Eurotherm Invensys 2408, Invensys 2404 Installation And Operating Handbook

Installation and operation
handbook

2404

2408

CONTROL SETPOINT
PROGRAMMER

ENG

Installation and Operat i on Handbook Contents

Issue 10.0 Nov-04 Appli es to 2408 and 2404 controller software version 4.0 i

MODELS 2408 and 2404 PID CONTROLLERS

INSTALLATION AND OPERATION HANDBOOK

Contents Page

Chapter 1 INSTALLATION .................................................................1-1

Chapter 2 OPERATION ......................................................................2-1

Chapter 3 ACCESS LEVELS..............................................................3-1

Chapter 4 TUNING..............................................................................4-1

Chapter 5 PROGRAMMER OPERATION ..........................................5-1

Chapter 6 CONFIGURATION .............................................................6-1

Chapter 7 USER CALIBRATION........................................................7-1

Appendix A UNDERSTANDING THE ORDERING CODE...................A -1

Appendix B SAFETY and EMC INFORMATION..................................B-1

Appendix C TECHNICAL SPECIFICATION……….……………………C-1
Appendix D LOAD CURRENT MONITORING AND DIAGNOSTICS..D-1

Appendix E PROFIBUS COMMUNICATIONS….……………………....E-1

“This product is covered by one or more of the following US Patents:

5,484,206; Additional patents pending.

PDS and INSTANT ACCURACY are trademarks of Eurotherm.”

Issue 10 of this handbook applies to software version 4.

Contents Installation and Operation Handbook

ii Issue 10.0 Nov-04 Appli es to 2408 and 2404 controller software version 4.0

Enhancements to Software Version 4

The following enhancements have been added to software versions 4.

• Isolated Single Logic Output Module

• Transducer Power Supply Module to provide 5 or 10Vdc to an external transducer. (Not

intended for melt pressure control)

• DeviceNet communication s

• Linear over range limits are +5% of high instrument range and –5% of low instrument

range for all process input ranges (i.e. 0-20mA, 4-20mA, 0-10V)

• Sensor break or input open circuit faults are detected on all analogue inputs (PV1.PV2

and remote input channels)

• PV2 alarm, full scale high and low limits default to maximum and minimum display

limits

• Deviation alarms are not inverted when direct acting control is selected. Alarm

behaviour when using reverse acting control is unchanged

• The PD track valve positioning parameter (Pd.tr) has been removed

Controllers Affected:-

Standard controllers – which include
programmers with up to 4 programs

Version 4.11 or later

Setpoint programming controllers with up to
20 programs

Version 4.61 or later

Profibus controllers – which include
programmers with up to 4 programs

Version 4.32 or later

• The 10Amp output relay in module 4 is not available on controllers supplied after Jan 04

Related Information

• DeviceNet Communications Handbook part no. HA027506 which includes the

parameter address map.

• Profibus Communications Handbook part no. HA026290

• EMC (Electromagnetic Compatibility) Installation Guide, part no. HA025464

These are available on www. eu rotherm.co. uk.

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-1

Chapter 1 INSTALLATION

Figure 1-1 2408 1/8 DIN controller

Figure 1-2 2404 1/4 DIN controller

Panel retaining clips

Ratchets

Sleeve

Terminal covers

Label

Latching ears

Panel sealing gasket

Display screen

Panel retaining clips

Ratchets

Sleeve

Terminal covers

Label

Latching ears

Panel sealing gasket

Display screen

Installation Installation and Operat i on Handbook

1-2

2

408 and 2404 Controller

Outline dimensions Model 2408

Outline dimensions Model 2404

The electronic assembly of the controller plugs into a rigid plastic sleeve, which in turn fits
into the standard DIN size panel cut-out shown in Figures 1-3 and 1-4.

2408

OP 1 OP2

SP2 REM

AUTO

MAN

RUN

HOLD

Figure 1-3

Outline dimensi ons of Model 2408 controller

150mm

5.91in

48mm

1.89in

96mm

3.78in

150mm

5.91in

96mm

3.78in

96mm

3.78in

2404

OP 1

OP2

SP2

REM

AUTO

MAN

RUN

HOLD

Panel cut-out

92 x 92 mm

3.62 x 3.62 in

-0

+0.8

-0

+0.03

Panel

cut-out

92 x 45mm

3.62x1.77in

-0

+0.8

-0

+0.6

-0

+0.03

-0

+0.02

38mm
(1.5in)

10mm
(0.4in)

(Not to
scale

)

Recommended

m

inimum s pacing

of controllers

R

ecommended
minimum
spacing of
controllers

38mm
(1.5in)

10mm
(0.4in)

(Not to
scale

)

Figure 1-4 Outline dimens i ons Model 2404 controller

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-3

INTRODUCTION

Models 2408 and 2404 are high stability, temperature or process controllers with self and
adaptive tuning. They have a modular hardware construction which accepts up to three plug­in Input/Output modules and two interface modules to satisfy a wide range of control
requirements. Two digital inputs and an optional alarm relay are included as part of the fixed
hardware build.

The instruments are available as:

• standard controllers - which include a basic 8-segment programmer
Models 2408/CC and 2404/CC

• setpoint programming controllers: Models 2408/CP, P4, CM and
2404/CP, P4, CM

• motorised valve controllers - which include a basic 8-segment programmer
Models 2408/VC and 2404/VC

• setpoint programming motorised valve controllers: Models 2408/VP, V4, VM and
2404/VP, V4, VM

Before proceeding, please read the chapter called, Safety and EMC Information.

Controller labels

The labels on the sides of the controller identify the ordering code, the serial number, and the
wiring connections.

Appendix A, Understanding the Ordering Code, explains the hardware and software
configuration of your particular controller.

MECHANICAL INSTALLATION

To install the controller

1. Prepare the control panel cut-out to the size shown in Figure 1-3, or 1-4.

2. Insert the controller through the panel cut-out.

3. Spring the upper and lower panel retaining clips into place. Secure the contro ller in
position by holding it level and pushing both retaining clips forward.

Note: If the panel 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.

Unplugging and plugging-in the controller

If required, the controller can be unplugged from its sleeve by easing the latching ears
outwards and pulling it forward out of the sleeve. When plugging the controller back into its
sleeve, ensure that t he latching ears click into place in order to secure the IP65 sealing.

Installation Installation and Operat i on Handbook

1-4

2

408 and 2404 Controller

NEW SLEEVE DESIGN MKIII

From Jan-03 an improved design of 1/8 DIN long sleeve is shipped with all new 2408
controllers and indicators. (The month and year of manufacture are shown in the last two
pairs of digits of the instrument serial number).

Details

A new sealing gasket will be fitted onto the instrument bezel !. This gasket replaces the
gasket which was moulded into the front of the sleeve of all previous instruments.
The gasket previously moulded into the sleeve where it fits behind the panel is now supplied
as a separate item ".

Reasons for the Change

This change is to ensure that IP65 sealing is reliably achieved and less physical effort is
required to insert the instrument into the new sleeve.

Recommendations

1. An instrument delivered after Jan 03 should be used with the sleeve supplied

2. If the instrument i s required to replace one already in use, the existing sleeve should
also be replaced

3. A new instrument can be fitted into an existing sleeve by carefully removing gasket
! but IP65 sealing will not be maintained

4. An existing instrument can be fitted into a new sleeve but IP65 sealing will not be
maintained

It is, however, possible to achieve IP65 sealing for 3 and 4 above. A gasket kit is available by
quoting Part No SUB24/GAS2408.
Then:-

5. To fit a new instrument in an older sleeve carefully remove gasket !. Replace it
with the thinner (1.25mm) gasket from the kit

6. To fit an existing instrument into a new sleeve fit the thicker (1.6mm) gasket from
the kit between th e i nstrument and the sleeve

The seal " supplied as a separate item with a new instrument, should be placed over the
sleeve prior to mounting it through the panel cut out as shown below:-

Panel

New

Instrument

Sleeve seal "
(supplied as a
separate item)

Instrument

sleeve

New gasket ! fitted onto bezel

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-5

ELECTRICAL INSTALLATION

This section consists of five topics:

• Rear terminal layouts

• Fixed connections

• Plug-in module connections

• Typical wiring diagrams

• Motorised valve connections.

WARNING

You must ensure that the controller is correctly configured for your application.
Incorrect configuration could result in damage to the process being controlled, and/or
personal injury. It is your responsibility, as the installer, to ensure that the configuration
is correct. The controller may either have been configured when ordered, or may need
configuri ng now. See Chapter 6, Configuration.

Model 2408 rear terminal layout

Figure 1-5 Rear terminal layout − Model 2408

* The ground connection is provided as a return for internal EMC filters. It is not required
for safety purposes, but must be connected in order to satisfy EMC requirements.

N

L

V+

VI

V-

Line
Neutral

G

round

*

2

D

2

B

2

A

2C

3

D

3

B

3

A

3

C

1

D

1

B

1

A

1

C

M

O D U L E

1

M O D U L E

3

M

O D U L E

2

J

F

J

D

JE

C

O M M S

2

Common

Input 1

Input 2

85 to 264Vac

L

C

LA

LB

AC

A

A

AB

A

larm

relay

H

F

H

D

H

E

C

O M M S

1

H

B

HA

H

C

JB

JA

JC

+

−

+

PV

−

R

TD/Pt100

T/C

Note: The plug-in sleeve suppl i ed with
high voltage controllers are keyed to

p

revent a low voltage unit being insert ed

into them.

20 − 29Vac/dc

Ground

*

24

24

Low voltage supply

Installation Installation and Operat i on Handbook

1-6

2

408 and 2404 Controller

All electrical connections are made to the screw terminals at the rear of the controller. If you
wish to use crimp connectors, the correct size is AMP part number 349262-1. They accept
wire sizes from 0.5 to 1.5 mm

2

(16 to 22 AWG). The terminals are protected by a clear

plastic hinged cover to prevent han ds, or metal, making accidental contact with live wires.

Rear terminal layouts

The rear terminal layouts are shown in Figures 1-5 and 1-6. The right-hand column carries
the connections to the power supply, digital inputs 1 and 2, alarm relay and sensor input. The
second and third columns from the right carry the connections to the plug-in modules. The
connections depend upon the type of module installed, if any. To determine which plug-in
modules are fitted, refer to the ordering code and wiring data on the controller side labels.

Model 2404 rear terminal layout

Figure 1-6 Rear terminal layout − Model 2404

RTD/Pt100

N

L

V+

VI

V-

L

ine

N

eutral

G

round*

2D

2B

2A

2C

3D

3B

3A

3C

1D

1B

1A

1C

M

O D U L E 1 M O D U L E 3 M O D U L E 2

HF

HD

HE

C

O M M S 1

JF

JD

JE

C

O M M S 2

C

ommon

Input 1

Input 2

85 to 264Vac

LC

LA

LB

AC

AA

AB

A

larm

relay

−

+

PV

−

T/C

HB

HA

HC

JB

JA

JC

+

5B

5A

4D

4B

4A

4C

20 − 29Vac/dc

Ground

*

24

24

Low voltage supply

6D

6C

6B

5D

5C

6A

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-7

Sensor input connections

The connections for the various types of sensor input are shown below.

Fig 1-7 Sensor input connections

PLUG-IN MODULE CONNECTIONS

Module 1, 2 and 3

Module positions 1, 2 and 3 are plug-in modules. They can be either two terminal modules of
the types shown in Figure 1-7, or four terminal modules of the types shown in Table 1-1.

The tables show the connections to each module and the functions that they can perform.
Module 1 is normally used for heating and module 2 for cooling although the actual functions
will depend upon how the controller has been configured.

