Despatch Protocol 3 Controller User Manual

Protocol 3 Owner’s Manual PREFACE

PROTOCOL 3™ Controller

OWNER’S MANUAL

E-105 PN 313327 VERSION 1.2 6/2013

Version 1.2 1

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

PREFACE Protocol 3 Controller Owner’s Manual

Revision

Date

Author

Description

1.0

1/2012

K. Livingston

Initial release

1.1

3/2013

K. Livingston

Modified instructions for delayed start and remote communication. Modbus User’s Programming Manual added (E-106/ PN320813, Version 3/2013, Updated for Engineering Issue 8).

1.2

6/2013

K. Livingston

Minor edits

2 Version 1.2

Revision History

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Owner’s Manual PREFACE Version 1.2 3

Table of Contents

1. About This Manual ................................................................................................. 6

1.1. Important User Information .......................................................................... 6

1.2. Manufacturer & Service ................................................................................ 7

1.3. Organization of this Manual ......................................................................... 8

1.4. Conventions .................................................................................................. 8

1.5. Specifications ................................................................................................ 9

2. Safety .................................................................................................................... 13

2.1. Safety Information ...................................................................................... 13

2.1.1. Lockout.................................................................................................... 13

2.1.1.1. Lockout Requirements ......................................................................... 13

2.1.1.2. Lockout Procedure with Despatch Products ........................................ 13

2.2. Maintenance ................................................................................................ 13

2.3. Electrical Power .......................................................................................... 14

2.4. Fire .............................................................................................................. 14

2.5. Equipment Lockout Requirements ............................................................. 14

3. Theory of Operation .............................................................................................. 15

3.1. System Control—In General....................................................................... 15

3.1.1. High-Limit Function ............................................................................... 15

3.1.2. Outputs .................................................................................................... 16

3.2. Remote Communication ............................................................................. 16

4. Assembly & Setup ................................................................................................ 18

4.1. Install the Protocol 3 Controller .................................................................. 18

4.2. Protocol 3 Controller Conversion with NO Options................................... 18

4.3. Setting Up Remote Communication ........................................................... 19

5. Working with Operating Modes ........................................................................... 20

5.1. User Controls .............................................................................................. 20

5.2. First Screens ................................................................................................ 23

5.2.1. Manual Mode .......................................................................................... 24

5.2.1.1. Display Manual Mode ......................................................................... 24

5.2.1.2. Start Manual Mode .............................................................................. 24

5.2.2. Timer Mode ............................................................................................. 25

5.2.3. Profile Mode ............................................................................................ 26

5.2.4. Main Menu .............................................................................................. 27

5.3. Setting up a Profile...................................................................................... 29

5.3.1. Prepare for Profile Setup ......................................................................... 33

5.3.2. Sample Profile ......................................................................................... 35

5.3.3. Key In the Sample Profile Setup ............................................................. 37

5.4. Recorder Control ......................................................................................... 40

5.5. USB Menu .................................................................................................. 41

5.5.1. Working with USB Memory Stick Folders and Files ............................. 43

5.5.2. File Naming Conventions........................................................................ 44

5.5.3. Create a New Name Before Writing to the USB Device ........................ 44

5.6. Configuration Menu .................................................................................... 45

5.6.1. Alarm Configuration ............................................................................... 49

means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

PREFACE Protocol 3 Controller Owner’s Manual 4 Version 1.2

5.6.1.1. Access the Configuration Menu .......................................................... 49

5.6.1.2. Work with the Alarm Menu ................................................................. 49

5.6.1.3. Using Alarms to Switch Relay Outputs ............................................... 50

5.6.1.4. Alarm Application Example ................................................................ 51

5.6.1.5. Glossary of Alarm Terms .................................................................... 52

5.6.2. Working with Calibration Offsets ........................................................... 54

5.6.2.1. Access the Configuration Menu .......................................................... 54

5.6.2.2. Working with Input Configuration ...................................................... 54

5.6.2.3. Factory Calibration .............................................................................. 55

5.6.2.4. Single Point Calibration....................................................................... 55

5.6.2.5. Two Point Calibration ......................................................................... 55

5.6.3. Setting Up Remote Communication ....................................................... 56

5.7. Automatic Tuning ....................................................................................... 56

5.8. Product Information .................................................................................... 57

5.9. Service Information .................................................................................... 57

5.10. Remote Operation ................................................................................... 58

5.11. Setting Up Digital Inputs......................................................................... 59

6. Maintenance .......................................................................................................... 61

