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2604

Eurotherm 2604 Installation And Operation Handbook

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Page 1
Installation and operation handbook
2604
CONTROLLER
ENG
Page 2
2604 Controller Contents
MODEL 2604 CONTROLLER
USER GUIDE
Contents Page Chapter 1 INTRODUCTION 1-1 Chapter 2 INSTALLATION 2-1 Chapter 3 OPERATION 3-1 Chapter 4 PROGRAMMER OPERATION 4-1 Chapter 5 ALARM OPERATION 5-1 Appendix A ORDER CODE A-1 Appendix B SAFETY AND EMC INFORMATION B-1 Appendix C TECHNICAL SPECIFICATION C-1
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Contents 2604 Controller
a-2 User Guide Part No HA026491 Issue 3.0 A pr-02
Issue Status of this Manual
Section Issue
Contents 3.0 Chapter 1 3.0 Chapter 2 3.0 Chapter 3 3.0 Chapter 4 3.0 Chapter5 3.0 Appendix A 3.0 Appendix B 3.0 Appendix C 3.0
Notes
1. Section are up-dated independentl y and so may be at different issues
2. The Contents section and the manual as a whole always t a ke the issue number of the
most recently up-dated section
3. This issue applies to software version 5.1
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2604 Controller Introduction
1. Chapter 1 INTRODUCTION ......................................2
1.1. WHAT IS 2604.........................................................................................2
1.2. BEFORE YOU BEGIN...........................................................................3
1.2.1. Unpacking.............................................................................................3
1.2.2. Contents of Packaging...........................................................................3
1.2.3. Does the Controller Match the Process?...............................................3
1.3. OPERATOR INTERFACE - OVERVIEW ..........................................5
1.3.1. LED Status Indicators........................................................................... 6
1.3.2. Operator Buttons...................................................................................7
1.4. INSTALLATION - OVERVIEW...........................................................8
1.5. I/O MODULES........................................................................................9
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Introduction 2604 Controller
1-2 User Guide Part No HA026491 Issue 3.0 A pr-02
1. Chapter 1 INTRODUCTION
Thank you for selecting the 2604 High Performance Programmer/Control ler.
This controller can be supplied or can be fully configured to be process specific.
It is important to note, therefore, that the actual d isplays shown in this guide may not be identical to those shown on your controller. This guide, therefore, is intended to describe the principle of operation and
installation of the controller, and is intended as a ‘Getting Started Guide’. A detailed Engineering Handbook is also available, part no. HA026761, f or those wishing to configure and commission the controll er.
1.1. WHAT IS 2604
The 2604 is a modular, fully configurable, high accuracy, high stability temperature and process controller which is available in a single, dual or three loop format.
It is supplied in accordance with an ordering code which can be found printed on a label on the si de of the instrument case. A description of t he or der code is given in Appendix A of this guide and should be checked with that shown on the label.
It has a dual 7-segment display of process value and setpoint with a LCD panel for displ a y of information and user defined messages.. The user interface is menu driven via the display and seven front panel keys.
Figure 1-1: General View of 2704 Controller
Features include:
• Advanced ramp/dwell programmer with storage of up to 50 programs.
• Application specific controlle r s such as Carbon Potential, Humidity and Melt Pressure
• A wide variety of inputs which can be configured, including thermocouples, Pt100
resistance thermometers and high level pr ocess inputs.
• Each loop can be defined to be PID, On/Off or motorised valve position and can control
using a variety of strategies including single, cascade, override and ratio cont r ol.
• PID control outputs can be relay, logic, triac or dc with motorised valve position outputs
being relay triac or logic.
• Auto tuning and PID gain scheduling are availa ble to simplify commissioning and
optimise the process
L
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2604 Controller Introduction
1.2. BEFORE YOU BEGIN
1.2.1. Unpacking
The packaging is designed to withstand reasonable tr ansit shocks. It is suggested that each item is unpacked carefully and the contents inspected for damage.
If there is evidence of shipping damage, please notify your supplier within 72 hours. The packaging should be retained for inspecti on.
All packaging contains anti-static materials to prevent the build up of static which can damage electronic assemblies.
1.2.2. Contents of Packaging
Each box contains the following parts:-
1. The 2604 controller fitted into its corresponding sleeve. Labels on the sleeve identify the
controller code, its serial number, and the customer reference number. These detai ls should be checked against your requirements before installing the unit into the panel.
2. Two panel retaining clips
3. Burden resistors for use with mA inputs
4. This User Guide Please refer to Figure 1-2 showing a general view of the controller.
1.2.3. Does the Controller Match the Process?
Every controller is supplied wi th a specific hardware configuration to match the process which
it is designed to control. For example, there are five ‘sl ots’ which can contain different plug in modules. These are defined by a hardware code as shown in Appendix A. Before installing the 2604 controller check the label on the side of the instrument against the instrument coding given in Appendix A for correct type.
Where possible the controller is supplied with its software configured to match the process. This is defined by a quick start order code given in Appendix A. This should also be checked on the instrument label to ensure that the controller is suitable for the process to be controlled.
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Introduction 2604 Controller
1-4 User Guide Part No HA026491 Issue 3.0 A pr-02
Figure 1-2: General View of 2604 Controller
ó
ø
í
ö
ú
÷
ì
í
ó
ö
KEY
Display screen ó Latching ears ì Panel sealing gasket ö Panel retaining clips ú Label ÷ Sleeve ø Terminal covers í Ratchets
Page 8
2604 Controller Introduction
1.3. OPERATOR INTERFACE - OVERVIEW
The front panel of the 2604 consists of two 5 digit numeric displays, one alpha numeric LCD panel for display of messages and other information, eight LED staus indicators and seven operator push-buttons. See F igure 1-3 below.
• The display is used to show the process conditions.
• The seven operator buttons allow adjustments t o be made to the controller.
Figure 1-3: Operator Interface
Upper Display (usually indicates Process Variable
)
Middle Display (usually indicates Setpoint
)
Lower Alpha/Numeric LCD Display (usually indicates messages)
Alarm Beacon
Standby Mode
LED status indicators (see
fi
g
ure 1–4
)
Operator buttons
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Introduction 2604 Controller
1-6 User Guide Part No HA026491 Issue 3.0 A pr-02
1.3.1. LED Status Indicators
Indicator Function
AUTO The selected loop is in automatic (closed loop) c ontrol MAN The select ed l oop i s in manual (open loop) control LP1 LP2 Indicates which control l oop i s selected LP3 AUX Indicates that the selected loop has a second control function.
For example, if a loop is confi gured as cascade, ratio or override then a second press of the loop button will cause t he AUX indicator to
illuminate together with the loop indicator. RUN Indicates a program i s activated HOLD Indicates a program i s hel d at its current levels ALARM BEACON This is a red LED which will flash when any new alarm occurs. It will
be accompanied by a mes sage displayed on the lower readout. The
beacon will be permanently lit when an alarm is acknowledged but is
still present. See Chapter 7 ‘Alarm Operation’ for further details. STANDBY
BEACON
This is a green LED which will be lit when the controller is in Standby
mode. When the controller is in standby mode all interfaces t o t he
plant are switched to a rest condi tion. For example, all control outputs
= 0.
When this beacon is lit the controller is no longer controlling the
process.
This beacon will be lit when:-
• The controller is in confi guration mode
• Standby mode has been selected through the user interface or via
an external digital input
• During the first few seconds after start up
Table 1-1: Status Messages
LP1 LP2
LP1
AUX
AUTO
MAN
RUN HOLD
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2604 Controller Introduction
1.3.2. Operator Buttons
Auto/Manual
button
The Auto/Manual button only operates f rom the loop view. When press ed, this toggles between automatic and manual mode:
• If the controller is i n automatic mode t he AUTO light will be lit.
• If the controller is i n manual mode, the MAN light will be lit.
The Auto/Manual button can be disabl ed i n configuration level.
Loop select
button
Repeat pressing to select :­Loop14 Loop2 4Loop 3 4Back to Loop1 If any one loop is cascade, ratio or override the
AUX indicator will illuminate as well as the loop indicator
Run/Hold button
• Press once to start a program (RUN light on.)
• Press again to hold a program (HOLD li ght on)
• Press again to cancel hold and continue running (HOLD light off and RUN light ON)
• Press and hold in for two seconds to reset a program (RUN and HOLD lights off )
The RUN light will flash at the end of a
program.
The HOLD light will flash during holdback.
Page button Press to select a new list of parameters.
Scroll button Press to select a new parameter in a l i st.
Down button Press to decrease a parameter val ue.
Up button Press to increase a parameter value.
Figure 1-4: Operator Buttons
AUTO MAN
RUN
HOLD
LP1 LP2
LP1
AUX
LP1 LP2
LP1
AUX
AUTO
MAN
RUN
HOLD
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Introduction 2604 Controller
1-8 User Guide Part No HA026491 Issue 3.0 A pr-02
1.4. INSTALLATION - OVERVIEW
The 2604 controller must be mounted and wired in accordance with t he i nstructions given in Chapter 2.
The controller is inte nded to be mounted through a cut out in the front panel of an electrical control cabinet. It is retained in position using the panel mounting clips supplied.
All wires are connected to terminals at the rear of the instrument. Each block of six terminals is protected by a hinged cover which cli c ks into closed position.
Figure 1-5: Rear Terminals
Hinged cover in open position
N
L
BB
BA
BC
2D
2B
2A
2C
1D
1B
1A
1C
M
O D U L E
1
M O D U
L E
3
HF
HD
HE
JF
JD
JE
D8
E2
E1
AC
AA
AB
HB
HA
HC
JB
JA
JC
D5
D4
D3
D1
DC
D2
D7
D6
V-
VI
VH
V+
M O D U
L E
4
M O D U
L E
5
M O D U
L E
6
Power Supply
Digital Input
Relay
Analogue input 0-10V
6D
6C
6B
6A
5D
5C
5B
5A
4D
4C
4B
4A
PV input
I/O Expander or Digital input
Digital I/O
3B
3A
3C 3D
C O M M S
M O D U L E
H
C O M M S
M O D U L E
J
Analogue input screen
The functionality of the two outer rows of terminals is common to all i nstrument variants, as follows:-
PV input VH, VI, V+, V­Analogue input BA, B B I/O expander E1, E2 Fixed changeover relay AA, A B, AC Digital I/O channels D1 to D8 and DC Power supply L, N, Earth
* Terminals 2A, 2B, 2C, 2D must not be wired to.
*
*
*
*
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2604 Controller Introduction
1.5. I/O MODULES
The 2604 controller has the facility to fit optional plug in modules. The connections for these modules are made to the inner three connector blocks as shown in Figure 1-6 The modules are:
• Communications modules See also section 2.4
• I/O modules See also section 2.4
These modules are fitted simply by sliding them into the relevant position as shown below.
Figure 1-6: View of the Plug-in Modules
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Introduction 2604 Controller
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2604 Controller Installation
2. CHAPTER 2 INSTALLATION....................................2
2.1. MECHANICAL INSTALLATION........................................................2
2.1.1. Positioning ............................................................................................2
2.1.2. Outline dimensions Model 2604 ...........................................................2
2.1.3. Mounting the Controller........................................................................3
2.1.4. Unplugging and Plugging in the Controller...........................................3
2.2. WIRING...................................................................................................4
2.2.1. Electrical Connections...........................................................................4
2.2.2. Rear Terminal Layout ...........................................................................4
2.3. STANDARD CONNECTIONS..............................................................6
2.3.1. Power Supply Wiring............................................................................6
2.3.2. Relay Output.........................................................................................7
2.3.3. Sensor Input Connections......................................................................8
2.3.4. Analogue Input Connections.................................................................9
2.3.5. I/O Expander (or Additional Digital Input) .........................................10
2.3.6. Digital I/O...........................................................................................11
2.4. OPTIONAL PLUG IN MODULE CONNECTIONS.........................12
2.4.1. Digital Communications Connections.................................................12
2.4.2. Devicenet Wiring................................................................................14
2.4.3. Master/Slave Communications............................................................16
2.4.4. I/O Modules........................................................................................18
2.5. TO CONNECT ZIRCONIA (DUAL SIGNAL) PROBE....................24
2.5.1. Zirconia Probe Screening....................................................................25
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Installation 2604 Controller
2-2 User Guide Part No HA026491 Issue 3.0 A pr-02
2. Chapter 2 INSTALLATION
2.1. MECHANICAL INSTALLATION
2.1.1. Positioning
The controller can be mounted verti cally or on a sloping panel of maximum thickness 15mm (0.6in). Adequate access space must be available at the rear of the instrument panel for wiring and servicing purposes. The outline dimensions are shown in figure 2-1. Take care not to cover ventilation holes in the top, bottom and sides of the instrument.
Before proceeding please read Appendix B ‘Safety and EMC Information’.
2.1.2. Outline dimensions Model 2604
Figure 2-1: Outline Dimensions
Front Panel Height 96mm (3.78in)
Overall depth behind panel 150mm (5.91in)
Front panel width 96mm (3.78in)
Panel thickness up to 12mm, 0.5in.
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2604 Controller Installation
2.1.3. Mounting the Controller
1. Prepare the panel cut-out to t he si ze shown in Figure 2-2. Ensure that there is sufficient
spacing between instruments as shown by the minimum dimensi ons given in Figure 2-2. Ensure also that the controller i s not mounted close to any device which is likely to produce a significant amount of heat which may affect the performance of the controller.
2. Insert the control ler through the panel cut-out.
3. Spring the upper and lower panel retaining clips into place. Secure the controller in
position by holding it level and pushing both retaining clips forw ard.
Note:- If the retaining clips subsequently need removing, in order to extract the controller from the control panel, they can be unhooked from the side with either your fingers or a screwdriver.
Figure 2-2: Panel Cut-out and Minimum Spacing Requirements
2.1.4. Unplugging and Plugging in the Controll er
If required, the control ler can be unplugged from its sleeve by easing the latching ears outwards and pulling the controll e r forward out of the sleeve. When pl ugging the controller back into its sleeve, ensure that the latching ears click into place.
It is recommended that the power to the controller is switched off when un-plugging or plugging the controller into it s sleeve. This is to prevent premature wear on the controller connectors when current is flowing through them.
Panel cut-out
92 x 92 mm
3.62 x 3.62 in
-0
+0.8
-0
+0.03
Recommended minimum spacing of controllers
38mm (1.5in)
10mm (0.4in)
(Not to scale
)
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Installation 2604 Controller
2-4 User Guide Part No HA026491 Issue 3.0 A pr-02
2.2. WIRING
WARNING
You must ensure that the controll er is correctly configured for your application. Incorrect confi gu ration could result in damage to the process being controlled, and/or personal injury. It is your responsibility, as the installer, to ensure that the con f iguration is correct. The controller may either have been configured wh en ordered, or may need configu ring now. See 2604
Engineering Manual Part Number HA026761 for details.
