Dwyer 1600 User Manual

INSTRUCTIONS FOR THE

1600 SERIES

MICROPROCESSOR BASED

TEMPERATURE / PROCESS

CONTROL

INCLUDES FUZZY LOGIC OPTION

LOVE CONTROLS DIVISION

Dwyer Instruments, Incorporated

®

Rev. 10/98 1 949-1239-3

PO Box 338 Michigan City, IN 46361-0338

[phone] [phone] FAX [phone]

❍

❍

www.love-controls.com

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TABLE OF CONTENTS

GETTING STARTED .............................................................................. 2

INSTALLATION.......................................................................................4

DIMENSIONS ......................................................................................... 5

INPUT SELECTION ................................................................................ 5

LOGIC JUMPER SELECTION................................................................ 6

WIRING................................................................................................... 7

FRONT PANEL KEY FUNCTIONS......................................................... 8

NOTATION CONVENTIONS FOR THE MENUS .................................10

THE HOME DISPLAY ........................................................................... 10

OPERATION OF SELF TUNE® FUNCTION........................................ 11

Theory of Operation .....................................................................11

Program Setup and Operation .................................................... 12

METHOD FOR SET UP OF A HEAT / COOL CONTROL WITH SELF

TUNE .................................................................................................... 12

PROGRAMMING AND OPERATION FOR RAMP / SOAK FEATURE13

Theory of Operation .....................................................................13

Program Setup .............................................................................. 13

Ramp / Soak Operation ................................................................ 14

MENU SELECTIONS........................................................................... 15

PRIMARY MENU ..................................................................................15

SECONDARY MENU ............................................................................ 15

SECURE MENU.................................................................................... 21

DIAGNOSTIC ERROR MESSAGES ....................................................28

CONFIGURATION MENU .................................................................... 30

SPECIFICATIONS ................................................................................ 35

GETTING STARTED

1. Install the control as described on page 4.

2. Make sure that the Input DIP switch is set correctly for the input
you wish to use. Instructions on page 5.

3. If you wish to use the Logic (5 VDC) output, make sure that the
Logic jumper is in the correct position. See page 6 for details.

4. Wire your control following the drawing on page 7.

5. Make any programming changes necessary first in the Secure
Menu (page 21), next in the Secondary Menu (page 15), and
finally in the Primary Menu (page 15). DO NOT make changes to
the Configuration Menu unless specifically instructed. If you need
to back up in a menu, press the INDEX and DOWN ARROW keys
together.

949-1239-3 2 Rev. 10/98

6. To quickly return to the HOME position, press the UP ARROW
and ENTER keys together, and then the INDEX and DOWN
ARROW keys.

Take the example of a Model 16010 that comes from the factory pro­grammed for type J thermocouples. Suppose for this example you wish to
change the input to 100 ohm Platinum DIN RTD and limit the set point range
between 0° and 500° C.

First, change the input DIP switch as shown on page 5. For RTD inputs
switches 1, 3, and 4 are off, switch 2 is on.

Next, enter the Secure menu as instructed on page 8. Press the INDEX key
until the display shows Inp and press the DOWN ARROW until the display
shows P385. Don't forget to press the ENTER key to retain your setting.

Next, press the INDEX key to display Unit. Press the DOWN ARROW until
the display shows C. Press ENTER.

Next, press the INDEX key until SPL is displayed (pass the dPt and InPt
selections). Press the UP ARROW until the display shows 0. Press
ENTER.

Finally, press INDEX key to display SPH. Press the DOWN ARROW until
the display shows 500. Press ENTER.

The necessary program changes are now complete. After 60 seconds the
display will switch back to the temperature reading. If you want to return
faster, press the UP ARROW and ENTER keys (at the same time) and then
press the DOWN ARROW and INDEX keys ( again at the same time). This
will 'back out' of the menu and immediately display the temperature reading.

If you want to use Self Tune®, Auto/Manual, or the Ramp/Soak Program­mer features, see the special sections on these items. Page numbers for

these are in the Contents section on the previous page.

Rev. 10/98 3 949-1239-3

INSTALLATION

Mount the instrument in a location that will not be subject to excessive
temperature, shock, or vibration. All models are designed for mounting in an
enclosed panel.

Select the position desired for the instrument on the panel. If more than one
instrument is required, maintain the minimum of spacing requirements as
shown on the drawing opposite. Closer spacing will structurally weaken the
panel, and invalidate the IP66, UL type 4 rating of the panel.

