Dwyer 32DZ User Manual

INSTRUCTIONS FOR THE 32DZ SERIES 1/32 DIN

DU AL ZONE MICROPROCESSOR B ASED

TEMPERA TURE /PROCESS CONTROL

LOVE CONTROLS

LOVE

June, 2000 Page 1 of 40 949-1318

a Division of Dwyer Instruments, Incorporated

PO Box 338 Michigan City, IN 46361-0338

(800) 828-4588 (219) 879-8000 FAX (219) 872-9057

❍

www.love-controls.com

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Contents

INSTALLATION....................................................................................... 3

WIRING...................................................................................................5

Wiring for Optional Inputs and Outputs...................................................6

Wiring for 4 to 20mA Transmitter inputs ................................................. 7

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

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

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

ALARM TYPE AND ACTION ................................................................ 11

OPERATION OF SELF TUNE® FUNCTION......................................... 12

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

Program Setup and Operation............................................................... 13

OPERATION AND PROGRAMMING OF OPTIONS ............................. 13

Option 992, Serial Communication. ...................................................... 13

FACTORY DEFAULT PROCEDURE .................................................... 14

MENU SELECTIONS ........................................................................... 14

PRIMARY MENU .................................................................................. 14

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

SECURE MENU.................................................................................... 25

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

DIAGNOSTIC ERROR MESSAGES ..................................................... 37

DIAGNOSTIC ERROR MESSAGES ..................................................... 38

DIMENSIONS ....................................................................................... 40

949-1318 Page 2 of 40 June, 2000

MODEL IDENTIFICATION

Model 3 2 D Z —

Options

Input 1

1 = Thermocouple J,K,E,L,N 2 = Thermocouple T,R,S,B,C 3 = 100 and 120 ohm RTDs 4 = 1000 Ohm RTD 5 = Current, 0 or 4 to 20 mA 6 = Voltage, 0 or 2 to 10 V

Input 2

1 = Thermocouple J,K,E,L,N 2 = Thermocouple T,R,S,B,C 3 = 100 and 120 ohm RTDs 4 = 1000 Ohm RTD 5 = Current, 0 or 4 to 20 mA 6 = Voltage, 0 or 2 to 10 V

Options: 992 RS-485 Serial Communications. Allows remote computer to read

and write all control parameters.

9502 12 - 24 Vdc/Vac 50-400Hz power supply (control operates on low

voltage equipment).

Output B

1 = SSR 2 = Switched Voltage 5 Vdc 3 = Relay 8 = DC SSR

Output A

1 = SSR 2 = Switched Voltage 5 Vdc 3 = Relay 5 = Proportional current 8 = DC SSR

INSTALLATION

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.

It is not necessary to remove the instrument chassis from the housing for installation. If the instrument chassis is removed from the housing, you must follow the ANSI/IPC-A-610 standard for handling electronic assemblies to avoid damage from Electro-Static Discharge (ESD). Failure to properly handle the instrument may cause damage to the instrument.

June, 2000 Page 3 of 40 949-1318

Prepare the panel by cutting and deburring the required opening(s).

25.4

(1.00)

45 + 0.6

(1.772 + 0.02)

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

20.5

(0.807)

22.2 + 0.3

(0.874 + 0.012)

Panel

Collar

Gasket

From the rear of the panel slide the mounting collar over the housing. Hold the housing with one 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. To remove, gently lift the ratchets and slide a piece of heavy paper or mylar sheet under each ratchet (a business card works well). Slide the collar off of the housing.

949-1318 Page 4 of 40 June, 2000

WIRING

WARNING: The inputs of the instrument are not isolated from each other. The input sources must be isolated from each other. Thermocouples MUST be of the isolated junction type. Process inputs may not share a common external ground.

FAILURE TO OBSERVE THIS WARNING MAY CAUSE DANGEROUS OR LETHAL VOLTAGES TO BE PRESENT IN THE INSTRUMENT WHICH MAY CAUSE SERIOUS INJURY OR DEATH.