PDS modes

Table 1-8 refers to PDS modes 1 and 2.
PDS stands for ‘Pulse Density Signalling’ Input/Output. This is a proprietary technique for
bi-directional transmission of analogue and digital data over a simple 2-wire connection.
PDS 1 mode uses a logic output module to control aTE10S solid state relay and provides a
load failure alarm.
PDS 2 mode uses a logic output module to control a TE10S solid state relay, provide
load/SSR failure al arms, and read back the load current for display on the controller.

VI

V+

V-

VI

V+

V-

VI

V+

V-

VI

V+

V-

Thermocouple

Resistance
thermometer

mA input Volts or mV inputs

+

-

PV

2.49Ω
current
sense
resistor

Installation Installation and Operat i on Handbook

1-8

2

408 and 2404 Controller

Two terminal modules

Note: Module 1 is connected to terminals 1A and 1B
Module 2 is connected to terminals 2A and 2B
Module 3 is connected to terminals 3A and 3B.

Terminal identit y
Module type A B C D P ossible functions
Relay: 2-pin

(2A, 264 Vac max.)

Unused Heating, cooling, al arm,

program event, valve

raise, or valve lower

Logic - non-isolated

(18Vdc at 20mA)

++++ −−−−

Unused Heating, cooling, P DS IO

mode 1, PDSIO mode 2,

program event

Triac

(1A, 30 to 264Vac)

Unused Heating, cooling,

program event, valve

raise, or valve lower

DC output:

- non-isolated

(10Vdc, 20mA max.)

++++ −

Unused Heating, or cooling, or

retransmission of PV,

setpoint, or cont rol output

Table 1-1 Two terminal module c onnections

Snubbers

The relay and triac modules have an internal 15nF/100Ω ‘snubber’ connected across their
output, which is used to prolong contact life and to suppress interference when switching
inductive loads, such as mechanical contactors and solenoid valves.

WARNING

When the relay contact is open, or the tri a c is off, the snubber cir c uit passes 0.6mA at
110Vac and 1.2mA at 240Vac. You must ensure that this current, passing through the
snubber, will not hold on low power electrical loads. It is your responsibility as the
installer to ensure that this does not happen. If the snubber circuit is not required, it can
be removed from the relay module (BUT NOT THE TRIAC) by breaking the PCB track
that runs crosswise, adjacent to the edge connectors of the module. This can be done by
inserting the blade of a small screwdriver into one of the two slots that bound it, and
twisting.

Line Load

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-9

Four terminal modules

Note: Module 1 is connected to terminals 1A, 1B, 1C and 1D
Module 2 is connected to terminals 2A, 2B, 2C and 2D
Module 3 is connected to terminals 3A, 3B, 3C and 3D

Module type Terminal identit y Possible func t i ons

A B C D

Relay: changeover

(2A, 264 Vac max.)

Heating, cooling,

alarm, or program

event output

DC control: Isol ated

(10V, 20mA max.)

++++ −−−−

Heating, or cooli ng

24Vdc transmitter

supply

+ −

To power process

inputs

Potentiomet er i nput

100Ω to 15KΩ

+0.5Vdc

0V

Motorised Valve

Position feedback

DC retransmission

+ −

Retrans. of setpoi nt,

or process value

DC remote input or

Process Value 2

(Module 3 only)

0-10Vdc RT source

±100mV

0-20mA

COM

Remote Setpoint

Second PV

Dual output modules

Dual relay

(2A, 264 Vac max.)

Heating + cooling

Dual alarms

Valve raise &

lower

Dual Triac

(1A, 30 to 264Vac)

Heating + cooling

Valve raise &

lower

Dual logic + relay

(Logic is non-isolated)

+ −

Heating + cooling

Dual Logic + triac

(Logic is non-isolated)

+ −

Heating + cooling

Triple logic input and output modules - see ratings on the next page

Triple contact input Input 1 Input 2 Input 3 Common

Triple logic input Input 1 Input 2 Input 3 Common

Triple logic output Output 1 Output 2 Output 3 Common

Program events

N/C

N/O

Line

Load

Line

Load

Line

Load

Installation Installation and Operat i on Handbook

1-10

2

408 and 2404 Controller

Module type Terminal identit y Possible func t i ons

A B C D

Isolated Logic

Output

+ -

This is a fully is ol ated module which can
be fitted in all t hree module slots. It may
be used for heating, cool i ng or events
outputs up to 18Vdc at 20mA.

Transducer

Power Supply

+ -

This provides fully isolated 5 or 10Vdc to
power external transmitters up t o 20mA. It
can be fitted in module slots 1 and 2.

Table 1-2 Four terminal module connections

Connections for Process Value 2 in module posi tion 3

The diagrams below show the connections for the various types of input.
The input will have been configured in accordance with the ordering code.

Triple Logic Input and output ratings

1. Triple logic input (current sinking)
OFF state: −3 to 5Vdc
ON state: 10.8 to 30Vdc(max), at 2 to 8mA

2. Triple contact closure or open collector transistor input
Internally generated switching Vdc & mA: 15 to 19Vdc at 10 to 14mA

OFF state >28KΩ input resistance
OFF state voltage >14Vdc
ON state <100Ω resistance
ON state voltage <1.0Vdc

3. Triple logic output (current sourcing)
OFF state output 0 to 0.7Vdc.
ON state output 12 to 13Vdc, at up to 8mA.

Thermocouple

3B

3C

3D

3A

+

−

C

urrent

sense

r

esistor

2.49Ω

mA input

3B

3C

3D

3A

+

−

Resistance
thermometer

3B

3C

3D

3A

Volts or
mV inputs

+

−

0-1.6Vdc

High Impedance

or

mVdc

3B

3C

3D

3A

10V inputs

+

−

0-10Vdc

3B 3C

3D

3A

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-11

COMMUNICATION MODULES 1 AND 2

All 2408 and 2404 controllers can be fitted with up to two plug-in communications modules.

Only one of the two modules can be for serial communications and this will normally be
installed in position COMMS 1 (although it is possible to install the serial communications
module in position COMMS 2. Serial communications may be configured for either Modbus
or EI bisynch protocol.

It is also possible to fit a PDS module in one or other of these positions.

Possible module types are shown in the table below.

Communications module 1

Terminal identit y (COMMS 1)
Module type HA HB HC HD HE HF
2-wire EIA-485 serial

communications

− − −

Common A (+)

B (−)

EIA-232 serial
communications

− − −

Common Rx Tx

4-wire EIA-485 serial
communications

− A′
(Rx+)

B′

(Rx−)

Common

A

(Tx+)

B

(Tx−)

PDS Setpoint retransmission

− − − −

Signal Common

Communications module 2

Terminal identit y (COMMS 2)
Module type JD JE JF
PDS Setpoint retransmission

−

Signal Common

PDS Setpoint input

−

Signal Common

Table 1-3 Communic ation modules 1 and 2 connections

Installation Installation and Operat i on Handbook

1-12

2

408 and 2404 Controller

Wiring of 2-wire EIA-485 serial communications link

Com

Note:

All resistors are 220 ohm 1/4W carbon composition.
Local grounds are at equipotential. Where equipotential is not available wire into
separate zones using a galvanic isolator.
Use a repeater (KD845) for more than 32 units.

A
B

PC

Eurotherm Universal

Communications Interface

KD485

RXTX

Com

Com

TXRX

Up to 32 S2000 controllers or
Interface Units may
be included on the network

232

Com B

A

Com

A
B

Com

A
B

Com

A
B

Local Earth

Local
Ground
Zone 1

Local
Ground
Zone 2

Area 1

Com

A
B

E

F

D

Local
Earth

HE
HF

HD

Series 2000
Controller

HE
HF

HD

Series 2000
Controller

For reasons of safety
do not connect to
local earth here.

Local
Earth

Local
Earth

Local
Earth

Local
Earth

Local
Earth

HE
HF

HD

Series 2000
Controller

Galvanic
Isolation

Barrier

Local
Ground
Zone 1

Local
Ground
Zone 1

Local
Ground
Zone 1

Figure 1-9 EIA-485 wiring

2-wire EIA-485 is a connect i on which al l ows up t o 32
controllers to be multi-

d

ropped from a single c ommunications
link over a distance of up to 1.2Km. To ensure reliabl e
operation of the com munications link, (without data
corruption due to noise or li ne reflections) the connecti ons

b

etween the controller should be made using a twisted pair of

w

ires inside a screened cable with the connections
terminated with resi stors in the manner shown in this
diagram. This diagram also shows the use of a KD485
converter to connect t he EIA-485 link into a standard E I A-

2

32

computer port.

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-13

DeviceNet

Instruments fitted with software versions 4 onwards can be fitted with DeviceNet
communications. The following shows the wiring connections for DeviceNet.

Terminal

Reference

CAN

Label

Color

Chip

Description

HA V+ Red DeviceNet network power positive terminal. Connect

the red wire of the DeviceNet cabl e here. If the
DeviceNet network does not supply the power,
connect to the pos i t i 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 connecti on. Connect the

DeviceNet cable shi el d here. To prevent ground
loops, ground the DeviceNet network in only one
location.

HD CAN_L B l ue DeviceNet CAN_L data bus terminal. Connect the

blue wire of the DeviceNet cabl e here.

HE V- Black DeviceNet network power negative term i nal .

Connect the black wire of the DeviceNet cable here.
If the DeviceNet network does not supply the power,
connect to the negati ve t erminal 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 include:

• 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 to the main supply earth terminal.

Installation Installation and Operat i on Handbook

1-14

2

408 and 2404 Controller

Example of Devicenet Wiring

To configure DeviceNet Communications see Chapter 6.

HA
HB

HC
HD
HE
HF

2400 Controller

(SLAVE)

A

ddress 11

V+
CAN-H

CAN-L

Drain

V-

V+ 5

CAN-H 4

CAN-L 2

Drain 3

V- 1

Red

Wht

Blu
Blk

* Fit 121!

resistor to

last instrument in

t

he

chain

Network

Supply

24Vdc ( +

1%)

250mV p-p

Ripple

HA
HB

HC
HD
HE
HF

2400 Controller

(SLAVE)

A

ddress N+1

V+

V-

V-

V+

Typical Interfac e

Card (MASTER)

Daisy chain to

further

instruments

121! terminating

r

esistor required if not

fitted internally

L
N
E

L
N
E

*

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-15

ProfiBus Wiring

Controllers supplied with model numbers 2408f and 2404f are fitted with ProfiBus
communications modules fitted in the H slot. Further details of ProfiBus communications is
given in Appendix E and the ProfiBus Communications handbook part number HA026290.
This handbook can be downloaded from www.eurotherm.co.uk

.

SHIELD

Station 1

HA

HB

HC

HD

HE

HF

Shield

VP (+5Vdc Voltage Potential)

B (Rx/Tx +ve)

A (Rx/Tx -ve)

DGND (Digital ground)

Not connected

B

390

Ω

Last Station

HA

HB

HC

HD

HE

HF

Shield

VP (+5Vdc Voltage Potential)

B (Rx/Tx +ve)

A (Rx/Tx -ve)

DGND (Digital ground)

Not connected

Intermediate stations

Last station only requires
terminating resistors

390

Ω

220

Ω

A

BAB

A

2408f or 2404f controller

2408f or 2404f controller

Twisted

pair

Twisted

pair

Installation Installation and Operat i on Handbook

1-16

2

408 and 2404 Controller

TYPICAL WIRING DIAGRAM

Fig 1-10 Typical wiring diagram, Model 2408 Cont rol l er

For logic drive capability see following chart:-

N

L

V+

VI

V-

2D

2B

2A

2C

3D

3B

3A

3C

1D

1B

1A

1C

M

O D U L E

3

HF

HD

HE

C

O M M S

1

JF

JD

JE

LC

LA

LB

AC

AA

AB

Cooling

Power Fuse

1A(T)

Heating power fuse

(load dependent)

Cooling

Solenoid

Heater

T/C

+

-

+

PV

-

Logic

h

eating

output

Triac

c

ooling

output

L

ine

N

eutral

C

ontroller

Fuse 2A(T)

Solid State

Relay *

+

−

C

O M M S

2

H

B

HA

H

C

Installation and Operat i on Handbook Installation

2408 and 2404 Controller 1-17

Logic Drive Fan Out

The logic outputs from the 2400 series controllers are capable of driving more than one solid
state relay (SSR) in series or parallel. The following table shows the number of SSRs which
can be driven depending on type of SSR. S = Series; P = Parallel.

