Despatch Protocol Plus Controller User Manual

E-101

PROTOCOL

PROTOCOL

PROTOCOL PROTOCOL

PLUS

PLUS

PLUSPLUS

™ CONTROL

CONTROL

CONTROLCONTROL

HEAT/COOL VERSION

HEAT/COOL VERSION

HEAT/COOL VERSIONHEAT/COOL VERSION
INSTRUCTION MANUAL

INSTRUCTION MANUAL

INSTRUCTION MANUALINSTRUCTION MANUAL
SOFTWARE VERSION 3.1

SOFTWARE VERSION 3.1

SOFTWARE VERSION 3.1SOFTWARE VERSION 3.1

PN 157427
REVISION B

6/2002

NOTICE

CAUTION

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

Setup and maintenance of the equipment should be performed by qualified personnel
who are experienced in handling all facets of this type of system. Improper setup and
operation of this equipment could cause an explosion that may result in equipment
damage, personal injury or possible death.

Dear Customer,
Thank you for choosing Despatch Industries. We appreciate the

opportunity to work with you and to meet your heat processing needs. We
believe that you have selected the finest equipment available in the heat
processing industry.

At Despatch, our service does not end after the purchase and delivery of
our equipment. For this reason we have created the Service Products
Division within Despatch. The Service Products Division features our
Response Center for customer service. The Response Center will direct
and track your service call to ensure satisfaction.

Whenever you need service or replacement parts, contact the Response
Center at 1-800-473-7373: FAX [phone].

Sincerely,
Despatch Industries

Despatch Industries

Product Warranty

Parts, Materials and Labor

Seller warrants the equipment manufactured by Seller and not by others, to be free
from defects in workmanship and material under normal use and service for a
period of (1) year from the date of delivery or the period of two thousand (2,000)
accumulated hours of use, whichever period is shorter. Use or service with
corrosive or abrasive chemicals or materials is not deemed normal. The period of
the foregoing warranty, in the case of furnaces, shall be ninety (90) days or five
hundred twenty-five (525) accumulated hours of use, whichever period is shorter.
Components manufactured by others, including expendable items, are warranted
only in accordance with the warranty, if any, issued by such other manufacturer.

Buyer shall give Seller written notice of any defects with 14 days after discovery
thereof, specifying each particular defect discovered. If such notice is properly
given, Seller will correct without charge any workmanship that is demonstrated to
Seller's satisfaction to have been defective at the time of installation, and will repair
or replace, at Seller's option, without charge, f.o.b. Seller's factory, parts covered by
this warranty that upon inspection are found defective under normal use within the
warranty period above stated. All work of removal and reinstallation, whether or not
found defective, and shipping charges for defective or replacement parts shall be at
the sole expense of Buyer.

The foregoing warranty shall not apply to (i) work done or materials furnished by
others in connection with installation work performed without supervision by Seller's
installation supervisors, or (ii) equipment repaired or altered by others unless such
repairs or alterations were specifically agreed to in writing by an Officer of Seller.
Seller shall not be liable for consequential damages of any kind which occur during
the course of installation of equipment, or which result from the use or misuse by
Buyer, its employees or others of the equipment supplied hereunder, and Buyer's
sole and exclusive remedy against Seller for any breach of the foregoing warranty
or otherwise shall be for the repair or replacement of the equipment or parts thereof
affected by such breach.

The foregoing warranty shall be valid and binding upon Seller if and only if Buyer
loads, operates and maintains the equipment supplied hereunder in accordance
with the instruction manual to be provided upon delivery of the equipment. Seller
does not guarantee the process of manufacture by Buyer or the quality of product to
be produced by the equipment supplied hereunder, and Seller shall not be liable for
prospective profits.

Despatch will repair or replace, at Despatch's option, FOB Despatch's factory, parts
and materials covered by this warranty. Despatch is not responsible for parts or
material failures resulting from misuse, abuse, inadequate preventive maintenance,
acts of nature, or non-conforming utilities, including electrical, fuel supply,
environmental and intake/exhaust provisions. This warranty also does not cover
normal wear or routine maintenance parts and materials expressly designed as
expendable/consumable and replaceable. (Note: Laboratory oven electric heaters
are warranted for a period of five [5] years from date of shipment; three [3] years
from date of shipment for Protocol Plus and DES 2000 temperature controllers.)

