User's Manual DIN EN ISO 9001 Certificate: 01 100 98505 R LIMIT CONTROL ZEL L91 Microprocessor Based Limit Controller UM0L911B ZESTA ENGINEERING LTD. Warning Symbol The Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury or damage to or destruction of part or all of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met. Use the Manual Installers System Designer Expert User Read Chapter 1, 2 Read All Chapters Read Page 12 NOTE: It is strongly recommended that a process should incorporate a LIMIT CONTROL like ZEL L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system. Information in this user's manual is subject to change without notice. This manual is applicable for the products with software version 17 and later version. Copyright October 2000, ZESTA ENGINEERING LTD, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of ZESTA ENGINEERING LTD. 2 UM0L911B Contents Page No Chapter 1 Overview Page No 35 1-1 General 5 3-4 PV Shift 3-5 Digital Filter 1-2 Ordering Code 6 3-6 Process Alarms 36 1-3 Programming Port 7 37 1-4 Keys and Display 7 3-7 RS-485 Communication 3-8 Display Mode 1-5 Menu Overview 12 1-6 Limit Control Operation 13 1-7 Parameter Descriptions 16 Chapter 2 Installation 2-1 Unpacking 22 2-2 Mounting 22 2-3 Wiring Precautions 23 2-4 Power Wiring 25 2-5 Sensor Installation Guidelines 25 2-6 Thermocouple Input Wiring 26 2-7 RTD Input Wiring 27 2-8 Linear DC Input Wiring 28 2-9 Event Input Wiring 29 2-10 Output 1 Wiring 30 2-11 Output 2 Wiring 31 2-12 RS-485 32 3-9 Signal Conditioner DC Power Supply 35 38 3-10 Remote Reset 38 40 3-11 Remote Lock 40 3-12 Limit Annunciator 41 3-13 Reference Data 41 Chapter 4 Applications 42 Chapter 5 Calibration 43 Chapter 6 Specifications 48 Chapter 7 Modbus Communications 52 Appendix A-1 Error codes 61 Chapter 3 Programming 3-1 Process Input 33 3-2 Limit Control 34 3-3 Set point Range 34 UM0L911B 3 Figures & Tables Page No Figure 1-1 Programming Port Location Figure 1-2 Front Panel Display Figure 1-3 Power Up Sequence Figure 1-4 High Limit Operation Figure 1-5 Low Limit Operation Figure 1-6 High/Low Limit Operation Figure 2-1 Mounting Diagram Figure 2-2 Lead Termination Figure 2-3 Rear Terminal Connection Diagram Figure 2-4 Power Supply Connections Figure 2-5 Thermocouple Input Wiring Figure 2-6 RTD Input Wiring Figure 2-7 Linear Voltage Input Wiring Figure 2-8 Linear Current Input Wiring Figure 2-9 Event Input Wiring Figure 2-10 Output 1 Wiring Figure 2-11 Output 2 Wiring Figure 2-12 RS-485 Wiring Figure 3-1 Conversion Curve for Linear Type Process Value Figure 3-2 Filter Characteristics Figure 3-3 Normal Process Alarm Figure 3-4 Latching Process Alarm Figure 3-5 DC Power Supply Application Figure 3-6 Remote Reset Application Figure 3-7 Remote Lock Application Figure 4-1 Over Temperature Protection with Remote Reset Figure 5-1 Flow chart for Manual Calibration Figure 5-2 Cold Junction Calibration Setup Figure 5-3 RTD Calibration 7 8 10 13 14 15 23 24 24 25 27 27 28 28 29 30 31 32 33 35 37 37 39 40 40 42 44 45 46 Table 1-1 Display Form of Characters Table 6-1 Input Characteristics 9 49 4 UM0L911B Chapter 1 Overview 1 - 1 General The limit control ZEL L91 is an over temperature protection or a high limit safety device with a latching output, that removes power in an abnormal condition during the process is higher than the high limit set point or lower than the low limit set point. The unit is powered by 11-26 or 90-264 VDC/VAC supply, incorporating a 2 amp. form C relay for limit control, an universal input which is fully programmable for PT100, thermocouple types J, K, T, E, B, R, S, N, L and 0~60mV, an option port available for one of the following functions: alarm output, RS-485 communication interface, DC power supply output, limit annunciator output and event input. Alternative output options include SSR drive and triac . The input signal is digitized by using a 18-bit A to D converter. Its fast sampling rate (5 times/second) allows the L91 to control fast process such as pressure and flow. Digital communication RS-485 is available as an additional option. This option allows ZEL L91 to be integrated with supervisory control system. An alarm output is another option. A variety of alarm function and alarm mode can be programmed for a specific application. The DC power supply output option is used for an external sensor or transmitter. The event input option can be programmed for remote reset or remote lock signal input. The limit annunciator option can be used to control an alarm buzzer. Three kinds of method can be used to program ZEL L91. 1. use keys on front panel to program the unit manually, 2. Use a PC and setup software to program the unit via RS-485 port and 3. Use a pc and configuration software to program the unit via programming port. High accuracy, maximum flexibility, fast response and user friendly are the main features of L91. UM0L911B 5 1 - 2 Ordering Code ZEL L91 1 Power Input 4: 90 - 264 VAC, 50/60 HZ 5: 11 - 26 VAC or VDC 9: Special Order Signal Input 1: Standard Input Thermocouple: J, K, T, E, B, R, S, N, L RTD: PT100 DIN, PT100 JIS mV: 0~60 mV 2: Voltage: 0-1 V 3: Voltage : 0-10 V 4: Current: 0-20mA 9: Special Order Example Standard Model: ZEL L91-4110 90 - 264 operating voltage Input: Standard Input Output 1: Relay Option: None 3 2 Option 0: None 1: Form A Relay 2A/240VAC 2: Pulsed voltage to drive SSR, 5V / 30mA 6: Triac Output, 1A / 240VAC, SSR 7: Isolated 20V / 25mA DC Output Power Supply 8: Isolated 12V / 40 mA DC Output Power Supply 9: Isolated 5V / 80mA DC Output Power Supply A: RS-485 B: Event input C: Pulsed voltage to drive SSR, 14V/40mA H: Special order Accessories OM94-6 = Isolated 1A / 240VAC Triac Output Module ( SSR ) OM94-7 = 14V/40mA SSR Drive Module DC94-1 = Isolated 20V / 25mA DC Output Power Supply DC94-2 = Isolated 12V / 40mA DC Output Power Supply DC94-3 = Isolated 5V / 80mA DC Output Power Supply CM96-1 = Isolated RS-485 Interface Module EI96-1 = Event Input Module CC91-2 = Programming port cable for ZEL L91 UM0L911B = ZEL L91 User's Manual 6 4 Output 1 1: Form C relay rated 2A/240VAC 2: Pulsed voltage to drive SSR, 5V/30mA 6: Triac Output 1A / 240VAC,SSR C: Pulsed voltage to drive SSR, 14V/40mA 9: Special order UM0L911B Related Products SNA10A = Smart Network Adaptor for Third Party Software, Converts 255 channels of RS-485 or RS-422 to RS-232 Network SNA10B = Smart Network Adaptor for ZEL-Net Software, Converts 255 channels of RS-485 or RS-422 to RS-232 Network SNA12A = Smart Network Adaptor for programming port to RS-232 interface. ZEL-Set = Configuration Software 1 - 3 Programming Port Programming Port pin 1 Control board Power board Open the housing Top view of ZEL L91 Figure 1-1 Programming Port Location Note: The programming port is used for off-line setup and calibration procedures only. Don't attempt to make any connection to these jumpers when the unit is used for a normal control purpose. 