DO NOT RUN SIGNAL (CLASS 2) WIRING IN THE SAME CONDUIT OR CHASE AS THE POWER WIRING. ERRATIC OPERATION OR DAMAGE TO THE INSTRUMENT CIRCUITRY WILL RESULT.

Use only the type of thermocouple or RTD probe for which the control has been programmed. Maintain separation between wiring of sensor, auxiliary in or out, and other wiring. See the "Secure Menu" for input selection.

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

For supply connections use No. 18 AWG wires rated for at least 75°C. Use copper conductors only. All line voltage output circuits must have a common disconnect and be connected to the same pole of the disconnect.

Input wiring for thermocouple, voltage, current, and RTD; and output wiring for current, DC SSR, and 5 VDC is rated CLASS 2.

June, 2000 Page 5 of 40 949-1318

Control wiring is as shown.

The wiring terminals for the 32DZ are compression type. To open the wiring terminal, turn the screw for that terminal counterclockwise. Slide the wire into the terminal space. While holding the wire in place, turn the screw clockwise to tighten. Maximum torque is

0.424 N·m(3.75 in. lb.). Do not overtighten. The wire should be held snugly in place.

Wiring for Optional Inputs and Outputs

Wire power and outputs as shown. Wiring for options is shown below. All wiring shown below is Class 2. Shielded twisted pair is required for Option 992.

Option 992: Terminal 5 is line A (-).

Terminal 6 is line B (+). Last control in chain must have 120 ohm ± 1% resistor across 5 and 6.

Option 9502: Connect 12 to 24 Volt ac or dc power to terminals 11 and

12. No polarity.

Note: Industry standard designation for

RS-485 lines is A and B. Some equipment manufacturers use a non-standard designation of plus and minus. The association of A to minus and B to plus is based on a sample of devices marked as plus and minus and is not intended to represent ALL such labelled devices. Final responsibility for correct identification of leads and terminals rests with the user/ installer and the manufacturer of the other device(s) installed in the system.

949-1318 Page 6 of 40 June, 2000

Wiring for 4 to 20mA Transmitter inputs

WARNING: The inputs of the instrument are not isolated from each other. The input sources must be isolated from each other. Process inputs may not share a common external ground.

FAILURE TO OBSERVE THIS WARNING MAY CAUSE DANGEROUS OR LETHAL VOLTAGES TO BE PRESENT IN THE INSTRUMENT WHICH MAY CAUSE SERIOUS INJURY OR DEATH.

Wire power and outputs as shown above. Two-wire transmitters wire as shown below.

External Power Supply

24 Vdc

Transmitter

+ -

Wiring for Z1 Input

External Power Supply

24 Vdc

+ -

Transmitter

+ -

Wiring for Z2 Input

For three or four wire transmitters follow the wiring instructions provided with your transmitter.

DO NOT WIRE THE 24 VOLT POWER SUPPLY ACROSS THE INPUT OF THE CONTROL. DAMAGE TO THE INSTRUMENT INPUT CIRCUITRY WILL RESULT.

June, 2000 Page 7 of 40 949-1318

FRONT PANEL KEY FUNCTIONS

Set Point 1 Lamp SP1 Process

Display Set Point 2 Lamp Scale Lamp °F SP2 Process Scale Lamp °C

Display

SERIES 32DZ

The decimal point flashes when Self-Tune is operating. Keys are illuminated when pressed. Key functions are as follows:

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. The maximum value obtainable is 9999 regardless of decimal point placement.

DOWN ARROW: Decrements a value, changes a menu item, or selects the item to OFF. The minimum value obtainable is -1999 regardless of decimal point placement.

ENTER: Pressing ENTER stores the value or the item changed. If

not pressed, the previously stored value or item will be retained. The display will flash once when ENTER is pressed.

