ABUS A9696 User Manual

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A9696

High End Universal Process Controller

User Manual

ABUS TECHNOLOGIES INC.

WARNING

 This manual should be passed on to the end user.

 The contents of this manual are subject to change without prior notice.

 ABUS gives no warranty of any kind with regard to this manual, including, but not limited to, fitness

for a particular purpose.

 If any question arises or errors are found, or if any information is missing from this manual, please

A9696

inform your supplier or inform at info@abustek.com

 The specifications mentioned in this manual are limited to those for the standard type under the

specified model number break-down and do not necessarily apply for customized instruments.

 Please note that changes in the specifications, construction, or component parts of the instrument

may not immediately be reflected in this manual at the time of change.

 If the customer or any third party is harmed by the use of this product, ABUS assumes no

responsibility for any such harm owing to any defects in the product which were not predictable, or

for any indirect damages.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of Technical Communications Department, ABUS Technologies

HEALTH AND SAFETY

To ensure that our products are safe and without risk to health, the following points must be noted:

1. The relevant sections of these instructions must be read carefully before proceeding.

2. Warning labels on containers and packages must be observed.

3. Installation, operation, maintenance and servicing must only be carried out by suitably trained

personnel and in accordance with the information given. Any deviation from these instructions will transfer the complete liability to the user.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when

operating in conditions of high pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept

dry. Normal safe handling procedures must be used.

6. When disposing of chemicals ensure that no two chemicals are mixed. Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be obtained from the Company address on the back cover, together with servicing and spares information.

ABUS TECHNOLOGIES INC.

A9696

CATALOGUE

Contents Page No.

1. Introduction 4

2. Presentation

1. Features Technical Parameters

3. Dimensions 5

4. Ordering Details 6

5. Connections

1. Electrical Connections

2. Routing of wires

6. Installation

Panel

7. Configuration

1. Programming the indicator

2. Input Type Selection

3. Output and Digital Input Configuration

4. Alarm Configuration Program security

Auto Tune Ramp and Soak Profile Program

Serial Communication

8. Safety Precautions 22

4 4

6 6 6

7 7

9 14 14 16 19 19 20 21

9. Warranty 22

ABUS TECHNOLOGIES INC.

1. INTRODUCTION

A9696 Big Digit Universal Process Controller is a real breakthrough in versatility

for holding in one single instrument for all the major features required in the vast

majority of industrial processes. With sophisticated and consistent software and its

advanced truly universal circuitry, the A9696 accepts configuration of both input signal

and control output through the front keyboard without any internal hardware change.

Power supply for remote loop powered transmitters is standard and is a must

for high-end applications. From the very simple applications as a temperature

A9696

controller to the most complex systems of distributed control with PLC’s or SCADA

networks, the A9696 is the right answer to your needs for industrial or laboratory

automation.

2. PRESENTATION

2.1 Features

1. Universal multi-sensor input without hardware change;

2. Sensor break protection in any condition;

3. Control outputs: relay, linear 4-20 mA, 0-20 mA, logic pulse;

4. Up to 4 alarms. Up to 2 timer relay alarms;

5. PV or SP 4-20mA or 0-20mA analog retransmission;

6. Auto/Manual “bump less” transfer;

7. Up to 2 digital inputs with 5 programmable functions;

8. 4-20 mA Remote Set-point input;

9. Programmable Soft Start (0 to 9999 seconds);

10. RS-485 digital communication; RTU MODBUS Protocol;

11. Firmware version displayed during power up;

12. Keyboard password protection;

13. RS-485, MODBUS RTU protocol, 1200 to 19200 bps;

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2.2 Technical Parameters

 Dimensions: 96 x 96 x 92 mm. Weight: 330 g  Front panel: IP65, Polycarbonate UL94 V-2.  Back panel: IP30, ABS+PC UL94 V-0  Panel cut-out: 93 x 93 mm (+0.5 -0.0 mm)  Terminal connection: 24 screws accepting 6.3 mm fork lugs  Power: 85 to 265 Vac/dc, 50/60 Hz. Max. Consumption: 3 VA  Environmental conditions: 0 to 55 C, humidity: 20 to 85 %

Installation category II, pollution degree 2. Altitude < 2000 m

 Keyboard selection of input type  Internal resolution: 19500 levels  Display resolution: 12000 levels (from -1999 to 9999)  Input sample rate: 5 per second  Accuracy: Thermocouples J, K and T: 0.25 % of span 1 ºC

Thermocouple N, R, S: 0.25 % of span 3 ºC

Pt100, 4-20 mA, 0-50 mV, 0-5 Vdc: 0.2 % of span

 Input impedance: 0-50 mV, Pt100 and T/C: >10M

0-5 V: >1 M 4-20 mA: 100 

 Pt100 measurement: DIN 43760 standard (=0.00385). Excitation current: 170 A. 3-wire

circuit, cable resistance compensation.