1 - 4 Keys and Display KEYPAD OPERATION SCROLL KEY This key is used to: 1. Select a set point to be displayed. 2. Select a parameter to be viewed or adjusted. 3. Advance display from a parameter code to the next parameter code UM0L911B 7 ENTER KEY 4 seconds, 8 seconds Press the scroll key for 4 seconds the display will enter the setup menu. Press this key for 8 seconds to enter the calibration mode. UP KEY This key is used to increase the selected parameter value during the lock indicator is off. DOWN KEY This key is used to decrease the selected parameter value during the lock indicator is off. RESET KEY RESET This key is used to: 1.Reset the limit condition after the process is within the limit. 2.Revert the display to the normal display. 3.Reset the latching alarm, once the alarm condition is removed. 4.Reset the limit annunciator. Note: If the RESET key is left pressed, only ONE reset operation will occur. If the unit subsequently goes into a state where reset is required again, the RESET key (or remote reset contacts) must be released (opened) and pressed (closed) again. UNLOCK KEY RESET 4 seconds Press the RESET key for 4 seconds to enable up/down key function, also to reset the reference data (Section 3-13) and the lock indicator will be extinguished. However, this function is disabled when remote lock is selected for EIFN (Event input function). See section 3-11. INDICATORS Op1: Output 1 status indicator OP2: Output 2 status indicator LC: Degree C indicator LF: Degree F indicator PV: Process value HSP1: High limit set point 1 LSP1: Low limit set point 1 SP2: Set point 2 for output 2 LOCK: Lock status indicator Figure 1-2 Front Panel Display 8 UM0L911A DISPLAY FORM Table 1-1 Display Form of Characters A B C c D E F G H h I J K L M N O P Q R S T U V W X Y Z ? = : These characters are displayed differently. How to display a 5-digit number: For a number with decimal point the display will be shifted one digit right: -199.99 will be displayed as -199.9, 4553.6 will be displayed as 4553 For a number without decimal point the display will be divided into two alternating phases: -19999 will be displayed as: -45536 will be displayed as: -9999 will be displayed as: NORMAL DISPLAY During normal operation, the unit can be configured to display the process value, high limit or low limit set point ( HSP1 or LSP1 dependent on OUT1 selection ) or the word SAFE. ABNORMAL DISPLAY Whenever the process is outside the normal range, the process value will be displayed. UM0L911A 9 SENSOR BREAK DISPLAY If a break is detected in the sensor circuit, the display will show: A-D FAILURE DISPLAY If failure is detected in the A-D converter circuit, the display will show: POWER UP SEQUENCE All segments of display and indicators are left off for 0.5 second. All segments of display and indicators are lit for 1 second. Display program code of the product for 1 second. The left diagram shows program no.2 with version 17. Display Date Code for 1 second. The left diagram shows Year 2001, Month February (2), Date 25'th. This means that the product is produced on February 25'th, 2001. Note that the month code A is for October, B is for November and C is for December. 10 UM0L911B Display the serial number ( 001~999 ) for 1 second. Display the hours used for 2 seconds. The left diagram shows that the unit has been used for 23456.7 hours since production. Figure 1-3 Power Up Sequence Verify all electrical connections have been properly made before applying power to the unit. During power up, a self-test procedure is performed within 6.5 seconds. During self-test period all outputs are left off. When the self-test procedure is complete, the unit reverts to normal operation. UM0L911A 11 1 - 5 Menu Overview Setup Mode Press for 4 sec. PV Value or SAFE INPT Process value HSP1 Value High limit setpoint 1 value LSP1 Value Low limit setpoint 1 value Input type UNIT Process unit RESO Display resolution Low scale value for linear IN.LO input IN.HI High scale value for linear input SHIF PV shift (offset) value FILT PV filter time constant OUT1 Output 1 function O1.HY Output 1 hysteresis value HSP.L Lower limit of HSP1 SP2 Value Set point 2 value HSP.H Upper limit of HSP1 LSP.L Lower limit of LSP1 LSP.H Upper limit of LSP1 OUT2 Output 2 function ADDR Address for digital communication BAUD Baud rate PARI Parity bit AL.FN Alarm function AL.MD Alarm mode AL.HY Alarm hysteresis value AL.FT Alarm failure transfer EIFN Event input function DISP Normal display format PV.HI Max. historical PV PV.LO Min. historical PV T.ABN Abnormal time 12 UM0L911A Note 1. The flow charts show a complete listing of parameters. For actual application the number of available parameters is dependent on the setup conditions, and should be less than that shown in the flow charts. Note 2. Press RESET key for 4 seconds to enable up/down key function, and the LOCK indicator will be extinguished. 1 - 6 Limit Control Operation HIGH LIMIT OPERATION If Hi. is selected for OUT1, the unit will perform high limit control. When power is applied the OUT1 relay is de-energized. After 6.5 seconds self-test period, if the process is below the high limit set point (HSP1), the output 1 relay will be energized and OP1 indicator will go off. If the process goes above the high limit set point, the relay will be de-energized, the OP1 indicator will go on and the display will show the process value. After the process falls below the high limit set point and the RESET key is pressed or the remote reset input is applied, the relay will be energized and the OP1 indicator will go off. PV HSP1 HSP1 - O1.HY OUT1 Relay ON OFF A B C A, B ,C=Reset is applied O1.HY= Output1 hysteresis Figure 1-4 High Limit Operation UM0L911A 13 LOW LIMIT OPERATION If Lo. is selected for OUT1, the unit will perform low limit control. When power is applied the OUT1 relay is de-energized. After 6.5 seconds self-test period, if the process is above the low limit set point (LSP1), the output 1 relay will be energized and OP1 indicator will go off. If the process goes below the low limit set point, the relay will be de-energized, the