UP ARROW & ENTER: Pressing these keys simultaneously brings

up the secondary menu starting at the alarm, tune, or cycle item (depending on programming). 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:

OPEn InP: Input error message bAd InP: Input error message CHEC CAL: Check calibration error

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

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

949-1318 Page 8 of 40 June, 2000

temperature value. While in the Secure Menu, if no key is pressed for a period of 60 seconds, the display will return to the HOME position displaying the temperature value. Outputs are disabled (turned off) when the Secure

Menu is active. 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.

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 ARROW and key. Refer to the password table (following) for the correct value to enter for the security level desired. The may be viewed or changed at any time regardless of the present security level.

DOWN ARROW keys and pressing the

SEC1SEC1

SEC1 or

SEC1SEC1

SEC2SEC2

SEC2 menu items security level

SEC2SEC2

ENTER

To set the access level to, for example,

UP ARROW key until the upper display shows the password, Press the value,

The password values shown in the table cannot be altered, so retain a copy of these pages for future reference. This is the only reference made to password values in this instruction book.

2, in the upper display.

Menu Status Primary Locked

Secondary Locked Secure Locked

Primary Unlocked Secondary Locked Secure Locked

Primary Unlocked Secondary Unlocked Secure Locked

Primary Unlocked Secondary Unlocked Secure Unlocked

ENTER key. The display will blink, and return with the level

PASSWORD TABLE

Security Level

Displayed Value

2, at the

When Viewed

SEC1SEC1

SEC1 menu item press the

SEC1SEC1

11011101

1101.

11011101

Password Value

To Enter

1110

1101

1011

111

June, 2000 Page 9 of 40 949-1318

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. This is used for certain repeated items such as in the Ramp/Soak Program section.

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) for Set Point 1 on the top display and the Process Variable for Set Point 2 on the bottom.

THE MENU EDIT FUNCTION

The Menu Edit function (Edit) allows quick access to operational and set up menu items for either or both of the zones. The Edit menu item appears at the top of the Secondary Menu and allows selection of the set point parameters. Setting Edit to 0 allows access to only the Peak (PEA1 and PEA2), Valley (UAL1 and UAL2), Local/Remote (LOre), and address (Addr) menu items.

Setting Edit for either 1 or 2 allows access to the Secondary and Secure Menus for the zone selected.

Setting Edit for 3 allows access to both the Secondary and Secure Menus for both Zone 1 and Zone 2. Each menu presents the menu items for Zone 1 first, followed by the menu items for Zone 2, followed by any common menu items that may be present.

949-1318 Page 10 of 40 June, 2000

Menu items that are dedicated to either Zone 1 or Zone 2 will have either a 1 or 2 in them for identification.

If Edit is set to any value other than 0, the setting will be retained for a period of five minutes to allow handy, repeated access to that zone's menues. After five minutes of keypad inactivity, the Edit setting will revert to 0, giving an added layer of security to prevent inadvertant changes to the instrument.

PROGRAMMING SET POINTS FOR ALARM FUNCTIONS

Caution: In any critical application where failure could cause expensive product loss or endanger personal safety, a redundant limit controller is required.

The 32DZ Series allows Zone 1 and / or Zone 2 to operate as limit or alarm type outputs. This function is available on both outputs. To enable a zone output to act as an alarm or limit, be set for

OnOfOnOf

OnOf.

OnOfOnOf

Out1Out1

Out1 (for Zone 1) or

Out1Out1

Out2Out2

Out2 (for Zone2) should

Out2Out2

Out1Out1

When

Out1 and / or

Out1Out1

will appear in the Secure Menu for the selected zone(s). When Set Point Power Interrupt (

Reset ( after a power failure and on subsequent power restoration if no alarm condition is present.