 Analog output: 0-20 mA or 4-20 mA, 1500 levels, 550  max.

 Two SPDT relays: 3 A / 250 Vac (3 A / 30 Vdc);  Two SPST relays: 3 A / 250 Vac (3 A / 30 Vdc);  Isolated 0-20 mA or 4-20 mA control output or PV or SP retransmission, 1500 level resolution,

550  max. Load;

 Logic pulse for SSR drive: 0 or 20 mA;  Any of the above can be selected as the main control output and the remaining outputs can

be set as alarms;

 Programmable PWM cycle from 0.5 sec. and 100 sec.;  Start up 3 seconds after power up;

 Up to 4 alarms can be set with 9 distinct functions for each one.

 2 Timing alarms, programmable from 0 to 6500 sec., with advanced functions, ideal for servo-

positioning.

 Independent power-up inhibition of the 4 alarms.

 Programmable hysteresis for the 4 alarms.

3. DIMENSIONS

A9696

PANEL

DIMENSION

CODE

A9696 96 96 91 91 100 93 923

PANEL

DIMENSION

W H W H D W H

CASE DIMENSION

HOLE

CUTOUT

DIMENSION

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4. ORDERING DETAILS

The basic unit includes one universal input, two SPST relays, two SPDT relays, 24Vdc

output for powering remote transmitters, one digital input, a 4-20 mA input for remote

set-point and one 4-20 mA output which can also be used as a digital input or output .

Option 1: RS485 digital communication interface with Modbus RTU protocol.

5. CONNECTIONS

5.1 Electrical Connections

All electrical connections are made to the screw terminals at the rear of the controller. They

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accept wire sizes from 0.5 to 1.5 mm2 (16 to 22 AWG). The terminals should be tightened to a torque

of 0.4 Nm (3.5 lb in).

5.2 Routing of Wires

To minimize the pick-up of electrical noise, the low voltage DC connections and the sensor

input wiring should be routed away from high-current power conductors. If this is impractical, use

shielded cables. In general, keep cable lengths to a minimum.

ABUS TECHNOLOGIES INC.

A9696

Controller Main Wiring

RTD Input Wiring

0 ~ 5 DC Wiring SPDT Relay Wiring in I/O1

Thermocouple and Voltage

Wiring

Current Wiring

6. INSTALLATION

Insert the unit into the panel cutout and slide the mounting clamp from the rear

to a firm grip at the panel.

Panel

Panel Attributes

ABUS TECHNOLOGIES INC.

A9696

S.No. Parameters

A1-A4

COM

TUNE

MAN

RUN

OUT

◄

▲

▼

Description

Show active alarms.

Flashes when communication messages are sent by the controller.

Lights during the execution of PID automatic tuning.

Lights when the controller is in manual.

Lights when the controller is active, with control and alarm outputs enabled.

For relay or pulse control output, reflects the actual state of the output. If an analog output is assigned for control, lights continuously.

Program Key: This key is used to access different displays with the programmable parameters of the device.

Back Key: This key is used to go back to the previous parameter displayed in the menu cycle.

UP / MAX Key: This key is used to increase parameter value, as well as to display maximum values stored in memory.

DOWN / MIN Key: This key is used to decrease parameter value, as well as to display minimum values stored in memory.

Display Shows the Process Variable (PV) and the programming prompts.

Display Shows the Set-Point Variable (SV) and the programming prompts.

S.NO. CYCLE ACCESS

This special function key is used for pre-programmed functions as explained in the table below.

Pre-Programmed Functions

1 Operation Free access parameters *

2 Tuning

3 R&S Program

4 Alarms Reserved access parameters **

5 Input Configuration

6 I/Os

7 Calibration

* These parameters can be viewed but not changed if the cycle is protected.