Before proceeding further, please read Appendix B, Safety and EMC information.
2.2.1. Electrical Connections
All electrical connections are made to the screw terminals at the rear of the controller. They accept wire sizes from 0.5 to 1.5 mm
2
(16 to 22 AWG) and should be tightened to a torque of
0.4Nm (3.5lbin). If you wish to use crimp connectors, the correct size is AMP part number 349262-1. The terminals are prot ected by a clear plastic hinged cover to prevent hands, or metal, making accidental contact wi th live wires.
2.2.2. Rear Terminal Layout
The rear terminal layout is shown i n Figure 2-3, which identifies terminal designations and their functions. Refer to the individual diagrams to wir e the controller to your require ments.
The two outer terminal strips have fixed hardware for all versions of the inst rument, as follows:-
• A Process Variable input which can be configur ed for:-
• Thermocouple, RTD, Pyrometer, Voltage (e.g. 0-10Vdc) or Milliamp (e.g. 4-
20mA) plus vacuum – log10
• Seven Digital I/O, configurable as input or output
• Inputs are logic (-1 to 35Vdc) or contact closure, and can be configured for:-
Manual, Remote, Run, Hold, Reset, etc,
• Outputs are open collector requir ing an external power supply, and can be
configured as event, status time proportioning or valve position outputs.
• One digital input
• An I/O expander which allows additional di gital I/O via an external unit, or an extra
digital input
• A changeover relay which can be configured as an alarm or event output. It cannot be
configured as a time proportioni ng output
• An analogue input for volts (e.g. 0-10Vdc) or Milliamp (e.g. 4-20mA) signals to a second
PID loop, setpoint, etc, . (This input can be characterised to mat ch a particular curve from a transmitter. It cannot accept thermocouple inputs directly)
• Power supply to the unit. The supply may be 85 - 264Vac 50 or 60 Hz,
!
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2604 Controller Installation
The three central terminal strips are for optional plug in modules, as follows:-
• Terminals marked 2A to 2D are reserved for a Memory Module only. No connections
should be made to these terminals
• Terminals marked HA to HF are connections for optional RS232, RS485, or RS422
communications modules
• Terminals marked JA to JF are connections for an optional slave communications module
or second communications port used to communicate with other instruments The modules fitted into the above two communications slots can be inter-changed
For a full list of avail able modules refer to the Ordering code - Appendix A and the T echnical Specification - Appendix C.
!
Figure 2-3: Rear Terminal Connections
N
L
BB
BA
BC
2D
2B
2A
2C
1D
1B
1A
1C
M O D U
L
E
1
M O
D U L E
3
HF
HD
HE
JF
JD
JE
D8
E2
E1
AC
AA
AB
HB
HA
HC
JB
JA
JC
D5
D4
D3
D1
DC
D2
D7
D6
V-
V1
VH
V+
M O D U
L
E
4
M O D U
L
E
5
M O D U
L
E
6
Power Supply
Digital Input
Relay
Analogue input Hi Level eg 0-10V
6D
6C
6B
6A
5D
5C
5B
5A
4D
4C
4B
4A
PV input
I/O Expander or Digital input
Digital I/O
3B
3A
3C
3D
C
O M M
S
M
O
D
U
L
E
H
C
O M M
S
M
O
D
U
L
E
J
Analogue input screen
Warning:- Take care that mains supplies are connected only to the power supply terminals (85 to 254Vac only), the fixed relay terminals or to relay or triac modules. Under no circumstances should mains supplies be connected to an
y
other terminals.
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Installation 2604 Controller
2-6 User Guide Part No HA026491 Issue 3.0 A pr-02
2.3. STANDARD CONNECTIONS
2.3.1. Power Supply Wiring
Controllers supplied wi th the VH Supply Voltage option are sui table for connection to a power supply of between 85 and 264Vac 50 or 60 Hz.
Controllers supplied with t he VL Supply Voltage option are suitable for connection to a power supply of between 20 and 29Vac 50 or 60 Hz or 20 to 29Vdc. Pola rity not important.
Notes:
1. Make sure the voltage corresponds to the description on the identification label
2. It is the user’s responsibility to provide an external fuse or circuit breaker. Suitable fuses
are :-85 to 264 volt supply T type (EN60127 time-lag type) rated at 1A 20 to 29 volt supply T type (EN60127 time-lag type) rated at 4A
3. Use copper conductors only
4. To avoid electric shock, connect the power line at the end of the wiring procedure
5. Do not run power cables with signal wires such as input, output or digital
communications
6. The safety requirements for Permanent ly Connected Equipment say:
A switch or circuit breaker shall be included in the building installation it shall be in close proximity to the equipment and within easy reach of the operator it shall be marked as the disconnecting device for the equipment a single switch or circuit breaker can drive more than one instrument
Figure 2-4: Supply Voltage Connections
Line 85 to 264Vac
85 to 264Vac Voltage Supply – Code VH
Neutral Earth
L
N
20 to 29ac/dc Voltage Supply – Code VL
20 to
29Vac/dc
Earth
24
24
Page 20
2604 Controller Installation
2.3.2. Relay Output
A single changeover relay is provided as st andard. It can be configured as a control output or an alarm or event output.
Notes:
1. To avoid electric shock, connect the power line at the end of the wiring procedure
2. Use copper conductors only
3. Do not run power wires with input or digital communications wiring
Figure 2-5: Wiring Connections For Fixed Relay Output
Fixed relay connections
AC
AA AB
Normally Open
Normally Closed
Common
Relay Rating Max 264Vac, 2A Min 1V, 1mA
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Installation 2604 Controller
2-8 User Guide Part No HA026491 Issue 3.0 A pr-02
2.3.3. Sensor Input Connections
The fixed PV input can accept a range of sensors including Thermocouple, RT D (Pt100), Pyrometer, Voltage (e.g. 0-10Vdc) or Milliamp (e.g. 4-20mA) signals. These sensors are used to provide inputs to Control Loop 1.
Notes:
1. Do not run input wires together with
power cables
2. Pay attention to line resistance; a high
line resistance may cause measurement errors
3. When shielded cable is used, it should
be grounded at one end only to avoid ground loop currents
4. The resistance of the 3 PRT wires must
be the same
5. For TC wiring use the appropriat e
compensating cable
Figure 2-6: Wiring Connections For PV Input
VH VI
V-
V+
Thermocouple or Pyrometer
Use the correct type of compensating cable to extend wiring
+
-
VH VI
V-
V+
Voltage 0 to 10V or 0 to 2V
+
-
0 - 10
Volt
source
VH VI
V-
V+
mV (up to 80mV)
+
-
mVolt
source
VH VI
V-
V+
Current 0 to 20mA (4 to 20mA)
+
-
2.49Ω
resistor
supplied
Current
source
VH
VI
V-
V+
RTD (Pt100)
3-wire platinum resistance thermometer
For 2-wire this is a local link
Page 22
2604 Controller Installation
2.3.4. Analogue Input Connections
The analogue input is supplied as standard and is intended to accept 0 to 10 Vdc from a voltage source. A milli-amp current source can be used by connecting a 100Ω resistor across terminals BA and BB. This input can be used as a remote setpoint input, remote setpoint tri m or as a high level PV input to a control loop. This input i s not isolated from the digita l IO.
Figure 2-7: Wiring Connections For Analogue Input
Isolated Voltage Source (0 to 10V)
Non-isolated Voltage Source (0 to 10V)
Non­isolated 0 to 10Vdc source
Screen
BC
BA BB
100Ω
If screened cable is used earth at the supply end
Non-isolated Current Source (0 - 20mA) (4 - 20mA)
Non­isolated current source
BC
BA BB
If screened cable is used earth at the supply end
Isolated 0 to 10Vdc source
BC
BA BB
100Ω
Isolated Current Source (0 - 20mA) (4 - 20mA)
Isolated current source
BC
BA BB
Screen
+
-
+
-
+
-
+
-
Page 23
Installation 2604 Controller
2.3.5. I/O Expander (or Additional Digital Input)
An I/O expander (Model No 2000IO) can be used with the 2604 t o al low the number of I/O points to be increased by a further 20 digital inputs and 20 digital outputs. Dat a transfer is performed serially via a two wire interface from instrument to expander. If the expander unit is not required it is possible to use terminals E1 & E 2 as a secondar y digital input. These terminals are not part of the digital I/O terminals D1 to D8 and if used in
this way connect a 2K2, ¼ W limiti ng resistor in series with the input, see Figure 2-8.
Figure 2-8: Wiring Connections for the I/O Expander
For details of the IO Expander r efer to the Operating Instructions HA026893. T he connections for this unit are reproduced bel ow f or convenience.
Figure 2-9: IO Expander Connections
I/O expander connections
E1 E2
20 Inputs
20 Outputs
Expander
Data
transfer
Ä
Â
I/O expander connections
E1 E2
+
-
Additional digital input i f the expander is not used
2K2
Limits:
-1V, +35V
+
-
1 2
3 4
5 6
7 8
21
22
9
10
23
24 25
26 27
28 29 30
24V Supply ac or dc dc polarity not important
E
24 24
+
-
Transmitter Out
Comms
E1 E2
Screen
Digital Inputs 1 to 10
Outputs 21 to 30
+
­+
­+
­+
­+
­+
­+
­+
­+
-
A B C
A C
A B C
A B
C A B C
A C
A C
A C
A C
A C
Digital Inputs 11 to 20
Digital Inputs 1 to 10
15 16 17 18 19 20
11 12 13 14
10
35 36
38 39
40
31 32 33 34
30
10 IO Expander Board
Additional IO Expander
Outputs 31 to 40
Outputs 21 to 30
+
­+
­+
­+
­+
­+
­+
­+
-
+
­+
-
A C
A C A C
A C
A C A C
A C
A C A C A C
Page 24
2604 Controller Installation
2.3.6. Digital I/O
Eight digital I/ O connections are provided as standard. They can be indi vidually configured as:
1. Inputs Run, Hold, Reset, Auto/Manual, etc, - logic or contact closure.
2. Outputs Configurable as Control outputs, Programmer Events, Alarms, etc. Digital IO is not i s olated from instrument ground.
Figure 2-10: Wiring Connections for Digital I/O
Digital Outputs (Relay, Thyristor or SSR Drive in any combination)
D5
D7
D6
D1
DC
D2
D4
D3
Outputs are open collector
_
+
Relay
Relay
Relay
Thyristor Unit
Thyristor Unit
SSR
SSR
External power supply 10 to 35 Vdc. Each output is current l i mited to 40mA
Digital Inputs (Logic Inputs or Contact Closure in any combination)
D5
D7
D6
D1
DC
D2
D4
D3
D8
This terminal can be used for Digital Input only (not DO)
Common
Common
Logic inputs
(1)
Contact closure inputs
Note 1: Logic inputs can accept drive signals from a voltage source where: <2V = Active (1) Limit -1V >4V = Inactive (0) Limit +35V This action is reversed if the input has
been configured as ‘Inverted’
Page 25
Installation 2604 Controller
2.4. OPTIONAL PLUG IN MODULE CONNECTIONS
2.4.1. Digital Communications Connecti ons
Digital Communications modules can be fitted in two positions in the 2604 controller. The connections are available on HA to HF or JA to JF depending on the position in which the module is fitted. The two positions could be used, for example, to communicate with a
configuration package, such as ‘iTools’ on one position and to a PC running a supervisory package on the second position OR with master/slave communications.
The connections shown in the following diagrams show RS232, 2-wire RS485, 4-wire RS422 and master/slave comms to a second controller.
Do not run digital communications wir ing with power cables. The following diagr ams show connections for ‘bench top test’ wiring. For a full description of the i nstallation of a communications link, including line resistors, see Communications Handbook, Part No. HA026230, and EMC Installat ion Guide, part no. HA025464.
Figure 2-11: RS232 Communications Connections
Figure 2-12: RS485 2- Wire Comm uni cati ons Connections
RS232
HF
HB
HA
HC
HE
HD
Common
Com
Rx
PC
Tx
TxRx
RS485 - 2 wire
HF
HB
HA
HC
HE
HD
Common
A(+)
B(-)
RS232 to
RS485
2-wire
converter
Tx
Rx
PC
Com
RxA
RxB
TxB
TxA
Com
Connections ‘daisy
chained’ to other
instruments
Page 26
2604 Controller Installation
Figure 2-13: RS485 4-Wire Comm uni cati ons Connections
Figure 2-14: Profibus Wiring Connections
RS485 4-wire (or RS422)
HF
HB
HA
HC
HE
HD
Common
A(Tx+)
B (Tx-)
Tx
Rx
PC
Com
A’ (Rx+)
B’ (Rx-)
RS232 to
RS422/RS485
4-wire
converter
RxB
RxA
TxB
TxA
Com
Connections ‘daisy
chained’ to other
instruments
Profibus
HF
HB
HA
HC
HE
HD
Rx/Tx +ve
Rx/Tx -ve
Dig Grnd
Shield
VP (+5V)
Connections ‘daisy
chained’ to other
instruments
HF
HB
HA
HC
HE
HD
Shield
390Ω
390Ω
220Ω
Last controller only
requires terminating
resistors
Rx/Tx +ve
Rx/Tx -ve
Dig Grnd
VP (+5V)
Twisted pairs
AB
Master
Page 27
Installation 2604 Controller
2.4.2. Devicenet Wiring
This section covers the DeviceNet digital communications option. To configur e DeviceNet communications refer to the 2604 Engineering Handbook Part No HA026761.
2.4.2.1. DeviceNet Terminal Functions
Terminal
Reference
CAN
Label
Color
Chip
Description
HA V+ Red DeviceNet network power positive terminal. Connect
the red wire of the DeviceNet cable here. I f the DeviceNet network does not suppl y t he power, connect to the positi ve t erminal of an external 11-25 Vdc power supply.
HB CAN_H White DeviceNet CAN_H data bus terminal. Connect the
white wire of the DeviceNet cable here.
HC SHIELD None Shield/Drain wire connection. Connect the
DeviceNet cable shield here. To prevent ground loops, the DeviceNet network shoul d be grounded i n only one location.
HD CAN_L Blue DeviceNet CAN_L data bus termi nal . Connect the
blue wire of the DeviceNet cable here.
HE V- Bl ac k DeviceNet network power negative terminal.
Connect the black wire of the Devic eNet cable here. If the DeviceNet network does not supply the power, connect to the negative terminal of an external 11-25 Vdc power supply.
HF Connect to instrument earth
Note: Power taps are recommended to connect the DC power supply to the DeviceNet trunk line. Power taps i nclude:
A Schottky Diode to connect the power supply V+ and allows for multiple power supplies to be connected.
