Despatch PROTOCOL PLUS Installation Manual

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Protocol Plus Owner’s Manual PREFACE

ULTRAFLEX DRYING AND FIRING FURNACE

MODELS 1000, 3615, 3630, 3640

C-204

PROTOCOL

PLUS™

Controller

OWNER’S MANUAL

E-98

Version 2 1

PN 143895 VERSION 2 12/2010

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PREFACE Protocol Plus Owner’s Manual

Revision

Date

Author

Description

C-195

7/10

K. Livingston

Revise format. Also based on E98 Rev P (12/2008).

2.0

12/2010

K. Livingston

Remove Protocol Plus Controller to separate Owner’s Manual

2 Version 2

Revision History

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Protocol Plus Owner’s Manual PREFACE Version 2 3

Table of Contents

1. Abo ut This Manua l .............................................................................................. 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 ................................................................................................................ 10

2.1. Safety I nforma tio n ................................................................................... 10

2.1.1. Lockout ................................................................................................ 10

2.1.1.1. Lockout Requirements ...................................................................... 10

2.1.1.2. Lockout Pro cedu r e with Despatch Products ....................................... 10

2.2. Maintenance ............................................................................................. 11

2.3. Electrical Power ....................................................................................... 11

2.4. Fire .......................................................................................................... 11

2.5. Equipment Lockout Requirements............................................................ 11

3. Theory of Operation........................................................................................... 12

3.1. System Control—In General .................................................................... 13

3.1.1. High-L im it Fu nction ............................................................................. 13

3.1.2. Optiona l Serial Commu nications Hard ware .......................................... 13

3.2. Display Functions .................................................................................... 13

3.3. Modes and Menus .................................................................................... 15

3.4. Indicators ................................................................................................. 16

3.5. Key Fu nc tions .......................................................................................... 16

3.6. Outputs .................................................................................................... 16

4. Assembl y & Set up ............................................................................................. 18

4.1. Install the Protocol Plus Controller ........................................................... 18

4.2. MRC5000 Setup (Optional) ...................................................................... 19

5. Working with Operating Modes ......................................................................... 21

5.1. Start-up Basics ......................................................................................... 21

5.2. Manual Mod e ........................................................................................... 22

5.3. Timer Mode ............................................................................................. 23

5.4. Profi le Mode ............................................................................................ 24

5.5. Auto Start Mode ....................................................................................... 24

5.6. Setup Mode .............................................................................................. 25

5.6.1. Enter and Exit Setup Mode ................................................................... 25

5.6.2. Temperature S cale Conversio n ............................................................. 26

5.6.3. Program Page ....................................................................................... 26

5.6.3.1. Using the Progr am Page .................................................................... 27

5.6.3.2. Programming Optional Relay Outputs ............................................... 27

5.6.4. Sa mp le Profile ...................................................................................... 30

5.6.5. Setting Up Auto Start............................................................................ 31

5.6.5.1. Configure Auto Start ......................................................................... 32

5.6.5.2. Activate Auto Start............................................................................ 33

5.6.5.3. Deactivate Auto Start ........................................................................ 33

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

PREFACE Protocol Plus Owner’s Manual 4 Version 2

5.6.6. Setting Up PID Page ............................................................................. 33

5.6.6.1. Access the PID Page ......................................................................... 33

5.6.6.2. Setting up Auto Tune ........................................................................ 34

5.6.7. Setting up the Control Page .................................................................. 34

5.6.7.1. Access Contro l Page ......................................................................... 34

5.6.8. Setting up the Communication Page ..................................................... 35

5.6.8.1. Access Communicat ion Page ............................................................ 35

5.6.8.2. Setting up the Real Time Clock Page ................................................ 36

5.6.8.3. Access Real Time Clock Page ........................................................... 36

5.6.9. Setting up the Relay Outputs Page ........................................................ 36

5.6.9.1. Access Relay Outputs Page ............................................................... 37

5.6.10. Setting up the Test Pag e .................................................................... 38

5.6.10.1. Access Relay Outputs Page ............................................................... 38

5.6.10.2. Set ting up the Zone Calibr a tion Page ................................................ 38

5.6.10.3. Access Zone Calibrat ion Page ........................................................... 39

5.6.10.4. Access Factor y Calibrat ion Recovery ................................................ 39

5.6.10.5. Adjusting Actua l Versus Displa yed Parameters................................. 40

5.6.10.6. Setting up the Sensor Calibration Page .............................................. 40

5.6.10.7. Access Sensor Calibration Page ........................................................ 40

5.6.11. Setting up the Enable Page ............................................................... 42

5.6.11.1. Access Enable Page .......................................................................... 42

5.6.12. Setting up Digital Inputs (Optional)................................................... 43

6. Maintenance ...................................................................................................... 45

6.1. Replacement Parts .................................................................................... 45

7. Troubleshooting: Error Messages and Alarm ..................................................... 45

8. Appendices ........................................................................................................ 47

8.1. Quick Reference and Default Values ........................................................ 47

8.1.1. Program Page Default Value s ............................................................... 47

8.1.2. Autostart Page Default Va lues .............................................................. 48

8.1.3. PID Page Default Values ...................................................................... 48

8.1.4. Programming Tab le Wo r ksheet ............................................................. 49

8.1.5. Control Page Default Values ................................................................. 50

8.1.6. Communication (Optional) Page Default Values ................................... 50

8.1.7. Real Time Clock Page Default Va lues .................................................. 51

8.1.8. Relay Outputs (Optional) Page Defau lt Values ..................................... 52

8.1.9. Test Page Default Values ...................................................................... 53

8.1.10. Zone Cal Page Default Values ........................................................... 53

8.1.11. Sensor Cal Page Default Values ........................................................ 53

8.1.12. Enable Page Default Values .............................................................. 54

8.2. Standard Pro du cts Warrant y ..................................................................... 55

Figures

Figure 1. Operato r Int er face. .......................................................................................... 12

Figure 2. Protocol Plus Displays and Control Buttons. ................................................... 14

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Protocol Plus Owner’s Manual PREFACE Version 2 5

Figure 3. Protocol Plus Controller Faceplate. ................................................................. 14

Figure 4. Protocol Plus Menu System—Setu p Det ail ..................................................... 15

Figure 5. Protocol Plus Controller with Rear Cover Removed, Showing Locations for

Op tional c omponents . .................................................................................................... 17

Figure 6. Protocol Plus Wiring Diagram. ....................................................................... 19

Figu re 7. Samp le Profile. ............................................................................................... 30

Figu re 8. Samp le Profile Values. ................................................................................... 31

Figure 9. Digital Inputs. ................................................................................................. 44

Tables

Table 1. MRC 5000 Settings. ......................................................................................... 20

Table 2. Program Page Menu It ems and Exp lanation. .................................................... 28

Table 3. Parameter Definit io ns and/o r Ranges. .............................................................. 29

Table 4. Auto Start Menu Parameters and Values. ......................................................... 31

Table 5. PID Page Parameter s and Values. .................................................................... 33

Table 6. Control Page Para meter s and Values. ............................................................... 34

Table 7. Communication Page Par ameters and Values. .................................................. 36

Table 8. Real Time Clock Page Parameters and Values. ................................................ 36

Table 9. Relay Outputs P age P ar ameters and Va lues. .................................................... 37

Table 10. Access Relay Out put s Pag e Parameters and Values. ....................................... 38

Table 11. Zone Calibrat ion Page Parameters and Values. .............................................. 39

Table 12. Sensor Calibration Page Parameters and Values. ............................................ 42

Table 13. Enable Page Para meter s and Values. .............................................................. 43

Table 14. Digital Input Par amet ers and Values. ............................................................. 44

Table 15. Error Messages and Next St ep s. ..................................................................... 45

Table 16. Program Page Defau lt Va lues. ....................................................................... 47

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in an y form or b y an y

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

ABOUT THIS MANUAL Protocol Plus Owner’s Manual 6 Version 2

1. About This Manual

1.1. Important User Information

All rights reserved. No p art of the cont ent s 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 info rmation storage and retrie val syst ems without the written permission o f the publisher, unless it is for the purchaser's personal use.

Printed and bound in the United St at es of Amer ica.

The i nformation in this manual is su bject to chang e 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 ed ito r ial omissio ns made herein, nor for direct, i ndirec t, s pec ial, i ncidental, or co ns e quential damages resu lting from the use or defect of this manual.

Values displayed on screens are examples only. Though

those values may be typical , cont act Despatch Industries for the final value.

Users of this equipment must comply with operating procedures and trainin g o f operation personnel as required by the Occupational S af et y and Health Act (OS HA) of 1970, Section 6 and relevant safety stand ards, 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 Associati on (NFPA), section 86 of 1990.

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in any for m or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the writ ten permission of Despatch Industrie s , unless for purchaser's personal use.

Protocol Plus Owner’s Manual ABOUT THIS MANUAL

Danger!

Global Headquarters

Contact

Service & Technical Support

Despatch Industries

International/Main: 1-952-469-5424

www.despatch.com

Service: 1-952-469-8230

Version 2 7

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 equipme nt dama ge , pe rsonal injury or possible death.

The i nformation in this doc ument is not intend ed to co ve r all possi ble c ond itions and situations that might o ccu r. The end user must exerc ise caut ion and common se ns e 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

The P r o tocol Plus™ controller is a proprietary controller designed by Despatch Industries.

Despatch has specialized in thermal processing for over 100 years. Technical expertise gained over those years helps pr ovide innovative solut ions to cr itical applications in vertical markets and cutting edge technology worldw ide. Despat ch products are backed by a drive for long-t er m custo mer satisfaction and a strong sense of responsib ilit y. T he worldwide network of factory-trained Serv ice Pr ofes sionals is ava ilable to support your Despatch equipment . From full service preventive mainte nanc e to ro ut ine repa ir and certified calibration and uniformity, the Despatch ser vice net wor k is posit ioned to respond to your business needs. O ur ser vice programs are customized to meet your specific needs using o u r Advant age S er vice Assurance P r ogram (ASAP). For more information on ASAP, visit www.despatch.com.

8860 207th Street Lakeville, MN 55044 USA

US toll free: 1-888-337-7282 Fax: 1-952-469-4513 info@despatch.com

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

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ABOUT THIS MANUAL Protocol Plus Owner’s Manual

Danger!

This icon signifies information that descr ibes an uns afe condition

Danger!

A condition that may res ult in deat h, serious injury, or damage to equipment.

Warning!

A condition that may res ult in ser ious injur y or dam age to equipment.

Caution!

A condition that may res ult in damage to equipment or product.

LOG OUT

Reversed-out, Bold, 10pt Arial typeface indicates a s pecific k ey or button on screen t o click.

8 Version 2

1.3. Organization of this Manual

This owner’s manual c ontains the most comprehensive s et of information for the Despatch Protocol Plus controller, including installation instructions, theory of operation, operating instructions, among other things.

