ALrS”
“SPSL”
“trnF”
“tUNE”
Enter setpoint
Enter output power
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Select configuration access point
Return to normal display mode
“Act1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Enter value to access unprotected parameters and
configuration parameters
“CYC2”
“GAN2”
“db-2”
“bAUd”
“PArb”
“Add”
“Abr”
“PoPt”
Select local (SP1 or SP2) or remote setpoint
Transfer between automatic (PID) control and manual control
Invoke/cancel PID Auto-tune
Reset latched alarms
“dSP1”
“INP1”
“dSP2”
“INP2”
“FLtr”
“bAnd”
“trnF”
The Configuration Parameter Mode allows the operator to set-up the basic
requirements of the controller. It is divided into sections which group together
related programming steps, such as inputs, outputs, alarms, etc. Upon
completion of each section, the program returns to the Configuration Access
Point, allowing the user to return to the Normal Display Mode.
- Enter cooling time proportioning cycle time
- Enter cooling relative gain
- Enter heat/cool deadband or overlap
-
Select baud rate
Select parity bit
Enter address
Select abbreviated or full transmission
Select print options
-
Enter remote setpoint display scaling value #1
Enter remote setpoint process scaling value #1
Enter remote setpoint display scaling value #2
Enter remote setpoint process scaling value #2
Enter remote setpoint filter time constant
Enter remote setpoint filter disable band
Select Local/Remote setpoint transfer response
Configuration 7 - Heater Current Parameters (7-N2) *
“Hcur”
Configuration 1, Inputs (1-IN)
-
Select operation mode of alarm #1, or select heat output
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2, or select cooling output
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
Configuration 7, Remote Setpoint Input (7-N2) *
CONFIGURATION PARAMETER MODE
“TYPE”
“SCAL”
“dCPt”
“FLtr”
“SHFt”
“SPLO”
“SPHI”
“SPrP”
“InPt”
-
Configuration 6, Serial Communications (6-SC) *
The Hidden Function Mode is accessible from the Normal Display Mode.
The functions in this mode may be locked-out individually in Configuration 3
parameter (lock-out section).
-
Select setpoint access level
Select power access level
Enable deviation display
Enable heater current display
Enable temperature scale display
Enter parameter access code
Select PID access level
Select alarm access level
Enable alarm reset access
Enable local/remote selection
Enable auto/manual mode selection
Enable auto-tune invocation
Configuration 5, Cooling (5-O2) *
HIDDEN FUNCTION MODE *
“SPSL”
“trnF”
“tUNE”
“ALrS”
-
Configuration 4, Alarms (4-AL) *
The Protected Parameters Mode is enabled when program disable is active.
This mode prevents access to the Configuration Parameter Modes without the
proper access code number. Only the parameters that are enabled in the
Configuration 3 parameter (lock-out section) can be accessed.
-
Enter time proportioning cycle time
Select output control action
Enter output power low limit
Enter output power high limit
Enter probe fail power preset
Enter output control dampening
Enter ON/OFF control hysteresis
Select auto-tuning dampening
Main Linear DC analog output range
Main Linear DC analog output source
Main Linear DC analog output update time
Main Linear DC analog output scaling low
Main Linear DC analog output scaling high
Configuration 3, Parameter Lock-Outs (3-LC) *
PROTECTED PARAMETERS MODE *
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CodE”
-
- Enter full scale rating of CT
Configuration 8, Second Linear DC Analog Output (8-A2) *
Select input probe type
Select temperature scale
Select temperature resolution
Select level of input filtering
Enter input correction shift (offset)
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function
“A2tP”
“A2LO”
“A2HI”
- Second linear DC analog range
- Second linear DC analog scaling low
- Second linear DC analog scaling high
Configuration 9, Factory Service Operations (9-FS)
“Code 48”
“Code 66”
- Calibrate Instrument
- Reset parameters to factory setting
* These parameters may not appear due to option configuration or other
programming.
5
MULTIPLE UNIT STACKING
ACCESSORY - EXTERNAL SSR POWER UNIT
The T48 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.
The external SSR Power Unit is used with T48’s equipped with Logic/SSR
Drive outputs to switch loads up to 240 VAC @ 45 Amps, 25°C ambient. The
unit is operated by applying a low level DC control signal to the isolated
input. The unit features zero cross detection circuits which reduces radiated
RFI when switching load currents. With no contacts to wear out, the SSR
Power Unit provides virtually limitless operational life. The unit is supplied
with an integral heat sink for immediate installation.
Note: When stacking units, provide adequate panel ventilation to ensure that
the maximum operating temperature range is not exceeded.
PANEL LATCH INSTALLED FOR
VERTICAL UNIT STACKING
PANEL LATCH INSTALLED FOR
HORIZONTAL UNIT STACKING
PANEL CUT-OUT SPACING FOR MULTIPLE UNIT STACKING.
HORIZONTAL ARRANGEMENT SHOWN.
External SSR Power Unit:
Part Number: RLY50000
Switched Voltage Range: 50 to 280 VAC
Load Current: 45 Amps max. @ 25°C ambient temperature
35 Amps max. @ 50°C ambient temperature
On State Input: 3 to 32 VDC @ 1500 Ω impedance. (isolated)
(Use Logic/SSR drive output .)
Off State Input: 0.0 to 1.0 VDC
Size: 5.5" (14 cm) L x 4.75" (12 cm) W x 2.62" (6.6 cm) H
ACCESSORY - CURRENT TRANSFORMER-50A
The external Current Transformer is used when specifying the T48’s
equipped with the Heater Current Monitor.
ACCESSORY - CURRENT TRANSFORMER-40A
The external Current Transformer is used when specifying the T48’s
equipped with the Heater Current Monitor.
Current Transformers:
Part Number: CT004001
Current Ratio: 40 : 0.1 (Amperes)
Max Heater Current: 50 A
Dielectric Strength: 1000 VAC (For 1 minute)
Vibration Resistance: 50 Hz (Approx 10 G)
Terminals: Solder Type
Window Diameter: 0.228" (5.8 mm)
Weight: 0.406 oz (11.5 g)
Part Number: CT005001
Current Ratio: 50 : 0.1 (Amperes)
Operation Frequency: 50 to 400 Hz
Insulation Class: 0.6 KV BIL, 10 KV full wave.VA 60 H2 Burden 2.5
Terminals: Brass studs No. 8-32 UNC with one flat washer, lockwasher,
and hex nut.
Window Diameter: 1.13" (28.7 mm)
Weight: 8 oz (226.0g)
6
APPLICATION
(Terminal assignments are model number dependent.)
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 to provide a readout of the
heater current. 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.
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 “time proportioning” 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). 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 on when the paint temperature is outside the
manufacturer’s specifications.
(Terminal assignments are model number dependent.)
MULTIPLE UNIT/REMOTE SETPOINT APPLICATION
Whenever the master controller’s setpoint is changed, the slave controller’s
setpoint changes automatically.
The remote setpoint input at each slave controller can be scaled
independently.
Eight T48 controllers are used in a drying oven. Each T48 controls a zone
within the oven. Depending upon the material to be dried, and its initial
moisture content, the drying setpoint temperature varies. A master T48
controller transmits setpoint via linear DC output. This signal is received as
a remote setpoint signal by the other slave controllers.
(Terminal assignments are model number dependent.)
7
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 RS-485 AND LINEAR DC ANALOG OUTPUT
DEDICATED
MAIN CONTROL
01 OUTPUT
DEDICATED
ALARM 1
A1 OUTPUT
(ALARM 2)
A2 OR 02
(COOL)*
REMOTE
SETPOINT
INPUT
HEATER
CURRENT
[email protected]
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
YES
YES
Logic/SSR
Logic/SSR
Relay
Logic/SSR
Relay
Relay
Logic/SSR
Relay
Relay
Logic/SSR
Relay
Relay
Triac
Logic/SSR
Logic/SSR
YES
YES
PART NUMBERS
REPLACEMENT
OUTPUT
BOARD
18-36 VDC/24 VAC
85 TO 250 VAC
RBD48100
T4810010
T4810000
RBD48111
NA
T4811000
RBD48111
T4811110
T4811100
RBD48111
T4811113
T4811103
RBD48111
T4811114
T4811104
RBD48200
T4820010
T4820000
RBD48211
NA
T4821000
RBD48211
T4821110
T4821100
RBD48211
T4821113
T4821103
RBD48211
T4821114
T4821104
NA
T4832210
T4832200
* - These part numbers have a single output, programmable as either Control (PID) or as an Alarm.
@ - These part numbers are software V4.0 or greater, and are equipped with a second setpoint.
Option Boards are installed at the factory for the appropriate models. These boards are only needed for field replacement.
MODELS WITH RS-485 OR LINEAR DC ANALOG OUTPUT
DEDICATED
MAIN CONTROL
O1 OUTPUT
MAIN CONTROL
O1 OR A1
(ALARM 1) *
DEDICATED
ALARM 1
A1 OUTPUT
(ALARM 2)
A2 OR O2
(COOL) *
REMOTE
SETPOINT
INPUT @
HEATER
CURRENT
INPUT @
Relay
RS485
@
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
NA
T4810002
T481010A
YES
T4810111
T4810101
YES
T4810115
T4810105
YES
T4810116
T4810106
YES
T4810117
T4810107
YES
T4810118
T4810108
YES
T4810119
T4810109
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Logic/SSR
Relay
YES
YES
YES
YES
Relay
Logic/SSR
1
YES
YES
2
T4811102
YES
T4820211
T4820201
YES
T4820215
T4820205
YES
T4820216
T4820206
YES
T4820218
T4820208
YES
T4820219
T4820209
YES
T4821112
T4821102
YES
YES
YES
Relay
YES
T4811112
YES
YES
PART NUMBERS
SECOND
ANALOG
OUTPUT** @ 18-36 VDC/24 VAC 85 TO 250 VAC
T481011A
YES
Relay
MAIN
ANALOG
OUTPUT** @
* - These part numbers have a single output, 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 software V4.0 or greater, and are equipped with a second setpoint.
- Replacement Output Board RBD48100 may be used.
2 - Replacement Output Board RBD48111 may be used.
1
ACCESSORIES
MODEL
DESCRIPTION
PART NUMBERS
RLY
External SSR Power Unit (for Logic/SSR output models)
RLY50000
CT
40 Ampere Current Transformer (for Heater Current Input models)
CT004001
CT
50 Ampere Current Transformer (for Heater Current Input models)
CT005001
SFT48
Red Lion Controls
20 Willow Springs Circle
York PA 17402
PC Configuration Software for Windows 3.x and 95 (3.5" disk) (for RS-485 models)
Red Lion Controls France
56 Boulevard du Courcerin, Batiment 21,
ZI Pariest F-77183 Croissy Beaubourg
SFT48
Red Lion UK Ltd
Tapton Park
Chesterfield S41 OTZ
Tel +1 (717) 767-6511
Tel +33 (64) 80 12 12
Tel +44 (1246) 22 21 22
Fax +1 (717) 764-6587
Fax +33 (64) 80 12 13
Fax +44 (1246) 22 12 22
Bulletin No. TCU-G
Drawing No. LP0314
Released 1/05
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL TCU - TEMPERATURE CONTROL UNIT
C
UL
R
US LISTED
IND. CONT. EQ.
G
SELF-DIAGNOSTICS
G
FULL PID CONTROL WITH REDUCED OVERSHOOT
G
OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE
G
OPTIONAL DUAL ALARM OUTPUTS (USES OUTPUT MODULES)
G
OPTIONAL COOLING OUTPUT (USES OUTPUT MODULE)
G
OPTIONAL LINEAR 4 to 20 mA or 0 to 10 VDC OUTPUT FOR
CONTROL OR TEMPERATURE RE-TRANSMISSION
G
OPTIONAL HEATER CURRENT MONITOR AND BREAK ALARM
G
OPTIONAL MOTORIZED VALVE POSITION CONTROL AND
VALVE FAIL ALARM
G
OPTIONAL SECOND ANALOG INPUT FOR REMOTE SETPOINT
AND CASCADE CONTROL
G
OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL
G
STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES
G
PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED
FLEXIBILITY
G
SENSOR ERROR COMPENSATION (Slope and Offset) AND
BREAK DETECTION
51EB
G
100 msec SAMPLING PERIOD WITH 0.15% ACCURACY
G
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
G
G
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
TEMPERATURE AND SETPOINT, SECOND ANALOG INPUT OR
HEATER CURRENT
MANUAL/AUTOMATIC AND LOCAL/REMOTE SETPOINT
CONTROL MODES
G
SETPOINT RAMPING FOR PROCESS STARTUP
G
PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS
ACCEPTS 10 DIFFERENT TYPES OF SENSOR INPUTS
(Thermocouple or RTD)
G
FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR Drive and Triac)
G
DESCRIPTION
The TCU Controller accepts signals from a variety of temperature sensors
(thermocouple or RTD elements), precisely displays the process temperature,
and provides an accurate output control signal (time proportional or linear) to
maintain a process at the desired control point. A comprehensive set of easy to
use steps allows the controller to solve various 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. The unit can be transferred to operate in the manual mode, providing
the operator with direct control of the output. The controller may also be
programmed to operate in the ON/OFF control mode with adjustable hysteresis.
DIMENSIONS In inches (mm)
Dual 4-digit displays allow viewing of the process temperature and setpoint
simultaneously. Front panel indicators inform the operator of the controller and
output status. Replaceable and interchangeable output modules (relay, SSR
drive, or triac) can be installed for the main control output, alarm output(s) and
cooling output.
Optional dual alarms can be configured to activate according to a variety of
actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT, Heater
Break and Valve Fail Detect) with adjustable hysteresis. A standby feature
suppresses the output during power-up until the temperature stabilizes outside
the alarm region. An optional secondary output is available (for processes that
require cooling) which provides increased control accuracy and response.
Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.
PANEL CUT-OUT
1
“-...”
“SLid”
“VALV”
DESCRIPTION (Cont’d)
OPTIONS
A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface
with actuators, chart recorders, indicators, or other controllers. The output
signal can be digitally scaled and selected to transmit one of the following: %
output power, process temperature value, process temperature value deviation
or setpoint value. For Linear DC control applications, the adjustable output
demand dampening, output deadband and output update time parameters
expand the versatility of the TCU with final control devices.
The optional Heater Current Monitor serves as a digital ammeter for heater
current monitoring. Current transformer accessory (CT005001), is required. An
alarm event output can be programmed to signal when the heater or heater
control devices have failed, before damage to process material occurs. The
Heater Break alarm triggers under two conditions:
1) The main output (OP1) is “on” and the heater current is below the heater
current alarm value, indicating an aged or failed heater.
2) Output (OP1) is “off” and the heater current is more than 10% of the alarm
value, indicating a shorted heater control device or other problem.
The optional Motorized Valve Positioner directly controls the position of a
valve by the use of twin outputs (open and close) to control the direction of
motor rotation. The motor position defines the opening position of the valve.
Two control modes are possible: position control, which makes use of the
slidewire feedback signal supplied with the positioner and velocity control, in
which no slidewire feedback signal is used. Parameters are provided to adjust
the operation of the valve. These include:
Valve activity hysteresis
Valve update time
Variable control dampening
Slidewire signal fail action
Adjustable valve position limits.
The valve positioner TCU achieves tight process control, yet minimizes
unnecessary valve activity. An alarm event output or display alarm can be
programmed under loss of slidewire feedback or under valve fail detection.
The optional Second Analog Input (0-20 mA DC) can be configured as a
remote setpoint signal or as a secondary process signal. Configuration of the
second analog input as a remote setpoint signal allows ratio control, master
setpoint/multiple slave operation, and the ability to cascade the TCU with
another controller (external cascade). Configuration of the second input as a
secondary process signal allows operation as a two-process cascade controller
within a single unit (internal cascade). In either control mode, parameters are
provided to scale, configure, communicate and monitor the activity of both
analog inputs. A square law linearizer function can be used to linearize signals
derived from flow transmitters.
The optional RS485 multidrop serial communication interface provides twoway communication between a TCU unit and other compatible equipment such
as a printer, a programmable controller, or a host computer. In multipoint
applications the address number of each unit on the line can be programmed from
0-99. Up to thirty-two units can be installed on a single pair of wires. The
Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be interrogated or
changed by sending the proper command code via serial communications. Alarm
output(s) may also be reset via the serial communications interface option.
An optional NEMA 4X/IP65 rated bezel is available for wash down and/or
dirty environments, when properly installed. Modern surface-mount
technology, extensive testing, plus high immunity to noise interference makes
the controller extremely reliable in industrial environments.
2. POWER: 115/230 VAC (+10%, -15%) no observable line variation effect, 48
to 62 Hz, 10 VA, switch selectable
3. ANNUNCIATORS:
LED Backlight Status Indicators (Model dependent):
%PW
DEV
OP1
AL1
AL2
OP2
OPN
CLS
CUR
SEC
MAN
REM
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 TCU to directly command motors, valves, or other actuators
not equipped with safeguards. To do so, can be potentially harmful to persons
or equipment in the event of a fault to the unit. An independent and redundant
temperature limit indicator with alarm outputs is strongly recommended. Red
Lion Controls model IMT (thermocouple) or model IMR (RTD) units may be
used for this purpose. The indicators should have input sensors and AC power
feeds independent from other equipment.
TC TYPE
T
E
J
K
R
S
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Temperature Display: 0.4" (10.2 mm) high red LED
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED
Display Messages (Model dependent):
-
Appears
Appears
Appears
Appears
Appears
when
when
when
when
when
- Lower auxiliary display shows power output in (%).
- Lower auxiliary display shows deviation (error)
from temperature setpoint.
- Main control output is active.
- Alarm #1 is active.
- Alarm #2 is active (for Dual Alarm Option).
- Cooling output is active (for Cooling Option).
- Valve positioner OPEN output is active
(for Valve Positioner option).
- Valve positioner CLOSE output is active
(for Valve Positioner option).
- Lower auxiliary display shows heater current
(for Heater Current Monitor option).
- Lower auxiliary display shows second analog input
(For Second Analog Input option).
- Flashing: Controller is in manual mode.
- ON: controller is in remote setpoint mode
(Second Analog Input option).
- OFF: controller is in local setpoint mode
(Second Analog Input option).
- Flashing: controller is in Manual control mode
(Second Analog Input optional).
4. CONTROLS: Four front panel push buttons for modifying and setup of
controller functions and one external input for parameter lockout or other
functions.
5. MAIN SENSOR INPUT:
Sample Period: 100 msec
Response Time: 300 msec (to within 99% of final value w/step input;
typically, response is limited to response time of probe)
Failed Sensor Response:
Main Control Output(s): Programmable preset output
Display: “OPEN”
Alarms: Upscale drive
DC Linear: Programmable preset output
Normal Mode Rejection: 40 dB @ 50/60 Hz (improves with increased
digital filtering.
Common Mode Rejection: 100 dB, DC to 60 Hz
Protection: Input overload 120 VAC for 30 seconds.
6. THERMOCOUPLE:
Types: T, E, J, K, R, S, B, N, Linear mV
Input Impedance: 20 M Ω all types
Lead resistance effect: 20 µV/350 Ω
Cold junction compensation: Less than ±1°C error over 0 - 50°C ambient
temperature range. Disabled for Linear mV type.
Resolution: 1°C/F all types, or 0.1°C/F for T, E, J, K, and N only.
7. RTD: 2, 3 or 4 wire, 100 Ω platinum, alpha = 0.00385 (DIN 43760),
alpha = 0.003916
Excitation: 0.175 mA
Resolution: 1 or 0.1 degree
Lead Resistance: 7 Ω maximum
8. RANGE AND ACCURACY:
Errors include NIST conformity and A/D conversion errors at 23°C after 20
min. warm-up. Thermocouple errors include cold junction effect. Errors are
expressed as ±percent of reading and ± 3/4 LSD unless otherwise noted.
SAFETY SUMMARY
“OLOL”
“ULUL”
“OPEN”
“SHrt”
“....”
- Appears when display values exceed - display range.
- Appears when loss of slidewire signal is detected.
- Appears when valve actuator error is detected.
B
N
mV
RTD
(385)
RTD
(392)
OHMS
measurement exceeds + sensor range.
measurement exceeds - sensor range.
open sensor is detected.
shorted sensor is detected (RTD only)
display values exceed + display range.
2
RANGE
ACCURACY
-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
+200 to +1820°C
+300 to +3308°F
-200 to +1300°C
-328 to +2372°F
-5.00 to 56.00
-200 to +600°C
-328 to +1100°F
-200 to +600°C
-328 to +1100°F
1.0 to 320.0
0.20% + 1.5°C
0.20% + 2.7°F
0.20% + 1.5°C
0.20% + 2.7°F
0.15% + 1.5°C
0.15% + 2.7°F
0.20% + 1.5°C
0.20% + 2.7°F
0.15% + 2.5°C
0.15% + 4.5°F
0.15% + 2.5°C
0.15% + 4.5°F
0.15% + 2.5°C
0.15% + 4.5°F
0.20% + 1.5°C
0.20% + 2.5°F
0.15% + 1 LSD
0.10% + 0.5°C
0.10% + 0.9°F
0.10% + 0.5°C
0.10% + 0.9°F
0.15% + 1 LSD
WIRE COLOR
(ANSI)
blue
violet
white
yellow
black
black
grey
orange
__
__
__
__
9. OUTPUT MODULES [Optional] (For All Output Channels):
Relay:
Type: Form-C (Form-A with some models. See Ordering Information.)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load)
Life Expectancy: 100,000 cycles at max. load rating. (Decreasing load
and/or increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA max.
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 Amp @ 35°C
0.75 Amp @ 50°C
Min. Load Current: 10 mA max.
Offstate Leakage Current: 7mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
10. MAIN CONTROL OUTPUT (Heating or Cooling):
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Auto-tune: When selected, sets proportional band, integral time, and
derivative time values.
Probe Break Action: Programmable
11 . COOLING OUTPUT (Optional):
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Proportional Gain Adjust: Programmable
Heat/Cool Deadband Overlap: Programmable
12. LINEAR DC OUTPUT (Optional): With digital scale and offset,
programmable deadband and update time.
4 to 20 mA:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 25 µA)
Compliance: 10 V (500 Ω max. loop impedance)
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV)
Min. Load Resistance: 10 KΩ (1 mA max.)
Source: % output power, setpoint, deviation, or temperature
(Available for heat or cool, but not both.)
13. HEATER CURRENT MONITOR (Optional):
Type: Single phase, full wave monitoring of load currents controlled by main
output (OP1)
Input: 100 mA AC output from current transformer RLC part number
CT005001 or any current transformer with 100 mA AC output
Display Scale Range: 1.0 to 999.9 amperes or 100.0%
Input resistance: 5 Ω
Accuracy: 1% of full scale ±1 LSD (10 to 100% of range)
Frequency: 50 to 400 Hz
Alarm mode: Dual acting; heater element fail detect and control device fail
detect
Overload: 200 mA (steady state)
Min. output “on” time for Heater break alarm detect: 400 msec
14. MOTORIZED VALVE POSITIONER (Optional):
Two Outputs: Valve open and valve close or Linear DC (optional)
Hardware: Plug-in, replaceable output modules
Three Inputs: Slidewire feedback, signal fail detect (Isolated from main
input)
Slidewire Resistance: 100 to 100 KΩ
Slidewire Exciting Voltage: 0.9 VDC
Slidewire Fail Action: programmable
Control Mode: Position mode (with slidewire) and velocity mode (w/o
slidewire).
Control Deadband: 1% to 25.0% (position mode)
0.1 to 25.0 seconds (velocity mode)
Update Time: 1 to 250 seconds
Motor Time (open, close): 1 to 9999 seconds
Position Limits: Adjustable 0.0 to 100.0% of valve stroke
Valve Fail Time: Off to 9999 seconds
Alarm mode: Dual acting; loss of slidewire feedback signal and valve fail
detection
15. SECOND ANALOG INPUT:
Range: 0 to 20 mA (Isolated from main input)
Overload: 100 mA (steady state)
Input Resistance: 10 Ω
Voltage Drop (@ 20 mA): 0.2 V
Accuracy: 0.15% of reading ±10 µA ±1 LSD
Scale Range: -999 to 9999
16. SERIAL COMMUNICATION:
Type: RS485 Multi-point, Balanced Interface
Communication Format:
Baud Rate: Programmable from 300 to 9600
Parity: Programmable for odd, even, or no parity
Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit
Unit Address: Programmable from 0 to 99, max. of 32 units per line
Transmit Delay: 100 msec min., 200 msec max.
RS485 Common: Isolated from signal input common
Auto Print Time: Off to 9999 seconds between print-outs
17. USER INPUT (Optional): Internally pulled up to +5 VDC.
VIN MAX = 5.25 VDC, VIL = 0.85 VMAX; VIH = 3.0 VMIN,
Available on all second input (HCM, MVP & ANA) models, and on models
with RS485.
Response Time: 100 msec max.
Functions: Program Lock
Integral Action Lock
Auto/Manual Mode Select
Setpoint Ramp Select
Reset Alarms
Print Request
Local/Remote Setpoint Select
18. ALARMS (Optional):
Hardware: Plug-in, replaceable output module
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Heater break
Valve fail
Second Analog Input monitoring
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Probe Break Action: Upscale
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with cooling output or motorized valve position option.)
19. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 50°C
Storage Temperature Range: -40 to 80°C
Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input
Operating and Storage Humidity:
85% max. (non-condensing) from 0 to 50°C
Zero Drift (maximum): 1 µV/°C, main input;2 µA/°C, second input
Altitude: Up to 2000 meters
20. ISOLATION BREAKDOWN RATINGS:
All inputs and outputs with respect to AC line: 2300 V
Analog Outputs, Second Analog Input, Heater Current Input or
Slidewire Input with respect to main input: 500 V
21. CERTIFICATIONS AND COMPLIANCES:
SAFETY
UL Listed, File #E137808, UL508, CSA C22.2 No. 14-M95
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
UL Recognized Component, File #E156876, UL873, CSA 22.2 No. 24
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
Type 2 or 4X Enclosure rating (Face only), UL50
IECEE CB Scheme Test Certificate # UL1239-156876/USA,
CB Scheme Test Report # 96ME50279-070794
Issued by Underwriters Laboratories, Inc.
IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part 1.
IP65 Enclosure rating (Face only), IEC 529
3
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2
Electromagnetic RF fields
EN 61000-4-3
Fast transients (burst)
EN 61000-4-4
RF conducted interference
EN 61000-4-6
Emissions to EN 50081-2
RF interference
EN 55011
Pressing the DSP button immediately returns the controller to the normal
operating mode when making a parameter change. The controller’s
configuration and parameter settings are stored in an internal E2PROM device.
Level 2; 4 Kv contact
Level 3; 8 Kv air
Level 3; 10 V/m1
80 MHz - 1 GHz
Level 4; 2 Kv I/O
Level 3; 2 Kv power
Level 3; 10 V/rms2
150 KHz - 80 MHz
HARDWARE FEATURES
The fast 100 msec input sampling rate provides quick controller response to a
process disturbance, thus providing excellent temperature control. Measurement
accuracy of 0.15% or better, provides closer process control conforming to the
desired control setpoint value. One model accepts a variety of both thermocouple
or RTD temperature probes. The AC input power is switch selectable, allowing
the unit to operate from either 115 VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the output modules may be easily changed
or replaced without disturbing the wiring behind the panel. No re-programming is
required when changing or replacing modules.
The optional NEMA 4X/IP65 rated model utilizes two bezel securing screws
and a neoprene gasket to guarantee a water tight seal, when properly installed.
The standard model simply requires pressing a latch to remove the unit.
Low-drift, highly stable circuitry ensures years of reliable and accurate
temperature control. The recommended two-year re-calibration interval is easily
accomplished via the programming menu.
Enclosure class A
Power mains class A
Notes:
1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:
Analog output signal, Heater Current Monitor input and Motorized
Valve Positioner input signal may deviate during EMI disturbance.
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent.
2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
Analog output signal may deviate during EMI disturbance.
For operation without loss of performance:
a. Install power line filter, RLC #LFIL0000 or equivalent.
b. Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to
cable at unit.
Refer to the EMC Installation Guidelines section of the manual for additional
information.
22. CONNECTION: Jaw-type terminal block
Wire Range: 12-30 AWG copper wire
Torque: 5-7 inch-lbs (56-79 N-cm)
23. CONSTRUCTION: NEMA 2 For Standard Models.
Front Panel: Flame and scratch resistant tinted plastic
Case: High impact black plastic. (Mounting collar included)
NEMA 4X/IP65 model only: Sealed bezel utilizing two captive mounting
screws (panel gasket included). This unit is rated for NEMA 4X/IP65
indoor use. Installation Category II, Pollution Degree 2
24. WEIGHT: 1.3 lbs (0.6 kgs)
SETPOINT FEATURES
The controller setpoint can be protected from out of range values by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can be programmed.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate. This feature reduces
thermal shock to the process and helps to minimize temperature overshoot.The
setpoint may also be transmitted by the optional linear DC output for slave
control loops.
The second analog input may be configured as a remote setpoint. As such, the
controller is easily switched from local/remote setpoint operation via the front
panel or user input. Ratio and bias parameters provide on-line scaling of the
remote setpoint. Absolute limit values and maximum rate of change of the
remote setpoint further enhance controller flexibility.
INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating temperature characteristics, helping to provide better
temperature control. A programmable temperature shift and slope function can
be used to compensate for probe errors or to have multiple TCU units indicate
the same nominal temperature.
The programmable User Input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), etc.
The second analog input has independent scaling parameters to match the
units of other processes or transmitters, or to match the controller’s range.
ACCESSORIES:
External SSR Power Unit:
Switched Voltage Range: 50 to 280 VAC (Nominal: 240 VAC)
Load Current: 45 Amps @ 25°C ambient temperature
35 Amps @ 50°C ambient temperature
On State Input: 3 to 32 VDC @ 1500 Ω impedance. (isolated)
(Use Logic/SSR drive output module.)
Off State Input: 0.0 to 1.0 VDC
Size: 5.5" (14 cm) L x 4.75" (12 cm) W x 2.62" (6.6 cm) H
Current Transformer:
Current Ratio: 50:0.1 (Amperes)
Accuracy: ±5.0%
Operating Frequency: 50 to 400 Hz
Insulation Class: 0.6 Kv BIL 10 Kv full wave
Terminals: Brass studs No. 8-36, (flat washer, washer, nut)
Weight: 8.0 oz (226 g)
Approvals: UL recognized component
OUTPUT FEATURES
Programmable output power limits provide protection for processes where
excessive power can cause damage. Automatic sensor probe break detection, for
fail-safe operation, causes the controller to default to a programmed output
power (upscale or downscale burnout). With adjustable time proportioningcycle time, and programmable DC linear output, the controller can satisfy a
wide variety of output requirements.
Programmable dampening output hysteresis and output update time parameters
can dramatically reduce actuator activity without degrading control accuracy.
The RS485 Communication option allows the user to access various
controller parameters such as the setpoint, % output power, % proportional
band, etc. The controller may be setup to transmit various parameters at a
programmable automatic print rate.
BASIC OPERATION
The TCU controls a process temperature by measuring the temperature via an
input probe, then calculating a control output power value by use of a modified
PID control algorithm. The unit controls the system with the new output power
value to keep the process temperature at setpoint. The PID control algorithm
incorporates features which provide for high control accuracy and low
temperature overshoot from process disturbances.
AUTO-TUNE
The TCU has an auto-tune feature which, on demand, automatically
determines the PID control parameters for a particular thermal process. After
completion of auto-tune, the PID parameters are automatically optimized for
that process and loaded into nonvolatile memory. The operator may view and
modify the parameters as desired.
Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
various levels of process control and response characteristics.
FRONT PANEL FEATURES
In the normal operating mode, the unit will display the process temperature
in the upper display. One of six other parameters can be viewed in the lower
display:
- Setpoint
- % Power Output
- Temperature Deviation
- Heater Current
- Second Input Process Value
- Temperature Symbol (F or C)
The six parameters can be scrolled through by pressing the DSP button. If
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the PAR
button and modified by use of the UP and DOWN buttons. Parameters are then
entered by the PAR button, which advances the user to the next parameter.
4
INTERNAL CASCADE
OPTIONS
HEATING AND COOLING CONTROL
Cascade control allows the process to be divided into two control loops: the
primary control loop and the secondary control loop. The secondary loop
receives it’s setpoint from the primary loop to control an intermediate variable
(steam pressure). The control level of the intermediate variable is the input to
the primary process. The primary loop (temperature) controller maintains loop
regulation by manipulating the setpoint of the secondary controller. The
setpoint of the secondary controller, in turn, changes the intermediate variable.
The secondary loop can react faster to disturbances of the intermediate variable,
thereby minimizing the effects to the primary control loop. Control loops
cascaded in such a manner provide greater control quality than would be
possible with single loop control. A single TCU can accomplish two-process
cascade control.
Internal Cascade Configuration Parameters
The TCU has dual outputs for providing heating and cooling to those
processes that require them. Many extruder applications require both heating
and cooling to maintain accurate extruder barrel and die temperatures. The TCU
is easily configured for these applications.
Cooling Configuration Parameters
“CYC2”
“GAN2”
“db-2”
- Enter cooling time proportioning cycle time
- Enter cooling relative gain
- Enter heat/cool deadband or overlap
HEATER CURRENT MONITOR
“OPer”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“OPd2”
-
Select cascade mode
Select second input square root linearization
Select second input decimal point
Enter scaling units of second input
Enter scaling units of second input
Enter scaling units of second input
Enter scaling units of second input
Output dampening of secondary
Internal Cascade Operational Parameters
“SP-2”
“Pb-2”
“It-2”
“dt-2”
The Heater Current Monitor serves as a heater element fail sentry, so
operators can take corrective action before significant process errors occur in
the event of a failure. The actual heater current can be viewed in the secondary
display and/or a heater break alarm output can be programmed.
Heater Current Monitor Configuration Parameters
“HCur”
ACt1”, “ACt2”
-
View secondary setpoint value
Enter secondary proportional band
Enter secondary integral time
Enter secondary derivative time
EXTERNAL CASCADE
- Enter full scale current of current transformer
- Program alarm(s) as heater break alarm
MOTORIZED VALVE POSITIONER
Similar to internal cascade control, external cascade control differs by the
employment of two controllers, one of which is equipped with a second analog
input configured as a remote setpoint. A PCU controls the secondary loop,
while a TCU controls the primary loop.
External Cascade Configuration Parameters
The motorized valve positioner controls the position of a valve directly, by use
of “open” and “close” control outputs. The slidewire feedback signals of the valve
may optionally be connected to the controller. Alternatively, the controller may be
configured for linear input valve control using the 4 to 20 mA DC output.
Motorized Valve Positioner Configuration Parameters
Position mode:
“VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
“Act1”
-
Enter or measure valve closed position
Enter or measure valve open position
Enter Valve update time
Enter valve control deadband
Enter valve fail detect time
Program alarm as valve fail output
Velocity mode:
“VUdt”
“VOPt”
“VCLt”
“VONt”
-
Enter Valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
-
Select ratio mode
Select second input square root linearization
Select second input decimal point
Enter scaling units of second input
Enter scaling units of second input
Enter scaling units of second input
Enter scaling units of second input
Local/Remote select options
External Cascade Operational Parameters
“rtio”
“bIAS”
5
- Remote setpoint ratio
- Remote setpoint bias
SETPOINT MASTER CONTROL
Setpoint Master Control allows automatic setpoint changes to slave
controller units (up to 50 units total) from a master TCU controller.
The linear DC output of the master is looped with the second analog
input of the slave TCU controllers. Each slave unit can have unique
remote setpoint ratio and bias values.
Setpoint Slave Configuration Parameters
“OPEr” - Select remote setpoint mode
“root” - Select second input square root
Linearization
“dPt2” - Select second input decimal point
“dSP1” - Enter scaling units of second input
“INP1” - Enter scaling units of second input
“dSP2” - Enter scaling units of second input
“INP2” - Enter scaling units of second input
“SPLO”
- Limit range of remote setpoint
“SPHI”
“SPrP” - Limit rate of change of remote
setpoint
Setpoint Slave Operational Parameters
“rtio”
“bIAS”
- Second input ratio
- Second input bias
Configuration 1, Inputs
CONTROLLER PROGRAMMING
“tYPE”
“SCAL”
“dCPt”
“FLtr”
“SPAN”
“SHFt”
“SPLO”
“SPHI”
“SPrP”
“InPt”
“HCur”
The TCU has been designed to reduce the operator interaction with the
controller while still maintaining a high degree of control accuracy and user
flexibility. Front Panel Program Disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial parameter set-up.
The programming of the controller is divided into four sections:
Unprotected Parameter Mode
Configuration Parameter Mode
Protected Parameter Mode
Hidden Function Mode
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“OPdP”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
“ANdb”
“ANUt”
UNPROTECTED PARAMETER MODE *
The unprotected parameter mode is accessible when program disable is
inactive or when the proper access code number from the protected mode is
entered.The configuration parameter modes can be accessed only from this mode.
*
-
“Pb-2”
-
“It-2”
-
“dt-2”
-
“AL-1”
“AL-2”
“CNFP”
“End”
-
Select input probe type
Select temperature scale
Select temperature resolution
Select level of input filtering
Enter input correction span (slope)
Enter input correction shift (offset)
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function *
Enter full scale heater current *
Configuration 2, Outputs
These four programming modes allow the controller to adapt to any required
user-interface level.
“SP”
“OP”
“ProP”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
-
Enter Setpoint
Enter output power
Enter proportional band
Enter integral time
Enter derivative time
Enter Remote Setpoint ratio value
Enter Remote Setpoint bias value
View internal cascade secondary setpoint
demand
Enter internal cascade, secondary
proportional band
Enter internal cascade, secondary integral
time
Enter internal cascade, secondary
derivative time
Enter value for alarm #1
Enter value for alarm #2
Select basic configuration mode
Return to normal display mode
-
Enter time proportioning cycle time
Select control action
Enter output power low limit
Enter output power high limit
Enter probe fail power preset
Enter output control dampening
Enter ON/OFF control hysteresis
Select auto-tuning dampening
Select linear DC output assignment *
Enter linear DC output low scaling value *
Enter linear DC output high scaling value *
Enter linear DC output control deadband *
Enter linear DC output update time *
Configuration 3, Parameter lock-outs
“SP”
“OP”
“dEv”
“IN-2”
“HCur”
“UdSP”
“CodE”
“PId”
“PId2”
“rtbS”
“AL”
“ALrS”
“SPSL”
“trnF”
“tUNE”
These parameters may not appear due to option configuration or other
programming.
CONFIGURATION PARAMETER MODE
The configuration parameter mode allows the operator to set-up the basic
requirements of the controller. It is divided into sections which group together
related programming steps, such as inputs, outputs, alarms, etc. Upon
completion of each section, the program returns to the configuration selection
stage allowing the user to return to the normal display mode.
-
Configuration 4, Alarms
“Act1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
-
Select degree of setpoint access
Select degree of power access
Enable deviation display *
Enable second input display *
Enable heater current display
Enable temperature scale display
Enter parameter access code
Select degree of PID access
Select degree of secondary PID access *
Select degree of ratio/bias access *
Select degree of alarm access *
Enable alarm reset access *
Enable local/remote setpoint selection *
Enable auto/manual mode selection
Enable auto-tune invocation
*
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
Configuration 5, Cooling
*
“CYC2” - Enter cooling time proportioning cycle time
“GAN2” - Enter cooling relative gain
“db-2” - Enter heat/cool deadband or overlap
6
Configuration 6, Serial Communications
“bAUd”
“PArb”
“Addr”
“Abrv”
“PrAt”
“PoPt”
-
HIDDEN FUNCTION MODE *
*
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic
transmissions
- Enter automatic print rate
- Select parameters to be included in print-out
Configuration 7, Second Input
The hidden function mode is accessible from the normal operating mode. The
four functions in this mode may be locked-out individually in configuration 3
parameter lock-out section.
“SPSL” - Select Local/Remote Setpoint
“trnF” - Transfer between automatic (PID) control
and manual control
“tUNE” - Invoke/cancel PID Auto-tune
“ALrS” - Reset latched alarms
*
“OPEr” - Select remote setpoint or internal
cascade mode
“root” - Select second input square root linearization
“dPt2” - Select second input decimal point
“dSP1” - Enter scaling parameters of second input
“INP1” - Enter scaling parameters of second input
“dSP2” - Enter scaling parameters of second input
“INP2” - Enter scaling parameters of second input
“SPtr” - Enter local/remote select options
“OPd2” - Enter Secondary output control dampening
Configuration 8, Motorized Valve Positioner
Position mode:
Velocity mode:
“VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
“VUdt”
“VOPt”
“VCLt”
“VONt”
-
PROTECTED PARAMETERS MODE *
The protected parameters mode is enabled when program disable is active.
This mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are selected in the configuration 3
parameter lock-out section can be accessed.
*
Enter or measure valve closed position
Enter or measure valve open position
Enter valve update time
Enter valve control deadband
Enter valve fail detect time
Enter valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
“ProP”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
“Pb-2”
-
“It-2”
-
“dt-2”
-
“AL-1” “AL-2” “CodE” -
*
Enter Proportional band
Enter integral time
Enter derivative time
Enter remote setpoint ratio value
Enter remote setpoint bias value
Enter internal cascade, secondary setpoint
Enter internal cascade, secondary
proportional band
Enter internal cascade, secondary
integral time
Enter internal cascade, secondary
derivative time
Enter value for alarm #1
Enter value for alarm #2
Enter access value to unprotected
parameters & configuration parameters
These parameters may not appear due to option configuration or other
programming.
ACCESSORY - EXTERNAL SSR POWER UNIT
ACCESSORY - CURRENT TRANSFORMER
The external SSR Power Unit is used with the Logic/SSR Drive Module
(OMD00003) to switch loads up to 240 VAC @ 45 amps, 25°C ambient.
The unit is operated by applying a low level DC control signal to the
isolated input. The unit features zero cross detection circuits which reduces
radiated RFI when switching load currents. With no contacts to wear out,
the SSR Power Unit provides virtually limitless operational life. The unit is
supplied with an integral heat sink for immediate installation.
The external Current Transformer is used when specifying TCUs
equipped with the Heater Current Monitor. The primary current rating is 50
amperes.
7
OUTPUT MODULES
TYPICAL CONNECTIONS
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 ampere @ 35°C
0.75 ampere @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
Relay:
Type: Form-C (Form-A with some models. See ordering information.)
Rating: 5 amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120
VAC (inductive).
Life Expectancy: 100,000 cycles at maximum load rating.
(Decreasing load and/or increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA maximum.
APPLICATION
Several TCU controllers are
employed to control the temperature of
a plastics extruder. Each TCU controls
a heating element and a cooling water
solenoid to maintain each extruder
zone at a desired temperature. The
heater current monitor of the TCU is
used for early detection of heater
element failure. The linear DC output
is used to retransmit the process
temperature to a control computer for
data logging purposes.
8
ORDERING INFORMATION
MODELS WITHOUT SECOND INPUT OPTIONS
4 to 20 mA
ANALOG
OUTPUT
NEMA 4X/P65
BEZEL
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
115/230 VAC
NO
NO
NO
NO
NO
NO
TCU00000
NO
NO
NO
2
NO
NO
TCU00001
NO
NO
NO
1
YES
NO
TCU00002
NO
YES
NO
2
NO
NO
TCU01001
NO
YES
NO
2
NO
YES
TCU01004
NO
YES
NO
1
YES
YES
TCU01005
YES
NO
NO
NO
NO
NO
TCU10000
YES
NO
NO
2
NO
NO
TCU10001
YES
NO
NO
1
YES
NO
TCU10002
YES
YES
NO
2
NO
NO
TCU11001
YES
YES
NO
1
YES
NO
TCU11002
YES
YES
NO
2
NO
YES
TCU11004
YES
YES
NO
1
YES
YES
TCU11005
YES
NO
YES
2
NO
NO
TCU12001
YES
NO
YES
2
NO
YES
TCU12004
YES
NO
YES
1
YES
YES
TCU12005
These models have dual alarm outputs, or single alarm with cooling outputs, with shared common terminals (Form A Type).
As a result, these outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with
any type of output module.
HEATER CURRENT MONITOR MODELS (HCM)
NEMA 4X/IP65
BEZEL
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
NO
NO
2
NO
YES
TCU10204
YES
YES
NO
2
NO
NO
TCU11208
These models have dual alarm outputs, or single alarm with cooling outputs, with shared common
terminals (Form A Type). As a result, these outputs should be fitted with the same type of output
module. The main output (OP1) may be fitted with any type of output module.
SECOND ANALOG INPUT MODELS (ANA)
NEMA 4X/IP65
BEZEL
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
NO
NO
2
NO
YES
TCU10104
YES
YES
NO
2
NO
NO
TCU11108
YES
NO
YES
2
NO
NO
TCU12108
These models have dual alarm outputs, or single alarm with cooling outputs, with shared
common terminals (Form A Type). As a result, these outputs should be fitted with the same type
of output module. The main output (OP1) may be fitted with any type of output module.
MOTORIZED VALVE POSITIONER MODELS (MVP)
4 to 20 mA
NEMA 4X/IP65
BEZEL
YES
YES
YES
04toto10
20 VDC
mA
0 ALARM
to 10 VDC
ANALOG
OUTPUT
COOLING
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
NO
YES
NO
NO
NO
YES
1
1
1
NO
NO
NO
YES
NO
NO
TCU10307
TCU11306
TCU12306
ACCESSORIES
DESCRIPTION
Relay Module
Triac Module
Logic/SSR Drive Module
SSR Power Unit
Single Phase 25 A DIN Rail Mount SSR
Single Phase 40 A DIN Rail Mount SSR
Three Phase DIN Rail Mount SSR
50:0.1 Ampere Current Transformer
40:0.1 Ampere Current Transformer
PART NUMBER
OMD00000
OMD00001
OMD00003
RLY50000
RLY60000
RLY6A000
RLY70000
CT005001
CT004001
Note: Output Modules are NOT supplied with the controller. When specifying the
controller, be sure to purchase the appropriate output module for the Main Control
Output and if necessary, the alarm output(s), the cooling output, and valve positioner
outputs. The controller can be fitted with any combination of output modules.
The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input
of an SSR power unit. It should never be connected to line voltage.
All output modules are packaged separately and must be installed by the user.
9
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10
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11
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship
for a period limited to one year from the date of shipment, provided the products have been stored,
handled, installed, and used under proper conditions. The Company’s liability under this limited
warranty shall extend only to the repair or replacement of a defective product, at The Company’s
option. The Company disclaims all liability for any affirmation, promise or representation with
respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against
damages, claims, and expenses arising out of subsequent sales of RLC products or products
containing components manufactured by RLC and based upon personal injuries, deaths, property
damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be
to any extent liable, including without limitation penalties imposed by the Consumer Product Safety
Act (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
herein and relies on no other warranties or affirmations.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. TP16KIT-A
Drawing No. LP0499
Released 7/03
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL TP16KIT - T16/P16 PROGRAMMING KIT
!
ALLOWS PC PROGRAMMING OF ANY T16 & P16
!
KIT CONTAINS EVERYTHING REQUIRED FOR
DIRECT PC LINK
!
PROGRAM WITHOUT POWERING CONTROLLER
!
WINDOWS® CONFIGURATION SOFTWARE
Product Features
GENERAL DESCRIPTION
CONSTRUCTION
The TP16KIT comes with everything you need to program any
T16 or P16 controller with your PC. The kit consists of the T/P16
Programming Module, a 7' length interface cable, T/P16 User
Software and DC wall-supply (T/P16KIT1 only). The Windows
based software allows easy configuration, file storage, download,
upload and calibration of T16 and P16 controllers. The module
converts the RS-232 signals from a PC’s serial port into the
required logic level for the controller’s PC link port.
The module is primarily intended for system designers or
customers who use T16 and P16 controllers. The kit provides the
ability to program multiple controllers quickly and easily, when
compared to programming through the front panel keypad.The
T16 and P16 controllers can be programmed prior to installation,
without having to connect power to the rear terminals. For the
end customer, programming changes to multiple controllers can
be made quickly and reliably on the factory floor by using the
programming module with a laptop computer.
The module kit is available in two versions. T/P16KIT1
includes a 115 VAC wall transformer. This provides power to the
module, and in addition, power for the T16 and P16 controllers.
This allows the T16 or P16 controller to be programmed prior to
installation, without having to make any connections to the
controller’s rear power terminals. T/P16KIT2 does not come with
the power supply. Power has to be supplied either to the
controller, or to the module with the customer’s own DC supply.
The module is housed in a plastic enclosure with connectors
located on both ends. The RS-232 end has a 9 pin female D-sub
connector and is designed to plug directly into the serial port
connector on a PC. The opposite end of the module has a
6-position terminal block header and a male pin-type power jack.
With the interface cable, the module is connected directly to the
T16 or P16 controller PC board through a cut out in the
controller’s case. The 4-wire interface cable consists of the serial
“transmit data” and “receive data” signals, along with “DC power”
and “common” lines for the T/P16 controller.
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.
CAUTION: Read complete
instructions prior to installation
and operation of the unit.
CAUTION: Risk of electric shock.
General Specifications
1. POWER:
AC to DC Wall Adapter (TP16KIT1):
Input: 120 VAC, 60 Hz, 5 W
Output: 9 VDC, 200 mA
DC Power Input: 7 to 11 VDC, 200 mA
2. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0°C to 50°C
Storage Temperature Range: -40°C to 80°C
Operating and Storage Humidity: 85% max relative humidity
(non-condensing) from 0°C to 50°C
Altitude: Up to 2000 meters
3. CONNECTIONS:
To Computer: 9 pin female D-Sub
To T16/P16: PC board edge connector
DC Power Jack: Male power jack for mating 2.1 x 5.5 mm
female barrel connector.