2 fuses or circuit breakers to protect the bus from excessive current which could damage the cable and connectors.
The earth connection, HF, to be connected t o the main supply earth terminal.
!
Page 28
2604 Controller Installation
2.4.2.2. Wiring I n terconnecti ons for Devi ceNet Communications
V+ 5
CAN-H 4
CAN-L 2
Drain 3
V- 1
5-Position
COMBICOM
Diag
DB-9M
RDY
RUN
NET M ON
Card
Top
Red
Wht
Blu Blk
Typical Interface Card
(MASTER)
HA HB HC HD HE HF
2604 Controller
(SLAVE) Address 11
V+ CAN-H
CAN-L
Drain
V-
HA HB HC HD HE HF
2604 Controller
(SLAVE) Address 12
V+ CAN-H
CAN-L
Drain
V-
HA HB HC HD HE HF
2604 Controller
(SLAVE) Address N+1
121
W
*
* Fit to last instrument in
the chain
Network Supply
24Vdc ( +1%)
250mV p-p Ripple
V+
V-
V-
V+
Daisy chain to further
instruments
L N E
L N E
L N
E
121W terminating resistor required fitted
if not internally
Page 29
Installation 2604 Controller
2.4.3. Master/Slave Communications
The following diagrams show connections f or a range of different controllers using RS422. These are representative of typical slaves which may be used but could also include third party products using Modbus protocol.
RS422 or RS485 4-wire
Figure 2-15: Example Wi ring RS422 or RS485 4-wire for Different Slaves
Slave Terminal Numbers for Different Instruments Terminal Function
2600 2700
2200 2400
94C 900
EPC
818/5 902/3
/4
Tx+ HE or JE HE 11 X1 15 F1 Tx- HF or JF HF 12 X2 16 F2
Rx+ HB or JB HB 13 X3 13 F3
Rx- HC or JC HC 14 X4 14 F4
Com HD or JD HD 15 X5 17 F5
Tx+
JE
Rx+
JB
Rx-
JC
Com
JD
2604 Master
220 ohm termination resistors across the Rx terminals of the last controller in the chain
220 ohm termination resistors across the Rx terminals of the master
Up to 32 instruments
Controller Type
902
Rx+
Com
Rx
-
Tx+
Tx
-
Controller Type
2200
Rx+
Com
Rx
-
Tx+
Tx
-
Controller Type
94C
Rx+
Com
Rx
-
Tx+
Tx
-
Controller Type
900EPC
Rx+
Com
Rx
-
Tx+
Tx
-
Twisted pair throughout
Comms cable should be ‘daisy chained’ as shown from one instrument to the next and not connected from a ‘star’ point. The screen should be connected through as shown:-
Tx-
JF
Screen grounded at one point
Page 30
2604 Controller Installation
RS485 2-wire
Figure 2-16: Example Wi ring RS485 2-wire for 2000 Series Instruments
RS232
Figure 2-17: Example Wiring RS232 for 2000 Series Instruments
Tx JF Rx JE
Com JD
2604
Master
2000 series controller
Tx HF
Rx HE
Com HD
Screen grounded at one point
Slave Terminal Numbers Terminal Function
2200 2400 2600 2700
AHEHE or JE BHFHF or JF
Com HD HD or JD
B
JF
A
JE
Com
JD
2604
Master
220 ohm termination resistors across the Rx terminals of the last controller in the chain
220 ohm termination resistors across the Rx terminals of the master
Up to 32 instruments
Twisted pair throughout
Comms cable should be ‘daisy chained’ as shown from one instrument to the next and not connected from a ‘star’ point. The screen should be linked through as shown:-
Screen grounded at one point
2000 series
controller
ComHDAHEB
HF
2000 series
controller
Com
HD
A
HE
B
HF
2000 series
controller
ComHDAHEB
HF
2000 series
controller
ComHDAHEB
HF
Page 31
Installation 2604 Controller
2.4.4. I/O Modules
The 2604 controller contains five positions in which 4-terminal I/O modules can be fitted. These positions are marked Module 1, Module 3, Module 4, Module 5, Module 6, in Figure 2-
3. Module 2 is reserved for the Memory Module which can only be fitted in this position. To find out which modules are fitted check the ordering code which is found on a label on the side of the instrument. Any module, listed in this section, can be fitted in any position, except the PV input - limited to positions 3 and 6 only; and the Analogue Input module - cannot be fitted in slot 5. Care should be taken, therefore, to ensure that modules are fitted as expected from the order code.
The instrument can be interrogated in ‘View Config’ level to locate the positions in which the modules are fitted. See Chapter 4, Access Levels. If modules have been added, removed or changed it is recommended that this is recorded on the instrument code label.
I/O Module Typical
usage
H/W
Code
Connections and examples of use
Note: The order code and terminal number is pre-fixed by the module num ber. Module 1 is connected to terminals 1A, 1B, 1C, 1D; module 3 to 3A, 3B, 3C, 3D, etc.
Relay (2 pin) and
Dual Relay
max 264Vac, 2A, min 12V, 100mA
Heating, cooling, alarm, program event, valve raise, valve lower
R2 and
RR
Change Over Relay
max 264Vac, 2A, min 12V, 10mA
Heating, cooling, alarm, program event, valve raise, valve lower
R4
Isolated Single Logic Output
18Vdc at 24mA max
Heating, Cooling, Program events
LO
A
B
D
C
Voltage supply
Contactor
Relay
Panel lamp
etc
Contactor
Relay
Panel lamp
etc
First relay
Second relay
(dual relay only)
A
B
D
C
Voltage supply
Contactor
Relay
Panel lamp
etc
A
B
D
C
+
__
_
+
Output A
Common
SSR or thyristor unit
+
-
Page 32
2604 Controller Installation
I/O Module Typical
usage
H/W
Code
Connections and examples of use
Triple Logic Output
(18Vdc at 8mA max. per channel)
Heating, cooling, program events
TP
Triac and Dual
Triac
(0.7A, 30 to 264Vac combined rating)
Heating, cooling, valve raise, valve lower
T2 and
TT
Note: Dual relay modules may be used in place of dual triac.
Note:­The combined current rating for the two triacs must not exceed 0.7A.
DC Control
(10Vdc, 20mA max)
Heating, cooling
e.g. to a 4-20mA
process actuator
D4
DC Re­transmission
(10Vdc, 20mA max)
Logging of PV, SP, output power, etc.,
(0 to 10Vdc, or
0 to 20mA)
D6
A
B
D
C
Actuator 0-20mA
or
0-10Vdc
-
+
A
B
D
C
To other
controllers
0-20mA
or
0-10Vdc
-
+
A
B
D
C
+
__
_
+
+
+
Output A Output B
Output C
Common
SSR or thyristor unit
+
-
A
B
D
C
Voltage supply
Motorised valve
Raise
Lower
Second triac
First triac
Page 33
Installation 2604 Controller
I/O Module Typical
usage
H/W
Code
Connections and examples of use
Dual DC Output
(each channel can be 4­20mA or 24Vdc power supply)
Control output 12 bit resolution
Can only be fitted in slots 1,4 or 5
DO
High Resolution DC Output
(one 15 bit 4­20mA plus one 24V power supply
Retransmis sion in
‘feedback mode’
Can only be fitted in slots 1,4 or 5
HR
A
B
D
C
-
+
-
+
Output 1
Output 2
20V – 30V
4-20mA
A
B
D
C
-
+
-
+
Output 1
Output 2
20V – 30V
4-20mA
Page 34
2604 Controller Installation
I/O Module Typical
usage
Order
Code
Connections and examples of use
PV Input
(Modules 3 & 6 only)
and
Analogue Input
(Modules 1, 3, 4 & 6 only)
Second or third PV input
mV, V, mA, TC, RTD (Pt100) Zirconia probe
Second or third PV input
mV, mA, TC, RTD (Pt100)
PV
AM
Voltage 0 to 10V or 0 to 2V
A B
D
C
+
-
0 - 10
Volt
source
AM (up to 100mV)
A B
D
C
+
-
mVolt
source
For 2-wire this is a local link
A
B
D
C
Thermocouple
-
+
A
B
D
C
3-wire RTD
Current 0 to 20mA (4 to 20mA)
A B
D
C
+
-
2.49Ω
resistor
supplied
Current
source
Page 35
Installation 2604 Controller
I/O Module Typical
usage
Order Code
Connections and examples of use
Triple Logic Input
Events
e.g. Program Run, Reset, Hold
TL
Triple Contact Input
Events
e.g. Program Run, Reset, Hold
TK
24V Transmitter Supply
(20mA)
To power an external transmitter
MS
A
B
D
C
+
-
Transmitter
A
B
D
C
Common
Input 1
Input 3
Input 2
Logic inputs <5V OFF
>10.8V ON Limits:
-3V, +30V
A
B
D
C
Common
External
Switches or
Relays
Input 1
Input 3
Input 2
Contact inputs <100W ON >28KW OFF
Page 36
2604 Controller Installation
Transducer Power Supply
Provide 5V or 10Vdc to
power Strain
Gauge
Transducer
+
Shunt
Contact
G3 or G5
Note: To minimi se noise pick up it is recommended that s creened cables are used for strain gauge power supply connections.
Potentio­meter Input
(100Ω to 15KΩ)
Motorised
valve
position
feedback
Remote SP
VU
Dual PV Input
(Modules 3 & 6 only)
To accept two inputs from a high level and a low level source.
The two inputs are not isolated from each other.
DP
The common connections to terminal D must be returned separately to D as shown in the dual current example above.
Figure 2-18: Wiring Connections for IO Modules
A
B
D
C
_
+
A
B
D
C
To Fixed or Module PV Input
External calibration resistor (may be fi tted in transducer).
A
B
D
0v
C
+0.5v
Wiper
A
B
D
C
+
-
Current
source
0-2V input
Current
source
0-20mA
input
100Ω
2.49Ω
+
-
Page 37
Installation 2604 Controller
2.5. TO CONNECT ZIRCONI A (DUAL SIGNAL) PROBE
A dual signal probe, such as a Zirconia probe, will normally be connected to a Dual PV Input module (Code DP). The module presents t w o channels, A and C, where A is the voltage input and C is the mV, thermocouple, RTD or mA input.
Example 1 shown below uses the Dual PV Input module wit h both channels configured. In this configuration the module runs at 4.5Hz. The two channels are un-i s olated from one­another but isolated from the rest of the instrument.
Example 2 uses two modules. The modules can eit her be two PV Input modules (code PV) or
a Dual PV Input module (code DP) wit h C hannel C configured as ‘None’ plus a PV Input module. This combination runs at 9Hz and may be used if the loop is unusually fast.
I/O Module Typical
usage
Order Code
Connections and examples of use
Dual PV Input
Zirconia probe
DP
Example 1:- Using the Dual PV Input Module.
Channel C is shown configured for therm ocouple. The temperature sensor of a zirconia probe is connected to this input , terminals C & D. The Volt Source is connec ted to the A channel, terminals A & D.
Two PV Input Modules
PV
Example 2:- Using Two Modules
The temperature sensor of t he zi rconia probe can be connected to the precisi on PV input of one I/O module, connections C & D, with the Volt Source connected to the second module, terminals A & D.
Figure 2-19: Wiring Connections for Zirconia Probe
A B
+
-
Zirconia
Volt
source
D
C
+
-
C D
A
B
D
C
+
-
Zirconia
Volt
source
+
-
Note: The +ve of the volt source must be connected to the-ve of the thermocouple.
Page 38
2604 Controller Installation
2.5.1. Zirconia Probe Screening
2.5.1.1. Zirconia Carbon Probe Construction
2.5.1.2. Screening connections when two modules are used
The zirconia sensor wires should be screened and connected to t he outer shell of the probe if it is situated in an area of high interference.
2.5.1.3. Screening connections when a dual input module is used
Both the thermocouple and the zirconia sensor wir es must be screened and connected to the outer shell of the probe if it is situated in an area of high interference.
Note the reverse connection of the zirconia sens or .
D
D
C
B
A
B
A
Outer Electrode
Inner Electrode
Screen
Zirc. mV
T.C.
-
+
-
+
C
-
+
-
+
Screened Cable
Outer Electrode
Inner Electrode
Screen
Zirc. mV
T.C.
­+
D
C
B
A
-
+
-
+
-
+
Screened Cable
Screened Compensating Cable
Outer Electrode
Inner Electrode
Ceramic Insulator
Zirconia Sensor
Hot End
Screen
Zirc. mV
Thermocouple
­+
-
+
Outer metallic shell of the probe
Page 39
Installation 2604 Controller
Page 40
2604 Controller Operation
User Guide Part No HA026491 Issue 3.0 Apr-02 3-1
3. CHAPTER 3 PRINCIPLE OF OPERATION................2
3.1. POWER UP...............................................................................................3
3.1.1. The HOME Page...................................................................................3
3.2. THE OPERATOR BUTTONS...............................................................4
3.3. THE AUTO MANUAL BUTTON .........................................................5
3.4. THE RUN/HOLD BUTTON..................................................................5
3.5. THE LOOP SELECT BUTTON
LP1 LP2
LP3
AUX
................................ 6
3.5.1. To Change Setpoint (when the loop is in Auto)....................................7
3.5.2. To Change Output Power (when the loop is in Manual).......................7
3.6. PARAMETERS AND HOW TO ACCESS THEM..............................8
3.6.1. Pages.....................................................................................................8
3.6.2. To Step Through Page Headers.............................................................9
3.6.3. Sub-headers...........................................................................................9
3.6.4. To Step Through Parameters...............................................................10
3.6.5. To Change Parameter Values..............................................................11
3.6.6. Parameter Tables.................................................................................13
3.7. SPECIFIC DISPLAYS FOR CASCADE, RATIO, OVERRIDE AND
VALVE POSITION..........................................................................................14
3.7.1. Loop Summary Parameters.................................................................15
3.8. BACKPAGE..........................................................................................16
3.9. BACKSCROLL.....................................................................................16
3.10. JUMP TO HOME DISPLAY...............................................................16
3.11. INVALID KEY ACTIONS...................................................................16
3.12. PARAMETER AVAILABILITY AND ALTERABILITY................17
Page 41
Operation 2604 Controller
3-2 User Guide Part No HA026491 Issue 3.0 Apr-02
3. Chapter 3 PRINCIPLE OF OPERATION
This chapter explains how to locate and change the value of parameters using the front panel buttons. Operation of these buttons changes the display view by bringing up diff erent pages. The pages and the location of parameters within these pages follows a set order. This chapter describes how to navigate between the pages.