Drive

mA

SVDA RVDA TE10S 425S

Logic

DC

Logic
DC

Logic
DC

Logic
10V

Logic
24V

Logic
20mA

Logic 18V@2

0

4S 6P 4S 3P 3S 2P 3S 3P 1S 2P 6S 1P

Triple
logic

12V@9 3S 3P 2S 1P 2S 1P 2S 1P 1 4S 1P

450 TC1027

CE

TE200S TC2000

CE

RS3D

A

Standard TTL Multi-

drive

Logic V Logic

DC

Logic
DC

Logic

DC
Logic 2S 3P 1S2P 6S 1P 3S 3P 3S 3P 3S 1P 4S 2P
Triple
logic

1 1 4S 1P 2S 1P 2S 1P 0 0

Installation Installation and Operat i on Handbook

1-18

2

408 and 2404 Controller

MOTORISED VALVE CONNECTIONS

Motorised valves will normally be wired either to dual relay, or dual triac, output modules
installed in the Module 1 position, or to single channel relay and triac outputs installed in
Module positions 1 and 2. In the latter case, the convention is to configure output 1 as the
raise output and output 2 as the lower output.
Depending on the configuration, control of the valve is achieved in one of three ways:

1. With no position feedback potentiometer.

2. With a feedback potentiometer used to monitor the valve’s position. It does not
influence the control.

3. With a feedback potentiometer, where the valve’s position is controlled in response to the
signal from it.

Fig 1-11 Motorised valve connections

N

L

V+

VI V-

Line

N

eutral

G

round

++++

−−−−

++++

PV

−−−−

2D

2B

2A

2C

3D

3B

3A

3C

1D

1B

1A

1C

M

O D U L E

2

HF

HD

HE

C

O M M S

1

JF

JD JE

C

O M M S

2

Common

Input 1

Input 2

8

5 to 264Vac

LC

LA

LB

AC

AA

AB

A

larm

relay

Motor supply

M

otorised

valve

R

A

I
S
E

L

O W E

R

Dual

relay, or

triac,

output

module

RTD/Pt100

H

B

HA

H

C

Motor

F

eedback

Potentiometer

(Optional)

++++

−−−−

Pot

Input

Module

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-1

Chapter 2 OPERATION

This chapter has nine topics:

• FRONT PANEL LAYOUTS

• BASIC OPERATION

• OPERATING MODES

• AUTOMATIC MODE

• MANUAL MODE

• PARAMETERS AND HOW TO ACCESS THEM

• NAVIGATION DIAGRAM

• PARAMETER TABLES

• ALARMS

Operation Installation and Operat i on Handbook

2-2

2

408 and 2404 Controller

FRONT PANEL LAYOUTS

2408

OP 1 OP2

SP2 REM

AUTO

MAN

RUN

HOLD

Figure 2-1 Model 2408 front panel layout

2404

OP 1

OP2

SP2

REM

AUTO

MAN

RUN

HOLD

Figure 2-2 Model 2404 front panel layout

O

utput 1

S

etpoint 2

Auto/Man button

Auto mode

Manual mode

Page

Button

Scroll

Button

Down

Button

Remote setpoint /
comms (flashing)

Output 2

U

pper

Lower readout

Program running

Program in Hold

Up

Button

Remote setpoint/
comms(flashing)

Output 2

Upper readout

Lower readout

Program running

Run/Hold button

Program in Hold

Up

Button

Output 1

Setpoint 2
Auto/Man

button

Auto mode

Manual mode

Page

Button

Scroll

Button

Down

Button

2408

2

404

OP 1 OP 2

OP 1 OP 2

SP2 REM

SP2 REM

Run/Hold

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-3

Button or

indicator

Name Explanation

OP1

Output 1

When lit , it indicates that t he out put installed in
module position 1 i s on. This is normally the
heating output on a tem perature controller.

OP2

Output 2

When lit , it indicates that t he out put installed in
module position 2 i s on. This is normally the
cooling output on a temperature controller.

SP2 Setpoint 2

When lit , this indicates that setpoint 2, (or a
setpoint 3-16) has been sel ected.

REM Remote setpoint

When lit , this indicates that a remote setpoint input
has been selected.
‘REM’ will also flash when communications is
active.

AUTO

MAN

Auto/Manual

button

When press ed, this toggles between automat i c
and manual mode:

• If the controller i s in automatic mode the AUTO
light will be lit.

• If the controll er i s in manual mode, the MAN
light will be lit.

The Auto/Manual button can be disabled in
configuration level.

RUN

HOLD

Run/Hold button

• Press once to s tart a program (RUN light on.)

• Press again to hold a program (HOLD light 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 of f)

The RUN light will flash at the end of a program .
The HOLD light will flash during holdback or when

a PDS retransmi ssion output is open circui t .

Page button Press to select a new list of parameters.

Scroll button Press to select a new parameter in a list.

Down button Press to decrease a value in the lower readout.

Up button Press to increase a value in lower readout.

Figure 2-3 Controller buttons and indi cators

Operation Installation and Operat i on Handbook

2-4

2

408 and 2404 Controller

BASIC OP ERATION

Switch on the power to the controller. It runs through a self-test sequence for about three
seconds and then shows the measured temperature, or process value, in the upper readout and
the target value, called the setpoint, in the lower readout. This is called the Home display.

2404

OP1

OP2

SP2

REM

AUTO

MAN

RUN

HOLD

Figure 2-4 Hom e di splay

You can adjust the setpoint by pressing the

or buttons. Two seconds after releasing

either button, the display blinks t o show that the contro l ler has accepted the new value.

OP1 will light whenever output 1 is ON. This is normally the heating output when used as a
temperature controller.
OP2 will light whenever output 2 is ON. This is normally the cooling output when used as a
temperature controller.

Note: You can get back to this display at any time by pressing

and together.
Alternatively, you will always be returned to this display if no button is pressed for 45
seconds, or whenever the power is turned on.

Alarms

If the controller det ects an alarm condition, it flash es an alarm message in the Home display.
For a list of all the alarm messages, their meaning and what to do about them, see Alarms at
the end of this chapter.

Measured temperature
or process value

Setpoint

SP2 REM

OP2

OP1

2

404

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-5

OPERATING MODES

The controller has two basic modes of operation:

• Automatic mode in which the output is automatically adjusted to maintain the

temperature or process value at the setpoint.

• Manual mode in which you can adjust the output independently of the setpoint.
You toggle between the modes by pressing the AUTO/MAN button. The displays which

appear in each of these modes are explained in thi s chapter.

Two other modes are also available:

• Remote Setpoint mode, in which the setpoint is generated from an external source.
In this mode, the REM light will be on.

• Programmer mode which is explained in Chapter 5, Programmer Operation.

Operation Installation and Operat i on Handbook

2-6

2

408 and 2404 Controller

A UTOMATIC MODE

You will normally work with the controller in automatic mode. If the MAN light is on, press
the AUTO/MAN button to select automatic mode. The AUTO light comes on.

Power on

x 2

The Home display

Check that the AUTO light is on.
The upper readout shows the measured temperature.
The lower readout shows the setpoint.
To adjust the setpoint up or down, press

or .

(Note: If Setpoint Rate Limit has been enabled, then the
lower readout will show the active setpoint. If

or
is pressed, it will change to show and allow adjustment
of, the target setpoint.)

Press once.

Display units

A single press of

will flash the display units for 0.5

seconds, after which you will be returned to the Home
display.
Flashing of the display units may have been disabled in
configuration in which case a single press will take you
straight to the display shown below.

Press

twice

% Output power demand

The % output power demand is displayed in the lower
readout. This is a read-only value. You cannot adjust it.
Press

and together to return to the Home display.

Press

Pressing

from the Output Power display may access further parameters. These may be in

this scroll list if the ‘Promote’ feature has been used (see Chapter 3, Edit Level). When you
reach the end of th i s scroll list, pressing

will return you to the Home display.

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-7

MANUAL MODE

If the AUTO light is on, press the AUTO/MAN button to select manual mode. The MAN
light comes on.

Power on

x 2

The Home display

Check that the MAN light is on.
The upper readout shows the measured temperature, or
process value. The lower readout shows the % output.
To adjust the output, press

or .

(Note: If Output Rate Limit has been enabled, then the
lower readout will show the working output. If

or
is pressed, it will change to show and allow adjustment of,
the target output.)

Press once.

Display units

A single press of

flashes the display units for 0.5
seconds, after which you are returned to the Home display.
Flashing of the display units may have been disabled in
configuration, in which case a single press will take you
straight to the display shown below.

Press

twice.

Setpoint

To adjust the setpoint value, press

or .

Press .

Pressing from the Output Power display may access further parameters. These may be in
this scroll list if the ‘Promote’ feature has been used (see Chapter 3, Edit Level). When you
reach the end of th i s scroll list, pressing

will return you to the Home display.

Operation Installation and Operat i on Handbook

2-8

2

408 and 2404 Controller

PARAMETERS AND HOW TO ACCESS THEM

Parameters are settings, within the controller, that determine how the controller will operate.
For example, alarm setpoints are parameters that set the points at which alarms will occur.
For ease of access, the parameters are arranged i n lists as shown in the n avi gation diagram on
Pages 2-10 and 2-11. The lists are:

Home list
Run list
Programming list
Alarm list
Autotune list

PID list
Motor list
Setpoint list
Input list
Output list

Communications list
Information list
Access list.

Each list has a ‘List Header’ display.

List header displays

Figure 2-5 Typical list header di splay

A list header can be reco gnised by the fact that it always shows ‘LiSt’ in the lower readout.
The upper readout is the name of the list. In the above example, ‘AL’ indicates that it is the
Alarm list header. List header displays are read-only.

To step through the list headers, press

. Depending upon how your controller has been
configured, a single press may momentarily flash the display units. If this is the case, a
double press will be necessary to take you to the first list header. Keep pressing

to step

through the list headers, eventually returning you to the Home display.
To step through the parameters within a particular list, press

.

When you reach the end of the list, you will return to the list header.
From within a list you can return to the current list header at any time can by pressing

.

To step to the next list header, press once again.

List name

A

lways displays ‘LiSt’

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-9

Parameter names

In the navigatio n diagram, each box shows the display for a selected parameter.
The Operator parameter tables, later in this chapter, list all the parameter names and their
meanings.

The navigation diagram shows all the parameters that can, potentially, be present in the
controller. In practice, a limited number of them appear, as a result of the particular
configuration.

The shaded boxes in the diagram indicate parameters that are hidden in normal operation. To
view all the available parameters, you must sel ect Full access level. For more information
about this, see Chapter 3, Access Levels.

Parameter displays

Figure 2-6 Typical parameter di splay

Parameter displays show the controller’s current settings. The layout of parameter displays is
always the same: the upper readout shows the parameter name and the lower readout its value.
In the above example, the parameter name is 1FSL (indicating Alarm 1, full scale low), and
the parameter value is 10.0.

To change the value of a parameter

First, select the required parameter.
To change the valu e, press either

or . During adjustment, single presses change the
value by one digit.
Keeping the button pressed speed s up the rate of change.
Two seconds after releasing either button, the display blinks to show that the controller has
accepted the n ew value.

