Dwyer Instruments 32A SERIES 1/32 DIN MICROPROCESSOR BASED TEMPERATURE CONTROL Users Manual
INSTRUCTIONS FOR THE 32A SERIES 1/32 DIN
MICROPROCESSOR BASED
TEMPERATURE / PROCESS CONTROL
LOVE CONTROLS DIVISION
DWYER INSTRUMENTS, INC.
CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Program Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
OPERATION AND PROGRAMMING OF OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Option 992, Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CHANGING PROGRAMMING FOR SET POINT 2 AND ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . .15
FACTORY DEFAULT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ALARM TYPE AND ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PRIMARY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SECONDARY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SECURE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
DIAGNOSTIC ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
GETTING STARTED
1. Install the control as described on page 4.
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 7. Option wiring instructions are on page 6. Option
descriptions are on page 4, and specific instructions start on page 15.
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 24) before making changes to the Secondary Menu (page 18). If error messages occur,
check the Diagnostic Error Messages on page 33 and 34 for help.
Take the example of a Model 32A010 that comes from the factory programmed 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 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.
Model 3 2 A
MODEL IDENTIFICATION
Options
Alarm
Programming
0 = No
1 = Yes
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).
Note: Only Option 9502 may be combined with another option. No other options may be
combined.
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.
1 = SSR 5 = Current
2 = 5 VDC 8 = DC SSR
3 = Relay
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.
Output 1
0 = None 3 = Relay
1 = SSR 8 = DC SSR
2 = 5 VDC
INSTALLATION
Output 2
Page 4
Prepare the panel by cutting and deburring the required opening(s).
From the front of the panel, slide the housing through the cutout. The housing gasket should be flat
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 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.
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. 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, current, and RTD; and output wiring for current, DC SSR, and 5 VDC
is rated CLASS 2.
Page 5
Control wiring is as shown.
The wiring terminals for the 32A 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 on page 5 and 6. Wiring for options is shown below. All wiring shown
below is Class 2. Shielded twisted pair is required for Option 992.
DO NOT RUN SIGNAL WIRING IN THE SAME CONDUIT OR CHASE AS THE
POWER WIRING. ERRATIC OPERATION OR DAMAGE TO THE CONTROL CIRCUITRY WILL RESULT.
OPTION
992
Note 1: Terminal 5 is line A (-). Terminal 6 is line
B (+). Last control in chain must have 120 ohms
±1% resistor across 5 and 6.
Term. 5
Note 1
Term. 6
Note 1
Page 6
Wiring for 4 to 20mA Transmitter Inputs
Wire power and outputs as shown above. 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 CONTROL INPUT CIRCUITRY WILL RESULT.
Page 7
FRONT PANEL KEY FUNCTIONS
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. To reset an alarm press and hold both
keys for three seconds.
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.
Page 8
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.
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
Primary
Secondary
Secure
Status
Locked
Locked
Locked
Displayed Value
When Viewed
1
Password Value
to Enter
1110
Primary
Secondary
Secure
Primary
Secondary
Secure
Primary
Secondary
Secure
Unlocked
Locked
Locked
Unlocked
Unlocked
Locked
Unlocked
Unlocked
Unlocked
2
3
4
1101
1011
111
Page 9
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.
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 is enabled, 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 oto 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 SP1to the Present Set Variable
as calculated by the Ramp/Soak Programmer function. See Programming and Operation for
Ramp/Soak Feature 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 33 and 34.
Page 10
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. Soak (dwell) times can be programmed, and the alarm output
relay can be programmed to open or close during any of the segments.
Theory of Operation
The 32A 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 32A does the calculation internally. 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.
Page 11
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