6.1. Replacement Parts ....................................................................................... 61

7. Troubleshooting .................................................................................................... 62

7.1. Error Messages and Alarm.......................................................................... 62

7.2. Controller Firmware Revision .................................................................... 62

7.3. Troubleshoot Protocol Manager/Protocol 3 Controller Communication.... 62

8. Appendices ............................................................................................................ 67

8.1. Standard Products Warranty ....................................................................... 67

8.2. Modbus Programming ................................................................................ 68

8.3. Programming Worksheet ............................................................................ 68

Figures

Figure 1. Operator Interface. ............................................................................................. 15

Figure 2. Typical Controller Output Sticker. .................................................................... 17

Figure 3. Protocol Plus to Protocol 3 Connection Conversions........................................ 17

Figure 5. Select a Mode Display. ...................................................................................... 20

Figure 6. Manual Mode Display Screen. .......................................................................... 24

Figure 7. Timer Mode Display Screen. ............................................................................. 25

Figure 8. Profile Mode. ..................................................................................................... 27

Figure 9. Main Menu. ....................................................................................................... 28

Figure 10. Profile Setup. ................................................................................................... 29

Figure 11. Profile Setup Menu. ......................................................................................... 31

Figure 12. Sample Profile. ................................................................................................ 35

Figure 13. Sample Profile Values. .................................................................................... 36

Figure 14. Recorder Control. ............................................................................................ 40

Figure 15. Recorder Status. ............................................................................................... 40

Figure 16. USB Menu. ...................................................................................................... 41

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Owner’s Manual PREFACE Version 1.2 5

Figure 17. USB Port on Front Panel. ................................................................................ 43

Figure 18. USB Files and Folders Requirements (as seen from Windows Explorer). ..... 43

Figure 19. Configuration Menu (see also Table 16 for more information). ..................... 46

Figure 4. How High, Low and Band process alarms are implemented. ........................... 53

Figure 20. Service Information Screen. ............................................................................ 58

Figure 21. Standard Digital Input Wiring. ........................................................................ 59

Figure 22. Check Cabling. ................................................................................................ 63

Figure 23. Older model serial converter schematic. ......................................................... 64

Figure 24. Newer model serial converter schematic. ....................................................... 65

Figure 25. USB Converter Schematic. .............................................................................. 66

Tables

Table 1. Process Input. ........................................................................................................ 9

Table 2. Outputs. ............................................................................................................... 10

Table 3. Operating Conditions (For indoor use). .............................................................. 11

Table 4. Conformance Norms. .......................................................................................... 11

Table 5. Display. ............................................................................................................... 11

Table 6. Data Recorder. .................................................................................................... 12

Table 7. Protocol Plus to Protocol 3 Controller Conversion. ........................................... 18

Table 9. Keypad Buttons and Functions. .......................................................................... 20

Table 10. LEDs and Functions.......................................................................................... 22

Table 11. Sub Menu Descriptions ..................................................................................... 28

Table 12. Profile Setup Options. ....................................................................................... 30

Table 13. Profile Setup Steps, Options and Descriptions. ................................................ 32

Table 14. Profile Parameter Options. ................................................................................ 39

Table 15. USB Menu Options. .......................................................................................... 42

Table 16. Configuration Menu in Tabular Format............................................................ 47

Table 8. Protocol 3 Possible Alarm Settings. ................................................................... 49

Table 17. Automatic Tuning Options. .............................................................................. 56

Table 18. Product Information Details. ............................................................................. 57

Table 19. Input settings. .................................................................................................... 59

Table 20. Error Messages and Next Steps. ....................................................................... 62

Table 21. Programming Worksheet. ................................................................................. 68

means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL Protocol 3 Controller Owner’s Manual



Values displayed on screens are examples only. Though those values may be typical, contact Despatch Industries for the final value.



Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 6 and relevant safety standards, as well as other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), section 86 of 1990.

6 Version 1.2

1. About This Manual

1.1. Important User Information

All rights reserved. No part of the contents of this manual may be reproduced, copied, or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of the publisher, unless it is for the purchaser's personal use.

