Despatch MIC 1462 Installation Manual
MIC 1462
MIC 1462
MIC 1462MIC 1462
SETPOINT PROGRAMMER
SETPOINT PROGRAMMER
SETPOINT PROGRAMMERSETPOINT PROGRAMMER
INSTRUCTION MANUAL
INSTRUCTION MANUAL
INSTRUCTION MANUALINSTRUCTION MANUAL
E-91
PN 136109
REVISION 10-07
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TABLE OF CONTENTS
SECTION 1: PRODUCT DESCRIPTION....................................................................... 1
1.1 General ................................................................................................................. 1
1.2 Displays................................................................................................................. 2
1.3 Control................................................................................................................... 2
1.4 Alarms................................................................................................................... 2
1.5 Re-Transmission (Analog) Output......................................................................... 2
1.6 Remote Inputs....................................................................................................... 2
1.7 Event Outputs ....................................................................................................... 3
1.8 Real-Time Clock.................................................................................................... 3
1.9 Communications ...................................................................................................3
SECTION 2: INSTALLATION & WIRING....................................................................... 5
2.1 Unpacking Procedure.......................................................................................... 5
2.2 Panel-Mounting The Setpoint Programmer........................................................ 5
2.3 Wiring Guidelines.................................................................................................. 7
2.4 Sensor Placement (Thermocouple Or RTD)..................................................... 10
2.5 Input Connections............................................................................................... 13
SECTION 3: OPERATION........................................................................................... 23
3.1 Control Responses............................................................................................... 23
3.2 Direct/Reverse Operation of Outputs ..................................................................23
3.3 On-Off Control..................................................................................................... 24
3.4 Time Proportioning Control .................................................................................24
3.5 Current Proportioning Control .............................................................................24
3.6 Power Up Procedure........................................................................................... 26
3.7 Keypad Operation............................................................................................... 26
3.8 Indicators............................................................................................................. 28
3.9 Displays............................................................................................................... 29
3.10 Viewing Setpoint And Control Status ...............................................................30
3.11 Viewing And Adjusting The Controller Setpoint................................................. 30
3.12 Viewing The Input Units ....................................................................................30
3.13 Base Mode And Off Mode Outputs................................................................... 31
3.14 Alarm Status Indication .....................................................................................31
3.15 Manual Control.................................................................................................. 31
3.16 Viewing The Time And Day............................................................................... 32
3.17 Selecting And Running A Program.................................................................... 32
3.18 Changing The Program Timebase .................................................................... 32
3.19 Holding A Program Manually............................................................................. 33
3.20 Jumping To The Next Segment ........................................................................ 33
3.21 Viewing Program Progress/Status ....................................................................34
3.22 Aborting A Program........................................................................................... 35
3.23 "End Of Program" Indication ............................................................................. 35
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SECTION 4: ACCESSING MODES OF THE CONTROLLER ..................................... 37
SECTION 5: USING THE PRETUNE AND AUTOTUNE FEATURES ......................... 39
5.1 Using The Pre-Tune Facility................................................................................ 39
5.2 Using The Auto-Tune Facility.............................................................................. 39
SECTION 6: PROFILE SET MODE............................................................................. 41
6.1 Entry Into Profile Set Mode .................................................................................41
6.2 Parameters Common To All Programs ...............................................................43
6.3 Parameters Which Apply To A Specific Program As A Whole............................ 45
6.4 Editing/Viewing Parameters In Any/Each Segment In A Specific Program.........47
6.5 Using Join, Repeat And End Segments And Cycling Programs ......................... 48
6.6 Basic Rules To Remember .................................................................................50
6.7 Exiting Profile Set Mode...................................................................................... 50
6.8 Sample Profile..................................................................................................... 51