DC Power Terminals: Wire clamping screw terminals
(alternate power connection)
4. CONSTRUCTION: Program Module is housed in a black
plastic Case
1
Ordering Information
MODEL NO.
TP16
TP16
DESCRIPTION
PART NUMBERS
Programming Cable, Software, Power Supply (115 VAC)
TP16KIT1
Programming Cable, Software
TP16KIT2
STEP 1 MAKING THE CONNECTIONS
Note: When powered only by the
programming cable, the controller’s input
circuit doesn’t function. T16 will display
“OPEN”.
STEP 2 INSTALLING SOFTWARE
Insert the diskette into the A: or B: drive. Then Run A:\SETUP (or B:\SETUP) to install RLCPro onto the hard drive. An icon labeled
RLCPro will be created under the group RLCPro.
STEP 3 PROGRAMMING - Getting Started
Run RLCPro by double-clicking the icon, or use the start
menu. Use the FILE pull-down menu to select a NEW file. Select
T16/P16 then choose the specific model number for your
controller. All configuration settings for the controller can be
made by selecting the individual categories.
STEP 4 PC PORT CONFIGURATION
Go to the SETTINGS pull-down menu, and select PC PORT
SETTINGS. The Communications Settings window allows you to
set up the software properly to perform a download. Select the
computer port (COMM 1-4) that the T16/P16 is connected to. Set
the following settings to match the T16/P16.
The serial settings are
Protocol: Modbus RTU
Unit Address: 247
Baud Rate: 9600
Data Bits: 8
Parity: none
STEP 5 UPLOADING and DOWNLOADING
Uploading: Go to the FILE pull-down menu, and select
UPLOAD. The software will automatically detect any controller
connected and its configuration will be loaded.
Downloading: Go to the FILE pull-down menu, and select
DOWNLOAD. A pop-up screen will prompt you to ensure that the
proper file is downloaded to the correct controller. Click “OK” to
continue.
Bulletin No. TSC-B
Drawing No. LP0326
Released 1/05
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL TSC - TEMPERATURE SETPOINT CONTROLLER
C
UL
R
US LISTED
AUTOMATIC PROGRAM DELAY FOR PROFILE CONFORMITY,
PLUS PROGRAM LINKING, REPEATING AND AUTO POWER-ON
FUNCTIONS FOR ENHANCED CAPABILITY
G
DUAL EVENT OUTPUTS FOR TIMED ACTIVATION OF PROCESS
EQUIPMENT SUCH AS STIRRERS, FANS, HEATERS, ETC. (Uses
Alarm Output Channels)
G
FOUR SETPOINT & PID PARAMETER SETS FOR QUICK RECALL
OF SETPOINTS AND/OR GAIN VALUES DURING BATCH OR
PROCESS CHANGEOVER
G
PROGRAMMABLE USER INPUT FOR CONTROLLER AND
SETPOINT PROGRAM CONTROL
G
100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY
G
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
G
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
TEMPERATURE AND SETPOINT OR TEMPERATURE AND
PROFILE STATUS
G
ACCEPTS ANY ONE OF 10 DIFFERENT TYPES OF SENSOR
INPUTS (Thermocouple or RTD)
G
FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR drive, and Triac)
G
OPTIONAL DUAL ALARM OUTPUTS (Uses Output Modules)
G
OPTIONAL COOLING OUTPUT (Uses Output Module)
G
OPTIONAL LINEAR 4 to 20 mA or 0 to 10 VDC OUTPUT FOR
CONTROL OR TEMPERATURE RE-TRANSMISSION
G
OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE
G
OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL
IND. CONT. EQ.
51EB
G
G
SETPOINT PROGRAM CONTROLLER FOR TIME VS.
TEMPERATURE (RAMP/SOAK) AND SPECIAL BATCH/RECIPE
APPLICATIONS
G
ADVANCED PROGRAM PROFILING IN A 1/8 DIN PACKAGE
G
ON-LINE MONITORING AND CONTROL OF PROGRAM STATUS,
TIME, AND SETPOINT VALUE (Program Run, Pause, Stop,
Advance, Modify Time, & Setpoint Value)
The controller can operate in the standard PID control mode for both heating
or cooling with on-demand auto-tune which establishes the PID gain set. The
PID gain set can be fine tuned by the operator at any time or may be locked from
further modification. The unit can be transferred to the manual control mode
providing the operator with direct control of the output.
The TSC features four programs or profile recipes, each with up to eight
ramp/soak segments, which can be easily stored and executed at any time.
Longer profiles can be achieved by linking one or more profiles together,
creating a single profile of up to 32 ramp/soak segments. Temperature profile
conformity is assured during either soak (hold) phases or both ramp and hold
phases by an adjustable error band parameter. The program repeat function
cycles the profile either continuously or a set number of times. Power-on options
automatically re-start, stop, or resume a running profile. The profile can be
controlled via the front panel buttons, the user input, or the optional serial
communications port.
Four control points, each having a setpoint and PID parameter set, are
available for instant front panel implementation during batch changeover, or
DESCRIPTION
The TSC is a setpoint controller suitable for time vs. temperature, process
control applications. The TSC accepts signals from a variety of temperature
sensors (thermocouple and RTD elements), precisely displays the process
temperature, and provides an accurate output control signal (time proportional
or linear) to maintain a process at the desired control point. A comprehensive set
of easy to use steps allows the controller to satisfy various applications. The user
input can be programmed to perform a variety of controller functions.
Dual 4-digit displays allow viewing of the measured temperature value and
setpoint or temperature and profile status simultaneously. Front panel indicators
inform the operator of controller status and output states. Replaceable output
modules (Relay, logic/SSR drive or Triac) can be fitted to the main control output,
alarm output(s) or timed event output(s), and cooling output.
The TSC has been designed to simplify the set-up and operation of a controlled
setpoint profile program. The setpoint program is easily entered and controlled
through the front panel. Full display capabilities keep the operator informed of the
process temperature, profile status, output states, and setpoint value.
DIMENSIONS In inches (mm)
Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.
PANEL CUT-OUT
1
Start Mode: Ramps from process temperature.
Program Auto Cycle: 1 to 249, or continuous.
Event Outputs: 2, time activated with profile [uses Alarm output(s)].
Control: Front panel buttons, user input, or RS485 communications.
6. CONTROL POINTS:
Setpoints: 4
PID gain sets: 4
Control: Front panel buttons or user input.
7. SENSOR INPUT:
Sample Period: 100 msec
Response Time: 300 msec (to within 99% of final value w/step input;
typically, response is limited to response time of probe).
Failed Sensor Response:
Main Control Output(s): Programmable preset output.
Display: “OPEN”.
Alarms: Upscale drive.
DC Linear: Programmable preset output.
Normal Mode Rejection: 40 db @ 50/60 Hz (improves with increased
digital filtering).
Common Mode Rejection: 100 db, DC to 50/60 Hz.
Protection: Input overload voltage; 240 VAC @ 30 sec max.
8. THERMOCOUPLE:
Types: T, E, J, K, R, S, B, N or Linear mV.
Input Impedance: 20 MΩ, all types.
Lead Resistance Effect: 20 µV/350 Ω.
Cold Junction Compensation: Less than ±1°C error over 0-50°C ambient
temperature range. Disabled for linear mV type.
Resolution: 1°C/F all types, or 0.1°C/F for T, E, J, K, and N only.
9. RTD: 2, 3 or 4 wire, 100 Ω platinum, alpha = 0.00385 (DIN 43760), alpha =
0.003916
Excitation: 0.175 mA
Resolution: 1 or 0.1 degree
Lead Resistance: 7 Ω max.
10. RANGE AND ACCURACY:
Errors include NIST conformity and A/D conversion errors at 23°C after 20
minutes warm-up. Thermocouple errors include cold junction effect. Errors
are expressed as ±(% of reading) and ±3/4 LSD unless otherwise noted.
DESCRIPTION (Cont’d)
other process conditions. A control point may have its PID gain set values
disabled when implementing the control point.
The optional RS485 multidrop serial communications interface provides the
capability of two-way communication between a TSC unit and other compatible
equipment such as a printer, a programmable controller, or a host computer. In
multipoint applications the address number of each unit on the line can be
programmed from 0-99. Up to thirty-two units can be installed on a single pair
of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be
interrogated or changed by sending the proper command code via serial
communications. Alarm output(s) may also be reset via the serial
communications interface option.
Optional alarm output(s) may be configured to operate as a timed event
output or as a standard alarm output. As an alarm output it may be configured to
activate according to a variety of actions (Absolute HI or LO, Deviation HI or
LO, or Band IN or OUT) with adjustable hysteresis. Also, a standby feature
suppresses the output(s) on power-up until the temperature stabilizes outside the
alarm region. Timed event output(s) allow the controller to activate other
equipment while a programmed profile is running. Each profile can define up to
16 event states (phases), for each output(s).
An optional secondary output is available for processes that require cooling
which provides increased control accuracy and response.
The optional linear 4 to 20 mA or 0 to 10 VDC output signal is available to
interface with final actuators, chart recorders, indicators, or other controllers. The
output signal can be digitally scaled and selected to transmit one of the following:
% Output Power
Measurement Value
Measurement Value Deviation
Setpoint Value
An optional NEMA 4X/IP65 rated bezel is available for washdown and/or
dirty environments, when properly installed. Modern surface-mount technology,
extensive testing, plus high immunity to noise interference, makes the controller
extremely reliable in industrial environments.
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 TSC to directly command motors, valves, or other actuators
not equipped with safeguards. To do so, can be potentially harmful to persons or
equipment in the event of a fault to the unit. An independent and redundant
temperature limit indicator with alarm outputs is strongly recommended. Red
Lion Controls model IMT (thermocouple) or model IMR (RTD) units may be
used for this purpose. The indicators should have input sensors and AC power
feeds independent from other equipment.
TC TYPE
T
E
J
K
R
SPECIFICATIONS
S
1. DISPLAY: Dual 4-digit
Upper Temperature Display: 0.4" (10.2 mm) Red LED
Lower Auxiliary Display: 0.3" (7.6 mm) Green LED
Display Messages:
“OLOL”
“ULUL”
“OPEN”
“SHrt”
“....”
“-...”
-
Appears
Appears
Appears
Appears
Appears
Appears
when
when
when
when
when
when
B
N
measurement exceeds + sensor range.
measurement exceeds - sensor range.
open sensor is detected.
shorted sensor is detected (RTD only).
display value exceeds + display range.
display value exceeds - display range.
mV
RTD
(385)
RTD
(392)
OHMS
2. POWER: 115/230 VAC (+10%, -15%) no observable line variation effect,
48-62 Hz, 10 VA, switch selectable.
3. ANNUNCIATORS:
6 LED Backlight Status Indicators:
%PW
PGM
-
MAN
OP1
AL1
AL2
OP2
-
RANGE
ACCURACY
-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
+200 to +1820°C
+300 to +3300°F
-200 to +1300°C
-328 to +2372°F
-5.00 to 56.00
-200 to +600°C
-328 to +1100°F
-200 to +600°C
-328 to +1100°F
1.0 to 320.0
0.20% + 1.5°C
0.20% + 2.7°F
0.20% + 1.5°C
0.20% + 2.7°F
0.15% + 1.5°C
0.15% + 2.7°F
0.20% + 1.5°C
0.20% + 2.7°F
0.15% + 2.5°C
0.15% + 4.5°F
0.15% + 2.5°C
0.15% + 4.5°F
0.15% + 2.5°C
0.15% + 4.5°F
0.20% + 1.5°C
0.20% + 2.5°F
0.15% + 1 LSD
0.10% + 0.5°C
0.10% + 0.9°F
0.10% + 0.5°C
0.10% + 0.9°F
0.15% + 1 LSD
WIRE COLOR
(ANSI)
blue
violet
white
yellow
black
black
grey
orange
__
__
__
__
11. OUTPUT MODULES [Optional] (For All Output Channels):
Relay:
Type: Form-C (Form-A with RS485 option)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load).
Life Expectancy: 100,000 cycles at max. rating.(Decreasing load and/or
increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical.
Drive: 45 mA max.
Triac:
Type: Isolated, Zero Crossing Detection.
Ratings:
Voltage: 120/240 VAC
Max Load Current: 1 AMP @ 35°C
0.75 AMP @ 50°C
Min Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 500 Hz
Protection: Internal Transient Snubber, Fused.
Lower auxiliary display shows power output in (%).
Lower auxiliary display shows profile status or profile
time remaining.
Controller is in manual mode.
Main control output is active.
Alarm #1 is active.
Alarm #2 is active (for Dual Alarm Option)
Cooling output is active (for Cooling Option).
4. CONTROLS: Four front panel push buttons for setup and modification of
controller functions and one external input.
5. SETPOINT PROFILE:
Profiles: 4
Segments Per Profile: 8 ramp/hold segments (linkable to 32 segments).
Ramp Rate: 0.1 to 999.9 degrees/minute or no ramp.
Hold Time: Off or from 0.1 to 999.9 minutes, can be extended to 500 hours
by linking.
Error Band Conformity: Off or from 1 to 9999 degrees deviation, + value
for hold phases, - value for both ramp and hold phases.
Power-On Modes: Stop, auto-start, or profile resume.
2
IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part 1.
IP65 Enclosure rating (Face only), IEC 529
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 2; 4 Kv contact
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3 Level 3; 10 V/m1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 Kv I/O
Level 3; 2 Kv power
RF conducted interference
EN 61000-4-6 Level 3; 10 V/rms2
150 KHz - 80 MHz
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
Notes:
1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:
Analog output signal may deviate during EMI disturbance.
For operation without loss of performance:
Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to power
lines at unit.
or
Install power line filter, RLC #LFIL0000 or equivalent.
2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
Analog output signal may deviate during EMI disturbance.
For operation without loss of performance:
a. Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to
power lines at unit.
or
Install power line filter, RLC #LFIL0000 or equivalent.
b. Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to
analog output cable at unit.
Refer to the EMC Installation Guidelines section of the manual for additional
information.
20. CONNECTION: Jaw-type terminal block.
21. CONSTRUCTION:
Front Panel: Flame and scratch resistant tinted plastic.
Case: High impact black plastic. (Mounting collar included).
NEMA 4X/IP65 model only: Sealed bezel utilizing 2 captive mounting
screws (panel gasket included).This unit is rated for NEMA 4X/IP65
indoor use. Installation Category II, Pollution Degree 2.
22. WEIGHT: 1.3 lbs. (0.6 kgs)
SPECIFICATIONS (Cont’d)
12. MAIN CONTROL OUTPUT (Heating or Cooling):
Control: PID or ON/OFF.
Output: Time proportioning or linear DC.
Hardware: Plug-in, replaceable output modules.
Cycle time: Programmable.
Auto-tune: When performed, sets proportional band, integral time, and
derivative time values.
Probe Break Action: Programmable.
13. COOLING OUTPUT (Optional):
Control: PID or ON/OFF.
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules.
Cycle time: Programmable.
Proportional Gain Adjust: Programmable.
Heat/Cool DeadBand: Programmable.
14. LINEAR DC DRIVE (Optional): With digital scale and offset,
programmable deadband and update time.
4 to 20 mA:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 25 µA).
Compliance: 10 V (500 Ω max. loop impedance).
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV).
Min. Load Resistance: 10 KΩ (1 mA max.)
Source: % output power, setpoint, deviation, or temperature.
(Available for heat or cool, but not both.)
15. ALARMS (Optional):
Hardware: Plug-in, replaceable output module.
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Timed event output(s)
Reset Action: Programmable; automatic or latched.
Delay: Programmable; enable or disable.
Hysteresis: Programmable.
Probe Break Action: Upscale.
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with cooling output).
16. SERIAL COMMUNICATIONS (Optional):
Type: RS485 Multi-point, Balanced Interface.
Communication Format:
Baud Rate: Programmable from 300-9600.
Parity: Programmable for odd, even, or no parity.
Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit.
Unit Address: Programmable from 0-99, max. of 32 units per line.
Transmit Delay: 100 msec min., 200 msec max.
RS485 Common: Isolated from signal input common.
Auto Print Time: Off to 9999 seconds between print-outs.
17. USER INPUT: VIN max = 5.25 VDC, VIL = 0.85 VMAX; VIH = 2.0 VMIN,
Response time 100 msec max.
Functions:
Program Lock
Integral Action Lock
Auto/Manual Transfer
Setpoint Ramp Select
Reset Alarms
BASIC OPERATION
The TSC controls the temperature profile of a system by measuring the
temperature via an input probe, compares the actual temperature to the setpoint
profile in progress, and calculates the new output power value by use of a
modified PID control algorithm. The unit controls the system with the new
output power value so the process temperature conforms to the programmed
profile. The PID control algorithm incorporates features which provide
minimum overshoot and excellent temperature control accuracy for a process.
FRONT PANEL FEATURES
Print Request
Load Control Point
Run/Hold Profile 1
Run/Stop Profile 1
In the normal display mode, the unit will display the process temperature in
the upper display. One of five other parameters may be selected for viewing in
the lower display:
Target Setpoint Profile Phase Time Remaining
% Output Power Temperature Symbol (F/C)
Profile Status
18. ENVIRONMENTAL CONDITIONS:
Operating Temperature: 0 to 50°C
Storage Temperature: -40 to 80°C
Operating and Storage Humidity: 85% max. (non-condensing) from 0°C to
50°C.
Span Drift: ≤ 100 ppm/°C
Zero Drift: ≤ 1 µ V/°C
Altitude: Up to 2000 meters
19. CERTIFICATIONS AND COMPLIANCES:
SAFETY
UL Listed, File # E137808, UL508, CSA C22.2 No. 14-M95
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
UL Recognized Component, File # E156876, UL873, CSA C22.2 No. 24
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
Type 2 or 4X Enclosure rating (Face only), UL50
IECEE CB Scheme Test Certificate # UL1239-156876/USA,
CB Scheme Test Report # 96ME50279-070794
Issued by Underwriters Laboratories, Inc.
The program profile status display indicates the active profile number with
the current ramp or hold phase of the profile. The profile can be started, stopped,
advanced, etc. from the front panel when the profile status display is viewed, if
not locked from access.
The phase time remaining display, shows the time remaining in a ramp or
hold phase and, if not locked from access, may be changed on-line to effect
temporary changes to the program. Additionally, the target setpoint and %
output power (manual mode only) may also be changed on-line or locked from
operator access.
From the normal operating mode, parameters are selected by use of the PAR
button and modified by use of the UP and DOWN buttons. Parameters are then
entered by the PAR button, which advances the user to the next parameter.
Pressing the DSP button immediately returns the controller to the normal
operating mode from any parameter module. The controller configuration and
parameter settings are stored in an internal E2PROM device.
3
CONFIGURATION MODE
Configuration 5,.Cooling *
“CYC2”
“GAN2”
“db-2”
The configuration modules serve to provide the basic set-ups required by
the controller. It is divided into sections which group together related
programming steps, such as inputs, outputs, alarms, etc. Upon completion of
each section, the program returns to the configuration selection stage, which
allows the user to return to the normal display mode, or advance to a later
configuration stage.
Configuration 6, Serial Communications *
“bAUd”
“PArb”
“Addr”
“Abrv”
Configuration 1, Inputs
“tYPE”
“SCAL”
“dCPt”
“FLtr”
“SPAN”
“SHFt”
“SPLO”
“SPHI”
“SPrP”
“InPt”
-
Select input probe type
Select temperature scale
Select temperature resolution
Select degree of input filtering
Enter input correction span (slope)
Enter input correction shift (offset)
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function
-
Enter time proportioning cycle time
Select control action
Enter output power low limit
Enter output power high limit
Enter probe fail power preset
Enter ON/OF control hysteresis
Select auto-tuning damping
Select linear DC output assignment *
Enter linear DC low scaling value *
Enter linear DC high scaling value *
“PrAt”
“PoPt”
“CSEt”
“SP-x”
“PId”
“PB-x”
“It-x”
“dt-x”
“P-tr”
“UdSP”
“CodE”
“PId”
“AL”
“ALrS”
“CPAC”
“PrAC”
“trnF”
“tUNE”
“PSEt”
“PnCC”
- Select degree of setpoint access
- Select degree of power access
- Select degree of profile status
access
- Select degree of phase time remaining
access
- Enable temperature units display
- Enter parameter access code
- Select degree of PID access
- Select degree of alarm access *
- Enable manual reset of alarms *
- Enable control point access
- Enable ramp/hold program access
- Enable automatic/manual transfer
- Enable auto-tune invocation
“PnLn”
“PnEb”
“PnPC”
“Pnr1”
“PnL1”
“PnH1”
.
.
.
.
“Pnr8”
“PnL8”
“PnH8”
“Pn 1”
.
.
.
.
“Pn16”
Configuration 4, Alarms *
“Act 1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
-
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic
transmissions
- Enter automatic print rate
- Select parameters to be included
in print-out
- Select control point number for set-up 1, 2,
3, & 4
- Enter setpoint value for selected control
point
- Select if PID gain set to be loaded with
setpoint
- Enter proportional band for selected
control point *
- Enter integral time for selected control
point *
- Enter derivative time for selected control
point *
Configuration 8, Profiles
Configuration 3, Parameter lock-outs
“SP”
“OP”
“P-CS”
-
Configuration 7, Control Points
Configuration 2, Outputs
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
- Enter cooling time proportioning cycle time
- Enter cooling relative gain
- Enter heat/cool deadband or overlap
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
- Select profile or event output for set-up 1,
2, 3, or 4
- Enter program-repeat cycle count for
selected profile
- Select link option for selected profile
- Enter error band for temperature
conformity for selected profile
- Enter power-down resume status for
selected profile
- Enter ramp rate 1 for selected profile *
- Enter setpoint level 1 for selected profile *
- Enter hold time 1 for selected profile *
-
Enter ramp rate 8 for selected profile *
Enter setpoint level 8 for selected profile
Enter hold time 8 for selected profile *
Select event outputs at phase 1 for
selected profile *
*
- Select event outputs at phase 16 for
selected profile *
Configuration 9, Factory Service Operations
(Detailed in the operator’s manual)
* These parameters may not appear due to option configuration or other
programming
HARDWARE FEATURES
SETPOINT FEATURES
NEMA 4X/IP65 BEZEL
The fast 100 msec input sampling rate
provides quick controller response to a
process disturbance for excellent temperature
control. Measurement accuracy of 0.15%
provides closer process control conforming to
the desired control setpoint value.
The unit accepts a variety of both
thermocouple or RTD temperature probes.
The A.C. input power is switch selectable,
allowing the unit to operate from either 115
VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the
output modules may be easily changed or
replaced without disturbing the wiring behind
the panel and NO re-programming is required.
The standard model simply requires pressing a
latch to remove the unit. The NEMA 4X/IP65
rated model utilizes two panel securing screws
and a neoprene gasket to guarantee a water
tight seal, when properly installed.
Low-drift, highly stable circuit design ensures years of reliable and accurate
temperature control. The recommended two year re-calibration interval is
easily accomplished via the programming menu.
The controller’s setpoint can be protected from out of range values, by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can also be programmed.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate, independent of a
programmed profile. This feature reduces thermal shock to the process and
also helps to minimize temperature overshoot.
The active setpoint, which can be a running profile, may also be transmitted
by the linear DC output for slave control loops.
Four control points are available which can be implemented at any time.
Each control point is programmed independently, with each having a setpoint
and a PID gain set value. With gain value changes, the output power control
signal will not “bump” resulting in a smooth control transition.
INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating temperature characteristics, helping to provide
better temperature control.
A programmable temperature shift and slope function can be used to
compensate for probe errors or to have multiple TSC units indicate the same
nominal temperature.
A programmable User Input is available to control a variety of controller
functions, such as profile control, auto/manual transfer, serial communication
print requests, etc.
4
OUTPUT FEATURES
HIDDEN FUNCTIONS MODE *
Programmable output power limits provide protection for processes where
too much power can cause damage. Automatic sensor probe break detection, for
fail-safe operation, causes the controller to default to a programmed output
power (upscale or downscale burnout). With adjustable time proportioningcycle time and programmable D.C. Linear output, the controller can satisfy a
wide variety of output requirements.
During execution of a profile, two independent, timed event outputs are
available to control or signal other equipment. The event outputs use the alarm
channels.
The RS485 Communication option allows the user to access various
controller parameters such as the setpoint, % output power, % proportional
band, etc. The controller may be setup to transmit various parameters at a
programmable automatic print rate.
The hidden mode is accessible from the normal operating mode by holding
the PAR button for 3 seconds. The five functions in this mode may be lockedout individually in configuration 3 parameter lock-outs section.
“ CP”
“Prun”
“trnF”
“tUNE”
“ALrS”
- Load control point x
- Control ramp/hold profile state
- Transfer between automatic (PID) control
and Manual control
- Invoke/Cancel PID auto-tune
- Reset latched alarms
OUTPUT VARIATIONS WITHOUT RS485 OPTION
The Dual Alarm or the Cooling with Alarm output, without the RS485 option,
has independent outputs. Therefore, the cooling output and/or alarm output(s)
can be installed with any combination of output modules.
AUTO-TUNE
The model TSC has an auto-tune feature which, on demand, automatically
determines the PID control parameters for a particular thermal process. After
completion of auto-tune, the PID parameters are automatically optimized for
that process and loaded into nonvolatile memory. The operator may view and
modify the parameters as desired.
Auto-tune may be invoked at start-up, while ramping, or at setpoint,
depending on the process requirements. A programmable auto-tune damping
factor produces various levels of process control and response characteristics.
PROFILE PROGRAMMING
Profiles are programmed independently of each other and are separate from
the configuration of other controller parameters. Each profile has parameters for
error band (profile conformity), linking, auto-start and program repeat cycles.
Profiles may be altered during execution, so changes take effect as the
programmed profile advances.
CONTROLLER PROGRAMMING
OUTPUT VARIATIONS WITH RS485 OPTION
The model TSC has been designed to reduce the operator interaction with the
controller while still maintaining a high degree of control accuracy and user
flexibility. Front panel program disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial parameter set-up.
The programming of the controller is divided into four sections:
Hidden Mode
Protected Mode
Unprotected Mode
Configuration Mode
These four programming modes allow the controller to adapt to any required
user-interface level.
The Dual Alarm or the Cooling with Alarm output, with RS485 option, does
not have independent outputs. In this case, the cooling output and/or alarm
output(s) must have the same type of output modules installed since they share
the common terminal.
UNPROTECTED PARAMETER MODE
The unprotected mode is accessible when program disable is inactive or when
the proper access code number from the protected mode is entered. Only from
this mode can the configuration modes be accessed.
“SP”
“OPOF”
“OP”
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CNFP”
“End”
-
Enter setpoint *
Enter %output power offset *
Enter output power *
Enter proportional band
Enter integral time *
Enter derivative time *
Enter value for alarm #1 *
Enter value for alarm #2 *
Select basic configuration module
Return to normal display mode
* These parameters may not appear due to option configuration or other
programming
PROTECTED PARAMETER MODE *
The protected mode is accessible when program disable is active, also this
mode prevents access to the configuration modes without the proper access code
number. Only the parameters that are selected in the configuration 3 parameter
lock-outs section can be accessed.
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CodE”
“End”
-
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Enter access value to unprotected mode
Return to normal display mode
5
OUTPUT MODULES
Units equipped with RS485 option must have the Dual Alarm or Cooling
w/alarm options fitted with the same type of output modules. The controller’s
main output (OP1) can be fitted with any output module. Output modules are
shipped separately and must be installed by the user.
TYPICAL CONNECTIONS
Logic/SSR Drive: can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical.
Drive: 45 mA max.
Relay:
Type: Form -C (Form-A with RS485 option only)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120
VAC (inductive).
Life Expectancy:100,000 cycles at maximum load rating.
(Decreasing load and/or increasing cycle time, increases life expectancy).
Triac:
Type: Isolated, Zero Crossing Detection.
Rating:
Voltage: 120/240 VAC.
Max. Load Current: 1 Amp @ 35°C
0.75 Amp @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 500 Hz.
Protection: Internal Transient Snubber, Fused.
APPLICATION
TSC GLASS TEMPERING APPLICATION
A manufacturer of glass items needs to
anneal (temper) their products to reduce the
brittleness of the glass structure. The tempering
process requires the glass to be heated and
subsequently cooled at a controlled rate to
change the structure of the glass. Different
tempering profiles are required for different
types of glass products.
A TSC is employed to control the
temperature profile of the annealing oven.
Four different temperature profiles are stored in
the controller. The 4 to 20 mA analog output
option is utilized to cool the annealing oven
during the cool down ramp phases. An event
output is used to quickly cool the oven at the
end of the batch run (alarm 1). Alarm 2 is used
to signal the operator whenever the
temperature is outside the prescribed program
profile.
Note: Units equipped with the RS485 option
have different terminal designators. See
“Output Variations with or without the
RS485 Option”.
The programming for this profile is as follows:
Parameter Value
“P1r1”
5.0
“P1L1”
“P1H1”
“P1r2”
“P1L2”
“P1H2”
300
40.0
3.0
150
0.0
“P1r3”
“P1 1”
“P1 2”
“P1 3”
“P1 4”
-0.1
1F2F
1F2F
1F2F
1N2F
Description
Ramp from ambient temp. during heat phase at
5.0°/min.
Target setpoint level 300°
Heat at 300° for 40.0 minutes
Ramp down 3.0°/min. during cooling phase
Target Setpoint is 150°
Do not hold at 150° (used as “phantom” hold time
for triggering event output for auxiliary cooling)
End Program
Turn off output 1 (output 2 is alarm)
Keep off output 1
Keep off output 1
Turn on output 1 for Auxiliary Exhaust Fan
6
ORDERING INFORMATION
MODEL NO.
TSC
PMK5
RLY
RLY6
DESCRIPTION
Temperature
Setpoint
Controller
NEMA 4X/IP65
BEZEL
4 to 20 mA
0 to 10 VDC
ALARM OUTPUTS COOLING OUTPUT
ANALOG OUTPUT ANALOG OUTPUT
RS485 COM
PART NUMBER
NO
YES
NO
2
NO
NO
TSC01001
YES
YES
NO
2
NO
NO
TSC11001
YES
YES
NO
1
YES
NO
TSC11002
YES
YES
NO
2
NO
YES
TSC11004
YES
YES
NO
1
YES
YES
TSC11005
YES
NO
YES
2
NO
YES
TSC12004
YES
NO
YES
1
YES
YES
TSC12005
Relay Module
OMD00000
Triac Module
OMD00001
Logic/SSR Drive Module
OMD00003
Panel Mount Adapter Kit (1/4 DIN to 1/8 DIN)
PMK50000
SSR Power Unit
RLY50000
Single Phase 25 A DIN Rail Mount Solid State Relay
RLY60000
Single Phase 40 A DIN Rail Mount Solid State Relay
RLY6A000
Three Phase DIN Rail Mount Solid State Relay
RLY70000
These models have dual alarm outputs, or single alarm with cooling outputs, with shared common terminals (Form A Type). As a result, these outputs should
be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.
Note: Output Modules are NOT supplied with the controller. When specifying the controller, be sure to purchase the
appropriate output module for the Main Control Output and if necessary, the alarm output(s) and cooling output.
The controller can be fitted with any combination of output modules that do not have the RS485 option.
The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an SSR power unit. It
should never be connected to a line voltage.
All modules are shipped separately and must be installed by the user.
7
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship
for a period limited to one year from the date of shipment, provided the products have been stored,
handled, installed, and used under proper conditions. The Company’s liability under this limited
warranty shall extend only to the repair or replacement of a defective product, at The Company’s
option. The Company disclaims all liability for any affirmation, promise or representation with
respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against
damages, claims, and expenses arising out of subsequent sales of RLC products or products
containing components manufactured by RLC and based upon personal injuries, deaths, property
damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be
to any extent liable, including without limitation penalties imposed by the Consumer Product Safety
Act (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
herein and relies on no other warranties or affirmations.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. T&P16-H(1)
Drawing No. LP0486
Released 7/07
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODELS T16 & P16 - TEMPERATURE/PROCESS CONTROLLERS
z PID CONTROL WITH REDUCED OVERSHOOT
z T16 ACCEPTS TC AND RTD
z P16 ACCEPTS 0-10 V AND 0/4-20 mA SIGNALS
z ON DEMAND AUTO-TUNING OF PID SETTINGS
z DC ANALOG OUTPUT (OPTIONAL)
z USER PROGRAMMABLE FUNCTION BUTTON
z PC OR FRONT PANEL PROGRAMMING
z PC CONFIGURABLE WITH TP16KIT
UL Recognized Component,
File #E156876
GENERAL DESCRIPTION
The Model T16 Controller accepts signals from a variety of temperature
sensors (thermocouple or RTD), while the Model P16 Controller accepts either a
0 to 10 VDC or 0/4 to 20 mA DC input signal. Both controllers can provide an
accurate output control signal (time proportional or DC Analog Output) to
maintain a process at a setpoint value. 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 comprehensive programming
allows these controllers to meet a wide variety of application requirements.
PC PROGRAMMING KIT
MAIN CONTROL
CONSTRUCTION
The optional TP16KIT contains a programming module with a 9 pin RS232
connector, cable and Crimson, a Windows® based configuration software. The
software allows downloading, uploading and storage of T16 and P16 program
files. All controllers have a communications port that allows configuration by
PC even without controller power connected. Controller calibration is also
possible using the software when the proper calibration equipment and
controller power is connected.
The controller operates in the PID Control Mode for both heating and
cooling, with on-demand auto-tune, that establishes the tuning constants. The
PID tuning constants may be fine-tuned through the front panel and then locked
out from further modification. The controller employs a unique overshoot
suppression feature, that allows the quickest response without excessive
overshoot. Switching to Manual Mode provides the operator direct control of the
output. The controller may also be programmed to operate in On/Off mode with
adjustable hysteresis.
The controller is constructed of a lightweight, high impact, black plastic
textured case and bezel with a clear display window. The front panel meets
NEMA 4X/IP65 specifications when properly installed. In applications that do
not require protection to NEMA 4X, multiple controllers 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
ALARMS
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 controller. An independent and redundant
temperature limit indicator with alarm outputs is strongly recommended.
Optional alarm(s) can be configured independently for absolute high or low
acting with balanced or unbalanced hysteresis. They can also be configured for
deviation and band alarm. In these modes, the alarm trigger values track the
setpoint value. Adjustable alarm hysteresis can be used for delaying output
response. The alarms can be programmed for Automatic or Latching operation.
A selectable standby feature suppresses the alarm during power-up until the
temperature stabilizes outside the alarm region.
ANALOG OUTPUT OPTION
The optional DC Analog Output (10 V or 20 mA) can be configured and
scaled for control or re-transmission purposes. The programmable output update
time reduces valve or actuator activity.
CAUTION: Risk of Danger.
Read complete instructions prior to
installation and operation of the unit.
CAUTION: Risk of electric shock.
DIMENSIONS In inches (mm)
PANEL CUT-OUT
1
GENERAL SPECIFICATIONS
Type 4X Enclosure rating (Face only), UL50
IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part I
IP65 Enclosure rating (Face only), IEC 529
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 2; 4 kV contact
Level 3; 8 kV air
Electromagnetic RF fields EN 61000-4-3 Level 3; 10 V/m 1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 kV I/O
Level 3; 2 kV power
RF conducted interference EN 61000-4-6 Level 3; 10 V/rms 2
150 KHz - 80 MHz
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
1. DISPLAY: 2 Line by 4-digit, LCD negative image transmissive with
backlighting.
Top (Process) Display: 0.3" (7.6 mm) high digits with red backlighting.
Bottom (Parameter) Display: 0.2" (5.1 mm) high digits with green
backlighting.
2. ANNUNCIATORS:
Status Annunciators:
O1 - Main control output is active.
O2 - Cooling output is active (when Alarm 2 is used for cooling).
A1 - Alarm 1 output is active.
A2 - Alarm 2 output is active.
°F, °C - Temperature units.
%PW - Output power percentage is shown in Bottom display.
MAN - Controller is in Manual Mode.
R - Ramping Setpoint indicator.
% - Percent indicator (P16 models only).
Display Messages:
OLOL - Measurement exceeds + sensor range
ULUL - Measurement exceeds - sensor range
OPEN - Open sensor is detected (T16 only)
SHrt - Shorted sensor is detected (RTD only)
SENS - Measurement exceeds controller limits (P16 only)
dddd - Display value exceeds + display range
-ddd - Display value exceeds - display range
3. POWER:
Line Voltage Models:
85 to 250 VAC, 50/60 Hz, 8 VA
Low Voltage Models:
DC Power: 18 to 36 VDC, 4 W
AC Power: 24 VAC, ±10%, 50/60 Hz, 7 VA
4. CONTROLS: Three rubber push buttons for modification and setup of
controller parameters. One additional button (F1) for user programmable
function. One external user input (models with alarms) for parameter lockout
or other user programmable functions.
5. MEMORY: Nonvolatile E2PROM retains all programmable parameters.
6. ISOLATION LEVEL:
AC power with respect to all other I/O: 250 V working (2300 V for 1 min.)
Sensor input to analog output: 50 V working (500 V for 1 minute)
Relay contacts to all other I/O: 300 V working (2300 V for 1 minute)
DC power with respect to sensor input and analog output: 50 V working
(500 V for 1 minute)
7. CERTIFICATIONS AND COMPLIANCES:
SAFETY
UL Recognized Component, File #E156876, UL873, CSA 22.2 No. 24
Recognized to US and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
Notes:
1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:
Measurement input signal may deviate during EMI disturbance.
For operation without loss of performance:
Install one ferrite core one turn, RLC #FCOR0000 or equivalent, to I/O
cables at unit.
2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
Process and analog output signal may deviate during EMI disturbance.
For operation without loss of performance:
Install one ferrite core one turn, RLC #FCOR0000 or equivalent, to I/O
cables and power cable at unit.
Refer to the EMC Installation Guidelines section of this bulletin for
additional information.
8. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 50°C
Storage Temperature Range: -40 to 80°C
Operating and Storage Humidity: 85% max relative humidity (noncondensing) 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, 2 g’s.
Shock According to IEC 68-2-27: Operational 20 g (10 g relay), 11 msec in
3 directions.
Altitude: Up to 2000 meters
9. CONNECTION: Wire-clamping screw terminals
10. CONSTRUCTION: Black plastic alloy case and collar style panel latch.
Panel latch can be installed for vertical or horizontal instrument stacking.
Black plastic textured bezel with transparent display window. Controller
meets NEMA 4X/IP65 requirements for indoor use when properly installed.
Installation Category II, Pollution Degree 2.
11. WEIGHT: 6.3 oz (179 g)
INPUT SPECIFICATIONS
3. THERMOCOUPLE INPUTS: (T16 only)
Types: T, E, J, K, R, S, B, N, C, and Linear mV
Input Impedance: 20 MΩ for all types
Lead Resistance Effect: 0.25 μV/Ω
Cold Junction Compensation: Less than ±1°C typical (1.5°C max) error
over ambient temperature range.
Resolution: 1° for types R, S, B and 1° or 0.1° for all other types
1. SENSOR INPUT:
Sample Period: 100 msec (10 Hz rate)
Step Response Time: 300 msec typical, 400 msec max to within 99% of final
value with step input.
Failed Sensor Response:
Main Control Output(s): Programmable preset output
Display: “OPEN”
Alarms: Upscale drive
Analog Output: Upscale drive when assigned to retransmitted input.
Normal Mode Rejection: >40 dB @ 50/60 Hz
Common Mode Rejection: >120 dB, DC to 60 Hz
Overvoltage Protection: 120 VAC @ 15 sec max
2. RTD INPUTS: (T16 only)
Type: 2 or 3 wire
Excitation: 150 μA typical
Lead Resistance: 15 Ω max per input lead
Resolution: 1° or 0.1° for all types
TYPE
INPUT TYPE
RANGE
STANDARD
385
100 Ω platinum,
Alpha = .00385
-200 to +600°C
-328 to +1112°F
IEC 751
392
100 Ω platinum,
Alpha = .003919
-200 to +600°C
-328 to +1112°F
No official
standard
672
120 Ω nickel,
Alpha = .00672
-80 to +215°C
-112 to +419°F
No official
standard
Ohms
Linear Resistance
0.0 to 320.0 Ω
N/A
TYPE
DISPLAY RANGE
-200 to +400°C
-328 to +752°F
-200 to +750°C
E
-328 to +1382°F
-200 to +760°C
J
-328 to +1400°F
-200 to +1250°C
K
-328 to +2282°F
0 to +1768°C
R
+32 to +3214°F
0 to +1768°C
S
+32 to +3214°F
+149 to +1820°C
B
+300 to +3308°F
-200 to +1300°C
N
-328 to +2372°F
C
0 to +2315°C
W5/W6 +32 to +4199°F
-5.00 mV to
mV
56.00 mV
T
2
WIRE COLOR
ANSI
(+) Blue
(-) Red
(+) Violet
(-) Red
(+) White
(-) Red
(+) Yellow
(-) Red
No
standard
No
standard
No
standard
(+) Orange
(-) Red
No
standard
N/A
BS 1843
STANDARD
(+) White
ITS-90
(-) Blue
(+) Brown
ITS-90
(-) Blue
(+) Yellow
ITS-90
(-) Blue
(+) Brown
ITS-90
(-) Blue
(+) White
ITS-90
(-) Blue
(+) White
ITS-90
(-) Blue
No
ITS-90
standard
(+) Orange
ITS-90
(-) Blue
No
ASTM
standard E988-96
N/A
N/A
INPUT SPECIFICATIONS (Cont’d)
5. TEMPERATURE INDICATION ACCURACY: (T16 only)
± (0.3% of span, +1°C) at 23 °C ambient after 20 minute warm up. Includes
NIST conformity, cold junction effect, A/D conversion errors and
linearization conformity.
Span Drift (maximum): 130 PPM/°C
6. USER INPUT: (Only controllers with alarms have a user input terminal.)
Internally pulled up to +7 VDC (100 KΩ), VIN MAX = 35 V, VIL = 0.6 V max,
VIH = 1.5 V min, IOFF = 40 μA max
Response Time: 120 msec max
Functions: Programmable
4. SIGNAL INPUT: (P16 only)
MAX
INPUT RANGE ACCURACY * IMPEDANCE CONTINUOUS RESOLUTION
OVERLOAD
10 VDC
(-1 to 11)
0.30 % of
reading
+0.03V
1 MΩ
50 V
10 mV
20 mA DC
(-2 to 22)
0.30 % of
reading
+0.04mA
10 Ω
100 mA
10 µA
* Accuracies are expressed as ± percentages over 0 to 50 °C ambient range
after 20 minute warm-up.
OUTPUT SPECIFICATIONS
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Sensor Fail Response: Upscale
Annunciator: “A1” and “A2” programmable for normal or reverse acting
4. COOLING: 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
5. ANALOG DC OUTPUT: (optional)
Action: Control or retransmission
Update Rate: 0.1 to 250 sec
1. CONTROL AND ALARM OUTPUTS:
Relay Output:
Type: Form A
Contact Rating: 3 A @ 250 VAC or 30 VDC; 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 Output (main control output only):
Rating: 45 mA max @ 4 V min., 7 V nominal
2. MAIN CONTROL:
Control: PID or On/Off
Output: Time proportioning or DC Analog
Cycle Time: Programmable
Auto-Tune: When selected, sets proportional band, integral time, derivative
time, and output dampening time. Also sets input filter and (if applicable)
cooling gain.
Probe Break Action: Programmable
3. ALARMS: (optional) 2 relay alarm outputs.
Modes:
None
Absolute High Acting (Balanced or Unbalanced Hysteresis)
Absolute Low Acting (Balanced or Unbalanced Hysteresis)
Deviation High Acting
Deviation Low Acting
Inside Band Acting
Outside Band Acting
Heat (Alarm 1 on Analog Output models only)
Cool (Alarm 2)
OUTPUT
RANGE **
ACCURACY *
COMPLIANCE
RESOLUTION
0 to 10 V
0.3% of FS
+ ½ LSD
10 kΩ min
1/8000
0.3% of FS
+ ½ LSD
0.3% of FS
+ ½ LSD
500 Ω max
1/8000
500 Ω max
1/6400
0 to 20 mA
4 to 20 mA
* Accuracies are expressed as ± percentages over 0 to 50 °C ambient range
after 20 minute warm-up.
** Outputs are independently jumper selectable for either 10 V or 20 mA. The
output range may be field calibrated to yield approximately 5% overrange
and a small underrange (negative) signal.
ORDERING INFORMATION
MODEL NO.
T16
P16
MAIN CONTROL
2 ALARMS & USER INPUT
Relay
PART NUMBERS
18-36 VDC/24 VAC
85 to 250 VAC
—
T1610010
T1610000
Relay
Yes
T1611110
T1611100
Logic/SSR
—
T1620010
T1620000
T1621100
Logic/SSR
Yes
T1621110
Analog Out *
Yes
T1641110
T1641100
Relay
—
P1610010
P1610000
Relay
Yes
P1611110
P1611100
Logic/SSR
—
P1620010
P1620000
Logic/SSR
Yes
P1621110
P1621100
Analog Out *
Yes
P1641110
P1641100
* Analog out may be used for retransmitted signals. When using analog output for retransmitted signals,
AL1 becomes main control O1, if selected for heating in the analog out models.
ACCESSORIES
MODEL NO.
TP16
RLY
DESCRIPTION
PART NUMBERS
Programming Kit 1 : Includes Software, Comms Module w/
9-pin connector and cable, and 115 VAC Power Adapter
TP16KIT1
Programming Kit 2 : Includes Software, Comms Module w/
9-pin connector and cable
TP16KIT2
External SSR Power Unit (for Logic/SSR models)
RLY50000
25 A Single Phase Din Rail Mount Solid State Relay
RLY60000
40 A Single Phase Din Rail Mount Solid State Relay
RLY6A000
Three Phase Din Rail Mount Solid State Relay
RLY70000
3
BLOCK DIAGRAM
*A1 becomes main control O1, if selected for heating in the
analog out models.
EMC INSTALLATION GUIDELINES
4. Signal or Control cables within an enclosure should be routed as far away as
possible from contactors, control relays, transformers, and other noisy
components.
5. In extremely high EMI environments, the use of external EMI suppression
devices, such as ferrite suppression cores, is effective. Install them on Signal
and Control cables as close to the controller 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
controller 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 (Red Lion Controls # FCOR0000)
TDK # ZCAT3035-1330A
Steward # 28B2029-0A0
Line Filters for input power cables:
Schaffner # FN610-1/07 (Red Lion Controls # LFIL0000)
Schaffner # FN670-1.8/07
Corcom # 1 VR3
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.
Snubber: Red Lion Controls # SNUB0000.
Although this controller is designed with a high degree of immunity to
Electromagnetic Interference (EMI), proper installation and wiring methods
must be followed to ensure electromagnetic compatibility (EMC) in each
application. The type of the electrical noise, source or coupling method into the
controller may be different for various installations. The controller becomes
more immune to EMI with fewer I/O connections. Cable length, routing, and
shield termination are very important and can mean the difference between a
successful or troublesome installation. Listed are some EMC guidelines for
successful installation in an industrial environment.
1. The controller should be mounted in a metal enclosure that 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 controller 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 more than 1 MHz.
c. Connect the shield to common of the controller 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 through 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
1.0 SETTING
THE
JUMPERS
(ANALOG OUTPUT MODELS ONLY)
To insure proper operation, the Analog Output jumpers must be set to the
same range selected in programming Module 2-OP. The default jumper
setting is for 20 mA. The default setting in Module 2-OP is 4-20
mA. To access the jumpers, insert a flat-blade screwdriver
between the front panel and the side case slot. This
should disengage the top and bottom front panel
latches from the case grooves. Pull the
front panel assembly with the controller
boards out of the case. The jumpers
are located inside the controller
on the left board along the
back top section.
VIEW FROM TOP OF UNIT
2.0 INSTALLING
THE
CONTROLLER
Instructions:
The T16 and P16 controllers meet NEMA 4X/IP65 requirements for indoor
use to provide a watertight seal in steel panels with a minimum thickness of
0.09", or aluminum panels with a
minimum thickness of 0.12". The
controllers are designed to be
mounted into an enclosed panel.
The bezel assembly must be in
place during installation of
the controller.
1. Prepare the panel cutout to the proper dimensions.
2. Remove the panel latch from the controller. Discard the cardboard sleeve.
3. Carefully remove the center section of the panel gasket and discard. Slide the
panel gasket over the rear of the controller, seating it against the lip at the
front of the case.
4. Insert the controller into the panel cutout. While holding the controller in
place, push the panel latch over the rear of the controller, 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 controller is snug in the
panel, torquing the screws to approximately 7 inlb (79 N-cm). Overtightening can result in
distortion of the controller, 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 by-products in which exposure
may affect proper operation.
Multiple Controller Stacking
The controller is designed to allow for close spacing of multiple controllers
in applications that do not require protection to NEMA 4X. Controllers can be
stacked either horizontally or vertically. For vertical stacking, install the panel
latch with the screws to the sides of the controller. For horizontal stacking, the
panel latch screws should be at the top and bottom of the controller. The
minimum spacing from centerline to centerline of controllers is 1.96" (49.8
mm). This spacing is the same for vertical or
horizontal stacking.
