Dwyer Instruments Microprocessor Based Temperature Control Series 16A2, Microprocessor Based Temperature Control Series 16A3 Users Manual
Instructions for the 16A2 & 16A3 Series
Microprocessor Based
Temperature / Process Control
LOVE CONTROLS DIVISION
DWYER INSTRUMENTS, INC.
CONTENTS
GETTING STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring for 4 to 20mA Transmitter Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Wiring for Optional Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
FRONT PANEL KEY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Security Level Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
NOTATION CONVENTIONS FOR THE MENUS . . . . . . . . . . . . . . . . . . . . . . . . . .10
THE HOME DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Programming and Operation for Ramp / Soak Feature (16A3 Only) . . . . . . .11
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
Program Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Ramp / Soak Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
AUTO / MANUAL OPERATION (16A3 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operation Self Tune Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6
Theory of Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Program Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6
OPERATION AND PROGRAMMING OF OPTIONS . . . . . . . . . . . . . . . . . . . . . . .17
MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PRIMARY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SECONDARY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SECURE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 8
ALARM TYPE AND ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37-39
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 0
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 4
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 6. Option wiring
instructions are on Page 7. Option descriptions and specific instructions start on
page 13.
3.
Most controls do not need many (if any) program changes to work on your
process. For best results when changing the programming, make all the necessary changes in the Secure Menu (page 28) before making changes to the
Secondary Menu (page 20). If error messages occur, check the Error Messages
on page 37-39 for help.
Take the example of a Model 16A3010 that comes from the factory programmed for
type J thermocouples. Suppose for this example you wish to change the input to a
100 ohm Platinum RTD and limit the set point range between 0° and 300°C.
First enter the Secure menu by pressing and holding the UP ARROW &
Page 2
ENTER keys for 5 Seconds (see Page 28.) Press the INDEX key until the display shows 1nP 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 1nPt 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 300. 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 or Auto/Manual features, see the special sections on
these items. Page numbers for these are in the Contents section on the previous
page.
MODEL IDENTIFICATION
16A ——
Features
2 = Standard
3 = Enhanced
Option Description
992* RS-485 Serial Communications, Lovelink™ protocol.
993* RS-232 Serial Communications, Lovelink™ protocol.
995* RS-232 Serial Communications, Modbus™ protocol.
996* RS-485 Serial Communications, Modbus™ protocol.
9502 12-24 Vdc/Vac 50-400 Hz power supply (control operates on low voltage equipment).
* These options may not be combined with each other. Option 9502 may be combined with any other
options.
Alarm
0 = No
1 = Yes
Output A
1 = SSR
2 = 15 VDC
3 = Relay, NO
4 = Relay, NC
5 = Current
8 = DC SSR
Output B
0 = None
1 = SSR
2 = 15 VDC
3 = Relay, NO
4 = Relay, NC
5 = Current
8 = DC SSR
Options
(blank if none)
Page 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 below. Closer spacing will structurally weaken the panel, and invalidate the
IP66, UL type 4X rating of the panel.
Prepare the panel by cutting and deburring the required opening.
All Tolerances are -0.00 +0.60mm (-0.000 + 0.020 in.)
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 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.
CAUTION: 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 industry standard
practice for control and protection against Electro-Static
Discharge (ESD). Failure to exercise good ESD practices may
cause damage to the instrument.
Page 4
WIRING
Do not run RTD, 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, optional inputs and outputs
and other wiring. See the “Secure Menu” for input selection.
For thermocouple inputs 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 hvave a common
disconnect and be connected to the same pole of the connect.
Input wiring for thermocouple, current, and RTD; and output wiring for current and
15 VDC is rated CLASS 2.
Control wiring is as shown (view is from the rear of instrument showing wiring terminals).
Page 5
OUTPUTS
(Rear View showing center block of wiring terminals.)
For AC SSR or relay type outputs
(Output Codes 1 or 3), 15 & 16, and 17
Output A
& 18 are normally open. See Rating
Label for details.
Output B
Note: Factory default assigns Output A to Set Point 1 and Output B to Set Point 2.
If necessary, these realtionships may be reversed. See SP 10 in the Secure Menu.