Labor services for parts and materials replacement and repair to support this
warranty are available at Despatch's normal service fees. This service is provided
worldwide by a network of factory trained professionals.

Transportation Costs

All transportation costs to transport defective parts or materials to Despatch, and to
transport repaired or replacement parts or materials to Customer, shall be the
responsibility of the Customer.

Terms and Conditions

This Warranty shall be deemed valid and binding upon Despatch if and only if the
Customer:

1. installs, loads, operates, and maintains the covered product supplied hereunder
in accordance with the instruction manual provided upon delivery and product
labeling affixed to the subject equipment:

THE REPRESENTATION AND WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE AND IN LIEU OF, AND CUSTOMER HEREBY WAIVES AND DISCLAIMS
RELIANCE UPON, ALL OTHER REPRESENTATIONS AND WARRANTIES OF EVERY KIND WHATSOEVER, WHETHER EXPRESS OR IMPLIED, OR ARISING BY
OPERATION OF LAW OR IN EQUITY, OR BY COURSE OF PERFORMANCE OR DEALING OR USAGE OF TRADE, INCLUDING, WITHOUT LIMITATION, ANY
IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

THIS WARRANTY IS PERSONAL TO THE CUSTOMER AND MAY NOT BE TRANSFERRED OR ASSIGNED. ALL LIMITATIONS HEREUNDER, HOWEVER, SHALL BE
BINDING ON ALL SUCCESSORS AND ASSIGNS OF CUSTOMER.

See separate warranty for Benchtop and Laboratory Ovens (Form BB7)

2. if applicable, follows the Emergency Procedure set forth in this Warranty; and

3. contacts Despatch's Helpline at 1-800-473-7373 for assistance in diagnosing
and troubleshooting the problem immediately upon discovering any damage or
malfunction.

Despatch's reasonable determination as to whether a repair, replacement, or
service is covered by this Warranty shall be final and binding.

Exclusions

This Warranty DOES NOT cover:

1. damage or malfunctions, or expenses incurred in the process of diagnosing
and/or repairing damage or malfunctions, resulting from any of the following:
operator error, misuse, abuse, inadequate preventive maintenance, normal wear
and tear, service or modifications by other than Despatch authorized technicians,
use of the covered product that is inconsistent with the operation manual or
labeling, acts of nature (including, without limitation, floods, fire, earthquake, or
acts of war or civil emergency), internal or external corrosion, or non-conforming
utilities (including, without limitation, electrical, fuel supply, environmental and
intake/exhaust installations);

2. repair or replacement of parts or materials designed and intended to be
expendable or consumable;

3. routine maintenance; or

4. labor costs incurred for troubleshooting, diagnostics, or testing (except for testing
required to verify that a covered defective part or material has been repaired).

Limitations of Liability

Despatch shall not, in any event, be liable for indirect, special, consequential,
incidental, or punitive damages or penalties of any kind, including, without limitation
loss of revenue, profits or business opportunities resulting from interruption of
process or production. In no event shall Despatch be liable for damages in excess
of the amounts paid by Customer to Despatch with respect to the applicable
product(s). This Warranty does not cover, and Despatch shall not be liable for any
losses, costs, damages or expenses resulting from delays in diagnosing or
repairing the products, supplying or obtaining replacement parts or materials,
strikes, labor stoppages or shortages, fires, accidents, government acts or
regulations, or any other causes beyond the control of Despatch.

Non-Compliance By Customer

Despatch reserves the right to suspend and withhold service under this Warranty in
the event of non-compliance by the Customer to any terms and conditions of this
Warranty or the applicable purchase order or invoice. Further, Despatch shall not
be liable for any loss of production, expenses, and inconveniences incurred due to
such suspension.