Note: When stacking
controllers, provide
adequate panel
ventilation to ensure
that the maximum
operating temperature
range is not exceeded.
5
3.0 WIRING
THE
CONTROLLER
WIRING CONNECTIONS
codes and regulations. It is recommended that power (AC or DC) supplied to the
controller 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.
All wiring connections are made to the rear screw terminals. When wiring the
controller, 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
VDC
CONTROLLER POWER CONNECTIONS
VAC
For best results, the power should be relatively “clean” and within
the specified limits. Drawing power from heavily loaded circuits or
from circuits that also power loads that cycle on and off should be
avoided. It is recommended that power supplied to the controller be
protected by a fuse or circuit breaker.
INPUT CONNECTIONS
the preferred method. If a sense wire is not used, then use a jumper. A
temperature offset error will exist. The error may be compensated by
programming a temperature offset.
For two wire RTDs, install a copper sense lead of the same gauge and length
as the RTD leads. Attach one end of the wire at the probe and the other end to
input common terminal. Complete lead wire compensation is obtained. This is
RTD and Resistance
Thermocouple and Millivolt
Voltage and Current
CONTROL AND ALARM OUTPUT CONNECTIONS
Alarm Models
Main Control Relay Models
Main Control Logic/SSR Models
*A1 becomes main control O1, if selected for
heating in the analog out models.
USER INPUT CONNECTIONS
ANALOG DC OUTPUT CONNECTIONS
6
4.0 REVIEWING
THE
FRONT KEYS
FRONT PANEL KEYS
AND
DISPLAY
The Arrow keys are used to scroll through parameter
selections/values and in the Configuration Loop they are used to
scroll to the appropriate Parameter Module.
The F1 key is pressed to exit (or escape) directly to the start of the
Display Loop. While in the Display Loop, the F1 key can be pressed to
activate its programmed function.
The Loop key is pressed to advance to the next parameter, to activate
a changed selection/value, and when held for three seconds, enter the
Hidden Loop.
5.0 PROGRAMMING: DISPLAY LOOP
DISPLAY LOOP
Note: Setpoint and Output Power are the only parameters visible in the Display Loop with Factory Settings. The remaining parameters can
be selected for the Display Loop within Module 3.
Parameter availability is model and programming dependent.
DISPLAY LOOP
When the
is pressed the controller advances to the next parameter in the
Display Loop. Except for Setpoint and % Output Power, the bottom display
alternates between the parameter name and its selection/value. The arrow keys
are pressed to change the selection/value for the shown parameter. The new
selection/value is activated when the
is pressed. Display Loop parameters
may be locked out or hidden in Lockout Module
. Some parameters are
model and programming dependent.
At power up, all display segments light, and then the programmed input type
and the controller’s software version will flash. Then the Temperature/Process
Value is shown in the top display, and the Setpoint Value is shown in the bottom
display. This is the Display Loop. If the Setpoint is hidden or locked, the Display
Loop will default to Output Power. If Output Power is also hidden or locked out,
the bottom display is blank. During programming, the F1 key can be pressed to
return the controller to this point. (Only in the Display Loop will the F1 key
perform the user
function programmed in Input Module
.)
7
The values shown for the displays are the factory settings.
INTEGRAL TIME
SETPOINT VALUE (SP1) *
SP
0
0.0
Intt «
ª 120
-999 to 9999
T16
Integral action shifts the center point position of the proportional band to
eliminate error in the steady state. The higher the integral time, the slower the
response. The optimal integral time is best determined during PID Tuning. If
time is set to zero, the previous Integral output power value is maintained.
Offset Power can be used to provide Manual Reset.
P16
SETPOINT VALUE (SP2) *
SP
2.0
-999 to 9999
DERIVATIVE TIME
T16
dErt «
ª
30
P16
Typically, the controller is operating with the Setpoint value in the bottom
display. There is no annunciator nor parameter indication for Setpoint in the
Display Loop. The parameter name alternates with the setpoint value in the
Hidden Loop. The Setpoint value can be changed, activated and stored by
pressing the arrow keys. This is the only parameter that can be configured as
read only in the Display Loop, but read/write in the Hidden Loop. It is possible
to store a second Setpoint value that can be selected in the Hidden Loop, by the
F1 key or the user input. Both Setpoint values are limited by the Setpoint Low
and High Limits in Input Module
.
ALARM 1 VALUE
AL-1 «
ª
0
0.0
-100 to 100.0
-999 to 9999
P16
ALARM 2 VALUE
AL-2 «
ª
0
0.0
OUTPUT POWER OFFSET
-100 to 100.0
T16
-999 to 9999
P16
On models with alarms, the value for Alarm 2 can be entered here. The value
is either absolute (absolute alarm types) or relative to the Setpoint value
(deviation and band alarm types.) When Alarm 2 is programmed for CooL or
NonE, this parameter is not available. For more details on alarms, see the Alarm
Module 4-AL.
When the Integral Time is set to zero and the controller is in the Automatic
Mode, this parameter will appear after % Output Power. It is also shown with
the %PW annunciator illuminated. The power offset is used to shift the
proportional band to compensate for errors in the steady state. If Integral Action
is later invoked, the controller will re-calculate the internal integral value to
provide “bumpless” transfer and Output Power Offset will not be necessary.
PROPORTIONAL BAND
ProP «
ª
4.0
T16
On models with alarms, the value for Alarm 1 can be entered here. The value
is either absolute (absolute alarm types) or relative to the Setpoint value
(deviation and band alarm types.) When Alarm 1 is programmed for HEAt or
NonE, this parameter is not available. For more details on alarms, see Alarm
Module "-.
The % Output Power is shown with the %PW annunciator. The parameter
name alternates with the % Output Power value in the Hidden Loop. While the
controller is in Automatic Mode, this value is read only. When the controller is
placed in Manual Mode, the value can be changed, activated and stored by
pressing the arrow keys. For more details on % Output Power, see Control
Mode Explanations.
OPOF «
ª
0.0
0 to 9999 seconds per repeat
Derivative time helps to stabilize the response, but too high of a derivative
time, coupled with noisy signal processes, may cause the output to fluctuate too
greatly, yielding poor control. Setting the time to zero disables derivative action.
% OUTPUT POWER *
OP
0.0
0 to 9999 seconds
* Alternating indication only used in the Hidden Loop.
0.0 to 999.9
(% of full input range)
The proportional band should be set to obtain the best response to a process
disturbance while minimizing overshoot. A proportional band of 0.0% forces
the controller into On/Off Control with its characteristic cycling at Setpoint. For
more information, see Control Mode and PID Tuning Explanations.
8
6.0 PROGRAMMING: HIDDEN LOOP
To enter Hidden Loop, press
for 3 seconds.
HIDDEN LOOP
Note: Parameters shown bold are the only parameters visible in the Hidden Loop with Factory Settings. Setpoint and Output Power are
factory set for the Display Loop. The remaining parameters can be selected for the Hidden Loop within Module 3.
Parameter availability is model and programming dependent.
HIDDEN LOOP
When
is pressed and held for three seconds, the controller advances to the
Hidden Loop. The Temperature/Process Value is shown in the top display. The
bottom display alternates between the parameter and its selection/value.
or
is pressed to change the selection/value for the shown parameter. The new
selection/value is activated after
is pressed. When
is pressed, the
controller returns to the Display Loop and stores changed selection/values to
permanent memory. Hidden Loop parameters may be locked out in Lockout
Module 3-LC. Some parameters are model and programming dependent.
SETPOINT RAMP RATE
SPrP «
ª
0.0
The setpoint ramp rate can reduce sudden shock to the process and reduce
overshoot on startup or after setpoint changes, by ramping the setpoint at a
controlled rate. R annunciator flashes while ramping. With the T16, the ramp rate
is always in tenths of degrees per minute, regardless of the resolution chosen for
the process display. With the P16, the ramp rate is in least-significant (display
units) digits per minute. A value of 0.0 or 0 disables setpoint ramping. 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 starting AutoTune, the ramping is suspended during Auto-Tune and then resumed afterward.
Deviation and band alarms are relative to the target setpoint, not the ramping
setpoint. A slow process may not track the programmed setpoint rate. At power
up, the ramping setpoint is initialized at the ambient temperature/process value.
ACCESS CODE
CodE «
ª
0
1 to 125
If the Access Code is set from 1 to 125, in Lockout Module
, Access
Code will appear here. By entering the proper Code, access to the Hidden Loop
is permitted. With the factory setting of 0, Access Code will not appear in the
Hidden Loop. A universal code of 111 can be entered to gain access,
independent of the programmed code number.
CONTROL MODE TRANSFER
trnF «
ª Auto
SETPOINT SELECT
SPSL «
ª SP1
0.0 to 999.9
SP1 or SP2
Auto USEr
In Automatic Mode, the percentage of Output Power is automatically
determined by the controller. In Manual/User USEr Mode, the percentage of
Output Power is adjusted manually while in the Display Loop. The Control
Mode can also be transferred through the F1 Key or User Input. For more
information, see Control Mode Explanations.
The SPSL function allows the operator to switch from or to, setpoint 1 and
setpoint 2. In the Display Loop, there is no annunciator indicating the selected
Setpoint, however, the selected Setpoint value is displayed and activated.
9
AUTO-TUNE START
tUNE «
ª
NO
ACCESS CODE
CodE «
ª
0
NO YES
The Auto-Tune procedure of the controller sets the Proportional Band,
Integral Time, Derivative Time, Digital Filter, Control Output Dampening
Time, and Relative Gain (Heat/Cool) values appropriate to the characteristics of
the process. This parameter allows front panel starting YES or stopping NO of
Auto-Tune. For more information, see PID Tuning Explanations.
-1 to -125
If the Access Code is set from -1 to -125, in Lockout Module 3-LC, Access
Code will appear here. By entering the proper Code, access to the Configuration
Loop is permitted (with a negative Code value, the Hidden Loop can be
accessed without the use of a code). With the factory setting of 0 or with an
active User Input configured for Program Lock (PLOC), Access Code will not
appear here. An active user input configured for Program Lock (PLOC) always
locks out the Configuration Loop, regardless of Access Code.
ALARMS RESET
ALrS «
ª 1-2
1-2
With alarm models, the alarms can be manually reset. The up key resets
Alarm 1 and the down key resets Alarm 2.
7.0 PROGRAMMING: CONFIGURATION LOOP
CONFIGURATION LOOP
To access the Configuration Loop, press the up key when CNFP/NO is displayed
in the Hidden Loop. The arrow keys are used to select the parameter module (19). To enter a specific module press
while the module number is displayed.
In the Configuration Loop, CNFP will alternate with the parameter number in the
bottom display. The Temperature/Process Value is shown in the top display.
After entering a parameter module, press
to advance through the
parameter names in the module. To change a parameter’s selection/value, press
the arrow keys while the parameter is displayed. In the modules, the top display
shows the parameter name, and the bottom display shows the selection/value.
Use
to enter any selection/values that have been changed. The change is not
committed to permanent memory until the controller is returned to the Display
Loop. If a power loss occurs before returning to the Display Loop, the new
values must be entered again.
At the end of each module, the controller returns to CNFP/NO. At this location,
pressing
again returns the display to the the Display Loop. Pressing the Up
key allows re-entrance to the Configuration Loop. Whenever
is pressed, End
momentarily appears as the parameters are stored to permanent memory and the
controller returns to the Display Loop.
10
7.1 MODULE 1 - INPUT PARAMETERS (
) T16 ONLY
PARAMETER MENU
INPUT TYPE
tYPE
tc-j
SELECTION TYPE
tc-t
tc-E
tctc-K
tc-r
tc-S
tc-b
T TC
E TC
J TC
K TC
R TC
S TC
B TC
SETPOINT LOW LIMIT
SELECTION
tc-N
tc-C
LIN
r385
r392
r672
rLIN
SPLO
0
TYPE
N TC
C TC
The controller has a programmable low setpoint limit value to restrict the
setting range of the setpoint. Set the limit so that the setpoint value cannot be
set below the safe operating area of the process.
Linear mV
RTD 385
RTD 392
RTD 672
SETPOINT HIGH LIMIT
Linear Ohms
SPHI
9999
Select the input type that corresponds to the input sensor.
TEMPERATURE SCALE
SCAL
°F
°F Fahrenheit
°C Celsius
USER INPUT FUNCTION (OPTIONAL)
InPt
PLOC
DECIMAL RESOLUTION
SELECTION
0 to 0.0 for temperature and resistance inputs
0.00 for mV inputs
NONE
PLOC
ILOC
trnF
Select whole degrees, or tenths of degrees for Temperature display, Setpoint
values, and related parameters. For Linear Resistance inputs rLIN, the same
parameter selections apply in ohms or tenths of an ohm. For mV inputs LIN,
only hundredths of a mV resolution is available.
0 = least to 4 = most
The filter is an adaptive digital filter that discriminates between measurement
noise and actual process changes. If the signal is varying too greatly due to
measurement noise, increase the filter value. If the fastest controller response is
needed, decrease the filter value.
SHIFT/OFFSET
SHft
0
FUNCTION
No Function
Program Lock
Integral Action Lock
SELECTION
SPt
SPrP
ALrS
FUNCTION
Setpoint 1 or 2 Select
Setpoint Ramp Disable
Reset Both Alarms
Auto/Manual Select
The controller performs the selected User Input function (User Input
available only on models with alarms), when the User terminal 1 is connected
(pulled low) to Common terminal 8.
No Function: No function is performed.
Program Lock: The Configuration Loop is locked, as long as activated
(maintained action).
Integral Action Lock: The integral action of the PID computation is disabled
(frozen), as long as activated (maintained action).
Auto/Manual Select: This function selects (maintained action) Automatic
(open) or Manual Control (activated).
Setpoint 1 or 2 Select: This function selects (maintained action) Setpoint
1(open) or Setpoint 2 (activated) as the active setpoint.
Setpoint Ramp Disable: The setpoint ramping feature is disabled, as long as
activated (maintained action). Any time the user input is activated with a
ramp in process, ramping is aborted.
Reset Alarms: Active alarms are reset, as long as activated (maintained action).
Active alarms are reset until the alarm condition is cleared and triggered
again (momentary action).
DIGITAL FILTERING
FLtr
1
-999 to 9999
The controller has a programmable high setpoint limit value to restrict the
setting range of the setpoint. Set the limit so that the setpoint value cannot be
set above the safe operating area of the process.
Select either degrees Fahrenheit or Celsius. For linear mV and ohms input
types, this has no effect. If changed, adjust related parameter values, as the
controller does not automatically convert them.
dCPt
0
-999 to 9999
-999 to 9999 degrees
This value offsets the controller’s temperature display value by the entered
amount. This is useful in applications in which the sensor cannot provide the
actual temperature signal due to mounting constraints, inaccuracy, etc.
11
F1 KEY FUNCTION
The controller performs the selected F1 Key Function, when
is pressed
while in the Display Loop. In any other loop or module location, pressing
will perform an escape to the Display Loop.
No Function: No function is performed.
Auto/Manual Select: This function toggles (momentary action) the controller
between Automatic and Manual Control.
Setpoint 1 or 2 Select: This function toggles (momentary action) the controller
between Setpoint 1 and Setpoint 2.
Reset Alarms: This function can be used to reset one or both of the alarms
when activated (momentary action) The alarm will remain reset until the
alarm condition is cleared and triggered again.
F1In
NONE
SELECTION
NONE
trnF
SPt
FUNCTION
SELECTION
No Function
A1rS
A2rS
ALrS
Auto/Manual Select
Setpoint 1 or 2 Select
FUNCTION
Reset Alarm 1
Reset Alarm 2
Reset Both Alarms
7.1 MODULE 1 - INPUT PARAMETERS (
) P16 ONLY
PARAMETER MENU
INPUT TYPE
tYPE
Curr
SELECTION
TYPE
Curr
VOLt
Current
Voltage
SCALING
To scale the controller, two scaling points are necessary. Each scaling point has
a coordinate pair of Display Values and Input Values. It is recommended that the
two scaling points be at the low and high ends of the input signal being measured.
Process value scaling will be linear between and continue past the entered points
to the limits of the input range. (Factory settings example will display 0.0 at 4.00
mA input and display 100.0 at 20.00 mA input.) Reverse acting indication can be
accomplished by reversing the two signal points or the Display value points, but
not both. If both are reversed, forward (normal) acting indication will occur. In
either case, do not reverse the input wires to change the action.
Select the input type that corresponds to the input signal.
PERCENT ANNUNCIATOR
PCt
NO
YES On
NO Off
DISPLAY VALUE SCALING POINT 1
dSP1
0.0
This only illuminates the % annunciator. It does not perform any type of
percent function, but is useful in applications that have been scaled in percent.
Enter the first coordinate Display Value by using the arrow keys.
DECIMAL RESOLUTION
dCPt
0.0
INPUT VALUE SCALING POINT 1
0 0.0 0.00 0.000
INP1
4.00
This selection affects the decimal point placement for the Process value, and
related parameters.
1 to 100
In steps of 1 least significant digit,
regardless of decimal point.
Rounding selections other than 1 cause the process value display to round to
the nearest rounding increment selected. (For example, rounding of 5 causes 122
to round to 120 and 123 to round to 125.) Rounding starts at the least significant
digit of the process value. Setpoint values, Setpoint limits, Alarm values, Input
Scaling values, and Analog Scaling values are not affected by rounding.
DISPLAY VALUE SCALING POINT 2
dSP2
100.0
DIGITAL FILTERING
FLtr
1
0.00 to 20.00 mA
0.00 to 10.00 V
For Key-in Method, enter the first coordinate Input Value by using the arrow
keys. To allow the P16 to “learn” the signal, use the Applied Method. For Applied
Method, press . The ° annunciator is turned on to indicate the applied method.
Adjust the applied signal level externally until the appropriate value appears
under INP1. Using either method, press
to store the value for INP1. (The
controller can be toggled back to the Key-in Method by pressing
before .)
ROUNDING INCREMENT
rnd
0.1
-999 to 9999
-999 to 9999
Enter the second coordinate Display Value by using the arrow keys.
0 = least to 4 = most
The filter is an adaptive digital filter that discriminates between measurement
noise and actual process changes. If the signal is varying too greatly due to
measurement noise, increase the filter value. If the fastest controller response is
needed, decrease the filter value.
12
INPUT VALUE SCALING POINT 2
INP2
20.00
F1 KEY FUNCTION
F1In
NONE
0.00 to 20.00 mA
0.00 to 10.00 V
SELECTION
For Key-in Method, enter the second coordinate Input Value by using the
arrow keys. To allow the P16 to “learn” the signal, use the Applied Method. For
Applied Method, press
. The ° annunciator is turned on to indicate the
applied method. Adjust the applied signal level externally until the appropriate
value appears under INP2. Using either method, press
to store the value for
INP2. (The controller can be toggled back to the Key-in Method by pressing
before .)
NONE
trnF
SPt
-999 to 9999
The controller has a programmable low setpoint limit value to restrict the
setting range of the setpoint. Set the limit so that the setpoint value cannot be
set below the safe operating area of the process.
SETPOINT HIGH LIMIT
SPHI
999.9
-999 to 9999
The controller has a programmable high setpoint limit value to restrict the
setting range of the setpoint. Set the limit so that the setpoint value cannot be
set above the safe operating area of the process.
USER INPUT FUNCTION (OPTIONAL)
InPt
PLOC
SELECTION
NONE
PLOC
ILOC
trnF
FUNCTION
No Function
Program Lock
Integral Action Lock
SELECTION
SPt
SPrP
ALrS
No Function
Auto/Manual Select
Setpoint 1 or 2 Select
SELECTION
A1rS
A2rS
ALrS
FUNCTION
Reset Alarm 1
Reset Alarm 2
Reset Both Alarms
The controller performs the selected F1 key function, when
is pressed
while in the Display Loop. In any other loop or module location, pressing
will perform an escape to the Display Loop.
No Function: No function is performed.
Auto/Manual Select: This function toggles (momentary action) the controller
between Automatic and Manual Control.
Setpoint 1 or 2 Selection: This function toggles (momentary action) the
controller between Setpoint 1 and Setpoint 2.
Reset Alarms: This function can be used to reset one or both of the alarms
when activated (momentary action). The alarm will remain reset until the
alarm condition is cleared and triggered again.
SETPOINT LOW LIMIT
SPLO
FUNCTION
FUNCTION
Setpoint 1 or 2 Select
Setpoint Ramp Disable
Reset Both Alarms
Auto/Manual Select
The controller performs the selected User Input function (User Input
available only on models with alarms), when the User terminal 1 is connected
(pulled low) to Common terminal 8.
No Function: No function is performed.
Program Lock: The Configuration Loop is locked, as long as activated
(maintained action).
Integral Action Lock: The integral action of the PID computation is disabled
(frozen), as long as activated (maintained action).
Auto/Manual Select: This function selects (maintained action) Automatic
(open) or Manual Control (activated).
Setpoint 1 or 2 Select: This function selects (maintained action) Setpoint
1(open) or Setpoint 2 (activated) as the active setpoint.
Setpoint Ramp Disable: The setpoint ramping feature is disabled, as long as
activated (maintained action). Any time the user input is activated with a
ramp in process, ramping is aborted.
Reset Alarms: Active alarms are reset, as long as activated (maintained action).
Active alarms are reset until the alarm condition is cleared and triggered
again (momentary action).
13
7.2 MODULE 2 - OUTPUT PARAMETERS (
)
PARAMETER MENU
SENSOR FAIL POWER LEVEL
CYCLE TIME
CYCt
2.0
OPFL
0
0.0 to 250.0 seconds
0 to 100 percent O1
-100 to 100 percent O1/O2
This parameter sets the power level for the control outputs in the event of a
sensor failure. If Alarm 2 is not selected for cooling, the range is from 0% (O1
output full off) to 100% (O1 output full on). If A2 is selected for cooling, the
range is from -100 to +100%. At 0%, both O1 and O2 are off; at 100%, O1 is
on; and at -100%, O2 is on. The alarm outputs are upscale drive with an open
sensor, and downscale drive with a shorted sensor (RTD only), independent of
this setting. Manual Control overrides the sensor fail preset.
The Cycle Time is entered in seconds with one tenth of a second resolution.
It is the total time for one on and one off period of the time proportioning
control output O1. With time proportional control, the percentage of power is
converted into an output on-time relative to the cycle time value set. (If the
controller calculates that 65% power is required and a cycle time of 10.0
seconds is set, the output will be on for 6.5 seconds and off for 3.5 seconds.)
For best control, a cycle time equal to one-tenth or less, of the natural period of
oscillation of the process is recommended. When using the Analog Output
signal for control, the Cycle Time setting has no effect. If the O1 output is not
being used, a cycle time of 0 can be entered to prevent the output and indicator
from cycling.
OUTPUT POWER DAMPENING
OPdP
3
1
CONTROL ACTION
OPAC
rEv
drct Direct (cooling)
rEv Reverse (heating)
ON/OFF CONTROL HYSTERESIS
CHYS
OUTPUT POWER LOWER LIMIT
2
0.2
0 to 100 percent O1
-100 to 100 percent O1/O2
1 to 250
T16
P16
The controller can be placed in the On/Off Control Mode by setting the
Proportional Band to 0.0%. The On/Off Control Hysteresis (balanced around
the setpoint) eliminates output chatter. In heat/cool applications, the control
hysteresis value affects both Output O1 and Output O2 control. It is suggested
to set the hysteresis band to Factory Setting prior to starting Auto-Tune. After
Auto-Tune, the hysteresis band has no effect on PID Control. On/Off Control
Hysteresis is illustrated in the On/Off Control Mode section.
This parameter may be used to limit controller power at the lower end due to
process disturbances or setpoint changes. Enter the safe output power limits for
the process. If Alarm 2 is selected for cooling, the range is from -100 to +100%.
At 0%, both O1 and O2 are off; at 100%, O1 is on; and at -100%, O2 is on.
When the controller is in Manual Control Mode, this limit does not apply.
OUTPUT POWER UPPER LIMIT
OPHI
100
P16
The Dampening Time, entered as a time constant in seconds, dampens
(filters) the calculated output power. Increasing the value increases the
dampening effect. Generally, dampening times in the range of one-twentieth to
one-fiftieth of the controller’s integral time (or process time constant) are
effective. Dampening times longer than these may cause controller instability
due to the added lag effect.
This determines the control action for the PID loop. Programmed for direct
action (cooling), the output power will increase if the Process value is above the
Setpoint value. Programmed for reverse action (heating), the output power
decreases when the Process Value is above the Setpoint Value. For heat and cool
applications, this is typically set to reverse. This allows O1 or A1 (models with
Analog Output) to be used for heating, and A2/O2 to be used for cooling.
OPLO
0
0 to 250 seconds
T16
AUTO-TUNE CODE
0 to 100 percent O1
-100 to 100 percent O1/O2
tcod
0
This parameter may be used to limit controller power at the upper end due to
process disturbances or setpoint changes. Enter the safe output power limits for
the process. If Alarm 2 is selected for cooling, the range is from -100 to +100%.
At 0%, both O1 and O2 are off; at 100%, O1 is on; and at -100%, O2 is on.
When the controller is in Manual Control Mode, this limit does not apply.
0 fastest to 2 slowest
Prior to starting Auto-Tune, this code should be set to achieve the necessary
dampening level under PID Control. This value allows customization of the PID
values that Auto-Tune will calculate. For the process to be controlled
aggressively (fastest process response with possible overshoot), set the AutoTune Code to 0. For the process to be controlled conservatively (slowest
response with the least amount of overshoot), set this value to 2. If the Auto-Tune
Code is changed, Auto-Tune needs to be reinitiated for the changes to affect the
PID settings. For more information, see PID Tuning Explanations Section.
14
ANALOG OUTPUT RANGE (OPTIONAL)
ANtP
4-20
ANALOG LOW SCALING (OPTIONAL)
0-10 V 0-20 mA
4-20 mA
to
0.0
Select the type of output and range. The Analog output jumpers are factory
set to current. They must be changed if voltage output is desired. The Analog
output can be calibrated to provide up to approximately 5% over range
operation (0 mA current can only go slightly negative).
The Analog Output assignment value that corresponds to 0 V, 0 mA or 4 mA
output as selected.
ANALOG HIGH SCALING (OPTIONAL)
ANHI
100.0
ANALOG OUTPUT ASSIGNMENT (OPTIONAL)
ANAS
OP
OP Main Control % Output Power
InP Input Signal Retransmission
SP Active Setpoint
-999 to 9999
The Analog Output assignment value that corresponds to 10 V or 20 mA
output as selected. An inverse acting output can be achieved by reversing the
low and high scaling points.
This setting selects the parameter that the Analog Output will retransmit or
track.
ANALOG UPDATE TIME (OPTIONAL)
ANUt
0
0 to 250 seconds
0 = update rate of 0.1 second
The update time of the Analog Output can be used to reduce excess valve
actuator or pen recorder activity.
7.3 MODULE 3 - LOCKOUT PARAMETERS (
)
PARAMETER MENU
SELECTION
dISP
HIdE
LOC
dSPr
ACCESS CODE
DESCRIPTION
CodE
0
Display: accessible in Display Loop.
Hide: accessible in Hidden Loop.
-125 to Locked: not accessible in either loop.
(SP only)
Display/read: read only in Display Loop,
but read/write in Hidden Loop.
0
-1 to -125
1 to 125
The following parameters can be configured for LOC, HIdE, and dISP.
SETPOINT
ACCESS
SP
dISP
OUTPUT
POWER
ACCESS
OP
dISP
PID VALUES
ACCESS
PId
HIdE
Full access to Display, Hidden,
and Configuration Loops
Code necessary to access
Configuration Loop only.
Code necessary to access
Hidden and Configuration Loops.
The following parameters can be configured for LOC or HIdE only.
ALARM
VALUES
ACCESS
SETPOINT
SELECT
ACCESS
AL
HIdE
SETPOINT
RAMP
ACCESS
CONTROL
TRANSFER
ACCESS
SPrP
HIdE
trnF
LOC
SPSL
LOC
AUTO-TUNE
START
ACCESS
tUNE
HIdE
15
RESET
ALARMS
ACCESS
ALrS
LOC
7.4 MODULE 4 - ALARM PARAMETERS (
) (OPTIONAL)
PARAMETER MENU
AVAILABLE ALARM ACTIONS
NONE
None
No action, the remaining Alarm
parameters are not available.
AbHI
Absolute High
(balanced hysteresis)
The alarm energizes when the Process
Value exceeds the alarm value + 1/2
the hysteresis value.
AbLO
Absolute Low
(balanced hysteresis)
The alarm energizes when the Process
Value falls below the alarm value -1/2
the hysteresis value.
AuHI
Absolute High
(unbalanced hysteresis)
AuLO
Absolute Low
(unbalanced hysteresis)
d-HI
Deviation High
Alarm 1 and 2 value tracks the
Setpoint value
d-LO
Deviation Low
Alarm 1 and 2 value tracks the
Setpoint value
b-IN
Band Acting
(inside)
Alarm 1 and 2 value tracks the
Setpoint value
b-ot
Band Acting
(outside)
Alarm 1 and 2 value tracks the
Setpoint value
The alarm energizes when the Process
Value exceeds the alarm value.
HEAt
Heat (A1 Analog
models only)
If heating is selected, the remaining
Alarm 1 parameters are not available.
The alarm energizes when the Process
Value falls below the alarm value.
CooL
Cool
(A2 only)
If cooling is selected, the remaining
Alarm 2 parameters are not available.
ALARM ACTION FIGURES
Note: Hys in the above figures refers to the Alarm Hysteresis.
16
ALARM ACTION ALARM 1
ACt1
AuHI
ALARM ANNUNCIATOR ALARM 2
Lit2
nor
NONE AbHI AbLO AuHI AuLO
d-HI d-LO b-IN b-ot HEAt
nor Normal
rEv Reverse
Select the action for the alarms. See Alarm Action Figures for a visual
explanation.
With normal selection, the alarm annunciator indicates “on” alarm output 2.
With reverse selection, the alarm annunciator indicates “off” alarm output.
ALARM ANNUNCIATOR ALARM 1
ALARM RESET MODE ALARM 2
-JU
nor
rSt2
Auto
nor Normal
rEv Reverse
In Automatic mode, an energized alarm turns off automatically after the
Temperature/Process value leaves the alarm region. In Latched mode, an
energized alarm requires an F1 key or user input alarm reset to turn off. After an
alarm reset, the alarm remains reset off until the trigger point is crossed again.
With normal selection, the alarm annunciator indicates “on” alarm output 1.
With reverse selection, the alarm annunciator indicates “off” alarm output.
ALARM RESET MODE ALARM 1
rSt1
Auto
Auto Automatic
LAtc Latched
ALARM STANDBY ALARM 2
Stb2
NO
In Automatic mode, an energized alarm turns off automatically after the
Temperature/Process value leaves the alarm region. In Latched mode, an
energized alarm requires an F1 key or user input alarm reset to turn off. After an
alarm reset, the alarm remains reset off until the trigger point is crossed again.
YES Standby on
NO Standby off
ALARM VALUE ALARM 2
AL-2
20
2.0
Standby prevents nuisance (typically low level) alarms after a power up or
setpoint change. After powering up the controller or changing the setpoint, the
process must leave the alarm region (enter normal non-alarm area of operation).
After this has occurred, the standby is disabled and the alarm responds normally
until the next controller power up or setpoint change.
AL-1
P16
-999 to 9999
ALARM HYSTERESIS
T16
AHYS
P16
The alarm values are entered as process units or degrees. They can also be
entered in the Display or Hidden Loops. When the alarm is configured as
deviation or band acting, the associated output tracks the Setpoint as it is
changed. The value entered is the offset or difference from the Setpoint.
1
0.1
0 to 250
T16
P16
The Hysteresis Value is either added to or subtracted from the alarm value,
depending on the alarm action selected. The same value applies to both alarms.
See the Alarm Action Figures for a visual explanation of how alarm actions are
affected by the hysteresis.
ALARM ACTION ALARM 2
ACt2
AuHI
-999 to 9999
T16
The alarm values are entered as process units or degrees. They can also be
entered in the Display or Hidden Loops. When the alarm is configured as
deviation or band acting, the associated output tracks the Setpoint as it is
changed. The value entered is the offset or difference from the Setpoint.
ALARM VALUE ALARM 1
0
0.0
YES Standby on
NO Standby off
Standby prevents nuisance (typically low level) alarms after a power up or
setpoint change. After powering up the controller or changing the setpoint, the
process must leave the alarm region (enter normal non-alarm area of operation).
After this has occurred, the standby is disabled and the alarm responds normally
until the next controller power up or setpoint change.
ALARM STANDBY ALARM 1
Stb1
NO
Auto Automatic
LAtc Latched
NONE AbHI AbLO AuHI AuLO
d-HI d-LO b-IN b-ot CooL
Select the action for the alarms. See Alarm Action Figures for a visual
explanation.
17
7.5 MODULE 5 - COOLING (SECONDARY) PARAMETERS (
)
PARAMETER MENU
To enable Cooling in Heat/Cool applications, the Alarm 2 Action must first
be set for Cooling. (For P16 Controllers, the cooling output is sometimes
referred to as secondary output.) When set to cooling, the output no longer
operates as an alarm but operates as a cooling output. The O2 terminals are the
same as A2, however a separate O2 annunciator indicates Cooling Operation.
Cooling output power ranges from -100% (full cooling) to 0% (no cooling,
unless a heat/cool overlap is used). The Power Limits in Output Module
also limit the cooling power. In applications requiring only a Cooling output,
the main 01 output should be used.
DEADBAND/OVERLAP
db-2
0
This defines the overlap area in which both heating and cooling are active
(negative value) or the deadband area between the bands (positive value). If a
heat/cool overlap is specified, the percent output power is the sum of the heat
power (O1) and the cool power (O2). If Relative Gain is zero, the cooling
output operates in the On/Off Control Mode, with the On/Off Control
Hysteresis CHYS in Output Module 2-OP becoming the cooling output hysteresis.
The function of Deadband is illustrated in the Control Mode Explanations. For
most applications, set this parameter to 0.0 prior to starting Auto-Tune. After
the completion of Auto-Tune, this parameter may be changed.
CYCLE TIME
CYC2
2.0
-999 to 9999
0.0 to 250.0 seconds
This cycle time functions like the O1 Output Cycle Time but allows
independent cycle time for cooling. A setting of zero will keep output O2 off.
RELATIVE GAIN
GAN2
1.0
0.0 to 10.0
This defines the gain of the cooling relative to the heating. It is generally set
to balance the effects of cooling to that of heating. This is illustrated in the
Heat/Cool Relative Gain Figures. A value of 0.0 places the cooling output into
On/Off Control.
HEAT/COOL RELATIVE GAIN FIGURES
Heat/Cool Deadband = 0
Heat/Cool Deadband < 0
Heat/Cool Deadband > 0
18
7.5 MODULE 9 FACTORY SERVICE OPERATIONS (
)
PARAMETER MENU
RTD Resistance (T16)
CALIBRATION
RTD calibration requires a precision 277.0 ohm resistor with an accuracy of
0.1 Ω (or better). Connect a jumper between terminals 9 and 10 with a 0 ohm
jumper between 9 and 8 at StP1 and the 277.0 ohm resistor between 9 and 8 at
StP2. If using thermocouple only, the RTD calibration need not be performed.
CodE
48
The controller is fully calibrated from the factory. Recalibration is
recommended every two years by qualified technicians using appropriate
equipment. Calibration may be performed by using the front panel or with the
TP16KIT. The front panel method is explained below. (Refer to the TP16KIT
bulletin for calibration instructions using TP16KIT cable and software.)
Calibration may be aborted by disconnecting power to the controller before
exiting Factory Service Module 9-FS. In this case, the existing calibration
settings remain in effect.
Note: Allow the controller to warm up for 30 minutes minimum and follow
the manufacturer’s warm-up recommendations for the calibration source or
measuring device.
PROMPT
[CodE]
[CAL]
[CJC]
[rtd]
[StP1]
[StP2]
APPLY
FRONT PANEL ACTION
Press
Press
.
Press
.
Press
0.0 ohm
until
for
48, press
.
YES, press
.
After 5 seconds (minimum), press
.
277.0 ohm After 5 seconds (minimum), press
.
Input Calibration (P16)
Process calibration requires a precision signal source with an accuracy of
0.03% (or better) that is capable of generating 10.0 V connected to terminals 8
(COMM) and 9 (+10V) and 20.00 mA connected to terminals 8 (COMM) and
10 (20mA). The current calibration can be skipped by pressing
at the not
applicable prompts if using the controller for process voltage only.
Millivolt Calibration (T16)
Millivolt calibration requires a precision voltage source with an accuracy of
0.03% (or better) connected to terminals 8 (comm.) and 9 (+). When calibrating
the input, the millivolt calibration must be performed first, then the Cold Junction
or RTD Resistance.
PROMPT
APPLY
[CodE]
[CAL]
[StP1]
[StP2]
[StP3]
[StP4]
[StP5]
PROMPT
FRONT PANEL ACTION
Press
until
48, press
.
Press
for
YES, press
.
0.0 mV
After 5 seconds (minimum), press
.
14.0 mV
After 5 seconds (minimum), press
.
28.0 mV
After 5 seconds (minimum), press
.
42.0 mV
After 5 seconds (minimum), press
.
56.0 mV
After 5 seconds (minimum), press
.
[CodE]
[CAL]
[StP1]
[StP2]
[StP3]
[StP4]
[StP5]
[StPA]
[StPb]
Cold Junction (T16)
Cold Junction calibration requires a thermocouple of known accuracy of
types T, E, J, K, C or N (connected to terminals 8 and 9) and a calibrated
external reference thermocouple probe measuring in °C with resolution to
tenths. The two probes should be brought in contact with each other or in some
way held at the same temperature. They should be shielded from air movement
and allowed sufficient time to equalize in temperature. (As an alternative, the
T16 thermocouple may be placed in a calibration bath of known temperature.)
If performing the millivolt calibration prior, verify that the correct input type is
configured in Input Module 1-IN before performing the following procedure.
(After the millivolt calibration the controller will default to type J.) If using RTD
only, the cold junction calibration need not be performed.
PROMPT
COMPARE
[CodE]
[CAL]
[CJC]
FRONT PANEL ACTION
Press
Press
Press
Top display to
external
reference
until
48, press
.
YES, press
.
.
for
Press
or
to adjust the
bottom display until the top
process display matches the
external reference then press
.
19
APPLY
FRONT PANEL ACTION
Press
until
48, press
.
Press
for
YES, press
.
0.0 V
After 5 seconds (minimum), press
.
2.5 V
After 5 seconds (minimum), press
.
5.0 V
After 5 seconds (minimum), press
.
7.5 V
After 5 seconds (minimum), press
.
10.0 V
After 5 seconds (minimum), press
.
0.0 mA
After 5 seconds (minimum), press
.
20.0 mA
After 5 seconds (minimum), press
.
Analog Output Calibration (T16 and P16)
RESTORE FACTORY SETTINGS
Set the controller Analog jumpers to the output type being calibrated.
Connect an external meter with an accuracy of 0.05% (or better) that is capable
of measuring 10.00 V or 20.00 mA to terminals 6 (+V/I) and 7 (-V/I). The
voltage or current calibration that is not being used must be skipped by pressing
until End appears.
PROMPT
[CodE]
[CAL]
[CJC]
[rtd]
[ANCL]
[C 0v]
EXTERNAL
METER
CodE
66
Press and hold
to display CodE 66. Press . The controller will display
rSEt and then return to CNFP. Press
to return to the Display Loop. This will
overwrite all user settings with Factory Settings.
FRONT PANEL ACTION
Press
until
, press
Press
.
Press
. (T16 only)
Press
. (T16 only)
Press
for
, press
.
NOMINAL CALIBRATION SETTINGS
CodE
77
.
0.00 V
Press
or
until external meter
matches listing, press .
C 10v
10.00 V
Press
or
until external meter
matches listing, press .
C 0c]
0.00 mA
Press
or
until external meter
matches listing, press .
C 20c
20.00 mA
Press
or
until external meter
matches listing, press .
Press and hold
to display CodE 77. Press . Press and hold
to display
CodE 77 again. Press . The controller will then return to CNFP. Press
to
return to the Display Loop. This will not overwrite any user settings but will
erase the controller calibration values. This procedure does not require any
calibration signals nor external meters. This can be used to clear calibration
error flag E-CL.
CAUTION: This procedure will result in up to ±10% reading error and the
controller will no longer be within factory specifications. For this reason, this
procedure should only be performed if meter error is outside of this range to
temporarily restore operation until the unit can be accurately calibrated.
TROUBLESHOOTING
For further technical assistance, contact technical support.
PROBLEM
NO DISPLAY
CAUSE
1.
2.
3.
4.
REMEDIES
Power off.
Brown-out condition.
Loose connection or improperly wired.
Bezel assembly not fully seated into rear of controller.
CONTROLLER NOT WORKING 1. Incorrect setup parameters.
1.
2.
3.
4.
Check power.
Verify power reading.
Check connections.
Check installation.
1. Check setup parameters.
E-E2 IN DISPLAY
1. Loss of setup parameters due to noise spike or other 1. Press F1 to escape, then check all setup parameters.
EMI event.
a. Check sensor input and AC line for excessive noise.
b. If fault persists, replace controller.
E-CL IN DISPLAY
1. Loss of calibration parameters due to noise spike or 1. Press F1 to escape, then check controller accuracy.
other EMI event.
a. Recalibrate controller. (See Factory Service Module code 77.)
b. Reset parameters to factory default settings.
dddd or -ddd IN DISPLAY
1.
2.
3.
4.
Display value exceeds 4 digit display range.
Defective or miscalibrated cold junction circuit.
Loss of setup parameters.
Internal malfunction.
1.
2.
3.
4.
Change resolution to display whole number and verify reading.
Perform cold junction calibration.
Check setup parameters.
Perform Input calibration.
OPEN IN DISPLAY (T16)
1.
2.
3.
4.
Probe disconnected.
Broken or burned-out probe.
Corroded or broken terminations.
Excessive process temperature.
1.
2.
3.
4.
Connect probe.
Replace probe.
Check connections.
Check process parameters.
SENS IN DISPLAY (P16)
1.
2.
3.
4.
Input exceeds range of controller.
Incorrect input wiring.
Defective transmitter.
Internal malfunction.
1.
2.
3.
4.
Check input parameters.
Check input wiring.
Replace transmitter.
Perform input calibration.
OLOL IN TOP DISPLAY
1. Input exceeds range of controller.
2. Temperature exceeds range of input probe.
3. Defective or incorrect transmitter or probe.
4. Excessive high temperature for probe.
5. Loss of setup parameters.
1.
2.
3.
4.
5.
Check input parameters.
Change to input sensor with a higher temperature range.
Replace transmitter or probe.
Reduce temperature.
Perform input calibration.
1. Input is below range of controller.
2. Temperature below range of input probe.
3. Defective or incorrect transmitter or probe.
4. Excessive low temperature for probe.
5. Loss of setup parameters.
1.
2.
3.
4.
5.
Check input parameters.
Change to input sensor with a lower temperature range.
Replace transmitter or probe.
Raise temperature.
Perform input calibration.
1. RTD probe shorted.
1. Check wiring and/or replace RTD probe.
ULUL
IN TOP DISPLAY
SHrt IN DISPLAY (T16)
CONTROLLER SLUGGISH OR 1. Incorrect PID values.
2. Incorrect probe location.
NOT STABLE
1. See PID control.
2. Evaluate probe location.
20
CONTROL MODE EXPLANATIONS
ON/OFF CONTROL
ON/OFF CONTROL - HEAT/COOL OUTPUT FIGURES
The controller operates in On/Off Control when the Proportional Band is set
to 0.0%. In this control mode, the process will constantly oscillate around the
setpoint value. The On/Off Control Hysteresis (balanced around the setpoint)
can be used to eliminate output chatter. Output O1 Control Action can be set to
reverse for heating (output on when below the setpoint) or direct for cooling
(output on when above the setpoint) applications.
ON/OFF CONTROL REVERSE OR DIRECT ACTING FIGURES
Note: CHYS in the On/Off Control Figures refers to the On/Off Control Hysteresis
(CHYS) in parameter Module 2.
For heat and cool systems, O1 Control Action is set to reverse (heat) and the
Alarm 2 Action is set to cooling (O2). The Proportional Band is set to 0.0 and
the Relative Gain in Cooling to 0.0. The Deadband in Cooling sets the amount
of operational deadband or overlap between the outputs. The setpoint and the
On/Off Control Hysteresis applies to both O1 and O2 outputs. The hysteresis is
balanced in relationship to the setpoint and deadband value.
PID CONTROL
TYPICAL PID RESPONSE CURVE
In PID Control, the controller processes the input and then calculates a
control output power value by use of a modified Proportional Band, Integral
Time, and Derivative Time control algorithm. The system is controlled with the
new output power value to keep the process at the setpoint. The Control Action
for PID Control can be set to reverse for heating (output on when below the
setpoint) or direct for cooling (output on when above the setpoint) applications.
For heat and cool systems, the heat (O1) and cool (O2) outputs are both used.
The PID parameters can be established by using Auto-Tune, or they can be
Manually tuned to the process.
21
TIME PROPORTIONAL PID CONTROL
MANUAL CONTROL MODE
In Time Proportional applications, the output power is converted into output
On time using the Cycle Time. For example, with a four second cycle time and
75% power, the output will be on for three seconds (4 × 0.75) and off for
one second.
The cycle time should be no greater than 1/10 of the natural period of
oscillation for the process. The natural period is the time it takes for one
complete oscillation when the process is in a continuously oscillating state.
In Manual Control Mode, the controller operates as an open loop system
(does not use the setpoint and process feedback). The user adjusts the
percentage of power through the % Power display to control the power for
Output O1. When Alarm 2 is configured for Cooling (O2), Manual operation
provides 0 to 100% power to O1 (heating) and -100 to 0% power to O2
(Cooling). The Low and High Output Power limits are ignored when the
controller is in Manual.
LINEAR PID CONTROL
MODE TRANSFER
In Linear PID Control applications, the Analog Output Assignment ANAS is set
to % Output Power, OP. The Analog Low Scaling, ANLO , is set to 0.0 and the
Analog High Scaling, ANHI , is set to 100.0. The Analog Output will then be
proportional to the PID calculated % output power for Heat or Cooling per the
Control Action OPAC. For example, with 0 VDC to 10 VDC (scaled 0 to 100%)
and 75% power, the analog output will be 7.5 VDC.
When transferring the controller mode between Automatic and Manual, the
controlling outputs remain constant, exercising true “bumpless” transfer. When
transferring from Manual to Automatic, the power initially remains steady, but
Integral Action corrects (if necessary) the closed loop power demand at a rate
proportional to the Integral Time.
AUTOMATIC CONTROL MODE
In Automatic Control Mode, the percentage of output power is automatically
determined by PID or On/Off calculations based on the setpoint and process
feedback. For this reason, PID Control and On/Off Control always imply
Automatic Control Mode.
PID TUNING EXPLANATIONS
AUTO-TUNE
AUTO-TUNE CODE FIGURE
Auto-Tune is a user-initiated function that allows the controller to
automatically determine the Proportional Band, Integral Time, Derivative Time,
Digital Filter, Control Output Dampening Time, and Relative Gain (Heat/Cool)
values based upon the process characteristics. The Auto-Tune operation cycles
the controlling output(s) at a control point three-quarters of the distance
between the present process value and the setpoint. The nature of these
oscillations determines the settings for the controller’s parameters.
Prior to initiating Auto-Tune, it is important that the controller and system be
first tested. (This can be accomplished in On/Off Control or Manual Control
Mode.) If there is a wiring, system or controller problem, Auto-Tune may give
incorrect tuning or may never finish. Auto-Tune may be initiated at start-up,
from setpoint or at any other process point. However, ensure normal process
conditions (example: minimize unusual external load disturbances) as they will
have an effect on the PID calculations.
Start Auto-Tune
Below are the parameters and factory settings that affect Auto-Tune. If these
setting are acceptable then Auto-Tune can be started just by performing two
steps. If changes are needed, then they must be made before starting Auto-Tune.
DISPLAY
PARAMETER
tYpE
Input Type
FLtr
Digital Filtering
CHYS
On/Off Control
Hysteresis
tcod
Auto-Tune Code
db-2
Deadband
tUnE
Auto-Tune Access
FACTORY
SETTING
AUTO-TUNE OPERATION
(REVERSE ACTING)
MODULE
tc- T16
Curr P16
1
2 T16
0.2 P16
[0]
1-IN
[0]
5-O2
[HidE]
3-LC
1-IN
2-OP
2-OP
1. Enter the Setpoint value in the Display Loop.
2. Initiate Auto-Tune by changing Auto-Tune Start tUNE to YES in the Hidden
Loop.
Auto-Tune Progress
The controller will oscillate the controlling output(s) for four cycles. The
bottom display will flash the cycle phase number. Parameter viewing is
permitted during Auto-Tune. The time to complete the Auto-Tune cycles is
process dependent. The controller should automatically stop Auto-Tune and
store the calculated values when the four cycles are complete. If the controller
remains in Auto-Tune unusually long, there may be a process problem. AutoTune may be stopped by entering NO in Auto-Tune Start tUNE.
22
PID Adjustments
In some applications, it may be necessary to fine tune the Auto-Tune
calculated PID parameters. To do this, a chart recorder or data logging device is
needed 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.
In some unusual cases, the Auto-Tune function may not yield acceptable
control results or induced oscillations may cause system problems. In these
applications, Manual Tuning is an alternative.