Parameter nam e

Parameter value

Operation Installation and Operat i on Handbook

2-10

2

408 and 2404 Controller

NAVIGATION DIAGRAM (PART A) (The parameters that appear depend upon how

the controller has been c onfigured)

Figure 2-7a Navigation diagram (P art A)

Home

List

P

rogrammer

List

(1)

Alarm

L

ist

A

utotune

List

Motor

List

(3)

Atun

LiSt

ProG

LiSt

Hb

OFF

PrG.n

1

Hb V

20

dwL.U

Hour

rmP.U

Hour

CYC.n

1

tYPE

rmP.r

SEG.n

1

tGt

200

SEG.n

2

rAtE

5.0

tYPE

dwEl

Pid

LiSt

PID
List

PrG.t

35.0

out.n

OFF

20.0

20.0

OP

100.0

m-A

Auto

AmPS

5

rAtE

5.0

run

LiSt

dur

1.0

StAt

run

PrG

1

PSP

20

CYC

1

SEG

1

SEG.t

1.0

StyP

rmP.r

Run
List

(1)

tGt

200

tYPE

End

SEG.n

3

AL

LiSt

2---

2

0

1---

2

100

3---

2

5

HY 2

1

HY 1

1

HY 3

1

Lb t

OFF

HY 4

1

diAG

no

4---

2

5

drA

OFF

tunE

OFF

drA.t

0.8

Adc

mAn

FF.tr

0

FF.dv

100.0

rEL.2

1.00

FF.Pb

0.0

Lcb2

Auto

Hcb2

Auto

mtr

LiSt

tm

30.0

In.t

OFF

bAc.t

OFF

mp.t

Auto

V.br

dwn

20.0

o

C

FASt

no

tYPE

dwEl

rES.2

0.0

Pb

5

SEt

Pid.1

ti

300

rES

0.0

td

60.0

Hcb

Auto

rEL.C

1.00

Lcb

Auto

Pb2

10

td.2

50.0

ti.2

300

G.SP

500

SYnc

no

SEG.d

YES

C.id

1

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-11

NAVIGATION DIAGRAM (PART B)

Figure 2-7b Navigation diagram (P art B)

SP

LiSt

sp3
to

sp16

if

configured

Setpoint

List

Notes:

1.

T

hese lists are present only in controllers with the programming

feature.

2. The last three characters depend upon the type of alarm
configured.

3. This lis t is only present in motori sed valve controllers.

4. Absolute setpoint limits are set in configuration, see Chapt er 6.

The shaded boxes are normally hidden in Operator level. To
see all the available parameters you must select Full level.
See Chapter 3, Access Levels.

L-r

Loc

SSEL

SP 1

SP 1

20.0

SP 2

0.0

rm.SP

0.0

rmt.t

0.0

SP L

4

0.0

rat

Off

SP H

4

100.0

Loc.t

0

For additional
parameters - see t abl es

iP

LiSt

oP

LiSt

cmS

LiSt

inFo

Li

t

ACCS

LiSt

Goto

OPEr

codE

PASS

Input

List

Output

List

Comms

List

I

nformation

List

Access

List

OP.Lo

0.0

OPrr

OFF

CYC.H

20.0

ont.H

Auto

Addr

1

LoG.H

100.0

LoG.L

0.0

LoG.A

50.0

LoG.t

1000

rES.

no

LoG.

0.0

mCt

0

hYS.H

1.0

hYS.C

1.0

HC.db

0.0

P OP

19

I OP

10

d OP

1.

FF.OP

0

FiLt

OFF

FLt.2

OFF

CAL

FACt

CYC.C

5.0

ont.C

Auto

di SP

Std

w.OP

0.0

FOP

0.0

Sb.OP

100.0

The parameters
that follow
depend upon the
controller
configuration.

Refer to the
parameter table.

They cover: user
calibration & the
2nd PV input
fiunctions.

OP.Hi

100.0

Operation Installation and Operat i on Handbook

2-12

2

408 and 2404 Controller

PARAMETER TABLES

Name Description

Home list

Home Measured value and Setpoi nt

OP

OPOP

OP

% Output level

SP

SPSP

SP

Target setpoint (if i n Manual mode )

mmmm----AAAA

Auto-man select

AmPS

AmPSAmPS

AmPS

Heater current (With PDSIO mode 2)

C.id

C.idC.id

C.id

Customer defined i dent i fication number

+ Extra parameters, if the ‘Promote’ feature has been used (see Chapter 3, Edit Level).

run

runrun

run

Program run list − Present only in s etpoint programming controllers

PrG

PrGPrG

PrG Active program number (Only on 4, or 20, program versions)
StAt

StAtStAt

StAt Program status (OFF, run, hoLd, HbAc, End)
PSP

PSPPSP

PSP

Programmer s et poi nt

CYC

CYCCYC

CYC

Number of cycles remaining in the program

SEG

SEGSEG

SEG

Active segment number

StyP

StyPStyP

StyP

Active segment type

SEG.t

SEG.tSEG.t

SEG.t

Segment time remaining in the segm ent uni ts

tGt

tGttGt

tGt

Target setpoint

rAtE

rAtErAtE

rAtE

Ramp rate (if a rate segment)

PrG.t

PrG.tPrG.t

PrG.t

Program tim e remaining in hours

FASt

FAStFASt

FASt Fast run through program (no / YES)
out.n

out.nout.n

out.n Event output st at es (OFF / on) (not 8-segment programmer)
SYnc

SYncSYnc

SYnc Segment synchroni sation (no / YES) (not 8-segment programmer)
SEG.d

SEG.dSEG.d

SEG.d Flash active s egment type in the lower readout of the home di splay (no / YES)

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-13

Name Description

ProG

ProGProG

ProG

Program edit list − Present only in setpoint programming controll er.
For a fuller explanation of t hese parameters refer to Chapter 5

PrG.n

PrG.nPrG.n

PrG.n Select program number (Only on 4, or 20, program versions)
Hb

HbHb

Hb Holdback type for the program as a whole (if conf i gured)(OFF, Lo, Hi, or bAnd)
Hb

HbHb

Hb VVVV

Holdback value (in display units)

rmP.U

rmP.UrmP.U

rmP.U Ramp units (SEc, min, or Hour) [for both rmP.r

rmP.rrmP.r

rmP.r and rmP.t

rmP.trmP.t

rmP.t type segments]

dwL.U

dwL.UdwL.U

dwL.U Dwell units (SEc, min, or Hour)
CYC.n

CYC.nCYC.n

CYC.n Number of program cycles (1 to 999, or ‘cont’)
SEG.n

SEG.nSEG.n

SEG.n

Segment number

tYPE

tYPEtYPE

tYPE

Segment type:

(End

EndEnd

End) (rmP.r

rmP.rrmP.r

rmP.r=ramp rate) (rmP

rmPrmP

rmP.t

.t.t

.t=ramp time) (dwel

dweldwel

dwel) (StEP

StEPStEP

StEP) (cALL

cALLcALL

cALL)

The following parameters depend on the tYPE selected, as shown below.

End rmP.r rmP.t dwEl StEP cALL

Hb

HbHb

Hb

Holdback type: OFF, Lo, Hi, or bAnd

tGt

tGttGt

tGt

✓ ✓

✓

Target setpoint for a ‘rmP’ or ‘StEP’ segment

rAtE

rAtErAtE

rAtE

✓

Ramp rate for a ‘rmP.r’ segment

dur

durdur

dur

✓ ✓

‘dwEl’ time / Time to target for a ‘rmP.t’ segment

PrG.n

PrG.nPrG.n

PrG.n

✓

cALLed ProGram number

cYc.n

cYc.ncYc.n

cYc.n

✓

No. of cycles of cALLed program

outn

outnoutn

outn

✓ ✓ ✓ ✓ ✓

Event output: OFF/on (not 8-segment programmer)

SYnc

SYncSYnc

SYnc

✓ ✓ ✓ ✓

Segment synchroni sation: no/YES

(not 8-seg progr)

End.t

End.tEnd.t

End.t

✓

End of prog − dwEl, RSEt, S OP

Pwr

PwrPwr

Pwr

Power level in end segment

Operation Installation and Operat i on Handbook

2-14

2

408 and 2404 Controller

Name Description

AL

ALAL

AL

Alarm list

1111 ---- ---- ----

Alarm 1 setpoi nt value

2222 ---- ---- ----

Alarm 2 setpoi nt value

3333 ---- ---- ----

Alarm 3 setpoi nt value

4444 ---- ---- ----

Alarm 4 setpoi nt value

In place of dashes, the last three characters
indicate the alarm type. See alarm types
table:

HY

HYHY

HY 1111

Alarm 1 Hysteresis (display units)

HY

HYHY

HY 2222

Alarm 2 Hysteresis (display units)

HY

HYHY

HY 3333

Alarm 3 Hysteresis (display units)

HY

HYHY

HY 4444

Alarm 4 Hysteresis (display units)

Lb

LbLb

Lb tttt

Loop Break Time in minutes

diAG

diAGdiAG

diAG Enable Diagnostic alarms ‘no’ /

‘YES’

Alarm types table

----FSL

FSLFSL

FSL

PV Full scale low alarm

----FSH

FSHFSH

FSH

PV Full scale high al arm

----dEv

dEvdEv

dEv

PV Deviation band alarm

----dHi

dHidHi

dHi

PV Deviation high alarm

----dLo

dLodLo

dLo

PV Deviation low alarm

----LCr

LCrLCr

LCr

Load Current low alarm

----HCr

HCrHCr

HCr

Load Current high alarm

----FL2

FL2FL2

FL2

Input 2 Full Scale low alarm

----FH2

FH2FH2

FH2

Input 2 Full Scale high al arm

----LOP

LOPLOP

LOP

Working Output low alarm

----HOP

HOPHOP

HOP

Working Output high alarm

----LSP

LSPLSP

LSP

Worki ng S etpoint low alarm

----HSP

HSPHSP

HSP

Working Setpoint high alarm

4rAt

4rAt4rAt

4rAt

Rate of change alarm (A L 4 onl y)

Atun

AtunAtun

Atun

Autotune list

tunE

tunEtunE

tunE

One-shot autotune enable

drA

drAdrA

drA

Adaptive tune enable

drA.t

drA.tdrA.t

drA.t

Adaptive tune trigger level i n
display units. Range = 1 to 9999

Adc

AdcAdc

Adc

Automatic Droop Compensation
(PD control only)

Name Description

Pid

PidPid

Pid

PID list

G.SP

G.SPG.SP

G.SP

If Gain Scheduling has been
enabled (see Chapter 4), this
parameter sets t he PV below
whic h ‘Pid.1’ is active and above
whic h ‘Pid.2’ is active.

SEt

SEtSEt

SEt ‘Pid.1’ or ‘Pid.2’ selected

Pb

PbPb

Pb Proportional B and (SEt 1)

(in display units)

ti

titi

ti Integral Time in secs (SEt 1)

td

tdtd

td Derivative Time in secs (SEt 1)

rES

rESrES

rES Manual Reset (%) (SEt 1)

Hcb

HcbHcb

Hcb Cutback High (SEt 1)

Lcb

LcbLcb

Lcb Cutback Low (SEt 1)

rEL.C

rEL.CrEL.C

rEL.C Relative Cool Gain (SEt 1)

Pb2

Pb2Pb2

Pb2 Proportional Band (SEt 2)

ti2

ti2ti2

ti2 Integral Time in secs (SEt 2)

td2

td2td2

td2 Derivative Time in secs (SEt 2)

rES.2

rES.2rES.2

rES.2 Manual Reset (%) (SEt 2)

Hcb2

Hcb2Hcb2

Hcb2 Cutback High (SEt 2)

Lcb2

Lcb2Lcb2

Lcb2 Cutback Low (SEt 2)

rEL.2

rEL.2rEL.2

rEL.2 Relative Cool Gain (SEt 2)

The following three parameters are used for
cascade control. If t his f acility is not being
used, then they can be i gnored.