OP1 indicator will go on and the display will show the process value. After the process rises above the low limit set point and the RESET key is pressed or the remote reset input is applied, the relay will be energized and the OP1 indicator will go off. LSP1+O1.HY LSP1 OUT1 Relay ON OFF A B C A, B ,C=Reset is applied O1.HY= Output1 hysteresis Figure 1-5 Low Limit Operation 14 UM0L911A HIGH/LOW LIMIT OPERATION If Hi.Lo is selected for OUT1, the unit will perform high/low limit control. When power is applied the OUT1 relay is de-energized. After 6.5 seconds self-test period, if the process is below the high limit set point (HSP1) and above the low limit set point (LSP1), the output 1 relay will be energized and OP1 indicator will go off. If the process goes above the high limit set point or below the low limit set point, the relay will be de-energized, the OP1 indicator will go on and the display will show the process value. After the process is within the normal operation range, and the RESET key is pressed or the remote reset input is applied, the relay will be energized and the OP1 indicator will go off. A BC D EF HSP1 HSP1 - O1.HY LSP + O1.HY LSP1 OUT1 Relay ON OFF A, B, C, D, E, F =Reset is applied O1.HY= Output1 hysteresis Figure 1-6 High/Low Limit Operation UM0L911A 15 1 - 7 Parameter Descriptions Parameter Notation Parameter Description HSP1 High Limit Set point 1 LSP1 Low Limit Set point 1 SP2 Set point 2 Value for Output 2 INPT 16 Range Low: HSP.L High: HSP.H Low: LSP.L High: LSP.H Low: -19999 High: 45536 0 : J type thermocouple 1 : K type thermocouple 2 : T type thermocouple 3 : E type thermocouple 4 : B type thermocouple 5 : R type thermocouple 6 : S type thermocouple 7 : N type thermocouple 8 : L type thermocouple 9 : Pt100 ohms DIN curve 10 : PT100 ohms JIS curve Input Type Selection UM0L911B Default Value 100.0 ZE (212.0 BF) 0 ZE (32.0 BF) 90.0 ZE (194.0 BF) 1 (0) Parameter Notation INPT Parameter Description Range Input Type Selection 11 : 4~20 mA linear current 12 : 0~20 mA linear current 13 : 0~60 mV linear voltage 14 : 0~1 V linear voltage 15 : 0~5 V linear voltage 16 17 0 UNIT RESO IN.LO Process Unit Low Scale Value for Linear Input : 0~10V linear voltage : Degree C unit : Degree F unit 2 : Process unit 0 : No decimal point 1 : 1 decimal point 2 : 2 decimal point 3 : 3 decimal point Low: -19999 High: IN.HI UM0L911A 1 (0) : 1~5 V linear voltage 1 Display Resolution Default Value 0 (1) 1 0 17 Parameter Notation IN.HI SHIF FILT Parameter Description Range High Scale Value for Linear Input Low: IN.LO High: 45536 PV Shift ( offset ) Value Low: -200.0 ZE (-360.0 BF) High: 200.0 ZE (360.0 BF) PV Filter Time Constant 0 : 0 second time constant 1 : 0.2 second time constant 2 : 0.5 second time constant 3 : 1 second time constant 4 : 2 seconds time constant 5 : 5 seconds time constant 6 : 10 seconds time constant 7 : 20 seconds time constant 8 : 30 seconds time constant 9 : 60 seconds time constant 2 OUT1 Output 1 Function 3 4 18 UM0L911A : High limit control : Low limit control : High/Low limit control Default Value 100.0 0.0 2 2 Parameter Notation Parameter Description Range Default Value O1.HY Output 1 Hysteresis Value Low: 0.1 High: 10.0 ZE (18.0 BF) HSP.L Lower Limit of HSP1 Low: -19999 High: HSP.H 0 ZE (32.0 BF) HSP.H Upper Limit of HSP1 Low: HSP.L High: 45536 1000.0 ZE (1832.0 BF) LSP.L Lower Limit of LSP1 Low: -19999 High: LSP.H -100.0 ZE (-148.0 BF) LSP.H Upper Limit of LSP1 Low: LSP.L High: 45536 0 ZE (32.0 BF) OUT 2 ADDR BAUD Output 2 Function Address Assignment of Digital COMM Baud Rate of Digital COMM 0 : No function 1 :DC power supply output 2 : RS-485 Communication 3 : Alarm output 4 : Limit annunciator 5 : Event input Low: 1 High: 255 0 : 0.3 Kbits/s baud rate 1 : 0.6 Kbits/s baud rate 2 : 1.2 Kbits/s baud rate 3 : 2.4 Kbits/s baud rate 4 : 4.8 Kbits/s baud rate UM0L911A 0.1 4 1 19 Parameter Notation BAUD PARI Parameter Description Range Baud Rate of Digital COMM Parity Bit of Digital COMM AL.FN Alarm function AL.MD Alarm mode 5 : 9.6 Kbits/s baud rate 6 : 14.4 Kbits/s baud rate 7 : 19.2 Kbits/s baud rate 8 : 28.8 Kbits/s baud rate 9 : 38.4 Kbits/s baud rate 0 : 8 bit even parity 1 : 8 bit odd parity 2 : 8 bit none parity 6 : Process value high alarm 7 : Process value low alarm 0 : Normal alarm action 1 AL.HY 20 Alarm hysteresis value 5 0 6 0 : Latching alarm action Low: 0.1 High: 10 ZE (18.0 BF ) UM0L911A Default Value 0.1 Parameter Notation AL.FT Parameter Description Range Alarm failure transfer 0 : Alarm output goes off as unit fails 1 : Alarm output goes on as unit fails 0 1 EIFN DISP Event input function : Remote reset for output 1, output 1 on. : Remote lock for the unit 0 : Display process value 1 : Display HSP1 or LSP1 value 2 0 0 : Display the word SAFE PV.HI Historical Max. value of PV Low: -19999 High: 45536 PV.LO Historical Min. value of PV Low: -19999 High: 45536 T.ABN Accumulated time during abnormal condition Low: 0 High:6553.5 minutes UM0L911A 1 : No event function 2 Normal display format Default Value 21 Chapter 2 Installation Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only. To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture. Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6. 2 - 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage. If any damage due to transit , report and claim with the carrier. Write down the model number, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) and date code (D/C) are labeled on the box and the housing of the unit. 2 - 2 Mounting Make panel cutout to dimension shown in Figure 2-1. 22 UM0L911A Install both mounting clamps and insert the housing into panel cutout. _ 45 +0.5 0 _ 45 +0.5 0 Panel cutout Figure 2-1 Mounting Diagram Panel 86 mm 94 mm 2 - 3 Wiring Precautions - Before wiring, verify the label for correct model number and options. Switch off the power when checking. - Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded. - It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible. - All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools. - All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring must be suitable for maximum voltage, current, and temperature rating of the system. - Take care not to over-tighten the terminal screws. UM0L911A 23 - Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit. - Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded. - Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes. This electrical noise can enter and adversely affect the operation of microprocessor-based controls. For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the unit. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to earth ground at the sensor end only. 7.0mm max. 3.2mm min. Figure 2-2 Lead Termination 3 PTA B 4 V_ B _ 5 6 N 7 NC NO C 2A 240 VAC 90-264VAC 47-63 Hz 10VA 8 OUT1 9 10 + + A RTD L _ 1 2 + + I 2A 240 VAC _ OUT2 TX2 RS-485 or Event Input TX1 CAT. I I Figure 2-3 Rear Terminal Connection Diagram 24 UM0L911A 2 - 4 Power Wiring The unit is supplied to operate at 11-26 VAC / VDC or 90-264VAC. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the unit. Fuse 1 6 2 7 3 8 4 9 5 10 90 ~ 264 VAC or 11 ~ 26 VAC / VDC Figure 2-4 Power Supply Connections This equipment is designed for installation in an enclosure which provides adequate protection against electric shock. The enclosure must be connected to earth ground. Local requirements regarding electrical installation should be rigidly observed. Consideration should be given to prevent from unauthorized person access to the power terminals. 2 - 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater. In a process where the heat demand is variable, the probe should be closed to the work area. Some experiments with probe location are often required to find this optimum position. UM0L911A 25 In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel will provide an average temperature readout and produce better results in most air heated processes. Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes the sensor might need to have different requirements such as leak-proof, anti-vibration, antiseptic, etc. Standard thermocouple sensor limits of error are A4degrees F (A 2degrees C ) or 0.75% of sensed temperature (half that for special ) plus drift caused by improper protection or an over-temperature occurrence. This error is far greater than controller error and cannot be corrected at the sensor except by proper selection and replacement. 2 - 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2-5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the entire distance between the unit and the thermocouple, ensuring that the correct polarity is observed throughout. Joints in the cable should be avoided, if possible. If the length of thermocouple plus the extension wire is too long, it may affect the temperature measurement. A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce approximately 1 degree C temperature error . 26 UM0L911A 1 6 2 7 3 8 4 9 5 10 Figure 2.5 Thermocouple Input Wiring 2 - 7 RTD Input Wiring RTD connection are shown in Figure 2-6, with the compensating lead connected to terminal 4. For two-wire RTD inputs, terminals 4 and 5 should be linked. The threewire RTD offers the capability of lead resistance compensation provided that the three leads are of same gauge and equal length. Two-wire RTD should be avoided, if possible, for the purpose of accuracy. A 0.4 ohm lead resistance of a two-wire RTD will produce 1 degree C temperature error. RTD 1 6 2 7 3 8 4 5 Three-wire RTD 1 6 2 7 3 8 9 4 9 10 5 10 RTD Two-wire RTD Figure 2-6 RTD Input Wiring UM0L911A 27 2 - 8 Linear DC Input Wiring DC linear voltage and linear current connections are shown in Figure 2-7 and Figure 2-8 . 6 2 7 3 8 4 9 5 10 + 0~60mV, 0~1V, 0~5V, 1~5V, 0~10V 1 Figure 2.7 Linear Voltage Input Wiring 0~20mA or 4~20mA 1 6 2 7 + 3 8 4 9 5 10 Figure 2.8 Linear Current Input Wiring 28 UM0L911A 2 - 9 Event Input wiring 1 6 1 6 2 7 2 7 3 8 3 8 4 9 4 9 5 10 5 10 Open Collector Input Switch Input Figure 2-9 Event Input Wiring The event input can accept a switch signal as well as an open collector signal. The event input function (EIFN) is activated as the switch is closed or an open collector (or a logic signal ) is pulled down. UM0L911A 29 2 - 10 Output 1 Wiring 1 6 2 7 3 8 Max. 2A Resistive 4 9 Load 5 10 Figure 2-10 Output 1 Wiring 120V/240V Mains Supply To Controller Output Relay or Triac Output Direct Drive 120V /240V Mains Supply 1 6 2 7 3 8 4 9 5 10 Relay or Triac (SSR) Output to Drive Contactor Contactor 7 3 8 4 9 5 10 + Load + 30mA / 5V Pulsed Voltage 33 10 + 33 9 0V SSR _ + 2 5V _ 6 30 Three Phase Delta Heater Load Three Phase Heater Power No Fuse Breaker Internal Circuit 1 Pulsed Voltage to Drive SSR To Controller Output UM0L911A 120V /240V Mains Supply To Controller Output 2 - 11 Output 2 Wiring Max. 2A Resistive LOAD 120V/240V Supply Relay or Triac Output 1 6 2 7 3 8 4 9 5 10 SSR 120V/240V Supply LOAD + Pulsed Voltage to Drive SSR Sensor or Transmitter + DC Power Supply Output 1 6 2 7 3 8 4 9 5 10 1 6 2 7 3 8 4 9 5 10 Figure 2-11 Output 2 Wiring UM0L911A 31 2 - 12 RS-485 Tx2 Tx1 1 6 2 7 3 8 4 9 5 10 RS-485 to RS-232 network adaptor SNA10A or SNA10B RS-485 Twisted-Pair Wire 1 6 2 7 3 8 4 9 5 10 TX1 TX2 RS-232 Max. 247 units can be linked Tx2 1 6 2 7 Tx1 Terminator 3 220 ohms/0.5W 32 8 4 9 5 10 UM0L911A Figure 2-12 RS-485 Wiring PC Chapter 3 Programming 3 - 1 Process Input Press for 4 seconds to enter setup mode. Press to select parameter. The display will indicate the parameter symbol and the value ( or selection ) for that INPT: Selects the sensor type and signal type for the process input. UNIT: Selects the process unit. RESO: Selects the location of the decimal point (Resolution) for most (not all) process related parameters. IN.LO: Selects the low scale value for the Linear type input Hidden if: T/C or RTD type is selected for INPT IN.HI: Selects the high scale value for the Linear type input Hidden if: T/C or RTD type is selected for INPT How to use IN.LO and IN.HI: If 4-20mA is selected for INPT, let SL specifies the input signal low (ie. 4mA), SH specifies the signal high (ie. 20mA), S specifies the current input signal value, the conversion curve of the process value is shown as follows: Process value IN.LO Figure 3-1 Conversion Curve for Linear Type Process Value PV IN.HI SL S SH input signal UM0L911A 33 S - SL SH - SL Example: a 4-20 mA current loop pressure transducer with range 0 - 15 kg/cm 2 is connected to input, then perform the following setup: Formula: PV = IN.LO + ( IN.HI - IN.LO ) INPT = 4-20 mA UNIT = PU RESO = 1-DP IN.LO = 0.0 IN.HI = 15.0 Of course, you may select other value for RESO to alter the resolution. 3 - 2 Limit Control OUT1: Select the output 1 function. The available output 1 functions are: High Limit Control, Low Limit Control and High/Low Limit Control. Refer to Section 1-6 for the limit control operation. O1.HY: Output 1 hysteresis value. The hysteresis value is adjusted to a proper value to eliminate the relay jitter in a noisy environment. 