PROCESS RESPONSE EXTREMES
MANUAL TUNING
A chart recorder or data logging device is necessary to measure the time
between process cycles. This procedure is an alternative to the controller’s AutoTune function. It will not provide acceptable results if system problems exist.
1. Set the Proportional Band (ProP) to 10.0% for temperature models (T16) and
100.0% for process models (P16).
2. Set both the Integral Time (Intt) and Derivative Time (dErt) to 0 seconds.
3. Set the Output Dampening Time (OPdP) in Output Module 2-OP to 0 seconds.
4. Set the Output Cycle Time [CYCt] in Output Module 2-OP to no higher than
one-tenth of the process time constant (when applicable).
5. Place the controller in Manual USEr Control Mode trnF in the Hidden Loop
and adjust the % Power to drive the process value to the Setpoint value.
Allow the process to stabilize after setting the % Power. Note: trnF must be
set to HidE in Parameter Lockouts Module 3-LC.
6. Place the controller in Automatic (Auto) Control Mode trnF in the Hidden
Loop. If the process will not stabilize and starts to oscillate, set the
Proportional Band two times higher and go back to Step 5.
7. If the process is stable, decrease Proportional Band setting by two times 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 three times the setting that caused the oscillation
in Step 7.
9. Set the Integral Time to two times the period of the oscillation.
10. Set the Derivative Time to 1/8 (0.125) of the Integral Time.
11. Set the Output Dampening Time to 1/40 (0.025) the period of the oscillation.
23
Programmer:______________________Date:_________
Controller Number:_______ Security Code:_______
PARAMETER VALUE CHART
DISPLAY LOOP
DISPLAY
PARAMETER
SP
SETPOINT VALUE SP1
SP
OP
ProP *
SETPOINT VALUE SP2
Intt *
INTEGRAL TIME
dErt *
AL-1 *
AL-2 *
DERIVATIVE TIME
OUTPUT POWER PERCENT
PROPORTIONAL BAND
ALARM 1 VALUE
ALARM 2 VALUE
OUTPUT MODULE (2-OP)
FACTORY SETTING
USER SETTING
DISPLAY
T16
P16
T16
P16
0
0.0
20
2.0
0.0
4.0 T16
100.0 P16
120 T16
40 P16
30 T16
4 P16
0
0
* Factory Setting places these parameters in the Hidden Loop (set to
Lockout Module 3-LC.
HidE in
PARAMETER
CYCt
OPAC
OPLO
OPHI
OPFL
OPdP
CYCLE TIME
CHYS
tcod
AntP
ANAS
ANUt
ANLO
ANHI
ON/OFF CONTROL HYSTERESIS
CONTROL ACTION
OUTPUT POWER LOWER LIMIT
OUTPUT POWER UPPER LIMIT
SENSOR FAIL POWER PRESET
OUTPUT POWER DAMPENING
AUTO-TUNE CODE
ANALOG OUTPUT RANGE
ANALOG OUTPUT ASSIGNMENT
ANALOG UPDATE TIME
ANALOG LOW SCALING
ANALOG HIGH SCALING
FACTORY
SETTING
USER SETTING
2.0
rEv
0
100
0
3 T16
1 P16
2 T16
0.2 P16
4-20
OP
0
0.0
100.0
HIDDEN LOOP
DISPLAY
SPSL
SPrP
trnF
tUNE
PARAMETER
FACTORY SETTING
SETPOINT SELECT
USER SETTING
LOCKOUT MODULE (3-LC)
SP1
0.0
Auto
NO
SETPOINT RAMP RATE
CONTROL MODE TRANSFER
AUTO-TUNE START
DISPLAY
SP
OP
PId
AL
CodE
SPSL
SPrP
trnF
tUNE
ALrS
INPUT MODULE (1-IN ) T16 ONLY
DISPLAY
tYPE
SCAL
dCPt
FLtr
SHFt
SPLO
SPHI
InPt
F1In
PARAMETER
FACTORY SETTING
INPUT TYPE
USER SETTING
tc°F
0
1
0
0
9999
PLOC
NONE
TEMPERATURE SCALE
DECIMAL RESOLUTION
DIGITAL FILTERING
SHIFT/OFFSET
SETPOINT LOW LIMIT
SETPOINT HIGH LIMIT
USER INPUT FUNCTION
F1 KEY FUNCTION
tYPE
PCt
dCPt
rnd
FLtr
dSP1
InP1
dSP2
InP2
SPLO
SPHI
InPt
F1In
PARAMETER
INPUT TYPE
PERCENT ANNUNCIATOR
DECIMAL RESOLUTION
ROUNDING INCREMENT
DIGITAL FILTERING
DISPLAY VALUE SCALING 1
INPUT VALUE SCALING 1
DISPLAY VALUE SCALING 2
INPUT VALUE SCALING 2
SETPOINT LOW LIMIT
SETPOINT HIGH LIMIT
FACTORY SETTING
SETPOINT ACCESS
OUTPUT POWER ACCESS
PID VALUE ACCESS
ALARM VALUE ACCESS
ACCESS CODE
SETPOINT SELECT ACCESS
SETPOINT RAMP ACCESS
TRANSFER CONTROL ACCESS
AUTO-TUNE ACCESS
RESET ALARMS ACCESS
FACTORY
SETTING
USER SETTING
dISP
dISP
HIdE
HIdE
0
LOC
HIdE
LOC
HIdE
LOC
ALARM MODULE (4-AL)
DISPLAY
ACt1
Lit1
rSt1
Stb1
AL-1
ACt2
Lit2
rSt2
Stb2
AL-2
AHYS
INPUT MODULE (1-IN ) P16 ONLY
DISPLAY
PARAMETER
USER SETTING
Curr
NO
0.0
0.1
1
0.0
4.00
100.0
20.00
0.0
999.9
PARAMETER
ALARM 1 ACTION
ALARM 1 ANNUNCIATOR
ALARM 1 RESET MODE
ALARM 1 STANDBY
ALARM 1 VALUE
ALARM 2 ACTION
ALARM 2 ANNUNCIATOR
ALARM 2 RESET MODE
ALARM 2 STANDBY
ALARM 2 VALUE
ALARM 1 & 2 HYSTERESIS
FACTORY
SETTING
USER SETTING
AuHI
nor
Auto
NO
0
AuHI
nor
Auto
/0
0
1 T16
0.1 P16
COOLING MODULE (5-O2)
DISPLAY
CYC2
GAN2
db-2
USER INPUT FUNCTION
F1 KEY FUNCTION
24
PARAMETER
CYCLE TIME
RELATIVE GAIN
DEADBAND
FACTORY
SETTING
2.0
1.0
0
USER SETTING
ª
HIDDEN
LOOP
«
25
Percent
Symbol
Heat/Cool
Deadband/Overlap
Cooling
Relative Gain
Factory
Service Code
Cooling
Cycle Time
Alarm 1
Value
Alarm 1
Standby
Alarm 1
Action
Alarm 1
Reset Mode
Output
Power
Access
Alarm 1
Annunciator
Analog Low
Scaling
Alarm 2
Standby
Alarm 2
Annunciator
Alarm 2
Action
Alarm 2
Reset Mode
Setpoint
Ramp Rate
Access
Setpoint
Select
Access
Analog High
Scaling
On/Off Control
Hysteresis
Alarm 2
Value
Alarm 1 & 2
Hysteresis
Reset Alarms
Access
- T16 only
- P16 only
Auto-Tune
Auto/Manual
Off/On Access
Transfer
Access
Auto-Tune
Code
F1 Key
Function
Input
Value 1
Advances to the next
module, then changes
parameter selection/value.
Display
Value 1
User Input
Function
Output Power
Dampening
Setpoint
High Limit
Sensor Fail
Power Preset
Access
Code
Analog Output
Update Time
Output Power
High Limit
Setpoint
Low Limit
Rounding
Increment
Alarm
Values
Access
Analog Output
Assignment
Decimal
Resolution
Shift/Offset
Output Power
Low Limit
Input
Value 2
Temp
Scale
Digital
Filtering
Enters displayed module,
then advances to the next
parameter.
PID
Values
Access
Analog
Output Range
Control
Action
Display
Value 2
Ends and returns to
start of Display Loop.
Parameter availability is model and program dependent.
Setpoint
Access
Cycle
Time
Input
Type
DISPLAY
LOOP
T16 & P16 PROGRAMMING QUICK OVERVIEW
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26
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27
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 sub-contractors 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
herein and relies on no other warranties or affirmations.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Printerweg 10
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17406
NL - 3821 AD Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Insert No.
DLCD-B
Drawing No. LP0535
Released 3/02
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL DLCD – DUAL LOOP CONTROLLER w/ DH-485
GENERAL DESCRIPTION
The Model DLCD, Dual Loop Controller with DH-485, has a similar feature
set and specifications as the standard Dual Loop Controller. The DLCD
provides a connection into an Allen Bradley DH-485 network allowing a fully
featured dual loop PID controller to be controlled and monitored by an Allen
Bradley PLC (SLC 500 controller, or similar), over a DH-485 network.
The DLCD communications port may be configured for DH-485, or as a
programming port allowing complete programming by our Windows based
RLCPro configuration software.
ORDERING INFORMATION
MODEL NO.
DLCD
CBJ
DRRJ11
USING THIS DOCUMENT
DESCRIPTION
PART NUMBER
Dual Loop Controller w/ DH-485
DLCD0001
Dual Loop Controller w/ 2 Analog
Outputs w/ DH-485
DLCD1001
SLC 500 (RJ45) to RJ11 Cable
CBJ11C07
RJ11 Connector to Terminal Adapter
DRRJ11T6
This document is an addendum to the bulletin describing the standard DLC
and describes the use of the DH-485 connection of the DLCD. This document
should be read in conjunction with the DLC Bulletin.
1.0 Using the DLCD on a DH-485 Network
Overview
The DLCD rapidly exchanges blocks of control and status information for
each PID loop with an Integer File that has been allocated in the PLC. Each
DLCD is assigned an Integer File by setting the appropriate DIP Switches on
the DLCD. By accessing this Integer File, the PLC is able to control and
monitor the operation of each PID loop within each DLCD. Most applications
will only require information contained in these Control and Status blocks. The
ability has been included to upload and download Parameter and Configuration
blocks on demand for each PID loop.
Integer File Structure
The Integer File for each DLCD is structured to include Control, Status,
Parameter and Configuration blocks for each PID Loop. Control and Status
blocks contain data that is transferred automatically by the DLCD on alternate
communication scans. Parameter Blocks contain DLCD operating parameters
and may be occasionally changed. Configuration Blocks contain system
configuration parameters and are rarely changed.
Table 1 gives the overall structure of the Integer File giving the location of
the various blocks for each PID loop or channel. The tables in the following
sections show the structure of each block and provide a cross-reference from the
Allen Bradley Integer File register to the equivalent MODBUS Holding
Register in the DLCD.
When using the Integer File tables in the following sections, refer to the
Register Table in the DLC Bulletin for register details such as factory setting,
limits and description.
Note: Modbus registers provided for reference only.
Nx:
Block
Reference
0..3 Control Block – Channel A
Table 2
4..7 Control Block – Channel B
Table 2
8..11 Status Block – Channel A
Table 5
12..15 Status Block – Channel B
Table 5
16..23 Parameter Block – Channel A
Table 8
24..31 Parameter Block – Channel B
Table 9
32..63 Configuration Block – Channel A
Table 10
64..95 Configuration Block – Channel B
Table 13
Table 1 - Overview of Integer File Structure
1
Control Block
Status Block
The Control block contains control values and commands, such as Set Point
and Control Mode. The DLCD continually reads the Control Blocks for each
PID loop from the PLC providing a means whereby the PLC program can
control the DLCD.
The Status block contains current operating values and status such as Process
Value and Input Status. The DLCD continually writes the Status Block for each
PID channel providing a means whereby the PLC can monitor the operating
status of the DLCD.
BIT POSITION
Nx:
15 14 13 12 11 10 9
8
7
6
5
4
3
2
1
0
BIT POSITION
REFERENCE/
MODBUS REGISTER
Nx:
15 14 13 12 11 10 9
8
0 Setpoint Channel A
40002
8 Process Value Channel A
1 Output Power Channel A
40005
9 Output Power Channel A
2 15 14 13
7
10
1 0 Table 3
6..5
3 2 1 0 Table 4
3
11 15
12 Process Value Channel B
5 Output Power Channel B
40021
13 Output Power Channel B
7
14
1 0 Table 3
6..5
4
CH. B
3 2 1 0 Table 7
40017
40021
7..5
4 3 2 1 0 Table 6
7 6
CH. A
CH. B
Input Error Status Register
40504
40504
Auto-Tune Phase
40012
40028
Control Output OP2
40016
40032
3
Control Output OP1
40014
40030
-
2
Set Point Ramping In Progress
40043
40051
-
1
Alarm Output AL2
40016
40032
0
Alarm Output AL1
40015
40031
40041
40049
15..8
14
Disable Integral Action
40044
40052
7..5
13
Disable Setpoint Ramping
40042
40050
4
12
Not Used
-
-
11
Not Used
-
10
Not Used
-
9
Not Used
-
-
8
Not Used
-
-
7
Auto-tune Request (See Note 2)
-
-
40013
40029
4
Not Used
-
-
3
Not Used
-
-
2
Not Used
-
-
1
Alarm Output AL2 (See Note 1)
40016
40032
0
Alarm Output AL1 (See Note 1)
40015
40031
Table 6 - Status Block for Nx:10 and Nx:14 Flags
MODBUS REGISTER
BITS
Table 3 - Control Block for Nx:2 and Nx:6 Flags
MODBUS REGISTER
BITS
3 2 1 0 Table 7
REGISTER NAME
Control Mode
Auto-tune Code
REFERENCE/
MODBUS REGISTER
0
MODBUS REGISTER
BITS
15
6..5
1
4 3 2 1 0 Table 6
MODBUS REGISTER
REGISTER NAME
CH. A
2
Table 5 - Status Block - Channel A and B
Table 2 - Control Block - Channel A and B
BITS
3
40005
7..5
15..8
15 15
3 2 1 0 Table 4
5
7 6
40018
7
6
40001
15..8
4 Setpoint Channel B
6 15 14 13
7
REGISTER NAME
CH. A
CH. B
15
Not Used
-
-
14
Not Used
-
-
13
Not Used
-
-
12
Not Used
-
-
11
Not Used
-
-
10
Not Used
-
-
9
Not Used
-
-
8
Not Used
-
-
7
Not Used
-
-
6
Not Used
-
-
5
Not Used
-
-
4
Not Used
-
-
3
Parameter Read Strobe (See Note 3)
-
-
2
Configuration Read Strobe (See Note 3)
-
-
1
Parameter Write Strobe (See Note 3)
-
-
0
Configuration Write Strobe (See Note 3)
-
-
REGISTER NAME
CH. A
CH. B
15
Bus Active (See Note 5)
-
-
14
Not Used
-
-
13
Not Used
-
-
12
Not Used
-
-
11
Not Used
-
-
10
Not Used
-
-
9
Not Used
-
-
8
Not Used
-
-
7
Auto-Tune In Progress (See Note 4)
-
-
6
Auto-Tune Done (See Note 4)
-
-
5
Not Used
-
-
4
Not Used
-
-
3
Parameter Block Read Acknowledge
(See Note 6)
-
-
2
Configuration Block Read Acknowledge
(See Note 6)
-
-
1
Parameter Block Write Acknowledge
(See Note 6)
-
-
0
Configuration Block Write Acknowledge
(See Note 6)
-
-
Table 7 - Status Block for Nx:11 and Nx:15 Flags
Table 4 - Control Block for Nx:3 and Nx:7 Flags
2
Notes:
1. Alarm Output Control
The Control flags Alarm Output AL1 and AL2 must set TRUE (1) for correct
Alarm operation when Control Mode is Automatic (0). Set to 0 to reset an
Alarm.
2. Auto-tune Request
Setting the Auto-tune Request flag forces the DLCD to start the auto-tune
process. Refer to section Auto-tune Request for more detail on how the PLC
program may auto-tune a PID loop in the DLCD.
3. Read/Write Strobes
Setting the Read/Write Strobe flags forces the DLCD to upload or download
the appropriate Parameter or Configuration block. Refer to section
Transferring Parameter and Configuration Data for more detail on how to
transfer these blocks between the PLC and the DLCD.
4. Auto-tune Status
Monitoring the Auto-Tune Done and Auto-Tune In Progress flags allows the
PLC program to detect the completion of the Auto-tune process in the DLCD.
Refer to section Auto-tune Request for more detail on how the PLC program
may auto-tune a PID loop in the DLCD.
5. Bus Active
Each DLCD toggles the Bus Active flag on each communication scan.
6. Read/Write Acknowledge
The DLCD sets the appropriate acknowledge flag once the requested upload
or download of the Parameter or Configuration block is complete. Refer to
section Transferring Parameter and Configuration Data for more detail on
how to transfer these blocks between the PLC and the DLCD.
7. Data flow is described with respect to the DLCD in exchanges with the PLC.
Thus, Read data is data transferred from the PLC to the DLCD and Write
data is data transferred from the DLCD to the PLC.
Parameter Block
The Parameter blocks contain values that may need to be changed while the
DLCD is operating, such as PID parameters. Each Parameter Block may be
uploaded to or downloaded from the PLC on demand by setting the appropriate
request bit in the Control Block. Refer to section Transferring Parameter and
Configuration Data to see how this is done.
BIT POSITION
Nx:
15 14 13 12 11 10 9
8
7
6
5
4
3
2
1
0
BIT POSITION
REFERENCE/
MODBUS REGISTER
Nx:
15 14 13 12 11 10 9
8
7
6
5
4
3
2
1
0
REFERENCE/
MODBUS REGISTER
16 Proportional Band
40007
24 Proportional Band
40023
17 Integral Time
40008
25 Integral Time
40024
18 Derivative Time
40009
26 Derivative Time
19 Cycle Time (Cooling)
Relative Gain (Cooling)
40141
27 Cycle Time (Cooling)
40142
40025
Relative Gain (Cooling)
40241
20 Deadband (Cooling)
40143
28 Deadband (Cooling)
40243
21 Alarm 1 Value
40003
29 Alarm 1 Value
40019
22 Alarm 2 Value
40004
30 Alarm 2 Value
40020
23 Not Used
-
31 Not Used
-
Table 8 - Parameter Block – Channel A
Table 9 - Parameter Block – Channel B
3
40242
Configuration Block
The Configuration blocks contain values that describe the DLCD setup such
as Input configuration and as such will not need to be changed during normal
operation. These blocks may be uploaded to and downloaded from the PLC on
demand by setting the appropriate request bit in the Control Block. Refer to
section Transferring Parameter and Configuration Data to see how this is done.
BIT POSITION
Nx:
15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
REFERENCE/
MODBUS
REGISTER
BIT POSITION
Nx:
15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
REFERENCE/
MODBUS
REGISTER
32 Offset Power
40010
64 Offset Power
40026
33 Span Correction
40106
65 Span Correction / Remote Setpoint Ratio Multiplier
40206
34 Offset Correction
40107
66 Offset Correction / Remote Setpoint Bias Offset
40207
35 Low Limit (Setpoint)
40108
67 Low Limit (Setpoint)
40208
36 High Limit (Setpoint)
40109
68 High Limit (Setpoint)
40209
37 Ramp Rate (Setpoint)
40110
69 Ramp Rate (Setpoint)
40210
38 Process Low (Scaling Points)
40111
70 Process Low (Scaling Points)
40211
39 Process High (Scaling Points)
40112
71 Process High (Scaling Points)
40212
40 Input Low (Scaling Points)
40113
72 Input Low (Scaling Points)
40213
41 Input High (Scaling Points)
40114
73 Input High (Scaling Points)
40214
42 Cycle Time (OP1)
40116
74 Cycle Time (OP1)
40216
43 On Delay (AL1)
40135
75 On Delay (AL1)
40235
44 On Delay (AL2)
40140
76 On Delay (AL2)
40240
45 Scaling Value Low (Analog Output)
40303
77 Scaling Value Low (Analog Output)
40311
46 Scaling Value High (Analog Output)
40304
78 Scaling Value High (Analog Output)
40312
47 Direct Entry Value (Analog Output)
40307
79 Direct Entry Value (Analog Output)
40315
48 Ramping Setpoint Value
40045
80 Ramping Setpoint Value
40053
49 15
Table 11
81 15
Table 11
50 Sensor Failure Power Preset (OP1)
40120
82 Sensor Failure Power Preset (OP1)
40220
51 Power Low Limit (OP1)
40118
83 Power Low Limit (OP1)
40218
52 Power High Limit (OP1)
40119
84 Power High Limit (OP1)
14..8
14..8
40219
53 Dampening Time (OP1)
On/Off Control Hysteresis (OP1) 40121 40122
85 Dampening Time (OP1)
On/Off Control Hysteresis (OP1) 40221 40222
54 Hysteresis (AL1)
Hysteresis (AL2)
40134 40139
86 Hysteresis (AL1)
Hysteresis (AL2)
40305 40306
87 Deadband (Analog Output) Update Time (Analog Output)
Table 12
88 15 14 13 12
Table 14
89 15..14
Table 15
90 15
40131 40136
91 Action (AL1)
60 Not Used
-
92 Not Used
-
61 Not Used
-
93 Not Used
-
62 Not Used
-
94 Not Used
-
63 Not Used
-
95 Not Used
-
55 Deadband (Analog Output) Update Time (Analog Output)
56 15 14 13 12
7
11..8
6
57 15..14 13..11
5
4..0
10..0
58 15
14..0
59 Action (AL1)
Action (AL2)
Table 10 - Configuration Block – Channel A
11..8
7
6
13..11
5
40234 40239
15
Channel B Assignment (Input)
14..8 Rounding (Input)
Table 14
14..0
Table 15
40231 40236
Action (AL2)
Table 13 - Configuration Block – Channel B
MODBUS REGISTER
REGISTER NAME
Remote/Local Setpoint Select
Table 12
10..0
MODBUS REGISTER
BITS
40313 40314
4..0
BITS
CH. A
CH. B
40046
-
-
40198
40104
40204
REGISTER NAME
15..14 Local/Remote Set Point Transfer Mode (Input)
13..11 Mode (Analog Output)
10..0 Assignment (Analog Output)
Table 11 - Configuration Block for Nx:49 and Nx:81 Flags
CH. A
CH. B
-
40199
40302
40310
40301
40309
Table 14 - Configuration Block for Nx:57 and Nx:89 Flags
MODBUS REGISTER
BITS
REGISTER NAME
Ch. A
Ch. B
15 Reset (AL2)
40137
40237
CH. A
CH. B
14 Reset (AL1)
40132
40232
15 Resolution (Input)
40103
40203
13 Enable Standby (AL2)
40138
40238
14..0 Input Type (Input)
40101
40201
12 Enable Standby (AL1)
40133
40233
11..8 Digital Input Filter (Input)
40105
40205
7 Temperature Scale (Input)
40102
40202
6 Control Action (OP1)
40117
40217
5 Filter (Analog Output)
40308
40316
40115
40215
4..0 Process Decimal Point (Scaling Points)
MODBUS REGISTER
BITS
REGISTER NAME
Table 15 - Configuration Block for Nx:58 and Nx:90 Flags
Table 12 - Configuration Block for Nx:56 and Nx:88 Flags
4
2.0 Setting the DIP Switches
Overview
The DIP Switches and the Default Serial Terminal set the DLCD serial
communication operating mode to either DH-485 mode or MODBUS mode.
DH-485 mode allows the DLCD to be connected to a DH-485 network.
MODBUS mode allows programming of the DLCD using RLCPro.
PLC Address
The DLCD transfers data with a target PLC. Switch B (SWB) allows the
address of the target PLC on the DH-485 network to be set in the range 0..7.
DH-485 Mode
PLC
ADDRESS
Integer File
Each DLCD is assigned a unique Integer File in the PLC that the DLCD uses
to transfer data. Switch A (SWA) sets the target Integer file in the range
N7..N70.
Note N8 and N9 are invalid Integer File numbers and therefore cannot be used.
SWITCH POSITION
1
2
3
4
5
6
N7
DN
DN
DN
DN
DN
DN
Valid File Number
N8
DN
DN
DN
DN
DN
UP
Invalid File Number
N9
DN
DN
DN
DN
UP
DN
Invalid File Number
N10
DN
DN
DN
DN
UP
UP
Valid File Number
N11
DN
DN
DN
UP
DN
DN
Valid File Number
UP
UP
UP
UP
UP
UP
COMMENT
..
7
8
DN
DN
DN
1
DN
DN
UP
2
DN
UP
DN
UP
UP
UP
7
Table 18 - Selections for PLC Address using DIP Switch B
Example 1
This example shows the DIP Switch settings for a DLCD operating in DH485 mode with the following configuration.
PLC Address
:1
DLCD Address
:8
Integer File
: 10 (N10)
Valid File Number
Valid File Number
Table 16 - Integer File settings using DIP Switch A
1
2
3
4
5
6
1
UP UP
DLCD Address
Each device on a DH-485 network must have a unique address. Switch B
(SWB) allows the DLCD address to be set in the range 0..31.
DN DN DN DN
2
3
4
5
6
7
UP
DN
8
UP
DN DN DN DN DN
Switch Position
DLCD
Address
1
2
3
4
5
0
DN
DN
DN
DN
DN
1
DN
DN
DN
DN
UP
2
DN
DN
DN
UP
DN
3
DN
DN
DN
UP
UP
UP
UP
UP
UP
UP
Communication Settings
..
31
6
0
..
INTEGER
FILE
N70
SWITCH POSITION
The DLCD has a fixed baud rate of 19200 when used in DH-485 mode.
Table 17 - Selections for DLCD Address using DIP Switch B
MODBUS Mode
Alternatively, set all DIP switches Down as shown in Example 2. The DLCD
leaves the factory in this state, and is therefore ready to be programmed using
RLCPro.
In MODBUS mode, the DLCD responds to MODBUS RTU frames and
therefore allows programming using RLCPro (refer to DLC Bulletin for
detailed information on using RLCPro with the DLCD). To configure the
DLCD for MODBUS without changing the DIP switches, use the Default Serial
Setting Terminal.
Example 2
This example shows the DIP Switch settings for a DLCD operating in
MODBUS mode with the default serial settings.
DEFAULT SERIAL SETTING CONNECTIONS
If using software selectable serial
settings and the serial settings are unknown
or forgotten, they can be temporarily reset
to the defaults by connecting the “Default
Serial Setting” terminal 7 to “Output
Common” terminal 4 with a jumper.
1
3
4
5
6
DN DN DN DN DN DN
Serial Communication Defaults:
Protocol: RTU
Address: 247
Baud Rate:9600
2
Data Bits: 8
Parity:
none
5
1
2
3
4
5
6
7
8
DN DN DN DN DN DN DN DN
EXAMPLE APPLICATIONS
Transferring Parameter and Configuration Data
Auto-tune Request
Parameter and Configuration blocks can be uploaded to and downloaded
from the PLC Integer File by setting the appropriate read/write strobe in the
relevant Control block. On completion of the data transfer the DLCD sets the
corresponding acknowledge bit in the Status block.
Figure 1 shows a fragment of a Program File, captured from Rockwell’s
RSLogix 500 that shows how the strobe and acknowledge flags may be used to
download a configuration block to the DLCD.
The Auto-tune Request flag allows the PLC program to start the auto-tune
process in the DLCD. While auto-tuning, the DLCD sets the Auto-tune In
Progress bit and when complete, sets the Auto-tune Done bit. By monitoring
this bit, the PLC program is able to detect when the auto-tune process is
complete.
Figure 3 shows a fragment of a program file, captured from RSLogix 500 that
shows how the request flag and done flag may be used to start the auto-tune
process in the DLCD.
Figure 3 - Auto-tune Request
Figure 1 - Configuration Block Download
Figure 2 shows a fragment of a program file, captured from RSLogix 500 that
shows how the strobe and acknowledge flags may be used to upload a
configuration block from the DLCD.
Figure 2 - Configuration Block Upload
6
APPLICATION 1: SLC 5/03 AND DLCD
Example showing direct connection of multiple DLCD units and a SLC 5/03, using
Red Lion Cable Jumper (CBJ11BD5) and SLC 500 to RJ11 Cable (CBJ11C07).
APPLICATION 2: DLCD with AIC MODULE
Example showing direct connection of multiple DLCD units to Red Lion DIN Rail
Mounted Terminal Connector (DRJ11T6) allowing a variety of connection options using
the AIC Module from Allen Bradley.
7
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship
for a period limited to one year from the date of shipment, provided the products have been stored,
handled, installed, and used under proper conditions. The Company’s liability under this limited
warranty shall extend only to the repair or replacement of a defective product, at The Company’s
option. The Company disclaims all liability for any affirmation, promise or representation with
respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against
damages, claims, and expenses arising out of subsequent sales of RLC products or products
containing components manufactured by RLC and based upon personal injuries, deaths, property
damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be
to any extent liable, including without limitation penalties imposed by the Consumer Product Safety
Act (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
herein and relies on no other warranties or affirmations.
Red Lion Controls
20 Willow Springs Circle
York PA 17402
Red Lion Controls France
56 Boulevard du Courcerin, Batiment 21,
ZI Pariest F-77183 Croissy Beaubourg
Red Lion Controls BV
Databankweg 6C
NL - 3821 AL Amersfoort
Tel +1 (717) 767-6511
Tel +33 (64) 80 12 12
Tel +31 (33) 472 32 25
Fax +1 (717) 764-0839
Fax +33 (64) 80 12 13
Fax +31 (33) 489 37 93
Bulletin No. CABLE-C
Drawing No. LP0491
Released 7/02
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
DLC & IAMS/ITMS CABLES
MODEL CBPRO - PROGRAMMING AND INTERFACE CABLE
DESCRIPTION
The CBPRO007 Programming Interface Cable is a port-powered device that can be used to
download or interface with Red Lion Controls products that have an RS485 RJ-11 port. The
cable converts the RS-232 TD and RD lines to balanced half-duplex RS-485 signals which
can transmit up to 4,000 feet at 19,200 baud. It is powered from the RS-232 data and
handshake lines whether the lines are high or low. An external 12 V power supply
can be connected to two terminals on the connector if handshake lines are
not available.
The CBPRO has a DB-9 female connector on the
RS-232 side for connection to a PC COM port.
The RS485 side, has a terminal block where
the 7' long RJ11 cable is connected.
SPECIFICATIONS
1. POWER REQUIREMENTS: Port powered *
* An external 12 VDC (unit draw @ 35 mA max.) can be applied if RS-232
output handshake lines are not available.
Note: When using an external supply, the supply should be connected only to
specifically labeled terminal block power inputs. Connecting an external
supply to the handshake lines may damage the unit.
2. BAUD RATE: 19200 Baud max.
3. RS-232 SIDE:
Connector: DB-9 female
SIGNAL
PIN
TD
RD
GND
RTS
CTS
DTR
DSR
CD
2
3
5
7
8
4
6
1
JUMPERED
to
to
to
to
to
pin
pin
pin
pin
pin
8
7
6, 1
4, 1
4, 6
4. RS485 SIDE:
Connector: terminal block
TERMINAL
TD(A)
TD(B)
GND
GND
+12V
RJ11 CABLE
Green
Yellow
Red
*
*
* External 12 VDC supply optional.
5. CERTIFICATIONS AND COMPLIANCE:
Immunity to EN 500082-1 Residential, Commercial and Light Industry
(IEC 801-2, IEC 801-3, IEC 801-4)
Emissions to EN 500081-1 Residential, Commercial and Light Industry
(EN 55022)
6. CONVERTER DIMENSIONS: L = 3.50" (88.9 mm) x W = 1.34" (34 mm)
x H = 0.67" (17 mm)
7. CABLE LENGTH: 7 feet (2.13 meters)
PARADIGM TO RS485 RJ-11 INTERFACE CABLE
DESCRIPTION
The Paradigm to RJ-11 Interface Cable allows the Paradigm operator
interfaces to be easily connected to any Red Lion Controls DIN rail module with
an RS485 RJ-11 port. Both ends of this 7-foot cable are pre-wired to provide
a reliable RS485 connection.
ORDERING INFORMATION
MODEL
DESCRIPTION
CBPRO
Programming Interface Cable
Paradigm to RJ-11 Interface Cable
PART NUMBER
CBPRO007
P893805Z
Bulletin No. DLCN-B
Drawing No. LP0552
Released 6/03
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL DLCN - DUAL LOOP CONTROLLER / DATA ACQUISITION MODULE
w/DEVICENET™
ORDERING INFORMATION
USING THIS DOCUMENT
This document is an addendum to the standard DLC bulletin and describes
the use of the DeviceNetTM connection to the DLCN. This document should be
read in conjunction with the DLC bulletin.
MODEL NO.
GENERAL DESCRIPTION
The Model DLCN, Dual Loop Controller with DeviceNet, has a similar
feature set and specifications as the standard Dual Loop Controller. The DLCN
operates as a DeviceNet Slave, providing a connection to a standard DeviceNet
network. Once a valid MAC ID and Baud Rate have been established, the
supported attributes (see table: DLCN DeviceNet SUPPORTED ATTRIBUTES)
can be accessed by a Master, providing control and status functions for each
PID loop. The DLCN can also be fully programmed via the built-in RS485
communications port using our Windows® based RLCPro configuration
software (refer to the DLC bulletin).
DLCN
In addition, the model DLCN can be used as a simple analog data acquisition
device for monitoring T/C's, RTD's, voltage and current over a DeviceNet
network.
DESCRIPTION
PART NUMBER
Dual Loop Controller, w/ 5 Pin Male
M12 connector
DLCN0001
Dual Loop Controller, w/ 2 analog
outputs, 5 Pin Male M12 connector
DLCN1001
Dual Loop Setpoint Controller, w/ 2
analog outputs, 5 Pin Male M12
connector
DLCN1101
Dual Loop Controller, w/
COMBICON screw flange
connector
DLCN0011
Dual Loop Controller, w/ 2 analog
outputs, COMBICON screw flange
connector
DLCN1011
Dual Loop Setpoint Controller, w/ 2
analog outputs, COMBICON screw
flange connector
DLCN1111
PROGRAMMING THE DLCN via RLCPro
MOD/NET STATUS LED
In order to program the DLCN via RLCPro, the DeviceNet bus cable must
be disconnected from the unit. This causes the internal DLCN communication
bus to automatically switch to the front panel Modbus programming port. When
programming is complete, the unit may be attached to the DeviceNet bus, thus
disabling the front panel port and enabling DeviceNet communications. The
DLCN Modbus communication parameters are fixed at 19200 baud, unit
address of 247, 8 data bits, no parity, RTU mode. The DIP and Rotary Switches,
as described below, are used for DeviceNet settings only.
The MOD/NET Status LED provides a visual indication to the operator of
the current status of the DeviceNet interface. The DLCN primary power and
DeviceNet power must be applied for correct LED function.
What to look for:
A. Startup:
LED flashes Green for 0.25 sec, then Red for 0.25 sec, then Off.
B. LED Off:
This device is the only device on the network (waiting for an
acknowledgment to its duplicate MAC ID check), or this device is not
powered.
C. Flashing Red LED:
An I/O connection has timed out, or a recoverable error has occurred.
D. Flashing Green LED:
The device is functioning correctly and is waiting to be
commissioned by a bus master.
E. Solid Red LED:
The device has encountered a non-recoverable fault, such as a
duplicate MAC ID response, and has removed itself from the bus.
F. Solid Green LED:
The device is on line, functioning correctly and has been
commissioned by a bus master.
SETTING THE MAC ID and BAUD RATE
The DLCN DeviceNet MAC ID is set using two rotary switches allowing the
ID to be set in standard decimal notation (e.g. MAC ID = 27, SWC = 2, SWB
= 7 ) from 0 to 63. (64-99 are not used.) The baud rate is set with DIP switches.
The following table explains the baud rate settings.
DIP SWITCH SETTING TABLE
SWITCH SWA
SETTING
1 off, 2 off
Force 125 K baud
1 on, 2 off
Force 250 K baud
1 off, 2 on
Force 500 K baud
1 on, 2 on
Autobaud Detect (factory default)
Autobaud will match the DLCN DeviceNet baud rate to the network baud
rate within 5 seconds every time the DLCN power is cycled. The DLCN
must be connected to a bus carrying valid message traffic. In noisy
environments autobaud may not be able to properly detect the network baud
rate. In this case, manually set the baud rate as required.
Note: Configuration of MAC ID and baud rate is not supported over
DeviceNet.
1
DeviceNet™ SPECIFICATIONS
SUPPORT CONNECTIONS
POWER SUPPLY
Source: Supplied by DeviceNet bus. The bus does not power the host.
Voltage: 11 to 25 VDC.
Current:
Nominal: 40 mA at 25 VDC.
Inrush: 550 mA for 5 msec at 25 VDC.
Polled Command: The Polled Command produces 4 bytes of data, and is used
to get, or set attributes. The device attribute is determined by the value in byte
0 of the data field. Refer to the Supported Attributes table for the appropriate
value. Byte 1 determines the action: 0 = get, 1 = set. The next 2 bytes are the
new attribute value for the set command. For get commands, enter 2 zeros.
The data response from the Polled Command is in the format of a 2 byte
hexadecimal number. For the get command (0), the response is the attribute
value. For the set command (1), the response is an echo of the data input.
NETWORK SPECIFICS
Compatibility: Group 2 Server Only, not UCMM capable.
Baud Rates: 125 Kbaud, 250 Kbaud, and 500 Kbaud.
Bus Interface: Phillips 82C250 or equivalent with mis-wiring protection
per DeviceNet Volume 1 Section 10.2.2.
Node Isolation: Bus powered, isolated node.
Host Isolation: 500 Vrms for 1 minute (50 V working) between
DeviceNet and DLC input common.
Bit Strobe Command: The data response from the Bit Strobe Command is in
the format of a 2 byte hexadecimal number. The register that will be read
using the Bit Strobe command is determined by setting Attribute 2, Instance
1, Class 100* (decimal) with a value that represents the desired attribute.
Refer to the Supported Attributes table for the appropriate value.
EXPLICIT MESSAGE COMMAND
INSTALLATION INFORMATION
Factory Settings:
Baud rate: Autobaud
MAC ID: 63
Strobe Register: 03h
Swap data flag: Off.
Get Attribute: The attribute that will be read using the Get Attribute command is
determined by setting Service Code 14, Instance 1, Class 100* (decimal), and
the attribute with a value that represents the desired meter attribute. Refer to the
Supported Attributes table for the appropriate value. The data response from
the Get Attribute Command is in the format of a 2 byte hexadecimal number.
Set Attribute: The attribute that will be set using the Set Attribute command is
determined by setting Service Code 16, Instance 1, Class 100* (decimal), and
the attribute with a value that represents the desired meter attribute. Refer to
the Supported Attributes table for the appropriate value. The data field for the
Set Attribute Command is entered as a 2 byte hexadecimal number.
Bus Connection - based on model chosen. See ORDERING INFORMATION,
Page 1. For Connection Options, See Diagram on Page 4.
COMBICON
M12
1 = SHIELD
2 = V+
3=V
4 = CAN H
5 = CAN L
3
4 5 2
1
V
CAN L
SHIELD
CAN H
V+
OTHER EXPLICIT MESSAGE ATTRIBUTES
1
2
3
4
5
Data Byte Swap: (1 byte), Attribute 1, Instance 1, Class 100* (decimal). Data
is normally sent and entered as follows: DLC value = 50000 (C350h). 2 byte
value sent would be 50C3. Setting the data swap value to 1 would result in
the data being sent as C350. This attribute can only be set to 0 or 1, all other
values are ignored. The factory setting value is 0. Data byte is saved in
EEPROM memory.
Note: Shield has no internal connection in the DLCN.
Data Update: The DeviceNet interface is continually requesting values from the
DLC main processor and updating buffer registers. As such, valid attribute
values are always available over DeviceNet at the maximum bus rate.
Standard Wire Colors:
V+
Red
V-
Black
CAN_H
White
CAN_L
Blue
1F (General Code)
Vendor Specific Error
SHIELD
Bare
1 (Additional Code)
Device Response Time-out
2 (Additional Code)
Vendor Service Not Supported
3 (Additional Code)
Command String Syntax Error
Vendor Specific Error Responses
CODE ERROR #
CONNECTION SIZES
Device Profile: This product conforms to the DeviceNet specification
Volumes I and II of version 2.0.
Device Configuration: No DeviceNet configuration is supported.
However, some DLC configuration is supported.
MESSAGE
PRODUCED
CONSUMED
Explicit
4 Bytes
2 Bytes
Polled
4 Bytes
2 Bytes
Bit Strobe
8 Bytes
2 Bytes
ERROR CODE MEANING
*Class 100 (decimal) is a vendor specific class.
2
DLCN DeviceNet SUPPORTED ATTRIBUTES
This subset of registers is supported via DeviceNet communications. Modbus registers are provided for reference only. See the DLC bulletin for complete register
and Modbus programming details.
REGISTERS
CHA
Modbus
Register
REGISTER NAME
LOW LIMIT
HIGH LIMIT
FACTORY
SETTING
SERVICE
CODES
SUPPORTED
CHB
Attribute
Modbus
Register
Attribute
1
-
-
Data Byte Swap
See description under OTHER EXPLICIT MESSAGE ATTRIBUTES
2
-
-
Bit Strobe
See description under SUPPORT CONNECTIONS
DEVICENET SPECIFIC ATTRIBUTES
CONTROLLING VALUES
40001
3
40017
8
Process Value
N/A
N/A
N/A
G
40002
4
40018
9
Setpoint Value
-32000
32000
0
G, S
40003
5
40019
10
Alarm 1 Value
-32000
32000
0
G, S
40004
6
40020
11
Alarm 2 Value
-32000
32000
0
G, S
PID PARAMETERS
40005
7
40021
12
Output Power
0 or -1000
1000
0
G, S
40007
13
40023
22
Proportional Band
0
9999
40
G, S
40008
14
40024
23
Integral Time
0
9999
120
G, S
40009
15
40025
24
Derivative Time
0
9999
30
G, S
40011
16
40027
25
Auto-Tune Start
0
1
0
G, S
40012
17
40028
26
Auto-Tune Phase
N/A
N/A
N/A
G
40013
18
40029
27
Auto-Tune Code
0
2
0
G, S
40014
19
40030
28
Control Output OP1
N/A
N/A
N/A
G
40015
20
40031
29
Alarm Output AL1
0
1
0
G, S
40016
21
40032
30
Alarm Output AL2 / OP2
0
1
0
G, S
OUTPUT STATUS
CONTROL STATUS
40041
31
40049
37
Control Mode
0
1
0
G, S
40042
32
40050
38
Disable Setpoint Ramping
0
1
0
G, S
40043
33
40051
39
Setpoint Ramping In Process
N/A
N/A
N/A
G
40044
34
40052
40
Disable Integral Action
0
1
0
G, S
40045
35
40053
41
Ramping Setpoint Value
N/A
N/A
N/A
G, S
40046
36
-
-
0
1
0
G, S
Remote / Local Setpoint Select
PROFILE OPERATION - SETPOINT CONTROLLER MODEL ONLY
40065
42
40073
48
Profile Operating Status
0
3
0
G, S
40066
43
40074
49
Profile Phase
N/A
N/A
N/A
G
40067
44
40075
50
Profile Segment
N/A
N/A
N/A
G
40068
45
40076
51
Profile Phase Time Remaining
1
9999
N/A
G, S
40069
46
40077
52
Profile Cycle Count Remaining
1
250
0
G, S
40070
47
40078
53
Advance Profile Phase
0
1
0
G, S
COOLING (OP2) PARAMETERS
40141
54
40241
57
Cycle Time
0
250
20
G, S
40142
55
40242
58
Relative Gain
0
100
10
G, S
40143
56
40243
59
Deadband
-32000
32000
0
G, S
N/A
N/A
N/A
G
0
N/A
0
G, S
CALIBRATION
40504
60
-
-
Input Error Status Register (See
COILS TABLE for bit definitions)
40505
61
-
-
Checksum Error Status Register
(See COILS TABLE for bit definitions)
3
DLCN DeviceNet SUPPORTED ATTRIBUTES, Setpoint Controller Model Only
REGISTERS
CHA
REGISTER NAME
LOW LIMIT
HIGH LIMIT
FACTORY
SETTING
SERVICE
CODES
SUPPORTED
CHB
Modbus
Register
Attribute
Modbus
Register
Attribute
40601 to
40620
62-81
40701 to
40720
122-141 Setpoint Value Segment 1-20
40621 to
40640
82-101
40721 to
40740
40641 to
40660
102-121
40741 to
40760
SETPOINT CONTROLLER PROFILE SEGMENTS - SETPOINT CONTROLLER MODEL ONLY
-32000
32000
-
G,S
142-161 Ramp Rate Segment 1-20
0
32000
-
G, S
162-181 Hold Time Segment 1-20
0
9999
-
G, S
COILS TABLE (Cross-Reference to attributes 60 and 61)
COIL ADDRESS
COIL NAME
MIRROR REGISTER
SERVICE
CODES
SUPPORTED
1
Calibration Checksum Error
40505 (bit 0)
G, S
2
Parameter Checksum Error
40505 (bit 1)
G, S
3
Integral and Offset/Manual Power Checksum Error
40505 (bit 2)
G, S
CH A
CH B
5
17
Shorted RTD Input Error
40504 (bit 0 / 4)
G
6
18
Open Thermocouple, RTD, or Extreme Process Input
Over/Under Range Input Error
40504 (bit 1 / 5)
G
Signal or Sensor Under Range Input Error
40504 (bit 2 / 6)
G
7
19
Process Value (<-32000) Under Range Input Error
40504 (bit 2 / 6)
G
Signal or Sensor Over Range Input Error
40504 (bit 3 / 7)
G
Process Value (>32000) Over Range Input Error
40504 (bit 3 / 7)
G
8
20
CONNECTION OPTIONS
M12
COMBICON
DeviceNet Cabling
Red Lion Controls Asia
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. DSP-A
Drawing No. LP0629
Released 5/06
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL DSP – DATA STATION PLUS
z PROTOCOL CONVERSION FEATURE CONVERTS NUMEROUS
PROTOCOLS SIMULTANEOUSLY
z COMPACTFLASH® SLOT ALLOWS PROCESS DATA TO BE
LOGGED DIRECTLY TO CSV FILES
z VIRTUAL HMI OFFERS BUILT-IN PC-BASED SCADA
FUNCTIONALITY
z WEBSERVER PROVIDES WORLDWIDE ACCESS TO DATA
LOGS AND VIRTUAL HMI
z EXTENSIVE BUILT-IN DRIVER LIST ALLOWS EASY DATA
MAPPING TO PLCs, PCs, AND SCADA SYSTEMS
z ALARM NOTIFICATIONS CAN BE SENT VIA EMAIL OR TEXT
MESSAGES
z 10 BASE-T/100 BASE-TX ETHERNET CONNECTION CAN
CONNECT TO AN UNLIMITED NUMBER OF DEVICES VIA FOUR
PROTOCOLS SIMULTANEOUSLY
GENERAL DESCRIPTION
SOFTWARE
The Data Station Plus was designed to act as a nexus for industrial data
collection and management. The unit offers multiple protocol conversion, data
logging and remote machine access. With three built in serial ports and a 10
Base-T/100 Base-TX Ethernet port, the unit performs protocol conversion,
allowing disparate devices to communicate seamlessly with one another. The
Ethernet port supports up to four protocols simultaneously so even Ethernet to
Ethernet protocols can be converted.
The CompactFlash card allows data to be collected and stored for later
review. The files are stored in simple CSV file format allowing common
applications, such as Microsoft Excel and Access, to view and manage the data.
The free Websync utility provides a means to synchronize the files with a PC’s
hard drive for permanent storage. The CompactFlash card may also be used to
load new configuration files into the Data Station.
The built-in web server allows log files to be retrieved manually, and also
provides access to the unique “virtual HMI”. The virtual HMI is programmed
just like Red Lion’s G3 series of HMI. Any standard web browser such as
Internet Explorer or Netscape may be used to monitor or control the HMI from
a PC anywhere in the world.
The USB port may be used for blazing fast file downloads, or to mount the
Data Station’s CompactFlash card as an external drive to your PC.
The Data Station’s DIN rail mounting saves time and panel space and snaps
easily onto standard top hat (T) profile DIN rail.
The Data Station is programmed with Windows® compatible Crimson 2.0
software. The software is an easy to use graphical interface which can be
purchased as part of a kit that includes a manual and cables, or downloaded free
of charge from www.redlion.net.
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 controller. An independent and
redundant temperature limit indicator with alarm outputs is strongly
recommended.
CAUTION: Risk of Danger.
Read complete instructions prior to
installation and operation of the unit.
DIMENSIONS In inches (mm)
CompactFlash is a registered trademark of CompactFlash Association.
1
SPECIFICATIONS
8. POWER CONNECTION: Removable wire clamp screw terminal block.
Wire Gage Capacity: 24 AWG to 12 AWG
Torque: 4.45 to 5.34 in/lb (0.5 to 0.6 N-m)
9. MOUNTING: Snaps onto standard DIN style top hat (T) profile mounting
rails according to EN50022 -35 x 7.5 and -35 x 15.
10. CERTIFICATIONS AND COMPLIANCES:
SAFETY
IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part 1.
ELECTROMAGNETIC COMPATIBILITY
Emissions and Immunity to EN 61326: Electrical Equipment for
Measurement, Control and Laboratory use.