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

1.4. Conventions

This icon signifies im por tant information.

that may result in deat h, ser ious injur y , or damage to the equipment.

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in any for m or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the writ ten permission of Despatch Industrie s , unless for purchaser's personal use.

Protocol Plus Owner’s Manual ABOUT THIS MANUAL

UL, cUL listed:

UL file E136675

CE compliance

Low Voltage Direc tive 2006/95/EC

Power supply:

12 to 24 VAC/VDC +/-10%, DC to 60Hz, 30VA Maxim um

Temperature:

Operating 0 to 50°C

Humidity:

90% or less, non-condensing

Sensor inputs:

Temperature

Readout Stability (+/-1°F/10°F Change in ambient temperature)

Message display:

0.2 inches high ( 5mm)

Time base:

+/- 4 seconds accuracy in 24 hours

Heat control output:

SSR Drive 24VDC nominal @ 70mA

Relay output: (plug-in module)

Form A dry contact, rated 3 amps @ 24-264VAC

Retransmit output:

1 to 5 VDC into > 100K ohm load

Communications:

• RS232 Single drop, isol ated RS485 Multi-dr op, isolated

Remote inputs: (plug-in module)

Dry-contact closure type with less than 250 ohm ON resistance

Front panel:

NEMA 4X (with gasket)

Dimensions:

3.57H x 7.24W x 2.84D inches (91H x 184W x 72D mm)

Panel opening:

3.63H x 7.30W inches (92H x 185W mm)

Version 2 9

1.5. Specifications

to:

display:

• EMC Directive 2004/108/ E C

•

• 100 to 240 VAC +10% -15%, 50-60Hz, 30VA Maximum

•

• Storage -20 to 60°C

•

• Type J thermocouple -73°C t o 760°C (-100° F t o 1400°F)

• Input impedance 1M ohm or great er

• Common mode noise rejection of 140db@60Hz

• Common mode input voltage of +/-12.0 VDC

• Sample rate of at least 1 sample per second

• Stability of +/- 0.5°C per 5°C change in ambient temperature

• Repeatability of +/- 0.5°C, or +/-0.1% of sensed temperature (whichever

is greater)

• Accuracy (@ 77°F + /-0.2 per c ent of span (+/-3°F)

• Supply Voltage Influence of +/-0.5°C per 10% change in nomi nal line

voltage

• 1 degree resolution ( C or F)

• Accuracy after calibration of +/- 1°C, or +/-0.2% of sensed temperature

(whichever is greater) @25°C

• Four-digi t seven-segment LCD, 0.43 inches high (11mm)

•

• Two-line, 16 alpha-numer ic 5x 7 dot matrix characters per line

•

(plug-in module)

• RS422 Multi-drop, isolated

•

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in an y form or b y an y means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the writ ten permission of Despatch Industrie s , unless for purchaser's personal use.

SAFETY Protocol Plus Owner’s Manual

Danger!

10 Version 2

2. Safety

2.1. Safety Information

Do not wo rk on the Protocol Plus 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 t he Protocol Plus controller into a zero energy state and prevents accidenta l machine start up. Always follow the Lockout Proced ur e descr ibed in this Section before cleaning, maintaining or repairing the Protocol Plus controller. An accidenta l start-up, while working on the Protocol Plus cont roller, can result in serious inju ry or death.

2.1.1.1. Lockout Requirements

1. Every power source that can energize any element o f the Protocol Plus controller

must be shut off at the closest po ss ible pow er source. This includes air, water and electricity, includ ing the Disconnect Switch.

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

2.1.1.2. Lockout Procedure with Despatch Products

Personnel author ized to lockout equipment must have the necessar y locks to perform the lockout.

1. Physically disconnect all electrical power to the machine or lockout 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 co nt ro ls.

4. Identify the Lockout Condition with a tag on the elect r ical disconnect and p neu matic

shut of f valve .

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

Electric a l pa ne ls contain high volt age. Disconnec t a nd loc k o ut the power supply before working inside any electrical panels. Failure to lock out the power supply can result in death or injury.

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in any for m or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the writ ten permission of Despatch Industrie s , unless for purchaser's personal use.

Protocol Plus Owner’s Manual SAFETY

Danger!

Version 2 11

2.2. Maintenance

Only qualified and trained personnel should perform maintenance or repair.

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 disco nnect s feeding power to the machine.

• Never clean or repair the controller whe n in op eration.

• Unauthorized alterat ions o r mod ifications to Protocol Plus controller are str ictly

forbidden. Never mod ify any electr ica l circu its. Unaut ho rized modifications can impair the fu nction a nd sa fety of the Protocol P lus controller.

Contact with energized electrical sources may result in serio us injury or death.

2.4. Fire

2.5. Equipment Lockout Requirements

Keep the Protocol Plus controller clean and free of scrap mat er ials, oil or solvents to pre vent the p ossibility of fire . In the e vent of fire, us e a fir e extinguisher as follows.

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

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

3. Extinguish the fire.

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

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

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in an y form or b y an y means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the writ ten permission of Despatch Industrie s , unless for purchaser's personal use.

THEORY OF OPERATION Protocol Plus Owner’s Manual

Figure 1. Operator Interface.

12 Version 2

3. Theory of Operation

The Protocol Plus is a modular micro pr ocessor based digital te mperatu r e cont roller (Figure 1). The Protocol Plus controller operates as a dualfunc tioning controller/high limit instru ment. The control po rtion u tiliz e s a time -pr oportioning voltage signal to control heating devices with minimal tempe rature fluctuations.

The h i gh limit portion protects the product and /or the oven from overheat ing. If the product being processed has a critical high te mperat ur e limit, t he high limit setpoint should be set to a temperatur e somewhat below the temperature at which the product could be damaged. If the product do es not ha ve a critical high te mperat ur e limit, t he high limit set p oint s ho uld be set 5 to 15 degrees higher tha n the maximum programmed setpoint at w hich the ove n will operate.

Th e Prot oc ol Plus controller provides three primary operat ing modes:

• Manual: Oven operates cont inuously at a fixed temperature until turned off.

• Timer: Oven operates at a fixed temperatu r e for a user-selected time period, then

automatically tu r ns off.

• Profile: Temperat u r es increase o r d ecr ease as defined by one of eight pre-

programmable ramp and soak profiles. Each pro file co nt ains up to eight r amp and soak segments. The profiles can be linked to provide additional temperatur e combinations.

In addition these primary operating modes, the Protocol Plus controller employs a Stopped Mode, Auto Start Mode, Setup Mode and Fast Start Mode:

• Stopped Mode: All control and relay outputs are off. Stopped Mode is integrated

into each of the modes of operat ion.

• Aut o Start Mode: C ontrol may au tomat ic ally star t Manual, Timer, or Prof ile

mode based on a preset time and day. Optional event outputs can be util ized during Manual, Timer, or Profile modes.

• Setup Mode: Provides access to control configuration and programming of

profiles. Set u p Mod e contains ten separate electronic “Pages” where con figuration and programming para meter s (Menu items) are found and can be manipulated .

• Fast Start Mode: Pro vides for automatic startup of an operating mode w hen

po w er is applied. Use Fast St art Mo d e if the same mode of operation is used every day. The user can turn on the power and the oven w ill start t he desired process automatically. The Fast Start Mode is controlled by the Power-Up St a rt parameters o n the Control page.

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Protocol Plus Owner’s Manual THEORY OF OPERATION Version 2 13

3.1. System Control—In Ge ner a l

• T he Proto col Plus controller provides outputs for the cooling fan, door lock

switch/door release pus hbutton, and optional beacon lig ht

• As many as eight profiles for oven hea ting cycles are stored in the Proto col Plus

controller. Access profiles using the Protocol Plus keypad.

• The Prot oco l Plus cont r ols the solenoid valves in an in ert atmosphere oven for p urg e

and maint ain operat ion

3.1.1. High-Limit Function

The Protocol Plus controller has an integ rated h igh limit function which d is able s the heater output when t ripped. Find High-Limit temperature readouts on LC D Line #2 in all Modes (Stop, Run, Hold, and Standby) except Setup Mode. High-Limit temperature is displayed for 10 seconds, alternating with current Mode and Status display for 10 seconds. The contro l will not allow t he high limit set point to be set below the current setpo int value.

If the high limit trips, the Hi-Limit indicator w ill light and the relay must be ma nu a ll y reset. Allow the o ven to cool several degrees (or increase t he high limit set point) and then press Reset. The indic ator will turn of f.

3.1.2. Optional Serial Communications Hardware

Optional MODBUS RS422/485 serial communications hardware may be installed on the Protoco l Plus controller, with a 9-pin communicatio ns port located on rear of oven. This provide s the a bility to netwo rk the oven(s) with a host PC.

3.2.

Display Functions

The Protocol Plus contro ller has t wo displa ys. A dedicated LED upper display shows t he oven temperatur e (Figure 2). A two line LCD lower display provides information on control stat u s, high limit temperat ur e and a llows changes to be made to the control settings. Figure 3 shows a schemat ic of the Protocol Plus face plate.

All rig hts reserved. No part of the contents of this m an u al m ay b e r ep roduced, copied or t ransmitted in an y form or b y an y

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

THEORY OF OPERATION Protocol Plus Owner’s Manual

Power

Heater

Profile

Timer

Manual

Cycle

Complete

Oven Temperature

Information

Hi-Limit

Alarm

Outputs 1-4

Adjust parameter

Select mode

of operation

Page

Reset

View

Run/Hold:Pr ess to activate

mode of operation

Stop: Press

Mode

Figure 2. Protocol Plus Displays and Control Buttons.

Figure 3. Protocol Plus C ontroller Faceplate.

14 Version 2

to Stop any

Soak Alarm

on control

status

settings up or down as

necessary

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Protocol Plus Owner’s Manual THEORY OF OPERATION

Figure 4. Protocol P lus Menu System—Set up Deta i l

Version 2 15

3.3. Modes and Menus

The Protocol Plus contro ller uses a menu system to display, setup and run the different modes and configurations available fo r the LCC O ven (Figure 4).

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THEORY OF OPERATION Protocol Plus Owner’s Manual

16 Version 2

3.4. Indicators

Refer to Figure 2:

• Power LED: Indicates power supplied to instrument

• Heater LED: Indicates heater output active

• Profile L ED: Indicates Pr ofile Mode is in operation

• Timer L ED: Indic a tes Timer Mode is in operat ion

• Manual LED: Indicat es Manual Mode is in operatio n

• Cycle Complete LED: Indicates co nt ro l is in Stopped or Standby modes.

• Hi-Limit Alarm LED: Indicates high limit r e lay has tripped (de-energized).

• S oak Alarm LED: Indicates the guarant eed soak deviation is in alarm condition.