3 - 3 Set Point Range HSP.L : Lower limit of HSP1 Hidden if LO is selected for OUT1 HSP.H : Upper limit of HSP1 Hidden if LO is selected for OUT1 LSP.L : Lower limit of LSP1 Hidden if HI is selected for OUT1 LSP.H : Upper limit of LSP1 Hidden if HI is selected for OUT1 HSP.L and HSP.H in setup menu are used to confine the adjustment range of HSP1. LSP.L and LSP.H are used to confine the adjustment range of LSP1. 34 UM0L911A 3 - 4 PV Shift In certain application it is desirable to shift the indicated value from its actual value. This can be easily accomplished with this unit by using the PV shift function. Cycle the unit to the SHIF parameter by using the scroll key. The number you adjust here, either positive or negative, will be added to the actual value. The SHIF function will alter PV only. SHIF: PV shift (offset) value 3 - 5 Digital Filter In certain applications the process value is too unstable to be read. To Improve this a programmable low pass filter incorporated in the ZEL L91 can be used. This is a first order filter with time constant specified by FILT parameter which is contained in setup menu. The FILT is defaulted to 0.5 sec. before shipping. Adjust FILT to change the time constant from 0 to 60 seconds. 0 second represents no filter is applied to the input signal. The filter is characterized by the following diagram. PV FILT=0 1sec FILT=30 FILT=1 1sec Time Figure 3-2 Filter Characteristics UM0L911A 35 3 - 6 Process Alarms The output 2 will perform process alarm function by selecting ALM for OUT2 and PV.H.A or PV.L.A for AL.FN. If PV.H.A is selected the alarm will perform process high alarm. If PV.L.A is selected the alarm will perform process low alarm. The process alarm sets an absolute trigger level. When the process exceeds that absolute trigger level an alarm occurs. The trigger level is determined by SP2 (Set point 2 value) and AL.HY (Alarm hysteresis value). The hysteresis value is introduced to avoid interference action of alarm in a noisy environment. Normally AL.HY can be set with a minimum value(0.1). Trigger levels for process high alarm are SP2 and SP2 AL.HY. Trigger level for process low alarm are SP2+AL.HY and Sp2. There are two types of alarm mode can be selected, these are: normal alarm and latching alarm. Normal Alarm: AL.MD= NORM When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm condition. Latching Alarm: AL.MD= LTCH If a latching alarm is selected, once the alarm output is energized, it will remain unchanged even if the alarm condition has been cleared unless the power is shut off or the RESET key (or remote reset button) is pressed. Failure Transfer: AL.FT = OFF or ON In case of Sensor Break or A-D Failure occurs, the alarm output will be on or off according to the selection of AL.FT. Examples: SP2 = 200 AL.MD = NORM 36 AL.HY = 10.0 AL.FN = PV.H.A UM0L911A Examples: Figure 3.3 Normal Process Alarm Process proceeds 200 200 190 190 SP2 = 200 AL.MD = LTCH ON 200 200 190 190 200 OFF 190 AL.HY = 10.0 AL.FN = PV.H.A Figure 3.4 Latching Process Alarm Process proceeds 200 200 190 190 ON 200 200 200 190 190 190 3 - 7 RS-485 Communication Using a PC for data communication is the most economic way. The signal is transmitted and received through the PC communication Port (generally RS-232). Since a standard PC can't support RS-485 port, a network adaptor (such as SNA10A, SNA10B) has to be used to convert RS-485 to RS-232 for a PC if RS-485 is required for the data communication. Many RS-485 units (up to 247 units) can be connected to one RS-232, that is a PC with 4 comm ports can communicate with 988 units. It is quite economic. UM0L911A 37 Select COMM for OUT2 in setup menu, the output 2 will perform RS-485 interface with Modbus RTU Mode protocol. Setup 1. Select COMM for OUT2 2. Set an unequal address (ADDR) for those units which are connected to the same port. 3. Set the Baud Rate (BAUD) and Parity Bit (PARI) such that these values are accordant with PC setup conditions. 3 - 8 Display Mode The DISP in the setup menu is used to select the display format for the normal condition. If PV is selected, the display will indicate the process value. If SP1 is selected, the display will indicate HSP1 value for high limit control (OUT1= HI) and high/low limit control (OUT1= HI.LO) or indicate LSP1 value for low limit control(OUT1=LO). IF SAFE is selected, the display will indicate the word SAFE for the normal condition. However the display will indicate the process value if the process value goes beyond high limit or low limit. If an error condition occurs, the display will indicate the error symbol. 3 - 9 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or sensor. These are 20V rated at 25mA, 12V rated at 40 mA and 5V rated at 80 mA. The DC voltage is delivered to the output 2 terminals by selecting DCPS for OUT2 in setup menu. 38 UM0L911A Two-line Transmitter + + 1 6 2 7 3 8 4 9 5 10 COM 1 6 IN 2 7 4-20mA Set OUT2 = DC Power Supply Figure 3-5 DC Power Supply Application Three-line Transmitter or sensor + OUT + V or mA 3 8 4 9 5 10 Bridge Type Sensor + + 1 6 2 7 3 8 4 9 5 10 Caution: Don't use the DC power supply beyond its rating current to avoid damage. Purchase a correct voltage to suit your external devices. See ordering code in section 1-2. UM0L911A 39 3 - 10 Remote Reset If EIFN is selected for OUT2 and REST is selected for EIFN, terminals 1 & 2 will act as remote reset input. Pressing remote reset button will perform the same function as pressing the RESET key. Refer to section 1-4 for RESET key function. Remote Reset 1 6 2 7 3 8 4 9 5 10 Setup OUT2 = EIFN EIFN = REST Figure 3-6 Remote Reset Application 3 - 11 Remote Lock If EIFN is selected for OUT2 and LOCK is selected for EIFN, terminals 1 & 2 will act as remote lock input. Turning the remote lock switch on will keep all the parameter setting from been changed. Remote Lock 40 1 6 2 7 3 8 4 9 5 10 UM0L911A Setup OUT2 = EIFN EIFN = LOCK Figure 3-7 Remote Lock Application 3 - 12 Limit Annunciator If L_AN (Limit annunciator) is selected for OUT2, the output 2 will act as a Limit Annunciator. If the limit is or has been reached and the RESET key (or remote reset contacts)has not been pressed since the limit was reached, then the limit annunciator output will be energized and the OP2 indicator will be lit and remain unchanged until the RESET key or remote reset input is applied. 