Dwyer 8600 User Manual

INSTRUCTIONS FOR THE 8600 SERIES

MICROPROCESSOR BASED

TEMPERATURE / PROCESS CONTROL

LOVE CONTROLS DIVISION

Dwyer Instruments, Incorporated

December, 1998 Page 1 949-1277-3

PO Box 338 Michigan City, IN 46361-0338

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

www.love-controls.com

CONTENTS

Installation ...............................................................................................4

Wiring ...................................................................................................... 5

Wiring for Transmitter inputs.............................................................6

Wiring for 15 VDC Outputs ............................................................... 6

Wiring for Optional Inputs and Outputs.............................................7

Front Panel Key Functions ...................................................................... 8

Notation Conventions for the Menus ..................................................... 10

The Home Display.................................................................................11

Programming and Operation for Ramp / Soak feature .......................... 11

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

Program Setup ...................................................................................... 12

Ramp / Soak Operation.........................................................................13

Auto / Manual Operation ....................................................................... 14

Operation of Self Tune® Function.........................................................15

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

Program Setup and Operation .............................................................. 15

Operation and Programming of Options................................................16

Menu Selections...................................................................................18

Primary Menu ........................................................................................ 18

Secondary Menu ................................................................................... 19

Secure Menu ......................................................................................... 26

Alarm Type and Action .......................................................................... 30

Diagnostic Error Messages ................................................................... 35

Specifications ........................................................................................ 37

Dimensions............................................................................................ 40

949-1277-3 Page 2 December, 1998

GETTING STARTED

1. Install the control as described on page 3.

2. Wire your control following the instructions on page 5. If you are using

a two-wire transmitter as an input, see the drawing and instructions on

page 6. Option wiring instructions are on Page 7. Option descriptions

and specific instructions start on page 16.

3. Most controls do not need many (if any) program changes to work on

your process. For best results when programming changes are

necessary, make all the necessary changes in the Secure Menu (page

26) before making changes to the Secondary Menu (page 19). If error

messages occur, check the Diagnostic Error Messages on page 35 for

help. Take the example of a Model 86010 that comes from the factory pro-

grammed for type J thermocouples. Suppose for this example you wish to change the input to type K and limit the set point range between 0° and 1000° C.

First, enter the Secure menu as instructed on page 5. Press the INDEX key until the display shows Inp and press the DOWN ARROW until the display shows CA. 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 1000. Press ENTER.

The necessary program changes are now complete. After 30 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.

December, 1998 Page 3 949-1277-3

MODEL IDENTIFICATION

Model 8 6 — — —

Alarm

0 = No 1 = Yes

Output 1

1 = SSR 2 = 15 VDC

3 = Relay 5 = Current

Output 2

0 = None 1 = SSR

3 = Relay 5 = Current

2 = 15 VDC

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. Prepare the panel by cutting and deburring the required opening.

From the front of the panel, slide the instrument 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 hand and using the other hand, push the collar evenly against the panel until the springs are compressed. The ratchets will hold the mounting collar and housing in place.

OPTIONS

Orientation

0 = Vertical 1 = Horizontal

PANEL CUTOUTS

Vertical

Horizontal

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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.

WIRING

Do not run thermocouple or other class 2 wiring in the same conduit as power leads. 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. 16 AWG or larger 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, current, and RTD; and output wiring for 15 VDC is rated CLASS 2.

Wiring to housing terminals while chassis is removed may cause distortion of the internal connector and possible damage to the connector when the chasis is reinstalled. It is strongly recomended that the control housing be wired with the chassis installed.

Control wiring is as shown.

T/C

RTD

ALARM 1

OUTPUT*

ALARM 2

OUTPUT*

24 VDC @ 50 mA ISOLATED

SET POINT 1 OUTPUT*

SET POINT 2 OUTPUT*

15VDC pulsed

RELAY

CURRENT

SSR

* IF SWITCHING INDUCTIVE LOADS (RELAYS, MOTORS, SOLENOIDS, ETC.) USE AN R/C SNUBBER ACROSS COIL.

F1 = 3/8A 250VAC MEDIUM LAG

LINE INPUT

UNUSED TERMINALS CAN NOT BE USED AS TIE POINTS FOR OTHER CIRCUITS.

SEE RATING LABEL

FOR DETAILS

December, 1998 Page 5 949-1277-3

Wiring for Transmitter inputs

Wire power and outputs as shown on previous page. Two-wire transmitters wire as shown below.

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 CON-

TROL INPUT CIRCUITRY WILL RESULT.

Wiring for Optional Inputs and Outputs

Wire power and outputs as shown on page 5. Wiring for options is shown opposite. All wiring shown below is Class 2. Shielded twisted pair is recommended for Option 992.

DO NOT RUN SIGNAL WIRING IN THE SAME CONDUIT OR CHASE AS THE POWER WIRING. ERRATIC OPERA-

TION OR DAMAGE TO THE CONTROL CIRCUITRY WILL RESULT.