• Outputs 1 through 4: Indicate that the optional relay outputs are in the ON state.

These output s may be configured as timed event outputs, process temperature trip po int outputs, alar m outputs, or as an end of cycle relay ou tput. T he ON state can be configured as energ ized or de-energized.

3.5. K ey Fun cti on s

Refer to Figure 2:

• Select: Press to select mode of operat ion. In Set u p Mode, to select profile number or

relay. In Profile/Run Mode, p r ess simulta neo usly with the UP key to advance a segment.

• Run/Hold: Press to activate a mode of operation. If a Profile (or T imer) Mo d e is

running, pressing the Run/Hold key will place the Profile (or Timer ) in Hold status. A subsequent press w ill resume the Pr ofile (Timer).

• Stop: Press to stop any mode of operation.

• Page/Reset: While in Setup Mo de, pr ess to access d ifferent P ages of configuration,

Press this key to silence an alarm if the instrument alarm sounds during operation. In an operating mode, if an alarm or er ror cond it ion occurs, p r ess t his key to retur n the instrument to normal oper ation once the condition is cleared.

• Menu/View: While running any operating mode, pressing this key will display the high

limit setpoint. While in Setup Mode, pressing this key will provide access to each Menu parameter.

• ▲▼: Press to adjust parameter settings. In Profile/ Stopp ed Mode, press to select

profile to run. In Prof ile/R un Mode, pr ess ▲ sim ultane ous ly with Select to force the program to advance one segment .

3.6. Outputs

The Protocol Plus contro ller comes standard with an out put s ignal that can transmit temperature data to a user-supplied recording device. Opt ional output relays (four) can also signal user-specified events or alarm to ext er nal devices (Figure 5).

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Protocol Plus Owner’s Manual THEORY OF OPERATION

Figure 5. Protocol Plus C ontroller with Rear Cover Removed, Showing Locati ons for Opti onal

Version 2 17

• Heati ng output: The cont rol output is a DC voltage open-collector output which is

time-proport ioned and des igned to control a heat control device such as a solid stat e relay.

• High limit: The high limit outpu t is a form C relay wh ic h is en erg ized un de r normal

operating condit ions. If t he co ntrol senses a tempe rature highe r t han t he high limit se tpoint, or if there is a sensor e rr or, the high l imit relay will de-energize until the condition is cleared and Reset is pressed. When the high limit relay is de-energized, the he ate r is d is abled.

• Retransmission: The r etransm ission outp ut is a D C 1 to 5 volt or 4 to 20 ma (DC)

signal that is proport ional to the process temperature. The signal can be an input to other devices such as a chart r eco r der.

• Relay (four optional outputs): T he four form A dry contact r elay output s can be

configured to funct ion as alar ms, event s, or end of cycle. The se o ut p ut s can be ut ilized in Manual, Timer, or Pro file Modes.

components.

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ASSEMBLY & SETUP Protocol Plus Owner’s Manual

Danger!

All grounding and safety equipment must be in compliance with

Warning!

18 Version 2

4. Assembly & Setup

applicable codes, ordinances and accepted safe practices.

Disconnect the main power swit ch or power cord before attempting any rep air o r adjustment.

4.1. Install the Protocol Plus Controller

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

1. Disconnect the power.

2. Remove the screws from the sides of the control panel and slide it forward.

3. Unplug all terminals on the rear of the control, noting the proper

connections (

4. Remove the four retaining clips for the control.

5. Remove the control.

6. Insert the new control into the panel.

7. Fasten the four retaining clips.

8. Re-plug all terminals.

9. Fasten the control panel.

Figure 6).

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Protocol Plus Owner’s Manual ASSEMBLY & SETUP

Figure 6. Protocol P lus Wi rin g D iagr am.

Version 2 19

4.2. MRC5000 Setup (Optional)

Refer to instruction s pro vid ed reco rder manufacturer for more

Temperature is retr ansmitt ed t o t he MRC5000 recorder from t he controller. Set up the recorder by:

1. Ensure hardware jumper JU1 is in place for t he 5 VDC setting (Refer to MRC5000

Manual included).

2. Move Mode to PROG/TEST/CAL to display Prog.

3. Press ▼ twice to d is pla y Inps. Move to each Parameter Co d e using ▼or ▲. Adjust

each Parameter Code using the setti ngs in Table 1.

4. After adjusting a ll set ti n g s , mov e Mode to RUN. Disp lay on bot h the Recorder and

controller shou ld read t he same.

specific installation notes.

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ASSEMBLY & SETUP Protocol Plus Owner’s Manual

Parameter Code

Degrees C

Degrees F

Inps

Icor 0 0

diSP

dPOS

0 0 EUU

400 752

EUL1

ChUP

400

800

ChLO

DFF

20 Version 2

Table 1. MRC 5000 Settings.

These values must match the settings RetOutLo and RetOutHi on the Protocol Plus Contr ol page. For

example, if RetOutLo is 32, EUL must read 32.

Chang e 0 -400 chart paper to 0-800 chart paper. Depending on th e equipment used, 0-600 paper may be

used if the maximum temperature is 500 degrees F.

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Protocol Plus Owner’s Manual OPERATION Version 2 21

5. Working wit h Oper at ing Modes

Users and operators of this controller must comply with operating procedures and training of operating personnel as required by the Occupatio nal Safety and Health Act (OSHA) of

5.1. Start-up Basics

1970, Section 5 and relevan t safety stand ards, and other safety rules and regulations of state and local go vernments. Refer to the relevant safety stand ards in OSHA and National Fire Protection Associati on (NFPA), Section 86 of 1990.

Configuration controls may need to be changed depending on

At initial power -up, control is in Manual/Stopped Mode (unless the Autostart or Fast Start Modes are active). To activate any o p er ating mode from Manual/Sto p ped Mod e, press Select until the desired mode is displayed and then pres s Run. If the prop e r Profile number is not displayed when t he Pro file Mod e is accessed, p r ess desired Profile number is d ispla yed, then press (displa y r ea ds None), no profiles ar e cur r ent ly progr ammed. Refer to Section 5.6 for instructions about setting up profiles.

Note that:

• When the lower LCD display reads HL Temp, the Hi limit ther moco up le actua l

temperature read ing is displa yed. Note that the actual temperature reading is not an error message.

• T he t emperat ur e setpoint can be adjusted while Manual or Timer Mode is running by

pressing ▲ or ▼.

• T o mo mentarily hold the Timer or Profile Mode, press Hold. To cont inue the Timer

or Profile Mode, press Run.

• To r eturn to St opped Mode at any time, press Stop and the Cycle Complete L ED wil l

illuminate.

Note that the control can be configured to automatically activate Manual, Timer or Profile Mode when power is applied (power switch turned ON). See Contro l Page in the Setup Mode to utilize the Fast St art mode (Section 5.6.7).

the mode used. Refer to the specifi c op erat in g instructions below, for more information.

▲ or ▼ until the

Run. If no profile numbers are displayed

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OPERATION Protocol Plus Owner’s Manual

22 Version 2

Control can be configu red to auto mat ically activate Manual,

5.2. Manual Mode

1. Press Select until Manual displays.

Timer or Profile Mode when po we r is ap plied (power swit c h ON). Refer to Section 5.5.

Press Run at any time in the procedure to activate Manual Mode.

2. Press Menu to display the Pro cess Temperat u r e Setpoint (Setpt). Change Setpoint

(Setpt) by pressing ▲ or ▼.

If the SPChange on the Enable page in Setup Mode ha s been set to DISABLED, it must be changed to ENABLED befo re any

3. Press

4. Optional feature: Press

5. To start Manual Mod e, press Run.

The display changes from Stop to Run. Return to Stopped Mode by pressing Stop. While in operation, the process set p oint can be adjusted by using ▲ or ▼ to cha nge t he valu e while the mode is running. Press Menu to display the High Limit Setpoint (HLSP) setting.

Menu a second time to display curre nt h igh limit setp oint (HLSP). T he valu e

can be adjusted pressing activated (see Cont rol page, Section 5.6.7) and the high limit cannot be adjusted.

event ON or ▼ to turn the even OFF. Repeat for all event s which are enab led (up to four eve nts).

changes to the process temperature an d high limit setpoints can be made.

▲ or ▼. If Band displays, the High Limit band feature is

Menu a third time to display Event1. Press ▲ to turn the

Changes to High Limit Setpoint or Eve n t Output Configuration must be accomplished from the Stop Mode.

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Protocol Plus Owner’s Manual OPERATION Version 2 23

5.3. Timer Mode

1. Press Select until Timer displays.

2. Press Menu to display the Pro cess Temperat u r e Setpoint (Setpt). C hange Set point

(Setpt) by using ▲ or ▼ to cha nge t he valu e.

Press Run at any time in the procedure to activate Timer Mode.

If the SPChange on the Enable page in Setup Mode ha s been set to DISABLED, it must be changed to ENABLED befo re any changes to the process temperature an d high limit setpoints can be made.

3. Press Menu a second time to display current hig h limit set point (Hi-Lim SP). Change

Setpo int (Hi-Lim SP) using ▲ or ▼. If Band displays, the high limit band feature is activated (see Cont rol page, Section 8.1.5) and the high limit cannot be adjusted.

4. Press

5. Optional Feature: Press

6. Press Menu a fifth time to display the current gu ar ant eed soak band (TmrGuarSoak)

7. To start Timer Mode, p r ess Run. The d ispla y changes from Stop to Run and the time

Pressing Run/Hold while in Time r Mo d e put s cont ro l in Hold status. The Time r LED will flash to indicate Hold status. Press Run/Hold key again to continue timing. The Timer LED will re turn to lit s tatus.

Menu a t hird t ime to display Time Set. Change the time se tting by using ▲ or ▼.

Menu a fourth time to display Event1. Press ▲ to turn the

event ON or ▼ to turn the even OFF. Repeat for all event s which are enab led (up to four eve nts).

value. If the process temperat u r e deviates from the setpoint by more than this value, the timer is placed in a Hold condition. T he timer continues whe n the process temperature falls wit hin range. Reference the Quick Reference and Default Values section (Section 8.1) for a vailable sett ings.

remaining displays. R eturn to Stopped Mode by pressing Stop. While in operation, the process setpoint can be adjusted by using ▲ or ▼ to change the value while the mode is running. Press Menu to disp l ay t he High Limit Setpoint.

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OPERATION Protocol Plus Owner’s Manual

24 Version 2

5.4. Profile Mode

1. Press Select until Profile is displayed. None may display if a profile has not been

selected or no profiles have bee n enter ed.

2. Press ▲ or ▼ to display the desired profile.

3. Start Profile Mode by pressing Run.

The display w ill chang e from Stop to Run and show segment time rema ining , Temperature S et po int, Pro file #, and the current segment number. To return to Stopped Mode, pr ess Stop.