FF.Pb

FF.PbFF.Pb

FF.Pb

SP, or PV, f eedf orward propband

FF.tr

FF.trFF.tr

FF.tr

Feedforward trim %

FF.dv

FF.dvFF.dv

FF.dv PID feedf orward limits ± %

mtr

mtrmtr

mtr

Motor list - see Tabl e 4-3

tm

Valve travel tim e i n seconds

In.t

Valve inertia time in secs

bAc.t

Valve backlash ti me in secs

mp.t

Minimum ON time of output pulse

U.br

Valve sensor break strategy

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-15

Name Description

SP

SPSP

SP

Setpoint list

SSEL Select SP 1 to SP16, depending

on configuration

L-r Local (Loc) or remote (rmt)

setpoint select

SP 1

Setpoint one value

SP 2

Setpoint two value

rm.SP

Remote setpoint value

rmt.t

Remote setpoint trim

rat

Ratio setpoint

Loc.t

Local setpoint tri m

SP L

Setpoint 1 low limit

SP H

Setpoint 1 high limit

SP2.L

Setpoint 2 low limit

SP2.H

Setpoint 2 high limit

SPrr

Setpoint Rate Limit

Hb.ty

Holdback Type for setpoi nt rate
limit (OFF, Lo, Hi, or bAnd)

Hb

Holdback Value for s etpoint rate
limit in display units. (Hb.ty ≠

Off)

iP

iPiP

iP

Input list

FiLt

IP1 filter time constant (0.0 -

999.9 seconds).

FLt.2

IP2 filter time constant (0.0 -

999.9 seconds).

Hi.IP
Lo.Ip

Transition of control between
ip.1 and ip.2. (if configured)
The transition region is set by the
values of ‘Lo.Ip’ and ‘Hi.Ip’.

PV = ip.1 below ‘Lo.Ip’
PV = ip.2 above ‘Hi.Ip’

F.1
F.2

Derived function, (if configured)
PV = (f.1 x iP1) + (f.2 x iP2).
‘F.1’ and ‘F.2’ are scalars with the

range -9.99 to 10.00

PV.ip Selects ‘ip.1’ or ‘ip.2’

Continued in next column

Name Description

iP

iPiP

iP

Input list - continued

The next 3 parameters appear if User
Calibration has been enabled. (Refer to

Chapter 7.) By default they are hidden
when in Operator level. To prevent
unauthorised adjustment, we recommend
that they are only made avai l abl e i n FuLL
access level.

CAL ‘FACt’ - reinstates the fact ory

calibration and disabl es User
calibration. Next 2 parameters
will not appear.

‘USEr’ - reinstates any prev i ously
set User calibration. All
parameters below now appear.

CAL.s Selected calibration point −

‘nonE’, ’iP1.L’, ‘ip1.H’, ’iP2.L’,
‘ip2.H’

AdJ * User cal i brat i on adj ust, if CAL.s =

’iP1.L’, ‘ip1.H’, ’iP2.L’, ‘ip2.H’

OFS.1

IP1 calibration of fset

OFS.2

IP2 calibration of fset

mV.1

IP1 measured value (at terminals)

mV.2

IP2 measured value (at
terminals), i f DC input in Module 3
position

CJC.1

IP1 cold juncti on temp. reading

CJC.2

IP2 cold juncti on temp. reading

Li.1

IP1 linearised value

Li.2

IP2 linearised value

PV.SL

Shows the currently selec ted PV
input - ‘ip.1’ or ‘ip.2’

* Do not make adjustments usi ng the AdJ
parameter unless you wish to change the
controller calibration.

Operation Installation and Operat i on Handbook

2-16

2

408 and 2404 Controller

Name Description

oP

oPoP

oP

Output list

Does not appear if Motorised Valve control
configured.

OP.Lo

Low power limit (%)

OP.Hi

High power limit (%)

OPrr

Output Rate Limit (% per sec)

FOP

Forced output level (%)

CYC.H

Heat cycle time (0.2S to 999.9S)

hYS.H

Heat hysteresis (display units)

ont.H

Heat output min. on-time (secs)
Auto (0.05S), or 0.1 - 999. 9S

CYC.C

Cool cycle time (0.2S to 999.9S)

hYS.C

Cool hysteresis (di splay units)

ont.C

Cool output min. on-time (secs)
Auto (0.05S), or 0.1 - 999. 9S

HC.db

Heat/cool deadband (display
units)

Sb.OP

Sensor Break Output P ower (%)

cmS

cmScmS

cmS

Comms list

Addr

Communications Address

cmS

cmScmS

cmS

DeviceNet (additional
parameters)

Nw.St

Indicates network s t atus

run

Network connected and
operational

rdy

Network connected but not
operational

oFF.L

Network not connected

inFo

inFoinFo

inFo

Information list

diSP

Configure lower readout of Home
display to show:

VPoS Valve position
Std Standard - display set poi nt
AmPS Load current in amps
OP Output
Stat Program status
PrG.t Program tim e remaining in

hours

Li 2 Proces s value 2
rAt Ratio setpoint
PrG Selected program number
rSP Remote setpoint

LoG.L

PV minimum

LoG.H

PV maximum

LoG.A

PV mean value

Log.t

Time PV above Threshold l evel

Log.v

PV Threshold for Tim er Log

Continued in next column

Name Description

inFo

inFoinFo

inFo

Information list - continued

rES.L

Logging Reset - ‘YES/no’

The following set of parameters is for
diagnostic purposes .

w.OP

Working output

FF.OP

Feedforward component of output

VO

PID output to motorised valve

ACCS

ACCSACCS

ACCS

Access List

codE

Access password

Goto Goto level - OPEr, FuLL, Edit or

conF

ConF

Configuration password

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-17

ALARMS

Alarm annunciation

Alarms are flashed as messages in the Home display. A new alarm is displayed as a double
flash followed by a pause, old (acknowledged) alarms as a single flash followed by a pause.
If there is more than one alarm con dition, the display cycles through all the relevant alarm
messages. Table 2-1 and Table 2-2 list all of the possible alarm messages and their meanings.

Alarm acknowledgement and resetting

Pressing both

and at the same time will acknowledge any new alarms and reset any

latched alarms.

Alarm modes

Alarms will have been set up to operate in one of several modes, either:

• Non-latching, which means that the alarm will reset automatically when the Process

Value is no longer in the alarm condition.

• Latching, which means that the alarm message will continue to flash even if the alarm

condition no longer exists and will only clear when reset.

• Blocking, which means that the alarm will only become active after it has first entered a

safe state on power-up.

Alarm types

There are two types of alarm: Process alarms and Diagnostic alarms.

Process alarms

These warn that there is a problem with the process which the controller is trying to control.

Alarm

Display

What it means

_FSL*

PV Full Scale Low alarm

_FSH*

PV Full Scale High al arm

_dEv*

PV Deviation Band alarm

_dHi*

PV Deviation High alarm

_dLo*

PV Deviation Low alarm

_LCr*

Load Current Low alarm

_HCr*

Load Current High alarm

* In place of the dash, the first character will indicate the alarm number.

Table 2-1 Process alarms

Alarm

Display

What it means

_FL2*

Input 2 Full Scale Low alarm

_FH2*

Input 2 Full Scale High al arm

_LOP*

Working Output Low alarm

_HOP*

Worki ng Out put High alarm

_LSP*

Working Setpoint Low alarm

_HSP*

Worki ng S etpoint High alarm

4rAt

PV Rate of change alarm
Always assigned to Alarm 4

Operation Installation and Operat i on Handbook

2-18

2

408 and 2404 Controller

Diagnostic alarms

These indicate th at a fau l t exists in either the controller or the con nected devices.

Display

shows

What it means What to do about it

EE.Er

EE.ErEE.Er

EE.Er

Electricall y Erasable
Memory Error:

The value of an operator,
or configuration,
parameter has been
corrupted.

This fault will automatically take you into
Configuration level. Chec k all of the
configuration param et ers before returning to
Operator level. Once in Operator l evel , check all
of the operator parameters before resuming
normal operation. I f the fault persists, or occurs
frequently, contac t your supplier

S.br

S.brS.br

S.br

Sensor Break:

Input sensor is unrel i abl e
or the input signal is out of
range.

Check that the s ensor is correctly connected.

L.br

L.brL.br

L.br

Loop Break

The feedback loop is open
circuit.

Check that the heati ng and cooling circuits are
working properly.

Ld.F

Ld.FLd.F

Ld.F

Load failure
Indication that there is a
fault in the heating c i rcuit
or the solid state relay.

This is an alarm generated by feedback from a
TE10S solid state relay (SSR) operating in
PDSIO mode 1 - see Chapt er 1, Electrical
Installation. It indicates either an open or short
circuit SS R, bl own fus e, missing supply or open
circuit heater.

SSr.F

SSr.FSSr.F

SSr.F

Solid state relay failure
Indication that there is a
fault in the solid state
relay.

This is an alarm generated by feedback from a
TE10S solid state relay (SSR) operating in
PDSIO mode 2 - see Chapt er 1, Electrical
Installation. It indicates either an open or short
circuit condition in the SSR.

Htr.F

Htr.FHtr.F

Htr.F

Heater failure
Indication that there is a
fault in heating ci rcuit.

This is an alarm generated by feedback from a
TE10S solid state relay (SSR) operating in
PDSIO mode 2 - see Chapt er 1, Electrical
Installation. It indicates either a blown fuse,
missing supply, or open circuit heater.

Ct.OP

Ct.OPCt.OP

Ct.OP

C

urrent Transformer Open

C

ircuit

Indicates that the PDS input is open circuit.
Mode 5 only

Ct.Sh

Ct.ShCt.Sh

Ct.Sh

C

urrent Transformer S hort

C

ircuit

Indicates that the PDS input is short ci rcuit
Mode 5 only

Hw.Er

Hw.ErHw.Er

Hw.Er

Hardware error

Indication that a module is
of the wrong type,
missing, or faulty.

Check that the c orrect modules are fitted.

Operation Installation and Operat i on Handbook

2408 and 2404 Controller 2-19

no.io

no.iono.io

no.io

No I/O
None of the expected I/O
modules is f i tted.

This error message normally occurs when pre­configuring a controller without installing any of
the required I/O modul es.

rmt.F

rmt.Frmt.F

rmt.F

Remote input failure.
Either the PDSIO input, or
the remote DC input, is
open or short circuit

Check for open, or short circuit wiring on the
PDSIO, or remote DC, input.

LLLL

LLLLLLLL

LLLL

Out of range low reading

Check the value of the i nput.

HHHH

HHHHHHHH

HHHH

Out of range high reading

Check the value of the i nput.

Err1

Err1Err1

Err1

Error 1: ROM self-test fail

Return the controller f or repai r.

Err2

Err2Err2

Err2

Error 2: RAM self-test fail

Return the controller f or repai r.

Err3

Err3Err3

Err3

Error 3: W at chdog fail

Return the controller f or repai r.

Err4

Err4Err4

Err4

Error 4: Keyboard failure
Stuck button, or a button
was pressed during power
up.

Switch the power off and then on, without
touching any of the cont rol l e r but tons.

Err5

Err5Err5

Err5

Error 5: Faulty internal
communications.

Check printed circ ui t board interconnections. I f
the fault cannot be c l eared, return the controller
for repair.

Err6

Err6Err6

Err6

Digital filter chip faulty or
loose board inside
controller

Return the controller f or repai r.

Err7

Err7Err7

Err7

PV id failure/P SU failure Return the controller for repair.