SECTION 7: TUNE MODE........................................................................................... 55
SECTION 8: ALARM MODE ........................................................................................59
8.1 Alarm Inhibit Facility............................................................................................ 61
8.2 Loop Alarm And Loop Alarm Time...................................................................... 61
SECTION 9: ENABLE MODE ......................................................................................63
SECTION 10: CONFIGURATION MODE ....................................................................65
10.1 Entering The Configuration Mode .....................................................................65
10.2 Hardware Definition Code................................................................................. 66
10.3 Configuration Mode Parameters .......................................................................69
10.4 Controller Parameters....................................................................................... 70
SECTION 11: TEST MODE ......................................................................................... 73
SECTION 12: CALIBRATION MODE........................................................................... 75
12.1 Calibration Procedure ....................................................................................... 75
Calibration Procedure ............................................................................................. 75
APPENDIX A: RANGE CODES ...................................................................................79
For Thermocouple Inputs........................................................................................... 79
For RTD Inputs........................................................................................................... 79
For DC Inputs............................................................................................................. 80
APPENDIX B: BOARD LAYOUT, JUMPER POSITIONING ........................................ 81
APPENDIX C: SPECIFICATIONS................................................................................ 87
Input Specifications.................................................................................................... 87
Output Specifications................................................................................................. 88
Control Specifications ................................................................................................ 91
Program Specifications.............................................................................................. 92
Performance............................................................................................................... 94
Environmental ............................................................................................................96
Physical...................................................................................................................... 96
APPENDIX D: SOFTWARE REFERENCE SHEET...................................................... 97
APPENDIX E: FLOW CHART OF OPERATION........................................................ 103
APPENDIX F: MODEL NUMBER HARDWARE MATRIX.......................................... 105
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SECTION 1: PRODUCT DESCRIPTION
1.1 General
This instrument is a powerful, easy-to-use 1/4 DIN setpoint programmer with full PID
control capability (complete with Self-Tune and Pre-Tune facilities).
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.
Standard features include:
• Up to eight programs of up to 16 free-format (i.e., dwell, ramp, join, or end)
segments each.
• Facility to join programs to one another in any sequence (maximum program length
121 segments)
• User can change currently-running program segment.
• Delayed Start of Program facility
• End of Program relay output
• Universal input-thermocouple, RTD (PT100) or DC linear user-selectable.
• Universal power supply (90 -264V AC 50/60 Hz)
• Configurable from front panel
• Comprehensive front panel displays
• Front panel sealing to NEMA 4 standard
• Behind-panel depth only 100mm (3.94 inches)
• Power failure recovery
Optional features include:
• Remote control and selection of program (plug-in option)
• Up to four Event relay outputs (plug-in option)
• Second control output
• Alarm outputs
• Recorder output (setpoint or process variable)
• RS-485 serial communications
• User-definable program tag names
• Support software (Off-line Configurator, On-line Graphic Program Editor) - operates
via RS-485 communications link.
• Real-time clock
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1.2 Displays
Each instrument is provided with two main displays, a message display, and status
indicators as shown in Figure 1 -1. The upper main display shows the value of the
process variable. The lower main display shows the setpoint value. The message
display shows parameter tag names and mode list items during various modes of
operation.
1.3 Control
The instrument can be programmed for on-off, time proportioning, or current
proportioning control implementations depending on the model number. A second
control output is an available option. Proportional control implementations are provided
with fully programmable PID parameters. In addition, setpoint programming is available
to step the controller through ramp and soak segments.
1.4 Alarms
Alarm indication is standard on all instruments. Up to two alarm outputs are possible.
Alarm type may be set as Process Direct or Reverse (high or low), Deviation Direct or
Reverse (above or below setpoint), Deviation Band Type (closed or open within band),
or Loop Reverse or Direct. Alarm status is indicated by LED. An Alarm Inhibit is
provided to prevent, when activated, unwanted alarms during power-up.
1.5 Re-Transmission (Analog) Output
If the instrument is specified with this option, the process variable or setpoint value can
be scaled over any desired range and re-transmitted
1.6 Remote Inputs
The optional remote inputs allow for external selection of a profile; profile start; hold; or
reset; and for selection of profile timebase.