Printed and bound in the United States of America.

The information in this manual is subject to change without notice and does not represent a commitment on the part of Despatch Industries. Despatch Industries does not assume any responsibility for any errors that may appear in this manual.

In no event will Despatch Industries be liable for technical or editorial omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual ABOUT THIS MANUAL

Danger!

Only fully-trained and qualified personnel should setup and maintain this equipment. Improper setup and operation of this equipment could cause an explosion that may result in equipment damage, personal injury or possible death.



Modbus communication protocols require the Protocol 3 controller be updated to version 2.3 or higher.

Global Headquarters

Contact

Service & Technical Support

Despatch Industries

8860 207th Street Lakeville, MN 55044 USA

International/Main: 1-952-469-5424 US toll free: 1-888-337-7282 Fax: 1-952-469-4513 info@despatch.com www.despatch.com

Service: 1-952-469-8230 US toll free: 1-800-473-7373 Service @despatch.com

Version 1.2 7

The information in this document is not intended to cover all possible conditions and situations that might occur. The end user must exercise caution and common sense when installing or maintaining Despatch Industries products. If any questions or problems arise, call Despatch Industries at 1-888-DESPATCH or 1-952-469-5424.

1.2. Manufacturer & Service

Despatch has specialized in thermal processing for over 100 years. Technical expertise gained over those years helps provide innovative solutions to critical applications in vertical markets and cutting edge technology worldwide. Despatch products are backed by a drive for long-term customer satisfaction and a strong sense of responsibility. The worldwide network of factorytrained Service Professionals is available to support your Despatch equipment. From full service preventive maintenance to routine repair and certified calibration and uniformity, the Despatch service network is positioned to respond to your business needs. Our service programs are customized to meet your specific needs using our Advantage Service Assurance Program (ASAP). For more information on ASAP, visit www.despatch.com.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL Protocol 3 Controller Owner’s Manual

Danger!

Failure to heed warnings in this instruction manual and on the oven could result in personal injury, property damage or death.

This icon signifies information that describes an unsafe condition that may result in death, serious injury, or damage to the equipment.

Danger!

Danger is the signal word used to indicate a hazardous situation that, if not avoided, will result in death or severe injury.

Warning!

Warning is the signal word used to indicate a hazardous situation that, if not avoided, could result in death or severe injury.

Caution!

Caution is the signal word used to indicate a hazardous situation that, if not avoided, could result in moderate or minor injury.

Notice

Notice is the signal word used to indicate a hazardous situation that, if not avoided, could result in property damage.



This icon signifies supplemental important information.

LOG OUT

Bold, 10 point sans-serif typeface indicates a specific key or button on screen to click.

8 Version 1.2

1.3. Organization of this Manual

This owner’s manual contains the most comprehensive set of information for the Despatch Protocol 3™ controller, including installation instructions, theory of operation, operating instructions, among other things.

1.4. Conventions

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual ABOUT THIS MANUAL

Item

Description

Sampling Rate:

4 per second

Resolution:

16 bits. Always four times better than display resolution.

Impedance:

>10MΩresistive, except DC mA (5Ω) and V (47kΩ)

Temp Stability:

Error <0.01% of span per °C change in ambient temperature

Supply Variation:

Supply voltage influence negligible within supply limits

Humidity Influence:

Negligible if non‐condensing

Process Display:

Displays up to 5% over and 5% under span limits

Process Variable Input Offset:

Reading adjustable ± Controller Span. Values added to Process Variable, Values subtracted from Process Variable.

Sensor Break Detection:

 Thermocouple & RTD—SSR output goes to 0  High Limit Sensor Break alarms activate  Linear (4 to 20mA, 2 to 10V and 1 to 5V only)—SSR

output goes to 0

Isolation:

Isolated from all outputs (except SSR driver) at 240V AC

Supported Thermocouple Types & Ranges:

Type

Range °C

Range °F

B

+100 to 1824°C

+211 to 3315°F

C

0 to 2320°C

32 to 4208°F

D

0 to 2315°C

32 to 4199°F

E

-240 to 1000°C

‐400 to 1832°F

J

-200 to 1200°C

-328 to 2192°F *

K

‐200 to 1200°C

‐328 to 2192°F *

L

0 to 762°C

32 to 1402°F *

N

0 to 1399°C

32 to 2551°F *

PtRh 20%: 40%

0 to 1850°C

32 to 3362°F R

0 to 1759°C

32 to 3198°F

Version 1.2 9

1.5. Specifications

Specifications for the Protocol 3 controller include six sets of information:

 Process Input (Table 1)  Outputs (Table 2)  Operating Conditions (Table 3)  Conformance Norms (Table 4)  Display (Table 5)  Data Recorder (Table 6)

Table 1. Process Input.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL Protocol 3 Controller Owner’s Manual

Item

Description

S

0 to 1762°C

32 to 3204°F

T

‐240 to 400°C

‐400 to 752°F *

Optional decimal place can be displayed up to 999.9°C/F

Thermocouple Calibration:

±0.1% of full range, ±1LSD (±1°C for internal CJC if enabled). Linearization better than better ±0.2°C (±0.05 typical) on ranges marked * in the table above. Linearization for other ranges is better than ±0.5°C. BS4937, NBS125 & IEC584.

Supported RTD Types & Ranges:

Type

Range °C

Range °F

3‐Wire PT100

‐199 to 800°C

‐328 to 1472°F

NI120

‐80 to 240°C

‐112 to 464°F

Optional decimal place can be displayed up to 999.9°C/F

RTD Calibration:

0.1% of full range, ±1LSD

Linearization:

Linearization better than ±0.2°C (±0.05 typical). PT100 input to BS1904 & DIN43760 (0.00385Ω/Ω/°C).

RTD Excitation:

Sensor current 150μA ±10%

Lead Resistance:

<0.5% of span error for max 50Ωper lead, balanced

Supported Linear Types & Ranges:

Type

Range

Offset Range

mA DC

0 to 20mA DC

4 to 20mA DC

mV DC

0 to 50mV DC

10 to 50mV DC

V DC

0 to 5V DC

1 to 5V DC

V DC

0 to 10V DC

2 to 10V DC

Scalable from ‐9999 to 10000. Decimal point selectable from 0 to 3 places, but limited to 5 display digits (e.g. 9999.9)

Maximum Overload:

1A on mA input terminals, 30V on voltage input terminals

DC Calibration:

±0.1% of full range, ±1LSD

DC Input Multi‐Point: Linearization:

Up to 15 scaling values can be defined anywhere between 0.1 and 100% of input

Item

Description

Relays

Type & Rating:

Single pole single throw (SPST); 2A resistive at 120/240VAC

Lifetime:

>200,000 operations at rated voltage/current

Isolation:

Basic Isolation

10 Version 1.2

Table 2. Outputs.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual ABOUT THIS MANUAL

Item

Description

Linear DC

Resolution:

8 bits in 250mS (10 bits in 1s typical, >10 bits in >1s typical)

Accuracy:

±0.25% of range, (mA @ 250W, V @ 2kW). Degrades linearly to ±0.5% for increasing burden (to specification limits)

Isolation:

Basic Isolation

Item

Description

Temperature:

 Operating: 0°C to 55°C (32°F to 131°F)  Storage: –20°C to 80°C (-4°F to 176°F)

Relative Humidity:

20% to 95% non‐condensing

Supply Voltage and Power:

100 to 240VAC ±10%, 50/60Hz, 20VA

Item

Description

EMI:

CE: Complies with EN61326

Safety Considerations:

CE: Complies with EN61010‐1. UL, cUL to UL61010C‐1. Pollution Degree 2, Installation Category II

Front Panel Sealing:

IP65 rating. IP20 behind the panel. (IP rating not recognized / approved by UL)

Front Panel Cleaning:

Wash with warm soapy water and dry immediately. Close the USB cover (if fitted) before cleaning.

Item

Description

Display Type:

160 x 80 pixel, monochrome graphic LCD with a dual color (red/green) backlight

Display Area:

66.54mm (W) x 37.42mm (H)

Display Characters:

0 to 9, a to z, A to Z, plus ( ) ‐ and _

Version 1.2 11

Table 3. Operating Conditions (For indoor use).

Table 4. Conformance Norms.