Err8

Err8Err8

Err8

Module 1 id error Faulty or loose module or may be isolat i on

problem

Err9

Err9Err9

Err9

Module 2 id error Faulty or loose module or may be isolat i on

problem

ErrA

ErrAErrA

ErrA

Module 3 id error Faulty or loose module or may be isolat i on

problem

DCF

DCFDCF

DCF

DC output fail Return the controller f or repai r

Tu.Er

Tu.ErTu.Er

Tu.Er

Tune error – shown If any
one stage of the auto­tuning process exceeds
two hours

Check response time of process: chec k that the
sensor has not fail ed: check that the loop is not
broken. Acknowledge by press i ng ‘ page’ key
and ‘scroll’ key together

P.br

P.brP.br

P.br

Potentiomet er break Check that the feedback potentiometer is

correctly connect ed or the pot is not open circuit

Table 2-2 Diagnostic alarms

Operation Installation and Operat i on Handbook

2-20

2

408 and 2404 Controller

Installation and Operat i on Handbook Access Levels

2408 and 2404 Controller 3-1

Chapter 3 ACCESS LEVELS

This chapter describes t he different levels of access to the operati ng parameters within the
controller.

There are three topics:

• THE DIFFERENT ACCESS LEVELS

• SELECTING AN ACCESS LEVEL

• EDIT LEVEL

THE DIFFERENT ACCESS LEVELS

There are four access levels:

• Operator level, which you will normally use to operate the controller.

• Full level, which is used to commission the controller.

• Edit level, which is used to set up the parameters that you want an operator to be able to

see and adjust when in Operator level.

• Config uration level, which is used to set up the fundamental characteristics of the

controller.

Access

level

Display

shows

What you can do Password

Protection

Operator

OPEr

In this level, operators can view and adjust the
value of parameters defined in Edit level (see
below).

No

Full

FuLL

In this level, al l the parameters relevant to a
particular configuration are visible. All alterabl e
parameters m ay be adj usted.

Yes

Edit

Edit

In this level, you can determine which
parameters an operator is able to view and
adjust in Operator level. Y ou can hide, or
reveal, complete lists, individual parameters
within each list and you can make parameters
read-only or alterable. (See Edit level at the
end of this chapter).

Yes

Configuration

conF

This special level allows access to set up the
fundamental characteristics of the controller.

Yes

Figure 3-1 Access l evels

A

ccess Levels Installation and Operat i on Handbook

3-2

2

408 and 2404 Controller

SELECTING AN ACCESS LEVEL

Access to Full, Edit or Configuration levels is protected by a password to prevent
unauthorised access.
If you need to change the password, see Chapter 6, Configuration.

Access list header

Press

until you reach the access list header ‘ACCS’.

Press

Password entry

The password is entered from the ‘codE’ display.
Enter the password using or . Once the correct p assword
has been entered, there is a two second delay after which the lower
readout will change to show ‘PASS’ indicating t hat access is now
unlocked.
The pass number is set to ‘1’ when the controller is shipped from
the factory.

Note; A special case exists if the password has been set to ‘0’. In
this case access will be permanently unlocked and the lower
readout will always show ‘PASS’.

Press

to proceed t o the ‘Goto’ page.

(If an incorrect password has been entered and the controller is
still ‘locked’ then pressing

returns you to the ‘ACCS’ list

header.)

Access to Read-only Configuration

From this display, pressing

and together will take you
into Read-Only Configuration without entering a password. This
will allow you to view all of the configuration parameters, but not
adjust them. If no button is pressed for ten seconds, you will be
returned to the Home display. Alternatively, pressing

and

together takes you immediately back to the Home display.

Installation and Operat i on Handbook Access Levels

2408 and 2404 Controller 3-3

Level selection

The ‘Goto’ display allows you to select the required
access level.
Use

and to select from the following display

codes: OPEr: Operator level

FuLL: Full level
Edit: Edit level
conF: Configuration level

Press

If you selected either ‘OPEr’, ‘FuLL’ or ‘Edit’ level
you will be returned to the ‘ACCS’ list header in the level
that you chose. If you select ed ‘conF’, you will get a
display showing ‘ConF’ in the upper readout (see below).

Configuration password

When the ‘ConF’ display appears, you must enter the
Configuration password in order to gain access to this
level. Do this by repeating the password entry procedure
described in the previous section.
The configuration password is set to ‘2’ when the
controller is shipped from the factory. If you need to
change the configuration password, see Chapter 6,

Configuration.

Press

Configuration level

The first display of configuration is shown. See Chapter
6, Configuration, for details of the configuration
parameters.
For instructions on leaving configuration level, see
Chapter 6, Configuration.

Returning to Operator Level

To return to operator level from either ‘FuLL’ or ‘Edit’ level, repeat entry of the password
and select ‘OPEr’ on the ‘Goto’ display.
In ‘Edit’ level, the controller will automatically return to operator level if no button is
pressed for 45 seconds.

A

lternative path if

‘conF’ selected

A

ccess Levels Installation and Operat i on Handbook

3-4

2

408 and 2404 Controller

EDIT LEVEL

Edit level is used to set which parameters you can view and adjust in Operator level. It also
gives access to the ‘Promote’ feature, which allows you to select and add (‘Promote’) up to
twelve parameters into the Ho me display list, thereby giving simple access to commonly used
parameters.

Setting operator access to a parameter

First you must select Edit level, as shown on the previous page.
Once in Edit level, you select a list, or a parameter within a list, in the same way as you
would in Operator, or Full, level − that is to say, you move from list header to list header by
pressing

, and from parameter to parameter within each list using .

However, in Edit level what is displayed i s not the value of a selected parameter, but a code
representing that param eter’s availability in Operator level.

When you have selected the required parameter, use and buttons to set its availability
in Operator level.

There are four codes:

ALtr

ALtrALtr

ALtr Makes a parameter alterable in Operator level.
PrO

PrOPrO

PrO Promotes a parameter into the Home display list.
rEAd

rEAdrEAd

rEAd Makes a parameter, or list header, read-only (it can be viewed but not altered).
HIdE

HIdEHIdE

HIdE Hides a parameter, or list header.

For example:

Hiding or revealing a complete list

To hide a complete list of parameters, all you have to do is hide the list header. If a list
header is selected, only two selections are available: rEAd and HIdE.
(It is not possible to hide the ‘ACCS’ list, which always displays the code: ‘LiSt’.)

Promoting a parameter

Scroll through the lists to the required parameter and choose the ‘PrO’ code. The parameter
is then automatically added (promoted) into the Home display list. (The parameter will also
be accessible, as no r mal, from the standard lists.) A maximum of twelve parameters can be
promoted. Promoted parameters are automatically ‘alterable’.

Please note, in the ‘PrOG List’, the parameters from segment number (SEG.n) onwards
cannot be promoted.

The parameter select ed i s Alarm 2, Full Scale Low

It will be alterable in Operator level

Installation and Operat i on Handbook Tuning

2408 and 2404 Controller 4-1

Chapter 4 TUNING

Before tuning, please read Chapter 2, Operation, to learn how to select and change a
parameter.

This chapter has five topics:

• W HA T IS TUNING?

• AUTOMATIC TUNING

• MANUAL TUNING

• COMMISSIONING OF MOTORISED VALVE CONTROLLERS

• GAIN SCHEDULING

WHAT IS TUNING?

In tuning, you match the characteristics of the controller to those of the process being
controlled in order to obtain good control. Good control means:

• Stable, ‘straight-line’ control of the temperature at setpoint without fluctuation

• No overshoot, or undershoot, of the temperature setpoint

• Quick response to deviations from the setpoint caused by external disturbances, thereby

rapidly restoring the temperature to the setpoint value.

Tuning involves calculating and setting the value of the parameters listed in Table 4-1. These
parameters appear in the ‘Pid’ list.

Parameter

Code

Meaning or Function

Proportional

band

Pb

The bandwidth, in display units , over which the output power is
proportioned between minim um and maximum.

Integral time

ti

Determines the time taken by the control l er to remove steady­state error signals .

Derivative time

td

Determines how strongly the cont roller will react to the rate-of­change of the meas ured val ue.

High Cutback

Hcb

The number of display units, above setpoint, at which t he
controller will increase the output power, in order to prevent
undershoot on cool down.

Low cutback

Lcb

The number of display units, below setpoint, at which the
controller will cutback the output power, in order to prevent
overshoot on heat up.

Relative cool

gain

rEL

Only present if cooling has been configured and a module is
fitted. Sets the cooling proportional band, which equals t he Pb
value divided by the rEL value.

Table 4-1 Tuning parameters

Tuning Installation and Operat ion Handbook

4-2 2408 and 2404 Controller

AUTOMATIC TUNING

Two automatic tuning methods are provided in the 2408 and 2404:

• A one-shot tuner, which automatically sets up the initial values of the parameters listed

in Table 4-1 on the previous page.

• Adaptive tuning, which continuously monitors the error from setpoint and modifies the

PID values, if necessary.

One-shot Tuning

The ‘one-shot’ tuner works by switching the output on and off to induce an oscillation in the
measured value. From the amplitude and period of the oscillation, it calculates the tuning
parameter values.
If the process cannot tolerate full heating or cooling being applied during tuning, then the
level of heating or cooling can be restricted by setting the heating and cooling power limits in
the ‘oP’ list. However, the measured value must oscillate to some degree for the tuner to be
able to calculate values.
A One-shot Tune can be performed at any time, but normally it is performed only once during
the initial commissioning of the process. However, if the process under control subsequently
becomes unstable (because its characteristics have changed), you can re-tune again for the
new conditions.
It is best to start tuning with the process at ambient temperature. This allows the tuner to
calculate more accurately the low cutback and high cutback values which restrict the amount
of overshoot, or undershoot.

How to tune

1. Set the setpoint to the value at which you will normally operate the process.

2. In the ‘Atun’ list, select ‘tunE’ and set it to ‘on’.

3. Press the Page and Scroll buttons together to return to the Home display. The display will

flash ‘tunE’ to indicate that tuning is in progress.

4. The controller induces an oscillation in the temperature by first turning the heating on,
and then off. The first cycle is not complete until the measured value has reached th e
required setpoint.

5. After two cycles of oscillation the tuning is completed and the tuner switches itself off.

6. The controller then calculates the tuning parameters listed in Table 4-1 and resumes
normal control action.

If you want ‘Proportional only’, ‘PD’, or ‘PI’ control, you should set the ‘ti’ or ‘td’
parameters to OFF before commencing the tuning cycle. The tuner will leave them off and
will not calculate a value for them.

Installation and Operat i on Handbook Tuning

2408 and 2404 Controller 4-3

Typical automatic tuning cycle

Calculation of the cutback values

Low cutback and High cutback are values that restrict the amount of overshoot, or
undershoot, that occurs during large step changes in temperature (for example, under start-up
conditions).
If either low cutback, or high cutback, is set to ‘Auto’ the values are fixed at three times the
proportional band, and are not changed during automatic tuning.

Adaptive tune

Adaptive tuning is a background algorithm, which continuously monitors the error from
setpoint and analyses the control response during process disturbances. If the algorithm
recognises an oscillatory, or under-damped, response it recalculates the Pb, ti and td
values.

Adaptive tune is tr i ggered whenever the error from setpoint exceeds a trigger level. This
trigger level is set in the parameter ‘drA.t’, which is found in the Autotune list. The value is
in display units. It is automatically set by the controller, but can also be manually
re-adjusted.

Adaptive tune should be used with:

1. Processes who s e characteristics change as a result of changes in the load, or set point.

2. Processes that cannot tolerate the oscillation induced by a One-shot tune.

Adaptive tune should not be used:

1. Where the pro cess i s subjected to regular external disturbances that could mislead the
adaptive tuner.

2. On highly interactive multiloop applications. However, moderately interactive loops,
such as multi-zone extruders, should not give a problem.