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1.7 Event Outputs
The optional event outputs may be used to control external components during either
single setpoint control (Base Mode) operation or during a profile (Program Run Mode).
The events can be configured as timed or process value events.
1.8 Real-Time Clock
The instrument may be fitted with a real-time clock which allows starting a profile at a
specific time and day. The clock may also be used by the controller to determine
whether to restart a profile or return to Base Mode when a power loss occurs.
1.9 Communications
The optional communications feature allows the instrument to be controlled from an
external source or to supply digital information. This feature provides for
uploading/downloading of profiles and configuration information.
FIGURE 1-1 Front Panel
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SECTION 2: INSTALLATION & WIRING
2.1 Unpacking Procedure
1. Remove the instrument from its packing. The instrument is supplied with a panel
gasket and push-fit strap. Retain the packing for future use, should it be necessary
to transport the instrument to a different site or return it to the factory for
repair/testing.
2. Examine the delivered items for damage or deficiencies. If any is found, notify the
carrier immediately. Check that the model number shown on the label affixed to the
instrument housing corresponds to that ordered (see Appendix D).
2.2 Panel-Mounting The Setpoint Programmer
The panel on which the instrument is to be mounted must be rigid and may be up to 6.0
mm (.25 inches ) thick. The cutout required for a single instrument is shown in Figure
2-1.
FIGURE 2-1
Cut-Out Dimensions
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The main dimensions of the instrument are shown below.
FIGURE 2-2
Main Dimensions
To panel-mount the instrument:
1. Insert the rear of the instrument housing through the cutout (from the front of the
mounting panel) and hold the instrument lightly in position against the panel.
Ensure that the panel gasket is not distorted and that the instrument is positioned
squarely against the mounting panel. Apply pressure to the front panel bezel only.
Caution: Do not remove the panel gasket, as this may result in inadequate
clamping of the instrument in the panel.
2. Slide the fixing strap in place (Figure 2-3) and push it forward until it is firmly in
contact with the rear face of the mounting panel (the tongues on the strap should
have engaged in matching ratchet positions on the instrument housing and the fixing
strap springs should be pushing firmly against the mounting panel rear face).
Once the instrument is installed in its mounting panel, it may be subsequently removed
from its housing, if necessary, as described in Appendix B.
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FIGURE 2-3
Panel-Mounting the Instrument
2.3 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.
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.
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.
WIRE ISOLATION
Four 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
• SSR driver outputs
• 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
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 the source.
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.
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.
FIGURE 2-4
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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 (1000 volts) is recommended. For circuits from 3 to 5 amps, connect 2 of
these in parallel. See Figure 2-5, below.
FIGURE 2-5
2.4 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
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FIGURE 2-6
Rear Terminal Connections
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FIGURE 2-6A
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2.5 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.
Caution: This equipment is designed for installation in an enclosure which
provide adequate protection against electric shock. Local regulations regarding
electrical installation should be rigidly observed. Consideration should be given
to prevention of access to the power terminations by unauthorized personnel.
Power should be connected via a two pole isolating switch (preferably situated
near the equipment) and a 1A fuse, as shown in Figure 2-7.
FIGURE 2-7
Line Supply
The instrument will operate on 90-264V AC 50/60 Hz electrical line supply. The power
consumption is approximately 4 VA. If the instrument has relay outputs in which the
contacts are to carry line voltage, it is recommended that the relay contact line supply
should be switched and fused in a similar manner but should be separate from the
instrument line supply.
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FIGURE 2-7A
24V Nominal AC/DC Supply
The supply connection for the 24V AC/DC option of the instrument are as shown below.