For Pulsed DC, Current, or DC SSR
ouputs (Output codes 2, 4, or 8), 15 &
17 are positive, 16 & 18 are negative.
Wiring for 4 to 20mA Transmitter Inputs
Wiring power and ouputs as shown above. Two-wire transmitters wire as shown
below. View is of instrument as seen from the rear to show wiring terminals.
For three or four-wire transmitters, follow the wiring instructions provided with your
transmitter.
CAUTION: DO NOT WIRE THE 24 VOLT POWER SUPPLY
ACROSS THE INPUT OF THE CONTROL. DAMAGE TO THE
CONTROL INPUT CIRCUITRY WILL OCCUR.
Wiring for Optional Inputs and Outputs
Options are described on Page 3. Detailed option programming and operation
starts on Page 13. Wire power and outputs as shown on Pages 5 and 6. Wiring
for options is shown opposite. All wiring shown above is CLASS 2. Shielded twisted pair is required for Options 992 and 994. Shielded cable is required for Options
993 and 995.
CAUTION: DO NOT RUN SIGNAL WIRING IN THE SAME CONDUIT OR CHASE AS THE POWER WIRING. ERRATIC OPERATION
OR DAMAGE TO THE CONTROL CIRCUITRY WILL OCCUR.
Page 6
OPTION/TERMINALS
PV1 PV/SV Retransmission,
Current (e.g. 4-20 mA)
PV2 PV/SV Retransmission,
Voltage (e.g. 0-10V)
992, 996 RS-485 Serial
Communications
993, 995 RS-232 Serial
Communications
11 12 6 7 8
+ + -
B A
Data In Data Out Signal Ground
na na na
na na na
na na na
na na
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: Menu Navigation. Pressing the INDEX key advances the dis-
play 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 (16A3): This key toggles the control output between
Automatic mode and Manual mode. Press and hold key for three seconds
to activate. See section on Ramp/Soak (Page 11) for further details.
RUN/HOLD (16A3): This key toggles the Ramp/Soak program functions
between Run mode (program runs as set up), and Hold mode (program
functions are suspended). Press and hold key for three seconds to activate. See section on Auto/Maunal Operation on page 14.
. UP ARROW & ENTER: Menu Access. Pressing these keys simul-
taneously 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: Menu navigation. 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.
INDEX & DOWN ARROW: Alarm Reset. If an alarm condition has
occurred, press and hold these keys for three seconds to reset the alarm.
Note that the alarm condition will not reset if the alarm condition
still exists.
. INDEX & ENTER: ‘Global Reset’. Pressing these keys simultaneous-
ly and holding them for 5 seconds forces a ‘warm boot’, restart-
Page 8
ing the control (similar to turning power off and on). ‘Global Reset’ will allow recovery from errors and reset the following menu items:
AL i.H: Alarm inhibit 0PEn 1nP: Input error
bA nP: Input err CHEC CAL: Check calibration
Correct the problems associated with the above conditions before using the reset
keys. More than one error could 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 HOME position displaying the temperature value. Outputs
are disabled (turned off) when the Secure Menu is active.
NOTE: To move 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
DOWN ARROW keys and press the ENTER key. Refer to the password
table 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.
Example: To set security access level to 2, at the SECr menu item, press the
UP ARROW key until the upper display shows the password for level 2 access,
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 reference. This is the only reference made to password values in
this intruction book.
Page 9
PASSWORD TABLE
Security Level
Menu Status
Displaying Value
When Viewed
Password Value To
Enter
Primary Locked
Secondary Locked
1 1110
Secure Locked
Primary Unlocked
Secondary Locked
2 1101
Secure Locked
Primary Unlocked
Secondary Unlocked
3 1011
Secure Locked
Primary Unlocked
Secondary Unlocked
4 111
Secure Unlocked
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 function 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 it’s “control” for proper setting
2. The “#” symbol is used in two ways. It is used inside 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.
3.
only to the 16A3 Series will be notated in the Roman serif type.
Page 10
Features that apply
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 Pro9 function, the Pct0 function, and any error message.
Description of these special displays follows.