Press Run/Hold while in Profile Mode puts the cont r ol into Hold.

4. To advance to the next segment while running a profile, press Select and ▲ at the

same time.

If Link To is set to Standby in the Prog r am Page, at the End of Program/Pro file,

1. Cycle Complete LED indication goes ON.

2. Controller be e ps if

3. Heater/control output keeps cont ro lling oven t emperature at last Soak setpoint.

4. All events pr ogrammed (if relay cards are installed a nd progr ammed a s an event) fo r

the last Soak Segment st ays act ive.

Press Run/Hold again to continue in Profile Mode. The Profile LED flashes to indicate Hold status.

End of Cycle beep is enabled.

Ramping down too fast may cause the high limi t relay to trip unexpectedly if the high limit band feature is used. Avoid

trippin g the high limit relay by using a separate cooling profile (one that does not use the high limit band) and then linking to that profile to perform rapid cooling.

5.5. Auto Start Mode

Auto Start allows the operato r to start Manual, Timer, or Profile modes automatically at a

preset time and day. See Setting Up Auto Start (Section 5.6.5) for the time, day, and operating mode sett ings.

If AutoStart is set to No in the Setup menu, AutoStart will not

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display on the main Menu. If AutoStart is set to Yes in the Setup menu, AutoStart will display on the main Menu.

Protocol Plus Owner’s Manual OPERATION

including the Enable page. The default security password values

Version 2 25

To activate Auto Start:

1. On Auto Start page, set Enable to Yes.

2. LCD displays Active, current dat e and time

To deactivate Auto Start, on Auto Start page, set Enable to No.

Once Auto Start is activat ed, co nt inue to u se all operat ing modes as you nor mally would. If an operating mode is running at the time of a preset Auto Start function (provided Auto Start is activated), the existing operating mode will overr ide the Auto Start function and the Auto S tart will not turn on.

All processes set to run in Auto St art must be at least one

minute long for all Run Modes (Manual, Timer, and Profile) .

5.6. Setup Mode

Use Setup to configure a number of control parameter s. To access Set up , the cont roller must read Stop.

5.6.1. Enter and Exit Setup Mode

Enter Setup from Stop by:

1. Press Select until Setup displays.

2. Press Page. Security displays.

3. Press Menu. Password displays. Use ▲ or ▼ to enter the proper password and press

Page.

Passwords Protection

The controller has two levels of password protected security. Level one provides access only to those menu pages ena ble d on the Enable page. Level two provides access to all menu pages,

are 1 for level one and 2 for level tw o.

If an improper password has been entered, the control will remain at Security. To enter the proper password, press Menu.

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OPERATION Protocol Plus Owner’s Manual

including the Enable page. The default security password values

26 Version 2

Exit Setup by pressing Page and holding for three seconds.

Access each of individual Setup pages by pressing Page until the desired heading displays. Press Menu to access Menu parameters. Press ▲ or ▼ to chang e Menu parameter sett ings. Re fer to the Quick Reference and Default Values Appendix (S ection

8.1) for default a nd a vai lab le settings.

5.6.2. Temperature Scale Conversion

The Protocol Plus contro ller can be operated for either Centigrade or Fahrenheit. The controller de faults to Centigrade. Chang from Centigrade to Fahre nheit by:

1. Enter Setu p M od e. a. Press Select until Setup displays. b. Press Page. Security displays. c. Press Menu. Password displays. Use ▲ or ▼ to enter the proper password and

press Page.

Passwords Protection

The controller has two levels of password protected security. Level one provides access only to those menu pages ena ble d on the Enable page. Level two provides access to all menu pages,

are 1 for level one and 2 for level tw o.

If an improper password has been entered, the control will remain at Security. To enter the proper password, press Menu.

2. Press Page until PID displays.

3. Press Menu. Temp Unit F or Temp Unit C displays.

4. Use ▲ or ▼ to toggle between and choose F and C.

5. Press a nd hold Page for approximately three seconds to exit Set up mode.

5.6.3. Program Page

Use the Program Page to prog r am the heat profiles. Table 16 show s t he me nu items available. Eight profiles are available with up to eight ramp and soak segments per profile. See Section 5.6.3.2 for infor mation on working with optional relay outputs.

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Protocol Plus Owner’s Manual OPERATION Version 2 27

5.6.3.1. Using the Program Page

After entering the Pro gr am Page, pr ess Select to reach the pro file you desire to enter/edit. Press Menu to select the profile. The first p ar ameter displays: Pr ofile #, Segment 1, Ramp Time. Adjust the value by pressing ▲ or ▼. When the proper value is displayed, pr ess

Menu to continue to the next parameter. Continue using the Menu to view and adjust each

parameter.

If the current seg ment’s ra mp time value is left at 0:00, the next press of Menu advances to the High Limit Setpoint parameter for that profile (Hi-Lim SP). Continue entering/verif ying all par ameters until arriving at the last parameter: Guaranteed So ak Band (Guar Band). After pro perly e ntering all parameter s, pr ess Page to r eturn to the to p of the Profile Page. Press Select to enter/ edit anot her pro file, press Page to access another page, or press and hold Page to exit Setup mode.

While editing any profile, press Select to advance the control to the time value for the next segment , unt il the last segmen t has

been reached. This allow s faster edit ing of the profile rather than pressing Menu to advance past each parameter.

If Link To Pro is set to Standby (Stby) in the Program Page at the end of running a Pro file,

1. Cycle Complete LED indication goes ON.

2. Controller be e ps if End of Cycle beep is enab led.

3. Heater/control output keeps cont ro lling oven t emperature at last Soak setpoint.

4. All events pr ogrammed (if relay cards are installed a nd progr ammed a s an event) fo r the last Soak Segment st ays act ive.

Run a profile indefinitely by linking the profile to itself.

5.6.3.2. Programming Optional Relay Outputs

Optional relay outputs must be configured prior to use. If optiona l relay outp uts a re installed, configure them as alarms or events on the Relay Outpu ts Page (Section 8.1.8) before using. If configured as event outputs, these relays can be used as time or temperature event s.

Check your schemat ic for relay use in your oven, but typical uses for optional rela ys include:

• R elay 1: Cooling event

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OPERATION Protocol Plus Owner’s Manual

Menu Item

Display

Description

28 Version 2

• Relay 2: End of cycle relay

• Re lay 3: Optional N2 purge event

• Re lay 4: Optional N2 maint ain e vent

Table 2. Program Page Menu Items and Explanation.

Ramp Time Seg 1 Event 1 Set Value Event 2 Set Value3 Event 3 Set Value3 Event 4 Set Value3 Soak Temp Seg 1 Soak Time Seg 1 Event 1 Set Value3 Event 2 Set Value3 Event 3 Set Value3 Event 4 Set Value3

High Limit Setpoi nt Loop From

Pro-1 Seg-1 Ramp Time

Pro-1 Seg-1 Ramp Event 1

Event 1 setting for segment 1 ramp of profile

Pro-1 Seg-1 Ramp Event 2 Pro-1 Seg-1 Ramp Event 3 Pro-1 Seg-1 Ramp Event 4 Pro-1 Seg 1 Soak Temp Pro-1 Seg 1 Soak Time Pro-1 Seg-1 Soak Even t 1 Pro-1 Seg-1 Soak Even t 2 Pro-1 Seg-1 Soak Even t 3 Pro-1 Seg-1 Soak Even t 4

Ramp time for segment 1 of profile

Event 2 setting for segment 1 ramp of profile Event 3 setting for segment 1 ramp of profile Event 4 setting for segment 1 ramp of profile Soak temperatur e for segment 1 of profile Soak time for segment 1 of profile Event 1 setting for segment 1 soak of profile Event 2 setting for segment 1 soak of profile Event 3 setting for segment 1 soak of profile Event 4 setting for segment 1 soak of profile

(Repeat for segments 2-8, until ramp = 00:00)

Profile-1 Hi-Lim SP Profile-1 Loop From Seg

High limit setpoi nt f or pr ofile To start a loop action in a profile

Loop To Loop Count Profile Link Guaranteed Soak

Profile-1 Loop To S eg Profile-1 Loop Number Profile-1 Link To Pro Profile-1 Guar Band

To end a loop action in a profile Number of times to execute loop To jump from this pr ofile to another Guaranteed soak band f or pr ofile

Available only if optional relay outputs are installed (repeat all for Profiles 2-8).

Set to Band to use the high limit band feature.

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Protocol Plus Owner’s Manual OPERATION

Parameter

Definition and/or Range Profile #

Eight profil es are available

Segment #

Program recipe segments one through eight. Give each segment its own set

Ramp Time

Time required to mov e ov en temper ature from one setpoint to another.

to the soak temperat ur e.

EV1 through 4

Program from one to four events into the ramp time portion of each segment.

install ed and is programmed for an event.

Soak Temp

Enter the temperat ur e setpoint of a particular segment . The setpoi nt can range from -18 to 540 °C (0 to 1000 °F).

Soak Time

Enter the durati on of soak. S oak Time c an r ange from 0 to 99: 59.

EV1 through 4

Program from one to four events into the soak portion of each segment.

install ed and is programmed for an event.

Hi Limit SP

Enter the high limit setpoint. If the temperature exc eeds this value, hi-limit will alarm and shut off the heater.

Loop From

Identify segm ent number to loop from.

Loop To

Identify segm ent number to loop to.

Loop Number

Enter value from 1-99 to preset the number of times to run the loop established in “Loop From” and “Loop To.”

Link t o Pro

Enter value to instruc t profile in steps to take when the profil e ends. V alues

Val ue 1 – 8: Jump to specified profile

Guaranteed

Enter value that determines if the process temperature has deviated from the

Version 2 29

Table 3. Parameter Definitions and/or Ra ng e s.

of events, ramp and soak tim es and soak temperature.

Values between 0 and 99:59 are allowed. The Protocol Plus cont r oller stores profile ramp and soak tim es without units. Times are set as hours and minutes (HH: M M ) or minutes and seconds (MM:SS). The setpoi nt aut om atically increments fr om the actual temperature

Events typic ally inv olv e ac tuating/disabli ng rel ay s to cl ose/open valves or perform other r elay -controlled functions.

NOTE: Events actuate only when the controller has the optional relay cards

Soak Band

Events typic ally inv olv e ac tuating/disabli ng rel ay s to cl ose/open valves or perform other r elay -controlled functions.

NOTE: Events actuate when the controller has the optional relay cards

include:

• STANDBY: Holds temperature setpoi nt while keeping event relay(s) at last status, actuates cycle relay(s)

• STOP: Turns heater and all relays to OFF status

• HOLD: Holds temper ature setpoint and all relays at last status, at end of

profile

•

setpoint. If the proc ess temperature deviates from the setpoint by more than the “Guaranteed S oak Band” value, the soak timer is placed in a hold condition. The timer continues when the process tem peratur e falls within range.

