Despatch MIC 1162 Installation Manual

MIC 1162

MIC 1162

MIC 1162MIC 1162
HIGH/LOW LIMIT CONTROLLER

HIGH/LOW LIMIT CONTROLLER

HIGH/LOW LIMIT CONTROLLERHIGH/LOW LIMIT CONTROLLER
INSTRUCTION MANUAL

INSTRUCTION MANUAL

INSTRUCTION MANUALINSTRUCTION MANUAL

E-89
PN 136107
REVISION 10-07

TABLE OF CONTENTS

TABLE OF CONTENTS................................................................................................... i

SECTION 1: PRODUCT DESCRIPTION.......................................................................1

1.1 General................................................................................................................. 1

1.2 Displays................................................................................................................ 1

1.3 Alarms .................................................................................................................. 1

1.4 Process Variable/Setpoint Value Retransmission Output..................................... 2

SECTION 2: INSTALLATION AND WIRING.................................................................. 3

2.1 General Information.............................................................................................. 3

2.2 Wiring Guidelines ................................................................................................. 5

2.2.1 Installation Considerations.............................................................................5

2.2.2 AC Power Wiring............................................................................................ 6

2.2.3 Wire Isolation................................................................................................. 6

2.2.4 Use Of Shielded Cable .................................................................................. 7

2.2.5 Noise Suppression At The Source.................................................................7

2.3 Sensor Placement (Thermocouple or RTD) .........................................................9

2.4 Input Connections............................................................................................... 10

2.5 Output Connections............................................................................................13

SECTION 3: OPERATION........................................................................................... 15

3.1 Power Up Procedure .......................................................................................... 15

3.2 Keypad Operation............................................................................................... 15

3.3 Displays.............................................................................................................. 16

3.3.1 Alarm Status Display.................................................................................... 16

3.3.2 Over-Range/Under-Range Display ..............................................................16

3.4 Front Panel Indicators ........................................................................................ 17

3.5 Exceeding Limit Setpoint.................................................................................... 17

3.6 Annunciator ........................................................................................................ 18

3.7 Remote Reset (Optional).................................................................................... 18

SECTION 4: CONTROL MODE...................................................................................19

SECTION 5: SETPOINT CHANGE MODE ..................................................................21

SECTION 6: CONFIGURATION.................................................................................. 22

SECTION 7: SET-UP MODE ....................................................................................... 25

SECTION 8: ENABLE MODE ....................................................................................... 28

SECTION 9: CALIBRATION ........................................................................................ 29

APPENDIX A: BOARD LAYOUT - JUMPER POSITIONING ........................................ 32

APPENDIX B: HARDWARE DEFINITION CODE.........................................................35

APPENDIX C: INPUT RANGE CODES........................................................................37

APPENDIX D: SPECIFICATIONS................................................................................. 38

APPENDIX E: ORDER MATRIX ...................................................................................42

APPENDIX F: SOFTWARE REFERENCE SHEET ......................................................43

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SECTION 1: PRODUCT DESCRIPTION

1.1 General

This instrument is a microprocessor based single loop controller capable of measuring
and displaying temperature, pressure, flow, and level from a variety of inputs. The
control is configurable to be either high-limit, low-limit, or both types.

Control functions, alarm settings and other parameters are easily entered through the
front keypad. E2 Technology (100 year life) protects against data loss during AC power
outages.

The input is user configurable to directly connect to either thermocouple, RTD, mVDC,
VDC or mADC inputs. The instrument can operate from either a 90-264 VAC, 50/60 HZ
power supply, or optional 24V AC/DC power supply.

1.2 Displays

Each instrument is provided with dual displays and status indicators as shown in Figure
1 -1. Typically, the upper display displays the value of the process variable, while the
lower display displays the setpoint value. Alternate displays can be selected in the
Setup Mode.

1.3 Alarms

Alarm indication is standard on all instruments. Up to two alarm outputs are optional.
Alarm type may be set as Process Direct or Reverse (high or low), Logical Combination
of the two alarms, Annunciator Direct or Reverse, High Limit, or Low Limit. Alarm
status is indicated by LED.

1

FIGURE 1-1 Keys and Indicators

1.4 Process Variable/Setpoint Value Retransmission Output

If the instrument is specified with this option, this output may be scaled over
any desired range and re-transmitted, through optional Output 3.

2

SECTION 2: INSTALLATION AND WIRING

2.1 General Information

Electrical code requirements and safety standards should be observed and installation
performed by qualified personnel.

The electronic components of the instrument may be removed from the housing during
installation. To remove the components, grip the side edges of the front panel and pull
the instrument forward. During re-installation, the vertically mounted circuit boards
should be properly aligned in the housing.

Ensure that the instrument is correctly orientated. A stop will operate if an attempt is
made to insert the instrument incorrectly.

Recommended panel opening sizes are illustrated in Figure 2-1. After the opening is
properly cut, insert the instrument into the panel opening. Ensure that the panel gasket
is not distorted and that the instrument is positioned squarely against the panel. Slide
the mounting clamp into place on the instrument and push it forward until it is firmly in
contact with the rear face of the mounting panel.

Note: The mounting clamp tongues may engage either on the sides or the
top/bottom of the instrument housing. Therefore when installing several
instruments side-by-side in one cut-out, use the ratchets on the top/bottom faces.

3

FIGURE 2-1
Panel Cut-Out Dimensions

FIGURE 2-2
Main Dimensions

4

FIGURE 2-3
Panel Mounting the Controller

2.2 Wiring Guidelines

Electrical noise is a phenomenon typical of industrial environments. The following are
guidelines that must be followed to minimize the effect of noise upon any
instrumentation.