Note: The 2604 controller is an application specific controller and can be conf igured to the preferences of a particular process, site or even user. This means that the displays shown in this and following chapters may not be identical to those shown in your instrument. Where the text on a d isplay is user configurable i t is shown in italics, eg
Loop1
About this chapter
This chapter describes:
◊ How to change setpoint ◊ The operator buttons ◊ Parameters and how to access them ◊ Pages ◊ How to step through pages ◊ How to step through parameters ◊ How to change parameter values ◊ The navigation diagram ◊ Parameter tables
Page 42
2604 Controller Operation
User Guide Part No HA026491 Issue 3.0 Apr-02 3-3
3.1. POWER UP
Install and wire up the controller in accordance with Chapter 2 and switch on. A short self test sequence takes place during which the controller identification is displayed together with the version number of software fitted.
3.1.1. The HOME Page
The controller then shows a default displ a y, referred to as the HOME page. It is possible to customise all three readouts of this display but the format is shown in Figure 3-2. It is also the default display on a new controlle r .
The HOME page will be displayed under the following conditions:-
1. When the controller is switched on
2. When the access mode is changed from configuration level to a different level
3. When
and are pressed together ( s ee 3.10)
4. When a timeout (if configured) occurs The upper and middle readouts can be configured to display any available parameter but the
default is Process Variable and S e tpoint respectively. The lower readout can be configured to show:-
1. Loop Views - LP1 to L P3 as shown
2. The Access page (see Chapter 4)
3. The Summary page (see Chapter 5)
4. The Run page (see Chapter 6)
5. Cycle each loop. LP1 t o L P3 pages are cycled in turn The configuration of these displ ays is described in the Engineering manual, Part No. HA026761.
Figure 3-1: The ’HOME’ Page (default)
Middle Display - (usually indic ates Setpoint when in Auto or Output Power when in Manual but can be customised)
Upper Display - (usually indicates Process Variable but c an be customised
)
Lower Alpha/Numeric LCD Display (usually indicates messages)
Alarm Beacon See Figure 1-4
Standby Mode See Figure 1-4
LED status indicators (see
Fi
g
ure 1–4
)
Operator buttons (see Figure 3-2)
Page 43
Operation 2604 Controller
3-4 User Guide Part No HA026491 Issue 3.0 Apr-02
3.2. THE OPERATOR BUTTONS
Auto/Manual
button
When pressed, this toggles between automati c and manual mode:
• If the controller is i n automatic mode t he A UTO l i ght will be on
• If the controller is i n manual mode, the MAN light
will be on
Loop select
button
The auxiliary
loop (A) is
used for ratio,
cascade or
override
control only
Each press selects: Loop 1 LP1 illuminates Loop 1A LP1 + AUX illuminates Loop 2 LP2 illuminates Loop 2A LP2 + AUX illuminates Loop 3 LP3 illuminates Loop 3A LP3 + AUX illuminates Back to Loop 1
Programmer
button
See also
Chapter 4
‘Programmer
Operation’
This button operates the programmer on all loops
• Press once to start a program (RUN light on.)
• Press again to hold a program (HOLD li ght on)
• Press again to cancel hold and continue running
(HOLD light off and RUN light ON)
• Press and hold in for two seconds to reset a program (RUN and HOLD lights off)
The RUN light will flash at the end of a program. The HOLD light will flash during holdback.
Page button Press to select the Page Header ‘Menu’.
Scroll button Press to select a new paramet er from the page
heading. If held down it will continuously scroll through the parameters.
Down button Press to dec rease an analogue value, or to change the
state of a digital value
Up button Press to inc reas e an anal ogue val ue, or to change the
state of a digital value
Note:- If buttons do not operate they may have been disabled in configuration l e vel. AUTO, LOOP, or PROG can be disabl ed individually OR all buttons may be disabl ed.
Figure 3-2: Operator Buttons
AUTO
MAN
LP1 LP2
LP3
AUX
RUN
HOLD
AUTO
MAN
LP1 LP2
LP3 AUX
RUN
HOLD
If configured
Page 44
2604 Controller Operation
User Guide Part No HA026491 Issue 3.0 Apr-02 3-5
3.3. THE AUTO MANUAL BUTTON
The controller has two basic modes of operation:
• Automatic Mode in which the output is automatically adjusted to maintain the process
value at the setpoint .
• Manual Mode in which you can adjust the output independently of the setpoi nt. The Auto/Manual button can only be operated f rom the loop view. Press the Loop Select
button to select the loop view, then press AUTO/MAN to toggle between auto and manual. When the controller is in AUTO, ‘AUT’ will be displayed on the loop summary page as
shown in Figure 3-3 (LP1). The middle readout will default to the Working Setpoint in a standard controller. When the controller is in MANUAL, ‘MAN’ will be displayed on the loop summary page as shown in Figure 3-3 (LP2). The middle readout will default to Output Power in a standard controller.
If the loop summary page is not being displayed, pressing the AUTO/MAN button will select the first available loop summary. Subsequent presses will change between Auto and Manual for the selected loop as above.
3.4. THE RUN/HOLD BUTTON
If the controller is conf igured as a programmer this button has thr ee functions:
• To put the programmer into RUN mode. This causes the working setpoint to follow the
profile set in the program bei ng used.
• To put the programmer into HOLD mode. This stops the program from running and
maintains the setpoint at the current level..
• To put the programmer into RESET mode. This resets the programmer to the controller
setpoint, the working setpoint can be changed manually using the Raise/Lower buttons.
If the controller is in reset or hold mode, press the RUN/HOLD button. The program begins to run, and the RUN LED illuminates. If the controller is in run mode, press the RUN/HOLD button. The program will hold at its current conditions, and the HOLD LED illuminates. If the controller is in run or hold mode, press the RUN/HOLD button and hold it pressed for two seconds. The program will reset, and the RUN and HOLD LEDs will extinguish.
This button operates all programmer loops simultaneously.
See also Chapter 4, ‘Programmer Operation’.
Page 45
Operation 2604 Controller
3-6 User Guide Part No HA026491 Issue 3.0 Apr-02
3.5. THE LOOP SELECT BUTTON
LP1 LP2
LP3
AUX
The 2604 controller can be supplied with up to three control loops. The L oop Select button allows you to select a summary of each loop from whatever page is being displayed at the time. Each press of the Loop Select button will change the display to the next loop summary. (If only one loop is configured further presses of the loop button have no effect).
A loop is designated by the mnemonic ‘LP’ followed by the loop number. If the loop is ratio, cascade or override the loop number may be followed by the character ‘A’. This shows a summary of the ‘inner’ or ‘auxiliary’ loop. This text could, however, have been replaced by user defined text.
In addition, each press of the loop select button causes the relevant beacon, LP1 to LP3, to illuminate to indicate which main loop is selected. If the auxiliary loop is configured the AUX beacon will also illuminate.
The upper and middle displays will show the PV and SP of the loop selected, (see also section 3.7).
To return to the original page view at any t ime, press the page button,
. Alternatively, a timeout may have been set which will return the display to the HOME page view after a set period. The timeout and period is set in configuration level , see Engineering Manual part no HA026761.
Figure 3-3: Operation of the Loop Button
Typical example of the loop summary display - the bar graph shows output power
-Page header (or parameter view)
PRG
LP1A
PRG
AUT
LP2
SP1
MAN
Repeat pressing
of the Loop
Select button
will display
further loops (if
fitted), returning
Field 1
Field 2
LP1 AUT
>C@
(A = Auxiliary)
Field 3
Notes: Field 1 Loop number or user defined loop name.
Can be up to 16 characters in length. If loop name > 6 characters (approx) - units are not shown If loop name > 8 characters (approx) - Field 2 is not shown
If loop name > 12 characters (approx) - Field 3 is not shown Units Optional Field 2 AUT(o)/ MA N(ual ) or CS D(cascade)/RAT(io)/OVR(override). Field 3 Set poi nt source - SP1/SP2/ RE M(ote)/PRG(program)
Units
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User Guide Part No HA026491 Issue 3.0 Apr-02 3-7
3.5.1. To Change Setpoint (when the loop i s in Auto)
Do This This Is The Display You
Should See
Additional Notes
3.5.2. To Change Output Power (when the loop is in Manual)
Do This This Is The Display You
Should See
Additional Notes
If a loop is configured as Cascade, Ratio, Override or motor valve position the names of parameters shown above will differ slightly. These are explained in section 3.7.
1. From any display pres s the Loop Select button,
LP1 LP2
LP3
AUX
, as many times as necessary to select the required loop number
2. Press
or to select
the Target SP
3. Press
or again to
raise or lower the setpoint.
Target SP
v
0.0
The lower readout will blink to accept the new value. At the same time the middle readout will also update.
LP1
AUT
>C@
SP1
Target SP
v
200.0
If no key is pressed for 5secs the display ret u rns to the loop overview
This is the loop overview
1. From any display pres s the Loop Select button,
LP1 LP2
LP3
AUX
, as many times as necessary to select the required loop number
2. Press
or to select
the Target OP
3. Press
or again to raise or lower the output power.
Target OP
v
0.0
The output power increases or decreases continuously whilst the raise/lower keys are held down. At the same time the middle readout will also update.
LP1
MAN
>C@
SP1
Target OP
v
30.0
If no key is pressed for 5secs the display ret u rns to the loop overview
This is the loop overview
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3-8 User Guide Part No HA026491 Issue 3.0 Apr-02
3.6. PARAMETERS AND HOW TO ACCESS THEM
Parameters are settings, within the controller, which determine how the controller will operate. They are accessed using the lower alpha-numeric display and can be changed by the user to suit the process. Selected parameters may be protected under different security access levels.
Examples of parameters are:­Values - such as setpoints, alarm trip levels, high and low limits, etc., or States - such as auto/manual, on/off, etc. These are often referred to as enumerated values.
3.6.1. Pages
The parameters are organised into diffe r e nt pages. A page shows information such as page headers, parameter names and parameter values.
Parameters are grouped in accordance with the function they perform. E ach group is given a
‘Page Header’ which is a generic description of the parameter group. Examples are ‘The Alarm Page’, ‘The Programmer Page’, etc,. A complete lis t of pages is shown in the navigation diagram in the Engineering manual.
The 2604 contains a set of default pages for most appl ications. It is possible to confi gure different start up pages as the Home page, but the principle of navigation is the same as the default pages.
Note:­A page only appears on the controller if the function has been ord ered and has been enabled in Configuration mode. For example, if a programmer is not configured the RUN page and the EDIT PROGRAM pages will not be displayed.
Figure 3-4: Page Concept
P
:PAGE HEADER
v
Sub Header
S
:Parameter 1
v
Value
S
:Parameter 2
v
Value
S
:Parameter 3
v
Value
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User Guide Part No HA026491 Issue 3.0 Apr-02 3-9
3.6.2. To Step Through Page Headers
Press - (The Page Button). At each press the first line of the alpha-numeric display will change to the name of the page
header. This is a continuous list which will eventually return to the starting point, as shown
in Figure 3-5 below. If t he page button, , is held down continuously the pages auto advance.
Figure 3-5: Stepping Through Page Headers
3.6.3. Sub-headers
The page header shown in Figure 3-6 contains sub-headers. . The sub-header appears in the lower right hand corner of the alpha- numer ic display.
The sub-header can be changed using the
or buttons, as prompted by the v symbol.
This is a continuous list which will return to the first sub-header.
Figure 3-6: Sub-header Selection
Hom
e
P
:RUN
P
: PROGRAM EDIT
P
:More Page
Headers
This symbol is us ed as a prompt to select t he next page header. It also indicates that the current message is t he page header
J Tip: See ‘Backpage’ Sect i on 3.7
This symbol is us ed as a prompt to select the next sub-header
P
:ALARMS
v
Summary Page
v
PV Input Page
v
More sub-headers
This is a continuous loop.
Pressing reverses the direction
J Tip: See ‘Backscroll’ Section 3.8
P
:ALARMS
P
:ALARMS
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3-10 User Guide Part No HA026491 Issue 3.0 Apr-02
3.6.4. To Step Through Parameters
When the page header (and sub-header) which contains the required parameter has been selected :-
Press
- (The Scroll Button)
This will access the first parameter on the page. At each subsequent press the next parameter in the list is displayed. This is a continuous list which will eventually return to the list header.
If the scroll button,
, is held down the parameters auto advance.
Figure 3-7: Parameter Selection
J Tip:- To return to the Page Header at any time press .
This is a continuous loop
P
:LOOP 1 SETUP
v
Output Page
Press to go to the next page header.
S
:Pwr Low Limit
v
0
S
:Pwr High Limit
v
100.0
S
:OP Rate Limit
v
Off
S
:More Parameters
v
More values
This symbol is used as a prompt to selec t the next parameter in a list. It also indicates t hat a parameter is being displayed
This symbol is only displayed if the parameter is alterable
%
[%]
J Tip: See ‘Backscroll’ Section 3.8
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User Guide Part No HA026491 Issue 3.0 Apr-02 3-11
3.6.5. To Change Parameter Values
When the required parameter has been selected its value is shown in the lower part of the alpha-numeric readout.
To change a parameter value press
or - (The Raise or Lower Buttons)
If an attempt is made to change a read only parameter, the parameter value will be replaced by
------ as long as the or buttons are held. For many paramet e rs an upper and lower limit can be set. When changing a parameter value its new value must be within these limits.
Parameter values can be displayed in different ways depending upon the parameter type. Figure 3-8 below shows the different types of parameter and how their values are changed.
1. Numerical Values
2. Enumerated Values
3. Digital Values (e.g. programmer event outputs)
4. Parameter Addresses
Note:- The above examples are generally only available in configuration level, but are included here to illustrate the principle of operation.
Figure 3-8: Changing a Parameter Value
Press
or to change the P aram eter address. A cursor flashes under the parameter address indicating t hat it can be changed The parameter name for that address (if it exists) is shown in the lower right of the readout
S
:Upper Param
L1.PV
S
:Upper Param
L1.PV
v
00001:
Press to change from parameter address to paramet er name
Press or to c hange t he parameter name. A cursor flashes under the parameter name indicating that it can be changed
v
00001:
Press
to increase the value
Press
to decrrease the value
S
:Pwr High Limit
v
100.0
Press to step along the values. The selected value flas hes. Press
or to turn the val ue on or of f
Prg: 1 Seg: 4
Press
to show next state Press
to show previous state
S
:Program Status
v
Reset
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3-12 User Guide Part No HA026491 Issue 3.0 Apr-02
5. Text (User definable)
6. Time
Figure 3-9: Changing a Parameter Value (continued)
3.6.5.1. CONFIRMATION MECHANISM
When the or key is released, the display will blink after a period of 1.5 seconds, indicating that the new parameter value has been accepted. If any other key is pressed during the 1.5 second period the parameter value is accepted immediately.