** Requires a key combination to access the cycle.

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(Green)

7. CONFIGURATION

7.1 Programming the Indicator

7.1.1 Operation Cycle

PARAMETER

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PROMPT PARAMETER DESCRIPTION

PV Indication

(Red)

SV Indication

avto

PV Indication

(Red)

MV Indication

(Green)

Pr n

rvn

7.1.2 Auto Tuning Cycle

PARAMETER

atvn

PV AND SV INDICATION: The status display shows the present value of PV (Process Variable). The parameter display shows SV (Set Variable).

The status display shows “- - - -“whenever PV exceeds the maximum range or there is no signal at the input. In case of hardware error the status display will show Ern, where n is the error code.

CONTROL MODE: YES indicates automatic control mode (closed loop, PID or ON/OFF). NO indicates manual control mode (open loop). Bumpless transfer from auto  to manual mode is available. If in doubt program YES.

MANIPULATED VARIABLE VALUE (MV): The upper display shows PV value and the lower display shows the percentage of MV applied to the control output. When in manual control the MV value can be manually changed. When in auto mode the MV value can only be viewed. To distinguish the MV display from the SV display, the MV is shown flashing intermittently.

RAMP AND SOAK PROGRAM SELECTION: Selects the ramp and soak program to be executed (7 programs possible).

CONTROL ENABLE: YES means that the control output and alarms are enabled and NO means they are disabled.

AUTO-TUNE: YES enables the auto tuning of the PID parameters and NO disables it.

PROMPT PARAMETER DESCRIPTION

xyst

‘ ir‘

bias

ovll

ovxl

sfst

PROPORTIONAL BAND: Percentage of maximum input span. Select zero for ON/OFF control.

CONTROL HYSTERESIS (in engineering units): This parameter is only shown for ON/OFF control (Pb=0).

INTEGRAL RATE: Integral time constant in repetitions per minute (Reset).

DERIVATIVE TIME: Derivative time constant, in seconds.

CYCLE TIME: PWM period in seconds. Can only be viewed if proportional band is other than zero.

Offset for MV (manual reset). Range: -100% to +100%. Default value: 0.

OUTPUT LOW LIMIT: minimum percentage value for MV (Manipulated Variable)

when in automatic control and PID. Default value: 0.0%

OUTPUT HIGH LIMIT: Maximum percentage value for MV when in automatic control and PID. Default value: 100.0%

SOFT START: Time in seconds during which the controller limits the MV value progressively from 0 to 100%. It is enabled at power up or when the control output is activated. If in doubt set zero.

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ALARM 1 PRESET: Tripping point for alarm 1.

Sp.a1

ALARM 2 PRESET: Tripping point for alarm 2.

Sp.a2

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Sp.a3

Sp.a4

7.1.3 Ramp and Soak Profile Programming Cycle

PARAMETER

tbas

Pr n

ptol

Psp0 Psp7

Pt1 Pt7

Pe1 Pe7

ALARM 3 PRESET: Tripping point for alarm 3.

ALARM 4 PRESET: Tripping point for alarm 4.

PROMPT PARAMETER DESCRIPTION

TIME BASE: Selects the time base for the ramp and soak. Valid for all profile programs.

0 - PT1 to PT7 values are in seconds; 1 - PT1 to PT7 values are in minutes;

PROGRAM TO BE VIEWED: Selects the ramp and soak profile program to be edited/viewed in the following cycle prompts (7 programs available).

RAMP AND SOAK TOLERANCE: maximum deviation between PV and SV. Whenever this deviation is exceeded the time counter is halted until deviation lowers to within the tolerance. Set zero to disable this function.

RAMP AND SOAK SET POINTS (0 to 7): Set of 8 SV values which define the ramp and soak profile segments. See also PT1 to 7 and PE1 to 7 below.

RAMP AND SOAK SEGMENTS TIME (1 to 7): Set of 7 time intervals for the 7 segments of the ramp and soak program. Up to 9999 seconds or minutes, according to tbAS parameter.

RAMP AND SOAK EVENT (1 to 7): Set of 7 values that define which alarms must be activated during a ramp and soak program segment.

Alarm function depends on “rS” setting (Table 7.4.2 ALARM FUNCTIONS).

tbas

Pr n

ptol

Psp0 Psp7

Pt1 Pt7

Pe1 Pe7

LINK TO PROGRAM: Number of the next profile program to be linked to follow the current profile. Profiles can be linked to make larger programs of up to 49 segments.