Table 5. Display.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL Protocol 3 Controller Owner’s Manual

Item

Description

Recording Memory:

1Mb non‐volatile flash memory. Data retained when power is turned off

Recording Interval:

1; 2; 5; 10; 15; 30 seconds or 1; 2; 5; 10; 15; 30 minutes

Recording Capacity:

Dependent on sample rate and number of values recorded. Two values can be recorded for up to 7 days at 10s intervals. More values or faster sample rates deduce the maximum duration.

RTC Battery Type:

VARTA CR 1616 3V Lithium. Clock runs for >1 year without power (Part # 274030)

RTC accuracy:

Real Time Clock error <1 second per day

12 Version 1.2

Table 6. Data Recorder.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual SAFETY

Danger!

Electrical panels contain high voltage. Disconnect and lock out the power supply before working inside any electrical panels. Failure to lock out the power supply will result in death or injury.

Version 1.2 13

2. Safety

2.1. Safety Information

Do not work on the Protocol 3 controller without reading and understanding this section which contains important information and warnings. Ignoring these warnings can result in death, serious injury or damage to the machine and product.

2.1.1. Lockout

Machine lockout places the Protocol 3 controller into a zero energy state and prevents accidental machine start up. Always follow the Lockout Procedure described in this Section before cleaning, maintaining or repairing the Protocol 3 controller. An accidental start-up, while working on the Protocol 3 controller, can result in serious injury or death.

2.1.1.1. Lockout Requirements

1. Every power source that can energize any element of the Protocol 3 controller must be shut

off at the closest possible power source. This includes air, water, nitrogen and electricity, including the Disconnect Switch.

2. After energy sources are locked out, test to ensure circuits are de-energized.

2.1.1.2. Lockout Procedure with Despatch Products

Personnel authorized to lockout equipment must have the necessary locks to perform the lockout.

1. Physically disconnect all electrical power to the machine or lockout (with a padlock) the

appropriate breaker or disconnects.

2. Close all valves and bleed off any pressure.

3. Test for power by attempting a start with the machine controls.

4. Identify the Lockout Condition with a tag on the electrical disconnect and pneumatic shut off

valves.

5. When work is complete, remove all tags and restore the machine to its working state.

2.2. Maintenance

Only qualified and trained personnel should perform maintenance or repair.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

SAFETY Protocol 3 Controller Owner’s Manual

Danger!

Contact with energized electrical sources will result in serious injury or death.

Danger!

Always disconnect all power before extinguishing a fire. Attempting to extinguish a fire in a machine connected to electrical power will result in serious injury or death.

14 Version 1.2

2.3. Electrical Power

Only qualified and trained personnel should perform electrical maintenance or electrical repair.

 Before performing maintenance, disconnect all electrical power from the machine. Use a

padlock and lockout all disconnects feeding power to the machine.

 Never clean or repair the controller when in operation.  Unauthorized alterations or modifications to Protocol 3 controller are strictly forbidden.

Never modify any electrical circuits. Unauthorized modifications can impair the function and safety of the Protocol 3 controller.

2.4. Fire

Keep the Protocol 3 controller clean and free of scrap materials, oil or solvents to prevent the possibility of fire. In the event of fire, use a fire extinguisher as follows.

1. De-energize the machine immediately by pushing an Emergency Stop push button (if

supplied).

2. Turn off the remote main disconnect (customer supplied disconnect).

3. If the fire is in the workspace, keep the door closed.

4. Extinguish the fire.

2.5. Equipment Lockout Requirements

To prevent injury or equipment damage during inspection or repair, the Protocol 3 controller must be locked out.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual THEORY OF OPERATION

Figure 1. Operator Interface.

Version 1.2 15

3. Theory of Operation

The Protocol 3 is a microprocessor based digital temperature controller designed for simple and flexible oven operation (Figure 1). The Protocol 3 controller operates as a dual-functioning controller/high limit instrument. The control portion utilizes a time-proportioning voltage signal to control heating devices with minimal temperature fluctuations.

The high limit portion protects the product and/or the oven from overheating. If the product being processed has a critical high temperature limit, the high limit setpoint should be set to a temperature somewhat below the temperature at which the product could be damaged. If the product does not have a critical high temperature limit, the high limit setpoint should be set 5 to 15 degrees higher than the maximum programmed setpoint at which the oven will operate.

The Protocol 3 controller provides three primary operating modes:

 Manual: Oven operates continuously at a fixed temperature until turned off.  Timer: Oven operates at a fixed temperature for a user-selected time period, and then

automatically turns off.