There are exceptions for specific parameters. Examples of these are:­Output Power adjustment when in Manual mode. The value is written continuously as the
value is changed.
Alarm Acknowledge. If the Alarm Acknowl e dge is changed from ‘No’ to ‘Acknowledge’ a confirmation message appears. Press
key to confirm the change. If no key is pressed for
10 seconds the value is restored to its previ ous value.
v
0:00:00
PSP1 Dwell Time
Press
or to increas e or decrease the time setting.
This is an accelerating di splay.
The first character alt ernates between the character and _ indicat i ng t hat it can be changed
Press
or to change the character.
S
:Program Name
Program 1
Press to change to the next character
Press or to c hange t he character . Up to 16 characters can be conf i gured
Program 1
S
:Program Name
J Tip: See ‘Backscroll’ Section 3.8 to if you need to re-enter a previously entered
character.
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User Guide Part No HA026491 Issue 3.0 Apr-02 3-13
3.6.6. Parameter Tables
In subsequent chapters parameters are listed in tables. The format of these tabl es is shown in the example below:-
Column 1 gives the name of the parameter as it appears on the lower readout of the alpha-
numeric display. Column 2 is a description and possible usage of the parameter Column 3 is the range of values which can be set. . This may be a numerical value, eg -n
to +n, or the condition (enumerat ion) of a parameter, eg the parameter ‘Program
Status’ has enumerations ‘Run’, ‘Hold’, ‘Reset’. Column 4 is the default value of the parameter set during manufacture Column 5 is the access level required to change the value of the parameter. R/O is Read
Only.
Table Number:
(same as secti on)
Description of the page Page
Header
1
Parameter Name
2
Parameter Description
3
Value4Default5Access
Level
Program Number The num ber of the selected program L1 Segment Number The currently running segment
number
L1
PSP1 Type Program Setpoint 1 type L1 PSP1 Working SP Program Setpoint 1 working setpoint L1 PSP1 Target Program Setpoint 1 target setpoint L1 PSP1 Dwell Time Program Setpoint 1 dwell time L1
This is a continuous loop which returns to the list header
This User Guide generally includes parameters in Operation Level (Level 1). In some cases, where it is relevant to the descri ption of a feature, a parameter shown in Level 2 or 3 may also be included.
It should also be noted that a parameter or a list of parameters can be pr omoted from a higher level (L3) to a lower level (L1) when the controller is configured by the user. If this has been done it will be necessary to refer to the 2604 Engineering Handbook, part number HA 026761,for further information.
Any parameter available in a lower access level is also availabl e in a higher level.
Note:­A parameter only appears if it is relevan t to the configuration of the controller. For example, a programmer configured as Time to Target will not display the Rate parameter.
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3.7. SPECIFIC DISPLAYS FOR CASCADE, RATIO, OVERRIDE AND VALVE POSITION
When the loop select button is pressed the upper and middle readouts generally show PV and SP, see section 3.5. If t he loops are configured as Cascade, Ratio, Override or Motor Valve Control the parameters displayed, specific to these configurations, are shown in the table below:-
Loop Main Aux Type Auto Manual Auto Manual
Upper Middle Upper Middle Upper Middle Upper Middle
Single
PVWSPPVWOP-- --
Cascade
PV WSP PV WOP Aux
PV
Aux WSP
Aux PV
WOP
Override
PV WSP PV WOP Aux
PV
Aux WSP
Aux PV
WOP
Ratio
PV WSP PV WOP RatioPVRatioSPRatioPVWOP
If any loop is configured as V al ve P osition, WO P i s replaced by Valve Position
In sections 3.5.1 and 3.5.2 it was shown how to access and change S e tpoint when in Auto and Output Power when in Manual. If t he loops are configured as Cascade, Ratio, Override or Motor Valve Control the specific par ameters displayed are shown in the table below:-
From the bar-graph display press
or
Loop Main Aux Type
Auto Main Loop Manual Main
Loop
Auto Aux Loop Manual Aux Loop
Single
Target SP Target OP -
-
Cascade
Target SP Target OP Target SP Target OP
Override
Target SP Target OP Override SP Target OP
Ratio
Target SP Target OP Ratio SP Target OP
If any loop is configured as V al ve P osition, Target OP is replaced by Valve Position If cascade is disabled Target SP reverts to Local S P.
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User Guide Part No HA026491 Issue 3.0 Apr-02 3-15
3.7.1. Loop Summary Parameters
When the Loop Select Button is pr essed a summary of the loop is displayed as shown in Figure 3-3.
Press
button to access up to 10 additional parameters which may have been promoted, in configuration level, to the loop summary page. If the loop types are configured as cascade, ratio or override some of these 10 parameters ar e pre-defined as shown in the following table.
Loop Main Aux
Type
Single
Working OP Target SP Plus up to 8 promoted
parameters
-
Cascade
Working OP Target SP Disable Csd Plus up to 7 promoted
parameters
Working OP Target SP Disable Csd Plus up to 7 promoted
parameters
Override
Working OP Target SP Disable OVR Active Loop Main OP Override OP Plus up to 4 promoted
parameters
Working OP OVR Target SP Disable OVR Active Loop Main OP Override OP Plus up to 4 promoted
parameters
Ratio
Working OP Target SP Enable Ratio Ratio Trim Lead PV Plus up to 5 promoted
parameters
Working OP Ratio SP Enable Ratio Ratio Trim Lead PV Plus up to 5 promoted
parameters
Note. If any of the loops have been configured as a programmer, the Working OP parameter is preceded by the Program Loop Summary display shown below:-
Prg: 1 Seg: 4
Program Name
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3.8. BACKPAGE
When stepping through list headers, a backpage short cut is provided by holding down and press . Each press of will step back one position of the list header in a
continuous loop.
This function is provided as a shor t cut and is not necessary to navigate through the pages.
3.9. BACKSCROLL
When stepping through parameters i n a list, a backscroll short cut is provided by holding down
and pressing . Each press of will step back to the previous parameter, until the
page header is reached.
This function is provided as a shor t cut and is not necessary to navigate through the parameters.
3.10. JUMP TO HOME DISPLAY
Press and together to return the display to the configured HOME screen.
3.11. INVALID KEY ACTIONS
At any time some state transitions may be invalid, due, for example, to contenti on with digital inputs or to the current operating st ate of the instrument. Examples are:-
1. Digital inputs have priority over the operator buttons.
2. If a parameter value cannot be changed the v prompt is not shown
3. If the
or button is pressed for a read only parameter a number of dashes, ----, is
displayed.
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3.12. PARAMETER AVAILABILITY AND ALTERABILITY
A parameter which appears on a page is described as available. Parameters are not availabl e if they are not appropriate for a particular configuration or instrument status. For example, relative cool gain does not appear in a heat only controller, and integral time does not appear in an On/Off controller.
A parameter described as alterable is, generally, preceded by the v symbol which indicates that its value can be changed. A parameter which is not alterable may be viewed (subject t o availability), but may be changed by an instrument algorithm.
A parameter is alterable only if the following conditions are satisfied:-
• The parameter is READ/WRITE
• The parameter does not conflict with the status of the instrument. For example, the
proportional band will not be alterable if autotune is active
• The instrument keys must be enabled. Keys can be disabled by a logic input, turned off in
configuration level or via digital communications. A logi c input can be configured to disable front panel keys; this will not remove remote control of the user interface via digital communications.
The Navigation Diagram which follows shows all pages which are available at Level 3. F or a particular configurati on not all pages are displayed on the controller. For example:­the programmer pages do not appear if a programmer is not configured; the Loop 2 and 3 set up pages do not appear for a single loop controller.
Any one or all of the pages shown in the navigation diagr am can also be displayed at Level 1 & 2. This, however, will have been pre-set in Configuration Level (see 2604 Engineering Manual Part No HA026761).
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4. CHAPTER 4 PROGRAMMER OPERATION .............2
4.1. CUSTOMISABLE PARAMETER NAMES.........................................2
4.2. WHAT IS SETPOINT PROGRAMMING ?........................................3
4.3. SETPOINT PROGRAMMER DEFINITIONS ....................................4
4.3.1. Run........................................................................................................4
4.3.2. Hold ......................................................................................................4
4.3.3. Reset......................................................................................................4
4.3.4. Servo.....................................................................................................4
4.3.5. Hot Start................................................................................................4
4.3.6. Power Fail Recovery.............................................................................4
4.3.7. Holdback (Guaranteed Soak)................................................................5
4.3.8. External Program Inputs........................................................................5
4.3.9. Wait.......................................................................................................6
4.4. PROGRAMMER TYPES.......................................................................7
4.4.1. Time To Target Programmer.................................................................7
4.4.2. Ramp Rate Programmer........................................................................7
4.5. SEGMENT TYPES.................................................................................7
4.5.1. Profile....................................................................................................7
4.5.2. Go Back Segment.................................................................................. 8
4.5.3. End Segment......................................................................................... 8
4.6. OTHER FEATURES NOT COVERED IN THIS USER GUIDE.......8
4.7. PROGRAMMER OPERATION............................................................9
4.7.1. To Run, Hold or Reset a Program.........................................................9
4.7.2. Run Parameters...................................................................................10
4.8. TO CREATE OR EDIT A PROGRAM..............................................14
4.8.1. To Define Parameters Common To A Program..................................15
4.8.2. PROGRAM EDIT (Program Page) Parameters..................................16
4.8.3. To Set Up Each Segment Of A Program.............................................18
4.8.4. PROGRAM EDIT(Segment Page) Parameters...................................19
4.9. EXAMPLES...........................................................................................21
4.9.1. Program Data Entry Example in a Ramp Rate Programmer ...............21
4.9.2. Prog Data Entry Example - Time to Target Programmer....................23
4.9.3. Holdback Example..............................................................................24
4.9.4. Wait Example......................................................................................25
4.9.5. Program Names example.....................................................................27
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4. Chapter 4 PROGRAMMER OPERATION
This chapter explains Setpoint Programming and how to Create, Edit and Run programs. Parameters which are associated with setpoint program operation are also listed in tables as a general reference.
Note: The 2604 controller is an application specific controller and can be conf igured to the preferences of a particular process, site or even user. This means that the displays shown in this and following chapters may not be identical to those shown in your instrument. Displays shown in italics are user definable and may, therefore, vary between instruments.
About this Chapter
This chapter describes:
◊ The meaning of setpoint programs ◊ Setpoint programming terminology ◊ Programmer types ◊ How to run, hold or reset a program ◊ How to create or edit a program ◊ Examples of how to set up specific features of a program
4.1. CUSTOMISABLE PARAMETER NAMES
Throughout this chapter parameter names shown in italics are customisable by the user when in configuration access level. The name of the parameter may vary, therefore, from instrument to instrument.
Typical customisable parameter names are:
Program names Profile Setpoint names
Segment names
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4.2. WHAT IS SETPOINT PROGRAMMING ?
In a setpoint programmer you can set up a profile in the controller in whi c h the setpoint varies in a pre-determind way over a period of time. Temperature is a very common application
where it is required to ‘ramp’ the process value from one level to another over a set period of time.
The 2604 controller will program up to three separate profiles. These may be temperature, pressure, light level, humidity, etc., depending on the appl ication, and are referred to as
Profiled Setpoints (PSPs).
The Program is divided into a flexible number of Segments - each being a single time duration, - and containing details for each profiled setpoint. The total number of segments available is 100 per program with a maximum of 500.
The 2604 programmer may store up to 20 programs as standar d, with up to 50 if purchased, and works on a single timebase for all programs.
It is often necessary to switch external devices at particular times during the program. Digital ‘event’ outputs can be programmed to operat e during those segments. An example containing three profil e setpoints and two event outputs is shown below.
Figure 4-1: A Setpoint Program
Segment
Profile
Setpoint1
Profile
Setpoint 2
Profile
Setpoint 3
Start (Run) 2h1h 3h 4h 5h 6h 7h 8h Time
Program
2
1
16 X Digital Events
PV
Segment 1 Tar
g
et
Segment 1
Time
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4.3. SETPOINT PROGRAMMER DEFINITIONS
This section defines the more common para meters to be found when running a 2604 programmer /controller. For an explanation of further features see the Engineering Handbook part no HA026761.
4.3.1. Run
In run the programmer varies the setpoint in accordance with the profile set in t he act ive program.
4.3.2. Hold
In hold the programmer is frozen at its current point. In this state you can make temporary changes to program parameters such as a target setpoint, ramp rates and dwells (if programmer configured for ramp rate) or segment duration (if programmer confi gured as Time to Target). Such changes will only remain effective until the end of the currently running segment, when they will be overwritten by the stored program values.
4.3.3. Reset
In reset the programmer is inactive and the controller behaves as a standard controller, with the setpoint determined by the raise/lower buttons.
4.3.4. Servo
Servo can be set in configuration so that when a program is run the setpoint can start fr om t he initial controller setpoint or from the current process value. Whichever it is, the starting point is called the servo point. This can be set in the program. Servo to PV will produce a smooth and bumpless start to the process. Servo to SP may be used in a Ramp Rate programmer to guarantee the time period of the first segment. (Note: in a Time to Target programmer the segment duration will always be determined by the setting of the Segment Duration parameter.)
4.3.5. Hot Start
Hot start can occur in any segment type, for any PSP but is most useful to ramp segments. When run is initiated it allows the program to automatically advance to the correct point in the profile which corresponds to the operati ng temperature of the process. Hot start i s enabled in configuration level and specifies whi ch programmed variable to use when deciding the correct segment.
4.3.6. Power Fail Recovery
In the event of power fail to the controller, a strategy may be set in configuration level, which defines how the controller behaves on restorat ion of the power. These strategies include:
Continue The program runs from the last setpoint. This may cause full
power to be applied to the process for a short peri od to heat the process back to its value prior to the power failure
Ramp back This will ramp the process value back to its original value at a
controlled rate. This will be the last encountered rate.
Reset The process is aborted by resetting the pr ogr am
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4.3.7. Holdback (Guaranteed Soak)
Holdback freezes the program if the process value (PV) do es not track the setpoint (SP) by an amount that can be set by the user. It may operate in any PSP type.
In a Ramp it indicates that the PV is lagging the SP by more than a settable amount and that the program is waiting for the process to catch up.
In a Dwell it freezes the d well time if the difference between the SP and PV exceeds set table limits.
In both cases it guarantees the correct soak period for the product.
Example: Holdback applied to a ramp up and a dwell.
Figure 4-2: Effect of Holdback to Produce Guaranteed Soak
4.3.8. External Program Inputs
Digital inputs may have been configured to allow the program to be operated by exter nal sources.