Power should be connected via a two pole isolating switch and a 315 mA slow-blow
(anti-surge type T) fuse. With the 24V AC/DC supply option fitted, these terminals will
accept the following supply voltage ranges:
• 24V (nominal) AC 50/6OHz - 20-50V
• 24V (nominal) DC - 22-65V
FIGURE 2-8
Thermocouple (T/C) Input
Make the thermocouple connections as illustrated below. Connect the positive leg of
the thermocouple to terminal 2 and the negative leg to terminal 3.
Note: Thermocouple must not be grounded! Damage to the cold junction in the
control will result!
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FIGURE 2-9
RTD Input
Make RTD connections as illustrated below. For a three wire RTD, connect the
resistive leg of the RTD to terminal 1 and the common legs to terminals 2 and 3. For a
two wire RTD, connect one leg to terminal 2 and the other leg to terminal 3 as shown
below. A jumper wire supplied by the customer must be installed between terminals 2
and 3. Input conditioning jumper must be positioned correctly (see Appendix B) and
Hardware Definition Code must be correct (see Section 10).
FIGURE 2-10
Volt, mV Input
Make volt and millivolt connections as shown below. Terminal 2 is positive and terminal
3 is negative. Input conditioning jumper must be positioned correctly (see Appendix B)
and Hardware Definition Code must be correct (see Section 10).
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FIGURE 2-11
mADC Input
Make mADC connections as shown below. Terminal 4 is positive and terminal 1 is
negative. Input conditioning jumper must be positioned correctly (see Appendix B) and
Hardware Definition Code must be correct (see Section 10).
FIGURE 2-12
Remote Digital Communications - RS485
Make digital communication connections as illustrated below.
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FIGURE 2-13
Relay Output 1 (Control Output 1)
Connections are made to Output 1 relay as illustrated below. The contacts
are rated at 2 amp resistive, 120/240 VAC .
FIGURE 2-14
SSR Driver Output 1 (Control Output 1)
Connections are made to Output 1 SSR Driver as illustrated below. The solid state
relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.
FIGURE 2-15
mADC Output 1 (Control Output 1)
Make connections for DC Output 1 as illustrated below.
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FIGURE 2-16
Relay Output 2 (Control Output 2 OR Alarm 2)
Connections are made to Output 2 relay as illustrated below. The contacts
are rated at 2 amp resistive, 120/240 VAC.
FIGURE 2-17
SSR Driver Output 2 (Control Output 2 OR Alarm 2)
Connections are made to Output 2 SSR Driver as illustrated below. The solid state
relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.
FIGURE 2-18
mADC Output 2 (Control Output 2)
Make connections for DC Output 2 as illustrated below.
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FIGURE 2-19
Relay Output 3 (Alarm 1)
Connections are made to Output 3 relay as illustrated below. The contacts
are rated at 2 amp resistive, 120/240 VAC.
FIGURE 2-20
SSR Driver Output 3 (Alarm 1)
Connections are made to Output 3 SSR Driver as illustrated below. The solid state
relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.
FIGURE 2-21
mADC Output 3 (Recorder Output Only)
Make connections for DC output 3 as illustrated below.
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FIGURE 2-22
End of Program Output
Connections are made to End of Program Output as shown below. The
contacts are rated at 5 amp resistive, 120/240 VAC.
FIGURE 2-23
Event Outputs (optional)
If the Event Outputs have been specified, make connections as shown below. The
contacts are rated at 5 amps, 120/240 VAC.
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FIGURE 2-24
Remote Program Inputs (optional)
If the Remote Program Control Inputs has been specified, make connections as shown.
Note: Only one remote connection shown for clarity.
Remote inputs may be used to control parameters normally operated via the keypad.
Remote inputs are operated by closing an external relay. R0, R1 and R2 form a threebit digital representation of the desired profile, with R0 being the least significant bit.
Closing the RESET input will cause a running profile to abort. Closing the RUN/HOLD
relay will start a profile. Subsequently opening this contact will hold the profile at its
current setting and closing it again will continue the profile. The X60 or JUMP input is
configurable to cause either a change to the profile timebase (X60) or jump to the next
segment (JUMP).