Time

Setpoint

Temperature

Tuning Installation and Operat ion Handbook

4-4 2408 and 2404 Controller

MANUAL TUNING

If for any reason automatic tuning gives unsatisfactory results, you can tune the controller
manually. There are a number of standard methods for manual tuning. The one described
here is the Ziegler-Nichols method.

With the process at its normal running temperature:

1. Set the Integral Time ‘ti’ and the Derivative Time ‘td’ to OFF.

2. Set High Cutback and Low Cutback, ‘Hcb’ and ‘Lcb’, to ‘Auto’.

3. Ignore the fact that the temperature may not settle precisely at the setpoint.

4. If the temperature is stable, reduce the proportional band ‘Pb’ so that the temperature just

starts to oscillate. If the temperature is already oscillating, increase the proportional band
until it just stops oscillating. Allow enough time between each adjustment for the loop to
stabilise. Make a note of the proportional band value ‘B’ and the period of oscillation
‘T’.

5. Set the Pb, ti, td parameter values according to the calcu l ations given in Table 4 - 2.

Type of control

Proportional

band ‘Pb’

Integral time ‘ti’

Derivative time

‘td’

Proportional only

2xB

OFF

OFF

P + I control

2.2xB

0.8xT

OFF

P + I + D control

1.7xB

0.5xT

0.12xT

Table 4-2 Tuning values

Installation and Operat i on Handbook Tuning

2408 and 2404 Controller 4-5

Setting the cutback values

The above procedu r e sets up the parameters for optimum steady state control. If unacceptable
levels of overshoot or undershoot occur during start-up, or for large step changes in
temperature, then manu al ly set the cutback parameters ‘Lcb’ and ‘Hcb’.

Proceed as follows:

1. Set the low and high cutback values to three proportional bandwidths (that is to say, Lcb
= Hcb = 3 x Pb).

2. Note the level of overshoot, or undershoot, that occurs for large temperature changes (see
the diagrams below).

In example (a) increase ‘Lcb’ by the overshoot value. In example (b) reduce ‘Lcb’ by the
undershoot value.

Example (a)

Example (b)

Where the temperature approaches setpoint from abo ve, you can set ‘Hcb’ in a similar
manner.

Temperature

Time

S

etpoint

Temperature

U

ndershoot

S

etpoint

O

vershoot

Tuning

Installation and Operat i on Handbook

4-6 2408 and 2404 Controller

Integral action and manual reset

In a full three-term controller (that is, a PID controller), the integral term ‘ti’ automatically
removes steady state errors from the setpoint. If the controller is set up to work in two-term
mode (that is, PD mode), the integral term will be set to ‘OFF’. Under these conditions the
measured value may not settle precisely at setpoint. When the integral term is set to ‘OFF’
the parameter manual reset (code ‘rES’) appears in the ‘Pid LiSt’ in ‘FuLL’ level. This
parameter represents the value of the power output that will be delivered when the error is
zero. You must set this value manually in order to remove the steady state error.

Automatic droop compensation (Adc)

The steady state error from the setpoin t , which occurs when the integral term is set to ‘OFF’
is sometimes referred to as ‘droop’. ‘Adc’ automatically calculates the manual reset value in
order to remove this droop. To use this facility, you must first allow the temperature to
stabilise. Then, in the autotune parameter list, you must set ‘Adc’ to ‘cALc’. The controller
will then calculate a new value for manual reset, and switch ‘Adc’ to ‘mAn’.

‘Adc’ can be repeated as often as you require, but b et ween each adjustment you must allow
time for the temperature to stabilise.

Tune Error

If any one stage of the automatic tuning process is not completed within two hours a
diagnostic alarm will occur. The display shows tU.Er - Tune Error.
This alarm could occur if:

1. The process to be tuned has a very slow response time

2. The sensor has failed or is incorrectly aligned

3. The loop is broken or not responding correctly

Installation and Operat i on Handbook Tuning

2408 and 2404 Controller 4-7

MOTORISED VALVE CONTROL

The 2408 and 2404 can be configured for motorised valve control as an alternative to the
standard PID control algorithm. This algorithm is designed specifically for positioning
motorised valves.
These are ordered pre-configured as Model numbers:

• 2408/VC and 2404/VC motorised valve controllers

• 2408/VP and 2404/VP motorised valve controllers with a single setpoint programmer

• 2408/V4 and 2404/V4 motorised valve controllers storing four setpoint programs.

• 2408/VM and 2404/VM motorised valve controllers storing twenty setpoint programs.

Figure 1-11 in Chapter 1 shows how to connect a motorised valve controller. The control is
performed by delivering open, or close, pulses in response to the control demand signal.

The motorised valve algorithm can operate in one of three ways:

1. The so-called boundless mode, which does not require a position feedback potentiometer
for control purposes; although one can be connected and used purely to display the
valve’s position.

2. Bounded, (or position), control mode, which requires a feedback potentiometer. This is
closed-loop control determined by the valve’s position.

The desired control mode is selected in the ‘inst’ list in configuration level.
The following parameter list will appear in the navigation diagram shown in Chapter 2, if

your controller is configured for motorised valve control.

Name Description Values

mtr

mtrmtr

mtr

Motor list Min Max Default

tm

Valve travel tim e i n seconds.
This is the time taken for the valve to travel from
its fully closed position to its full y open position.

0.1 240.0 30.0

In.t

Valve inertia time in seconds.
This is the time taken for the valve to st op moving
after the output pulse is switched off.

OFF 20.0 OFF

bAc.t

Valve backlash ti me in seconds.
This is the m i ni mum on-time required to reverse
the direction of the val ve. i.e. the time to
overcome the m echanical backlash.

OFF 20.0 OFF

mp.t

Output pulse mini mum on-time, i n s econds.

Auto 100.0 Auto

U.br

Valve sensor break strategy.

rESt, uP, dwn rESt

Table 4-3 Motorised valve parameter l i st

Tuning

Installation and Operat i on Handbook

4-8 2408 and 2404 Controller

COMMISS I ONING THE MOTORISED VALVE CONTROLLER

The commissioning procedure is the same for both bounded and boundless control modes,
except in bounded mode you must first calibrate the position feedback potentiometer, as
described in the section below.
Proceed as foll ows:

1. Measure the time taken for the valve to be raised from its fully closed to its fully open

position and enter this as the value in seconds into the ‘tm’ parameter.

2. Set all the other parameters to the default values shown in Table 4-3.
The controller can then be tuned using any of the automatic, or manual, tuning procedures

described earlier in this chapter. As before, the tuning process, either automatic or manual,
involves setting the values of the parameters in Table 4-1. The only difference with
boundless control is that the derivative term ‘td’, although present, will have no effect.

Adjusting the minimum on-time ‘mp.t

mp.tmp. t

mp.t’

The default value of 0.2 seconds is satisfactory for most processes. If, however, after tuning
the process, the valve activity is excessively high, with constant oscillation between raise and
lower pulses, the minimum on-t ime can be increased.
The minimum on-time determines how accurately the valve can be positioned and therefore
the control accuracy. The shorter the time, the more precise the control. However, if the
time is set too short, process noise will cause an excessively busy valve.

Inertia and backlash settings

The default values are satisfactor y for most processes, i.e. ‘OFF’.
Inertia is the time taken for the valve to stop after the output pulse is turned off. If this
causes a control problem, the inertia time needs to be determined and then entered into the
parameter, ‘In.t’. The inertia time is subtracted from the raise and lower output pulse
times, so that the valve moves the correct distance for each pu l se.
Backlash is the output pulse time required to reverse the direction of the valve, i.e. the time
taken to overcome the mechan ical backlash of the linkages. If the backlash is sufficient to
cause a control problem, then the backlash time needs to be determined and then entered into
the parameter, ‘bac.t’.
The above two values are not part of the automatic tuning procedure and must be entered
manually.

CALIBRATING THE POSITION FEEDBACK POTENTIOMETER

Before proceeding with the feedback potentio meter calibration, you should ensure, in
configuration level, that module position 2 (2a), or 3 (3a), has its ‘id’ indicating ‘Pot.i’,
(meaning Potentiometer Input). Continue to scroll down the module configuration list.
‘func’ should be set to ‘Vpos’, ‘VAL.L’ must be set to ‘0’ and ‘VAL.H’ to ‘100’.
Exit from configuration and you are now ready to calibrate the position feedback
potentiometer. Proceed as follows.

1. In Operator level , press the AUTO/MAN button to put the controller in Manual mode.

2. Drive the valve to its fully open position using

.

3. Press

until you get to ‘ip-List’.

4. Press

to get to ‘PCAL-OFF’.

Installation and Operat i on Handbook Tuning

2408 and 2404 Controller 4-9

5. Press or to turn ‘PCAL’ to ‘on’.

6. Press

and the upper readout indicates ‘Pot’.

7. Press

or to get to ‘Pot-3A.Hi’. (Assuming that the Potentiometer Input

Module is in module position 3.)

8. Press

to go to ‘GO-no’.

9. Press

or to see ‘GO-YES’, which starts the calibration procedure.

10. Calibration is complete when the display returns to ‘GO-no’.

11. Press

and together to return directly to the Operator level.

12. The controller should still be in Manual mode.

13. Drive the valve to its fully closed position using

.

14. Press

until you get to ‘ip-List’.

15. Press

to get to ‘PCAL-OFF’.

16. Press

or to turn ‘PCAL’ to ‘on’.

17. Press

and the upper readout indicates ‘Pot’.

18. Press

or to get to ‘Pot-3A.Lo’

19. Press

to go to ‘GO-no’.

20. Press

or to see ‘GO-YES’, which starts the calibration procedure.

21. Calibration is complete when the display returns to ‘GO-no’.

22. Press

and together to return directly to the Operator level.

23. Press the AUTO/MAN button to place t he controller in AUTO and the calibration of the
position feedback potentiometer is now complete.

Tuning

Installation and Operat i on Handbook

4-10 2408 and 2404 Controller

GAIN SCHEDULING

Gain scheduling is the automatic transfer of control between one set of PID values and
another. In the case of the 2408 and 2404 controllers, this is done at a presettable process
value. It is used for the more difficult to control processes which exhibit large changes in
their response time or sensitivity at, for example, high and low temperatures, or when heating
or cooling.

The 2408 and 2404 has two sets of PID values. You can select the active set from either a
digital input, or from a parameter in the PID list, or you can transfer automatically in gain
scheduling mode. The transfer is bumpless and will not disturb the process being controlled.

To use gain scheduling, follow the steps below:

Step1: Enable in configuration level

Gain scheduling must first be enabled in Configuration level.
Goto the Inst Conf list, select the parameter Gsch, and
set it to YES.

Step 2: Set the transfer point

Once gain schedu l ing has been enabled, the parameter G.SP
will appear at the top of the Pid list in FuLL access level.
This sets the value at which transfer occurs. PID1 will be
active when the process value is below this setting and PID2
when the process value is above it. The best point of
transfer depends o n the characteristics of the process. Set a
value between the co ntrol regions that exhibit the greatest
change.

Step 3: Tuning

You must now set up the two sets of PID values. The values can be manually set, or
automatically tuned as described earlier in this chapter. When tuning automatically you must
tune twice, once above the switching point G.SP and again below the switching point. When
tuning, if the process value is below the transfer point G.SP the calculated values will
automatically be inserted into PID1 set and if the process value is above G.SP, the calculated
values will automatically be inserted into PID2 set.

GSch

YES

G.Sp

350

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-1

Chapter 5 PROGRAMMER OPERATION

This chapter deals with the setpoint programming option. All 2408 / 2404 instruments have
a basic 8-segment programmer built-in as standard. This facility must be enabled by the user,
as explained in the section, Configuring the Programmer.

Other programmer versions are listed below, and have 16-segments in each program.
16-segment programmer with:

a single program: Models 2408/CP and 2404/CP.
four stored programs: Models 2408/P4 and 2404/P4.
twenty stored programs: Models 2408/CM and 2404/CM.