Run Allows the program to be run from a pushbutton or other event Hold Allows the program to be held from a switch or other event. Reset Allows the program to be reset from a pushbutton or other event. Run/Hold Allows the program to be run or held from a single external source Run/Reset Allows the program to be run or reset from a single external sour ce Advance Segment Selects the next segment from an external source Advance Program Selects the next program from an external source. When this event
occurs, the controller display will change to programmer view. Subsequent changes of this source will cause the program number to increment.
Holdback disabled Disables holdback from an external source
SP as set in the program
SP as modified by holdback follows the rate at which the process is capable
PV
PV lags SP. Holdback stops the ramp until SP cat ches up. Set by a deviation low alarm
Dwell starts when PV reaches correct value
Dwell held if PV
falls beyond limit s
Dwell extended by t1+t2
t1
t2
SP/PV
Time
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4.3.9. Wait
An event can be configured at the end of each segment, which, when active, will cause the program to wait before progressing to the next segment. Three wait conditions are provided which may be wired, in configuration level, to an external source using digital inputs or to internal sources, e.g. a loop alarm. Each segment may then select No-Wait, Wait on Event A, Wait on Event B or Wait on Event C. The program will not proceed until all profile segments are complete.
Figure 4-3: Wait Events
Event OP
Event OP
Event A or digital input
Event B or digital input
WaitA
WaitB
WaitC
Programmer
Segment 1 Segment 2 Segment 3
Wait = Wait on Event A
Wait = OFF
Wait = Wait on Event B
Segment 1 extended by the wait period
Segment 3 extended by the wait period
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4.4. PROGRAMMER TYPES
The programmer can be configured as Time to Target or Ramp Rate. A time to target programmer requires fewer settings and i s simple to use since all segments are the same. A time to target programmer can, in general contain more segments than a ramp rate.
4.4.1. Time To Target Programmer
Each segment consists of a single duration parameter and a set of target values for the profiled variables.
1. The duration specifies the time that the segment takes to change the profiled variables
from their current values to the new targets.
2. A dwell type segment is set up by leaving the ta r get setpoint at the previous value.
3. A Step type segment is set up by setting the segment time to zero.
4.4.2. Ramp Rate Programmer
Each segment can be specified as Ramp Rate, Dwell or Step.
1. Each profiled setpoint must complete its segment before the programmer will move to the
next segment. If one ramp reaches its target setpoint ahead of the ot her variables, it will dwell at that value until the other variables have completed. The program will then move to the next segment.
2. The duration parameter for a segment is read only unless the segment contains only
dwells. In this case the dwell peri od can be changed when the program is in Hold..
3. The duration is determined by the longest profile setting.
4.5. SEGMENT TYPES
A segment type can be defined as Profile, Go Back or End.
4.5.1. Profile
A profile segment may be set as:-
Ramp The setpoint ramps linearly, from its current value to a new
value, either at a set rate (c al l ed
ramp-rate programming
), or in a
set time (called
time-to-target programming).
You must specify the ramp rate or the ramp t i me, and the target setpoint, when creating or modifying a program.
Dwell The setpoint remains constant for a specified period at the
specified target. When creating programs the target is inherited from the previous segment. When edit i ng an existing program it is necessary to re-enter the target value. This allows the dwell target to be matched t o a go-back segment.
Step The setpoint steps instantaneously from its current value t o a
new value at the beginning of a segment.
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4.5.2. Go Back Segment
Go Back allows segments in a program to be repeated by a set number of times. It is the
equivalent of inserting ‘sub-programs’ on some controllers. Figure 4-4 shows an example of a program which is required to re peat the same section a number of times and then conti nue the program. A Go Back segment is used to save the total number of segments r e quired in a program and to simplify setting up. W hen pl anning a program it is advisable to ensure that the end and start setpoints of the program are the same otherwise it will step to the different levels. A Go Back segment is defined when editing a program.
Figure 4-4: An Example of a Program with Repeating Section
4.5.3. End Segment
The last segment in a program is normally def ined as an End segment The program either ends, repeats or resets in th i s segment. You specify which is the case when you create, or modify, the program. When the program ends, the programmer is put into either, a continuous dwell state wi th all outputs staying unchanged, or the reset state.
4.6. OTHER FEATURES NOT COVERED IN THIS USER GUIDE
Other programmer features, described in the Engineering Handbook, are:-
Program User Values Chapter 6 Pattern Generator Chapter 14 Program, Segment and other user defined names Chapter 6
Segment 1
Segment 2
Segment 7Segments 3 to 6
At this point Go Bac k to segment 3
Segment 6 is defined as a Go Back segment
This section is repeat ed ‘ n’ t i mes
PV
Time→
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4.7. PROGRAMMER OPERATION
4.7.1. To Run, Hold or Reset a Program
A selected program may be run, reset or held as follows:
1. Press the RUN/HOLD button once, the RUN beacon will illuminate. Press the
RUN/HOLD button again, the HOLD beacon will illuminate. Press and hold the RUN/HOLD button for 3 seconds, the program will reset and both beacons will extinguish.
2. If digital i nputs have been configured and wired for an external RUN, HOLD or RESET,
activate the relevant digi tal input.
3. By selecting the P rogram Status parameter (in the Run List). This met hod may be
preferred if the number of the program to be r un must also be selected.
4.7.1.1. To Run, Hold or Reset a Program from the Run List
Do This This Is The Display You
Should See
Additional Notes
1. From any display pres s as many times as
necessary until the
‘PROGRAM RUN’ (General Page) header is
displayed
2. Press
3. Press
4. Press
5. Press until ‘Program
Status’ is displayed
6. Press
or to select
‘Run’
This page provides access to paramet ers of a
running program.
Prg: 1 Seg 1
Program 1
Shows selected program number, current segm ent number and name of the program. Text shown in
italics
is user definable
S
:Program Status
v
Reset
The choices are:-
Run see 4.3.1 Hold see 4.3.2 Reset see 4.3.3
v
General Page
Prg: 1 Seg 1
0:06:56
Shows the program time remaining
Prg: 1 Seg 1
v
Shows the current status of the event ouputs.
 (YHQW2Q
= Event Off Up to 16 may be configured
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4.7.2. Run Parameters
The Run list provides status infor mation on a running program, as follows:-
Table Number:
4.7.2a.
These parameters show the status of the overall program
PROGRAM RUN
(General Page)
Parameter
Name
Parameter Description Value Default Access
Level
Program Number R/O These Segment Number displays may be Program Name promoted by the Digital outputs states. L1. Can be user as an Only appears if digital changed in over-view of the outputs configured Hold program status Program
Time
Remaining
R/O
Fast Run Allows the program to fast
run
Warning!
Fast run allows the program to be tested by quickly running through the program segments. If the controller is connected to the process , ensure that it is not af fected if fast run is selected.
The default value, No, m eans that the program will run at the set rate
No
Yes
L3. Alterable in reset or complete
Program Status Displays the status of the
program
Reset
Run
Hold
Complete
L1.
Prog Time Elap Program t i me elapsed d: h: m: s R/O Prog Cycle Rem Remaining number of cycles 1 to 999 R/O Total Segments Number of segments in the
running program
0 to 100 R/O
Segment Number
The currently running segment number
1 to 100 R/O
Segment Type Running program segment
type Profile = normal segment Go Back =repeat part of prog
Profile
End
Segment
Go Back
R/O
Prg: 1 Seg: 4
Program Name
Prg: 1 Seg: 4
d h: m: s
Prg: 1 Seg: 4
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Seg Time Rem Time remaining in the current
segment
d: h: m: s L1. Read or
alterable if Time To Target prog and in Hold
Wait Status Wait Status No Wait
Event A Event B Event C
R/O
Wait Conditi on Wait condition for the running
segment
No Wait Event A Event B Event C
L1. Alterable in Hold
Prog User Val 1 Programmer User Val ue 1
currently active
Usr 0 to 99 L1
Prog User Val 2 Programmer User Val ue 2
currently active
Usr 0 to 99 L1
PID Set PID values used in running
program
PID Set 1 to PID Set 3
R/O - Only shown if configured
Goback Rem Number of repeat cycles
remaining
1 to 999 R/O
End Action The state required in the end
segment
Dwell Reset
R/O
Prog Reset DO These are the di gi tal events
in Reset
R/O Only shown
if configured.
Note: The above table shows a complete list of al l possible parameters. If a feature is not configured parameters associated with that feature will not show.
S
:Prg Reset DO
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4-12 User Guide Part No HA026491 Issue 3.0 Apr-02
Table Number:
4.7.2b.
These parameters are associated with Profiled Setpoint number 1
PROGRAM RUN
(PSP1 Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
Seg Time Rem Segment time remaining h: m: s PSP1 Type Running segment type for
profiled setpoint 1
Step Dwell Ramp
R/O - shown in Ramp Rate prog.
PSP1 WSP Working setpoint for profiled
setpoint 1
Display range
1
L1. Alterable in Hold
PSP1 Target Running segment target for
profiled setpoint 1
Display range
1
L1. Alterable in Hold
PSP1 Dwell Tm Time remaining in running
segment for profiled S P 1
Display range
L1. Alterable in Hold
PSP1 Rate Running segment rate for
profiled setpoint 1
Display range
1
L1. Not in Time To Target prog
PSP1 HBk Appl Holdback applied for profiled
setpoint 1
No Yes
R/O - shown if configured
1. Range limited by us er defined upper and lower limits
Note: The above table shows a complete list of al l possible parameters. If a feature is not configured parameters associated with that feature will not show.
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Table Number:
4.7.2c
These parameters are associated with PSP2 and only appear if PSP2 is configured
PROGRAM RUN
(PSP2 Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
Seg Time Rem Segment time remaining h: m: s PSP2 Type Running segment type for
profiled setpoint 2
Step Dwell Ramp
L1. Read Only shown in Ramp Rate prog.
PSP2 WSP Working setpoint for profiled
setpoint 2
Display range
1
L1. Alterable in Hold
PSP2 Target Running segment target for
profiled setpoint 2
Display range
1
L1. Alterable in Hold
PSP2 Dwell Tm Time remaining in running
segment for profiled S P 2
Display range
L1. Alterable in Hold
PSP2 Rate Running segment rate for
profiled setpoint 2
Display range
1
L1. Not in Time To Target prog
PSP2 HBk Appl Holdback applied for profiled
setpoint 2
No Yes
L1. Read only shown if configured
1. Range limited by us er defined upper and lower limits
Note: The above table shows a complete list of al l possible parameters. If a feature is not configured parameters associated with that feature will not show.
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4-14 User Guide Part No HA026491 Issue 3.0 Apr-02
Table Number:
4.7.2d
These parameters are associated with PSP3 and only appear if PSP3 is configured
PROGRAM RUN
(PSP3 Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
Seg Time Rem Segment time remaining h: m: s PSP3 Type Running segment type for
profiled setpoint 3
Step Dwell Ramp
L1. Read Only shown in Ramp Rate prog.
PSP3 WSP Working setpoint for profiled
setpoint 3
1
Display range
L1. Alterable in Hold
PSP3 Target Running segment target for
profiled setpoint 3
1
Display range
L1. Alterable in Hold
PSP3 Dwell Tm Time remaining in running
segment for profiled S P 3
Display range
L1. Alterable in Hold
PSP3 Rate Running segment rate for
profiled setpoint 3
1
Display range
L1. Not in Time To Target prog
PSP3 HBk Appl Holdback applied for profiled
setpoint 3
No Yes
L1. Read only shown if configured
1
Range limited by user defined upper and l ower limits
Note: The above table shows a complete list of al l possible parameters. If a feature is not configured parameters associated with that feature will not show.
4.8. TO CREATE OR EDIT A PROGRAM
• A running program cannot be edited, it must be put into Reset mode.
• Changes can be made to remaining segments of a running program but these are
‘temporary’ changes which apply only to the current run. These changes will not apply to subsequent runs.
• Other programs can be created or edited when anot her program is running. To create or edit a program it is first necessary to define the effect that various parameters wi ll
have on the overall program. These parameters will be found under the page header PROGRAM EDIT (Program Page), see section 4.8.1. and 4.8.2.
When these parameters have been defined then set up the parameters which define each individual segment. These parameters will be found under the page header PROGRAM EDIT (Segments Page), see section 4.8.3. and 4.8.4.
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4.8.1. To Define Parameters Common To A Program
Do This This Is The Display You
Should See
Additional Notes
1. From any display pres s as many times as
necessary until the ‘PROGRAM EDIT’ page header is displayed
2. Press
if necessary to
select ‘Program Page’
3. Press
. to select ‘Edit
Prog: 1’. This is the first
parameter in the list
4. Press
or to choose the program number to be edited. The second line of the lower readout will change to the program name. This is shown in
italics
to indicate that the program name is user definable.
5. Press
. to select. the next parameter in the list. This is ‘HBk Mode’.
6. Continue pressing
to access the further parameters in this page
7. Continue pressing
or
to change the
parameter values or states
The PROGRAM EDIT page is not available in Access levels 1 & 2.
It is available as read only in View Config level
The upper display shows the selected program number.
The middle display shows the total number of segments
Up to 20 programs as standard. 50 programs as an option.
v
v
S
-HBk Mode
Ä
v
Edit Prg: 1
Program 1
0

Further parameters may be set up in the same way. These are listed together with an explanation of their function in the following table
This enables Holdback. The choices are:­None Per Program Per Segment
v
S
:PSP1 HBk Type
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4.8.2. PROGRAM EDIT (Program Page) Parameters
Table
Number:
4.8.2
These parameters affect the overall program. Only shown at Level 3.
PROGRAM EDIT
(Program Page)
Parameter
Name
Parameter Description Value Defau lt Access Level
Edit Prg: 1 Sel ects the program
number to be edited
1 to 20 or 1 to 50
1L1
Hbk Mode Holdbac k mode
None = no holdback applied
Per prog = common to prog
Per seg = active in every segment
None Per Program Per
Segment
None L1
PSP1 HBk Type
Holdback type for PSP1 These are deviation
values between setpoint and process value
Off Low High Band
Off L1
Only displayed if Holdback Mode = Per Program
PSP1 Hbk Value
Holdback value for PSP1 SP1 hi limit
to SP1 lo limit
0L1
Only displayed if HBk Type
Off The next four parameters are only displayed if PSP2 and PSP3 are configured PSP2 Hbk
Type
Holdback type for PSP2 These are deviation
values between setpoint and process value
Off Low High Band
Off L3
PSP2 Hbk Value
Holdback value for PSP2 SP1 hi limit
to SP1 lo limit
0L3
PSP3 Hbk Type
Holdback type for PSP3 These are deviation
values between setpoint and process value
Off Low High Band
Off L3
PSP3 Hbk Value
Holdback value for PSP3 SP1 hi limit
to SP1 lo limit
0L3
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Hot Start PSP
Allows hot start to be applied to each PSP.