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OPERATION Protocol Plus Owner’s Manual

Figure 7. Sample Profile.

30 Version 2

5.6.4. Sample Profile

Figure 7 shows a graphic representation of the samp le profile, whi le Figure 8 s hows the parameters entered to achieve that profile.

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Protocol Plus Owner’s Manual OPERATION

Enable Autostart

Auto Start Enable

Enable (yes) or disable (no) the Autostart function

Sunday mode

Auto Start Sun Mode

Set mode on Sunday to activate

Off, Manual, Timer , Pr o-1 to Pro-8

Sunday time

Auto Start Sun Time

Set time on Sunday for mode to activate

Monday mode

Auto Start Mon Mode

Set mode on Monday to activate

Off, Manual, Timer , Pr o-1 to Pro-8

Monday time

Auto Start Mon Time

Set time on Monday for mode to activate

Tuesday mode

Auto Start Tue Mode

Set mode on Tuesday to activate

Off, Manual, Timer , Pr o-1 to Pro-8

Figure 8. Sample Profile Values.

Version 2 31

5.6.5. Setting Up Auto Start

Auto Start allows the operato r to start Manual, Timer, or Profile modes auto matical ly at a

preset time and day. Table 4 show s the menu items availa ble.

Table 4. Auto Start Menu Parameters and Values.

Menu Item Display Description Range

No, Yes

00:00 to 23:59

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OPERATION Protocol Plus Owner’s Manual

Tuesday time

Auto Start Tue Time

Set time on Tuesday for mode to activate

Wednesday

Auto Start Wed

Set mode on Wednesday to

Off, Manual, Timer , Pr o-1 to

Wednesday time

Auto Start Wed Time

Set time on Wednesday for mode to activate

Thursday mode

Auto Start Thu Mode

Set mode on Thursday to activate

Off, Manual, Timer , Pr o-1 to Pro-8

Thursday

Auto Start Thu

Set time on Thursday for m ode

Friday mode

Auto Star t Fri Mode

Off, Manual, Timer , Pr o-1 to Pro-8

Auto Star t Fri Time

Set time on Friday for mode to activate

Saturday mode

Auto Start Sat Mode

Set mode on Saturday to activate

Off, Manual, Timer , Pr o-1 to Pro-8

Saturday

Auto Start Sat

Set time on Saturday for m ode

32 Version 2

Menu Item Display Description Range

00:00 to 23:59

mode

time

Friday time

time

Mode

Time

activate

to activate Set mode on Friday to activate

to activate

5.6.5.1. Configure Auto Start

1. Access Setu p Mode.

2. Press Page until Auto Start displays.

3. Press

Menu.

Pro-8 00:00 to 23:59

00:00 to 23:59

If the display does not change, the controller may not have the

realtime clo ck option.

4. Set

Auto Start Enable to Yes.

5. Using Menu, sc r oll through the o ptions ava ilab l e and press ▲ or ▼ to set the desired

mode for each day of the week. Select from Manual, Timer or Profile 1 through 8.

6. After setting mode, press Menu.

7. Enter the time of day you wish the mode to activate.

8. Continue through the week by pressing Menu, or press Page if changes are complete. a. One Auto Start mode can be set for each da y of the week. b. Exit Setup by pressing Page and holding f or three seconds. c. Press Select until Auto Start displays. d. Make sure the correct time and day is displayed. If not correct, set time a nd

day to the Real Time Clock Page in the Setup mode.

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Protocol Plus Owner’s Manual OPERATION

Proportional band

Set proportional band for tuning

Integral

PID

Derivative Rate

PID Rate In Sec

Version 2 33

5.6.5.2. Activate Auto Start

1. On Auto Start page, set Enable to Yes.

2. LCD displays Active, current d ate and time

5.6.5.3. Deactivate Auto Start

On Auto Start page, set Enable to No.

Once Auto Start is activat ed, co nt inue to u se all operat ing modes as you nor mally would. If an operating mode is running at t he time of a preset Auto Start funct ion (pro vided Auto Start is activated), t he exist ing op er ating mode w ill override the Auto Start function and the Auto S tart will not turn on.

All processes set to run in Auto St art must be at least one

minute long for all Run Modes (Manual, Timer, and Profile).

5.6.6. Setting Up PID Page

The PID Page contains para meter s that control the response to t he setpo int and process var ia ble inpu t . Table 5 show s the menu items ava ilab l e .

Table 5. PID Page Parameters and Values.

Menu Item Display Description Range

Display units PID Temp Unit Set display units to °C or °F °C or °F

PID Prop Band

reset

AutoTune PID AutoTune Enable auto tuning f unction Di sabl e, Enable

Reset/Rep/Min

Set integral reset for tuning 0.0 to 100 seconds/repeat Set derivative rate for tuning 0.0 to 500 seconds

5.6.6.1. Access the PID Page

1. Enter Setu p M ode.

2. Press Page u ntil P ID displays.

3. Press Menu.

4. Change parameters by pressing Menu until the desired parameter is displayed. P ress

▲ or ▼ to set the desired value.

1 to 56°C (1 to 100°F)

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OPERATION Protocol Plus Owner’s Manual

Menu Item

Display

Description

Range

Cycle Time

Control Cycle Time Sec

Set cycle time in seconds for control out put

1 to 60 seconds

High limit setpoint

Control Hi-Lim SP

Maximum value for all high limit setpoi nts

MinHiLimSP - MaxHiLimSP

High limit

Control Hi-Lim

If=0, high limit setpoint=

Band

Off, 3°C to 11°C (5°F to 20°F)

34 Version 2

5.6.6.2. Setting up Auto Tune

The AutoTune paramet er d isables o r enables the Aut oT u ne function. To use AutoTune:

1. Enter Setup M od e.

2. Press Page k ey until AutoTune displays.

3. Enable Autotune by pressing ▲ .

4. Press Page for three seconds to exit Setup Mode.

5. Cycl e power to the instrument.

6. Set Manual Mode to Run. The display will alternate betw een AutoTune and Manual.

If the Manual Mode setpoint is less tha n 50 degr ees hig her than the actual process temperature, the AutoT une funct ion creat es an error cond ition. Clear t he error by cooling the process temperatu r e or increas ing the setpoint until more than 50 degrees bet ween them. After AutoTune has completed tuning, the AutoTune parameter will disable by itself.

Cancel AutoTune by pressing STOP. Access the PID page in Setup Mode, and set the AutoTune parameter to D isable.

5.6.7. Setting up the Control Page

The Control Page contains parameters that control miscellaneous functions. Table 6 shows the menu items available.

5.6.7.1. Access Control Page

1. Enter Setu p M od e.

2. Press Page until Control displays.

3. Press the Menu.

4. Change each parameter by pressing Menu unt il the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

Table 6. Control Page Parameters and Values.

band

Band

Control Hi-Lim SP If>0, high limit setpoi nt= Cont r ol SP6 +

High lim it setpo int is a read-on ly item wh ich is calculated on Enable page

Inc lude s ramping setpoints during profiles a nd controlled ramp s

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Protocol Plus Owner’s Manual OPERATION

Menu Item

Display

Description

Range

Power fail recovery

Control PwrFRec

Controls response to l oss of power

Stop, Restart, H old, R esum e

Recovery

Control PFRTim e

Control abort s to Stopped period longer then set value

00m00s to 99m59s

Powerup

ControlPwrUpStrt

Allows mode to automatically

Disabl e, Enable

Powerup Start Mode

Control StrtMode

Operating mode for powerup start

Off, Manual , Timer, Pro-1 to Pro-8

Hysteresis

Control Hysteresis

Hysteresis for all alarms and temperature events

1°C to 56°C (1°F to 100°F)

Process out low

Control RetOutLo

Process value for retransmit output = 1VDC

-73°C to 760°C (-100°F to

Process out high

Control RetOut Hi

Process value for ret r ansmit output = 5VDC

-73°C to 760°C (-100°F to

Time scale

Control TimeScale

Time scale setting f or program and timer mode

hh:mm o r mm:ss

Key press beep

Control KeyBeep

Internal beeper sounds when key is pressed

On or Off

End of cycle beep

Control EOCBeep

Internal beeper sounds at end of cycle

On or Off

Alarm beep

Control AlarmBeep

Internal beeper sounds f or alarms

On or Off

Version 2 35

time limit

start enable

mode if power is lost for time

start when power is first applied

1400°F) 1400°F)

5.6.8. Setting up the Communication Page

The Communication Page co nt ains parameters for the communications feature. Table 7 shows the menu items available.

5.6.8.1. Access Communication Page

1. Enter Setu p M od e.

2. Press

3. Press Menu.

4. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

Power fail recovery time limit is always MM:SS r egardless of time scale setting

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Page until Communication displays.

If the display does not change, the controller does not have the commun ic a tion board installe d.

OPERATION Protocol Plus Owner’s Manual

Menu Item

Display

Description

Range

Address

Communication CommAddr

Sets address node for control

1 to 247

Mode

Communication Comm Mode

Turns on/off communications

OFF, Modbus

Baud Rate

Communication Baud Rate

Sets interf ac e speed

2400, 4800, 9600,

19.2K, 38.4K

Parity

Communication Parity

Sets parity for interface

None, Odd, Even

Menu Item

Display

Description

Range

Day of the week

Clock Day

Setting for current day of the week

Sun, Mon, Tue, Wed, Thu, Fri, Sat

Time of day

Clock Hh:mm

Setting for current time of the day

00:00 to 23:59

Reset

Clock clock to entered v alues

Ready, Done

36 Version 2

Table 7. Communication Page Parameters and Values.

5.6.8.2. Setting up the Real Time Clock Page

The real time clock is a seven day, 24-hour clock with battery backup. The Real Time Clock Page allows an oper ating mode to begin automat ically at a specific time on a specific day of the week. The rea l time clock feature also for use of the Po wer Failure Recovery mode Time Limit featur e ( see S ett ing up the Co nt ro l Page Sect ion 5.6.7). Table 8 shows the menu items available.

5.6.8.3. Access Real Time Clock Page

1. Enter Setu p M od e.

2. Press

3. Press

Page until Clock displays. Menu.

4. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

Table 8. Real Time Cl ock Page Parameters and Value s.

Press the ▲ key to set the

clock

UP to Reset

5.6.9. Setting up the Relay Outputs Page

The Relay Outputs Pag e configures the four alarm/event out put s. Each outp ut has a dedicated indicator light and can be configured as a temperat ur e alarm, profile event, or end of cycle output. Temperatu r e alarms can be of type process high, pro cess low, deviation high, deviation low, or deviation band. Table 9 shows the menu items available.

If the ▲ key is not pressed, clock values retain original values. The display changes to Done if the clock

is reset.