Prepare the panel by cutting and deburring the required opening.

45mm

(1.77in)

45mm

(1.77in)

Cut Out

19mm

(0.75in)

45mm

(1.77in)

Cut Out

45mm

(1.77in)

All Tolerances are -0.00 +0.60mm (-0.000 +0.020)

From the front of the panel, slide the housing through the cut out. The
housing gasket should be against the housing flange before installing.

From the rear of the panel slide
the mounting collar over the hous­ing. Hold the housing with one

PANEL

10mm (0.25")

MAX.

GASKET

SPRING LOOP

hand and using the other hand,
push the collar evenly against the
panel until the spring loops are
slightly compressed. The ratch­ets will hold the mounting collar
and housing in place.

MOUNTINGCOLLAR(SHOWNINPOSITION)
SLIDE COLLAR ONTO T HE HOUSING
BEFORE WIRING THE REAR T ERMINALS

It is not necessary to remove the control chassis from
the housing for installation. If the control chassis is
removed from the housing, you must follow industry
standard practice for control and protection against
Electro-Static Discharge (ESD). Failure to exercise
good ESD practices may cause damage to the control.

949-1239-3 4 Rev. 10/98

DIMENSIONS

(All dimensions in millimeters with inches in parenthesis.)

125 (4.925)

48 (1.880)

LOVE

CONTROLS CORP.

R

48

(1.880)

SP1

SP2

AL

˚F
˚C

INDEX

AL

R

ENTER

AL

MADE IN USA

PV

SV

12 (0.450) * 3 (0.125)

Panel cutout for all models is 45mm x 45mm (1.775 in x 1.775 in).
Allow for 13 mm (0.5 in) clearance at the rear of the instrument.
* Present for SSR outputs.

INPUT SELECTION

Before removing the instrument from its housing, make sure you take
appropriate precautions to avoid electro-static discharge (ESD). See
caution on opposite page. To change the input type, remove the instru­ment from its housing by grasping the front bezel sides and pulling
forward to release it from
the housing lock.

114 (4.475)

(1.760)

DIP SWITCH LOCATION

45

Locate the dip switch on
the right pcb. Determine
the input type desired and
change the dip switch
setting as shown at the
right.

1

Reinstall the instrument
into the housing.

THERMOCOUPLE INPUTS

2 3 4

After changing input selec­tion with the DIP switches,

RTD INPUTS

be sure to change the InP
menu item (page 11) in the
Secure Menu.

CURRENT INPUT

VOLTAGE INPUT

Rev. 10/98 5 949-1239-3

LOGIC JUMPER SELECTION

Instruments with SSR or RELAY type outputs can be changed to and from a
LOGIC output in the field.

CAUTION: Damage to the instrument may result from an
incorrectly installed jumper strip. Follow the instructions
carefully. Damage to the instrument may also result from
improper handling. Use appropriate precautions to avoid
Electro-Static Discharge (ESD).

1. Remove the instrument from its housing. Grasp the front bezel sides and

pull forward to release it from the housing lock.

2. Locate the desired logic jumper strip on the left printed circuit board. The

OUTPUT A jumper
strip is always lo-

OUTPUT A SET FOR LOGIC TYPE OUTPUT

cated near the top
edge

3. To remove the logic

jumper strip, carefully
insert a small flat
blade screwdriver be­tween the retaining
clip and the jumper
at one end of the
jumper strip. Apply slight pressure to

OUTPUT B SET FOR SSR or RELAY TYPE OUTPUT

SLIGHT PRESSURE TO RELEASE

RETAINING CLIP

move the clip away from the jumper end
until it is released, then lift it up and out of
the clip.

4. To re-install the jumper strip, hold it with the spring contacts in the desired

position. Face springs up for SSR or RELAY outputs, or face springs down
for LOGIC outputs. Insert one end of the jumper strip under the retaining
clip and press the other end down until the remaining clip engages the
jumper.

SPRINGS DOWN

INSTALLING JUMPER FOR

LOGIC TYPE OUTPUT

SPRINGS UP

INSTALLING JUMPER FOR

SSR or RELAY TYPE

OUTPUT

5. To avoid any damage, recheck the jumper installation and the housing rear

terminal panel output wiring.