See also 6.2.5.
None PSP1 PSP2 PSP3
None L3. Onl y
appears if Hot Start option has been enabled in config level.
Rate Units Rate units for a Ramp
Rate Programmer
Per Second Per Minute Per Hour
L3. Only displayed if the programmer is Ramp Rate
Prog Cycles Sets the number of times
the complete program i s executed.
Continuous to 999
Continuous L1
End Action Defines the action in the
end segment. Dwell - the program will
dwell indefinitely at the conditions set in t he end segment, see 6.5. 3.
Reset - the program will reset to the start conditions.
Dwell Reset
L1
Program Name
Allows a user defined name to be given to the program number
User string L1
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4-18 User Guide Part No HA026491 Issue 3.0 Apr-02
4.8.3. To Set Up Each Segment Of A Program
Do This This Is The Display You
Should See
Additional Notes
.
1. From any display pres s as many times as
necessary until the ‘PROGRAM EDIT’ page header is displayed
2. Press
if necessary to
select Segment Page
3. Press
. To select. Edit
Prg: 1. This is the first
parameter in the list
4. Press
or to choose the program number to be edited
5. Press
. To select. Segment Number.
6. Press
or to choose the segment t o be edited
7. Continue pressing
to access the further parameters in this page
8. Continue pressing
or
to change the
parameter value or state
This page allows each segment to be edited.
Ä
P
: PROGRAM EDIT
v
Further parameters may be set up in the same way. These are listed together with an explanation of their function in the following table
The upper display shows the selected program number
The middle display shows the current segment number
v
S
:Segment Number
If the program exists, go to next parameter.
If the program is new, confirm as inst ructed on the display
Edit Prg: 2
P
Cancel SOK
D
v
Edit Prg: 1
Program 1
After x
secs or when P is pressed the display returns to that shown above
Up to 100 segments are available per program
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User Guide. Part No HA026491 Issue 3.0 Apr-02 4-19
4.8.4. PROGRAM EDIT(Segment Page) Parameters
Table Number:
4.8.4.
These parameters allow you to set up each segment in the program
PROGRAM EDIT
(Segment Page)
Parameter
Name
Parameter Description Value Default Access
Level
Edit Prg: 1 (to 20 or 50)
Selects the program number and name
1 to 20 (or 50)
L1
Segment Number
Selects the segment number to be edited
1 to 100 L1
Segment Type Segment type
Profile = a normal segment End Segment = the last
segment in the program (press S to confirm)
Go Back = repeat part of prog. Not shown for segment
1.
Profile End
Segment Go Back
Profile L1
PSP1
Type
Profile setpoint 1 type Step
Dwell Ramp
L1. Only shown for Ramp Rate programmer and not End
PSP1
Target
Profile setpoint 1 target value SP1 lo limit
to SP1 hi limit
0L1
PSP1
Dwell Tm
Profile setpoint 1 dwell time d : h : m : s L1. Onl y
shown for Ramp Rate programmer , a Dwell segment and not End
PSP1
Rate
Profile setpoint 1 rate L1. Only
shown for Ramp Rate programmer , a ramp segment and not End
PSP1
Hbk Type
Profile setpoint 1 holdbac k type
Off Low High Band
Off L1. Only
shown if holdback is configured per segment
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The above five parameters are repeated for
PSP2
and
PSP3
if they are configured
Seg Duration Duration for Time to Target
programmer
d : h : m : s L1. Does
not appear for Ramp Rate Programmer or End segment
Wait Event Wait i f selected event is true No wait
Event A Event B Event C
No Wait L1. Only
shown if wait events configured
Prog User Val 1
Allows a programmer user value to be chosen.
Only appears if Prog User Val 1 is configured
0 to 100 0 L1
Prog User Val 2
Allows a programmer user value to be chosen.
Only appears if Prog User Val 2 is configured
0 to 100 0 L1
PID Set Selects a set of PID values PID S et 1
to PID Set 3
L3. Only shown if PID sets configured
Prog DO Values S et s programmer event
outputs on or off
L1. Only shown if Dout configured
Go Back Seg Allows repeat segments to be
set up within a profile. Go back defines the point i n t he program where the repeat segments are entered.
1 to number of segments
L1. Only shown if segment. type is Go Back
Go Back Cycles Sets up the number of times
the segments are repeated
1 to 999 1 L1. Only
shown if segment. type is Go Back
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4.9. EXAMPLES
4.9.1. Program Data Entry Example in a Ramp Rate Programmer
Do This The Display You Should See Additional Notes
1. Select the PROGRAM
EDIT (Segment Page)
2. Press
to select Edit
Prg: 1
3. Press
or to select
the program to be edited
4. Press
to select
Segment Number
5. Press
or to select
segment (1)
6. Press
to select
Segment Type
7. Press
or to select
Profile
8. Press
to select
PSP1
Type 1
9. Press
or to select
Ramp
10. Press
to select
PSP1
Target
11. Press
or to set the setpoint which to ramp to
12. Press
to select
PSP1
Rate
13. Press
or to set the rate at which you wish to ramp to setpoint
P
:PROGRAM EDIT
v
Segment Page
Program 1
Edit Prg: 1
Select:­Profile for a normal segment
End for an end segment GoBack to repeat
segments in the program
The setpoint will ramp to 40
S
:Segment Type
vProfile
S
:
PSP1
Target
v
40
S
:
PSP1
Type
v
Ramp
Select:­Ramp to ramp the set poi nt up or down
Dwell to dwell Step to jump from the
current setpoint to a new target
S
:
PSP1
Rate
v
1
The setpoint will ramp to 40 at the rate of 1 unit per sec, min or hour.
If
PSP1
Type = Dwell
This parameter is Dwell Tm If
PSP1
Type = Step
This parameter is omitted
S
:Segment Number
v1
The name of the program may have been customised
If this is a new program, the message ‘Create Prog 1?’ will be displayed.
Press
to confirm
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4-22 User Guide Part No HA026491 Issue 3.0 Apr-02
If PSP 2 is configured, steps 4 to 7 are repeated for PSP2. If PSP 3 is configured, steps 4 to 7 are again repeated for PSP3.
If Wait Events are configured:-
If Digital Event Outputs have been Configured:-
J Tip:- To avoid scrolling through parameters you do not need to change, press to
return to the page header, then
to select Segment Number.
v
No Wait
14. Press
to select Wait
Event
15. Press
or to select
the wait event
S
:Wait Event
The choice are:­No Wait Event A Event B EventC
See also 6.6.4
The first digital output will alternate between
and indicating that it c an be changed.
= Off
= On
16. Press
to select Prg
DO Values
17. Press
or to select the digital out put event to be On or Off
18. Press
to scroll through each event output in turn
19. Press
to return to
Segment Number
20. Press
or to select the next required segment and repeat the above.
S
:Segment Number
v1
S
:Prg DO Values
S
:Prg DO Values
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4.9.2. Prog Data Entry Example - Time to Target Programmer
This is the same as the previous procedure except that there are no Dwell, Rat e or Step segments. They are all Time segments. From the PROGRAM EDIT (segment Page) header:-
Do This This Is The Display You
Should See
Additional Notes
J Tip:- To avoid scrolling through parameters you do not need to change, press to
return to the page header, then
to select Segment Number.
1. Press to select
Segment Number
2. Press
or to
select the segm ent
3. Press
to select
Segment Type
4. Press
or to
select Profile
5. Press
to select PSP1
Target
6. Press
or to set the start level of the segment (if neces s ary)
7. Press
to select Seg
Duration
8. Press
or to set the segment time
9. Press
as many times as necessary to select Segment Number again
10. Press
or to select the next segment (2) and repeat the above.
For any segment 1, this value will normally be inherited from the Target level of the previous segment.
S
:Segment Type
vProfile
S
:PSP1 Target
v40
S
:Seg Duration
v
0:01:00
The setpoint will ramp to 40 at the rate of 1 unit per sec, min or hour
As in the previous example, if
PSP2, PSP3
, Wait Events and Event Outputs have been configured they will appear here.
S
:Segment Number
v1
For a ramp
PSP1
- Seg
No. 1&
PSP1
- Seg No. 2
will be different values. For a dwell
PSP1
Seg No.
1&
PSP1
- Seg No. 2 will
be the same value.
S
:Segment Number
v2
The choices are :­Profile End Segment Go Back for segment s after the first
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4.9.3. Holdback Example
To apply holdback (see also 6.2.8) to each segment of the program or to the overall program, follow this procedure:-
Do This This Is The Display You
Should See
Additional Notes
1. Select the PROGRAM EDIT
(Program Page)
2. Press
until Edit Prg: is
displayed
3. Press
or to choose the required program
4. Press
to display HBk
Mode
5. Press
or to choose Per Program (or Per Segment)
6. Press
to select PSP1
HBk Type
7. Press
or to choose Low, (or High or Band)
8. Press
to select PSP1
HBk Val
9. Press
or to choose the value which will hold the program
10. Repeat the above steps for
PSP2
and
PSP3
if
configured
To select the page header which contains the holdback parameters
P
:PROGRAM EDIT
v
Program Page
S
:Hbk Mode
v
Per Program
S
:PSP1 HBk Type
v
Low
Only appears if Holdback has been configured.
If per program is chos en press
or to choose the holdback type to be applied to the whole program.
If per segment is chosen the parameter Holdback Type does not appear.
P
:PSP1 HBk Val
v
5
If holdback per segm ent is chosen the holdback type can be chosen for each segment but the holdback value is the same for each segment.
In this example holdback will occur in any segment of the program if the PV falls by more than 5 unit s below the SP.
Edit Prg: 2
Program 2
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4.9.4. Wait Example
The wait feature prevents the programmer from proceeding to the next segment if an event is
true (see also section 4.3.9.). It only applies to controllers which have been ‘wired’ for wait events in configuration level . If the controller has been configured for ‘Wait’, the operator can set up the conditions as follows:-
Do This This Is The Display You
Should See
Additional Notes
1. Select the PROGRAM EDIT page header, and select
Segment Page
2. Press
until the parameter Wait Event is displayed
3. Press
or to choose the event on which the programmer should wait eg Event A
P
:PROGRAM EDIT
v
Segment Page
S
:Wait Event
v
Event A
This selects the Wait Event which will prevent the program from proceeding to the next segment. The choices are:-
No Wait
The wait condition does not apply to the selected
segment Event A (B or C)
The selected
segment will
wait for event
A (B or C) to
become false
before the
program
continues
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4-26 User Guide Part No HA026491 Issue 3.0 Apr-02
4.9.4.1. Wait Example - How Wait is Displayed in Run Mode
The status of the Wait conditi on is displayed in a running program as follows:-
Do This This Is The Display You
Should See
Additional Notes
1. Select the PROGRAM
RUN (General Page)
2. Press
until the parameter Wait Status is displayed
3. Press
once - the parameter Wait Condition is displayed
4. Press
or to override the condition (No Wait), or to select a different event (Event A (B or C).
P
:PROGRAM RUN
v
General Page
v
No Wait
S
:Wait Status
The status is off i f not waiting and true if waiting. The choices are:-
No Wait
The program is not waiting
Event A (B or C)
The program is waiting on event A (B or C)
v
Event A
S
:Wait Condition
The condition for the running segment is displayed. The choices are:-
No Wait
The program is not waiting
Event A (B or C)
The program is waiting on event A (B or C)
v
No Wait
S
:Wait Condition
The condition can be changed if the program is in Hold
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4.9.5. Program Names example
To produce a user defined program name:-
Do This This Is The Display You
Should See
Additional Notes
1. Select the PROGRAM
EDIT (Program Page)
page header
2. Press
until Program
Name is displayed
3. The first charac ter alternates between _ and P
4. . Press
or to change the character to one of your choice
5. Press
to select the
next character
6. Press
or to change the next character to one of your choice
P
:PROGRAM EDIT
v
Program Page
Program 1
S
:Program Name
Program 1
is the default
name of a program. A full range of characters
is available including capitals, numbers and common sym bol s
Program 1
S
:Program Name
Repeat the above steps until t he program name of your choice is displayed. A name of up to 16 characters can be entered. This name will be displayed on every view which contains Program Name.
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Page 86
2604 Controller Alarm Operation
5. CHAPTER 5 ALARM OPERATION...........................2
5.1. DEFINITION OF ALARMS AND EVENTS........................................2
5.1.1. Customisable Parameter Names............................................................2
5.2. TYPES OF ALARM USED IN 2604 CONTROLLER.........................3
5.2.1. Grouped Alarms ....................................................................................4
5.3. HOW ALARMS ARE INDICATED......................................................5
5.3.1. To Acknowledge an Alarm ...................................................................5
5.3.2. Alarm Delay Time.................................................................................6
5.4. THE ALARM SUMMARY PAGE ........................................................7
5.4.1. Alarms (Summary) Parameters..............................................................8
5.5. ALARM ACKNOWLEDGEMENT ......................................................9
5.6. TO SET ALARM TRIP LEVELS........................................................11
5.7. ALARM PARAMETERS.....................................................................12
5.7.1. ALARMS (LP1 Page) Parameters.......................................................12
5.7.2. ALARMS (PV Input Page) Parameters...............................................13
5.7.3. ALARMS (An Input Page) Parameters...............................................13
5.7.4. ALARMS (Module 1 Page) Parameters..............................................14
5.7.5. ALARMS (User 1 Page) Parameters...................................................14
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Alarm Operation 2604 Controller
5-2 User Guide Part No HA026491 Issue 3.0 A pr-02
5. Chapter 5 ALARM OPERATION
5.1. DEFINITION OF ALARMS AND EVENTS
Alarms are used to alert an operator when a pre-set level has been exceeded. They are
normally used to switch an output – usually a relay – to provide external actions to the process.
Soft Alarms are indication only and do not operate an output. Events are generally defined as conditions, which occur as par t of the operation of the plant.
They do not require operator int e r vention and, therefore, do not cause an alar m message to be displayed. They can be attached to operate an output (relay) in the same way as an alarm.
5.1.1. Customisable Parameter Names
Throughout this chapter parameter names shown in italics are customisable by the user when in configuration access level. The name of the parameter may vary, therefore, from instrument to instrument.
Typical customisable parameter names are:
Alarm names Loop names Module and input names Custom units Promoted parameters
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2604 Controller Alarm Operation
5.2. TYPES OF ALARM USED IN 2604 CONTROLLER
This section shows graphically the operation of different types of alarm used in t he cont roller. The graphs show changes in PV plotted against time.