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Protocol Plus Owner’s Manual OPERATION

Menu Item

Display

Description

Range

Type of relay

Relay 1 RelayType

Set functi on of relay

Off, Alarm, Cycl, Ev1 to Ev4

Action of

Relay 1

Set coil and

energized Latching)

Type of alarm

Relay 1 AlarmType

Set alarm type for relay

High, Low, Plus, Mi nus, B and

Alarm setpoint10

Relay 1 AlmHi/Lo SP

Setpoint for alarm

-73°C to 760°C (-100°F to 1400°F)

Alarm deviation10

Relay 1 AlmDevBand

Deviation band for alarm

1 to 56°C (1 to 100°F)

Inhibit

Relay 1

Inhibits alarm unti l reached

En or Dis

Type of event

Relay 1 EventType

Set event type for relay

Time or Temp

Event setpoint

Relay 1 Event SP

Setpoint for temperature event

SPLoLim to SPUpLim

Repeat for relay outputs 2-4, if available

Version 2 37

5.6.9.1. Access Relay Outputs Page

1. Enter Setu p M od e.

2. Press Page until Relay displays.

3. Press Select until the desired rela y output is selected.

4. Press Menu.

5. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

6. To configure a specific relay, press Select until the desired relay displays.

If Relay 0 appears, no relays are installed. See relay kit assembly

p.n. 144562.

Table 9. Relay Outputs Page Parameters and Values.

relay

alarm10

If the relay output has been configured as l atching, the RESET key must be pressed to return the output to

the non alarm stat e once the alarm condit ion has cleared.

Appears only for alarm types.

Tur ning on the Alarm Inhibit function di sabl es the alarm output on p ower up until t he proc ess

temperature has reached a non alarmi ng co ndition ("safe").

Appears only for time or temp er ature event typ es .

Appears only for temperature event types.

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RelayAction

ALMInhibit

contact state of relay

"safe" condition is

• NDE (Normally de-energized)

• NE (Normally energized)

• NDEL (Normally de-energized

Latching), NEL (Normally

OPERATION Protocol Plus Owner’s Manual

he Test Page only for testing the functionality of the control

Menu Item

Display

Description

Range

Heater output

Test HeatOut

Activate SSR output 100%

OFF or ON

High limit relay

Test HiLimOut

Activate high limit alarm (de-energize relay)

OFF or ON

Relay 1 output

Test Rly1 Out

Energize relay output 1

OFF or ON

Relay 2 output

Test Rly2 Out

Energize relay output 2

OFF or ON

Relay 3 output

Test Rly3 Out

Energize relay output 3

OFF or ON

Relay 4

Test Rly4 Out

Energize relay output 4

OFF or

HiLim Sensor

Test HL Temp (push and hold up)

Displays sensor reading

OFF or ON

38 Version 2

5.6.10. Setting up the Test Page

The Test Page cont ains paramet er s whic h allow manual cont rol of the heat control and optional re lay o utputs. Table 10 sho w s the menu items avai lable .

Use t

5.6.10.1. Access Relay Outputs Page

1. Enter Setu p M od e.

2. Press Page until Test displays.

3. Press Menu.

4. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

Table 10. Access Relay Outputs Page Parameters and Values.

instrument. Do not operate the oven for proce s ses using the Test Page.

output

When entering the Test Page, all outputs are automatically set

OFF. When exiting the Test Page, all outputs return to their previous conditio n reg ardl ess of Test Page settings.

5.6.10.2. Setting up the Zone Calibration Page

The Zone Calibration Page allows adjustment of the displayed temperature versus the actual temperatur e measured b y t he co nt ro l ther moco u ple. This may be des irable in

Press ▲ to refresh display.

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Protocol Plus Owner’s Manual OPERATION

Menu Item

Display

Description

Range

Zone 1 actual

Zone Cal Zone1Act

Point at which Zone 1 is set (center of chamber)

-73°C to 760°C (-100°F to 1400°F)

Zone1 displayed

Zone Cal Zone1Dis

Desired displayed value for Zone 1 setting

-73°C to 760°C (-100°F to 1400°F)

Zone 2

Zone Cal

Point at which Zone 2 is set

-73°C to 760°C (-100°F to

Zone2 displayed

Zone Cal Zone2Dis

Desired displayed value for Zone 2 setting

-73°C to 760°C (-100°F to 1400°F)

Factory calibration

Zone Cal FactCal

Restores the fact or y calibration values

Ready or Done (push-key)

Version 2 39

certain conditions wher e the center of the oven chamber is not the same temperatu r e as the control thermoco up le. T his te mperat ur e d ifferential may occur when the oven is not allowed to soak at a constant t emperatu r e for long periods of time, or when the oven is being used at high temperature. Table 11 s hows the menu items a vailable .

5.6.10.3. Access Zone Calibration Page

1. Enter Setu p M od e.

2. Press Page until Zone Cal displays.

3. Press Menu.

4. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

5. Press Page to exit the Zone Calibration Page.

Use Factory Calibrat io n on ly when no calibration instrument is

available. Push ▲ to restore factory values.

Table 11. Zone Calibration Page Parameters and Value s.

actual

Zone2Act

(center of chamber)

1400°F)

5.6.10.4. Access Factory Calibration Recovery

Factory Calibrat ion Recovery restores the original factory calibration values. This may be helpfu l if the cal i bration has be en lost a nd a calibr ation inst rument is not r ead ily available. To use the Facto r y Calibration Recovery feature on ly, bypass t he Zone 1 and Zone 2 calibration parameters by pressing Menu.

Use only when no calibration instrument is a vailable, push ▲ to restore factory values.

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OPERATION Protocol Plus Owner’s Manual

40 Version 2

5.6.10.5. Adjusting Actual Versus Displayed Parameters

Two points of display calibration (temperature o ffset) are available. The Zone 1 Actual and Zone 2 Actual parameters are t he t wo temperat ur e points where t he offset is to tak e effect. These values are ad just able. The Zone 1 and Zone 2 Displayed parameter s ar e the values the user wishes to have displayed at the Actual temperatur es, and are also adjustable.

For example, the control is displaying 400°F with the set point being 400°F, but the center of the oven chamber is actually 395 °F. This can occur du e to oven wall losses and product loading var iat ions. T he o p er ato r may change the zone calibration so that the center of t he oven is 400 °F when the display r eads 400°F. I n t his case operate the oven in manual mode with a setpo int of 400°F. Reco r d the center o f the chamber (as measured with an independent senso r ) . Access the Zone Calibration Page and enter th is measured value as the Zone 2 Actual value, with 400 ° as the Zone 2 D ispla yed value.

Zone 1 can be adjusted using the same metho d at a lower temperat u r e. The instrument will then create a linear offset based o n t he Zone1 and Zone 2 Act u al temperature values. Note that the oven does not have to be heated to adjust the zone parameters if the zone values are known based on pr ior experience.

5.6.10.6. Setting up the Sensor Calibration Page

The Sensor Calibration Page has parameters which can change t he inter na l calibration of the temperatur e sensor input signal. There is a low and high ca libration point for bo th the co ntrol sensor a nd the high limit senso r. To calibra te the instrument, a llow the contr ol to warm up for at least 30 minutes.

5.6.10.7. Access Sensor Calibration Page

1. Enter Setu p M od e.

2. Press Page until Sensor Cal displays.

3. Press Menu.

4. Change each parameter by pressing Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change the value.

The c ontrol may ha ve the optiona l process value retransmission output feature. The output is a 1 to 5VD C s ignal. To calibrat e the ret ransm it signal, t he RetOutLo and

RetOutHi values fro m the Cont r ol Page mu s t be k nown. Bypass calibrating the control

and high l imit s ensor inp ut and access t he retransmit calibration by press ing the Menu until RetCalLo d ispla ys ( skip step s 4 -17). Table 12 shows the menu items available.

To re-calibrate the instrument:

1. Disco nnect the control and h igh limit s ensor thermocouples.

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

Protocol Plus Owner’s Manual OPERATION Version 2 41

2. Connect a calibration instrument with a type J thermoco uple output to the control

sensor input. Allo w the control to warm up at leas t 30 minutes.

3. Access Setu p Mode.

4. Press Page until Sensor Cal displays.

5. Press Menu k ey until Sensor Cal -100F displays.

6. With Ctrl S ens -100F displayed, adjust the calibration instrument to Type J

thermocouple, -100 degrees Fahrenheit output.

7. Wait 30 seconds. Pr e ss ▲.

8. With Ctrl S ens 1400F displayed, adjust the calibration instrument to 1400 degrees

Fahren heit out p ut (Type J thermocouple).

9. Wait 30 seconds. Pr e ss ▲.

10. When Ctrl S ens Done displays, disconnect the cali bration inst ru me nt from the control

sens or input and c onne ct it to the hig h limit se nso r input. Re c onnec t the co ntrol sensor thermocouple.

11. Press the Menu until HL Sens -100F is displayed.

12. With the cont r ol displaying HL S ens -100F, adjust the calibration instr u ment to -100

degrees Fahrenheit o ut put (T ype J thermocouple).

13. Wait 30 seconds. P ress ▲.

14. With the cont r ol displays HL Sens 1400F, adjust the calibration instrument to 1400

degrees Fahrenheit o ut put (T ype J thermocouple).

15. Wait 30 seconds. P ress ▲.

16. When the contr ol dis pla ys HL Sens Done, disconnect the calibration instrument from

the high limit sens or input. Re-conne c t the high limit senso r thermocouple.

17. To skip calibration of the retransmit signa l, press Page twice to exit the Sensor

Calibration Page.

18. To calibrate the retransmit signal, press Menu until RetCalLo displays.

19. Connect a calibration instru ment with a type J t hermoco uple output to the control

sens or input.

20. Connect a voltage measurement device to the retransmit output ter minals.

21. Set the calibration instrument output to the temperatur e value of the RetOutLo

parameter from the Control Page.

22. Adjust the RetCalLo

value by pressing ▲ or ▼ to chang e the value until t he voltag e

measurement d evice reads 1VDC.

23. Press Menu.

24. Set the calibration instrument output to the temperatur e value of the RetOutHi

parameter from the Control Page.

25. Adjust the RetCalHi16 by pressing ▲ or ▼ to change the value of the voltage

measurement d evice to r eads 5VD C.

26. Press Menu.

27. Press Page to ex it the Sensor Calibration Page.

28. Calibration is now complete. Discon nect the calibration instru ment and vo ltage

measurement d evice (if used).

The “RetCalLo” and “RetCalHi” valu es are only chan ge indicators. The actual va lue is not meaningful.

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OPERATION Protocol Plus Owner’s Manual

Menu Item

Display

Description

Range

Control

Ctrl Sens -100F

Calibrat e Sensor Low End

Complete

-100 to 1400°F

HiLim Sensor

HL Sens -100F

Calibrat e HiLim Sensor Low

HiLim Sensor Cal Complete

-100 to 1400°F Retransmit

RetCalLo XXXX

Calibrat e Retransmit Output

High

0 to 4096

42 Version 2

29. Verify that the control and high limit sensor t her mo co uples are connected.

Table 12. Sensor Calibration Page Parameters and Values.