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 percent output is indicated by the use of an overline on
i
the o. Access to the SP2 value is made by the INDEX key. See Auto/ Manual
Operation on Page 14 for further information.
If Pro9 is turned 0n, 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 Pct0 (Secondary Menu) is turned 0n, 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 percent indicators (o,o) 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.
i
Error messages are listed on Pages 37-39.
PROGRAMMING AND OPERATION FOR RAMP / SOAK
FEATURE (16A3 ONLY)
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 relay can be programmed to open or close during
any of the segments.
Theory of Operation
The 16A3 Series controls offer a very simple approach to programming a ramp.
Rather than requiring the operation to calculate an approach rate (usually in degrees
per minute), the 16A3 does the calculation internally. Thus, the operator only needs
Page 11
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 Pro9 and make sure that Pro9 is set to 0FF.
INDEX to PSEt and turn 0n. Press ENTER.
Skip the StAt setting (this is discussed later) and press INDEX to tbAS.
The time base menu item, tbAS, allows selection of the amount of time that is counted per time unit. Setting tbAS to 1 makes all time settings use a time base of one
second. A tbAS setting of 60 makes all times settings use a time base of 60 seconds, or one minute. Make the appropriate selection and then press ENTER
and INDEX to 1ti.
The following items repeat in the following order: 1ti , 1SP, 1A1 (if AL1 in the Secure
Menu is programmed set to EUnt), 2ti , 2SP, 2A1, . . . , 16ti, 16SP, 16A1. 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 ENTER.
Page 12
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.
Press INDEX to continue. If Alarm 1 is programmed as an event (AL1 = EUnt),
then 1A1 will appear. If you wish the Alarm 1 contact to function for this segment,
set 1A1 is set to 0n. If not, set for 0FF. Press ENTER. When 1A1 is set 0n, the
Alarm 1 function will be active for entire period set 1t above.
Complete setting the segment times (2ti . . . 16ti ), segment set point (2SP . . .
16SP), and event alarms (2A1 . . . 16A1) to 0n or 0FF.
For unneeded or unused segments set the segment times (2ti . . . 16ti ) to 0, and
set the segment set point (2SP . . . 16SP) to the same value as the last active set
point. A segment alarm may be set to indicate “end of run” at the segment number
you select.
The last menu item for the ramp / soak function is PEnd. PEnd determines what the
control does when the program has ended. You may choose to have the program
repeat (LooP), HoLd the last set point (16SP), revert to the local SP1, or turn the outputs off (0oFF).
It is important to remember that if you want the program to repeat, you must allow
the process to return to the same condition that existed when the program first started. Remember that the ramp function calculates the slope by drawing a line from the
beginning PV to the ramp target set point. If the PV at the end of the program is different than the PV at the initial start, the ramp will calculate differently.
Ramp / Soak Operation
When you wish to start the program, enter the Secondary Menu and set the Pro9
menu item on 0n. Return to the HOME position by waiting for the display to time out
or by pressing the UP ARROW & ENTER keys and then the
DOWN ARROW & INDEX keys.
The home display will read as it normally does. The HOLD indicator by the RUN /
HOLD key will be lit. To start the program press the RUN / HOLD key for
three seconds. The HOLD indicator will go out, and the program will start.
To suspend the program at any time, press the RUN / HOLD key. Press the key
again to resume.
Page 13
Pressing the AUTO / MANUAL key will also suspend the program operation.
The difference is that AUTO / MANUAL also puts the control into manual mode. See
Auto / Manual operation on page 14.
The function of the Primary Menu will change depending on the setting of the
StAt menu
item in the Secondary Menu. If StAt is 0FF then the Primary Menu is not changed.
If the StAt menu item is set 0n, then the Primary Menu has three additional information items added before SP1 appears. The first INDEX item displays the time remaining in the current segment in the top display (####), and the message ti , in the
lower display. The next INDEX item displays the total time for the active segment in
the upper display (####) and the message ##ti (1ti . . . 16ti ), in the lower display. The third INDEX item displays the segment set value (####) in the top display,
and the message ##SP (1SP . . . 16SP) in the lower display. The next INDEX press
resumes the normal Primary Menu.
Page 14
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