2.2.1 Installation Considerations

Listed below are some of the common sources of electrical noise in the
industrial environment:

• Ignition Transformers

• Arc Welders

• Mechanical contact relay(s)

• Solenoids

Before using any instrument near the device listed, the instructions below
should be followed:

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1. If the instrument is to be mounted in the same panel as any of the listed devices,

separate them by the largest distance possible. For maximum electrical noise
reduction, the noise generating devices should be mounted in a separate enclosure.

2. If possible, eliminate mechanical contact relay(s) and replace with solid state relays.

If a mechanical relay being powered by an instrument output device cannot be
replaced, a solid state relay can be used to isolate the instrument.

3. A separate isolation transformer to feed only instrumentation should be considered.

The transformer can isolate the instrument from noise found on the AC power input.

4. If the instrument is being installed on existing equipment, the wiring in the area

should be checked to insure that good wiring practices have been followed.

2.2.2 AC Power Wiring

Neutral (For 115 VAC)
It is good practice to assure that the AC neutral is at or near ground potential. To verify
this, a voltmeter check between neutral and ground should be done. On the AC range,
the reading should not be more than 50 millivolts. If it is greater than this amount, the
secondary of this AC transformer supplying the instrument should be checked by an
electrician. A proper neutral will help ensure maximum performance from the
instrument.

2.2.3 Wire Isolation

Three voltage levels of input and output wiring may be used with the unit:

• Analog input or output (i.e. thermocouple, RTD, VDC, mVDC, or mADC)

• SPDT Relays

• AC power

The only wires that should run together are those of the same category. If they need to
be run parallel with any of the other lines, maintain a minimum 6 inch space between
the wires. If wires must cross each other, do so at 90 degrees. This will minimize the
contact with each other and reduces "cross talk". "Cross Talk" is due to the EMF
(Electro-Magnetic Flux) emitted by a wire as current passes through it. This EMF can
be picked up by other wires running in the same bundle or conduit.

In applications where a High Voltage Transformer is used (i.e. ignition systems) the
secondary of the transformer should be isolated from all other cables.

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This instrument has been designed to operate in noisy environments, however, in some
cases even with proper wiring it may be necessary to suppress the noise at its source.

2.2.4 Use Of Shielded Cable

Shielded cable helps eliminate electrical noise being induced on the wires. All analog
signals should be run with shielded cable. Connection lead length should be kept as
short as possible, keeping the wires protected by the shielding. The shield should be
grounded at one end only. The preferred grounding location is the sensor, transmitter
or transducer.

2.2.5 Noise Suppression At The Source

Usually when good wiring practices are followed no further noise protection is
necessary. Sometimes in severe electrical environments, the amount of noise is so
great that it has to be suppressed at the source. Many manufacturers of relays,
contactors, etc. supply “surge suppressors" which mount on the noise source.

For those devices that do not have surge suppressors supplied, RC (resistance­capacitance) networks and/or MOV (metal oxide varistors) may be added.

Inductive Coils - MOV's are recommended for transient suppression in inductive coils
connected in parallel and as close as possible to the coil. See Figure 2-4. Additional
protection may be provided by adding an'RC network across the MOV.

7

FIGURE 2-4

Contacts - Arcing may occur across contacts when the contact opens and closes. This
results in electrical noise as well as damage to the contacts. Connecting a RC network
properly sized can eliminate this arc.

For circuits up to 3 amps, a combination of a 47 ohm resistor and 0.1 microfarad
capacitor (1 000 volts) is recommended. For circuits from 3 to 5 amps, connect 2 of
these in parallel. See Figure 2-5.

FIGURE 2-5

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2.3 Sensor Placement (Thermocouple or RTD)

Two wire RTD's should be used only with lead lengths less than 10 feet.
If the temperature probe is to be subjected to corrosive or abrasive conditions, it should

be protected by the appropriate thermowell. The probe should be positioned to reflect
true process temperature:

In liquid media - the most agitated area
In air - the best circulated area

FIGURE 2-6
Wiring Label

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2.4 Input Connections

In general, all wiring connections are made to the instrument after it is installed. Avoid
electrical shock. AC power wiring must not be connected to the source distribution
panel until all wiring connection procedures are completed.

FIGURE 2-7A
Main Supply
The instrument will operate on 90-264V AC 50/6OHz main supply. The power
consumption is approximately 4 VA. Connect the line voltage, hot and neutral, to
terminals 9 to 10 respectively as illustrated below.

FIGURE 2-7B
24V (Nominal) AC/DC Supply
The supply connections for the 24V AC/DC versions of the instrument are
shown below.

FIGURE 2-8
Thermocouple (T/C) Input
Make thermocouple connections as illustrated below. Connect the positive
leg of the thermocouple to terminal 5 and the negative leg to terminal 4.

FIGURE 2-9

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RTD Input
Make RTD connections as illustrated below. For a three wire RTD, connect the
resistive leg of the RTD to terminal 6 and the common legs to terminals 4 and 5. For a
two wire RTD, connect one leg to terminal 5 and the other leg to terminal 6 as shown
below. A jumper wire supplied by the customer must be installed between terminals 4
and 5. Input conditioning jumper must be positioned correctly (see Appendix A) and
Hardware Definition Code must be correct (see Appendix B).

FIGURE 2-10
Volt, mV Input
Make volt and millivolt connections as shown below. Terminal 5 is positive and terminal
4 is negative. Input conditioning jumper must be positioned correctly (see Appendix A)
and Hardware Definition Code must be correct (see Appendix B).

mADC Input
Make mADC connections as shown below. Terminal 4 is positive and terminal 6 is
negative. Input conditioning jumper must be positioned correctly (see Appendix A) and
Hardware Definition Code must be correct (see Appendix B).

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