1. POWER: 24 VDC ± 10%
200 mA min., without expansion card
4 Amps maximum with expansion card fitted
Must use Class 2 or SELV rated power supply.
2. COMMUNICATIONS:
USB/PG Port: Adheres to USB specification 1.1. Device only using Type B
connection.
Serial Ports: Format and Baud Rates for each port are individually software
programmable up to 115,200 baud.
RS232/PG Port: RS232 port via RJ12
COMMS Ports: RS422/485 port via RJ45, and RS232 port via RJ12
DH485 TXEN: Transmit enable; open collector, VOH = 15 VDC,
VOL = 0.5 V @ 25 mA max.
Ethernet Port: 10 BASE-T / 100 BASE-TX
RJ45 jack is wired as a NIC (Network Interface Card).
3. LEDs:
STS – Status LED indicates condition of Data Station.
TX/RX – Transmit/Receive LEDs show serial activity.
Ethernet – Link and activity LEDs.
CF – CompactFlash LED indicates card status and read/write activity
4. MEMORY:
On-board User Memory: 4 Mbytes of non-volatile Flash memory.
On-board SDRAM:
DSPSX: 2 Mbytes
DSPGT: 8 Mbytes
Memory Card: CompactFlash Type II slot for Type I and Type II cards.
5. REAL-TIME CLOCK: Typical accuracy is less than one minute per month
drift. Crimson 2.0’s SNTP facility allows synchronization with external servers.
Battery: Lithium Coin Cell. Typical lifetime of 10 years at 25 ºC.
A “Battery Low” system variable is available so that the programmer can
choose specific action(s) to occur when the battery voltage drops below
its nominal voltage.
6. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 50°C
Storage Temperature Range: -30 to +70°C
Operating and Storage Humidity: 80% max relative humidity,
non-condensing, from 0 to 50°C
Altitude: Up to 2000 meters
7. CONSTRUCTION: Case body is burgundy high impact plastic and
stainless steel. Installation Category I, Pollution Degree 2.
Immunity to Industrial Locations:
Electrostatic discharge
EN 61000-4-2
Electromagnetic RF fields
EN 61000-4-3
Fast transients (burst)
EN 61000-4-4
Surge
EN 61000-4-5
RF conducted interference
EN 61000-4-6
Emissions:
Emissions
EN 55011
Criterion A 2
4 kV contact discharge
8 kV air discharge
Criterion A
10 V/m
Criterion A
2 kV power
2 kV signal
Criterion A
1kV L-L,2 kV L&N-E power
Criterion A
3 V/rms
Class A
Notes:
1. Criterion A: Normal operation within specified limits.
2. This device was designed for installation in an enclosure. To avoid
electrostatic discharge to the unit in environments with static levels above
4 kV precautions should be taken when the device is mounted outside an
enclosure. When working in an enclosure (ex. making adjustments, setting
jumpers etc.) typical anti-static precautions should be observed before
touching the unit.
11. WEIGHT: 15.1 oz (456.4 g)
HARDWARE
INSTALLATION
Figure 1 - Attach Data Station To DIN Rail
2
POWER SUPPLY REQUIREMENTS
COMPACTFLASH® CARD
It is very important that the power supply is mounted correctly if the unit is
to operate reliably. Please take care to observe the following points:
– The power supply must be mounted close to the unit, with usually not more
than 6 feet (1.8 m) of cable between the supply and the Data Station.
Ideally, the shortest length possible should be used.
– The wire used to connect the Data Station’s power supply should be at least
22-gage wire. If a longer cable run is used, a heavier gage wire should be
used. The routing of the cable should be kept away from large contactors,
inverters, and other devices which may generate significant electrical
noise.
– A power supply with a Class 2 or SELV rating is to be used. A Class 2 or
SELV power supply provides isolation to accessible circuits from
hazardous voltage levels generated by a mains power supply due to single
faults. SELV is an acronym for “safety extra-low voltage.” Safety extralow voltage circuits shall exhibit voltages safe to touch both under normal
operating conditions and after a single fault, such as a breakdown of a
layer of basic insulation or after the failure of a single component has
occurred.
CompactFlash socket is a Type II socket that can accept either Type I or II
cards. Use cards with a minimum of 4 Mbytes with the Data Station’s
CompactFlash socket. Cards are available at most computer and office supply
retailers. CompactFlash can be used for configuration transfers, data logging,
and trending.
Visit www.redlion.net for a complete list of our PSDR Series of Class 2
power supplies.
Note: Do not remove or insert
the CompactFlash card while
power is applied.
Information stored on a CompactFlash card can be read by a card reader
attached to a PC. This information is stored in IBM (Windows®) PC compatible
FAT16 file format.
NOTE
For reliable operation in all of our products, Red Lion recommends the
use of SanDisk® and SimpleTech brands of CompactFlash cards.
Industrial grade versions that provide up to two million write/erase cycles
minimum are available from Red Lion.
EMC INSTALLATION GUIDELINES
Although Red Lion Controls Products are designed with a high degree of
immunity to Electromagnetic Interference (EMI), proper installation and wiring
methods must be followed to ensure compatibility in each application. The type
of the electrical noise, source or coupling method into a unit may be different for
various installations. Cable length, routing, and shield termination are very
important and can mean the difference between a successful or troublesome
installation. Listed are some EMI guidelines for a successful installation in an
industrial environment.
4. 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 through 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. Also, 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. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
6. In extremely high EMI environments, the use of external EMI suppression
devices is effective. The following EMI suppression devices (or equivalent)
are recommended:
Ferrite Suppression Cores for signal and control cables:
Fair-Rite part number 0443167251 (RLC part number FCOR0000)
TDK part number ZCAT3035-1330A
Steward part number 28B2029-0A0
Line Filters for input power cables:
Schaffner part number FN610-1/07 (RLC part number LFIL0000)
Schaffner part number FN670-1.8/07
Corcom part number 1 VR3
Visit RLC's web site at www.redlion.net for more information on EMI
guidelines, Safety and CE issues as they relate to Red Lion Controls products.
1. To reduce the chance of noise spikes entering the unit via the power lines,
connections should be made to a clean source. Connecting to circuits that also
power loads such as contactors, relays, motors, solenoids etc. should be avoided.
2. The unit should be mounted in a metal enclosure, which is properly connected
to protective earth.
3. 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 to earth ground (protective earth) at one end where the
unit is mounted.
b. Connect the shield to earth ground at both ends of the cable, usually when
the noise source frequency is over 1 MHz.
c. Connect the shield to common of the Data Station and leave the other end
of the shield unconnected and insulated from earth ground.
3
WIRING
POWER CONNECTION
PROGRAMMING PORTS
RS232/PG
USB/PG
ETHERNET
COMMUNICATION PORTS
RS232/PG
4
RS232
* Use appropriate communications cable. See Ordering
Information for descriptions of the available cables.
RS485
WARNING: Do NOT use a standard DH-485
cable to connect this port to Allen Bradley
equipment.
PORT 3 - ETHERNET CONNECTION
Standard Ethernet cable
DATA STATION PORT PIN OUTS
TROUBLESHOOTING
If for any reason you have trouble operating,
connecting, or simply have questions concerning your
new Data Station, contact Red Lion’s technical support.
For contact information, refer to the back page of this
bulletin for phone and fax numbers.
EMAIL: [email protected]
Web Site: http://www.redlion.net
5
COMMUNICATING WITH THE DATA STATION
CONFIGURING A DATA STATION
RS232 PORTS
The Data Station is configured using Crimson 2.0 software. Crimson 2.0 is
available as a free download from Red Lion’s website, or it can be ordered on
CD. Updates to Crimson 2.0 for new features and drivers are posted on the
website as they become available. By configuring the Data Station using the
latest version of Crimson 2.0, you are assured that your unit has the most up to
date feature set. Crimson 2.0 software can configure the Data Station through
the RS232/PG port, USB/PG port, Ethernet, or CompactFlash. The USB/PG
port is connected using a standard USB cable with a Type B connector.
The driver needed to use the USB port will be installed with Crimson 2.0.
The RS232/PG port uses a programming cable made by Red Lion to connect to
the DB9 COM port of your computer. If making your own cable, refer to the
“Data Station Port Pin Outs” for wiring information.
The CompactFlash can be used to program a Data Station by placing a
configuration file and firmware on the CompactFlash card. The card is then
inserted into the target Data Station and powered. Refer to the Crimson 2.0
literature for more information on the proper names and locations of the files.
The Data Station has two RS232 ports. There is the RS232/PG port and the
COMMS port. Although only one of these ports can be used for programming,
both ports can be used for communications with a PLC. The RS232/PG port can
be used for either master or slave protocols.
RS422/485 PORT
The Data Station has one RS422/485 port. This port can be configured to act
as either RS422 or RS485.
RS422/485 4-WIRE
CONNECTIONS
RS485 2-WIRE
CONNECTIONS
CABLES AND DRIVERS
Red Lion has a wide range of cables and drivers for use with many different
communication types. A list of these drivers and cables along with pin outs is
available from Red Lion’s website. New cables and drivers are added on a
regular basis. If making your own cable, refer to the “Data Station Port Pin
Outs” for wiring information.
USB, DATA TRANSFERS FROM THE
COMPACTFLASH CARD
In order to transfer data from the CompactFlash card via the USB port, a
driver must be installed on your computer. This driver is installed with Crimson
2.0 and is located in the folder C:\Program Files\Red Lion Controls\Crimson
2.0\Device\ after Crimson 2.0 is installed. This may have already been
accomplished if your Data Station was configured using the USB port.
Once the driver is installed, connect the Data Station to your PC with a USB
cable, and follow “Mounting the CompactFlash” instructions in the Crimson 2.0
user manual.
Note that using the USB port for frequent data transfers is not recommended.
For frequent data transfers it is recommended that the Ethernet connection be
used. Through the Ethernet connection a web page can be set up to view logged
data. Refer to the Crimson 2.0 manual for details.
Note: All Red Lion devices connect A to A and B to B, except for Paradigm
devices. Refer to www.redlion.net for additional information.
DH485 COMMUNICATIONS
The Data Station’s RS422/485 COMMS port can also be used for Allen
Bradley DH485 communications.
WARNING: DO NOT use a standard DH485 cable to connect this port to Allen
Bradley equipment. A cable and wiring diagram are available from Red Lion.
Note: The USB port is for system set-up and diagnostics and is not intended for
permanent connection.
ETHERNET COMMUNICATIONS
Ethernet communications can be established at either 10 BASE-T or 100
BASE-TX. The Data Station’s RJ45 jack is wired as a NIC (Network Interface
Card). For example, when wiring to a hub or switch use a straight-through
cable, but when connecting to another NIC use a crossover cable.
The Crimson 2.0 manual contains additional information on Ethernet
communications.
6
LEDS
USER COMMUNICATION PORTS - TX/RX LEDS
STS – STATUS LED
LED
INDICATION
The green Status LED provides information regarding the state of the Data
Station. This includes indication of the various stages of the start-up routine
(power-up), and any errors that may occur.
GREEN
Transmitting
RED
Receiving
Note: LEDs are not available on the Programming Port: RS232/PG.
Startup Routine
INDICATION
Rapidly Flashing
Data Station is currently running the boot loader and/or
being flash upgraded by Crimson.
Steady
Data Station is operating properly.
ETHERNET LEDS
CF – COMPACTFLASH LED
LED
INDICATION
Off
No CompactFlash Card is present.
Steady
Valid CompactFlash card is present.
Flashing Rapidly
CompactFlash card is being checked.
Flickering
Unit is writing to the CompactFlash, either because
it is storing data, or because the PC connected via
the USB port has locked the drive. 1
Flashing Slowly
Incorrectly formatted CompactFlash card present.
LED
INDICATION
YELLOW (Solid)
Link Established
YELLOW (Flashing)
Network Activity
GREEN
10 BASE-T Communications
AMBER
100 BASE-TX Communications
1. Do not turn off power to the unit while this light is flickering. The unit writes
data in two minute intervals. Later Microsoft operating systems will not lock
the drive unless they need to write data; Windows 98 may lock the drive any
time it is mounted, thereby interfering with logging. Refer to “Mounting the
CompactFlash” in the Crimson 2.0 User Manual.
ORDERING INFORMATION
MODEL NO.
Data Station
Plus
DESCRIPTION
DSPSX000
Data Station with multiple protocol converter, data logger,
web server and expansion slot with increased SDRAM.
DSPGT000
4
G3CF064M
64 MB CompactFlash Card
G3CF
PSDR
SFCRM2
CBL
256 MB CompactFlash Card
4
G3CF256M
512 MB CompactFlash Card
4
G3CF512M
DIN Rail Power Supply
PSDRxxxx
2
Crimson 2.0 , Manual and Download Cable
SFCRM200
RS-232 Programming Cable
CBLPROG0
USB Cable
CBLUSB00
Communications Cables
DR
PART NUMBER
Data Station with multiple protocol converter, data logger,
web server and expansion slot.
1
DIN Rail Mountable Adapter Products
CBLxxxxx
3
DRxxxxxx
1
Visit www.redlion.net for a list of communication drivers and cables.
2
Use this part number to purchase Crimson on CD with a printed manual, USB cable, and RS-232
cable. Otherwise, download free of charge from www.redlion.net.
3
Red Lion offers RJ modular jack adapters. Refer to the DR literature for complete details.
4
Industrial grade two million write cycles.
7
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 sub-contractors 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
herein and relies on no other warranties or affirmations.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. DLC-E
Drawing No. LP0495
Released 9/02
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL DLC - DUAL LOOP CONTROLLER
UL Recognized Component,
File #E156876
!
MODULAR BUILDING BLOCK FOR MULTI-ZONE PROCESS CONTROL
!
TWO INDEPENDENT PID CONTROL LOOPS
!
PID CONTROL WITH REDUCED OVERSHOOT
!
UNIVERSAL INPUTS ACCEPT TC, RTD, 0-10 V and 0/4-20 mA
SIGNALS
!
ON DEMAND AUTO-TUNING OF PID SETTINGS
!
INPUT CHANNELS FULLY ISOLATED
!
TWO DC ANALOG OUTPUTS (OPTIONAL)
!
WINDOWS® CONFIGURATION SOFTWARE
!
RS485 MODBUS™ PROTOCOL
!
CHANNEL B CAN BE ASSIGNED AS A SECOND ANALOG INPUT TO
CHANNEL A FOR REMOTE SETPOINT OPERATION
!
SETPOINT CONTROLLER OPTION FOR TIME VS.
TEMPERATURE/PROCESS (RAMP/SOAK) AND SPECIAL
BATCH/RECIPE APPLICATIONS
GENERAL DESCRIPTION
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 controller. An independent
and redundant temperature limit indicator with alarm outputs is strongly
recommended.
The Model DLC, Dual Loop Controller, is a full featured, DIN rail mounted,
dual input PID controller. The DLC is designed as a modular building block for
multi-zone process control applications. The controller has two independent “A”
& “B” input channels. Each channel’s input can be configured to accept a wide
range of thermocouple, RTD, 0-10 V, 0/4-20 mA, or resistive signals. Channel B
can be also assigned as a Remote Setpoint for Channel A. The two timeproportioning or DC Analog outputs can be programmed to control two
independent processes. The two alarms per channel can be configured for various
alarm modes, or provide a secondary control output for heat/cool applications.
The control and alarm outputs are N channel open drain MOSFETs capable
of switching up to 1 Amp DC. For applications requiring larger loads or A/C
loads, several DIN rail mount relays are available.
The controller operates in the PID Control Mode for both heating and
cooling, with on-demand auto-tune, that establishes the tuning constants. The
PID tuning constants may be fine-tuned through the serial interface. The
controller employs a unique overshoot suppression feature, which allows the
quickest response without excessive overshoot. The controller can be
transferred to operate in the Manual Mode, providing the operator with direct
control of the output, or the On/Off Control Mode with adjustable hysteresis.
The controller’s high density packaging and DIN rail mounting saves time
and panel space. The controller snaps easily onto standard top hat (T) profile
DIN rails.
CAUTION: Read complete
instructions prior to installation
and operation of the unit.
ALARMS
The DLC’s two solid-state alarms can be configured independently for
absolute high or low acting with balanced or unbalanced hysteresis. They can
also be configured for deviation and band alarm. In these modes, the alarm
trigger values track the setpoint value. Adjustable alarm trip delays can be used
for delaying output response. The alarms can be programmed for Automatic or
Latching operation. Latched alarms must be reset with a serial command. A
standby feature suppresses the alarm during power-up until the temperature
stabilizes outside the alarm region. The outputs can also be manually controlled
with Modbus register or coil commands.
DIMENSIONS In inches (mm)
ORDERING INFORMATION
MODEL NO. DESCRIPTION
DLC
SF
CBPRO
PART NUMBERS
Dual Loop Controller
DLC00001
Dual Loop Controller w/ 2 Analog Outputs
DLC01001
Dual Setpoint Controller w/ 2 Analog Outputs
DLC11001
PC Configuration Software for Windows
SFDLC
Programming Interface Cable
CBPRO007
CBJ
Cable RJ11 to RJ11 (6 inch jumper)
CBJ11BD5
DRR
RJ11 to Terminal Adapter
DRRJ11T6
P89
Paradigm to RJ11 Cable
P893805Z
See our RSRLYB, RLY6, and RLY7 literature for details on DIN rail
mountable relays.
1
6. RTD INPUTS:
Type: 2 or 3 wire
Excitation: 150 µA
Lead Resistance: 15 Ω max
Resolution: 1 or 0.1° for all types
SETPOINT CONTROLLER OPTION
The Setpoint Controller option is suitable for time vs. temperature/process
control applications. The controller allows a profile of up to 20 ramp/soak
segments. Profile conformity is assured by using the Error Band Mode and
Error Band parameter. The Profile Cycle Count allows the profile to run
continuously or a fixed number of cycles. Power-on options automatically stop,
abort, start, resume, or pause a running profile.
TYPE
RANGE
385
100 Ω platinum, Alpha = .00385
-200 to +600°C
-328 to +1100°F
392
100 Ω platinum, Alpha = .003919
-200 to +600°C
-328 to +1100°F
672
120 Ω nickel, Alpha = .00672
-80 to +215°C
-112 to +419°F
COMMUNICATIONS
The RS485 serial communications allows the DLC to be multi-dropped, with
Baud rates up to 38400. The CBPRO007 programming cable converts the
RS232 port of a PC to RS485 and is terminated with an RJ11 connector. The bidirectional capability of the CBPRO007 allows it to be used as a permanent
interface cable as well as a programming cable.
INPUT TYPE
ohms
0 to 320 Ω
Linear Resistance
7. TEMPERATURE INDICATION ACCURACY: ± (0.3% of span, +1°C).
Includes NIST conformity, cold junction effect, A/D conversion errors,
temperature coefficient and linearization conformity at 23 °C after 20 minute
warm up.
8. PROCESS INPUT:
SOFTWARE
The DLC is programmed with Windows® based SFDLC software. The
software allows configuration and storage of DLC program files, as well as
calibration. Additionally, all setup and control parameters can be interrogated
and modified through MODBUS™ register and coil commands.
ANALOG OUTPUT OPTION
The optional dual DC Analog Output (10 V or 20 mA) can be independently
configured and scaled for control or re-transmission purposes. These outputs can
be assigned to separate channels, or both outputs can be assigned to the same
channel. Programmable output update time reduces valve or actuator activity.
INPUT RANGE
ACCURACY *
(18 to 28°C)
(10 to 75% RH)
MAX
IMPEDANCE CONTINUOUS RESOLUTION
OVERLOAD
10 VDC
(-1 to 11)
0.10% of reading
+0.02 V
1 MΩ
50 V
1 mV
20 mA DC
(-2 to 22)
0.10% of reading
+0.03 mA
10 Ω
100 mA
1 µA
SPECIFICATIONS
* Accuracies are expressed as ± percentages after 20 minute warm-up.
9. ISOLATION LEVEL: 500 V @ 50/60 Hz, for one minute (50 V working)
between the following groups:
Ch A Input
Ch B Input
Control and Alarm Outputs
RS485/Analog Output 1
Power Supply
Note:
1
RS485 and Analog Outputs are not internally isolated. Their commons
must not be connected together externally for proper unit function (i.e.,
earth ground).
10. SERIAL COMMUNICATIONS:
Type: RS485; RTU and ASCII MODBUS modes
Baud: 300, 600, 1200, 2400, 4800, 9600, 19200, and 38400
Format: 7/8 bits, odd, even, and no parity
Transmit Delay: Programmable: See Transmit Delay explanation.
Transmit Enable (TXEN): (primarily for 20 mA loop converter) open
collector VOH = 10 VDC max, VOL = 0.5 VDC @ 5 mA max current limit
11. A/D CONVERTER: 16 bit resolution
12. CONTROL AND ALARM OUTPUTS:
Type: Non-isolated switched DC, N Channel open drain MOSFET
Current Rating: 1 A max
VDS ON: 0.3 V @ 1 A
VDS MAX: 30 VDC
Offstate Leakage Current: 0.5 mA max
13. MAIN CONTROL:
Control: PID or On/Off
Output: Time proportioning or DC Analog
Cycle Time: Programmable
Auto-Tune: When selected, sets proportional band, integral time, derivative
time values, and output dampening time
Probe Break Action: Programmable
14. ALARM: 1 or 2 alarms
Modes:
Manual (through register/coil)
Absolute High Acting (Balanced or Unbalanced Hysteresis)
Absolute Low Acting (Balanced or Unbalanced Hysteresis)
Deviation High Acting
Deviation Low Acting
Inside Band Acting
Outside Band Acting
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Sensor Fail Response: Upscale
1. POWER:
18 to 36 VDC, 13 W
(4 W if +24 VDC Output excitation is unused)
24 VAC, ±10% 50/60 Hz, 15 VA
(7 VA if +24 VDC Output excitation is unused)
Must use a Class 2 or SELV rated power supply.
2. +24 VDC OUTPUT POWER: 24 VDC, +15%, -5%, 200 mA max
3. MEMORY: Non-volatile memory retains all programmable parameters.
4. INPUT:
Sample Time: 100 msec (9.5 Hz)
Failed Sensor Response: Open or shorted (RTD only) sensor coils
indication, error code returned in Process Value
Common Mode Rejection: >110 dB, 50/60 Hz
Normal Mode Rejection: >40 dB, 50/60 Hz
Temperature Coefficient: 0.013%/°C
Overvoltage: 50 VDC max
Step Response Time: 300 msec typ., 400 msec max
5. THERMOCOUPLE INPUTS:
Types: T, E, J, K, R, S, B, N, C, linear mV
Input Impedance: 20 MΩ
Lead Resistance Effect: 0.25 µV/Ω
Cold Junction Compensation: Less than ±1°C typical (±1.5°C max) over
0 to 50°C ambient temperature range or less than ±1.5°C typical (2°C
max) over -20 to 65°C maximum ambient temperature range.
Resolution: 1° or 0.1° for all types except linear mV (0.1 or 0.01 mV)
WIRE COLOR
MEASUREMENT
RANGE
ANSI
BS 1843
T
-200 to +400°C
-328 to +752°F
(+) Blue
(-) Red
(+) White
(-) Blue
E
-200 to +750°C
-328 to +1382°F
(+) Violet
(-) Red
(+) Brown
(-) Blue
J
-200 to +760°C
-328 to +1400°F
(+) White
(-) Red
(+) Yellow
(-) Blue
K
-200 to +1250°C
-328 to +2282°F
(+) Yellow
(-) Red
(+) Brown
(-) Blue
R
0 to +1768°C
+32 to +3214°F
No Standard
(+) White
(-) Blue
S
0 to +1768°C
+32 to +3214°F
No Standard
(+) White
(-) Blue
B
+149 to +1820°C
+300 to +3308°F
No Standard
No Standard
N
-200 to +1300°C
-328 to +2372°F
(+) Orange
(-) Red
(+) Orange
(-) Blue
C
W5/W6
0 to +2315°C
+32 to +4199°F
No Standard
No Standard
mV
-5 mV to 56 mV
N/A
N/A
TYPE
2
18. CERTIFICATIONS AND COMPLIANCE:
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.
IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment for
measurement, control, and laboratory use, Part I
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 3; 8 kV air 1
Electromagnetic RF fields
EN 61000-4-3 Level 3; 10 V/m
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 kV I/O
Level 3; 2 kV power
RF conducted interference
EN 61000-4-6 Level 3; 10 V/rms
150 KHz - 80 MHz
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
1
This controller was designed for installation in an enclosure. To avoid
electrostatic discharge to the unit in environments with static levels above
6 kV, precautions should be taken when the device is mounted outside an
enclosure. When working in an enclosure (ex. making adjustments, setting
switches etc.), typical anti-static precautions should be observed before
touching the controller.
19. CONSTRUCTION: Case body is black high impact plastic. Installation
Category I, Pollution Degree 2.
20. CONNECTIONS: Wire clamp screw terminals. Removable terminal blocks.
21. MOUNTING: Snaps on to standard DIN style top hat (T) profile mounting
rails according to EN50022 -35 x 7.5 and -35 x 15.
22. WEIGHT: 10.5 oz. (298 g.)
15. COOLING: Software selectable (overrides Alarm 2).
Control: PID or On/Off
Output: Time proportioning or DC Analog
Cycle Time: Programmable
Proportional Gain Adjust: Programmable
Heat/Cool Deadband Overlap: Programmable
16. ANALOG DC OUTPUTS: (optional)
Control or retransmission, programmable update rate from 0.1 sec or
1 to 250 sec
Step Response Time: 100 msec
OUTPUT RANGE**
ACCURACY *
(18 to 28°C)
(10 to 75% RH)
COMPLIANCE
RESOLUTION
(TYPICAL)
0 to 10 V
0.10% of FS
+ 1/2 LSD
10 KΩ min
1/18000
0 to 20 mA
0.10% of FS
+ 1/2 LSD
500 Ω max
1/18000
4 to 20 mA
0.10% of FS
+ 1/2 LSD
500 Ω max
1/14400
* Accuracies are expressed as ± percentages after 20 minute warm-up.
** 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.
17. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: -20 to +65°C
Storage Temperature Range: -40 to +85°C
Operating and Storage Humidity: 85% max relative humidity,
noncondensing, from -20 to +65°C
Altitude: Up to 2000 meters
BLOCK DIAGRAM
3
and portable two-way radios are used in close proximity or if the installation
is near a commercial radio transmitter.
3. Signal or Control cables within an enclosure should be routed as far away as
possible from contactors, control relays, transformers, and other noisy
components.
4. In extremely high EMI environments, the use of external EMI suppression
devices, such as ferrite suppression cores, is effective. Install them on Signal
and Control cables as close to the controller 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
controller to suppress power line interference. The following EMI
suppression devices (or equivalent) are recommended:
Ferrite Suppression Cores for signal and control cables:
Fair-Rite # 0443167251 (Red Lion Controls # FCOR0000)
TDK # ZCAT3035-1330A
Steward # 28B2029-0A0
Line Filters for input power cables:
Schaffner # FN610-1/07 (Red Lion Controls # LFIL0000)
Schaffner # FN670-1.8/07
Corcom # 1 VR3
Note: Reference manufacturer’s instructions when installing a line filter.
5. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
6. Switching of inductive loads produces high EMI. Use of snubbers across
inductive loads suppresses EMI.
Snubber: Red Lion Controls # SNUB0000.
EMC INSTALLATION GUIDELINES
Although this controller is designed with a high degree of immunity to
Electromagnetic Interference (EMI), proper installation and wiring methods
must be followed to ensure compatibility in each application. The type of the
electrical noise, source or coupling method into the controller may be different
for various installations. The controller becomes more immune to EMI with
fewer I/O connections. Cable length, routing, and shield termination are very
important and can mean the difference between a successful or troublesome
installation. Listed are some EMC guidelines for successful installation in an
industrial environment.
1. 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 DIN rail where the controller 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 over 1 MHz.
c. Connect the shield to common of the controller and leave the other end of
the shield unconnected and insulated from earth ground.
2. 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 through metal conduit that is properly
grounded. This is especially useful in applications where cable runs are long
STEP 1 SETTING THE JUMPERS AND DIP SWITCHES
The jumpers are accessible from the bottom of the controller. Needle-nose
pliers are needed to remove the jumpers. They should be set prior to installation.
To insure proper operation, the jumpers must match the controller software
configuration.
ANALOG DC OUTPUTS (OPTIONAL)
Analog Output 1 and Analog
Output 2 can be configured for voltage
(V) or current (I), independent of each
other. Both V/I + and V/I - jumpers of
the same channel must be set for the
same type of output signal.
INPUTS
Channel A and Channel B can be
configured independent of each
other. Jumper position can be
ignored for thermocouple and
millivolt inputs.
SERIAL DIP SWITCH SETTINGS
The DLC Serial Communications Settings can be set via DIP Switches or
through the serial communications port (software selectable). The software
selectable serial settings method using the serial communications port must be
set using "RLCPRO" or another software program to write to the DLC Modbus
registers (40401-40407). When using the DIP switches to configure the serial
settings, the Modbus mode is limited to "RTU" mode only.
4
SWA
DEFAULT SERIAL
SETTINGS
SWITCH
POSITION
BAUD RATE
DN
Use Default Serial
Settings
UP
5
6
300
DN
DN
DN
600
DN
DN
UP
1200
DN
UP
DN
2400
DN
UP
UP
4800
UP
DN
DN
9600
UP
DN
UP
19200
UP
UP
DN
38400
UP
UP
UP
DN
DN
None
DN
UP
Even
UP
DN
Odd
UP
UP
Software Selectable
Serial Settings
1
1
(128)
2
(64)
3
(32)
4
(16)
5
(8)
6
(4)
7
(2)
8
(1)
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
UP
DN
DN
DN
DN
DN
DN
UP
DN
3
DN
DN
DN
DN
DN
DN
UP
UP
4
DN
DN
DN
DN
DN
UP
DN
DN
5
DN
DN
DN
DN
DN
UP
DN
UP
6
DN
DN
DN
DN
DN
UP
UP
DN
Serial Communication Defaults:
7
DN
DN
DN
DN
DN
UP
UP
UP
Protocol: RTU
Address: 247
Baud Rate:9600
8
DN
DN
DN
DN
UP
DN
DN
DN
UP
UP
UP
UP
DN
UP
UP
UP
3
None
UNIT ADDRESS
2
SWITCH POSITION
2
SWITCH POSITION / (BIT WEIGHT)
SWITCH POSITION
4
1
Use DIP Switch or
Software Serial Settings
PARITY
SWB
Stop Bit: 1
Parity:
none
Start Bit 1
…
247*
*- Unit will use address 247 for binary switch settings above 247
STEP 2 INSTALLING THE CONTROLLER
INSTALLATION
The controller is designed for attachment to standard DIN style top hat (T)
profile mounting rails according to EN50022 -35 x 7.5 and -35 x 15. The
controller should be installed in a location that does not exceed the maximum
operating temperature and provides good air circulation. Placing the controller
near devices that generate excessive heat should be avoided.
T Rail Installation
To install the DLC on a “T” style rail, angle the controller so that the top
groove of the mounting recess is located over the lip of the top rail. Push the
controller toward the rail until it snaps into place. To remove a controller from
the rail, insert a screwdriver into the slot on the bottom of the controller, and pry
upwards until it releases from the rail.
STEP 3 IDENTIFYING THE LEDs - LED FUNCTIONALITY
On power-up, all LEDs are turned on briefly in an alternating pattern to allow visual check of LED functionality.
CONDITION
Power Applied
Communicating
OP1 On (Channel A) **
OP1 On (Channel B) **
AL1 On (Channel A) *
AL1 On (Channel B) *
AL2 On (Channel A) *
AL2 On (Channel B) *
OP2 On [Cool](Channel A)
OP2 On [Cool](Channel B)
Auto-Tune On (Channel A)
Auto-Tune On (Channel B)
Input Error (Channel A)
Input Error (Channel B)
Calibration Mode
Checksum Error
PRIORITY
PWR/COMM
CH A OP
CH A ALM
AUTOTUNE
CH B OP
CH B ALM
1
1
4
4
4
4
4
4
5
5
3
3
3
3
2
1
On
Flashing
-------------------------------------------------------------------------------------
------------On
-------------------
------------------------On
------Fast Flashing
------------------------------Slow Flashing
------On
Slow Flashing
------------------------------------------------------------On
Fast Flashing
------------On
Slow Flashing
------------------On
------------------------------Fast Flashing
------------------Slow Flashing
On
Slow Flashing
------------------------------On
------Fast Flashing
------------------------------Slow Flashing
On
Slow Flashing
------Fast Flashing
------------------Slow Flashing
------On
Slow Flashing
* If AL1 & AL2 outputs are on at the same time, the ALM annunciator will alternate between On and Fast Flashing every ½ second.
** If OP1 and AL2/OP2 (configured for cool) outputs are on at the same time, the annunciator will only show the OP1 state. The OP2 state is only shown when OP1 is off.
5
STEP 4 WIRING THE CONTROLLER
WIRING CONNECTIONS
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. When wiring the controller, use the numbers on the label to identify the position number with the
proper function. Strip the wire, leaving approximately 1/4" (6 mm) of bare wire exposed. Insert the wire into the terminal, and tighten the screw
until the wire is clamped tightly. (Pull wire to verify tightness.) Each terminal can accept up to one #14 AWG (2.55 mm), two #18 AWG (1.02
mm), or four #20 AWG (0.61 mm) wires.
24 VAC POWER
18 to 36 VDC POWER
CONTROLLER POWER CONNECTIONS
For best results, the power should be relatively “clean” and within the
specified limits. Drawing power from heavily loaded circuits or from circuits
that also power loads that cycle on and off should be avoided. It is
recommended that power supplied to the controller be protected by a fuse or
circuit breaker.
INPUT CONNECTIONS
Thermocouple and Millivolt
RTD and Resistance *
CH A = Terminals 4, 5 & 6
CH B = Terminals 1, 2 & 3
CH A = Terminals 4, 5 & 6
CH B = Terminals 1, 2 & 3
Voltage or Current
CH A = Terminals 4, 5 & 6
CH B = Terminals 1, 2 & 3
3 Wire Current or Voltage Signal Requiring DLC Excitation **
2 Wire Current Signal Requiring DLC Excitation **
CH A = Terminals 4, 5 & 6
CH B = Terminals 1, 2 & 3
CH A = Terminals 4, 5 & 6
CH B = Terminals 1, 2 & 3
* For two wire RTDs, install a copper sense lead of the same gauge and length as the RTD leads. Attach one end of the wire at the probe and the other end to input
common terminal. Complete lead wire compensation is obtained. This is the preferred method. If a sense wire is not used, then use a jumper. A temperature offset
error will exist. The error may be compensated by programming a temperature offset.
** +24 VDC OUT (Terminal 3) shares common with Ch A Inputs & All Control/Alarm Outputs.
CONTROL AND ALARM OUTPUT CONNECTIONS
Load Power from DLC
External Controller Power
CH A = Terminals 5, 6, & 7
CH B = Terminals 8, 9, & 10
Separate External Power
For Load and Controller
CH A = Terminals 5, 6, & 7
CH B = Terminals 8, 9, & 10
6
Combined External Power
For Load and Controller
CH A = Terminals 5, 6, & 7
CH B = Terminals 8, 9, & 10
ANALOG DC OUTPUT CONNECTIONS
DEFAULT SERIAL SETTING CONNECTIONS
If using software selectable serial
settings and the serial settings are
unknown or forgotten, they can be
temporarily reset to the defaults by
connecting the “Default Serial
Setting” terminal 7 to “Output
Common” terminal 4 with a jumper.
Output 1 = Terminals 8 & 9
Output 2 = Terminals 10 & 11
Defaults:
Note: Analog Outputs & RS485 are not internally isolated and must not
share the same common (i.e., earth ground).
Protocol: RTU
Address: 247
Baud Rate: 9600
Data Bits: 8
Parity:
none
RS485 SERIAL CONNECTIONS
There are two modular connectors located on the front for paralleling
communications. For single device communications, either connector can be
used. Reverse A+ and B- wiring for Red Lion Controls Paradigm products.
The CBPRO007 programming cable converts the RS232 port of a PC to
RS485 and is terminated with an RJ11 connector. The bi-directional capability
of the CBPRO007 allows it to be used as a permanent interface cable as well as
a programming cable.
STEP 5 INSTALLING SFDLC (Software for DLC)
Insert the SFDLC diskette into the A: or B: drive. Then Run
A:\SETUP (or B:\SETUP) to install RLCPro onto the hard drive. An
icon labeled RLCPro will be created under the group RLCPro.
STEP 6 PROGRAMMING - Getting Started
You will be prompted to
select the proper device,
Run RLCPro by double-clicking the icon, or use the start menu.
Use the FILE pull-down menu
to select a NEW file.
and then the model.
7
STEP 7 PROGRAMMING THE PID SETTINGS
Note: The register numbers correspond to (Channel A/Channel B).Channel B PID control is not functional
when the input is assigned as a Remote Setpoint.
The Auto-Tune procedure of the controller sets the Proportional Band, Integral Time, Derivative Time,
Digital Filter, Control Ouput Dampening Time, and Relative Gain (Heat/Cool) values appropriate to the
characteristics of the process.
Proportional Band (40007/40023): Proportional band, entered as percent of full input range, is the band from
the setpoint where the controller adjusts the percent output power based on how close the process value is
to the setpoint. For temperature inputs, the input range is fixed per the entered thermocouple or RTD type.
For process inputs, the input range is the difference between the entered Process Low Scaling Value and the
Process High Scaling Value. The proportional band should be set to obtain the best response to a process
disturbance while minimizing overshoot. A proportional band of 0.0% forces the controller into On/Off
Control with its characteristic cycling at setpoint.
Integral Time (40008/40024): Integral time is defined as the time, in seconds, it takes the output power due to integral action alone to equal
the output power due to proportional action alone during a constant process error. As long as the 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 higher the integral time, the slower the response. The optimal integral time is best determined during PID Tuning. If time
is set to zero, the previous Integral output power value is maintained. Offset Power can be used to provide Manual Reset. Integral Action
can be disabled by writing a ‘1’ to the Disable Intergral Action register (40044/40052).
Derivative Time (40009/40025): Derivative time, entered as seconds per repeat, is the time that the controller looks ahead at the ramping
error to see what the proportional contribution will be and it matches that value every Derivative time. As long as the ramping error exists,
the Derivative action is repeated by Proportional action every derivative time. Increasing the derivative time helps to stabilize the response,
but too high of a derivative time, coupled with noisy signal processes, may cause the output to fluctuate too greatly, yielding poor control.
Setting the time to zero disables Derivative Action.
Control Mode (40041/40049): In Automatic Mode, the percentage of Output Power is automatically determined by PID or On/Off Control.
In Manual Mode, the percentage of Output Power is entered manually. For more information, see Control Mode Explanations Section.
Output Power (40005/40021): This parameter can only be changed by direct entry in Manual Mode. For more details on this parameter, see
the Control Mode Explanations Section.
Offset Power (Manual Reset) (40010/40026): 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 offset power is used to shift the proportional band to compensate for errors in the
steady state. If Integral Action is later invoked, the controller will re-calculate the internal integral value to provide “bumpless” transfer.
Auto-Tune Code (40013/40029): Prior to starting Auto-Tune, this code should be set to achieve the necessary dampening level under PID
Control. When set to zero, it yields the fastest process response with possible overshoot. A setting of 2 yields the slowest response with
the least amount of overshoot. If the Auto-Tune Code is changed, Auto-Tune needs to be reinitiated for the changes to affect the PID
settings. Auto-tune is initiated by writing a ‘1’ to the Auto-Tune start register (40011/40027). The Auto-Tune phase will be shown in
register (40012/40028). For more information, see PID Tuning Explanations Section.
STEP 8 PROGRAMMING THE INPUT SETUP
Input Type (40101/40201): Select the proper input type from the pull down menu. Make sure the input
jumpers are set to match the input signal selection.
Scale (40102/40202): Select either degrees Fahrenheit or Celsius. For mV, resistance, voltage or current
types, this has no effect. If changed, check all temperature related values, as the DLC does not
automatically convert these values.
Resolution (40103/40203): For all temperature and ohms Input Types low (x1) resolution selects whole
units of measure. In these same modes, high (x10) resolution selects tenth of units of measure. For mV
mode, low selects tenths of mV and high selects hundredths of mV. If changed, be sure to check all
parameters because the controller does not automatically convert related parameter values. For voltage
or current types, this has no effect.
Rounding (40104/40204): Rounding selections other than 1 cause the process value to round to the
nearest rounding increment selected. (For example, rounding of 5 causes 122 to round to 120 and 123
to round to 125.) Rounding starts at the least significant digit of the process value. If the signal is
inherently jittery, the process value may be rounded to a value higher than 1. If the range of the signal
exceeds the required resolution (for example, 0-1000 psi, but only 10 psi resolution is required), a
rounding increment of 10 will effectively make the reading more stable.
Digital Filtering (40105/40205): The filter is an adaptive digital filter that discriminates between
measurement noise and actual process changes. If the signal is varying too greatly due to measurement
noise, increase the filter value. If the fastest controller response is needed, decrease the filter value.
Span Correction (40106/40206): This value is the correction slope. A span of 1.0000 applies no correction.
Span only applies to temperature sensor, millivolt, and ohms inputs.
Offset Correction (40107/40207): This value offsets the temperature value by the entered amount. Offset only
applies to temperature sensor, millivolt, and ohms inputs
Channel B Assignment (40198): This is used to configure Channel B to operate as a Remote Setpoint to
Channel A. Channel B PID control is not functional when the input is assigned as a Remote Setpoint.
8
Local/Remote Setpoint Transfer Mode (40199): When cycling from/to Local or Remote Setpoint (register 40046), the response of the controller can be
programmed to act in a variety of ways. The table summarizes the responses for Setpoint transfer options.
LOCAL/REMOTE SETPOINT TRANSFER
MODE
0 - Normal
LOCAL TO REMOTE
REMOTE TO LOCAL
Output may bump.
Output may bump.
1 - Auto
No output bump. Process error
eliminated at rate of integral action.
Ramping disabled during transfer.
No output bump. Process error
eliminated at rate of integral action.
Ramping disabled during transfer.
2 - Track
Output may bump.
Local Setpoint (40002) assumes
value of Remote Setpoint (tracks).
No output bump.
Note: In situations where an output bump may occur, the Setpoint ramp function can be used to reduce or eliminate bumping when
switching Setpoint modes. The setpoint ramp feature ramps the setpoint from the old setpoint to the new Setpoint.
Remote Setpoint Ratio Multiplier (40206): This value is used for channel B when it is assigned as a Remote Setpoint Input. The Ratio Multiplier applies to
all input types (0-15).
Remote Setpoint Bias Offset (40207): This value is used for channel B when it is assigned as a Remote Setpoint Input.
Scaling Points (40111-40114/40211-40214): Low and high scaling points are necessary to scale the controller for process voltage and current inputs. Each scaling
point has a coordinate pair of input and process value entries. The process value will be linear between and continue past the entries up to the limit of the input
range. Reverse acting measurement can be accomplished by reversing the Input or Process entries, but not both. (Do not reverse the input wires to change the
action.) To scale a 4-20 mA Input signal to provide process values of 0 to 100.00 (% in hundredths), the Input Low (40113/40213) and Input High
(40114/40214) values would be 4000 and 20000 (0.001 mA resolution), and the Process Low (40111/40211) and Process High (40112/40212) values would
be 0 and 10000.
Process Decimal Point (Dec Pt) (40115/40215): The decimal point position is used to enable SFDLC display in desired engineering units for voltage and current
Process values. It is not used internally by the DLC.
STEP 9 PROGRAMMING THE SETPOINTS
Setpoint (40002/40018): Enter the setpoint value. Deviation of Process Value (40001/40017) from
setpoint value can be viewed in the Setpoint Deviation register (40006/40022).
Low Limit (40108/40208); High Limit (40109/40209): The controller has programmable high and low
setpoint limit values to restrict the setting range of the setpoint. Set the limits so that the setpoint value
cannot be set outside the safe operating area of the process.
Ramp Rate (40110/40210): The setpoint ramp rate can reduce sudden shock to the process and reduce
overshoot on startup or after setpoint changes, by ramping the setpoint at a controlled rate. The ramp
rate is 0.1° for input types 0-11, 0.1 Ω for input type 12, 0.01 for input type 13, and 0.1 unit for input
types 14-15 per minute. Writing a ‘0’ disables setpoint ramping. The Disable Setpoint Ramping register
(40042/40050) can also be used to disable ramping. The Setpoint Ramping In-Process register
(40043/40051) will be a ‘1’ during setpoint ramping. While ramping is enabled, the Ramping Setpoint
can be viewed in register (40045/40053). The Ramp Rate for CHB is not functional when it is assigned
as a Remote Setpoint Input.
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 starting Auto-Tune, the ramping is suspended during Auto-Tune and then
resumed afterward using the present Process value as a starting value. Deviation and band alarms are relative to the target setpoint, not the ramping setpoint.
A slow process may not track the programmed setpoint rate. At power-up, the ramping setpoint is initialized to the starting process value.
Remote/Local Setpoint Select (40046): Channel A setpoint mode can be switched between Local Setpoint operation and Remote Setpoint operation. The
Channel B input must be assigned as a remote setpoint (register 40198).
STEP 10 PROGRAMMING PROFILE SETUP (Optional)
Profile Power Cycle Mode (40321/40421): Upon controller power-on several profile operating modes
exist.
Stop: If the Profile was running when powered down, upon power-up, "Stop" places the profile into the
stop or off mode, regardless of the mode prior to the power-down. The active Setpoint is the setpoint
of the last segment that ran before power-down.
Abort: If the Profile status was running, paused, or in Error Delay when powered down, upon powerup, "Abort" will place the controller in manual mode at 0% Output Power. The Setpoint and Ramp
Rate are the values they were prior to running the profile. If the Setpoint Controller was 'paused,' they
will be set to the values that they were at power-down.
Start: The Start power cycle mode causes the controller to automatically start the profile at Power-up.
This will occur if the unit was in manual or automatic control mode. During maintenance or at other
times when this action is not desired, the Profile Power Cycle mode should be changed appropriately.
Resume: At Power-up, Resume causes the profile to continue from the point and phase when power
was removed. If the unit was in ramp phase, the ramping setpoint will start ramping from the initial
process value at power-up.
Pause: Upon Power-up, the controller pauses and maintains control at the initial process value (on
power-up), at the phase where the controller was powered down. The user can then determine how to
proceed based on the process that is being controlled.
9
Profile Error Band Mode (Guaranteed Soak) (40322/40422): Profile conformity can be assured by using the profile Error Band Mode and Error Band
parameter. If the process value deviates outside the error band value while a profile is running, the controller enters the delay mode. In the delay mode,
the profile phase timer is held (delayed) until the process value is within the deviation error band value - the Error band hysteresis value. At this time, the
profile continues running unless the process value again deviates. These actions assure that the actual process value conforms to the profile.
Disable Error Band: Error band operation is disabled.
Ramp Phase Only Error Band: The Profile Error Band only applies to the ramp phases of the running profile.
Hold Phase Only Error Band: The Profile Error Band only applies to hold phases of the running profile.
Ramp & Hold Phase Error Band: The Profile Error Band applies to both ramp and hold phases of the running profile.
Profile Error Band (40323/40423): During a hold phase, the profile is paused when the process error is >= the Profile Error Band. The profile will remain
paused until the process error (deviation) is within the Profile Error Band (Error Band-Error Band Hysteresis).
Profile Error Band Hysteresis (40324/40424): Controls the process value at which the profile will come out of an error band delay. If in error band delay,
the profile phase timer is held (delayed) until the process value is within the deviation error band value - the Error band hysteresis value.
Profile End Segment (40325/40425): The Profile End Segment indicates the last segment (i.e., the number of segments to be used in a profile) that is to be
ran in the profile before it stops or re-starts (dependent on Profile Cycle Count/Profile Cycle Count remaining).
Profile Cycle Count (40326/40426): Once a profile is started, it runs the number of cycles programmed in this register and then automatically defaults to
the Profile End Control Mode. If this parameter is changed while the profile is active, the new value (if less than 250) will not take effect until the profile
is stopped and re-started. If the Profile Cycle Count is set to 250 (continuous profile cycling), the change will take affect immediately.
Profile End Control Mode (40327/40427): This parameter sets the type of control action that will be used when the number of profile cycles as programmed
in the Profile Cycle Count parameter has run to completion.
Control Outputs Off : Control is turned off by putting the controller in manual mode at 0% Power. Control can be resumed by changing the Control
Mode (40041/40049) to Automatic.
Automatic: When configured for Automatic the controller will continue controlling at the last setpoint value.
Setpoint Controller Setpoint Segment Registers 1-20 (40601-40620[ChA]/4070140720[ChB]): The setpoints for the profile are written in these registers. The values are limited
by the Setpoint Lo and Setpoint Hi limits registers. Register (40601/40701) is the Setpoint for
the 1st segment of the profile.
Setpoint Controller Ramp Rate Segment Registers 1-20 (40621-40640[ChA]/4072140740[ChB]): The Ramp Rates for the profile are written in these registers. Register
(40621/40721) is the Ramp Rate for the 1st segment of the profile. A ramp rate of 0 disables
setpoint ramping.
Setpoint Controller Hold Time Segment Registers 1-20 (40641-40660[ChA]/4074140760[ChB]): The Hold Times for the profile are written in these registers. Register
(40641/40741) is the Hold Time for the 1st segment of the profile. Segment Hold times of 0
can be used to achieve a ramp with multiple slopes.