Sensor Cal

Cal

Ctrl Sens 1400F Ctrl Sens Done

HL Sens 1400F HL Sens Done

RetCalHi XXXX

Calibrat e Sensor High E nd Control Sensor Cal

End Calibrat e HiLim Sensor Hi gh End

Low Calibrat e Retransmit Output

-100 to 1400°F (read only)

0 to 4096

5.6.11. Setting up the Enable Page

The Enable Page contro ls access to the other Setup Pages when Leve l 1 Passwor d is used . The setpoint minimum and max imum value s, and the security passwords are also set on the Enable Page. Table 13 show s the menu items a vailable.

5.6.11.1. Access Enable Page

1. Enter Set up Mo de using a level 2 access code (See S ection 5.6 for more on using

access codes).

2. Press Page until Enable displays.

3. Press

4. Change each parameter by pressing

Menu.

Menu until the desired parameter is displayed,

and then press ▲ or ▼ to change t he valu e.

The “RetCalLo” and “RetCalHi” valu es are only chan ge indicators. The actual va lue is not mean ingful.

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Changing Enable to Yes for each page will allow access to the page in Level 1 security.

Protocol Plus Owner’s Manual OPERATION

Menu Item

Display

Description

Range

Profiles

Enable Profile 1-8

Controls access to Program Page

Yes or No

Autostart

Enable Auto

Controls access to AutoStart

Yes or No

PID Enable PID

Controls access to PID Page

Yes or No

Control

Enable Control

Controls access to Control Page

Yes or No

Communication

Enable Communication

Controls access to Communication P age

Yes or No18

Real Time Clock

Enable Clock

Controls access to Real Time Clock Page

Yes or No18

Relay outputs

Enable Relay

Controls access to Relay

Yes or No18

Test

Enable Test

Controls access to Test Page

Yes or No

Zone Calibration

Enable Zone Cal

Controls access to Zone Calibrati on P age

Yes or No

Sensor Calibration

Enable Sensor Cal

Controls access to Sensor Calibration Page

Yes or No

Setpoint lower limit

Enable SPLowerLim

Sets minimum setpoint allowed

-73°C to 759°C (-100°F to

Setpoint upper limit

Enable SPUpperLim

Sets maximum setpoint allowed

-73°C to 760°C (-100°F to

High limit overhead

Enable HiLimOH

Sets maximum high limit setpoint allowed

3 to 11°C (5 to 20°F)

Password level 1

Enable Password 1

Sets password for acc ess level 1

0 to 999

Password level 2

Enable Password 2

Sets password for acc ess level 2

0 to 999

Setpoint

Enable

Set to DISABLE to lock out

and Timer Modes

Yes or No Analog Output

Type

Enable Analog Type

Sets Analog Output type

Ctrl or Proc

Version 2 43

Table 13. Enable Page Parameters and Values.

Start

1-4

Page

1399°F) 1400°F)

Change

5.6.12. Setting up Digital Inputs (Optional)

The Protocol Plus control can be run by external in puts wire d to the cont rol from an external source such as a PLC or control panel swi tches (Figure 9). The ext erna l r un operation can Run, Hold or Stop profiles 1 through 7 (profile 8 cannot be operated externally). See Table 14 for the inputs required for t he desired o per at ion.

If the controller does not ha ve this feature, No is the only option.

Maximu m high limit setpo int = SPUpperLim + HiLimOH

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SPChange

setpoint and high limi t setpoint changes in Manual

OPERATION Protocol Plus Owner’s Manual

Input 1

Input 2

Input 3

Profile Select ed

OFF

ON 4 ON

OFF

ON 5 OFF

OFF

none

Figure 9. Digital Inputs.

44 Version 2

A profile must be created in th e program pag e before trying to run a profile number.

Table 14. Digital Input Parameters and Values.

• T o start t he selected pro file, set Inputs 1, 2 and 3. The n s et Input 4 to ON.

• T o hold a profile, set Input 4 to OFF.

• T o stop a profile, set all inputs to OFF.

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Protocol Plus Owner ’s Manual MAINTENANCE & TROUBLESHOOTING

Global Headquarters

Contact

Service & Technical Support

Despatch Industries

International/Main: 1-952-469-5424

www.despatch.com

Service: 1-952-469-8230

Alarm Status

Possible Problem

Next Step

Hi-Limit LED flashing

exceeded.

Once the problem has correc ted,

Soak LED flashing

Oven temperat ur e has not

Program a slower ramp rate or if

Top LED displays OPEN

CONTROL SENS ERR

Control thermocouple is

Repair or replace t he

Lower LCD displays HI LIM

Hi limit thermocouple is

Repair or replace t he

Lower LCD displays HIGH

Hi limit temperature setpoint

Determine if:

Err4

Analog to digital c onv er si on control hardware failure.

Test thermocouple or consult

Err5 (Beep code: five beeps

Program memory fault. Control

Consult factory

Version 2 45

6. Maintenance

6.1. Replacement Parts

To order or return part s, contact the Ser vice Pro duct s Division at Despatch. The Service Product s features ou r Respo nse Center for cust omer service. When returning parts, a Despatch represent ative will provide you with an MRA (Material Retur n Aut ho r izat ion) numb er. Attach t he M RA nu mber to the returned p art for identific ation. When ord ering parts, expedite your process by providing model number, serial number and part number.

8860 207th Street Lakeville, MN 55044 USA

US toll free: 1-888-337-7282 Fax: 1-952-469-4513 info@despatch.com

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

7. Troubleshooting: Error Messages and A larm

Table 15 lists t he more co mmon error messages, t he po ssible prob lems a nd re medies.

Table 15. Err or Messa g e s and Next Steps.

• Probl em with thermocouple press Reset.

oven is not heating check heater circuit.

thermocouple.

and lower LCD displays

SENS ERR

• Hi-limit setpoint has been

entered (or dropped out of ) the soak band and the soak tim er has stopped

disconnected or broken

LIMIT ALARM

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has been exceeded

circuit fault. Therm oc ouple or

• the setting is too close to the

• the SSR is defec tive

• calibration is incorrect

factory

setpoint

MAINTENANCE & TROUBLESHOOTING Protocol Plus Owner’s Manual

Alarm Status

Possible Problem

Next Step

in rapid succession)

memory failure.

Batt (Beep code: three beeps in rapid succession)

Weak or dead battery. Battery failure.

Consult factory

RTC (Beep code: two

Loss of time in real time cl ock

Reset time in real time cloc k

46 Version 2

beeps in rapid succession)

circuit. Control memory loss .

The lower LC D inte r m it tently display HL Temp. This is not an

error message, but the Hi limit thermocouple temperature reading.

page.

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Protocol Plus Owner ’s Manual APPENDICES

Menu Item

Display

Default

Range

Setting

Ramp Time Seg20

Pro-1 Seg-1 Ramp Time

00:00

00m00s to 99h59s

Event 1 Set Value

Pro-1 Seg-1 Ramp Event

Off

Off, On

Event 2 Set Value

Pro-1 Seg-1 Ramp Event

Off

Off, On

Event 3 Set Value

Pro-1 Seg-1 Ramp Event

Off

Off, On

Event 4 Set Value

Pro-1 Seg-1 Ramp Event

Off

Off, On

Soak Temp Seg

Pro-1 Seg 1 Soak Temp

68°F

SPLowerLim to SPUpperLim21

Soak Time Seg

Pro-1 Seg 1 Soak Time

00:00

00m00s to 99h59s

Event 1 Set Value

Pro-1 Seg-1 Soak Event

Off

Off, On

Event 2 Set Value

Pro-1 Seg-1 Soak Event

Off

Off, On

Event 3 Set Value

Pro-1 Seg-1 Soak Event

Off

Off, On

Event 4 Set Value

Pro-1 Seg-1 Soak Event

Off

Off, On

(repeat for segm ents 2-8)

High Limit Setpoi nt

Pro-1 Hi-Lim SP

Max

MinHiLimSP to Band22

Loop From

Pro-1 Loop From XX

No, Seg-1 to Seg-8

Loop To

Pro-1 Loop To XX

No, Seg-1 to Seg-8

Loop Count

Pro-1 Loop Number

0 to 99

Profile Link

Pro-1 Link To XX

Stop

Standby23, Stop, Hold, Pro-1 to Pro-8

Guaranteed Soak

Pro-1 Guar Band

Off

Off, 1 to 778°C

(repeat for profiles 2-8)

Version 2 47

8. Appendices

8.1. Quick Reference and Default Values

8.1.1. Program Page Default Values

Table 16. Program Page Default Values.

Cycle Complete LED in dication goes ON.

See Enable Page (5.6.11)

Band value is set on Control Page (5.6.7)

If Standby: (1) Cycle Compl ete LED indication goes ON. (2) Controller beeps if End Of Cycle beep is enabled. (3) Heater /control output keeps controlling oven temperature at last Soak setpoint. (4) All even ts progr ammed (if relay cards install ed and programmed as an even t) for the la s t Soak Segmen t s tays active.