6. Replace the instrument into its housing.

949-1239-3 6 Rev. 10/98

Rev. 10/98 7 949-1239-3

WIRING

INPUTS

ocouple

RTD*

Current

Voltage

Therm

+

+

-

-

ALARM OUTPUT

Terminals 4 & 5 are
Normally Open. See
Rating Label.

F1
3/8 A @250 VAC
Medium Lag

* For 2-wire 1000 Ω RTD use terminals 1 & 3.

For 2-wire 100 Ω RTD use terminals 1 & 3, and
place a jumper wire between terminals 3 & 4.

INPUT WIRING: Do not run thermocouple of other signal wiring in the same conduit as power
leads. Use only the type of thermocouple or RTD probe for which the instrument has been
programmed. See Secure Menu for Input Programming.

For thermocouple input always use extension leads of the same type designated for your
thermocouple.

Outputs A and B may be logically swiched. See Secure Menu for details.

AL1

Line Input See Rating

Label for details

F1

}{
}{

Relay**
N.O.

Solid State Relay
N.O.

SSR Derating Chart
˚C ˚F CURRENT

25 77 3.50
35 95 2.75
45 113 2.00
55 131 1.25

5VDC Output
5V = On, 0V = Off

5VDC @

25mA

5VDC @

25mA

For Relay or SSR
outputs use type MDA or
3AB 3.5A medium lag
fuse.

** R/C snubber is
recommended for driving
solenoid or contactor
loads.

-

+

-

+

Current or

Voltage

+

}{

-

+

}{

-

Output

A

Output

B

OPTIONS

948

936

992

+

0 to 10 VDC @ 25 mA

-

B (+)

A (-)

FRONT PANEL KEY FUNCTIONS

Set Point 1 Lamp Process Variable
Alarm Lamp
Set Point 2 Lamp Set Variable

°F Indicator
°C Indicator

INDEX: Pressing the INDEX key advances the display to the
next menu item. May also be used in conjunction with other
keys as noted below.

UP ARROW: Increments a value, changes a menu item, or
selects the item to ON in the upper display.

DOWN ARROW: Decrements a value, changes a menu
item, or selects the item to OFF in the upper display.

ENTER: Pressing ENTER stores the value or the item
changed. If not pressed, the previously stored value or item will
be retained.

UP ARROW & ENTER: Pressing these keys simultaneously brings up the
secondary menu starting at the auto/manual selection. Pressing these
keys for 5 seconds will bring up the secure menu.

INDEX & DOWN ARROW: Pressing these keys simultaneously will allow

backing up one menu item, or if at the first menu item they will cause the
display to return to the primary menu. If an alarm condition has occurred,
these keys may be used to reset the alarm.

INDEX & ENTER: Pressing these keys simultaneously and holding them
for 5 seconds allows recovery from the various error messages. The
following menu items will be reset:

LPbr: Loop break SEnC: Sensor rate of change
ALiH: Alarm inhibit OPEn InP: Open input error message
ArEA: Area error message bAd InP: Bad input error message
CHEC CAL: Check calibration error message

Correct the problems associated with the above conditions first before
using these reset keys. More than one error could be present. Caution is
advised since several items are reset at one time.

949-1239-3 8 Rev. 10/98

While in the Primary or Secondary menu, if no key is pressed for a period
of 30 seconds, the display will return to the HOME position displaying the PV
and SV values. The time is increased to 1 minute when in the Secure menu.

NOTE: To move to the primary menu quickly from any other menu, press
the UP ARROW & ENTER keys followed by pressing the INDEX & DOWN

ARROW keys.

NOTE: Program the Secure Menu first, the Secondary Menu second,
and the Primary Menu last.

SECURITY LEVEL SELECTION

Four levels of security are provided. The display shows the current security
level. To change security levels change the password value using the UP &
DOWN ARROW keys and pressing the ENTER key. Refer to the password
table below for the correct value to enter for the security level desired. The
SECr menu item security level may be viewed or changed at any time
regardless of the present security level. The password values shown in the
table cannot be altered, so retain a copy of this page for future reference.
This will be the only reference made to password values in this instruction
book.