STEP 11 MONITORING PROFILE OPERATION (Optional)
Profile Operating Status/Mode (40065/40073)
Stop/Off: The Stop/Off status indicates the profile is dormant or off. A profile can be stopped by setting this register to 0, by allowing a profile to run to
completion, or by removing and re-applying power when the Power Cycle Mode is configured for stop. If the profile was terminated during a ramp
phase, the unit will continue to ramp to the active setpoint.
Abort: Abort is a command action that can be used quickly to stop the profile and turn off the control outputs. The controller is placed into manual mode
at 0% output power. Following the abort command the Profile Operating Status will go to 0 (Stop/Off).
Run/Start: The profile is in the run mode when it is executing. While running, the profile can be stopped (0), paused (3), or advanced to the next phase.
A profile can be started and placed into the Run mode automatically when the controller is powered-up (see Profile Power Cycle Mode). If the profile
was previously stopped, when it is placed in to the Run/Start mode (2), the controller will be put into automatic control (if it was in manual) and start
the profile at the first segment. If the controller was in manual mode prior to starting the profile, the controller will start ramping from the current
process value. If the profile was "paused," it will resume operation. The advancement of the profile can be viewed in the Profile Phase (40066/40074)
and Profile Segment register (40067/40075).
10
Pause: Pause signifies that a profile is active but the time base (Profile Phase Timer) is paused. The pause mode can only be invoked by writing a
3 in the Profile Operating Status register. Pausing a profile during a ramp phase pauses the ramp and the controller maintains control at the
ramping setpoint value (40045/40053) at the instant of the pause action. The use of pause, effectively lengthens the total run time of a profile.
The unit will remain in pause mode until it is placed back in the run mode by writing a 2 (Run/Start) into the Profile Operating Status Register.
Error Delay (Guaranteed Soak): The Error Delay Setting is used only as a status indication. It indicates that a profile is active but the phase timer
or profile advancement has stopped. This is caused by automatic action of the controller when the process deviates more than a specified amount
from the active profile segment. The Error Delay is similar to pause, except the error delay status can only be invoked automatically. See "Profile
Error Band Mode (40322/40422)." Do not write a "4 - Error Delay," to the Profile Operating Status Register. Doing so will instead put the
controller in pause mode (3).
Profile Phase (40066/40074): When the profile is active, this register indicates whether the controller is in a ramp (0) or hold (1) phase.
Profile Segment (40067/40075): Indicates the current active segment while the profile is running. A zero indicates that the profile is stopped or off.
Profile Phase Timer (40068/40076): This register shows the remaining segment phase time in 10ths of minutes. The remaining phase time can be
changed "on the fly" to accelerate or decelerate the phase time. The change in phase time will only affect the running profile and not the stored
parameters. If the phase time is changed during the ramp phase, a new ramp rate will be calculated which will achieve the desired phase time. The
Profile Phase Timer will stop while the unit is paused or during an error delay caused by Profile Error Band operation (guaranteed soak).
Profile Cycle Count Remaining (40069/40077): Indicates the number of profile cycles that are yet to be run. If the Profile Cycle Count register
(40326/40426) is set to 250, the Profile Cycle Count Remaining Register will run continuously, resetting to "250" when reaching "0". This register
value can be changed, however, it will only affect the current run cycle. When the profile is stopped and re-started, the Profile Cycle Count
Remaining Register will be reloaded based on the "Profile Cycle Count (40326/40426)" value.
Advance Profile Phase (40070/40078): Writing a "1" to this register while the profile is running will cause the controller to advance immediately to
the beginning of the next ramp or hold phase. Using the advance operation shortens the total run time of the profile. If the profile is "paused," the
profile will advance but the profile will remain paused. The Profile can also be advanced while in the error delay mode.
STEP 12 PROGRAMMING THE OUTPUTS
Cycle Time (40116/40216): The cycle time, entered in seconds, is the combined time of an on and off
cycle of a time proportioning control output OP1/OP2. With time proportional output, the percentage
of control power is converted into output on time of the cycle time value. (If the controller calculates
that 65% power is required and has a cycle time of 10 seconds, the output will be on for 6.5 seconds
and off for 3.5 seconds.) For best control, a cycle time equal to one-tenth of the process time constant,
or less, is recommended. When using the DC Analog output signal for control, a setting of zero will
keep output OP1 off. The status of OP1 can be read through registers 40014/40030.
Control Action (40117/40217): This determines the control action for the PID loop. Programmed for
direct action (cooling), the DLC output power will increase if the Process value is above the Setpoint
value. Programmed for reverse action (heating), the output power decreases when the Process Value is
above the Setpoint Value. For heat and cool applications, this is typically set to reverse. This allows
OP1 to be used for heating, and AL2/OP2 to be used for cooling.
Power Low Limit (40118/40218); High Limit (40119/40219): These parameters may be used to limit controller power due to process disturbances
or setpoint changes. Enter the safe output power limits for the process. If Alarm 2 is selected for cooling, the range is from -100 to +100%. At 0%,
both OP1 and OP2 are off; at 100%, OP1 is on; and at -100%, OP2 is on. When the controller is in Manual Control Mode, these limits do not apply.
Sensor Fail Power Preset (40120/40220): This parameter sets the power level for the control outputs in the event of a sensor failure or extreme
overdriven/underdriven input. If Alarm 2 is not selected for cooling, the range is from 0% (OP1 output full off) to 100% (OP1 output full on). If
AL2 is selected for cooling, the range is from -100 to +100%. At 0%, both OP1 and OP2 are off; at 100%, OP1 is on; and at -100%, OP2 is on. The
alarm outputs are upscale drive with an open sensor, and downscale drive with a shorted sensor (RTD only), independent of this setting. Manual
Control overrides the sensor fail preset.
Dampening Time (40121/40221): The dampening time, entered as a time constant in seconds, dampens (filters) the calculated output power.
Increasing the value increases the dampening effect. Generally, dampening times in the range of one-twentieth to one-fiftieth of the controller’s
integral time (or process time constant) is effective. Dampening times longer than these may cause controller instability due to the added lag effect.
On/Off Control Hysteresis (40122/40222): The controller can be placed in the On/Off Control Mode by setting the Proportional Band to 0.0%. The
On/Off Control Hysteresis (balanced around the setpoint) eliminates output chatter. In heat/cool applications, the control hysteresis value affects
both Output OP1 and Output OP2 control. It is suggested to set the hysteresis band to 2 (Factory Setting) prior to starting Auto-Tune. After AutoTune, the hysteresis band has no effect on PID Control. On/Off Control Hysteresis is illustrated in the the On/Off Control Mode section.
11
STEP 13 PROGRAMMING THE ALARMS
Alarm 1 and 2: The controller is equipped with two alarms for each channel. The status of these alarms
can be read through AL1 registers 40015/40031 and AL2 registers 40016/40032.
Action (40131/40231), (40136/40236): Select the action for the alarms. See Alarm Action Figures for a
visual explanation.
Manual: In Manual mode, the alarms are forced on and off by writing ‘0’ or ‘1’ to the appropriate
alarm output register. In this mode, the alarms will not respond to Alarm and Hysteresis Values.
Absolute HI (balanced or unbalanced hysteresis): The alarm energizes when the Process Value exceeds
the alarm.
Absolute LO (balanced or unbalanced hysteresis): The alarm energizes when the Process Value falls
below the alarm.
Deviation HI, Deviation LO, Band Acting: In these actions, Alarm 1 and 2 value tracks the Setpoint
value.
Cooling (OP2): For heat/cool applications, select Cool for Alarm 2. The controller then utilizes the
Alarm 2 output as the Cooling Output (OP2). If cooling is selected, the remaining Alarm 2
parameters are not available.
ALARM ACTION FIGURES
Note: Hys in the above figures refers to the Alarm Hysteresis.
Value (40003/40019), (40004/40020): The alarm values are entered as process units or degrees.
Hysteresis (40134/40234), (40139/40239): The Hysteresis Value is either added to or subtracted from the alarm value, depending on the alarm action selected.
See the Alarm Action Figures for a visual explanation of how alarm actions are affected by the hysteresis.
Trigger Points: Trigger points are the Process Values where the alarm state changes. Their values cannot be entered directly, but are shown as a reference in the
SFDLC software. The alarm value, hysteresis value, and setpoint alarm type determine the trigger points. With Deviation or Band actions, the alarm value and
setpoint value are combined to determine the trigger points. Trigger points must not be greater than +32000 or less than -32000. If these limits are exceeded,
the alarm may not function properly.
Reset (40132/40232), (40137/40237): The alarms can be programmed for Automatic or Latched. In Automatic mode, an energized alarm turns off automatically
once the Process Value leaves the alarm region. In Latched mode, an energized alarm requires a manual reset. This is done by writing ‘0’ to the appropriate
output status register. After writing ‘0’, the Automatic or Latched alarm will not turn on again until after the Process Value first returns to the alarm off region.
Only alarms configured for Manual action can be energized by writing a ‘1’ to its’ alarm output status register.
On Delay (40135/40235), (40140/40240): The time, in seconds, required for the Process Value to be in the alarm region before the alarm will activate. It is used
to allow temporary or short excursions into the alarm region without tripping the alarm.
Enable Standby Delay (40133/40233), (40138/40238): Standby prevents nuisance (typically low level) alarms after a power up or setpoint change. After
powering up the controller or changing the setpoint, the process must leave the alarm region. Once this has occurred, the standby is disabled and the alarm
responds normally until the next controller power up or setpoint change.
12
STEP 14 PROGRAMMING THE COOLING
To enable Cooling in Heat/Cool applications, the Alarm 2 Action must first be set for Cooling. When
set to cooling, the output no longer operates as an alarm but operates as an independent cooling output.
The OP2 terminals are the same as AL2. Cooling output power ranges from -100% (full cooling) to 0%
(no cooling, unless a heat/cool deadband overlap is used). The Power Limits in the Output category also
limits the cooling power.
Cycle Time (40141/40241): This cycle time functions like the OP1 Output Cycle Time but allows
independent cycle time for cooling. A setting of zero will keep output OP2 off. The status of OP2 can
be read through registers (40016/40032).
Relative Gain (40142/40242): This defines the gain of the cooling relative to the heating. It is generally
set to balance the effects of cooling to that of heating. This is illustrated in the Heat/Cool Relative Gain
Figures. A value of 0.0 places the cooling output into On/Off Control. This may be done independent
of the OP1 Output PID or On/Off Control Modes.
Deadband (40143/40243): This defines the area in which both heating and cooling are active (negative
value) or the deadband area between the bands (positive value). If a heat/cool overlap is specified, the
percent output power is the sum of the heat power (OP1) and the cool power (OP2). If Relative Gain
is zero, the cooling output operates in the On/Off Control Mode, with the Deadband value becoming
the cooling output hysteresis (positive value only). This is illustrated in the On/Off Control Mode
section. For most applications, set this parameter to 0.0 prior to starting Auto-Tune. After the
completion of Auto-Tune, this parameter may be changed.
HEAT/COOL RELATIVE GAIN FIGURES
Heat/Cool Deadband = 0
Heat/Cool Deadband > 0
Heat/Cool Deadband < 0
13
STEP 15 PROGRAMMING THE ANALOG OUTPUT (Optional)
Note: The register numbers correspond to (Analog Output 1/Output 2).
Assignment (40301/40309): This setting selects the value that the Analog Output will retransmit, or track.
The Analog output can be assigned for the following:
SELECTION
DESCRIPTION
Output Power A
Transmits the Output Power demand of Channel A. Used if linear control is desired.
Process Value A
Retransmits Process Value Channel A
Setpoint A
Retransmits Setpoint Value Channel A
Ramping Setpoint A
Retransmits Ramping Setpoint Channel A
Deviation A
Retransmits Deviation (difference of Setpoint Value - Process Value) Channel A
Direct Entry Value 1
Retransmits Direct Entry Value 1 (Manual Analog Control)
Output Power B
Transmits the Output Power demand of Channel B. Used if linear control is desired.
Process Value B
Retransmits Process Value Channel B
Setpoint B
Retransmits Setpoint Value Channel B
Ramping Setpoint B
Retransmits Ramping Setpoint Channel B
Deviation B
Retransmits Deviation (difference of Setpoint Value - Process Value) Channel B
Direct Entry Value 2
Retransmits Direct Entry Value 2 (Manual Analog Control)
Mode (40302/40310): Select the type of output and range. The Analog output jumpers must be set to match the
output type and range selected. The Analog output can be calibrated to provide up to 5% of over range operation.
Output Scaling Values: The Scaling Low value (40303/40311) corresponds to 0 V, 0 mA or 4 mA, depending on
the range selected. The Scaling High value (40304/40312) corresponds to 10 V or 20 mA depending on the
range selected. An inverse acting output can be achieved by reversing the Scaling Low and Scaling High points.
Deadband (40305/40313): The output power change must be greater than the deadband value in order for the
Analog output to update. This only applies when the Analog Output is assigned to Output Power. This setting
can be used to reduce actuator activity.
Update Time (40306/40314): To reduce excess valve actuator or pen recorder activity, the update time of the
analog output can be set in seconds. A value of zero seconds results in an update time of 0.1 second.
Direct Entry Value (40307/40315): If the analog output is programmed for Direct Entry, it retransmits this value.
This value may be controlled by the host.
Filter (40308-40316): Entering a 1 will apply averaging when the Update Time >=1.
STEP 16 PROGRAMMING THE DLC COMMS PORT
Note: If the software selectable communication settings are changed and then a download is performed, the
controller will immediately respond to the new settings. Any further attempts to communicate to the controller
must target the new address, with the new settings.
MINIMUM TRANSMIT DELAY
SERIAL SETTINGS
BAUD
RTU
ASCII
MODBUS Protocol (40405): RTU or ASCII
Unit Address (40401): 1-247
38400
2 msec
2 msec
Baud Rate (40402): 300 to 38400
19200
3 msec
2 msec
Data Bits (40404): 7 or 8
9600
5 msec
2.3 msec
Parity (40403): odd, even, or none
4800
9 msec
4.6 msec
Transmit Delay (40406): Programmable from 2-250 milliseconds.
2400
17 msec
9.2 msec
The Transmit Delay is the time the DLC waits to respond to a serial
1200
33 msec
18.4 msec
command, UNLESS the values in the table are larger.
600
65 msec
36.7 msec
Note: Changing the above parameters by writing to their registers directly
300
129 msec
73.4 msec
will not update the DLC until Load Serial Settings register 40407 is a
‘1’. After a write, this register will return to ‘0’.
DIP Switch Serial Settings: The DIP switches can be used to select the baud rate, parity, and unit address. When
using the DIP switches to configure the serial settings, the Modbus communications mode will be RTU only. There
is also a "Default Serial Settings" switch to quickly configure the DLC for use with the "RLCPRO" Programming
Software.
Software Selectable Serial Settings: Setting all of the DIP switches to the "off" position and having the "Default
Serial Setting" terminal un-connected, enables Software Selectable Serial settings. When leaving the factory the
Software Selectable serial settings are set to the Serial Communication Defaults. Software Selectable Serial
Settings allows set-up of all serial settings including the choice of RTU or ACSII communications modes and the
number of data bits. If the Software Selectable Serial Settings are changed, the load serial register must be used
or power to the DLC must be removed and re-applied in order for the settings to take effect. The use of RLCPRO
Programming software or another software program supporting Modbus protocol is required to write to the DLC
serial settings registers (40401-40407).
14
Default Serial Settings: The DLC serial port can be temporarily set to the factory defaults by setting the Default serial communications DIP switch to
the “up” position OR by placing a jumper from the “Default Serial Setting” terminal 7 (TBB) to Output common terminal 4 (TBA). Both of these
have precedence over the DIP switch serial settings and the software selectable serial settings. Once the serial default DIP switch is set to the “off”
position or the jumper is removed, the DLC serial settings will immediately change as programmed by the DIP switches or the software selectable
serial settings if all of the DIP switches are in the “off” position. The Default Serial Settings are NOT loaded into the software selectable serial
registers when the serial default setting switch/terminal is active, they must be explicitly changed.
Serial Communication Defaults: 9600 baud, 1 start bit, no Parity, 1 stop bit, address 247, and RTU mode.
Communications Diagnostics: The Communications Diagnostics function (MODBUS Function Code 08) can be used to troubleshoot systems that are
experiencing communication errors. Press the Read button to retrieve the diagnostics information. The Commands Received and the Commands
Processed values are automatically reset when the values are read, at each controller power-up, and when the Commands Received reaches 65536.
Commands Received: The total number of messages received that started with the controller’s own address since the last reset or power up.
Commands Processed: The number of “good” messages received. A “good” message is considered one that contained the correct unit address,
parity, and checksum (CRC or LRC).
STEP 17 PC PORT CONFIGURATION
Go to the SETTINGS pull-down menu, and select PC PORT SETTINGS.
The Communications Settings window allows you to set up the software properly to perform a download.
Connection: Select the computer port (COMM 1-4) that the DLC is connected to.
Note: The following settings must match the DLC. If you do not know or cannot recall the DLC settings, they can
be temporarily set to factory defaults. Simply jumper the Default Serial Setting terminal 7 to Input Common
terminal 4 or put the Default Serial Settings DIP switch in the “UP” position. The serial settings will default
to RTU mode, 9600 baud, 8 data bits, no parity, with an address of 247.
Protocol: RTU or ASCII
Unit Address: 1-247
Baud Rate: 300, 600, 1200, 2400, 4800, 9600, 19200, 38400
Data Bits: 7 or 8
Parity: odd, even, or none
Connect the DLC to the computer with the CBPRO007 interface cable (or any suitable RS232/RS485 converter).
Apply power to the supply terminals of the DLC.
Note: The CBPRO007 download cable DOES NOT
typically require power. In most cases it will derive
its power from the PC. If communications can not be
established, follow the troubleshooting guide. If it is
determined that the converter requires power, attach
a 12 VDC power supply to the VDC and common
terminals of the cable.
STEP 18 DOWNLOADING
Go to the FILE pull-down menu, and select DOWNLOAD.
The following screen prompts you to
ensure that the proper file is downloaded
to the correct controller. Click “OK” to
continue.
15
STEP 19 SCRATCH PAD MEMORY
The Scratch Pad category can be used to read or write to the Scratch Pad memory locations (4110141116). The Scratch Pad locations can be used to store user information.
Data Format: Allows registers to be viewed in decimal or hexadecimal format.
Upload: The Upload button causes SFDLC software to read the Scratch Pad registers from the controller.
Download: The Download button causes SFDLC software to write to the Scratch Pad registers in the
controller.
Note: Downloading new values to the controller Scratch Pad locations overwrites the information that is
currently stored in those registers.
Defaults: For this category, there are no controller factory defaults. The defaults for this category are only
SFDLC software basic default values.
STEP 20 VIEW REGISTERS
The View Registers category can be used as a method of diagnostics. Use the DLC Register Table as a
reference of register assignments and data.
First Register: This specifies the first register to be read in a block.
# of Registers: This is the length of the block to be read. The controller supports block read and write
commands up to 32 registers in length. The SFDLC software only allows 16 to be read in a block.
Data Format: Allows registers to be viewed in decimal or hexadecimal format.
Read: Clicking the Read button causes SFDLC software to read the selected registers from the controller.
Write: Clicking the Write button causes SFDLC software to write the selected registers to the controller.
Note: The Write button overwrites the existing register values, and may change the module setup and
operation.
Defaults: For this category, there are no controller factory defaults. By clicking Defaults, the present
entries from the other SFDLC software category screens will be displayed.
STEP 21 CALIBRATION
The DLC is fully calibrated from the factory. Recalibration is recommended every two years. Each channel is calibrated separately. All calibration settings
are stored in the non-volatile memory. Calibration may be performed by using SFDLC software or MODBUS commands. When using SFDLC for calibration,
connect the signal or measuring source to the proper DLC terminals, verify the input or output jumper positions, select the type of calibration to be performed,
and click the Calibrate button. Follow the calibration procedures in the software.
Note: Allow the DLC to warm up for 30 minutes minimum and follow the manufacturer’s warm-up recommendations for the calibration source.
INPUT CALIBRATION
When calibrating the input, the millivolt calibration must be performed first. All other input types use the
millivolt points. Each input range (non-thermocouple) also has its own internal references that are recalled
when the range is selected. Non-used types need not be calibrated.
Calibration Type: This specifies the type of calibration to be performed.
Millivolt: Millivolt calibration requires a precision voltage source with an accuracy of 0.03% or better.
It is used for thermocouple inputs and as a basis for all other input calibration types.
RTD: RTD calibration requires a 0.1% (or better) precision 277.0 ohm resistor.
Process Voltage: Process calibration requires a precision signal source with an accuracy of 0.03% (or
better) that is capable of generating 10.00 V.
Process Current: Process current calibration requires a precision signal source with an accuracy of
0.03% (or better) that is capable of generating 20.00 mA.
Cold Junction: Cold Junction calibration requires a thermocouple of known accuracy of types T, E, J, K, C or N only and a calibrated external reference
thermocouple probe.
TC Type: This selects the type of TC that is being used to calibrate the cold junction.
Scale: This selects the scale in which the Thermometer temperature is entered and the controller temperature is displayed.
Thermometer: Enter the reference thermometer temperature here.
DLC: This displays the DLC process temperature value after a cold junction calibration is completed to verify the accuracy.
Calibrate: The Calibrate button initiates the calibration process after the appropriate settings are selected.
16
ANALOG OUTPUT CALIBRATION
Calibration Type: This specifies the Analog Output point to be calibrated.
Volts: Analog Output Voltage calibration requires a precision meter with an accuracy of 0.05% (or better)
that is capable of measuring 10.00 V.
mA: Analog Output Current calibration requires a precision meter with an accuracy of 0.05% (or better)
that is capable of measuring 20.00 mA.
Meter Value: After pressing the Calibrate button, this shows the value the DLC is outputting. Measure the
actual output with an external meter and enter that value here. Press the Calibrate button again and follow
the prompts.
Calibrate: The Calibrate button initiates the calibration process after the appropriate settings are selected.
APPLICATION
A plastic extrusion company was building a four-zone extruder, and wanted a centrally located,
multi-zone interface. The interface needed to display the temperature and setpoint values, as well as the
screw RPM and barrel pressure. The customer provided a speed proportional 0-10 Volt signal from a
motor drive, and installed a 4-20 mA output pressure sensor in the extruder barrel. Each of the four
heat/cool zones were equipped with a thermocouple.
Three DLC-Dual Loop Controllers, with a Paradigm HMI, allowed the customer to build his own
control system. Only three DLCs were required; two were needed to control the four temperature zones,
and one was needed to monitor the two process signals.
All three units were
connected to the RS485 port
of the Paradigm display. The
customer created his own
displays on the HMI, which
allowed him to monitor and
control the setpoints and
alarms within the DLCs. The
Paradigm’s multi-protocol
capability allowed it to tie the
DLCs to his PLC, creating a
true centralized interface.
CONTROL MODE EXPLANATIONS
MANUAL CONTROL MODE
MODE TRANSFER
In Manual Control Mode, the controller operates as an open loop system
(does not use the setpoint and process feedback). The user enters a percentage
of power through the Output Power register (40005/40021) to control the heat
(reverse) or cool (direct) for Output OP1. When Alarm 2 is configured for
Cooling (OP2), Manual operation provides 0 to 100% power to OP1 (heating)
and -100 to 0% power to OP2 (Cooling). The Low and High Power limits are
ignored when the controller is in Manual.
For time proportional outputs, the output power is converted into output On
time using the Cycle Time. For example, with a four second cycle time and 75%
power, the output will be on (4 × 0.75) for three seconds and off for one second.
For Analog Outputs (0-10 VDC or 0/4-20 mA), the percent output power is
converted into a linear value according to the Percent Low and High scaling set
for the analog output. For example, with 0 VDC (scaled 0.0%) to 10 VDC
(scaled 100%) and 75% power, the analog output will be 7.5 VDC.
When transferring the controller mode from or to Automatic, the controlling
outputs remain constant, exercising true bumpless transfer. When transferring
from Manual to Automatic, the power initially remains steady, but Integral
Action corrects (if necessary) the closed loop power demand at a rate
proportional to the Integral Time. The Control Mode can be changed through
the Control Mode register (40041/40049).
AUTOMATIC CONTROL MODE
In Automatic Control Mode, the percentage of output power is automatically
determined by PID or On/Off calculations based on the setpoint and process
feedback. For this reason, PID Control and On/Off Control always imply
Automatic Control Mode.
17
ON/OFF CONTROL - HEAT/COOL OUTPUT FIGURES
ON/OFF CONTROL
The controller operates in On/Off Control when the Proportional Band is set
to 0.0%. In this control, the process will constantly oscillate around the setpoint
value. The On/Off Control Hysteresis (balanced around the setpoint) can be
used to eliminate output chatter. Output OP1 Control Action can be set to
reverse for heating (output on when below the setpoint) or direct for cooling
(output on when above the setpoint) applications.
ON/OFF CONTROL - REVERSE OR DIRECT ACTING FIGURES
For heat and cool systems, OP1 Control Action is set to reverse (heat) and the
Alarm 2 Action is set to cooling (OP2). The Proportional Band is set to 0.0 and
the Relative Gain in Cooling to 0.0. The Deadband in Cooling sets the amount
of operational deadband or overlap between the outputs. The setpoint and the
On/Off Control Hysteresis applies to both OP1 and OP2 outputs. The hysteresis
is balanced in relationship to the setpoint and deadband value.
Note: HYS in the On/Off Control Figures refers to the On/Off Control Hysteresis.
TYPICAL PID RESPONSE CURVE
PID CONTROL
In PID Control, the controller processes the input and then calculates a
control output power value by use of a modified Proportional Band, Integral
Time, and Derivative Time control algorithm. The system is controlled with the
new output power value to keep the process at the setpoint. The Control Action
for PID Control can be set to reverse for heating (output on when below the
setpoint) or direct for cooling (output on when above the setpoint) applications.
For heat and cool systems, the heat (OP1) and cool (OP2) outputs can be used
together in the PID Control. The PID parameters can be Auto-Tune or Manual
Tune to the process.
REMOTE SETPOINT
Channel B can operate as a Remote Setpoint Input to Channel A. Channel B
PID control is not functional when the input is assigned as a Remote Setpoint.
This mode of operation enables Cascade control (external), Ratio control, and
Temperature Setpoint Slave control, among others.
The Remote Setpoint value used internally by the controller is:
Remote Setpoint = (Scaled CHB Input * Remote Setpoint Ratio Multiplier)
+ Remote Setpoint Bias Offset
where Ratio Multiplier
= 0.0001 to 3.2000
Bias Offset
= -32000 to 32000
The Ratio Multiplier and Bias Offset parameters offer on-line scaling of the
Remote Setpoint to adjust control ratios or biases among related processes.
The Remote Setpoint is restricted to the setpoint low and high limit values for
channel B. These parameters may be used to limit the range of the Remote
Setpoint to a safe or more stable control range. For Remote Setpoint signal
sources that change wildly or are too sensitive to process upsets, the CHA
Setpoint Ramp Rate parameter (40110) can be used to ramp (rate limit) the
Remote Setpoint reading. This can subsequently reduce the fluctuations of the
secondary control loop.
18
PID TUNING EXPLANATIONS
AUTO-TUNE
AUTO-TUNE CODE FIGURE
Auto-Tune is a user-initiated function where the controller automatically determines the
Proportional Band, Integral Time, Derivative Time, Digital Filter, Control Ouput Dampening
Time, and Relative Gain (Heat/Cool) values based upon the process characteristics. The
Auto-Tune operation cycles the controlling output(s) at a control point three-quarters of the
distance between the present process value and the setpoint. The nature of these oscillations
determines the settings for the controller’s parameters.
Prior to initiating Auto-Tune, it is important that the controller and system be first tested.
(This can be accomplished in On/Off Control or Manual Control Mode.) If there is a wiring,
system or controller problem, Auto-Tune may give incorrect tuning or may never finish.
Auto-Tune may be initiated at start-up, from setpoint or at any other process point. However,
insure normal process conditions (example: minimize unusual external load disturbances) as
they will have an effect on the PID calculations. Auto-Tune cannot be initiated while running
a profile.
Start Auto-Tune
1. Enter the On/Off Control Hysteresis value.
(For most applications, 10 is a suggested value.)
2. Enter the Deadband value, if using OP2.
(For most applications, 0 is a suggested value.)
3. Enter the Setpoint value.
(If Auto-Tune overshoot is unacceptable, then lower the value and restart.)
4. Enter the Auto-Tune Code. (See Figure for details)
5. Enter ‘1’ in the Auto-Tune Start register . (Channel A 40011/Channel B 40027).
6. The Auto-Tune LED will come on.
Auto-Tune Progress
The controller will oscillate the controlling output(s) for four cycles. The cycling
phase can be monitored from the Auto-Tune Phase Register (Channel A
40012/Channel B 40028). The time to complete the Auto-Tune cycles is process
dependent. The controller should automatically stop Auto-Tune and store the
calculated values when the four cycles are complete. If the controller remains in AutoTune unusually long, there may be a process problem. Auto-Tune may be stopped by
entering ‘0’ in Auto-Tune Start Register (Channel A 40011/Channel B 40027).
PID Adjustments
starting value and allow the process sufficient time to stabilize before evaluating
the effects of the new parameter settings.
In some unusual cases, the Auto-Tune function may not yield acceptable
control results or induced oscillations may cause system problems. In these
applications, Manual Tuning is an alternative.
In some applications, it may be necessary to fine tune the Auto-Tune
calculated PID parameters. To do this, a chart recorder or data logging device is
needed 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
PROCESS RESPONSE EXTREMES
19
MANUAL TUNING
Output Power (40005/40021) to drive the process value to the Setpoint value.
Allow the process to stabilize after setting the Output Power.
6. Place the controller in Automatic Control Mode (40041/40049). If the
process will not stabilize and starts to oscillate, set the Proportional Band two
times higher and go back to Step 5.
7. If the process is stable, decrease Proportional Band setting by two times 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 three times the setting that caused the oscillation
in Step 7.
9. Set the Integral Time to two times the period of the oscillation.
10. Set the Derivative Time to one-eighth (0.125) of the Integral Time.
11. Set the Output Dampening Time to one-fortieth (0.025) the period of the
oscillation.
A chart recorder or data logging device is necessary to measure the time
between process cycles. This procedure is an alternative to the controller’s
Auto-Tune function. It will not provide acceptable results if system problems
exist. This procedure should be performed by directly accessing the controller’s
registers. The register numbers correspond to (Channel A/Channel B).
1. Set the Proportional Band (40007/40023) to 10.0% for temperature inputs
and 100.0% for process inputs.
2. Set both the Integral Time (40008/40024) and Derivative Time
(40009/40025) to 0 seconds.
3. Set the Output Dampening Time (40121/40221) to 0 seconds.
4. Set the Output Cycle Time (40116/40216) to no higher than one-tenth of the
process time constant (when applicable).
5. Place the controller in Manual Control Mode (40041/40049) and adjust the
MODBUS INFORMATION
The remaining sections of this bulletin list information for MODBUS conformity with DLC registers and coils data.
MODBUS SUPPORTED FUNCTION CODES
FC01: Read Coils
FC16: Preset Multiple Registers
1. Valid coil addresses are 1-33.
2. All coils can be requested.
3. Block starting point can not exceed coil 33.
1. Valid write (preset) register addresses are are 40002-40005, 40007-40011,
40013, 40015-40016, 40018-40021, 40023-40027, 40029, 40031-40032,
40041-40042, 40044, 40046, 40049-40050, 40052-40053, 40065, 4006840070, 40073, 40076-40078, 40100-40122, 40131-40143, 40198-40222,
40231-40243, 40301-40316, 40321-40327, 40401-40407, 40421-40427,
40501-40505, 40601-40660, 40701-40760, 41101-41116.
2. No response is given with an attempt to write to more than 32 registers at a
time.
3. Block starting point can not exceed the read and write boundaries.
4. If a multiple write includes read only registers, then only the write registers
will change.
5. If the write value exceeds the register limit (see Register Table), then that
register value changes to its high or low limit.
FC05: Force Single Coil
1. Valid write (force) coil addresses are 1-4, 10-13, 15-16, 22-25, 27-33.
2. HEX <8001> is echoed back for a request to write to a read only coil, to
indicate that the coil did not change.
FC15: Force Multiple Coils
1. Valid write (force) coil addresses are 1-4, 10-13, 15-16, 22-25, 27-33.
2. Block starting point can not exceed coil 33.
3. If a multiple write includes read only coils, then only the write coils will
change.
FC04: Read Input Registers
1. Valid register addresses are 30001-30032, 30041-30046,
30065-30070, 30073-30078, 30100-30122, 30131-30143,
30231-30243, 30301-30308, 30309-30316, 30321-30327,
30421-30427, 30501-30505, 30601-30660, 30701-30760,
31101-31116.
2. Up to 32 registers can be requested at one time.
3. Block starting point can not exceed register boundaries.
4. HEX <8000> is returned in registers beyond the boundaries.
5. Input registers are a mirror of Holding registers.
FC03: Read Holding Registers
1. Valid register addresses are 40001-40032, 40041-40046,
40065-40070, 40073-40078, 40100-40122, 40131-40143,
40231-40243, 40301-40308, 40309-40316, 40321-40327,
40421-40427, 40501-40505, 40601-40660, 40701-40760,
41101-41116.
2. Up to 32 registers can be requested at one time.
3. Block starting point can not exceed the register boundaries.
4. HEX <8000> is returned in registers beyond the boundaries.
5. Holding registers are a mirror of Input registers.
40049-40053,
40198-40222,
40401-40407,
41001-41010,
30049-30053,
30198-30222,
30401-30407,
31001-31010,
FC08: Diagnostics
The following is sent upon FC08 request:
Module Address, 08 (FC code), 04 (byte count), “Total Comms” count,
“Total Good Comms” count, checksum of the string
“Total Comms” is the total number of messages received that were addressed to
the DLC. “Total Good Comms” is the total messages received by the DLC
with good address, parity and checksum. Both counters are reset to 0 upon
response to FC08, on power-up, and when Total Comms register rolls over.
FC06: Preset Single Register
1. Valid write (preset) register addresses are 40002-40005, 40007-40011, 40013,
40015-40016, 40018-40021, 40023-40027, 40029, 40031-40032, 4004140042, 40044, 40046, 40049-40050, 40052-40053, 40065, 40068-40070,
40073, 40076-40078, 40100-40122, 40131-40143, 40198-40222, 4023140243, 40301-40316, 40321-40327, 40401-40407, 40421-40427, 4050140505, 40601-40660, 40701-40760, 41101-41116.
2. HEX <8001> is echoed back that the register did not change during the
request to write to a read only register.
3. If the write value exceeds the register limit (see Register Table), then that
register value changes to its high or low limit. It is also returned in the
response.
FC17: Report Slave ID
The following is sent upon FC17 request:
Unit Address, 17 (FC code), RLC-DLCxx000 (model number), 0200 (for code
version 2.00), 32 (number of read supported registers), 32 (number of writes
supported registers), 16 (number of registers available for GUID/Scratch pad
memory), checksum of the string.
20
SUPPORTED EXCEPTION CODES
01: Illegal Function
7. Repeat steps 5 and 6 for each range to be calibrated for that channel.
8. To save the calibration results and end calibration, enter 0 into register
40501.
Issued whenever the requested function is not implemented in the controller.
02: Illegal Data Address
Cold Junction Calibration *
Issued whenever an attempt is made to access a single register or coil that
does not exist (outside the implemented space) or to access a block of registers
or coils that falls completely outside the implemented space.
Cold Junction calibration requires a thermocouple of known accuracy of
types T, E, J, K, C or N only and a calibrated external reference thermocouple
probe.
1. Connect the thermocouple probe source to the proper DLC terminals.
2. Enter the connected thermocouple type into register 40101 (Ch A) or 40201
(Ch B).
3. Enter the scale (F or C) that matches the thermometer and the controller
temperature, preferrably °C into register 40102 (Ch A) or 40202 (Ch B).
4. Enter 1 for high resolution into register 40103 (Ch A) or 40203 (Ch B).
5. Place an external reference thermometer probe at the end of the DLC probe.
The two probes should be shielded from air movement and allowed sufficient
time to equalize in temperature. (As an alternative, the DLC probe may be
placed in a calibration bath of known temperature.)
6. To open calibration mode, enter 48 into register 40501.
7. To start CJ calibration, enter 10 (Ch A) or 110 (Ch B) into register 40501.
8. Read the Process Value register 40001 (Ch A) or 40017 (Ch B).
9. Subtract the external reference reading from the Process Value register
reading. Adjust the results to tenths position, drop decimal point, and
maintain the results sign. (If the difference is -2 degrees, then adjust to -2.0
and remove decimal point yielding a value of -20.)
10. Add the value from step 9 (maintain the sign) to the value existing in register
40502.
11. If necessary, continue to adjust the register 40502 value until the Process
Value register 40001 (Ch A) or 40017 (Ch B) matches the external reference
reading.
12. To exit CJ calibration, enter 11 (Ch A) or 111 (Ch B) into register 40501.
13. To save the calibration results and close calibration mode, enter 0 into
register 40501.
03: Illegal Data Value
Issued when an attempt is made to read or write more registers or coils than
the controller can handle in one request.
07: Negative Acknowledge
Issued when a write to coil or register is attempted with an invalid string
length.
CHECKSUM ERRORS
1. Calibration checksum covers the area that contains calibration values for all
ranges. When a calibration checksum error occurs, coil 1 becomes a “1”.
2. Parameter checksum covers the area that contains the stored Holding register
settings. When this checksum error occurs, coil 2 becomes a “1”.
3. Integral and Offset/Manual Power checksum covers the area that contains the
stored Integral register settings. When this checksum error occurs, coil 3
becomes a “1”.
4. Setpoint Controller Segment Memory checksum covers the memory area that
contains the profile segments for channel A and B. When this checksum
error occurs, coil 29 becomes a "1".
5. Setpoint Controller Status Memory checksum covers the memory area that
contains the profile operating status. When this checksum error occurs, coil
30 becomes a "1" and aborts the profile putting channel in manual control at
0% power.
6. All LEDs except PWR/COMMS will flash as long as one of the errors exist.
7. The control and alarm outputs are disabled as long as one of the errors exist.
8. These errors can be cleared or activated manually by writing to the
appropriate coil. (This does not correct the reason for the error. It may be
necessary to reconfigure or calibrate.)
9. The checksums are verified at power up.
RTD Calibration *
Note: Allow the DLC to warm up for 30 minutes minimum and follow the
manufacturer’s warm-up recommendations for the calibration or measuring
source.
RTD calibration requires a 0.1% (or better) precision 277.0 ohm resistor.
1. Connect a precision 277.0 ohm resistor, and a short, to terminals 1 & 2 (Ch
B) or 4 & 5 (Ch A). During the complete procedure, short terminals 2 & 3
(Ch B) or 5 & 6 (Ch A).
2. Verify the input jumper is in the RTD position.
3. Enter 12 (ohms mode) into register 40101 (Ch A) or 40201 (Ch B).
4. To open calibration mode, enter 48 into register 40501.
5. To start RTD calibration, enter 20 (Ch A) or 120 (Ch B) into register 40501.
6. Leave 0 ohms (short) on terminals 1 & 2 (Ch B) or 4 & 5 (Ch A) for 10
seconds.
7. To store 0 ohm results, enter 21 (Ch A) or 121 (Ch B) into register 40501.
8. Apply 277 ohms by removing the short from terminal 1 & 2 (Ch B) or 4 & 5
(Ch A) for 10 seconds.
9. To store 277 ohm results, enter 22 (Ch A) or 122 (Ch B) into register 40501.
10. To save the calibration results and close calibration mode, enter 0 into
register 40501.
mV Calibration
Process Voltage Calibration *
CALIBRATION USING MODBUS COMMANDS
The DLC is fully calibrated from the factory. Recalibration is recommended
every two years. Each channel is calibrated separately. All calibration settings
are stored in the non-volatile memory. The DLC may be calibrated using
MODBUS. However, the preferred method of calibrating the controller is
through the SFDLC software.
When calibrating the input, a successful millivolt calibration must be
performed first. All other input types use the millivolt points. Each input range
(non-thermocouple) also has its own internal references that are recalled when
the range is selected. Non-used types need not be calibrated.
Each of the procedures below show the calibration steps/register numbers for
both channels A & B, however, only one channel can be calibrated at a time.
Millivolt calibration requires a precision signal source with an accuracy of
0.03% (or better) that is capable of generating the range to be calibrated. It is
used for thermocouple inputs and as a basis for all other input calibration types.
1. Connect the signal source to the proper DLC terminals.
2. Enter 13 (for mV input) into register 40101 (Ch A) or 40201 (Ch B).
3. To open calibration mode, enter 48 into register 40501.
4. To start mV calibration, enter 1 (Ch A) or 101 (Ch B) into register 40501.
5. Apply the appropriate calibration voltage for a minimum of 10 seconds.
6. To store the mV calibration reading, enter the corresponding range number
into register 40501:
RANGE
Ch A
Ch B
0 mV
14 mV
28 mV
42 mV
56 mV
2
3
4
5
6
102
103
104
105
106
Process calibration requires a precision signal source with an accuracy of
0.03% (or better) that is capable of generating 10.00 V.
1. Connect the signal source to the proper DLC terminals.
2. Verify the input jumper is in the 10 V position.
3. Enter 14 (for voltage input) into register 40101 (Ch A) or 40201 (Ch B).
4. To open calibration mode, enter 48 into register 40501.
5. To start voltage calibration, enter 12 (Ch A) or 112 (Ch B) into register 40501.
6. Apply 0.00 V for a minimum of 10 seconds.
7. To store 0.00 V reading, enter 13 (Ch A) or 113 (Ch B) into register 40501.
8. Apply 10.00 V for a minimum of 10 seconds.
9. To store 10.00 V reading, enter 14 (Ch A) or 114 (Ch B) into register 40501.
10. To save the calibration results and close calibration mode, enter 0 into
register 40501.
* - Dependent on successful mV calibration.
21
Process Current Calibration *
Process current calibration requires a precision signal source with an
accuracy of 0.03% (or better) that is capable of generating 20.00 mA.
1. Connect the signal source to the proper DLC terminals.
2. Verify the input jumper is in the 20 mA position.
3. Enter 15 (for current input) into register 40101 (Ch A) or 40201 (Ch B).
4. To open calibration mode, enter 48 into register 40501.
5. To start current calibration, enter 15 (Ch A) or 115 (Ch B) into register 40501.
6. Apply 0.00 mA for a minimum of 10 seconds.
7. To store 0.00 mA reading, enter 16 (Ch A) or 116 (Ch B) into register 40501.
8. Apply 20.00 mA for a minimum of 10 seconds.
9. To store 20.00 mA reading, enter 17 (Ch A) or 117 (Ch B) into register 40501.
10. To save the calibration results and close calibration mode, enter 0 into
register 40501.
5. Adjust register 40502 value until the external meter displays 0.00 mA.
6. To start 20 mA calibration, enter 33 (Out 1) or 133 (Out 2) into register 40501.
7. Adjust register 40502 value until the external meter displays 20.00 mA.
8. To save the calibration results and close calibration mode, enter 0 into register
40501.
Restore Factory Settings
The Factory Settings are listed in the DLC Register Table. This restore does
not affect the calibration or communication settings of the DLC but may change
all other settings for the channel.
1. To open calibration mode, enter 48 into register 40501.
2. To restore Factory Settings, enter 66 (Input Ch A and Analog Out 1) or 166
(Input Ch B and Analog Out 2) into register 40501.
3. To save the restore results and close calibration mode, enter 0 into register
40501.
Analog Output Voltage Calibration
Analog Output Voltage calibration requires a precision meter with an
accuracy of 0.05% (or better) that is capable of measuring 10.00 V.
Clear Setpoint Controller Segment Memory
1. To open calibration mode, enter 48 into register 40501.
2. To clear Setpoint Controller Segment memory, enter 67 (CHA Segment
memory) or 167 (CHB Segment Memory) into register 40501.
3. To save the Clear results and close calibration mode, enter 0 into register
40501.
1. Connect the meter to the proper DLC terminals.
2. Verify the output jumpers are in the V positions.
3. To open calibration mode, enter 48 into register 40501.
4. To start 0 volt calibration, enter 30 (Out 1) or 130 (Out 2) into register 40501.
5. Adjust register 40502 value until the external meter displays 0.00 V.
6. To start 10 volt calibration, enter 31 (Out 1) or 131 (Out 2) into register 40501.
7. Adjust register 40502 value until the external meter displays 10.00 V.
8. To save the calibration results and close calibration mode, enter 0 into register
40501.
Nominal Calibration Settings
Nominal Calibration Settings does not require any calibration signals nor
meters. This calibration should not be performed under normal circumstances.
Caution: This procedure results in up to ±10% reading error and the DLC will
no longer be within factory specifications.
Analog Output Current Calibration
1. To open calibration mode, enter 48 into register 40501.
2. To enter Nominal Calibration Settings, enter 77 (Input Ch A and Analog Out
1) or 177 (Input Ch B and Analog Out 2) into register 40501.
3. To save the Nominal Calibration Settings and close calibration mode, enter 0
into register 40501.
Analog Output Current calibration requires a precision meter with an
accuracy of 0.05% (or better) that is capable of measuring 20.00 mA.
1. Connect the meter to the proper DLC terminals
2. Verify the output jumpers are in the I position.
3. To open calibration mode, enter 48 into register 40501.
4. To start 0 mA calibration, enter 32 (Out 1) or 132 (Out 2) into register 40501.
* - Dependent on successful mV calibration.
22
DLC REGISTER TABLE
The below limits are shown as Integers or HEX < > values. Read and write functions can be performed in either Integers or Hex as long as the conversion was done
correctly. Negative numbers are represented by two’s complement.
Note 1: The DLC should not be powered down while parameters are being changed. Doing so may corrupt the non-volatile memory resulting in checksum errors.
REGISTER
ADDRESS 1
REGISTER NAME
LOW LIMIT
2
HIGH LIMIT
2
FACTORY
SETTING 3
ACCESS
COMMENTS
CH A
CH B
CONTROLLING VALUES
40001
40017
Process Value
N/A
N/A
N/A
Read Only
Process value of present input level. This value is
affected by Input Type, Resolution, & Scaling.
40002
40018
Setpoint Value
-32000
32000
0
Read/Write
Limited by Setpoint Limit Low and Setpoint Limit High.
40003
40019
Alarm 1 Value
-32000
32000
0
Read/Write
40004
40020
Alarm 2 Value
-32000
32000
0
Read/Write
0 or -1000
1000
0
Read/Write
1 = 0.1%, 0.0 = Off; Limited by Power Low Limit and
Power High Limit in Automatic Control Mode. Negative
percent is cooling (direct) available when AL2 is
Cooling. Write only possible during Manual mode.
N/A
Read Only
Deviation = Process Value - Setpoint Value; During
Auto-Tune: Process Value - Auto-Tune Setpoint Value
PID PARAMETERS
40005
40021
Output Power
40006
40022
Setpoint Deviation
N/A
N/A
40007
40023
Proportional Band
0
9999
40
Read/Write
0 = On/Off Control, 1 = 0.1%
40008
40024
Integral Time
0
9999
120
Read/Write
0 = Off, 1= 1 second
40009
40025
Derivative Time
0
9999
30
Read/Write
0 = Off, 1= 1 second
40010
40026
Offset Power
-1000
1000
0
Read/Write
1 = 0.1%; Applied when Integral Time is 0.
40011
40027
Auto-Tune Start
0
1
0
Read/Write
0 = Stop, 1 = Start; Mirror of Coil 16/28.
40012
40028
Auto-Tune Phase
N/A
N/A
N/A
Read Only
0 = Off, 4 = Last phase during Auto-Tune
40013
40029
Auto-Tune Code
0
2
0
Read/Write
0 = Fastest response, 2 = Slowest response
N/A
N/A
N/A
Read Only
0 = Off, 1 = On; Mirror of Coil 9/21.
OUTPUT STATUS
40014
40030
Control Output OP1
40015
40031
Alarm Output AL1
0
1
0
Read/Write
40016
40032
Alarm Output AL2 / OP2
0
1
0
Read/Write
0 = Off, 1 = On; A write of 1 is only possible when alarm
is set for Manual. Mirror of Coil 10/22.
0 = Off, 1 = On; A write of 1 is only possible when alarm
is set for Manual. Mirror of Coil 11/23.
CONTROL STATUS
40041
40049
Control Mode
0
1
0
Read/Write
0 = Automatic, 1 = Manual; Mirror of Coil 12/24.
40042
40050
Disable Setpoint Ramping
0
1
0
Read/Write
0 = Enabled, 1 = Disabled; Mirror of Coil 13/25.
40043
40051
Setpoint Ramping In Process
N/A
N/A
N/A
Read Only
0 = No, 1 = Yes; Mirror of Coil 14/26.
40044
40052
Disable Integral Action
0
1
0
Read/Write
40045
40053
Ramping Setpoint Value
N/A
N/A
N/A
Read/Write
0
1
0
Read/Write
0 = Enabled, 1 = Disabled; Mirror of Coil 15/27
Actual Setpoint Value used for control (ramps when
ramping enabled.) Limited by Setpoint Limit Low and
Setpoint Limit High.