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HiLimSP

MaxHiLimSP,21

(1400°F)

APPENDICES Protocol Plus Owner’s Manual

Menu Item

Display

Default

Range

Setting

Enable Autostart

Auto Start Enable

No, Yes

Sunday mode

Auto Start Sun Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Sunday time

Auto Start Sun Time

00:00

00:00 to 23:59

Monday mode

Auto Start Mon Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Monday time

Auto Start Mon Time

00:00

00:00 to 23:59

Tuesday mode

Auto Start Tue Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Tuesday time

Auto Star t Tue Tim e

00:00

00:00 to 23:59

Wednesday mode

Auto Start Wed Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Wednesday time

Auto Start Wed Time

00:00

00:00 to 23:59

Thursday mode

Auto Start Thu Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Thursday time

Auto Star t Thu Time

00:00

00:00 to 23:59

Friday mode

Auto Start Fri Mode

Off

Off, Manual, Timer,

Friday time

Auto Star t Fr i Tim e

00:00

00:00 to 23:59

Saturday mode

Auto Start Sat Mod e

Off

Off, Manual, Timer, Pro-1 to Pro-8

Saturday time

Auto Start Sat Ti me

00:00

00:00 to 23:59

Menu Item

Display

Default

Range

Setting

Display units

PID Temp U nit

°C

°C or °F

Proportional band

PID Prop Band

6°C

1 to 56°C (1 to 100°F)

Integral reset

PID Reset

0 to 100 seconds/repeat

Derivative Rate

PID Rate

0 to 500 seconds

AutoTune

PID AutoTune

Disable

Disable, Enable

48 Version 2

8.1.2. Autostart Page Default Values

8.1.3. PID Page Default Values

Pro-1 to Pro-8

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Protocol Plus Owner ’s Manual APPENDICES

Profile Name: Profile Number:

Seg-

Ramp

Soak

Time

Events

Temp-

Time

Events

1 2 3 4 1 2 3

Version 2 49

8.1.4. P r ogra mm ing Tabl e Worksheet

ment

erature

1 2 3 4 5 6 7

8 High Limit Setpoi nt Loop From Seg Loop To Seg Loop Number Link To Profile Guar Soak Band

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APPENDICES Protocol Plus Owner’s Manual

Menu Item

Display

Default

Range

Setting

Cycle Time

Control Cycle Time

1 to 60 seconds

High limit setpoint

Control Hi-Lim SP

Max HiLimSP

MinHiLimSP – MaxHiLimSP

High limit band

Control Hi-Lim Band

Off

Off, 3°C to 11°C (5°F to 20°F )

Power fail recovery

Control PwrFRec

Stop

Stop, Restart, Hold, Resume

Recovery time limit

Control PwrFTime

00m00s

00m00s to 99m59s

Powerup start enable

Control EPwrStrt

Dis

Dis, En

Powerup Start Mode

Control StrtMode

Off

Off, Manual, Timer , Pr o-1 to Pro-8

Hysteresis

Control Hyst

3°C

1°C to 56°C (1°F to 100°F)

Process out low

Control RetOutLo

80°C

-73°C to 760°C (-100°F to 1400°F)

Process out high

Control RetOutHi

400°C

-73°C to 760°C (-100°F to 1400°F)

Time scale

Control TimeScale

hh:mm

hh:mm or mm:ss

Key press beep

Control KeyBeep

On or Off

End of cycle beep

Control EOCBeep

Off

On or Off

Alarm beep

Control AlarmBeep

Off

On or Off

Menu Item

Display

Default

Range

Setting

Address

Communication CommAddr

1 to 247

Mode

Communication CommMode

OFF

OFF, Modbus

Baud rate

Communication Baud

19.2K

2400, 4800,

38.4K

Parity

Communication Pari t y

None

None, Odd, Even

50 Version 2

8.1.5. Control Page Default Values

8.1.6. Communication (Optional) Page Default Values

See Enable Page (5.6.11)

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Rate

9600, 19.2K,

Protocol Plus Owner ’s Manual APPENDICES

Menu Item

Display

Default

Range

Setting

Day of the week

Clock Day

Mon

Sun, Mon, Tue, Wed, Thu, Fri, Sat

Time of day

Clock HH:MM

00:00

00:00 to 23:59

Reset clock

Clock UP to Reset CLK

Ready

Ready, Done

Version 2 51

8.1.7. Real Time Clock Page Default Values

If ▲ is not pressed, th e clock will retain original values, the display will change to Done if th e clock is

reset.

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APPENDICES Protocol Plus Owner’s Manual

Menu Item

Display

Default

Range

Type of relay

Relay 1 RelayType

Off

Off, Alarm, Cycl, Ev1 to Ev4

Action of relay

Relay 1 RelayActi on

NDE

NDE, NE, NDEL, NEL

Type of alarm

Relay 1 AlarmType

High

High, Low, Plus, Mi nus, B and

Alarm setpoint27

Relay 1 AlmHi/Lo SP

538°C

-73°C to 760°C (-100°F to 1400°F)

Alarm deviati on27

Relay 1 AlmDevBand

3°C

1 to 56°C (1 to 100°F)

Inhibit alarm27

Relay 1 ALMInhibit

En or Dis

Ty pe of event

Relay 1 EventType

Time

Time or Temp

Event setpoint

Relay 1 Event SP

SPUpLim

SPLoLim to SPUpLim

(repeat for relay outputs 2-4, if ava ilab le )

52 Version 2

8.1.8. Relay Outputs (Optional) Page Default Values

Press Select to choose relay. If Relay 0 displays, no relays are installed.

Norma lly de-energized and non-latching, norm a lly energized and non-latching, normally de-energized

and latching, normally energized a nd latching.

Appear s only for alarm types.

Appear s only for time or temperature event types .

Appear s only for temper ature event types.

See enabl e page.

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Protocol Plus Owner ’s Manual APPENDICES

Menu Item

Display

Default

Range

Setting

Heater output

Test HeatOut

Off

On High limit relay

Test HiLimOut

Off

On Relay 1 output

Test Rly1 Out

Off

On Relay 2 output

Test Rly2 Out

Off

On Relay 3 output

Test Rly3 Out

Off

On Relay 4 output

Test Rly4 Out

Off

On High Limit Sensor

Test HL Temp

(sensor reading)

Menu Item

Display

Default

Range

Setting

Zone 1 actual

Zone Cal Zone1Act

38°C

-73°C to 760°C (-100°F to 1400°F)

Zone1 displayed

Zone Cal Zone1Dis

38°C

-73°C to 760°C (-100°F to 1400°F)

Zone 2 actual

Zone Cal Zone2Act

260°C

-73°C to 760°C (-100°F to

Zone2 displayed

Zone Cal Zone2Dis

260°C

-73°C to 760°C (-100°F to 1400°F)

Factory calibration

Zone Cal FactCal

Ready

Ready or Done (push- key)

Menu Item

Display

Default

Range

Setting

Control Sensor

Ctrl Sens 0F Ctrl Sens Done

-100°F Done

-100 to 1400°F (read only)

HiLim Sensor Cal

HL Sens 0F HL Sens Done

-100°F Done

-100 to 1400°F (read only)

Retransmit Cal

RetCalLo XXXX

RetCalHi XXXX

0 4096

0 to 4096 0 to 4096

Version 2 53

8.1.9. Test Page Default Values

8.1.10. Zone Cal Page Default Values

8.1.11. Sensor Cal Page Default Values

Cal

Use only when no calibration instrumen t is available.

The “RetCalLo” and “RetCalHi” valu es are only chan ge indicators. The actual va lue is not mean ingful.

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1400°F)

Ctrl Sens 1000F

HL Sens 1000F

1400°F

-100 to 1400°F

APPENDICES Protocol Plus Owner’s Manual

Menu Item

Display

Default

Range

Setting

Profiles

Enable Profile 1-8

Yes

Yes or No

Autostart

Enable Auto Start

Yes or No

PID

En able P ID

Yes

Yes or No

Control

Ena ble Control

Yes or No

Communication

Enable Communication

Yes or No

Real Time Clock

Ena ble Cloc k

Yes or No

Relay outputs

Enable Relay 1-4

Yes or No

Test

Enable Test

Yes or No

Zone Calibration

Ena ble Zone Cal

Yes or No

Sen sor Cal ibration

Ena ble Sensor Cal

Yes or No

Setpoi nt lower limit

Enable SPLowerLim

20°C

-73°C to 759° C (-100° F to 1399°F)

Setpoi nt u p per limit

Ena ble SPU pperLim

260°C

-73°C to 760°C (-100°F to 1400°F)

High l imit overhead

Enable HiLimOH

5°C

3 to 11°C (5 to 20°F)

Pas sword l evel 1

Enable Password 1

0 to 999

Pas sword l evel 2

Enable Password 2

0 to 999

Manual/Timer mode

Enable SPChange

Yes

Yes or No

Analog Output Type

Ena ble Analog Type

Proc

Ctrl or Pr oc

54 Version 2

8.1.12. Enable Page Default Values

setpoint change

If the controller does not ha ve this feature, No is the only option.

Maximu m high limit setpo int (MaxHiLimSP) = SPUpperLim + HiLimOH. Minimum high limit

setpoint (MinHiLimSP) = SPLowerLim + HiLimOH.

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Protocol Plus Owner ’s Manual APPENDICES Version 2 55

8.2. Standard Products Warranty

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

APPENDICES Protocol Plus Owner’s Manual 56 Version 2

3rdDraft—

Despatch

GLOBAL HEADQUARTERS

Despatch Industries 8860 207th Street West Minneapolis, MN 55044 USA

US toll free: 1-888-337-7282 international/main: 1-952-469-5424 fax: 1-952-469-4513

info@despatch.com www.despatch.com

INDUSTRIES

SERVICE AND TECHNICAL SUPPORT

service parts: 1-800-473-7373 international service/main: 1-952-469-8230 service fax: 1-952-469-8193

service@despatch.com

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Despatch PROTOCOL PLUS Installation 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 Ge ner a l

3.1.1. High-Limit Function

3.1.2. Optional Serial Communications Hardware

Display Functions

3.3. Modes and Menus

3.4. Indicators

3.5. K ey Fun cti on s

3.6. Outputs

4. Assembly & Setup

4.1. Install the Protocol Plus Controller

4.2. MRC5000 Setup (Optional)

5. Working wit h Oper at ing Modes

5.1. Start-up Basics

5.2. Manual Mode

5.3. Timer Mode

5.4. Profile Mode

5.5. Auto Start Mode

5.6. Setup Mode

5.6.1. Enter and Exit Setup Mode

5.6.2. Temperature Scale Conversion

5.6.3. Program Page

5.6.3.1. Using the Program Page

5.6.3.2. Programming Optional Relay Outputs

5.6.4. Sample Profile

5.6.5. Setting Up Auto Start

5.6.5.1. Configure Auto Start

5.6.5.2. Activate Auto Start

5.6.5.3. Deactivate Auto Start

5.6.6. Setting Up PID Page

5.6.6.1. Access the PID Page

5.6.6.2. Setting up Auto Tune

5.6.7. Setting up the Control Page

5.6.7.1. Access Control Page

5.6.8. Setting up the Communication Page

5.6.8.1. Access Communication Page

5.6.8.2. Setting up the Real Time Clock Page

5.6.8.3. Access Real Time Clock Page

5.6.9. Setting up the Relay Outputs Page

5.6.9.1. Access Relay Outputs Page

5.6.10. Setting up the Test Page

5.6.10.1. Access Relay Outputs Page

5.6.10.2. Setting up the Zone Calibration Page

5.6.10.3. Access Zone Calibration Page

5.6.10.4. Access Factory Calibration Recovery

5.6.10.5. Adjusting Actual Versus Displayed Parameters

5.6.10.6. Setting up the Sensor Calibration Page

5.6.10.7. Access Sensor Calibration Page

5.6.11. Setting up the Enable Page

5.6.11.1. Access Enable Page

5.6.12. Setting up Digital Inputs (Optional)

6. Maintenance

6.1. Replacement Parts

7. Troubleshooting: Error Messages and A larm

8. Appendices

8.1. Quick Reference and Default Values

8.1.1. Program Page Default Values

8.1.2. Autostart Page Default Values

8.1.3. PID Page Default Values

8.1.4. P r ogra mm ing Tabl e Worksheet

8.1.5. Control Page Default Values