If Set Point Inhibit ( upon power up until the process value passes through the alarm set point once. Alarm inhibit can be restored as if a power up took place by pressing both the

June, 2000 Page 11 of 40 949-1318

rErE

rE) is programmed for

rErE

Out2Out2

Out2 are set to

Out2Out2

iHiH

iH) is selected

iHiH

INDEX and

Warning: If inhibit is on and a power failure occurs during a high alarm, on restoration of power inhibit will suppress the alarm. Do not use the Set Point Inhibit feature if a hazard may be created by this action. Be sure to test all combinations of high and low set point inhibit actions before placing control into operation.

OnOFOnOF

OnOF, then the alarm function menu items

OnOFOnOF

PiPi

Pi) is programmed

PiPi

HoldHold

Hold, the alarm will automatically reset

HoldHold

ONON

ON, an alarm condition is suspended

ONON

ENTER keys for 5 seconds.

ONON

ON and Set Point

ONON

Set Point 2 Tracking

Some applications will call for Set Point 2 to follow or 'track' the setting for Set Point 1. This can be done by changing the S2t setting in the Secure Menu (edit set for 2 or 3). For a tracking SP2, set S2t to dE.

The Factory Default setting for S2t is ABS, making SP2 completely independent of SP1.

When setting

dEdE

dE), set the difference in value from the Set Point 1 (

dEdE

example if Set Point 2 is required to be 5 degrees below the

SP2SP2

SP2 to

-5. If Set Point 2 is required 20 degrees above the

SP2SP2

2020

20. If

2020

relationship as originally set. When setting SP2 value when Set Point 2 is programmed as absolute (S2t

= AbS), simply set the value at which the alarm is to occur.

Self Tune® allows automatic selection of the necessary parameters to achieve best control operation from your 32DZ Series control. If you are using the control output as a simple on-off function (e.g. none of the following will apply.

Theory of Operation

The Self Tune function calculates the

PID1 tunEPID1 tunE

the

PID1 tunE selection,

PID1 tunEPID1 tunE

selection, the 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 on-off 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 and Fuzzy Logic values. The effect of Fuzzy Logic on the process is still controlled by the

Fi 1Fi 1

Fi 1 or Fi 2 is

Fi 1Fi 1

have no effect.

SP2SP2

SP2 value when Set Point 2 is programmed as deviation (

SP2SP2

-5-5

-5-5 SP1SP1

SP1 is changed, the

SP1SP1

OPERATION OF SELF TUNE® FUNCTION

Pb2Pb2

Pb2,

Pb2Pb2

Fbd1Fbd1

Fbd1 and

Fbd1Fbd1

Frt1Frt1

Frt1 parameters, and the

Frt1Frt1

Fbd1Fbd1

0, the

Fbd1,

Fbd1Fbd1

SP2SP2

SP2 setting will continue to hold the same

SP2SP2

Pb1Pb1

rES2rES2

rES2, and

rES2rES2

Frt1Frt1

Fbd2Fbd2

Frt1,

Fbd2, and

Frt1Frt1

Fbd2Fbd2

rES1rES1

Pb1,

rES1, and

Pb1Pb1

rES1rES1

rtE2rtE2

rtE2 parameters under the

rtE2rtE2

Fi 1Fi 1

Fi 1 and Fi 2 (fuzzy intensity) settings.

Fi 1Fi 1

rtE1rtE1

rtE1 parameters under

rtE1rtE1

Fbd2Fbd2

Fbd2 and

Fbd2Fbd2

Frt2Frt2

Frt2 will be calculated, but will

Frt2Frt2

SP1SP1

SP1) desired. For

SP1SP1

SP1, then set

SP1SP1

SP1, then set

SP1SP1

Out1Out1

Out1 set for

Out1Out1

Frt2Frt2

Frt2 parameters,

Frt2Frt2

S2tS2t

S2t

S2tS2t

SP2SP2

SP2

SP2SP2

OnOFOnOF

OnOF),

OnOFOnOF

PID2 tunEPID2 tunE

PID2 tunE

PID2 tunEPID2 tunE

The calculations for Zone 1 and Zone 2 are completely independent. Each zone has separate Self Tune and Fuzzy Logic parameters.

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