Customer Furnished Equipment Warranty Limitation

This Warranty does not cover diagnosis or repairs of defects in or caused by, lack
of performance of, or fitness for purpose of customer-supplied parts or equipment
unless specifically noted in the Despatch written order acceptance confirmation.

Performance Commitment

Despatch provides no guarantee of process performance or fitness for purpose,
unless specifically noted otherwise in Despatch written order acceptance
confirmation. Despatch is providing equipment with design parameters specific only
to its equipment.

Procedure Upon Discovery of Defects and Emergencies

In the event Customer becomes aware of any defect in the applicable products,
Customer must immediately: (a) shut off fuel or energy supply (gas and electricity),
(b) call for emergency assistance, if needed, and (c) notify Despatch Service.

Worldwide Phone [phone]; Worldwide Fax [phone]; North American Phone [phone]

Service

e-mail [e-mail]; www.despatch.com

Please see reverse side for other service offerings BB5 (5/28/02)

Despatch Industries

Advantage Service Assurance Program (ASAP)

CONTACT: DESPATCH SERVICE AGREEMENTS SPECIALIST at 800-473-7373 or 612-781-5356

or e-mail: [e-mail]

Despatch continues to deliver exceptional products backed by a strong sense of responsibility and drive for long term customer
satisfaction. Your partnership with Despatch can offer even higher value through your subscription to one of Despatch's Advantage
Service Assurance Program (ASAP).

Warranty

Despatch's exclusive, comprehensive service programs start with the 1 year parts only warranty which is described on the other
side of this document. This warranty can be expanded immediately to meet your most stringent service needs. Despatch Service
Products Group will be able to answer your service questions and provide a quotation for the immediate expansion of your product
warranty. Call 800-473-7373 or 612-781-5356; or e-mail [e-mail].

Immediate Service Response

The key to an effective service program is response. Wherever your location, Despatch is only a phone call away. Our U.S. and
Canadian customers can reach Despatch at 1-800-473-7373. Worldwide customers can call 1-612-781-5356 or FAX
1-612-781-5485. Our Customer Service Technicians have over 150 years combined experience and access to detailed design and
manufacturing documentation specific to your Despatch unit(s). This exacting level of service is a benefit only Despatch can provide
and means that you can expect speedy, accurate and the most cost effective response.

Field Service Network

A worldwide network of factory trained Service Professionals is available to support your Despatch equipment. From routine repair
to certified instrument calibration, the Despatch service network is positioned to respond to your needs. As a manufacturer of
custom equipment, our service programs are customized to meet your specific needs regarding:

Sustained Service Support

At Despatch, long term customer satisfaction means more than just responding quickly and effectively to our customers' service
needs. It means offering comprehensive customer support well beyond the scope and duration of our initial warranty. Despatch
offers two basic service packages which are customized to each individual customer's need. These service packages are titled Full
Service and Preventive Maintenance Plus+ service agreement products. Each is unique in the industry and offer the following
benefits:

1. Service scope

2. Response time

3. Preventive maintenance frequency and content

4. Payment method

1. Priority response for minimum production interruption

2. Preventive maintenance for longer product life

3. Discounts on parts and services

4. Various payment plans to ease budgeting and recording expenses

5. Reduce purchase ordering costs

Worldwide Phone [phone]; Worldwide Fax [phone]; North American Phone [phone]

e-mail [e-mail]; www.despatch.com

Service

TABLE OF CONTENTS

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

INTRODUCTION.............................................................................................................1

Theory of Control Operation ........................................................................................1

Operating Modes......................................................................................................3

Setup Mode.............................................................................................................. 3

Fast Start Mode........................................................................................................3

High Limit.................................................................................................................4

Indicators .................................................................................................................4

Displays ...................................................................................................................5

Key Functions ..........................................................................................................5

Outputs ....................................................................................................................6

Relay (Continued)....................................................................................................7

Communication........................................................................................................7

Optional Software.....................................................................................................7

INSTRUCTIONS .............................................................................................................8

Start-Up.......................................................................................................................8

Operation.....................................................................................................................9

Manual Mode ...........................................................................................................9

Timer Mode............................................................................................................10

Profile Mode...........................................................................................................11