 Profile: Temperatures increase or decrease as defined by 255 segments that can be allocated

to 64 ramp and soak profiles. The profiles can be linked to provide additional temperature combinations.

The Protocol 3 controlled is equipped to allow a ramp/soak temperature control, which maintains oven temperature with either a fixed setpoint or a ramp/soak profile.

3.1. System Control—In General

 The Protocol 3 controller provides outputs for the cooling fan, door lock switch/door release

pushbutton, and optional beacon light

 A number of profiles for oven heating cycles are stored in the Protocol 3 controller. Access

profiles using the Protocol 3 keypad

 The Protocol 3 controls the solenoid valves in an inert atmosphere oven for purge, maintain

and water cooling operation

 The Protocol 3 can also be operated remotely with a PC running Protocol Manager software.

3.1.1. High-Limit Function

The Protocol 3 controller has an integrated high limit function which disables the heater output when tripped. The High-Limit temperature is displayed as HLPV (Manual Mode only).

If the high limit trips, the Hi-Limit indicator will light and the relay must be manually reset. Allow the oven to cool several degrees below the setpoint (or increase the high limit setpoint) and

then press . The indicator will turn off.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

THEORY OF OPERATION Protocol 3 Controller Owner’s Manual 16 Version 1.2

3.1.2. Outputs

The Protocol 3 controller comes standard with an output signal that can transmit temperature data, setpoint data or control power to a user-supplied recording device. Output relays (five) can also signal user-specified events or alarm to external devices (Figure 2 and Figure 3).  Heating output: The control output is a DC voltage open-collector output which is

time-proportioned and designed to control a heat control device such as a solid state relay.

 High limit: The high limit output is a SPDT relay which is energized under normal operating

conditions. If the control senses a temperature higher than the high limit setpoint, or if there is a sensor error, the high limit relay will de-energize until the condition is cleared and Reset is pressed. When the high limit relay is de-energized, the heater is disabled.

 Retransmission: The retransmission output is a signal that is proportional to the process

temperature, setpoint or control power:

o 0-5V o 0-10V o 2-10V o 020 ma o 4-20 ma o 0-10VDC Power Supply

The signal can be an input to other devices such as a chart recorder.

 Relays: The five SPST dry contact relay outputs can be configured to function as alarms,

events, or end of cycle. These outputs can be utilized in Manual, Timer or Profile Modes.

3.2. Remote Communication

When used with a PC running Protocol Manager™ software, the Protocol 3 controller allows an operator to remotely control the oven, download recipes and log data.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual THEORY OF OPERATION

Protocol Plus Rear Panel

Protocol 3 Rear Panel

Former Connections

New Power Connections

Former SSR Connections

New SSR Connections

Former Control Connections

Former Hi-limit Connections

New Control Connections

New Hi-limit Connections

Relays

Figure 3. Protocol Plus to Protocol 3 Connection Conversions.

Figure 2. Typical Controller Output Sticker.

Version 1.2 17

and Hi-Limit

Thermocouple

Power

Thermocouple

and Hi-Limit

Thermocouple

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ASSEMBLY & SETUP Protocol 3 Controller Owner’s Manual

Danger!

All grounding and safety equipment must be in compliance with applicable codes, ordinances and accepted safe practices.

Terminal Block

Former

Protocol Plus Connections

New

Protocol 3 Connections

Three pin terminal block for power leads

Terminals 30, 31, 32

Terminals 1, 2, 3

Five pin terminal block for SSR and Hi-limit

Terminals 17, 18, 19, 20, 21

Terminals 26, 27, 28, 29, 30

Remove the four-pin terminal block from thermocouples and rewire with two three-pin blocks.

Control Thermocouple

Terminals 13, 14

Control Thermocouple

Terminals 17, 18

Hi-limit Thermocouple

Terminals 15, 16

Hi-limit Thermocouple

Terminals 32, 33

Warning!

Disconnect the main power switch or power cord before attempting any repair or adjustment.

18 Version 1.2

4. Assembly & Setup

4.1. Install the Protocol 3 Controller

When replacing a Protocol 3 controller, follow the steps below. Tools required for installation include ¼” socket set with #1 bit, #2 Philips screwdriver.