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OPTION 10 21 22

948 & 949 Truth Table

948 Sig. Ground B A 936 Not Used + 924 Not Used + 926 Not Used + 928 Not Used CCW Wiper

A to Gnd. B to Gnd. SP OPEN OPEN 1SP1 CLOSED OPEN 2SP1 OPEN CLOSED 3SP1 CLOSED CLOSED 4SP1

SWITCH CONTACTS FOR OPTIONS 948 AND 949 MUST BE ISOLATED AND CAN NOT SHARE WIRING WITH OTHER CONTROLS.

RS-232 DB-25 WIRING

(VIEWED FROM WIRE SIDE)

DATA IN 23 DATA OUT 24 DATA GROUND 10

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25

PIN DESCRIPTION 1 SHIELD 2 TRANSMIT 3 RECEIVE 4 RTS 5 CTS

RS-232 DB-9 WIRING

(VIEWED FROM WIRE SIDE)

1 2 3 4 5

6 7 8 9

PIN DESCRIPTION 6 DSR 7 GROUND 8 DCD 20 DTR

DATA OUT 24 DATA IN 23 DATA GROUND 10

PIN DESCRIPTION 1 DCD 2 RECEIVE 3 TRANSMIT 4 DTR 5 GROUND 6 DSR 7 RTS 8 CTS

OPTION 10 23 24 992 Not Used B A

993 Signal Ground Data In Data Out 949 Signal Ground A B

December, 1998 Page 7 949-1277-3

FRONT PANEL KEY FUNCTIONS

Set Point 1 Lamp Alarm Lamps Set Point 2 Lamp °F Indicator Process Display °C Indicator Set Point Display Remote Set Lamp Manual Indicator Per Cent Lamp Heater Break Indicator Hold Lamp

The decimal point flashes when Self-Tune is operating.

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.

AUTO/MANUAL: This key toggles the control output between Automatic mode and Manual mode. Press and hold key for three seconds to activate. See section on AUTO/MANUAL operation on Page 13.

RUN/HOLD: This key toggles the Ramp/Soak programmer functions between Run mode (program runs as set up), and Hold mode (program functions are suspended). Press and hold key for three seconds to activ ate. See section on Programmer Functions (Page 10) for further details.

949-1277-3 Page 8 December, 1998

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:

ALiH: Alarm inhibit 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 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 & DOWN ARROW keys and pressing the ENTER key. Refer to the password table (following) 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.

To set the access level to, for example, 2, at the SECr menu item press the UP ARROW key until the upper display show the password, 1101. Press the ENTER key. The display will blink, and return with the level value, 2, in the upper display.

December, 1998 Page 9 949-1277-3

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.

PASSWORD TABLE

Security Level

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

Displayed Value

When Viewed

Password Value

To Enter

1110

1101

1011

111

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 or functions shown in this book are contextual. This means that Menu Items may or may not appear, depending on other Menu Item selections. Whenever this occurs, a notation is made in the Menu Item that "controls" or "directs" 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.

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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 Run/Hold function, the Prog function, the PCtO function, and any error message. Description of these special displays follow.

If the Auto/Manual key is pressed, the Manual indicator lights, and 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. 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.

Error messages are listed on Page 35.

PROGRAMMING AND OPERATION FOR RAMP / SOAK

FEATURE

The ramp / soak feature offers a great deal of flexibility by allowing changes in the set point to be made over a predetermined period of time. Dwell times can be programmed, and the alarm output relays can be programmed to open or close during any of the segments.

Theory of Operation

The 8600 Series controls offer a very simple approach to programming a ramp. Rather than requiring the operator to calculate an approach rate (usually in degrees per minute), the 8600 does the calculation internally.

December, 1998 Page 11 949-1277-3

Thus, the operator only needs to program the target set point and the time desired to reach that point. When the ramp segment is executed by the control, it calculates the ramp required to move the process from the starting value (current PV) to the desired value (programmed SP) in the time allowed.

Soaks (or dwells) are ramp segments where the target set point is the same as the beginning process value. This allows for multistage ramps without wasting intermediate soak steps. Care must be taken, however, that the process does actually reach the soak value before the soak time starts. If not, the next segment will calculate a slope from the starting PV to the target SP. Depending on your process requirements, this difference may be important. Make sure to test any program for desired results before running production material.

Do not operate Self Tune while a ramp function is operating. The ramp function will prevent the Self Tune from operating properly. Make sure that all tuning is set up before operating Ramp / Soak.

Program Setup

All of the programming for the Ramp / Soak function is done in the Secondary Menu. You may wish to work out your program on paper before going into the programmer menu sequence.

In the Secondary Menu INDEX to Prog and make sure that Prog is set to OFF.

INDEX to PSEt and turn On. Skip the StAt setting (this is discussed later) and press INDEX to 1ti. The following items repeat in the following order: 1ti, 1SP, 1A1 (if alarm 1

is programmed as an event), 1A2 (if alarm 2 is programmed as an event), 2ti, 2SP, 2A1, 2A2, . . . , 16ti, 16SP, 16A1, 16A2. To avoid repetition each item will only be described once.

Set 1ti to the amount of time you want for the first ramp. This value is in time units (determined by the tbAS menu item) from 0 to 9999. Press INDEX

Set 1SP to the target value desired for the first ramp. This value is in actual units just like SP1. If the control is programmed for temperature, then the SP displays are in temperature. If the control is programmed for some other engineering unit, the SP is set in that unit.

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