3 - 13 Reference Data There are three reference data contained in setup menu. The reference data are read only data. The maximum historical PV, displayed by ,which shows the maximum process value since the last UNLOCK operation. The minimum historical PV, displayed by , which shows the minimum process value since the last UNLOCK operation. The abnormal time, displayed by ,which shows the total accumulated time (minutes) during the process has been in abnormal condition since the last UNLOCK operation. The values of reference data will be initiated as soon as the RESET key is pressed for 4 seconds (UNLOCK operation). After UNLOCK operation, the PV.HI and PV.LO values will start from the current process value and T.ABN value will start from zero. UM0L911A 41 Chapter 4 Application An oven uses a single phase heater to heat the process. A single loop temperature control ZEL C91 is used to regulate the temperature. A limit control ZEL L91 is used to protect the process from being over heated. The wiring diagram is shown below. Temperature Control L 1 6 2 7 3 8 4 9 5 10 ZEL C91-4120 Rear View Reset Button Limit Control 1 6 2 7 3 8 4 9 5 10 Heater ZEL L91-411B Rear View Mechanical Contactor Figure 4-1 Over Temperature Protection with Remote Reset 42 UM0L911A N Chapter 5 Calibration Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be lost. Do not attempt re-calibration unless you have appropriate calibration equipment. If calibration data is lost, you will need to return the unit to your supplier who May change you a service fee to re-calibrate the unit. Entering calibration mode will break the control loop. Make sure that if the system is allowable to apply calibration mode. Equipments needed for calibration: (1) A high accuracy calibrator (Fluck 5520A Calibrator recommended) with following function: 0-100mA millivolt source with A0.005% accuracy 0-10V voltage source with A0.005% accuracy 0-20mA current source with A0.005% accuracy 0-300 ohm resistant source with A0.005% accuracy (2) A test chamber providing 25 ZE - 50ZE temperature range (3) A switching network (SCANER 80, optional for automatic calibration) (4) A calibration fixture equipped with programming units (optional for automatic calibration) (5) A PC with calibration software ZEL-Net and Smart Network Adaptor SNA10B (optional for automatic calibration) Since each unit needs 30 minutes to warm up before calibration, calibrating one unit each is inefficient. An automatic calibration system for small quantity well as for unlimited quantity is available upon request. The calibration procedures described in the following are a step by step manual procedures. Apply Enter Key (press See Figure 5-1. for 8 seconds) to enter the calibration mode. UM0L911A 43 Normal Mode 4 seconds RESET Figure 5-1 Flow Chart for Manual Calibraton Setup Mode 4 seconds RESET Step 1 Ad0 4 seconds RESET Step 2 ADG 4 seconds RESET Step 3 CJTL 4 seconds RESET Step 4 CJG 4 seconds RESET Step 5 REF 4 seconds RESET Step 6 SR 4 seconds Step1: Calibrate Zero of A to D converter. Short terminal 4 and 5, then press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. 44 UM0L911A Step 2: Calibrate Gain of A to D converter. Send a span signal to terminal 4 and 5 with correct polarity. The span signal is 60 mV for thermocouple input, 1V for 0-1V input, 10V for 0-10V input and 20mA for 0-20 mA input. Press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. Step 3: Calibrate offset of cold junction. Setup the equipment according to the following diagram for calibrating the cold junction compensation. Note that a K type thermocouple must be used. 5520A Calibrator K-TC K+ 4 ZEL L91 5 KStay at least 20 minutes in still-air room room temperature 25 A 3 LC Figure 5-2 Cold Junction Calibration Setup The 5520A calibrator is configured as K type thermocouple output with internal compensation. Send a 0.00 ZE signal to the unit under calibration. The unit under calibration is powered in a still-air room with temperature 25A3 ZE. Stay at least 20 minutes for warming up. Press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. UM0L911A 45 Step 4: Calibrate gain of cold junction. Setup the equipment same as step 3. The unit under calibration is power in a still-air room with temperature 50A3 ZE. Stay at least 20 minutes for warming up. The calibrator source is set at 0.00 ZE with internal compensation mode. Press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. Step 5: Calibrate RTD reference voltage. Send a 100 ohms signal to terminal 3, 4 and 5 according to Figure 5-3. 100 ohms 1 6 2 7 3 8 4 9 5 10 Figure 5-3 RTD Calibration Press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. Step 6: Calibrate RTD serial resistance. Change the ohm's value of the calibrator to 300 ohms. Press for at least 4 seconds. The display will blink a moment. If the display didn't blink, then the calibration fails. * Input modification and recalibration procedures for a linear voltage or a linear current input: 1. Remove R61(3.3K) and install two 1/4 W resistors RA and RB on the control board with the recommended values specified in the following table. The low temperature coefficient resistors with A1% A50ppm should be used for RA and RB. 46 UM0L911B Input Function RA RB R61 T/C, RTD, 0~60mV X X 1.8K 0~1V 61.9K 3.92K X 0 ~ 5V, 1 ~ 5V 324K 3.92K X 0 ~ 10 V 649K 3.92K X 39W 3.01W X 0~20mA, 4~20mA 2. Perform Step 1 to calibrate the linear input zero. 3. Perform Step 2 but send a span signal to the input terminals instead of 60mV. The span signal is 1V for 0~1V input, 5V for 0~5V or 1~5V input, 10V for 0~10V input and 20mA for 0~20mA or 4~20mA input. UM0L911B 47 Chapter 6 Specifications Power 90-264 VAC, 49-63 Hz, 10 VA, 5W maximum 11-26 VAC/VDC, 10 VA, 5W maximum Input Resolution: 18 bits Sampling: 5 times/second Maximum Rating: -2 VDC minimum, 12 VDG maximum (1 minute for mA input) Temperature Effect: A1.5uV /ZE Sensor Lead Resistance Effect: T/C: 0.2 uV/ohm 3-wire RTD: 2.6 ZE/ohm of resistance difference of two leads 2-wire RTD: 2.6 ZE/ohm of resistance sum of two leads Burn-out Current: 200nA Common Mode Rejection Ratio (CMRR): 120db Sensor Break Detection: Sensor open for TC, RTD and mV inputs, below 1 mA for 4-20 mA input, below 0.25V for 1-5 V input, unavailable for other inputs. Sensor Break Responding Time: Within 4 seconds for TC, RTD and mA inputs, 0.1 second for 4-20 mA and 1-5V inputs. 