0 = Local Setpoint, 1= Remote Setpoint
40046
Remote / Local Setpoint Select
PROFILE OPERATION
40065
40073
Profile Operating Status
40066
40074
40067
40075
40068
40076
40069
40070
SETPOINT CONTROLLER MODEL ONLY
Read/Write
(0-3 only)
0 = Off; 1 = Abort; 2 = Run/Start, 3 = Pause, 4 = Error
Delay (status only - writing a “4” will revert unit to mode
“3” Pause)
0 = Ramp; 1 = Hold
0
3
0
Profile Phase
N/A
N/A
N/A
Read Only
Profile Segment
N/A
N/A
N/A
Read Only
Profile Phase Time Remaining
1
9999
N/A
Read/Write
40077
Profile Cycle Count Remaining
1
250
0
Read/Write
40078
Advance Profile Phase
0
1
0
Read/Write
1 = Advances “running” Profile to next ramp or hold
phase
(0 = Stop, 1-20 = Current Segment)
1= 0.1 Minute; Can make temporary change on the fly
Value Over-range = 32003 (may occur on extremely
slow ramp; Ramp will function properly)
0-250; If Cycle Count (40326/40426) is 250 (Continuous
operation), value will reset to 250 at 0.
INPUT PARAMETERS
1
2
3
40198
Ch B Assignment
0
1
0
Read/Write
0 = PID, 1 = Remote Setpoint
40199
Local / Remote Setpoint
Transfer Mode
0
2
0
Read/Write
0 = Normal (Output may bump)
1 = Auto (Output may bump)
2 = Track (Local Setpoint assumes value of Remote SP
for Remote to Local Transfer)
40101
40201
Input Type
0
15
2
Read/Write
See Input Listing
40102
40202
Temperature Scale
0
1
0
Read/Write
40103
40203
Resolution
0
1
0
Read/Write
40104
40204
Rounding
1
100
1
Read/Write
0 = °F, 1 = °C, For Input Types 0-11.
Input Types 0-12 0=Low (x1) whole input units, 1 = High
(x10) tenth of input units, Input Type 13 0 = 0.1 mV, 1 =
0.01 mV, Input Types 14-15, N/A
Greater than 1 causes rounding starting at least
significant digit.
For Input Registers, replace the 4xxxx with a 3xxxx in the above register address. The 3xxxx are a mirror of the 4xxxx Holding Registers.
An attempt to exceed a limit will set the register to its high or low limit value.
See MODBUS Calibration for procedure on restoring Factory Settings.
23
DLC REGISTER TABLE Continued
REGISTER
ADDRESS 1
REGISTER NAME
LOW LIMIT
2
HIGH LIMIT
2
FACTORY
SETTING 3
ACCESS
COMMENTS
CH A
CH B
INPUT PARAMETERS
40105
40205
Digital Input Filter
0
4
1
40106
40206
Span Correction / Remote
Setpoint Ratio Multiplier
1
32000
10000
40107
40207
Offset Correction / Remote
Setpoint Bias Offset
-32000
32000
0
Read/Write
40108
40208
Low Limit
-32000
32000
0
Read/Write ChB value also applies to Remote Setpoint
40109
40209
High Limit
-32000
32000
32000
Read/Write ChB value also applies to Remote Setpoint
40110
40210
Ramp Rate
0
32000
0
Read/Write
40111
40211
Process Low
-32000
32000
0
Read/Write For Input Types 14-15
40112
40212
Process High
-32000
32000
1000
Read/Write For Input Types 14-15
40113
40213
Input Low
-32000
32000
4000
Read/Write 1 = 0.001 V or 0.001 mA, For Input Types 14-15.
40114
40214
Input High
-32000
32000
20000
Read/Write 1 = 0.001 V or 0.001 mA For Input Types 14-15.
40115
40215
Process Decimal Point
0
5
3
Read/Write
Read/Write 0 = Least, 4 = Highest
10000 = 1.0000 (applies no correction), 1 = 0.0001, For
Read/Write Input Types 0-11. Applies to all inputs (0-15) for ChB
when ChB is configured for Remote Setpoint (40198).
For Input Types 0-13/ Applies to all inputs (0-15) for ChB
when ChB is configured for Remote Setpoint (40198).
SETPOINT PARAMETERS
1 = 0.1° per minute for input types 0-11, 0.1 ohms for
input type 12, 0.01 mV for input type 13, 0.1 process units
for input types 14-15, 0 = off (ChB Ramp Rate is Nonfunctional in remote setpoint mode)
SCALING POINTS PARAMETERS
Can be used by host to determine resolution of input. For
Input Types 14-15.
CH A
CH B
CONTROL (OP1) PARAMETERS
40116
40216
Cycle Time
0
2500
20
Read/Write 1 = 0.1 second
40117
40217
Control Action
0
1
0
Read/Write 0 = Reverse Acting, 1 = Direct Acting
40118
40218
Power Low Limit
0 or -100
100
0
Read/Write
40119
40219
Power High Limit
0 or -100
100
100
40120
40220
Sensor Failure Power Preset
0 or -100
100
0
40121
40221
Dampening Time
0
250
3
Read/Write 1 = 1 second
40122
40222
On/Off Control Hysteresis
1
250
2
Read/Write
NON-FUNCTIONAL IN REMOTE SETPOINT MODE (SEE 40198)
1 = 1%; Negative percent is only available to OP2 when
AL2 is set for Cooling.
1 = 1%; Negative percent is only available to OP2 when
Read/Write
AL2 is set for Cooling.
1 = 1%; Negative percent is only available to OP2 when
Read/Write
AL2 is set for Cooling.
ALARM 1 (AL1) OUTPUT PARAMETERS
40131
40231
Action
0
8
3
Read/Write See Alarm Action Register Table.
40132
40232
Reset
0
1
0
Read/Write 0 = Automatic, 1 = Latched
40133
40233
Enable Standby Delay
0
1
0
Read/Write 0 = Disable, 1 = Enable
40134
40234
Hysteresis
1
250
1
Read/Write
40135
40235
On Delay
0
32000
0
Read/Write 1 = 1 second
ALARM 2 (AL2) OUTPUT PARAMETERS
40136
40236
Action
0
9
3
Read/Write See Alarm Action Register Table.
40137
40237
Reset
0
1
0
Read/Write 0 = Automatic, 1 = Latched; Not for Cooling Action.
40138
40238
Enable Standby
0
1
0
Read/Write 0 = Disable, 1 = Enable; Not for Cooling Action.
40139
40239
Hysteresis
1
250
1
Read/Write Not for Cooling Action.
40140
40240
On Delay
0
32000
0
Read/Write 1 = 1 second; Not for Cooling Action.
0
2500
20
Read/Write 1 = 0.1 second; 0 = OP2 Off
0
100
10
Read/Write 1 = 0.1; 0 = On/Off Control
-32000
32000
0
Read/Write
11
0(Out 1)
6(Out 2)
COOLING (OP2) PARAMETERS
1
2
3
40141
40241
Cycle Time
40142
40242
Relative Gain
40143
40243
Deadband
OUT 1
OUT 2
ANALOG OUTPUT PARAMETERS
NON-FUNCTIONAL IN REMOTE SETPOINT MODE (SEE 40198)
ANALOG MODEL ONLY
40301
40309
Assignment
0
Read/Write See Analog Output Assignment Register Table.
40302
40310
Mode
1
3
3
Read/Write 1 = 0-10 V, 2 = 0-20 mA, 3 = 4-20 mA
40303
40311
Scaling Value Low
-32000
32000
0
Read/Write Corresponds with 0 V, 0 mA or 4 mA output.
40304
40312
Scaling Value High
-32000
32000
1000
40305
40313
Deadband
0
250
0
Read/Write 1 = 0.1%; Applies when Assignment is Output Power.
40306
40314
Update Time
0
250
0
Read/Write 0 = scan rate (10 updates/ sec) 1 = 1 second
40307
40315
Direct Entry Value
-32000
32000
0
Read/Write Applies when Assignment is Direct Entry Value.
40308
40316
Filter
0
1
0
Read/Write 1 = Applies averaging when Update Time is >=1
Read/Write Corresponds with 10 V or 20 mA output.
For Input Registers, replace the 4xxxx with a 3xxxx in the above register address. The 3xxxx are a mirror of the 4xxxx Holding Registers.
An attempt to exceed a limit will set the register to its high or low limit value.
See MODBUS Calibration for procedure on restoring Factory Settings.
24
DLC REGISTER TABLE Continued
REGISTER
ADDRESS 1
REGISTER NAME
LOW LIMIT
2
HIGH LIMIT
2
FACTORY
SETTING 3
ACCESS
SETPOINT CONTROLLER PROFILE PARAMETERS
COMMENTS
CH A
CH B
SETPOINT CONTROLLER MODEL ONLY
40321
40421
Profile Power Cycle Mode
0
4
1
Read/Write
0 = Stop (control at current active SP); 1 = Abort
(manual control, 0% power); 2 = Start; 3 = Resume; 4 =
Pause
40322
40422
Profile Error Band Mode
0
3
0
Read/Write
0 = Disable Error Band, 1 = Error Band applies to Ramp
Phase 2 = Error Band applies to Hold Phase
3 = Error Band applies to Both Ramp and Hold Phase
40323
40423
Profile Error Band
1
32000
10
Read/Write
1 = 1 process unit; During Hold phase, profile is paused
when process error >= error band until process error
(deviation) is within the Error band (Error Band - Error
Band Hysteresis)
40324
40424
Profile Error Band Hysteresis
0
250
2
Read/Write
1 = 1 Process Unit
40325
40425
Profile End Segment
1
20
1
Read/Write
Segment that ends the profile
40326
40426
Profile Cycle Count
1
250
1
Read/Write
1 - 249 = Number of times to run profile
250 = Run Profile continuously
40327
40427
Profile End Control Mode
0
1
0
Read/Write
0 = Manual Mode, 0% power; 1 = Automatic Control at
last Setpoint
SERIAL COMMUNICATION SETTINGS
40401
Unit (Node) Address
1
247
247
Read/Write
Node serial DLC address.
40402
Baud Rate
0
7
5
Read/Write
See Serial Baud Rate Register Table.
40403
Parity
1
3
1
Read/Write
1 = None, 2 = Even, 3 = Odd
40404
Data Bits
0
1
1
Read/Write
0 = 7 bits, 1 = 8 bits
40405
MODBUS Protocol
0
1
1
Read/Write
0 = ASCII Mode, 1 = RTU Mode
40406
Transmit Delay
2
250
2
Read/Write
2 = 2 msec; See Transmit Delay explanation.
40407
Load Serial Settings
0
1
0
Read/Write
Changing 40401-40406 will not update the DLC until
40407 is 1. After a write, the communicating device
must be changed to the new DLC settings and 40407
returns to 0.
CALIBRATION
1
2
3
40501
Unit Calibration
N/A
N/A
N/A
Read/Write
See MODBUS Calibration explanation.
40502
Calibration Data Register
N/A
N/A
N/A
Read/Write
See MODBUS Calibration explanation.
40503
Non-Volatile Memory Write
Disable
0
1
0
Read/Write
0 = Enable writes, 1 = Disable writes; Returns to 0 at
power cycle. Mirror of Coil 4.
40504
Input Error Status Register
N/A
N/A
N/A
Read Only
Bits 0-7 are mirror of Coils 5-8/17-20, See Coils Table.
40505
Checksum Error Status Register
0
N/A
0
Read/Write
Bits 0-3 are mirror of Coils 1-3, See Coils Table.
CHA
CHB
SETPOINT CONTROLLER PROFILE SEGMENTS
40601
to
40620
40701
to
40720
Setpoint Value Segment 1 - 20
40621
to
40640
40721
to
40740
40641
to
40660
40741
to
40760
SETPOINT CONTROLLER MODEL ONLY
-32000
32000
Read/Write
Limited by Setpoint Limit Low and Setpoint Limit High.
Ramp Rate Segment 1 - 20
0
32000
Read/Write
1 = 0.1° per minute for input types 0-11, 0.1 ohms for
input type 12, 0.01 mV for input type 13, 0.1 process
units for input types 14-15, 0 = Off
Hold Time Segment 1 - 20
0
9999
Read/Write
1 = 0.1 minute
41001-41010
Slave ID
N/A
N/A
N/A
Read Only
RLC-DLC1xx00 (model) 2.00 version (maybe higher)
32 reads, 32 writes 16 scratch. See FC17 explanation.
41101-41116
GUID/Scratch Pad
N/A
N/A
N/A
Read/Write
This area is for the user to store any related
information. This register area does not affect DLC
operations.
For Input Registers, replace the 4xxxx with a 3xxxx in the above register address. The 3xxxx are a mirror of the 4xxxx Holding Registers.
An attempt to exceed a limit will set the register to its high or low limit value.
See MODBUS Calibration for procedure on restoring Factory Settings.
25
COILS TABLE
COIL ADDRESS
COIL NAME
MIRROR REGISTER
ACCESS
COMMENTS
1
Calibration Checksum Error
40505 (bit 0)
1 = Error; Causes Process Value to be 32100, Disables control and alarm outputs,
Read/Write
causes flashing LEDs. Writing a zero clears the error.
2
Parameter Checksum Error
40505 (bit 1)
Read/Write
1 = Error; Causes Process Value to be 32100, Disables control and alarm outputs,
causes flashing LEDs. Writing a zero clears the error.
3
Integral and Offset/Manual
Power Checksum Error
40505 (bit 2)
Read/Write
1 = Error; Causes Process Value to be 32100, Disables control and alarm outputs,
causes flashing LEDs. Writing a zero clears the error.
4
Non-Volatile Memory Write
Disable
40503
Read/Write
1 = Disables writes to the non-volatile memory; Returns to 0(writes are enabled) at
power cycle.
CH A
CH B
5
17
Shorted RTD Input Error
40504
Read Only
1 = Shorted RTD; Causes process value to be -32002, disables alarms, sets control
output(s) to sensor failure power preset level, causes flashing LEDs.
6
18
Open Thermocouple, RTD, or
Extreme Process Input
Over/Under Range Input Error
40504
Read Only
1 = Input Error; Causes process value to be 32002, disables alarms, sets control
output(s) to sensor failure power preset level, causes flashing LEDs.
Signal or Sensor Under
Range Input Error
40504
Read Only
1 = Under Range Error; Causes process value to be -32001, maintains control
output at present level, causes flashing LEDs.
Process Value (<-32000)
Under Range Input Error
40504
Read Only
1 = Under Range Error; Causes process value to be -32003, maintains control
output at present level until input causes Sensor FailurePower Preset Level, causes
flashing LEDs.
Signal or Sensor Over
Range Input Error
40504
Read Only
1 = Over Range Error; Causes process value to be 32001, maintains control output
at present level, causes flashing LEDs.
Process Value (>32000)
Over Range Input Error
40504
Read Only
7
19
8
20
1 = Over Range Error; Causes process value to be 32003, maintains control output
at present level until input causes Sensor FailurePower Preset Level, causes
flashing LEDs.
0 = Off, 1 = On
9
21
Control Output OP1 State
40014/40030
Read Only
10
22
Alarm 1 Output AL1 State
40015/40031
Read/Write 0 = Off, 1 = On; A write of 1 is only possible when alarm is set for Manual.
11
23
Alarm 2 Output AL2/OP2 State
40016/40032
Read/Write 0 = Off, 1 = On; A write of 1 is only possible when alarm is set for Manual.
12
24
Control Mode
40041/40049
Read/Write 0 = Automatic Mode, 1 = Manual Mode
13
25
Disable Setpoint Ramping
40042/40050
Read/Write 0 = Enabled, 1 = Disabled
14
26
Setpoint Ramping In Process
40043/40051
Read Only
15
27
Disable Integral Action
40044/40052
Read/Write 0 = Enabled, 1 = Disabled
16
28
Auto-Tune Start
40011/40027
Read/Write 0 = Stop, 1 = Start
SETPOINT CONTROLLER MODEL ONLY
29
Setpoint Controller Segment
Memory Checksum Errror
40505 (bit 4)
30
Setpoint Controller Status
Memory Checksum Error
40505 (bit 5)
Advance Profile Phase
40070/40078
31
32
33
Local/Remote Setpoint Select
40046
0 = No, 1 = Yes
40011/40027
1 = Checksum Error in A or B Setpoint Controller Segment memory (40601-40760),
Read/Write causes process value to be 32100 disables control and alarm outputs, causes
flashing LEDs.
1 = Checksum Error in A or B Setpoint Controller Operating Status memory, disables
Read/Write control and alarm outputs, causes flashing LEDs, and aborts profile putting channel
in manual control at 0% power.
Read/Write 1 = Advance running Profile to next phase
Read/Write 0 = Local Setpoint; 1 = Remote Setpoint
ALARM 1 (40131/40231) AND ALARM 2
(40136/40236) ACTION REGISTER TABLE
INPUT TYPE REGISTER (40101/40201) TABLE
MODE
0
1
2
3
4
5
6
7
TYPE
Thermocouple
Thermocouple
Thermocouple
Thermocouple
Thermocouple
Thermocouple
Thermocouple
Thermocouple
MODE
-
T
E
J
K
R
S
B
N
8
9
10
11
12
13
14
15
TYPE
Thermocouple - C
RTD platinum 385
RTD platinum 392
RTD nickel 672
Linear Ohms
Linear mV (1 = 10mV)
Process Voltage
Process Current
MODE
ANALOG OUTPUT ASSIGNMENT REGISTER
(400301/40309) TABLE
MODE
0
1
2
3
4
5
6
7
8
9
10
11
ACTION
0
1
2
3
4
5
6
7
8
9
Manual
Absolute HI (Balanced)
Absolute LO (Balanced)
Absolute HI (Unbalanced)
Absolute LO (Unbalanced)
Deviation HI
Deviation LO
Band Inside Acting
Band Outside Acting
Cooling (Alarm 2 only)
ASSIGNMENT
Output Power A
Process Value A
Setpoint A
Ramping Setpoint A
Deviation A
Direct Entry Value 1
Output Power B
Process Value B
Setpoint B
Ramping Setpoint B
Deviation B
Direct Entry Value 2
SERIAL BAUD RATE REGISTER (40402) TABLE
26
MODE
BAUD
0
1
2
3
4
5
6
7
300
600
1200
2400
4800
9600
19200
38400
TROUBLESHOOTING
PROBLEM
CAUSE
REMEDIES
Power LED will not light
Controller power
Check controller power connections and voltage level
Process Value not changing or incorrect
Input signal
Incorrect channel
Incorrect programming
Check input signal connections and signal level
Check proper channel setup, reading and connections
Check input setup, scaling values, and re-download
Alarms not functioning properly
Calculated trigger points are over +32000 or below -32000
Adjust alarm value, alarm hysteresis, and setpoint
value to ensure valid trigger points
Process Value stays at -32001 or +32001
Input Signal (sensor) under-range or over-range *
Check input type, level, channel, jumpers and
re-download. Replace sensor. Perform calibration.
Process Value stays at -32002
Shorted RTD sensor *
Check input sensor, level, channel, jumpers and
re-download. Replace probe.
Process Value stays at +32002
Open TC or RTD sensor *
Check input sensor, level, channel, jumpers and
re-download. Replace probe.
Process Value stays at -32003 or +32003
Process Value underrange (<-32000) or overrange (>+32000) Check input level, scaling, jumpers and re-download
Process Value stays at +32100, All LEDs
Flashing, Alarms disabled
Parameter checksum error †
Calibration checksum error †
Integral and Offset/Manual Power checksum error †
Setpoint Controller Segment Memory checksum error †
Will not communicate (Comm. LED not flashing)
Setpoint Controller Status Memory checksum error †
Re-download SFDLC file
Perform calibration procedure
Consult Factory
Check A & B Setpoint Ramp Rate and Hold Time
Segments. Change minimum of 1 segment register for
each channel to cause a new checksum to be written
Consult Factory
Incorrect serial settings (DLC port)
Incorrect serial settings (computer port)
Incorrect wiring
Verify DLC communications setup
Go to pull down menu SETTINGS,PC PORT SETTING
Try switching A+ and B- lines
Note: The DLC serial settings must match the device that it is communicating with. If you do not know or cannot recall
the DLC settings, they can be reset back to factory defaults. Simply jumper the Default Serial terminal to Input
Common or by putting the Default Serial setting DIP switch in the “UP” position.
* Can also be monitored by accessing coils 5-8 and 17-20, or register 40504.
† Can also be monitored by accessing coils 1-3, 29-30 or register 40505.
For further technical assistance, contact technical support.
27
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship
for a period limited to one year from the date of shipment, provided the products have been stored,
handled, installed, and used under proper conditions. The Company’s liability under this limited
warranty shall extend only to the repair or replacement of a defective product, at The Company’s
option. The Company disclaims all liability for any affirmation, promise or representation with
respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against
damages, claims, and expenses arising out of subsequent sales of RLC products or products
containing components manufactured by RLC and based upon personal injuries, deaths, property
damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be
to any extent liable, including without limitation penalties imposed by the Consumer Product Safety
Act (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
herein and relies on no other warranties or affirmations.
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
Red Lion Controls Asia
31, Kaki Bukit Road 3 #06-02 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. P48-D
Drawing No. LP0464
Released 2/06
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL P48 - 1/16 DIN PROCESS CONTROLLER
O
PID CONTROL WITH REDUCED OVERSHOOT
O
ACCEPTS 0 to 10 VDC or 0/4 to 20 mA DC INPUTS
O
OPTIONAL TWO LINEAR DC OUTPUTS (0 to 10 V, 0/4 to 20 mA)
O
OPTIONAL DUAL ALARM OUTPUTS
O
OPTIONAL REMOTE SETPOINT INPUT (0/4 to 20 mA)
O
OPTIONAL RS485 SERIAL COMMUNICATIONS
O
SECOND SETPOINT SETTING
O
SETPOINT RAMPING FOR PROCESS STARTUP
O
PROGRAMMABLE USER INPUT (Digital) FOR ADDED FLEXIBILITY
O
PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS
O
STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES
O
MANUAL/AUTOMATIC CONTROL MODES
O
PC SOFTWARE AVAILABLE FOR CONTROLLER CONFIGURATION
O
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
O
NEMA 4X/IP65 BEZEL
O
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
PROCESS AND SETPOINT
UL Recognized Component,
File # E156876
DESCRIPTION
The P48 Controller accepts either a 0 to 10 VDC or a 0/4 to 20 mA DC signal,
precisely displays the input process signal according to the programmable
scaling points, and provides an accurate output control signal (time proportional
or linear DC) to maintain the process at the desired control point. The
controller’s comprehensive yet simple programming allows it to meet a wide
variety of application requirements.
In the PID control mode the controller operates with on-demand auto-tune,
which will establish the tuning constants. The PID tuning constants may be finetuned by the operator at any time and then locked out from further modification.
The controller employs a unique overshoot suppression feature, which allows
the quickest response without excessive overshoot. The unit can be transferred
to operate in the manual mode, providing the operator with direct control of the
output. The controller may also operate in the ON/OFF control mode with
adjustable hysteresis. a second setpoint is available to allow quick selection of
a different setpoint setting.
Dual 4-digit displays allow viewing of the process and setpoint
simultaneously. Front panel indicators inform the operator of the controller and
output status. On some models, the main control output and the alarm outputs
are field replaceable.
Optional alarm(s) can be configured to activate according to a variety of
actions (Absolute HI or LO, Deviation HI or LO, and Band IN or OUT) with
CAUTION: Risk of Danger.
Read complete instructions prior to
installation and operation of the unit.
adjustable hysteresis. A standby feature suppresses the alarm during power-up
until the process stabilizes outside the alarm region. The second alarm can be
configured as a secondary PID output (heat/cool applications).
Optional Main Linear DC output (10 V or 20 mA) can be used for control or
process re-transmission 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 re-transmission, while the main Linear DC output is being used for
control. The output range can be scaled independent of the input range.
Optional Remote Setpoint input (0/4 to 20 mA) allows for cascade control
loops; 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 expand the controller’s flexibility.
The optional RS485 serial communication interface provides two-way
communication between a P48 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 P48 on the line can be programmed separately from 0 to
99. Data from the P48 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 surfacemount technology, extensive testing, plus high immunity to noise interference
makes the controller extremely reliable in industrial environments.
CAUTION: Risk of electric shock.
DIMENSIONS In inches (mm)
PANEL CUT-OUT
1
SAFETY SUMMARY
9. 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.
10. ALARMS: 1 or 2 alarms (optional)
Modes:
Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Annunciator: LED backlight for “A1”, “A2”
11. SECONDARY OUTPUT: Software selectable (overrides alarm 2)
Control: PID or ON/OFF
Output: Time Proportioning
Cycle time: Programmable
Proportional Gain Adjust: Programmable
Deadband /Overlap: Programmable
12. 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
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 P48 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 controller. An independent and
redundant process limit indicator with alarm outputs is strongly recommended.
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Process Display: 0.4" (10.2 mm) high red LED
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED
Display Messages:
“OLOL”
“ULUL”
“SENS”
“...”
“-..”
-
Appears
Appears
Appears
Appears
Appears
when
when
when
when
when
measurement exceeds + input range.
measurement exceeds - input range.
measurement exceeds controller limits.
display values exceed + display range.
display values exceed - display range.
LED Status Annunciators:
%P
MN
DV
O1
A1
A2
- Lower auxiliary display shows power output in (%).
- Flashing: Controller is in manual mode.
On: Local Setpoint (Remote Setpoint option)
Off: Remote Setpoint
- Lower auxiliary display shows deviation (error) from
setpoint.
- Main control output is active.
- Alarm #1 is active (for A1 option).
- Alarm #2 is active OR
- Secondary output (02) is active.
OUTPUT **
RANGE
0 to 10 V
0 to 20 mA
4 to 20 mA
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.
4. MEMORY: Nonvolatile E2 PROM retains all programmable parameters
and values.
5. RANGE AND ACCURACY:
INPUT
RANGE
10 VDC
(-1 to 11)
20 mA DC
(-2 to 22)
0.30% of
reading
+0.03 V
0.30% of
reading
+0.04 mA
1 M ohm
300 V
10 mV
10 ohm
100 mA
10 µA
* Accuracies are expressed as ± percentages after 20 minutes 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.
6. MAIN SIGNAL INPUT:
Sample Period: 100 msec
Response Time: Less than 300 msec typ., 400 msec max. (to within 99% of
final value w/step input; typically, response is limited to response time of
sensor)
Normal Mode Rejection: 40 dB @ 50/60 Hz (improves with increased
digital filtering.)
Common Mode Rejection: Greater than 120 dB, DC to 60 Hz
Protection: Input overload 120 VAC max. for 15 sec. max.
7. USER INPUT: Internally pulled up to +5 VDC (1 MΩ).
VIN MAX = 5.25 VDC; VIL = 0.85 V max.; VIH = 3.65 V min.;
IOFF = 1µA max.
Response Time: 120 msec max.
Functions:
Program Lock
Auto/Manual Mode Select
Reset Alarms
Local/Remote Setpoint Select
ACCURACY *
(0 to 50°C)
0.10% of FS
+ 1/2 LSD
0.10% of FS
+ 1/2 LSD
0.10% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
0.30% of FS
+ 1/2 LSD
COMPLIANCE
RESOLUTION
10k ohm min.
1/3500
500 ohm max.
1/3500
500 ohm max.
1/2800
* Accuracies are expressed as ± percentages after 20 minutes 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 sensor range
reflects the coeffecient 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 approximately 10% overrange
and a small underrange (negative) signal.
13. REMOTE SETPOINT INPUT: (optional)
Input type: 0/4 to 20 mA
Input Resistance: 10Ω
Overrange: -5% to 105%
Overload: 100 mA (continuous)
Scale Range: -999 to 9999
Resolution: 1 part in 10,000.
Accuracy:
At 25° C: ±(0.1 % of full scale +½ LSD)
Over 0 to 50°C range: ±(0.2% of full scale +½ LSD)
Reading Rate: 10/sec.
Setpoint Filtering: Programmable Digital
Setpoint Ramping: Programmable, 1 to 9999 units/minute.
14. SERIAL COMMUNICATIONS: (optional)
Type: RS485 multipoint, balanced interface
Baud Rate: 300 to 9600
Data Format: 7O1, 7E1, 7N2, 8N1
Node Address: 0 to 99, max of 32 units per line
Transmit Delay: 2 to 100 msec or 100 to 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 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 (ie. earth ground).
15. ENVIRONMENTAL CONDITIONS:
Operating Range: 0 to 50°C
Storage Range: -40 to 80°C
Operating and Storage Humidity:
85% max. relative humidity (non-condensing) from 0°C to 50°C.
Altitude: Up to 2000 meters
16. 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 and Remote Setpoint 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 Output and Remote Setpoint commons.
MAX
ACCURACY * ACCURACY *
IMPEDANCE CONTINUOUS RESOLUTION
(18 to 28°C)
(0 to 50°C)
OVERLOAD
0.10% of
reading
+0.02 V
0.10% of
reading
+0.03 mA
ACCURACY *
(18 to 28°C)
Integral Action Lock
Setpoint Ramp Enable
Setpoint 1/Setpoint 2 Select
Serial block print
8. CONTROL AND ALARM OUTPUTS:
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.)
2
FRONT PANEL FEATURES
17. 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
Issued by Underwriters Laboratories, Inc.
IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment for
measurement, control, and laboratory use, Part 1.
IP65 Enclosure rating (Face only), IEC 529
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 2; 4 Kv contact
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3 Level 3; 10 V/m 1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 Kv I/O
Level 3; 2 Kv power
RF conducted interference
EN 61000-4-6 Level 3; 10 V/rms 2
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
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
In the normal operating mode, the unit displays the process value in the upper
display. One of the following parameters can be viewed in the lower display:
- Setpoint
- % Power Output
- Process Deviation
- Blank Display
The user scrolls through these parameters by pressing the D button. If
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the P button
and modified by use of the UP and DOWN buttons. Parameters are then entered
by the P button, which advances the user to the next parameter. Pressing the D
button immediately returns the controller to the normal operating mode without
changing the currently selected parameter.
HARDWARE FEATURES
A fast 100 msec input sampling rate provides quick controller response to a
process disturbance, thus providing excellent process control. Measurement
accuracy of 0.1% or better, provides close process control conforming to the
desired control setpoint value.
Low-drift, highly stable circuitry ensures years of reliable and accurate
process control. The recommended two year re-calibration interval is easily
accomplished via the programming menu.
REMOTE SETPOINT INPUT
The remote setpoint input facilitates the use of a remote signal to drive the
controller’s setpoint. The remote signal can be scaled independent to that of the
controller’s range. The controller’s response to local/remote setpoint transfers
can be programmed. Also, the remote signal is filtered by use of an adaptive
filter. With this filter, relatively large filtering time constants can be used
without suffering from long settling times. The time constant and filter disable
band are programmable. Additionally, the remote signal can also be velocity
limited (or ramped) to slow the controller’s response to changes in setpoint. This
results in a steady control response with no overshoot.
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.
18. CONNECTION: Wire clamping screw terminals
19. 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.
20. WEIGHT: 0.38 lbs (0.17 kgs)
LINEAR DC ANALOG OUTPUTS
The Main Linear DC output has independent scaling, programmable output
update time and filter (damping) time. These parameters permit flexibility in
process configuration. The output can be set for 0 to 10 V, 0 to 20 mA or 4 to
20 mA ranges and can be configured for control or for re-transmission of input
or setpoint values.
A Second Linear DC output is dedicated for the re-transmission of the
process input signal. The output can be scaled and converted independent of the
input signal and Main Linear DC output. This output is isolated from the input.
SETPOINT FEATURES
The controller setpoint can be protected from out of range values by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can be programmed.
A second setpoint can be selected by the user input and/or through the front
panel.
The setpoint ramp feature can be used to control the setpoint value at start-up
or any time a setpoint change is made, at a user programmable rate. This feature
reduces shock to the process and helps to minimize overshoot.
INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating process characteristics, helping to provide better
control.
The programmable user input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), etc.
BASIC OPERATION
The P48 controls a process by receiving a linear DC signal representing the
process value, then calculating a control output power value by use of a
modified PID control algorithm. The unit controls the system with the new
output power value to keep the process at setpoint. The PID control algorithm
incorporates features which provide for high control accuracy and low
overshoot from process disturbances.
OUTPUT FEATURES
Programmable output power limits provide protection for processes where
excessive power can cause damage. Programmable output cycle time, output
hysteresis, and dampening can reduce output activity without degrading control
accuracy. The main outputs can operate in PID, ON/OFF, or manual control
modes.
CONTROL AND ALARM OUTPUTS
In addition to the Linear DC output, there are up to three relay outputs
available. Relay outputs can switch user applied AC or DC voltages for control
or alarm purposes.
3
AUTO-TUNE
CONFIGURATION PARAMETER MODE
The Configuration Parameter Mode allows the operator to set-up the basic
requirements of the controller. It is divided into sections which group together
related programming steps, such as inputs, outputs, alarms, etc. Upon
completion of each section, the program returns to the Configuration Access
Point allowing the user to return to the Normal Display Mode.
The P48 has an auto-tune feature which, on demand, automatically
determines the PID control parameters for a particular process. After completion
of auto-tune, the PID parameters are automatically optimized for that process
and loaded into non-volatile memory. The operator may view and modify the
parameters as desired.
Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
various levels of process control and response characteristics.
Configuration 1, Inputs (1-IN)
“tYPE”
“dCPt”
“rnd”
“FLtr”
“dSP1”
“InP1”
“dSP2”
“InP2”
“SPLO”
“SPHI”
“SPrP”
“InPt”
RS485 SERIAL COMMUNICATIONS
The RS485 communications option allows the connection of up to 32 devices
on a single pair of wires with a distance of up to 4,000 feet and a maximum baud
rate of 9600. Since the same pair of wires are used for both transmit and receive,
only one way communication is possible at any given time. The controller has
a programmable response time to allow the host device adequate time to release
the communication line for a transmission.
Selected parameters from the P48 can be interrogated or changed, and alarm
output(s) may be reset by sending the proper command code via serial
communications. It is also possible to invoke Auto-tune through the serial port.
Serial communications used with SFCRM software allows for easy controller
parameter configuration by computer.
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPdP”
“CHYS”
“tcOd”
“ANtP”
“ANAS”
“ANut”
“ANLO”
“ANHI”
The P48 is available with dual time proportional outputs. The dual outputs
can be used for level or heat/cool applications. The A2 output can be configured
for Secondary (cool) control. This allows for dual PID control or ON/OFF
control with unbalanced hysteresis.
CONTROLLER PROGRAMMING
“SP”
“OP”
“dEv”
“bdSP”
“CodE”
“PId”
“AL”
“ALrS”
“SPSL”
“trnF”
“tUNE”
UNPROTECTED PARAMETER MODE *
The Unprotected Parameter Mode is accessible from the Normal Display
mode when program disable is inactive or when the proper access code number
from the Protected Parameter Mode is entered. The Configuration Parameter
Modes can be accessed only from this mode.
“ACt1”
“rSt1”
“Stb1”
“AL-1”
“ACt2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
Enter setpoint
Enter output power
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Select configuration access point
Return to normal display mode
“CYC2”
“GAN2”
“db-2”
“bAUd”
“ConF”
“Addr”
“Abrv”
“PoPt”
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Enter value to access unprotected parameters and
configuration parameters
Enter time proportioning cycle time
Select output control action
Enter output power low limit
Enter output power high limit
Enter output control dampening
Enter ON/OFF control hysteresis
Select auto-tuning dampening
Main Linear DC analog output range
Main Linear DC analog output source
Main Linear DC analog output update time
Main Linear DC analog output scaling low
Main Linear DC analog output scaling high
-
Select setpoint access level
Select power access level
Enable deviation display
Enable blank display
Enter parameter access code
Select PID access level
Select alarm access level
Enable alarm reset access
Enable local/remote selection
Enable auto/manual mode selection
Enable auto-tune invocation
-
Select operation mode of alarm #1, or select main output
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2, or select second output
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
- Enter time proportioning cycle time
- Enter relative gain
- Enter deadband or overlap
-
Select baud rate
Select character frame format
Enter address
Select abbreviated or full transmission
Select print options
Configuration 7, Remote Setpoint Input (7-N2) *
“dSP1”
“INP1”
“dSP2”
“INP2”
“FLtr”
“bAnd”
“trnF”
The Hidden Function Mode is accessible from the Normal Display Mode.
The functions in this mode may be locked-out individually in Configuration 3
parameter (lock-out section).
-
-
Configuration 6, Serial Communications (6-SC) *
HIDDEN FUNCTION MODE *
“SPSL”
“trnF”
“tUNE”
“ALrS”
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function
Configuration 5, Second Output (5-O2) *
The Protected Parameters Mode is enabled when program disable is active.
This mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are enabled in the Configuration 3
parameter (lock-out section) can be accessed.
-
-
Configuration 4, Alarms (4-AL) *
PROTECTED PARAMETERS MODE *
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CodE”
- Scale main input
Configuration 3, Parameter Lock-Outs (3-LC) *
Front Panel Program Disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial set-up.
The following four programming modes allow the controller to adapt to any
required user-interface level:
Unprotected Parameter Mode
Protected Parameter Mode
Hidden Function Mode
Configuration Parameter Mode
-
Select input signal type
Select scaled display decimal point position
Enter rounding increment and trailing zeros for scaled display
Select level of input filtering
Configuration 2, Outputs (2-OP) *
DUAL TIME PROPORTIONAL SYSTEMS
“SP”
“OP”
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CNFP”
“End”
-
-
Enter remote setpoint display scaling value #1
Enter remote setpoint process scaling value #1
Enter remote setpoint display scaling value #2
Enter remote setpoint process scaling value #2
Enter remote setpoint filter time constant
Enter remote setpoint filter disable band
Select Local/Remote setpoint transfer response
Configuration 8, Second Linear DC Analog Output (8-A2) *
“A2tP”
“A2LO”
“A2HI”
Select local (SP1 or SP2) or remote setpoint
Transfer between automatic (PID) control and manual control
Invoke/cancel PID Auto-tune
Reset latched alarms
- Second linear DC analog range
- Second linear DC analog scaling low
- Second linear DC analog scaling high
Configuration 9, Factory Service Operations (9-FS)
“Code 48”
“Code 66”
- Calibrate Instrument
- Reset parameters to factory setting
* These parameters may not appear due to option configuration or other
programming.
4
MULTIPLE UNIT STACKING
APPLICATION
The P48 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.
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 can be used to control the position of water
output values per the desired flow setpoint value. The P48 relay outputs can
be 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
converted from 0-10 V to 4-20 mA and retransmitted to a 4-20 mA chart
recorder.
Note: When stacking units, provide adequate panel ventilation to ensure that
the maximum operating temperature range is not exceeded.
ALARM
POWER
+
CHART
RECORDER
HIGH
ALARM
PANEL LATCH INSTALLED FOR
VERTICAL UNIT STACKING
LOW
ALARM
PANEL LATCH INSTALLED FOR
HORIZONTAL UNIT STACKING
PANEL CUT-OUT SPACING FOR MULTIPLE UNIT STACKING.
HORIZONTAL ARRANGEMENT SHOWN.
UNIT POWER
CONTROL
VALVE
FLOW
SENSOR
WATER FLOW
(Terminal assignments are model number dependent.)
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.
DEDICATED MAIN CONTROL DEDICATED
MAIN CONTROL
O1 or
ALARM 1
O1 OUTPUT
A1(ALARM 1)* A1 OUTPUT
A2 (ALARM 2)
OR O2
(SECONDARY)*
REMOTE
SETPOINT
INPUT @
RS485 @
PART NUMBERS
MAIN
SECOND
REPLACEMENT
ANALOG
ANALOG
OUTPUT
OUTPUT** @ OUTPUT** @
BOARD
18-36 VDC/24 VAC 85 to 250 VAC
YES
NA
P4800011
RBD48100
P4810010
P4810000
YES
NA
P4810111
P4810101
YES
NA
P4810115
P4810105
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
YES
YES
YES
YES
YES
YES
P4800001
NA
P4810117
P4810107
NA
P481011A
P481010A
RBD48111
P4811110
P4811100
RBD48111
P4811112
P4811102
* These part numbers have a single output programmable as either Control (PID) or as an Alarm.
** These part numbers are jumper and program selectable for either a current or a voltage Linear DC output.
@ These part numbers are equipped with a second setpoint.
Option Boards are installed at the factory for the appropriate models. These boards are only needed for field replacement.
ACCESSORIES
MODEL NO.
SFCRM
DESCRIPTION
PART NUMBERS
Crimson 2 PC Configuration Softwware for Windows 98, ME, 2000 and XP (for RS485 models)
SFCRM
ICM4
RS232/RS485 Serial Converter Module
ICM40030
ICM5
Three Way Isolated RS232/RS485 Serial Converter Module
ICM50000
*Crimson Software is available for download from http://www.redlion.net
5
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6
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7
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 sub-contractors 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
herein and relies on no other warranties or affirmations.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
Bulletin No. PCU-E
Drawing No. LP0338
Released 1/05
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL PCU - PROCESS CONTROL UNIT
C
UL
R
US LISTED
IND. CONT. EQ.
51EB
G
100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY
G
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
G
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
PROCESS VALUE AND SETPOINT OR SECOND ANALOG INPUT
G
ACCEPTS EITHER 0 to 10 VDC OR 0 to 20 mA DC INPUTS
G
SELF-DIAGNOSTICS
G
FULL PID CONTROL WITH REDUCED OVERSHOOT
G
OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE
G
OPTIONAL DUAL ALARM OUTPUTS (USES OUTPUT MODULES)
G
OPTIONAL SECONDARY OUTPUT (USES OUTPUT MODULE)
G
OPTIONAL LINEAR 4 to 20 mA OR 0 to 10 VDC OUTPUT FOR
CONTROL OR PROCESS VALUE RE-TRANSMISSION
G
OPTIONAL MOTORIZED VALVE POSITION CONTROL AND
VALVE FAIL ALARM
G
OPTIONAL SECOND ANALOG INPUT FOR REMOTE SETPOINT
AND CASCADE CONTROL
G
OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL
G
STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES
G
PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED
FLEXIBILITY
G
MANUAL/AUTOMATIC AND LOCAL/REMOTE SETPOINT
CONTROL MODES
G
SETPOINT RAMPING FOR PROCESS STARTUP
G
PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS
G
FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR Drive and Triac)
DESCRIPTION
The PCU Controller accepts either 0 to 10 VDC or a 0 to 20 mA DC input
signal, precisely scales the process signal according to programmable scaling
points, and provides an accurate output control signal (time proportional, linear,
or valve position) to maintain a process at the desired control point. A
comprehensive set of easy to use program instructions allows the controller to
solve various applications.
The controller can operate in the PID control mode for both the main output
and optional secondary output, with on-demand auto-tune, that establishes the
tuning constants. The PID tuning constants may be fine-tuned by the operator
at any time and then locked-out from further modification. The controller
employs a unique overshoot suppression feature, which allows the quickest
response without excessive overshoot. The unit can be transferred to operate in
the manual mode, providing the operator with direct control of the output. The
controller may also be programmed to operate in the ON/OFF control mode
with adjustable hysteresis.
Dual 4-digit displays allow viewing of the process value and setpoint
simultaneously. Front panel indicators inform the operator of the controller and
output status. Replaceable and interchangeable output modules (Relay,
Logic/SSR Drive, or Triac) can be installed for the main control output, alarm
output(s) and secondary output.
DIMENSIONS In inches (mm)
Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.
PANEL CUT-OUT
1
“....”
“-...”
“SLid”
“VALV”
OPTIONS
Optional dual alarms can be configured to activate according to a variety of
actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT and Valve
Fail Detect) with adjustable hysteresis. A standby feature suppresses the output
during power-up until the process stabilizes outside the alarm region. An
optional secondary output is available (for processes that require cooling) that
provides increased control accuracy and response.
A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface
with actuators, chart recorders, indicators, or other controllers. The output
signal can be digitally scaled and selected to transmit one of the following: %
output power, measurement value, process measurement value deviation or
setpoint value. Valve Positioner and Second Analog Input Models have the
adjustable output demand dampening, output deadband and output update time
parameters to expand the versatility of the PCU to control devices.
The optional Motorized Valve Positioner directly controls the position of a
valve by the use of twin outputs (open and close) to control the direction of
motor rotation. The motor position defines the opening position of the valve.
Two control modes are possible: position control, that makes use of the
slidewire feedback signal supplied with the positioner and velocity control, in
which no slidewire feedback signal is used. Parameters are provided to adjust
the operation of the valve. These include:
-
Appears
Appears
Appears
Appears
when
when
when
when
display values exceed + display range.
display values exceed - display range.
loss of slidewire signal is detected.
valve actuator error is detected.
2. POWER: Switch selectable 115/230 VAC (+10%, -15%) no observable line
variation effect, 48 to 62 Hz, 10 VA.
3. ANNUNCIATORS:
LED Backlight Status Indicators (Model dependent):
%PW
DEV
OP1
AL1
AL2
OP2
OPN
CLS
SEC
MAN
REM
Valve activity hysteresis
Valve update time
Variable control dampening
Slidewire signal fail action
Adjustable valve position limits
- Lower auxiliary display shows power output in (%).
- Lower auxiliary display shows deviation (error)
from process setpoint.
- Main control output is active.
- Alarm #1 is active.
- Alarm #2 is active (for Dual Alarm Option).
- Secondary output is active
(for Secondary Output Option).
- Valve positioner OPEN output is active
(for Valve Positioner Option).
- Valve positioner CLOSE output is active
(for Valve Positioner Option).
- Lower auxiliary display shows second analog input
(for Second Analog Input Option).
- Flashing: Controller is in Manual control mode.
- ON: controller is in remote setpoint mode
(Second Analog Input Option).
- OFF: controller is in local setpoint mode
(Second Analog Input Option).
- Flashing: controller is in Manual control mode
(Second Analog Input Optional).
4. CONTROLS: Four front panel push buttons for modifying and setup of
controller functions and one external input for parameter lockout or other
functions.
5. SIGNAL INPUT:
Sample Period: 100 msec typ.
Response Time: 300 msec typ. (to within 99% of final value w/step input)
Signal Overdrive Threshold:
10 V Range: 13 V typ.
20 mA Range: 26 mA typ.
Signal Overdrive Response:
Main Control Output: Programmable preset output
Display: “SENS”
Alarms: Upscale drive
DC Linear: Programmable preset output
Normal Mode Rejection: 40 dB typ. @ 50/60 Hz (improves with increased
digital filtering).
Common Mode Rejection: 100 dB typ., DC to 60 Hz
Protection: Input overload 120 VAC for 30 seconds.
Range And Accuracy:
The Valve Positioner PCU achieves tight process control, yet minimizes
unnecessary valve activity. An alarm event output or display alarm can be
programmed under loss of slidewire feedback or under valve fail detection.
The optional Second Analog Input (0 to 20 mA DC) can be configured as a
remote setpoint signal or as a secondary process signal. Configuration of the
second analog input as a remote setpoint signal allows ratio control, master
setpoint/multiple slave operation, and the ability to cascade the PCU with
another controller (external cascade). Configuration of the second input as a
secondary process signal allows operation as a two-process cascade controller
within a single unit (internal cascade). In either control mode, parameters are
provided to scale, configure, communicate and monitor the activity of both
analog inputs. A square law linearizer function can be used to linearize signals
derived from flow transmitters.
The optional RS485 multidrop serial communication interface provides twoway communication between a PCU unit and other compatible equipment such
as a printer, a programmable controller, or a host computer. In multipoint
applications the address number of each unit on the line can be programmed
from zero to ninety-nine. Up to thirty-two units can be installed on a single pair
of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be
interrogated or changed by sending the proper command code via serial
communications. Alarm output(s) may also be reset via the serial
communications interface option.
An optional NEMA 4X/IP65 rated bezel is available for wash down and/or
dirty environments, when properly installed. Modern surface-mount
technology, extensive testing, plus high immunity to noise interference makes
the controller extremely reliable in industrial environments.
SIGNAL
RANGE
ACCURACY (%
OF UNSCALED
READING)
MAXIMUM
INPUT
INPUT
IMPEDANCE
RESOLUTION
0 to 10 VDC
±(0.15% + 3 mV)
300 VDC
1 MΩ
10 mV
10 Ω
10 µA
0 to 20 mA DC ±(0.15% + 6 µA) 200 mA DC
6. OUTPUT MODULES [Optional] (For All Output Channels):
Relay:
Type: Form-C (Form-A with some models. See Ordering Information.)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load) max.
Life Expectancy: 100,000 cycles at max. load rating. (Decreasing load
and/or increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typ.
Drive: 45 mA max.
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 Amp @ 35°C
0.75 Amp @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
7. MAIN CONTROL OUTPUT:
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Auto-tune: When selected, sets proportional band, integral time, and
derivative time values.
Signal Overdrive Action: Programmable
SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Do not use the PCU to directly command motors, valves, or other actuators
not equipped with safeguards. To do so, can be potentially harmful to persons
or equipment in the event of a fault to the unit. An independent and redundant
limit indicator with alarm outputs is strongly recommended. Red Lion Controls
offers various units (such as an IMP, IMD1 or IMD2) that may be used for this
purpose. The indicators should have input sensors and AC power feeds
independent from other equipment.
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Process Display: 0.4" (10.2 mm) high red LED
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED
Display Messages (Model dependent):
“OLOL”
“ULUL”
“SENS”
-
- Appears when measurement exceeds +105% input range.
- Appears when measurement exceeds -5% input range.
- Appears when measurement exceeds “OLOL” & “ULUL”
range.
2
Signal Overdrive Action: Upscale
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with secondary output or motorized valve position option.)
15. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 50°C
Storage Temperature Range: -40 to 80°C
Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input
Zero Drift (maximum):
4 to 20 mA DC Range: 0.5 µA/°C
0 to 10 VDC Range: 0.2 mV/°C
Second Input: 2 µA/°C
Relative Humidity: Less than 85% RH (non-condensing)
Altitude: Up to 2000 meters
16. ISOLATION BREAKDOWN RATINGS:
All inputs and outputs with respect to AC line: 2300 VMIN
Analog Outputs, Second Analog Input or Slidewire Input with respect to
main input: 500 VMIN
17. CERTIFICATIONS AND COMPLIANCES:
SAFETY
UL Listed, File #E137808, UL508, CSA C22.2 No. 14-M95
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
UL Recognized Component, File # E156876, UL873, CSA C22.2 No. 24
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
Type 2 or 4X Enclosure rating (Face only), UL50
IECEE CB Scheme Test Certificate #UL1239-156876/USA,
CB Scheme Test Report #96ME50279-070794
Issued by Underwriters Laboratories, Inc.
IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part 1.
IP65 Enclosure rating (Face only), IEC 529
ELECTROMAGNETIC COMPATIBILITY:
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2
Level 2; 4 Kv contact
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3
Level 3; 10 V/m1
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4
Level 4; 2 Kv I/O
Level 3; 2 Kv power
RF conducted interference
EN 61000-4-6
Level 3; 10 V/rms2
150 KHz - 80 MHz
Power frequency magnetic fields EN 61000-4-8
Level 4; 30 A/m
Emissions to EN 50081-2
RF interference
EN 55011
Enclosure class A
Power mains class A
Notes:
1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:.
Process and/or analog output signals may deviate during EMI
disturbance.
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent.
2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
Process and/or analog output signals may deviate during EMI disturbance.
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent and 1 ferrite
core 1 turn, RLC #FCOR0000 or equivalent, to cable at unit.
Refer to the EMC Installation Guidelines section of the manual for additional
information.
18. CONNECTION: Jaw-type terminal block
Wire Range: 12-30 AWG copper wire
Torque: 5-7 inch-lbs (56-79 N-cm)
19. CONSTRUCTION: NEMA 2 For Standard Models.
Front Panel: Flame and scratch resistant tinted plastic
Case: High impact black plastic. (Mounting collar included)
NEMA 4X/IP65 model only: Sealed bezel utilizing two captive mounting
screws (panel gasket included) This unit is rated for NEMA 4X/IP65
indoor use. Installation Category II, Pollution Degree 2
20. WEIGHT: 1.3 lbs (0.6 kgs)
SPECIFICATIONS (Cont’d)
8. SECONDARY OUTPUT (Optional):
Control: PID or ON/OFF
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules
Cycle time: Programmable
Proportional Gain Adjust: Programmable
Deadband Overlap: Programmable
9. LINEAR DC OUTPUT (Optional): With digital scale and offset,
programmable deadband and update time.
4 to 20 mA:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 25 µA)
Compliance: 10 V (500 Ω max. loop impedance)
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV)
Min. Load Resistance: 10 KΩ (1 mA max.)
Source: % output power, setpoint, deviation, or process value
(Available for OP1 or OP2, but not both.)
10. MOTORIZED VALVE POSITIONER (Optional):
Two Outputs: Valve open and valve close or Linear DC (optional)
Hardware: Plug-in, replaceable output modules
Three Inputs: Slidewire feedback, signal fail detect (Isolated from main
input)
Slidewire Resistance: 100 Ω to 100 KΩ
Slidewire Exciting Voltage: 0.9 VDC typ.
Slidewire Fail Action: programmable
Control Mode: Position mode (with slidewire) and velocity mode (w/o
slidewire).
Control Deadband: 1% to 25.0% (position mode)
0.1 to 25.0 seconds (velocity mode)
Update Time: 1 to 250 seconds
Motor Time (open, close): 1 to 9999 seconds
Position Limits: Adjustable 0.0 to 100.0% of valve stroke
Valve Fail Time: Off to 9999 seconds
Alarm mode: Dual acting; loss of slidewire feedback signal and valve fail
detection
11. SECOND ANALOG INPUT:
Range: 0 to 20 mA (Isolated from main input)
Overload: 100 mA MIN (steady state)
Input Resistance: 10 Ω typ.
Voltage Drop (@ 20 mA): 0.2 V typ.
Accuracy: 0.15% of reading ±10 µA ±1 LSD
Scale Range: -999 to 9999
12. SERIAL COMMUNICATION:
Type: RS485 Multi-point, Balanced Interface
Communication Format:
Baud Rate: Programmable from 300 to 9600
Parity: Programmable for odd, even, or no parity
Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit
Unit Address: Programmable from 0 to 99, max. of 32 units per line
Transmit Delay: 100 msec min., 200 msec max.
RS485 Common: Isolated from signal input common
Auto Print Time: Off to 9999 seconds between print-outs
13. USER INPUT (Optional): Internally pulled up to +5 VDC.
VIN = 5.25 VDC MAX, VIL = 0.85 VMAX; VIH = 3.0 VMIN,
Available on all second input (MVP & ANA) models, and on models with
RS485.
Response Time: 100 msec max.
Functions: Program Lock
Integral Action Lock
Auto/Manual Mode Select
Setpoint Ramp Select
Reset Alarms
Print Request
Local/Remote Setpoint Select
14. ALARMS (Optional):
Hardware: Plug-in, replaceable output module
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Valve fail
Second Analog Input monitoring
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
3
The PCU controls a process by measuring the input signal and then calculating
a control output power value by use of a modified PID control algorithm. The unit
controls the system with the new output power value to keep the process at
setpoint. The PID control algorithm incorporates features that provide for high
control accuracy and low overshoot from process disturbances.
Programmable dampening output hysteresis and output update time parameters
can dramatically reduce actuator activity without degrading control accuracy.
The RS485 Communication option allows the user to access various
controller parameters such as the setpoint, % output power, % proportional
band, etc. The controller may be set up to transmit various parameters at a
programmable automatic print rate.
FRONT PANEL FEATURES
AUTO-TUNE
BASIC OPERATION
The PCU has an auto-tune feature that, on demand, automatically determines
the PID control parameters for a particular process. After completion of autotune, the PID parameters are automatically optimized for that process and
loaded into nonvolatile memory. The operator may view and modify the
parameters as desired.
Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
various levels of process control and response characteristics.
In the normal operating mode, the unit displays the scaled process value in the
upper display. One of four other parameters can be viewed in the lower display:
- Setpoint
- % Power Output
- Deviation
- Second Input Process Value
The parameters can be scrolled through by pressing the DSP button. If
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the PAR
button and modified by use of the UP and DOWN buttons. Parameters are then
entered by the PAR button, which advances the user to the next parameter.
Pressing the DSP button immediately returns the controller to the normal
operating mode when making a parameter change. The controller’s configuration
and parameter settings are stored in an internal E2PROM device.
OPTIONS
RATIO CONTROL
HARDWARE FEATURES
The fast 100 msec input sampling rate provides quick controller response to
a process disturbance, thus providing excellent process control. Measurement
accuracy of 0.15% or better, provides closer process control conforming to the
desired control setpoint value. The unit accepts either a 0 to 10 VDC or a 0 to
20 mA DC input signal. The AC input power is switch selectable, allowing the
unit to operate from either 115 VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the output modules may be easily
changed or replaced without disturbing the wiring behind the panel. No reprogramming is required when changing or replacing modules.
The optional NEMA 4X/IP65 rated model utilizes two bezel securing screws
and a neoprene gasket to guarantee a water tight seal, when properly installed.
The standard model simply requires pressing a latch to remove the unit.
Low-drift, highly stable circuitry ensures years of reliable and accurate
process control. The recommended two-year re-calibration interval is easily
accomplished via the programming menu.
The PCU configured for ratio operation controls a process as a ratio of
another process or to another variable. Ratio control is commonly used for flow
applications, however, any two process variables can be controlled in a
ratio mode.
Ratio Control Configuration Parameters
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
“InPt”
SETPOINT FEATURES
The controller setpoint can be protected from out of range values by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can be programmed.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate. This feature reduces
shock to the process and helps to minimize overshoot. The setpoint may also be
transmitted by the optional linear DC output for slave control loops.
The second analog input may be configured as a remote setpoint. As such, the
controller is easily switched from local/remote setpoint operation via the front
panel or user input. Ratio and bias parameters provide on-line scaling of the
remote setpoint. Absolute limit values and maximum rate of change of the
remote setpoint further enhance controller flexibility.
- Select ratio mode
- Select second input square root linearization
- Select second input decimal point
- Enter scaling units of second input
- Local/Remote Select options
- Program User Input for Local/Remote
Setpoint selection
Ratio Control Operational Parameters
“rtio”
“bIAS”
- Remote setpoint ratio
- Remote setpoint bias
MOTORIZED VALVE POSITIONER
INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating characteristics, helping to provide better process
control. Programmable scaling points allow the controller to display in any
engineering unit; flow, level, pressure, etc. Scaling points are used in
conjunction with the programmable rounding increment to stabilize a jittery or
otherwise hard to read process signal for better indication.
The programmable User Input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), etc.
The second analog input has independent scaling parameters to match the
units of other processes or transmitters, or to match the controller’s range.
The motorized valve positioner controls the position of a valve directly, by
use of “open” and “close” control outputs. The slidewire feedback signals of
the valve may optionally be connected to the controller. Alternatively, the
controller may be configured for linear input valve control using the 4 to 20 mA
DC output.
OUTPUT FEATURES
Programmable output power limits provide protection for processes where
excessive power can cause damage. Automatic signal overdrive detection, for
fail-safe operation, causes the controller to default to a programmed output
power (upscale or downscale burnout). With adjustable time proportioning
cycle time, and programmable DC linear output, the controller can satisfy a
wide variety of output requirements.
4
Motorized Valve Positioner Configuration Parameters
Position mode:
Velocity mode:
“VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
“Act1”
“VUdt”
“VOPt”
“VCLt”
“VOnt”
-
Internal Cascade Operational Parameters
Enter or measure valve closed position
Enter or measure valve open position
Enter Valve update time
Enter valve control deadband
Enter valve fail detect time
Program alarm as valve fail output
Enter Valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
“SP-2”
“Pb-2”
“It-2”
“dt-2”
-
View secondary setpoint value
Enter secondary proportional band
Enter secondary integral time
Enter secondary derivative time
EXTERNAL CASCADE
INTERNAL CASCADE
Similar to internal cascade control, external cascade control differs by the
employment of two controllers, one of which is equipped with a second analog
input configured as a remote setpoint. A PCU controls the secondary loop, while
a TCU controls the primary loop.
External Cascade Configuration Parameters
Cascade control allows the process to be divided into two control loops: the
primary control loop and the secondary control loop. The secondary loop receives
its setpoint from the primary loop to control an intermediate variable (steam
pressure). The control level of the intermediate variable is the input to the primary
process. The primary loop (main input) controller maintains loop regulation by
manipulating the setpoint of the secondary controller. The setpoint of the
secondary controller, in turn, changes the intermediate variable. The secondary
loop can react faster to disturbances of the intermediate variable, thereby
minimizing the effects to the primary control loop. Control loops cascaded in such
a manner provide greater control quality than would be possible with single loop
control. A single PCU can accomplish two-process cascade control.
Internal Cascade Configuration Parameters
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“OPd2”
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
“rtio”
“bIAS”
- Enter scaling units of second input
- Output dampening of secondary
Setpoint Master Control allows automatic setpoint changes to slave
controller units (up to 50 units total) from a master PCU controller. The
linear DC output of the master is looped with the second analog input
of the slave PCU controllers. Each slave unit can have unique remote
setpoint ratio and bias values.
Setpoint Slave Configuration Parameters
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPLO”
“SPHI”
“SPrP”
- Select remote setpoint mode
- Select second input square root
linearization
- Select second input decimal point
- Enter scaling units of second input
- Limit range of remote setpoint
- Limit rate of change of remote
setpoint
Setpoint Slave Operational Parameters
“rtio”
“bIAS”
- Enter scaling units of second input
- Local/Remote select options
External Cascade Operational Parameters
- Select cascade mode
- Select second input square root linearization
- Select second input decimal point
SETPOINT MASTER CONTROL
“OPEr”
“root”
- Select ratio mode
- Select second input square root linearization
- Select second input decimal point
- Second input ratio
- Second input bias
5
- Remote setpoint ratio
- Remote setpoint bias
Configuration 3, Parameter lock-outs
CONTROLLER PROGRAMMING
“SP”
“OP”
“dEv”
“IN-2”
“bdSP”
“CodE”
“PId”
“PId2”
“rtbS”
“AL”
“ALrS”
“SPSL”
“trnF”
“tUNE”
The PCU has been designed to reduce the operator interaction with the
controller while still maintaining a high degree of control accuracy and user
flexibility. Front Panel Program Disable allows all of the controller’s set-ups to be
locked-out from further operator intervention after the initial parameter set-up.
The programming of the controller is divided into four sections:
Unprotected Parameter Mode
Configuration Parameter Mode
Protected Parameter Mode
Hidden Function Mode
These four programming modes allow the controller to adapt to any required
user-interface level.
Configuration 4, Alarms
UNPROTECTED PARAMETER MODE *
The unprotected parameter mode is accessible when program disable is
inactive or when the proper access code number from the protected mode is
entered. The configuration parameter modes can be accessed only from this mode.
“SP”
“OP”
“Prop”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
-
“Pb-2”
-
“It-2”
-
“dt-2”
-
“AL-1”
“AL-2”
“CNFP”
“End”
-
Enter Setpoint
Enter output power
Enter proportional band
Enter integral time
Enter derivative time
Enter Remote Setpoint ratio value
Enter Remote Setpoint bias value
View internal cascade secondary setpoint
demand
Enter internal cascade, secondary
proportional band
Enter internal cascade, secondary integral
time
Enter internal cascade, secondary derivative
time
Enter value for alarm #1
Enter value for alarm #2
Select basic configuration mode
Return to normal display mode
“CYC2”
“GAN2”
“db-2”
“FLtr”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPLO”
“SPHI”
“SPrP”
“InPt”
“bAUd”
“PArb”
“Addr”
“Abrv”
“PrAt”
“PoPt”
“OPEr”
“root”
“dPt2”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPtr”
“OPd2”
Position mode:
Velocity mode:
-
Enter time proportioning cycle time
Select control action
Enter output power low limit
Enter output power high limit
Enter signal overdrive power preset
Enter output control dampening
Enter ON/OFF control hysteresis
Select auto-tuning dampening
Select linear DC output assignment *
Enter linear DC output low scaling value *
Enter linear DC output high scaling value *
Enter linear DC output control deadband *
Enter linear DC output update time *
-
*
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic
transmissions
- Enter automatic print rate
- Select parameters to be included in print-out
*
- Select remote setpoint or internal cascade
mode
- Select second input square root linearization
- Select second input decimal point
- Entering scaling parameters of second input
- Enter local/remote select options
- Enter Secondary output control dampening
“VPS1”
“VPS2”
“VUdt”
“VPdb”
“VFAL”
“VUdt”
“VOPt”
“VCLt”
“VOnt”
-
*
Enter or measure valve closed position
Enter or measure valve open position
Enter valve update time
Enter valve control deadband
Enter valve fail detect time
Enter valve update time
Enter valve open time
Enter valve close time
Enter valve control deadband
(minimum on time)
HIDDEN FUNCTION MODE *
The hidden function mode is accessible from the normal operating mode. The
four functions in this mode may be locked-out individually in configuration 3
parameter lock-out section.
Configuration 2, Outputs
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“OPdP”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
“ANdb”
“ANUt”
*
- Enter time proportioning cycle time
- Enter relative gain
- Enter deadband or overlap
Configuration 8, Motorized Valve Positioner
- Scale main input
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function *
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
Configuration 7, Second Input
- Select input signal type
- Select square root linearization of main
input *
- Select scaled display decimal point position
- Enter rounding increment and trailing zeroes
for scaled display
- Select level of input filtering
-
-
Configuration 6, Serial Communications
Configuration 1, Inputs
“dCPt”
“rnd”
Select degree of setpoint access
Select degree of power access
Enable deviation display *
Enable second input display *
Enable blank display
Enter parameter access code
Select degree of PID access
Select degree of secondary PID access *
Select degree of ratio/bias access *
Select degree of alarm access *
Enable alarm reset access *
Enable local/remote setpoint selection *
Enable auto/manual mode selection
Enable auto-tune invocation
Configuration 5, Secondary Output
CONFIGURATION PARAMETER MODE
The configuration parameter mode allows the operator to set up the basic
requirements of the controller. It is divided into sections which group together
related programming steps, such as inputs, outputs, alarms, etc. Upon
completion of each section, the program returns to the configuration selection
stage allowing the user to return to the normal display mode.
“tYPE”
“root”
*
“Act1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
-
“SPSL”
“trnF”
“tUNE”
“ALrS”
*
6
- Select Local/Remote Setpoint
- Transfer between automatic (PID) control
and manual control
- Invoke/cancel PID Auto-tune
- Reset latched alarms
These parameters may not appear due to option configuration or other
programming.
PROTECTED PARAMETERS MODE *
The protected parameters mode is enabled when program disable is active.
This mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are selected in the configuration 3
parameter lock-out section can be accessed.
“ProP”
“Intt”
“dErt”
“rtio”
“bIAS”
“SP-2”
“Pb-2”
“It-2”
“dt-2”
-
Enter Proportional band
Enter integral time
Enter derivative time
Enter remote setpoint ratio value
Enter remote setpoint bias value
Enter internal cascade, secondary setpoint
Enter internal cascade, secondary
proportional band
- Enter internal cascade, secondary integral
time
- Enter internal cascade, secondary derivative
time
“AL-1”
“AL-2”
“CodE”
*
- Enter value for alarm #1
- Enter value for alarm #2
- Enter access value to unprotected
parameters & configuration parameters
These parameters may not appear due to option configuration or other
programming.
OUTPUT MODULES
TYPICAL CONNECTIONS
Relay:
Type: Form-C (Form-A with some models. See ordering information.)
Rating: 5 amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120
VAC (inductive) maximum.
Life Expectancy: 100,000 cycles at maximum load rating.
(Decreasing load and/or increasing cycle time, increases life expectancy).
Triac:
Type: Isolated, Zero Crossing Detection
Rating:
Voltage: 120/240 VAC
Max. Load Current: 1 ampere @ 35°C
0.75 ampere @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA maximum.
APPLICATION
A chemical company would like to
maintain the level of an acid solution tank to
insure constant availability for their process.
They have chosen a PCU controller which
has a continuous level probe with a 4 to 20
mA output proportional to tank level,
connected to the input terminals. The tank is
filled by controlling the position of a
proportional control valve. The control valve
is controlled by a 3 to 15 PSI air signal.
The PCU uses the level control input as its
feedback. The 4 to 20 mA input signal is
scaled so that 4 mA equals 0% and 20 mA
equals 100%.
The 4 to 20 mA output of the PCU is taken
to an I/P converter to convert the 4 to 20 mA
output to a 3 to 15 PSI signal for the control
valve. The relay outputs of the PCU are used
for high and low level alarms.
7
ORDERING INFORMATION
MODELS WITHOUT SECOND INPUT OPTIONS
NEMA 4X/IP65
BEZEL
4 to 20 mA
ANALOG OUTPUT
0 to 10 VDC
ANALOG OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
NO
2
NO
2
1
NO
2
1
2
1
2
2
1
NO
NO
NO
NO
YES
NO
NO
YES
NO
YES
NO
NO
YES
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
NO
YES
YES
PCU01000
PCU01001
PCU10000
PCU10001
PCU10002
PCU11000
PCU11001
PCU11002
PCU11004
PCU11005
PCU12001
PCU12004
PCU12005
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common terminals (Form A Type). As a result,
these outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.
SECOND ANALOG INPUT MODELS (RSP)
NEMA 4/XIP65
BEZEL
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
YES
YES
NO
YES
NO
NO
NO
YES
2
2
2
NO
NO
NO
YES
NO
NO
PCU10104
PCU11108
PCU12108
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common
terminals (Form A Type). As a result, these outputs should be fitted with the same type of output module.
The main output (OP1) may be fitted with any type of output module.
MOTORIZED VALVE POSITIONER MODELS (MVP)
NEMA 4/XIP65
BEZEL
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
YES
YES
YES
NO
YES
NO
NO
NO
YES
1
1
1
NO
NO
NO
YES
NO
NO
PCU10307
PCU11306
PCU12306
ACCESSORIES
DESCRIPTION
PART NUMBER
Relay Module
OMD00000
Triac Module
OMD00001
Logic/SSR Drive Module
OMD00003
SSR Power Unit
RLY50000
Single Phase 25 A DIN Rail Mount Solid State Relay
RLY60000
Single Phase 40 A DIN Rail Mount Solid State Relay
RLY6A000
Three Phase DIN Rail Mount Solid State Relay
RLY70000
Note: Output Modules are NOT supplied with the controller. When specifying the controller, be sure to
purchase the appropriate output module for the Main Control Output and if necessary, the alarm output(s),
the secondary output, and valve positioner outputs.
The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an SSR power unit.
It should never be connected to line voltage.
All modules are packaged separately and must be installed by the user.
Red Lion Controls AP
Red Lion Controls
20 Willow Springs Circle
Red Lion Controls BV
Basicweg 11b
31, Kaki Bukit Road 3,
#06-04/05 TechLink
York PA 17402
NL - 3821 BR Amersfoort
Singapore 417818
Tel +1 (717) 767-6511
Tel +31 (0) 334 723 225
Tel +65 6744-6613
Fax +1 (717) 764-0839
Fax +31 (0) 334 893 793
Fax +65 6743-3360
BULLETIN NO. PSC-A
DRAWING NO. LP0315
REVISED 3/97
MODEL PSC - PROCESS SETPOINT CONTROLLER
l
DUAL EVENT OUTPUTS FOR TIMED ACTIVATION OF PROCESS
EQUIPMENT SUCH AS STIRRERS, FANS, HEATERS, ETC. (Uses
Alarm Output Channels)
l
FOUR SETPOINT & PID PARAMETER SETS FOR QUICK
RECALL OF SETPOINTS AND/OR GAIN VALUES DURING BATCH
OR PROCESS CHANGEOVER
l
PROGRAMMABLE USER INPUT FOR CONTROLLER AND
SETPOINT PROGRAM CONTROL
l
100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY
l
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
l
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
PROCESS AND SETPOINT OR PROCESS AND PROFILE STATUS
l
ACCEPTS EITHER 0 to 10 VDC OR 4 to 20 mA DC INPUT SIGNAL
l
SETPOINT PROGRAM CONTROLLER FOR TIME VS. PROCESS
(RAMP/SOAK) AND SPECIAL BATCH/RECIPE APPLICATIONS
FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR drive, and Triac)
l
OPTIONAL DUAL ALARM OUTPUTS (Uses Output Modules)
l
ADVANCED PROGRAM PROFILING IN A 1/8 DIN PACKAGE
l
OPTIONAL SECONDARY OUTPUT (Uses Output Module)
l
ON-LINE MONITORING AND CONTROL OF PROGRAM STATUS,
TIME, AND SETPOINT VALUE (Profile Run, Pause, Stop, Advance,
Modify Time, & Setpoint Value)
l
OPTIONAL LINEAR 4 to 20 mA OR 0 to 10 VDC OUTPUT FOR
CONTROL OR PROCESS RE-TRANSMISSION
l
OPTIONAL RS-485 SERIAL COMMUNICATIONS INTERFACE
l
OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL
l
l
AUTOMATIC PROGRAM DELAY FOR PROFILE CONFORMITY,
PLUS PROGRAM LINKING, REPEATING AND AUTO POWER-ON
FUNCTIONS FOR ENHANCED CAPABILITY
and
informed of the process value, profile status, output states, and setpoint value.
The controller can operate in the standard PID control mode for both Output
1 and Output 2 with on-demand auto-tune which establishes the PID gain set.
The PID gain set can be fine tuned by the operator at any time or may be locked
from further modification. The unit can be transferred to the manual control
mode providing the operator with direct control of the output.
The PSC features four programs or profile recipes, each with up to eight
ramp/soak segments, which can be easily stored and executed at any time.
Longer profiles can be achieved by linking one or more profiles together,
creating a single profile of up to 32 ramp/soak segments. Process profile
conformity is assured during either soak (hold) phases or both ramp and hold
phases by an adjustable error band parameter. The program repeat function
cycles the profile either continuously or a set number of times. Power-on
options automatically re-start, stop, or resume a running profile. The profile can
be controlled via the front panel buttons, the user input, or the optional serial
communications port.
DESCRIPTION
The PSC is a setpoint controller suitable for time vs. process control
applications. The PSC Controller accepts either a 0 to 10 VDC or a 4 to 20 mA
DC input signal, precisely scales the process signal, according to programmable
scaling points, and provides an accurate output control signal (time proportional
or linear) to maintain a process at the desired control point. A comprehensive
set of easy to use steps allows the controller to satisfy various applications. The
user input can be programmed to perform a variety of controller functions.
Dual 4-digit displays allow viewing of the measured process value and
setpoint or the process and profile status simultaneously. Front panel indicators
inform the operator of controller status and output states. Replaceable output
modules (Relay, logic/SSR drive or Triac) can be fitted to the main control
output, alarm output(s) or timed event output(s), and secondary output.
The PSC has been designed to simplify the set-up and operation of a
controlled setpoint profile program. The setpoint program is easily entered and
controlled through the front panel. Full display capabilities keep the operator
DIMENSIONS “In inches (mm)”
UL Recognized Component,
File #E156876
Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5” (140) H x 2.1” (53.4) W.
PANEL CUT-OUT
774
Ramp Rate: 0.1 to 999.9 units/minute or no ramp.
Hold Time: Off or from 0.1 to 999.9 minutes, can be extended to 500 hours
by linking.
Error Band Conformity: Off or from 1 to 9999 units deviation, + value for
hold phases, - value for both ramp and hold phases.
Power-On Modes: Stop, auto-start, or profile resume.
Start Mode: Ramps from process value.
Program Auto Cycle: 1 to 249, or continuous.
Event Outputs: 2, time activated with profile [uses Alarm output(s)].
Control: Front panel buttons, user input, or RS-485 communications.
6. CONTROL POINTS:
Setpoints: 4
PID gain sets: 4
Control: Front panel buttons or user input.
7. SIGNAL INPUT:
Sample Period: 100 msec
Response Time: 300 msec (to within 99% of final value w/step input).
Signal Overdrive Threshold:
10V Range: 13 V
20mA Range: 26 mA
Signal Overdrive Response:
Main Control Output: Programmable preset output.
Display: “SENS”
DC Linear: Programmable preset output.
Normal Mode Rejection: 40 db @ 50/60 Hz (improves with increased
digital filtering).
Common Mode Rejection: 100 db, DC to 50/60 Hz.
8. RANGE AND ACCURACY:
DESCRIPTION (Cont’d)
Four control points, each having a setpoint and PID parameter set, are
available for instant front panel implementation during batch changeover, or
other process conditions. A control point may have its PID gain set values
disabled when implementing the control point.
The optional RS-485 multidrop serial communications interface provides the
capability of two-way communication between a PSC unit and other compatible
equipment such as a printer, a programmable controller, or a host computer. In
multipoint applications the address number of each unit on the line can be
programmed from 0 to 99. Up to thirty-two units can be installed on a single pair
of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be
interrogated or changed by sending the proper command code via serial
communications. Alarm output(s) may also be reset via the serial
communications interface option.
Optional alarm output(s) may be configured to operate as a timed event
output or as a standard alarm output. As an alarm output it may be configured
to activate according to a variety of actions (Absolute HI or LO, Deviation HI
or LO, or Band IN or OUT) with adjustable hysteresis. Also, a standby feature
suppresses the output(s) on power-up until the process stabilizes outside the
alarm region. Timed event output(s) allow the controller to activate other
equipment while a programmed profile is running. Each profile can define up to
16 event states (phases), for each output(s).
An optional secondary output is available for processes that require cooling
which provides increased control accuracy and response.
The optional linear 4 to 20 mA or 0 to 10 VDC output signal is available to
interface with final actuators, chart recorders, indicators, or other controllers.
The output signal can be digitally scaled and selected to transmit one of the
following:
% Output Power
Measurement Value
Measurement Value Deviation
Setpoint Value
An optional NEMA 4X/IP65 rated bezel is available for washdown and/or
dirty environments, when properly installed. Modern surface-mount
technology, extensive testing, plus high immunity to noise interference, makes
the controller extremely reliable in industrial environments.
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 PSC to directly command motors, valves, or other actuators
not equipped with safeguards. To do so, can be potentially harmful to persons
or equipment in the event of a fault to the unit. An independent and redundant
temperature limit indicator with alarm outputs is strongly recommended. Red
Lion Controls offers various units (such as an IMP, IMD1 or IMD2) that may
be used for this purpose. The indicators should have input sensors and AC
power feeds independent from other equipment.
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Process Display: 0.4” (10.2 mm) Red LED
Lower Auxiliary Display: 0.3” (7.6 mm) Green LED
Display Messages:
“....”
“-...”
- Appears when measurement exceeds +105% of input range.
- Appears when measurement exceeds -5% of input range.
- Appears when measurement exceeds “OLOL” & “ULUL”
range.
- Appears when display value exceeds + display range.
- Appears when display value exceeds - display range.
2. POWER: 115/230 VAC (+10%, -15%) no observable line variation effect,
48-62 Hz, 10 VA, switch selectable.
3. ANNUNCIATORS:
6 LED Backlight Status Indicators:
%PW
PGM
MAN
OP1
AL1
AL2
OP2
Accuracy
(% of Unscaled Reading)
Max. Input
0 to 10 VDC
0 to 20 mADC
±(0.15% + 3 mV)
±(0.15% + 6 µA)
300 VDC
200 mADC
Input
Impedance Resolution
1M W
10 W
10 mV
10 µA
9. OUTPUT MODULES (For All Output Channels):
(Optional - Must be ordered separately)
Relay:
Type: Form-C (Form-A with RS-485 option)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load).
Life Expectancy: 100,000 cycles at max. rating. (Decreasing load and/or
increasing cycle time, increases life expectancy).
Logic/SSR Drive: Can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA max.
Triac:
Type: Isolated, Zero Crossing Detection.
Ratings: Voltage: 120/240 VAC
Max Load Current: 1 AMP @ 35oC
0.75 AMP @ 50oC
Min Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 500 Hz
Protection: Internal Transient Snubber, Fused.
10. MAIN CONTROL OUTPUT:
Control: PID or ON/OFF.
Output: Time proportioning or linear DC.
Hardware: Plug-in, replaceable output modules.
Cycle time: Programmable.
Auto-tune: When performed, sets proportional band, integral time, and
derivative time values.
Probe Break Action: Programmable.
11. SECONDARY OUTPUT (Optional):
Control: PID or ON/OFF.
Output: Time proportioning or linear DC
Hardware: Plug-in, replaceable output modules.
Cycle time: Programmable.
Proportional Gain Adjust: Programmable.
DeadBand Overlap: Programmable.
12. LINEAR DC DRIVE (Optional): With digital scale and offset,
programmable deadband and update time.
4 to 20 mA:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 25 µA).
Compliance: 10 V (500 W max. loop impedance).
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35mV).
Min. Load Resistance: 10 K W (1 mA max.)
Source: % output power, setpoint, deviation, or process value.
(Available for OP1 or OP2, but not both.)
SAFETY SUMMARY
“OLOL”
“ULUL”
“SENS”
Signal Range
- Lower auxiliary display shows power output in (%).
- Lower auxiliary display shows profile status or profile time
remaining.
- Controller is in manual mode.
- Main control output is active.
- Alarm #1 is active.
- Alarm #2 is active (for Dual Alarm Option).
- Secondary output is active (for Secondary Option).
4. CONTROLS: Four front panel push buttons for modifying and setup of
controller functions and one external input.
5. SETPOINT PROFILE:
Profiles: 4
Segments Per Profile: 8 ramp/hold segments (linkable to 32 segments).
775
19. CONSTRUCTION:
Front Panel: Flame and scratch resistant tinted plastic.
Case: High impact black plastic. (Mounting collar included).
NEMA 4X/IP65 model only: Sealed bezel utilizing 2 captive mounting
screws (panel gasket included). This unit is rated for NEMA 4X/IP65 indoor
use. Installation Category II, Pollution Degree 2.
20. WEIGHT: 1.3 lbs. (0.6 kgs)
SPECIFICATIONS (Cont’d)
13. ALARMS (Optional):
Hardware: Plug-in, replaceable output module.
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Timed event output(s)
Reset Action: Programmable; automatic or latched.
Delay: Programmable; enable or disable.
Hysteresis: Programmable.
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with secondary output).
14. SERIAL COMMUNICATIONS (Optional):
Type: RS-485 Multi-point, Balanced Interface.
Communication Format:
Baud Rate: Programmable from 300 to 9600.
Parity: Programmable for odd, even, or no parity.
Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit.
Unit Address: Programmable from 0-99, max. of 32 units per line.
Transmit Delay: 100 msec min., 200 msec max.
RS-485 Common: Isolated from signal input common.
Auto Print Time: Off to 9999 seconds between print-outs.
15. USER INPUT: VIN MAX = 5.25 VDC, VIL = 0.85 VMAX; VIH = 2.0 VMIN
Response time: 100 msec max.
Functions:
Program Lock
Integral Action Lock
Auto/Manual Transfer
Setpoint Ramp Select
Reset Alarms
ACCESSORY:
External SSR Power Unit:
Switched Voltage Range: 50 to 280 VAC (Nominal: 240 VAC)
Load Current: 45 Amps @ 25oC ambient temperature
35 Amps @ 50oC ambient temperature
On State Input: 3 to 32 VDC @ 1500 W impedance. (isolated)
(Use Logic/SSR drive output module)
Off State Input: 0.0 to 1.0 VDC
Size: 5.5” (14 cm)L x 4.75” (12 cm)W x 2.62” (6.6 cm)H
BASIC OPERATION
The PSC controls the process profile of a system by measuring the input
signal, comparing it to the setpoint value of the profile in progress, and
calculates the new output power value by use of a modified PID control
algorithm. The unit controls the system with the new output power value so the
process value conforms to the profile. The PID control algorithm incorporates
features which provide high control accuracy and low disturbance overshoot.
FRONT PANEL FEATURES
In the normal display mode, the unit will display the scaled process value in
the upper display. One of five other parameters may be selected for viewing in
the lower display:
Target setpoint
% Output Power
Profile Status
Profile phase time remaining
Blank the lower display.
The profile status display indicates the active program number with the
current ramp or hold phase of the program. The profile can be started, stopped,
advanced, etc., from the front panel when the profile status display is viewed, if
not locked from access.
The phase time remaining display, shows the time remaining in a ramp or
hold phase and, if not locked from access, may be changed on-line to effect
temporary changes to the profile. Additionally, the target setpoint and % output
power (manual mode only) may also be changed on-line or locked from
operator access.
From the normal operating mode, parameters are selected by use of the PAR
button and modified by use of the UP and DOWN buttons. Parameters are then
entered by the PAR button, which advances the user to the next parameter.
Pressing the DSP button immediately returns the controller to the normal
operating mode from any parameter module. The controller configuration and
parameter settings are stored in an internal E2PROM device.
Print Request
Load Control Point
Run/Hold Profile 1
Run/Stop Profile 1
16. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0o to 50oC
Storage Temperature Range: -40o to 80oC
Span Drift: 90 ppm/oC
Zero Drift: 0 to 10 VDC Range - 0.2 mV/oC
4 to 20 mA DC Range - 0.5 µA/oC
Relative Humidity: Less than 85% RH (non-condensing)
Altitude: Up to 2000 meters
17. CERTIFICATIONS AND COMPLIANCES:
UL Recognized Component, File #E156876
Recognized to U.S. and Canadian requirements under the Component
Recognition Program of Underwriters Laboratories, Inc.
EMC EMISSIONS:
Meets EN 50081-2: Industrial Environment.
CISPR 11 Radiated and conducted emissions
EMC IMMUNITY:
Meets EN 50082-2: Industrial Environment.
ENV 50140 - Radio-frequency radiated electromagnetic field 1
ENV 50141 - Radio-frequency conducted electromagnetic field 2
EN 61000-4-2 - Electrostatic discharge (ESD)
EN 61000-4-4 - Electrical fast transient/burst (EFT)
Notes:
1. No loss of performance during EMI disturbance at 7 V/m.
Permissible loss of performance during EMI disturbance at 10 V/m:
Process signal deviation less than 1 % of full scale
Analog output deviation less than 3 % of full scale
For operation without loss of performance:
Install power line filter, RLC #LFIL0000 or equivalent.
OR
Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to power
lines at unit.
2. Permissible loss of performance during EMI disturbance at 10 Vrms:
Process signal deviation less than 1 % of full scale
Analog output deviation less than 3 % of full scale
For operation without loss of performance:
a. Install power line filter, RLC #LFIL0000 or equivalent.
OR
Install 1 ferrite core 1 turn, RLC #FCOR0000 or equivalent, to power
lines at unit.
b. Install 1 ferrite core, RLC #FCOR0000 or equivalent, to analog out
cable at unit.
Refer to the EMC Installation Guidelines section of the manual for additional
information.
18. CONNECTION: Jaw-type terminal block.
HARDWARE FEATURES
The fast 100 msec input sampling rate
NEMA 4X/IP65 BEZEL
provides quick controller response to a
process disturbance for excellent process
control. Measurement accuracy of 0.15%
provides closer process control conforming
to the desired control setpoint value.
The unit will accept either a 0 to 10 VDC
or a 4 to 20 mADC input signal. The A.C.
input power is switch selectable, allowing
the unit to operate from either 115 VAC or
230 VAC. Since the controller is
serviceable from the front of the panel, the
output modules may be easily changed or
replaced without disturbing the wiring
behind the panel and NO re-programming
is required. The standard model simply
requires pressing a latch to remove the unit.
The NEMA 4X/IP65 rated model utilizes
two panel securing screws and a neoprene
gasket to guarantee a water tight seal, when
properly installed.
Low-drift, highly stable circuit design
ensures years of reliable and accurate process control. The recommended two
year re-calibration interval is easily accomplished via the programming menu.
776
CONFIGURATION MODE
Configuration 4, Alarms *
“Act 1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
The configuration modules serve to provide the basic set-ups required by
the controller. It is divided into sections which group together related
programming steps, such as inputs, outputs, alarms, etc. Upon completion of
each section, the program returns to the configuration selection stage, which
allows the user to return to the normal display mode, or advance to a later
configuration stage.
Configuration 1, Inputs
“TYPE”
“dCPt”
“rnd”
display
“FLtr”
“dSP1”
“INP1”
“dSP2”
“INP2”
“SPLO”
“SPHI”
“SPrP”
“InPt”
- Select current or voltage
- Select scaled display decimal point position
- Enter rounding increment and trailing zeros for scaled
-.
-.
-.
-.
-.
-.
-.
-.
-.
-.
“CYC2”
“GAN2”
“db-2”
Select degree of input filtering
Enter display reading for scaling point #1
Key-in or apply signal level for scaling point #1
Enter display reading for scaling point #2
Key-in or apply signal level for scaling point #2
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function
-
- Enter time proportioning cycle time
- Enter relative gain
- Enter deadband or overlap
Configuration 6, Serial Communications *
“bAUd”
“PArb”
“Addr”
“Abrv”
“PrAt”
“PoPt”
-
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic transmissions
Enter automatic print rate
Select parameters to be included in print-out
Configuration 7, Control Points
“CSEt”
“SP-x”
“PID”
“PB-x”
“It-x”
“dt-x”
Enter time proportioning cycle time
Select control action
Enter output power low limit
Enter output power high limit
Enter signal overdrive power preset
Enter ON/OFF control hysteresis
Select auto-tuning damping
Select linear DC output assignment *
Enter linear DC low scaling value *
Enter linear DC high scaling value *
-
Select control point number for set-up 1, 2, 3, & 4
Enter setpoint value for selected control point
Select if PID gain set to be loaded with setpoint
Enter proportional band for selected control point *
Enter integral time for selected control point *
Enter derivative time for selected control point *
Configuration 8, Profiles
“PSEt”
“PnCC”
“PnLN”
“PnSt”
“PnEb”
“Pnr1”
“PnL1”
“PnH1”
.
.
“Pnr8”
“PnL8”
“PnH8”
“Pn 1”
.
.
“Pn16”
Configuration 3, Parameter lock-outs
“SP”
“OP”
“P-CS”
“P-tr”
“bdSP”
“Code”
“PId”
“AL”
“ALrS”
“CPAC”
“PrAC”
“trnF”
“tUNE”
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
Configuration 5, Secondary Output *
Configuration 2, Outputs
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
-
Select degree of setpoint access
Select degree of power access
Select degree of profile status access
Select degree of phase time remaining access
Enable blank display
Enter parameter access code
Select degree of PID access
Select degree of alarm access *
Enable manual reset of alarms *
Enable control point access
Enable ramp/hold program access
Enable automatic/manual transfer
Enable auto-tune invocation
-
Select profile or event output for set-up 1, 2, 3, or 4
Enter program-repeat cycle count for selected profile
Select link option for selected profile
Enter power-down resume status for selected profile
Enter error band for process conformity for selected profile
Enter ramp rate 1 for selected profile *
Enter setpoint level 1 for selected profile *
Enter hold time 1 for selected profile *
Enter ramp rate 8 for selected profile *
Enter setpoint level 8 for selected profile *
Enter hold time 8 for selected profile *
Select event outputs at phase 1 for selected profile
*
Select event outputs at phase 16 for selected profile
*
Configuration 9, Factory Service Operations
(Detailed in the operator’s manual)
* These parameters may not appear due to option configuration or other
programming
SETPOINT FEATURES
OUTPUT FEATURES
The controller’s setpoint can be protected from out of range values, by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can also be programmed.
The setpoint ramp feature ramps the setpoint value at start-up or any time a
setpoint change is made, at a user programmable rate, independent of a
programmed profile. This feature reduces shock to the process and also helps to
minimize overshoot.
The active setpoint, which can be a running profile, may also be transmitted
by the linear DC output for slave control loops.
Four control points are available which can be implemented at any time. Each
control point is programmed independently, with each having a setpoint and a
PID gain set value. With gain value changes, the output power control signal
will not “bump” resulting in a smooth control transition.
Programmable output power limits provide protection for processes where
too much power can cause damage. Automatic signal overdrive detection can be
used to define the state of the output channels, when this situation occurs. With
adjustable time proportioning-cycle time and programmable D.C. Linear
output, the controller can satisfy a wide variety of output requirements.
During execution of a profile, two independent timed event outputs are
available to control or signal other equipment. The event outputs use the alarm
channels.
The RS-485 Communication option allows the user to access various
controller parameters such as the setpoint, % output power, % proportional
band, etc. The controller may be setup to transmit various parameters at a
programmable automatic print rate.
AUTO-TUNE
INPUT FEATURES
The model PSC has an auto-tune feature which, on demand, automatically
determines the PID control parameters for a particular process. After
completion of auto-tune, the PID parameters are automatically optimized for
that process and loaded into nonvolatile memory. The operator may view and
modify the parameters as desired.
Auto-tune may be invoked at start-up, while ramping, or at setpoint,
depending on the process requirements. A programmable auto-tune damping
factor produces various levels of process control and response characteristics.
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating characteristics, helping to provide better process
control.
Scaling points allow the controller to display in any engineering unit; flow,
level, pressure temperature, etc. Scaling points are used in conjunction with the
programmable rounding increment to stabilize a jittery or otherwise hard to read
process signal for better indication.
A programmable User Input is available to control a variety of controller
functions, such as profile control, auto/manual transfer, serial communication
print requests, etc.
PROFILE PROGRAMMING
Profiles are programmed independently of each other and are separate from
the configuration of other controller parameters. Each profile has parameters for
error band (profile conformity), linking, auto-start and program repeat cycles.
Profiles may be altered during execution, so changes take effect as the profile
advances.
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CONTROLLER PROGRAMMING
OUTPUT VARIATIONS WITH RS-485 OPTION
The model PSC has been designed to reduce the operator interaction with the
controller while still maintaining a high degree of control accuracy and user
flexibility. Front panel program disable allows all of the controller’s set-ups to
be locked-out from further operator intervention after the initial parameter setup.
The programming of the controller is divided into four sections:
Hidden Mode
Protected Mode
Unprotected Mode
Configuration Mode
These four programming modes allow the controller to adapt to any required
user-interface level.
The Dual Alarm or the Secondary with Alarm output, with RS-485 option,
does not have independent outputs. In this case, the secondary output and/or
alarm output(s) must have the same type of output modules installed since they
share the common terminal.
UNPROTECTED PARAMETER MODE
The unprotected mode is accessible when program disable is inactive or
when the proper access code number from the protected mode is entered. Only
from this mode can the configuration modes be accessed.
“SP”
“OPOF”
“OP”
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CNFP”
“End”
-
Enter setpoint *
Enter %output power offset *
Enter output power *
Enter proportional band
Enter integral time *
Enter derivative time *
Enter value for alarm #1 *
Enter value for alarm #2 *
Select basic configuration module
Return to normal display mode
OUTPUT MODULES
Units equipped with RS-485 option must have the Dual Alarm or Secondary
w/alarm options fitted with the same type of output modules. The controller’s
main output (OP1) can be fitted with any output module. Output modules are
shipped separately and must be installed by the user.
TYPICAL CONNECTIONS
PROTECTED PARAMETER MODE *
The protected mode is accessible when program disable is active, also this
mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are selected in the configuration 3
parameter lock-outs section can be accessed.
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“Code”
-
Enter
Enter
Enter
Enter
Enter
Enter
proportional band
integral time
derivative time
value for alarm #1
value for alarm #2
access value to unprotected mode
Relay:
Type: Form -C (Form-A with RS-485 option only)
Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120
VAC (inductive).
Life Expectancy: 100,000 cycles at maximum load rating.
(Decreasing load and/or increasing cycle time, increases life expectancy).
* These parameters may not appear due to option configuration or other
programming
HIDDEN FUNCTIONS MODE *
The hidden mode is accessible from the normal operating mode by holding
the PAR button for 3 seconds. The five functions in this mode may be lockedout individually in configuration 3 parameter lock-outs section.
“ CP”
“Prun”
“trnF”
“tUNE”
“ALrS”
- Invoke control point x
- Control ramp/hold profile state
- Transfer between automatic (PID) control and Manual
control
- Invoke/Cancel PID auto-tune
- Reset latched alarms
* These parameters may not appear due to option configuration or other
Logic/SSR Drive: can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical.
Drive: 45 mA max.
programming
OUTPUT VARIATIONS WITHOUT RS-485
OPTION
The Dual Alarm or the Secondary with Alarm output, without the RS-485
option, has independent outputs. Therefore, the secondary output and/or alarm
output(s) can be installed with any combination of output modules.
Triac:
Type: Isolated, Zero Crossing Detection.
Rating:
Voltage: 120/240 VAC.
Max. Load Current: 1 Amp @ 35oC
0.75 Amp @ 50oC
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max @ 60 Hz.
Operating Frequency: 20 to 500 Hz.
Protection: Internal Transient Snubber, Fused.
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APPLICATION
A chemical treatment process requires the PH level of a solution
be ramped at staged levels over specific time periods during startup. The PSC unit is installed to meet this requirement.
After the tank is filled, the PSC’s user input is triggered to run
profile 1 to start the process. Alarm output 2 signals the operator if
the PH level deviates outside the running profile. The error band
(profile conformance) is programmed to the desired value to
prevent the PH level from deviating from the programmed setpoint
profile. Timed event output 1 signals that the profile process is
complete.
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ACCESSORY EXTERNAL
SSR POWER UNIT
The external SSR Power Unit is used
with the Logic/SSR Drive Module
(OMD00003) to switch loads up to
240VAC @ 45amps, 25oC ambient. The
unit is operated by applying a low level
DC control signal to the isolated input.
The unit features zero cross detection
circuits, which reduce radiated RFI when
switching load currents.
With no
contacts to wear out, the SSR power unit
provides virtually limitless operational
life. The unit is supplied with an integral
heat sink for immediate installation.
ORDERING INFORMATION
MODEL
NO.
DESCRIPTION
PSC
Process Setpoint Controller
PMK5
NEMA 4X/IP65
BEZEL
4 to 20 mA
ANALOG
OUTPUT
0 to 10 VDC
ANALOG
OUTPUT
DUAL
ALARM
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
NO
NO
NO
NO
YES
YES
YES
YES
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
SECONDARY RS485 COM
OUTPUT
W/USER
W/ALARM
INPUT
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
NO
YES
YES
NO
NO
YES
YES
NO
NO
YES
YES
NO
NO
YES
YES
Relay Module
Triac Module
Logic/SSR Drive Module
Panel Mount Adapter Kit (1/4 DIN to 1/8 DIN)
SSR Power Unit
PART NUMBER
PSC01001
PSC01002
PSC01004
PSC01005
PSC02001
PSC02002
PSC02004
PSC02005
PSC11001
PSC11002
PSC11004
PSC11005
PSC12001
PSC12002
PSC12004
PSC12005
OMD00000
OMD00001
OMD00003
PMK50000
RLY50000
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common terminals (Form A Type). As a result, these
outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.
Note: Output Modules are NOT supplied with the controller. When specifying the controller, be sure to
purchase the appropriate output module for the Main Control Output and if necessary, the alarm output(s)
and secondary output. The controller can be fitted with any combination of output modules that do not
have the RS-485 option.
The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an SSR power
unit. It should never be connected to a line voltage.
All modules are shipped separately and must be installed by the user.
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