Full Scale Low
On On
Deviation Low
On On
Deviation High
On
Deviation Band
On On On
Full Scale High
On
Rate of Change
On
Figure 5-1: Types of Alarm
Rate of change alarms detect if the rate of change in PV, set as units per minute or per second, exceeds the setpoint value. An alarm setpoint set + will detect positive rates of change. An alarm setpoint set - will detect negative rates of change. Therefore, if it is required to measure the rate of change in both di r ections then two alarms must have been configured. Since rate of change alarms are calculated over a period of time a small delay may be apparent before the alarm is indicated. This is generally only noticeable if the PV changes very quickly.
Time
Full Scale High
Full Scale Low
Deviation High
Deviation Low
PV
Rate of Change
Process Variable (PV)
Alarm
Type
Output
State
Deviation
Band
Setpoint (SP)
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Alarm Operation 2604 Controller
5-4 User Guide Part No HA026491 Issue 3.0 A pr-02
Deviation Alarms. The setpoint used f or deviation alarms is normally derived as a remote input from another device - for example, a temperature controller. The setpoi nt can also be internally set within the controller - in this case called the local setpoint value.
Blocking Alarms only occur after the start up phase when the alarm has first entered a safe state. The alarm is only indicated the next time it is acti ve. It is used, for example, to i gnore start up conditions which are not representative of running conditions.
Hysteresis is the difference between the point at which the alarm switches ON and the point at which it switches OFF. It is used to prevent relay chatter.
Delay a settable time between an alarm occur ring and it being displayed on the indicator Latching Alarms The alarm is indicated until it is acknowledged by the user.
Acknowledgement of an alarm can be through the contr oller front buttons, from an external source using a digital input t o the controller or through digital communications.
There are two ways that the alarm can be acknowledged:
1. Automatic Reset. The alarm continues to be active until both the alarm condition is
removed AND the alarm is acknowledged. The acknowledgement can occur BEFORE the alarm condition is removed.
2. Manual Reset. The alarm continues to be active until both the alarm condition is
removed AND the alarm is acknowledged. The acknowledgement can only occur AFTER the alarm condition is removed.
5.2.1. Grouped Alarms
Alarms can be associated with different aspects of the process. They are grouped in accordance with the functions they perform as follows:
Loop Alarms
Alarms associated with each control loop. Examples are: High, Low, Deviation and Rate of Change. Two alarms are available for each loop. On a new controller these are the only alarms which are configured - those listed below must be enabled in configuration level, see 2604 Engineering Handbook HA026761.
PV Input Alarms
Alarms which operate on the PV input. Examples are: High and Low. Two alarms are available with this input.
Analogue Input Alarms
Alarms which operate on the analogue input. Examples are: High and Low. Two alarms are available with this input.
Module Alarms
Alarms which operate on each plug in module. These can be input or output alarms depending upon the function of the module fitted. These alarms are associated with modules 1, 3, 4, 5, & 6, since module 2 is reserved as a an extra memory module
User Alarms
Eight undedicated alarms which can be wired to any variable.
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2604 Controller Alarm Operation
5.3. HOW ALARMS ARE INDICATED
When an alarm occurs the red ALM beacon in the middle display will flash. This will be accompanied by a message on the lower display which will indicate the source and the type of alarm. The format of this alarm message is:
If a relay has been connected to the output of the alarm the relay it will operate to allow an external beacon or audible device to be activated.
Events will not cause either a message or the beacon to be illuminated.
5.3.1. To Acknowledge an Alarm
Press P+S as instructed. The action which follows depends upon the type of alarm configured.
If the alarm is non latching Any relay connected to the alarm output will be reset
The red alarm beacon will illuminate permanently if the alarm condition still exists The red alarm beacon will extinguish as soon as the alarm condition no longer exists
Alarm is latching – ‘Auto’ Any relay connected to the alarm output will remain set if the
alarm condition still exists The red alarm beacon will illuminate permanently if the alarm condition still exists As soon as the alarm condition is no longer present the alarm beacon will extinguish and any relay will be reset
Alarm is latching – ‘Manual’ Any relay connected to the alarm output will remain set if the
alarm condition still exists The red alarm beacon will illuminate permanently if the alarm condition still exists The alarm indication and any relay connected to it must now be reset. This may be done as described in section 5.4 ‘The Alarm Summary Page’, or by choosing the appropriate Alarm Page, select ‘Alarm Ack’ - set to ‘Yes’, Press S as instructed.
This section describes the usual method to acknowl edge an alarm. Section 5.5 describes alternative ways.
%
:
LP1
Press P+S to Ack
%
:
LP1
Full Scale Low
Alarm source (user defi nabl e text)
Alarm mess age
Alarm source Instruction
Alternating message
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Alarm Operation 2604 Controller
5-6 User Guide Part No HA026491 Issue 3.0 A pr-02
5.3.2. Alarm Delay Time
A delay time may have been set for each alarm between the occurrence of the alarm and the indication of the alarm in the contr ol ler. This is useful to prevent spur ious alarms from being indicated in some noisy or rapidly changing processes. To set delay time the controller must be placed in Configuration level. This is described in the 2604 Engineering Handbook Part No HA026761.
If you notice a delay between an alarm occurring and it being indicated by the controller then a delay may have been set in conf iguration level.
L
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2604 Controller Alarm Operation
5.4. THE ALARM SUMMARY PAGE
The status of alarms is displayed in the Alarm Summary page. To i nspect the status:
Do This This Is The Display You
Should See
Additional Notes
1. From any display pres s as many times as
necessary until the
‘Alarms’ page (Summary) header is
displayed
2. Press
The first
parameter displayed is
‘New Alarm’
3. Press
to see the
alarm
4. Press .
or to
acknowledge - ‘Yes’
5. Press
as instructed
To access the Alarm Summary page header.
S
:New Alarm
No
v
Summary Page
No There are no new
alarms
Yes One or more new
alarms have occurred since the last acknowledgement
Further pages only appear if the alarms have been configured.
The first of these pages i s
‘
LP1 Alm 1-2’
This shows the name of the alarm in the upper readout
The lower readout alternates between the alarm type and an invitation to acknowledge
Note: Customised Parameter name in
italics
:
LP1 Alm 1 & 2
P
→Cancel S→OK
S
:
LP1 Alm 1 & 2
Full Scale Low
S
:
LP1 Alm 1 & 2
Ack:
v
No
A full list of pos sible alarm parameters in this page i s given in the following table
Ä
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Alarm Operation 2604 Controller
5-8 User Guide Part No HA026491 Issue 3.0 A pr-02
5.4.1. Alarms (Summary) Parameters
Table Number:
5.4.1
These parameters indicate alarm status ALARMS
(Summary Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
New Alarm Only available over digital
communicat i ons to flag that a new alarm has occurred
No Yes
L1 R/O
LP1 Ack
Status and acknowledge loop 1 alarms
No Yes
L1
LP2 Ack
Status and acknowledge loop 2 alarms
No Yes
L1
LP3 Ack
Status and acknowledge loop 3 alarms
No Yes
L1
PV Input Ack
Status and acknowledge PV input alarms
No Yes
L1
An Input Ack
Status and acknowledge analogue input alarms
No Yes
L1
Module 1 Ack
Status and acknowledge module 1 alarms
No Yes
L1
Module 3 Ack
Status and acknowledge module 3 alarms
No Yes
L1
Module 4 Ack
Status and acknowledge module 4 alarms
No Yes
L1
Module 5 Ack
Status and acknowledge module 5 alarms
No Yes
L1
Module 6 Ack
Status and acknowledge module 6 alarms
No Yes
L1
User 1 Ack
Status and acknowledge User 1alarm
No Yes
L1
to to
User 8 Ack
Status and acknowledge User 8 alarm
No Yes
L1
Ack All Acknowledges all alarms No
Yes
L1
Page 94
2604 Controller Alarm Operation
5.5. ALARM ACKNOWLEDGEMENT
A new alarm can be acknowledged in five ways:
1. By pressing
and simultaneously
2. Through the alarms ‘Summar y’ page
3. Through the ‘Alar ms’ page
4. From an external sour ce, such as a pushbutton, connected to a suitably conf igured digital
input
5. Through digital communications The message will remain on the screen and the alarm symbol, %, will continue to flash until
the alarm is acknowledged - you are prompted to do this by pressing
and
simultaneously. The symbol will stop flashing and remain illuminated until all alarm conditions are removed. If a further alarm occurs the symbol will start flashing again and a new alarm message will pop up.
The message displayed indicates the source of the alar m and may be customised to the users terminology. The source will inherit the name of the channel or the loop or the user alarm name.
The operation of the alarm acknowledgement depends whether the alarm is non-latching or latching, auto or manual reset. This is shown in the following tables:-
Non Latched Alarms
Alarm Condition
Acknowledge Symbol
%
Message Ext rel ay
(if fitted)
ON No Flashing Alarm message On Off No Off Former display Off
Alarm Condition
Acknowledge Symbol
%
Alarm message Ext relay
(if fitted)
ON No Flashing Alarm message On On Yes Steady Former display Off Off Off Former message Off
Latched Alarm - Auto
Alarm Condition
Acknowledge Symbol
%
Message Ext rel ay
(if fitted)
ON No Flashing Alarm message On Off No Flashing Alarm message On Off Yes
Alarm Condition
Acknowledge Symbol
%
Message Ext rel ay
(if fitted)
ON No Flashing Alarm message On ON Yes Steady
S
:Access Level
Off
Off - Off Normal display Off
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Alarm Operation 2604 Controller
Latched Alarm - Manual
Alarm Condition
Acknowledge Symbol
%
Message Ext rel ay
(if fitted)
ON No Flashing Alarm message On Off No Flashing Alarm message On Off Yes Off Access Level Off
Alarm Condition
Acknowledge Symbol
%
Message E xt rel ay
(if fitted)
ON No Flashing Alarm message On ON Yes Steady Former display Off Off - Steady Former dis pl ay Off Off To acknowledge
see below
Off Former display Off
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2604 Controller Alarm Operation
5.6. TO SET ALARM TRIP LEVELS
The alarm trip level (setpoint) i s available in access level 1 and is adjusted by accessing the page header for the chosen alarm. The following example adjusts these parameters for Alarm 1/Loop 1:
Do This This Is The Display You
Should See
Additional Notes
1. From any di splay press as many times as necessary
to access the ‘ALARMS’
menu
2. Press
or to select
the source of the alarm, in
this example ‘
LP1’
3. Press to display the Alarm Type
4. Press
again to display
the ‘Alm1 setpoint’
5. Press
or to adjust
the value
This example sets the alarm trip level to 173
O
C.
Other units will be shown if they have been
Text
‘LP1’
is user
definable. The alarm type must have
been selected in config level, otherwise the alarm parameters will not be available
Alm1 Type is read only. The alarm type is set in
configuration level
v
LP1
Page
S
:
Alm1
Type
Full Scale High
S
:
Alm1
Setpoint
[
o
C] v173.0
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Alarm Operation 2604 Controller
5.7. ALARM PARAMETERS
The parameter tables listed in this section are only displayed if an alarm has been configured for the particular loop, input or module.
5.7.1. ALARMS (
LP1
Page) Parameters
Table Number:
5.7.1.
These parameters set up the Loop 1 alarms ALARMS
(
LP1
) Page
Parameter Name Parameter Descrip ti on Value Default Access
Level
Alm1 Type Al arm 1 Type
Off Full Scale Low Full Scale
High Deviation
Band Deviation High Deviation Low Rate of
Change If True If False Goes True Goes False If Changed
R/O
LP1 Ack Acknowledges alarms on
loop 1
No Yes
L1
Alm1 Setpoint Alarm 1 Setpoint Controller
range
L1
Alm1 Output Alarm 1 output
Off On
Off R/O
Alm2 Type Al arm 2 Type As Alm1 Type R/O Alm2 Setpoint Alarm 2 Setpoint Controller
range
L1
Alm2 Output Alarm 2 output
Off On
Off R/O
The above table is repeated for L P2 and LP3 if these control loops have been configured.
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2604 Controller Alarm Operation
5.7.2. ALARMS (PV Input Page) Parameters
Table Number:
5.7.2.
These parameters set up the alarms associated with the PV input signal.
ALARMS
(PV Input Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
PV Alarm Ack Alarm acknowledge for PV
input
No Yes
No L1
FS Hi Setpoint Full Scale High Alarm (1)
Setpoint
Controller range
L1
FS Hi Output Full Scale High al arm (1)
output
Off On
Off R/O
FS Lo Setpoint Full Scale Low Alarm (2)
Setpoint
Controller range
L1
FS Lo Output Full Scale Low alarm (2)
output
Off On
Off R/O
5.7.3. ALARMS (An Input Page) Parameters
Table Number:
5.7.3.
These parameters set up the alarms associated with the analogue input signal.
ALARMS
(An Input Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
An Alm Ack Group alarm acknowledge
for analogue input
No Yes
No L1
FS Hi Setpoint Full Scale High alarm (1)
Setpoint
Controller range
L1
FS Hi Output Full Scale High al arm (1)
output
Off On
Off R/O
FS Lo Setpoint Full Scale Low Alarm (2)
Setpoint
Controller range
L1
FS Lo Output Full Scale Low alarm (2)
output
Off On
Off R/O
Page 99
Alarm Operation 2604 Controller
5.7.4. ALARMS (Module 1 Page) Parameters
Table Number:
5.7.4.
These parameters set up the alarms associated with module 1.
ALARMS
(Module 1 Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
Module 1 Ack Group alarm acknowledge
for module 1
No Yes
No L1
FS Hi Setpoint Full Scale High alarm (1)
Setpoint
Controller range
L1
FS Hi Output Full Scale High al arm (1)
output
Off On
Off R/O
FS Lo Setpoint Full Scale Low Alarm (3)
Setpoint
Controller range
L1
FS Lo Output Full Scale Low alarm (3)
output
Off On
Off R/O
The above table is repeated for: Module 3 Module 4 Module 5 M odule 6
5.7.5. ALARMS (User 1 Page) Parameters
Table Number:
5.7.5.
These parameters set up user defined alarms.
ALARMS
(User 1 Page)
Parameter Name Parameter Descrip ti on Value Default Access
Level
Alm1 Type Al arm 1 Type
Same as
5.7.1.
R/O
User 1 Ack Group alarm acknowledge
for user alarm 1
No Yes
No L1
Setpoint Al arm 1 Setpoint Control l er
range
L1
Output Alarm 1 output Off
On
Off R/O at
L1
The above table is repeated for: User alarm 2 User alarm 3 User alarm 4 User alarm 5 User alarm 6
User alarm 7 User alarm 8
Page 100
2604 Controller Appendix A
User Guide. Part No HA026491 Issue 3.0 Apr-02 A-1
A. APPENDIX A ORDER CODE ....................................2
A.1. HARDWARE CODE..............................................................................2
A.2. CONFIGURATION CODING (OPTIONAL)......................................3
A.3. QUICK START CODE EXAMPLE:.....................................................4
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