Auto Start Mode.....................................................................................................11

Setup Mode............................................................................................................12

Instructions for Setup Mode Pages............................................................................13

Program Page........................................................................................................13

Profile # ..............................................................................................................15

Sample Profile........................................................................................................16

Auto Start Page (optional)......................................................................................17

Control Page..........................................................................................................20

Communication Page (optional).............................................................................21

Real Time Clock Page (optional)............................................................................21

Relay Outputs Page (optional)............................................................................... 22

Test Page...............................................................................................................23

Zone Calibration Page ...........................................................................................24

Sensor Calibration Page ........................................................................................26

Enable Page ..........................................................................................................28

Digital Inputs (optional) ..........................................................................................29

Error Messages and Alarms ......................................................................................30

Quick Reference and Default Values.........................................................................31

Technical Specifications ............................................................................................38

APPENDIX: Temperature Scale Conversion and Optional MRC5000 Setup................39

Temperature Scale Conversion (C/F)........................................................................39

i

ii

INTRODUCTION

The special features of the Protocol PlusTM control include:

• PID tuning

• Ramp/Soak programming of up to 64 segments

• Segment looping and profile linking

• Built-in manual reset high limit control

• Built-in process timer

• Dedicated LED display for process temperature

• Multi-purpose two-line LCD display with backlight

• Auto-tuning

• Security access

• Digital inputs for remote profile control

• Optional relay outputs for events, alarms, or end-of-cycle signal

• Optional real-time-clock

•

Optional RS232/RS422/RS485 MODBUS communications

Theory of Control Operation

The Protocol Plus is a modular microprocessor based digital temperature controller. The
Protocol Plus operates as a dual functioning controller/high limit instrument. The control
portion utilizes a time-proportioning voltage signal to control heating devices with
minimal temperature fluctuations.

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

1

Protocol Plus Faceplate and Wiring Diagram

2

Operating Modes

The Protocol Plus control has five modes of operation available:
Stopped Mode: All control and relay outputs are off. Stopped Mode is integrated

into each of the following four modes of operation.

Manual Mode: Control operates as a single setpoint control until Stopped mode is

accessed

Timer Mode: Control operates as a single setpoint control until preset time period

has expired.

Profile Mode: Control operates as a ramp/soak profiling control until the end of

the profile. 8 profiles are available with up to 8 ramp/soak segments
in each profile.

Auto Start Mode (optional): Control may automatically start Manual, Timer, or

Profile mode based on a preset time and day.
Requires the optional real-time clock feature.

The optional event outputs can be utilized during Manual, Timer, or Profile modes.

Setup Mode

The control has a Setup Mode which provides access to control configuration and
programming of profiles. The Setup Mode contains ten separate electronic Pages where
the configuration and programming parameters (Menu items) are found. The Setup
Mode Pages are described in detail elsewhere in this manual.

Fast Start Mode

The Protocol Plus control has the ability to automatically start an operating mode when
power is applied. This feature may be useful if the same mode of operation is used
everyday. The user can turn on the power and the oven will start the desired process
automatically. The Fast Start Mode is controlled by the Power-Up Start parameters on
the Control page (see Setup Mode).

3

High Limit

The control has an integrated high limit function which will disable the heater output
when tripped. If the high limit does trip, the relay will need to be manually reset. When
the high limit relay is tripped, the Hi-Limit indicator will be lit. Allow the oven to cool
several degrees (or increase the high limit setpoint) and then press the Reset key. The
indicator will turn off.

The control will not allow the high limit setpoint to be set below the current setpoint
value.

Indicators

The Protocol Plus control has 12 indicating LEDs that provide operational information to
the user.

Χ Power LED: Indicates that power is supplied to the instrument.
Χ Heater LED: Indicates that the heater output is active.
Χ Profile LED: Indicates that the Profile Mode is in operation.
Χ Timer LED: Indicates that the Timer Mode is in operation.
Χ Manual LED: Indicates that the Manual Mode is in operation.
Χ Cycle Complete LED: Indicates that the control is in Stopped mode.
Χ Hi-Limit Alarm LED: Indicates that the high limit relay has tripped (de-energized).
Χ Soak Alarm LED: Indicates that the guaranteed soak deviation is in alarm

condition.