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SECTION 3: OPERATION
3.1 Control Responses
Each instrument may be configured to provide three mode proportional control.
Proportional control is provided with Proportional Band, Integration, and Derivative
responses. The PID parameters are defined as follows:
Out 1 Out2
P (Proportional) Proportional Band Pb1 Pb2
I (integration) Automatic Reset ArSt ArSt
D (Derivative) Rate rAtE rAtE
Manual Reset is provided for use in lieu of, or in conjunction with automatic reset. A
cycle time adjustment parameter is provided for use with each time proportioning
control output.
3.2 Direct/Reverse Operation of Outputs
Direct operation is typically used with cooling applications. On-Off direct output(s) will
turn on when the process variable exceeds setpoint. Proportional direct output(s) will
increase the percentage of output as the process value increases within the
proportional band.
Reverse operation is typically used with heating applications. On-Off reverse output(s)
will turn off when the process variable exceeds setpoint. Proportional reverse output(s)
will decrease the percentage of output as the process value increases within the
proportional band.
Output 2 will be Direct when Output 1 is selected as Reverse and Reverse
when Output 1 is selected as Direct.
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3.3 On-Off Control
On-Off control can be implemented with SPDT relay or SSR driver output(s) by setting
the corresponding proportional band (Pb) to 0.0. On-Off operation can be assigned to
Output 1 only (Output 2 not present), Output 1 AND Output 2, or Output 2 only (Output
1 is time proportional or current proportional). A hysteresis adjustment is provided for
On-Off outputs, "HySl " for Output 1 only, "HySt" for Output 1 AND Output 2, or "HyS2"
for Output 2 only. This adjustment is in % of input span and defines the bandwidth of
the hysteresis. Relay chatter can be eliminated by proper adjustment of this parameter.
When operating in On-Off control, the output(s) will turn on or off depending upon the
setpoint, the process value, and the hysteresis adjustment.
3.4 Time Proportioning Control
Time Proportioning control can be implemented with a SPDT relay or SSR driver. Time
proportioning control can be selected for either Output 1 or Output 1 and Output 2,
depending on hardware configuration. Time proportioning control is accomplished by
cycling the output on and off during a prescribed period of time when the process
variable is within the proportional band.
Ex: Calculated output % = 40%; Cycle time adjustment = 32 seconds
Output on time =.4 x 32 = 12.8 seconds
Output off time = .6 x 32 = 19.2 seconds
When the unit is operating in the Control Mode, the control algorithm determines the
output % required to correct for any difference between the process value and the
setpoint. The output calculation is affected by Tune Mode parameter adjustments. See
Figure 3-1 for proportional bandwidth effect on the output.
3.5 Current Proportioning Control
Current Proportioning control can be implemented on units provided with mADC current
output(s). Current Proportioning control provides a 4 to 20 mADC or 0-20 mADC output
in response to process value and setpoint. As with Time proportioning, the calculated
output % for Current proportioning is affected by the Tune Mode parameter
adjustments.
See Figure 3-1 (below) for proportional bandwidth effect on the output.
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FIGURE 3-1
Proportional Band 1
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3.6 Power Up Procedure
Verify all electrical connections have been properly made before applying power to the
instrument.
If the instrument is being powered for the first time, it may be desirable to disconnect
the controller output connections. The instrument will be into control following the
power up sequence and the output(s) may turn on. During Power up, a self-test
procedure is initiated during which all LED segments in the two front panel displays
appear and all LED indicators are on. When the self-test procedure is complete, the
instrument reverts to normal operation.
Note: When power is first applied, a delay of approximately 3 seconds will be seen
before the displays light up.
3.7 Keypad Operation
MODE Key - Cycles through modes available in the instrument.
SCROLL Key - Displays the next parameter in sequence (indicated by
Message display).
UP Key
Increments displayed parameter value/cycles through options.
DOWN Key
Decrements displayed parameter value/cycles through options.
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