48 UM0L911A Characteristics: Type Range Accuracy @ 25 C Input Impedance J -120 C - 1000 C ( -184 F - 1832 F ) A2 LC 2.2 M K -200 C - 1370 C ( -328 F - 2498 F ) A2 LC 2.2 M T -250 C - 400 C ( -418 F - 752 F ) A2 LC 2.2 M E -100 C - 9 00 C ( -148 F - 1652 F ) A2 LC 2.2 M B 0 C - 1820 C ( 32 F - 3308 F ) A2 LC ( 200 C 1800 C ) 2.2 M R 0 C - 1767.8 C ( 32 F - 3214 F ) A2 LC 2.2 M S 0 C - 1767.8 C ( 32 F - 3214 F ) A2 LC 2.2 M N -250 C - 1300 C ( -418 F - 2372 F ) A2 LC 2.2 M L -200 C - 900 C ( -328 F - 1652 F ) A2 LC 2.2 M A0.4 LC 1.3 K A0.4 LC 1.3 K 2.2 M PT100 -210 C - 700 C ( DIN ) ( -346 F - 1292 F ) PT100 -200 C - 600 C ( JIS ) ( -328 F - 1112 F ) MV -8mV - 70mV A0.05 % mA -3mA - 27mA A0.05 % 100 V -1.3V - 11.5V A0.05 % 510 K Table 6-1 Input Characteristics UM0L911A 49 Event Input Logic Low: -10V minimum, 0.8V maximum. Logic High: 2V minimum, 10V maximum. Functions: Remote reset, remote lockout. Output 1 / Output 2 Relay Rating: 2A/240 VAC, life cycles 200,000 for resistive load. Pulsed Voltage: Source Voltage 5V, current limiting resistance 66 ohms. Triac (SSR) Output Rating: 1A/240 VAC Inrush Current: 20A 1 cycle Min. Load Current: 50 mA rms Max. Off-state Leakage: 3 mA rms Max. On-state Voltage: 1.5 V rms Insulation Resistance: 1000 Mohms min. at 500 VDC Dielectric Strength: 2500 VAC for 1 minute DC Voltage Supply Characteristics ( Installed at Output 2 ) Type Tolerance Max. Output Current Ripple Voltage Isolation Barrier 20 V A1 V 25 mA 0.2 Vp-p 500 VAC 12 V A0.6 V 40 mA 0.1 Vp-p 500 VAC 5V A0.25 V 80 mA 0.05 Vp-p 500 VAC Data Communication Interface: RS-485 (up to 247 units) Protocol: Modbus Protocol RTU mode Address: 1 - 247 Baud Rate: 0.3 - 38.4 Kbits/sec Data Bits: 8 bits Parity Bit: None, Even or Odd Stop Bit: 1 or 2 bits Communication Buffer: 50 bytes 50 UM0L911B User Interface 4-digit LED Displays: 0.4" (10mm), keypad: 4 keys Programming Port: For automatic setup, calibration and testing. Communication Port: Connection to PC for supervisory control. Limit Control: High Limit, Low limit and High/Low Limit programmable Digital Filter Function: First order Time Constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable Environmental & Physical Operating Temperature: -10 ZE to 50 ZE Storage Temperature: -40 ZE to 60 ZE Humidity: 0 to 90 % RH (non-condensing) Insulation Resistance: 20 Mohms min. ( at 500 VDC) Dielectric Strength: 2000 VAC, 50/60 Hz for 1 minute Vibration Resistance: 10 - 55 Hz, 10 m/s for 2 hours Shock Resistance: 200 m/s ( 20 g ) Moldings: Flame retardant polycarbonate Dimensions: 48 mm(W) X 48 mm(H) X 94 mm(D), 86 mm depth behind panel Weight: 150 grams Approval Standards Safety: FM Class 3545 (Oct. 1998) U1873 (11’th edition, 1994) CSA C22.2 No. 24-93 EN61010-1 (IEC1010-1) Protective Class: Ip30 front panel, indoor use, IP 20 housing and terminals (with protective cover) EMC EN61326 UM0L911B 51 Chapter 7 Modbus Communications This chapter specifies the Modbus Communications protocol as RS-232 or RS-485 interface module is installed. Only RTU mode is supported. Data is transmitted as eight-bit binary bytes with 1 start bit, 1 stop bit and optional parity checking (None, Even or Odd). Baud rate may be set to 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800 and 38400. 7 - 1 Functions Supported Only function 03, 06 and 16 are available for this series of controllers. The message formats for each function are described as follows: Function 03: Read Holding Registers Response ( from slave ) Query ( from master ) Slave address (0-255) Function code (3) Starting address of register Hi (0) Starting address of register Lo (0-61, 128-143) No. of words Hi (0) No. of words Lo (1-22) CRC16 Hi CRC16 Lo Byte count Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo Function 06: Preset single Register Response ( from slave ) Query ( from master ) Slave address (0-255) Function code (6) Register address Hi (0) Register address Lo (0-61, 128-143) Data Hi Data Lo CRC16 Hi CRC16 Lo 52 UM0L911B Function 16: Preset Multiple Registers Response ( from slave ) Query ( from master ) Slave address (0-255) Function code (16) Starting address of register Hi (0) Starting address of register Lo (0-61, 128-143) No. of words Hi (0) No. of words Lo (1-18) Byte count (2-36) Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo CRC16 Hi CRC16 Lo UM0L911B 53 7 - 2 Exception Responses If the controller receives a message which contains a corrupted character (parity check error, framing error etc.), or if the CRC16 check fails, the controller ignores the message. However, if the controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows: slave address +offset function code + exception code + CRC16 Hi + CRC16 Lo Where the offset function code is obtained by adding the function code with 128 (ie. function 3 becomes H'83), and the exception code is equal to the value contained in the following table: Exception Code 54 Name Cause 1 Bad function code Function code is not supported by the controller 2 Illegal data address Register address out of range 3 Illegal data value Data value out of range or attempt to write a read-only or protected data UM0L911B 7 - 3 Parameter Table Register Parameter Parameter Address Notation Reserved 0 1 HSP1 High limit set point 1 2 LSP1 Low limit set point 1 3 Set point 2 value for output 2 SP2 Reserved 4 Reserved 5 6 PV.HI Historical max. value of PV 7 PV.LO Historical min. value of PV Reserved 8 9 INPT Input type selection 10 UNIT Process unit 11 RESO Display resolution 12 IN.LO Low scale value for linear input 13 IN.HI High scale value for linear input 14 SHIF PV shift (offset) value 15 FILT PV filter time constant 16 T.ABN Accumulated time during abnormal condition 17 OUT1 Output 1 function 18 Reserved Reserved 19 20 O1.HY Output 1 hysteresis value Reserved 21 Reserved 22 Reserved 23 Reserved 24 25 Reserved 26 Reserved 27 Reserved 28 HSP.L Lower limit of HSP1 29 HSP.H Upper limit of HSP1 UM0L911B Scale Low Scale High Notes *1 *1 *1 *1 *1 *1 R/W R/W R/W *1 *1 *1 *1 R R 0 0 0 *1 *1 *1 0 0 0 65535 65535 65535 *1 *1 *1 65535 6553.5 65535 R/W R/W R/W R/W R/W R/W R/W R R/W *2 *2 R/W *1 *1 *1 *1 R/W R/W 55 Register Parameter Parameter Address Notation 30 LSP.L Lower limit of LSP1 31 LSP.H Upper limit of LSP1 32 Reserved Reserved 33 Reserved 34 35 OUT2 Output 2 function Reserved 36 Reserved 37 Reserved 38 Reserved 39 ADDR Address 40 BAUD Baud rate 41 PARI Parity bit 42 Reserved 43 Reserved 41 Reserved 43 AL.FN Alarm function 44 AL.MD Alarm mode 45 AL.HY Alarm hysteresis value 46 AL.FT Alarm failure transfer 47 EIFN Event input function 48 DISP Normal display format 49 Reserved 50 AD0 mV calibration low coefficient 51 ADG mV calibration high coefficient 52 CJTL