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

These outputs may be configured as timed event outputs, process temperature trip
point outputs, alarm outputs, or as an end of cycle relay output. The ON state can
be configured as energized or de-energized.

4

Displays

The Protocol Plus control has two displays. A dedicated LED upper display shows the
oven temperature. A two-line LCD lower display provides information on control status
and allows changes to be made to the control settings.

Key Functions

The Protocol Plus control has seven keys that provide operation.

• Select key: Press to select mode of operation. In Setup Mode, to select profile
number or relay. In Profile/Run Mode, press simultaneously with the UP key to
advance a segment.

• Run/Hold key: Press to activate a mode of operation. If a Profile (or Timer)
Mode is running, pressing the Run/Hold key will place the Profile (or Timer) in
Hold status. A subsequent press will resume the Profile (Timer).

• Stop key: Press to stop any mode of operation.

• Page/Reset key: While in Setup Mode, press to access different Pages of

configuration, Press this key to silence an alarm if the instrument alarm sounds
during operation. In an operating mode, if an alarm or error condition occurs,
press this key to return the instrument to normal operation once the condition is
cleared.

• Menu/View key: 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.

• keys: Press these keys to adjust parameter settings. In Profile/Stopped
Mode, press to select profile to run. In Profile/Run Mode, press key
simultaneously with the Select key to force the program to advance one
segment.

5

Outputs

The Protocol Plus control has seven different outputs available.

• Heating output: The control output is a DC voltage open-collector output which
is time-proportioned and designed to control a heat control device such as a solid
state relay.

• Cooling output: The cooling output is a 4 to 20 ma DC output which is designed
to control a cooling device such as a damper motor.

• High limit: The high limit output is a form C relay which is energized under
normal operating conditions. If the control senses a temperature higher than the
high limit setpoint, or if there is a sensor error, the high limit relay will de-energize
until the condition is cleared and the Reset key is pressed. When the high limit
relay is de-energized, the heater is disabled.

• Relay (four optional outputs): The four form A dry contact relay outputs can be
configured to function as alarms, events, or end of cycle. These outputs can be
utilized in Manual, Timer, or Profile Mode.

Layout for Optional Components

6

Relay (Continued)
Use the Relay Card Optional Ay p/n 144562 to add relays to the standard controller.
Each relay card contains two relays (maximum of two cards Ay’s allowed).

Communication

The Protocol Plus control has optional MODBUS communication available which can
communicate via RS232, RS422, or RS485 to a computer. See communications option
assembly p/n 161957 for board and cable assembly. Please refer to the MODBUS
communications manual which comes with this option.

Optional Software

The Protocol Manager program allows the operator to start/stop multiple ovens (32
maximum) from a personal computer. A data log can also be used to record process
information (p.n. 140008).

7

INSTRUCTIONS
Start-Up

These instructions are provided as a quick reference for operating the Protocol Plus
control. If the Profile Mode is to be used, or the configuration of the control needs to be
changed, please refer to the Setup Mode instructions before operating the control. For
more detailed operating instructions refer to the Operation instructions for the mode you
wish to use.

Upon initial power-up the control is in Manual/Stopped Mode (unless the Autostart or
Fast Start Modes are active). To activate any operating mode from Stopped Mode,
press the Select key until the desired mode is displayed, then press the Run key. If the
proper Profile number is not displayed when the Profile Mode is accessed, press the
or keys until the desired Profile number is displayed, then press the Run key. If no
profile numbers can be displayed (display only reads NONE) then no profiles are
currently programmed (see Setup Mode).

The temperature setpoint can be adjusted while Manual or Timer Mode is running by
pressing the UP or DOWN key.

To momentarily hold the Timer or Profile Mode, press the Hold key. To continue the
Timer or Profile Mode, press the Run key.

To return to Stopped Mode at any time, press the Stop key and the cycle complete LED
will 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 Control Page in the
Setup Mode to utilize the Fast Start mode.

8