1. Disconnect the power.

2. Unplug all terminals on the rear of the control, noting the proper connections (Figure 3).

3. Remove the retaining clips for the controller.

4. Remove the controller.

5. Insert the new controller into the panel.

6. Fasten the retaining clips.

7. Re-plug all terminals.

8. Secure the control panel.

4.2. Protocol 3 Controller Conversion with NO Options

To replace the older model Protocol Plus controller with the newer Protocol 3 controller, connect terminal blocks as indicated in Table 7 and Figure 3.

Table 7. Protocol Plus to Protocol 3 Controller Conversion.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual ASSEMBLY & SETUP Version 1.2 19

4.3. Setting Up Remote Communication

Remote communication between the Protocol 3 controller and a PC running the Despatch Protocol Manager software involves providing each controller with a unique address and following the communication protocol procedures. Up to 32 separate controllers can be run from a PC running the Despatch Protocol Manager software. See the Protocol Manager Instruction Manual for the complete set-up procedure.

means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

WORKING WITH OPERATING MODES Protocol 3 Controller Owner’s Manual



Users and operators of this controller must comply with operating procedures and training of operating personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 5 and relevant safety standards, and other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), Section 86 of 1990.

Keypad Button

Function

Figure 4. Select a Mode Display.

20 Version 1.2

5. Working with Operating Modes

5.1. User Controls

Each Protocol 3 Controller has six keypad switches (Table 8). Use the buttons to navigate user menus, adjust parameter values and control outputs. In configuration screens, a context sensitive scrolling help-text displays user-guides about the function of the keys across the bottom of the screen.

The Protocol 3 Controller has nine LEDs which indicate a variety of instrument functions (Table

9).

When the Protocol 3 Controller is first powered ON, the screen displays Select a Mode (Figure

4). Use and to navigate and to select the highlighted mode.

Table 8. Keypad Buttons and Functions.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Protocol 3 Controller Owner’s Manual WORKING WITH OPERATING MODES

Keypad Button

Function

Navigate to previous screen

Press to move back to the previous parameter or screen in the current mode.



NOTE: Pressing this switch updates the instrument to the value displayed. If editing a parameter, ensure the current (highlighted) parameter value is correct before pressing.

Navigate down through menu/parameter lists

 Menus and configuration choice screens: Press to move to the next item on

the list.

 Editable values: Press to decrease. Press and hold to speed the change.  Trend View: press to move the Cursor Line back through stored data

points.

Navigate up through menu/parameter lists

 Menus and configuration choice screens: Press to move to the previous

item on the list.

 Editable values: Press to increase. Press and hold to speed the change.  Trend View: press to move the Cursor Line forward through stored data

points.

Navigate to next item on a screen or to next screen

 Press to move forward to the next parameter or screen in the current mode.  Enables Edit on parameters in the Main Mode selections.



NOTE: Pressing this switch updates the instrument to the value displayed. If editing a parameter, ensure the current (highlighted) parameter value is correct before pressing.

Manual, Timer and Profile Mode: press to stop current process

 In Manual Mode, pressing switch disables the controlling output  In Timer Mode, pressing switch stops timer and disables controlling output  In Profile Mode, pressing switch stops current profile and disables

controlling output

Reset Latched High Limit relay if below alarm condition

If High Limit alarm is active, press to release the High Limit relay.



NOTE: This switch releases the High Limit relay only if the controller is

Version 1.2 21

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Despatch Protocol 3 Controller User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. About This Manual

1.1. Important User Information

1.2. Manufacturer & Service

1.3. Organization of this Manual

1.4. Conventions

1.5. Specifications

2. Safety

2.1. Safety Information

2.1.1. Lockout

2.1.1.1. Lockout Requirements

2.1.1.2. Lockout Procedure with Despatch Products

2.2. Maintenance

2.3. Electrical Power

2.4. Fire

2.5. Equipment Lockout Requirements

3. Theory of Operation

3.1. System Control—In General

3.1.1. High-Limit Function

3.1.2. Outputs

3.2. Remote Communication

4. Assembly & Setup

4.1. Install the Protocol 3 Controller

4.2. Protocol 3 Controller Conversion with NO Options

4.3. Setting Up Remote Communication

5. Working with Operating Modes

5.1. User Controls