PASSWORD TABLE

MENU SECURITY

SECURITY LEVEL

Primary Locked
Secondary Locked
Secure Locked

Primary Unlocked
Secondary Locked
Secure Locked

Primary Unlocked
Secondary Unlocked
Secure Locked

Primary Unlocked
Secondary Unlocked
Secure Unlocked

DISPLAYED VALUE

WHEN VIEWED

1

2

3

4

PASSWORD

VALUE TO ENTER

1110

1101

1011

111

Rev. 10/98 9 949-1239-3

NOTATION CONVENTIONS FOR THE MENUS

Because of the number of features available in this control, information is
included that may not apply to your specific control. All usable features are
included in this book, but may not be used in your process. To increase
clarity the following conventions are used:

1. Certain features, Menu Items, and functions shown in this book may or
may not appear on your control, depending on other Menu Item selections.
At various places in the Menus there are notes identifying Menu Items that
"control" or "direct" other menu items. If you are looking for a particular
menu item and can't find it, check the menu item that is its "control" for
proper setting.

2. The "#" symbol is used in two ways. It is used inside a group of
characters to indicate which set point function (SP1 or SP2) is being
affected. It is also used before a group of characters of a menu item to
indicate that there may be more than one selection or value for that menu
item.

3.

Features that apply only to Options will be printed in Italics.

THE HOME DISPLAY

The home display is the normal display while the control is operating. If no
errors or functions are active, the HOME display will indicate the Process
Variable (the temperature, pressure, flow, RH, etc., that is being measured)
on the top display and the Set Variable (Set Point 1) on the bottom.

Items that can change the HOME display are the Auto/Manual function, the
Prog function, the PctO function, and any error message. Description of
these special displays follow.

If Auto/Manual Menu Item is On, the home display is changed. The upper
display continues to show the Process Variable (PV), but the lower display
changes to show the percentage of output in tenths of a percent to 99.9%
(0.0 to 99.9), or 100 if 100%. The display digit to the right of the number
shows a flashing letter o to indicate that the value displayed is no longer the
SV, but percent output. The SP2 output is indicated by the use of an
overline on the letter õ. Access to the SP2 value is done by the INDEX key.
See Auto/Manual Operation on Page 13 for further information.

If Prog is turned On, the HOME display changes the SV display from SP1
to the Present Set Variable as calculated by the Ramp/Soak Programmer
function. When Prog is On the StAt Menu Item changes the hHOME display
firther. When StAt is selected OFF, the HOME display alternately indicates
the normal HOME and the Ramp/Soak partial status in the Lower Display.

949-1239-3 10 Rev. 10/98

The partial status display sequences with the set value showing the ramp
(S1rA) or soak (S1So) segment being processed at that moment. It will also
show the Program output status if at Hold or OoFF.

When StAt is selected On, the HOME Display alternately indicates the
normal HOME and the Ramp/Soak full status in both the upper and lower
displays. The full status display sequences with the set value; Program run,
Hold, or OoFF; and with the time remaining for the ramp S1rA or the soak
S1So segments.See Programming and Operation for Ramp/Soak Feature
below for more information.

If PctO (Secondary Menu) is turned On, the lower display changes to show
the active percentage of output as required to maintain SP1. The display
is similar to the Auto/Manual display above, except that the letter indicators
do not flash, and the output is displayed in whole percentages of output, not
in tenths of a percent. If the control has both SP1 and SP2, the lower display
will alternate between the SP1 percent output and the SP2 percent output.

OPERATION OF SELF TUNE® FUNCTION

Self Tune® allows automatic selection of the necessary parameters to
achieve best control operation from your 1600 Series control. If you are
using the control output as a simple on-off function (S#Ot set for OnOF),
none of the following will apply.

Theory of Operation

The Self Tune function calculates the Pb1, rES, and rtE parameters under
the PID tunE selection as shown in the Secondary Menu . These values are
determined by measuring the response of the process connected to the
control. When Self Tune is started, the control temporarily acts as an on­off control. While in this mode the control measures the overshoot and
undershoot of the process, and the period of the process (the time from peak
value to the next peak value). These measurements are collected over a
period that lasts three periods of overshoot and undershoot. The data
collected over this time is then compared and calculated into final PID
values. The calculations for the PID values are the same as used in the
standard Ziegler - Nichols equations that have been recognized as standard
for decades.

The only modification to the application of the Ziegler - Nichols equations is
controlled by the dFAC menu item. This menu item controls the amount of
rate (derivative) that is applied. A dFAC setting of 3 (factory default) or less
allows for less damping. A dFAC setting of 4 allows for critical damping as

Rev. 10/98 11 949-1239-3