Cold junction calibration low coefficient 53 CJG Cold junction calibration high coefficient 54 55 REF RTD calibration low coefficient RTD calibration high coefficient 56 SR Reserved 57 DATE Manufacturing date of the product 58 NO Serial number of the product 59 60 HOUR Working hours of the product 61 HRLO Fractional value of hour 56 UM0L911B Scale Scale Low High *1 *1 *1 *1 Notes R/W R/W 0 65535 R/W 0 0 0 65535 65535 65535 R/W R/W R/W 0 0 *2 0 0 0 65535 65535 *2 65535 65535 65535 R/W R/W R/W R/W R/W R/W -1999.9 -1999.9 -199.99 -1999.9 -1999.9 -1999.9 4553.6 4553.6 455.36 4553.6 4553.6 4553.6 R/W R/W R/W R/W R/W R/W 0 0 0 0 65535 65535 65535 65535 R/W R/W R/W R/W Register Parameter Parameter Address Notation Process value 128 PV 140 PROG Program code *3 142 CMND Command code Job code 143 JOB Scale Scale High Low *1 *1 0.00 655.35 0 65535 65535 0 Notes R R R/W R/w *1: The scale high/low values are defined in the following table for the parameters HSP1, LSP1, SP2, PV.HI, PV.LO, IN.LO, IN.HI, SHIF, HSP.L, HSP.H, LSP.L, LSP.H and PV: Conditions Non-linear input Linear input RESO = 0 Linear input RESO = 1 Linear input RESO = 2 Linear input RESO = 3 Scale low -1999.9 -19999 -1999.9 -199.99 -19.999 Scale high 4553.6 45536 4553.6 455.36 45.536 *2: The scale high/low values are defined in the following table for the parameters O1.HY and AL.HY : Conditions Non-linear input Linear input RESO = 0 Linear input RESO = 1 Linear input RESO= 2 Linear input RESO = 3 Scale low 0.0 0 0.0 0.00 0.000 Scale high 6553.5 65535 6553.5 655.35 65.535 *3: The PROG code is defined by 2.XX, where XX denotes the software version number. For example : PROG=2.17 means the product is L91 with software version 17. UM0L911B 57 7 - 4 Data Conversion The word data are regarded as unsigned ( positive ) data in the Modbus message. However, the actual value of the parameter may be negative value with decimal point. The high/low scale values for each parameter are used for the purpose of such conversion. Let M = Value of Modbus message A = Actual value of the parameter SL = Scale low value of the parameter SH = Scale high value of the parameter The conversion formulas are as follows: 65535 ( A - SL) M= SH-SL A= SH-SL 65535 M + SL 7 - 5 Communication Examples Example 1: Down load the default values via the programming port The programming port can perform Modbus communications regardless of the incorrect setup values of address, baud, parity, stop bit etc. It is especially useful during the first time configuration for the controller. The host must be set with 9600 baud rate, 8 data bits, even parity and 1 stop bit. The Modbus message frame with hexadecimal values is shown as follows: 58 UM0L911B (1) Unlock the controller 06 Func. Addr. 00 8E Reg. Addr. 68 2C CMND=26668 HI LO CRC16 (2) Preset the first group of the parameters 0E 10 00 09 00 07 Addr. Func. Starting Addr. No. Of words Bytes 00 01 RESO=1 4E 1F IN.LO=0 00 01 INPT=1 52 07 4E 1F IN.HI=100.0 SHIF=0.0 00 00 UNIT=0 00 02 FILT=2 HI LO CRC16 (3) Preset the second group of the parameters 10 00 01 00 03 06 52 07 4E 1F Addr. Func. Starting Addr. No. of words Bytes HSP1=100.0 LSP1=0.0 51 A3 HI LO SP2=90.0 CRC16 (4) Preset the third group of the parameters 10 00 11 00 13 26 00 02 00 00 00 00 Addr. Func. Starting Addr. No. of words Bytes OUT1=2 Reserved Reserved 00 01 O1.HY=0.1 00 00 00 00 00 00 00 00 00 00 00 00 00 00 4E 1F Reserved Reserved Reserved Reserved Reserved Reserved Reserved HSP.L=0 52 07 HSP.H=100.0 4A 37 4E 1F 00 00 00 00 00 00 00 04 LSP.L=-100.0 LSP.H=0 Reserved Reserved Reserved OUT2=4 HI LO CRC16 (5) Preset the rest parameters 10 00 28 00 0A 14 00 01 00 05 Addr. Func. Starting Addr. No. of words Bytes ADDR=1 BAUD=5 00 06 AL.FN=6 00 00 00 01 AL.MD=0 AL.HY=0.1 00 01 AL.FT=1 UM0L911B 00 00 EIFN=0 00 00 00 00 PARI=0 Reserved 00 00 DISP=0 HI LO CRC16 59 Example 2: Read the process value (PV) Send the following message to the controller via the COMM port or the programming port : Query 00 03 00 80 01 LO HI Addr. Func. No. of words CRC16 Starting Addr. Example 3: Perform reset function ( same effect as pressing Query 00 06 68 8E 25 Addr. Func. CMND=26661 Starting Addr. Example 4: Read 22 parameters at most one time Query 03 00 16 Addr. Func. No. of words Starting Addr. 60 UM0L911B RESET key ): HI LO CRC16 HI LO CRC16 Table A.1 Error Codes and Corrective Actions Error Display Error Description Corrective Action Code Symbol Communication error: bad function Correct the communication 10 software to meet the protocol code requirements. Don't issue an over-range Communication error: register 11 register address to the slave. address out of range Communication error: attempt Don't write a read-only data or a 14 to write a read-only data or a protected data to the slave. protected data Don't write an over-range data Communication error: write a 15 to the slave register. value which is out of range to a register Input sensor break, or input current below 1 mA if 4-20 mA is Replace input sensor. 39 selected, or input voltage below 0.25V if 1 - 5V is selected 40 A to D converter or related component(s) malfunction UM0L911B Return to factory for repair. 61 WARRANTY ZESTA ENGINEERING LTD, is pleased to offer suggestions on the use of its various products. However, ZESTA makes no warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The selection, application or use of ZESTA products is the Purchaser's responsibility. No claims will be allowed for any damages or losses, whether direct, indirect, incidental, special or consequential. Specifications are subject to change without notice. In addition, ZESTA reserves the right to make changes-without notification to Purchaser-to materials or processing that do not affect compliance with any applicable specification. ZESTA products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use. An extended period is available with extra cost upon request. ZEST’s sole responsibility under this warranty, at ZESTA’s option, is limited to replacement or repair, free of charge, or refund of purchase price within the warranty period specified. This warranty does not apply to damage resulting from transportation, RETURNS No products return can be accepted without a completed Return Material Authorization ( RMR ) form. 62 UM0L911A User’s Manual ZEL-L91 Limit Control UMOL911B 212 Watline Avenue Mississauga, Ontario, Canada L4Z 1P4 Voice: (905) 568 - 3100 Fax: (905) 568 - 3131 Website: www.zesta.com Email: [email protected] ZESTA ENGINEERING LTD. ZESTA ENGINEERING LTD.