16-segment Motorised Valve programmer with:
a single program: Models 2408/VP and 2404/VP.
four stored programs: Models 2408/V4 and 2404/V4.
twenty stored programs: Models 2408/VM and 2404/VM.

The 8-segment programmer differs from the other programmers in that it will not provide
event outputs and program synchronisation. Otherwise they all operate in the same way.

There are eight topi cs:

• WHAT IS SETPOINT PROGRAMMING?

• PROGRAMMER STATES

• RUNNING A PROGRAM FROM THE RUN LI ST

• RUNNING A PROGRAM USI NG T HE RUN/HOLD BUTTON

• AUTOMATIC BEHAVIOUR

• CONFIGURING THE PROGRAMMER

• CONFIGURING DIGI T AL INPUTS TO SELECT PROGRAM NUMBE R

• CREATING A NEW PROGRAM, OR MODIFYING AN EXISTING PROGRAM.

To understand how to select and change parameters in this chapter you need to have read
Chapter 2, Operation and Chapter 3, Access Levels.

Programmer Operati on Installation and Operat i on Handbook

5-2 2408 and 2404 Controller

WHAT IS SETPOINT PROGRAMMING?

Many applications need to vary temperature, or pr ocess value, with time. Such ap plications
need a controller which varies a setpoint as a function of time; all 2408 and 2404 models can
do this.

The setpoint is varied by using a setpoint program. Within each 2408 and 2404 controller,
there is a software module called the programmer, which stores one, or more, such programs
and drives the setpoint according to the selected program. The program is stor ed as a series
of ‘ramp’ and ‘dwell’ segments, as shown below.

(If the 8-segment programmer is being used, then the information in the next paragraph does not apply.)

In each segment you can define t he state of up to eight (8 ) digital outputs, each of which can
be used to tr i gger external events. These are called event outputs and can drive either relay,
logic, or triac outputs, depending on the modules installed.

A program is executed either, once, repeated a set number of times, or repeated continuously.
If repeated a set number of times, then t he number of cycles must be specified as part of the
program.

Fig 5-1 Setpoint profile

T

ime

Setpoint

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-3

There are five different types of segment:

Ramp

The setpoint ramps linearly, from its current value

to a new value, either at a set rat e (called ramp-rate
programming), or in a set time (called time-to-target
programming). You must spec ify the ramp rate or the

ramp time, and the target setpoint, when creating or
modifying a program.

Dwell

The setpoint remains constant for a specified

period.

Step

The setpoint steps instantaneously from its current

value to a new value.

Call

The main program calls another program as a
subroutine. The called program then drives the

setpoint until i t returns control to the main program.
This facility is available on those controllers with 4, or
20, stored programs .

End

The program either ends in this segment, or
repeats. You specify which i s the case when you

create, or modif y, the program (see the final topic i n
this chapter). When the program ends, the
programmer is put into either, a continuous Dwell
state with all outputs staying unchanged, or the Reset
state, or to a se t table power level.

Table 5-1 Segment Types

Programmer Operati on Installation and Operat i on Handbook

5-4 2408 and 2404 Controller

PROGRAMMER STATES

The programs have five states: Reset, Run, Hold, Holdback and End.

State Description Indication

Reset

In Reset, the programmer is inactive and the
controller behaves as a standard controller, with the
setpoint determined by the value set in the lower
readout.

Both the RUN and
HOLD lights are OFF

Run

In Run, the programmer varies the setpoint
according to the active program.

RUN light on

Hold

In Hold, the program i s frozen at its current point. In
this state you can make temporary changes to any
program parameter (f or exampl e, a target setpoint, a
dwell time, or the ti me remaining in the current
segment). Such changes will only remain

effective until the program is reset and run
again, when they will be overwritten by the
stored program values.

Note: When a program is running, you cannot

alter

a cALL

cALLcALL

cALLed program until it becomes active within

that program.

HOLD light on

Holdback

Holdback indicates that the measured value is
lagging the setpoint by more than a preset amount
and that the program is in Hold, waiting for the
process to cat ch up. See Holdback in the section
on Automatic behaviour later this chapter.

HOLD light flashes

A master c ont roller can re-transmit a s et poi nt value
to a number of slave uni t s using PDSIO setpoint
retransmission. Any of the slave units can generate
a holdback signal which will also flash the HOLD
light. Holdback will also occur if the PDSIO output is
open circuit. This can be disabled in configuration
by selecting the PdS out put as SP.nH - ‘setpoint
retransmission without holdback’

HOLD light flashes

End

The program is complete.

RUN light flashes

Table 5-2 Program States

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-5

RUNNING A PROGRAM FROM THE RUN LIST

The Run List

From the Home display, press until you reach the ‘run’ list
header.

Press

Program number

This display only appears on programmers that can store more
than one program. Use

or to select the required program

number, from 1 to 4, or 1 to 20, depending on the particular
controller.
Alternatively, the program number can be selected remotely, using
digital inputs on the rear terminals. See the section on
Configuring Digital Inputs to Select a Program Number for
information on how this is done.

Press

Status selection

Use

or to select:

• run

runrun

run: Run program.

• hoLd

hoLdhoLd

hoLd: Hold program.

• OFF

OFFOFF

OFF: Program reset.

After two seconds, the lower readout blinks and the chosen state is
now active.

To return to the Home display press

and together.

Other parameters

To access the other parameters in th e ‘run’ list, continue to press

. These parameters are shown in the ‘Program run list’ in

Chapter 2, Parameter Tables. They show the current status of the
active program.

Temporary changes

Temporary changes can be made to the parameters in this ‘run’ list, (for example a setpoint,
ramp rate, or an un

elapsed time), by first placing the programmer into ‘hoLd’. Such chan ges

remain active only for the duration of the segment; the segment parameters will revert to their
original (stored) values whenever the segment is re-executed.

Programmer Operati on Installation and Operat i on Handbook

5-6 2408 and 2404 Controller

RUNNING A PROGRAM USING THE RUN/HOLD BUTTON

If you are using a 4, or 20, program version of the controller, you must first select the number
of the program that you want to run. Do this in the ‘run’ list − see the previous topic,

Running a program from the Run list.

Then:

RUN

HOLD

RUN / HOLD

button

Press once to run a program (RUN light on)
Press again to hold a program (HOLD light on)
Press again to cancel hold and continue running
(HOLD light off, RUN light on)
Press and hold in for two seconds to reset a
program (RUN and HOLD lights off).

Note: The RUN/HOLD button can be disabled, either when ordering the controller, or
subsequently in configuration. This will force you to operate the programmer from the ‘run’
list all the time. The main advantage of this method is that it will reduce the chance of
accidentally changi ng the state of a program.

AUTOMATIC BEHAVIOUR

The preceding to pics explain how to operate the programmer manually.
The following topics cover aspects of its automatic behaviour: Servo, Holdback and Power
Failure.

Servo

When a program is RUN, the setpoint can start either from the initial controller setpoint, or
from the process value. Whichever it is, the starting point is called the ‘servo’ point and you
set it up in configuration. When the program starts, the transition of the setpoint to its starting
point is called ‘servoing’.

The normal method is to servo to the process value, because this will produce a smooth and
bumpless start to the process. However, if you want to guarantee the time period of the first
segment, you should set the controller to servo to its setpoint.

Holdback

As the setpoint ramps up, or down (or dwells), the measured value may lag behind, or deviate
from, the setpoint by an undesirable amount. ‘Holdback’ is available to freeze the program at
its current state, should this occur. The action of Holdback is the same as a deviation alarm.
It can be enabled, or disabled. Holdback has two parameters - a value and a type.
If the error from the setpoin t exceeds the set ‘holdback’ value, then the Holdback feature, if
enabled, will automatically freeze the program at its current point and flash the HOLD light.
When the error comes within the holdback value, the program will resume normal running.

There are four different Holdback types. The choice of type is made by setting a parameter
when creating a program, and may be one of the following:−
‘OFF’ − Disables Holdback − therefore no action is taken.

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-7

‘Lo’ − Deviation Low Holdback holds the program back when the process variable

deviates below the setpoint by more than the holdback value.

‘Hi’ − Deviation High Holdback holds the program back when the process variable

deviates above the setpoint by more than the holdback value.

‘bAnd’ − Deviation B and Holdback is a combination of the two. It holds the program back

when the process vari able deviates either above, or below, the setpoint by more
than the h oldback value.

There is a single Holdback Value which applies to the whole program. However, the
Holdback type and whether or not it is enabled, can be applied to the program as a whole, or
individually in each segment.

Power failure

If power is lost and then restored, while a program is running, the behaviour of the
programmer is determined by the setting of the parameter ‘Pwr.F’ Power fail strategy in
Programmer configuration. This can have one of three settings:− cont (Continue), rmP.b
(Ramp from PV), or rSEt (Reset).

If ‘cont’ is selected, then when power is restored the program continues from where it was
interrupted when power was lost. All parameters, such as the setpoint and time remaining in
the active segment, will be restored to their power-down values. For applications that need to
bring the measured process value to the setpoint as soon as possible, this is the best strategy.

If ‘rmP.b’ is selected, t hen when power is restored the setpoint starts at (‘servos to’) th e
current measured value, and then ramps to the target setpoint of the active segment at t he last
ramp rate used by the program. This strategy provides a smoother recovery. The two
diagrams below illustrate the respective responses, Fig 5-2 if power fails during a dwell
segment and Fig 5-3 if it fails during a ramp segment.

Figure 5-2 Continue after a power fail

Figure 5-3 Ramp back aft er a power fail

If ‘rSEt’ is selected, th en when power is restored the program terminates.

Setpoint

Ramp

Segment

Dwell Segment

Time

t1

t2

Segment dwell

time = t1 + t2

Power off

Power on

Setpoint

Ramp Segment

Time

Power off

Power on -
Servo to new PV level

Target setpoint

Programmer Operati on Installation and Operat i on Handbook

5-8 2408 and 2404 Controller

CONFIGURING THE PROGRAMMER

When first installing a programmer you should check that the configuration conforms to your
requirement.
Configuration defines:

• the number of stored programs (multi-programmer only)

• the holdback strategy

• the power fail strategy

• the servo type

• if event out puts are available (not 8-segment programmer)

• if program synchronisation is available. (not 8-segment programmer)

• selection of program number using digital inputs (multi-programmer only)

To check, or change, the configuration, select Configuration level. See Chapter 6.

Programmer list header

After selecting Configuration mode, press

until the PROG

ConF header is displayed.

Press

Number of programs

Use or to select:

•••• nonE: Disable built-in 8-segment programmer

•••• 1: Enable built-in 8-segment programmer

For 16-segment programmers:

•••• nonE

nonEnonE

nonE: no programs

•••• 1: One stored program

•••• 4: Four stored programs

• 20: Twenty stored programs

Press

Holdback Strategy

Use

or to select:

• SEG: Holdback type to be set in each segment

• ProG: Holdback type to be set for the whole program

Press

Continued on the next page.

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-9

Power fail strategy

Use

or to select

•

cont: Continue from last setpoint

• rmP.b: Ramp from PV to setpoint at last ramp rate

• rSEt: Reset the program.

Press

Servo type

Use

or to select:

• to.PV: Servo to PV

• to.SP: Servo to SP

Press

Event Outputs (not in 8-segment programmer)

Use

or to select:

• no: Event outputs disabled

• YES: Event outputs enabled

Press

Synchronisation (not in 8-segment programmer)

Use

or to select:

• no: Synchronisation disabled

• YES: Synchronisation enabled

Press

to return the list header.

Programmer Operati on Installation and Operat i on Handbook

5-10 2408 and 2404 Controller

CONFIGURING DIGITAL INPUTS TO SELECT PROGRAM NUMBER

The program number can be selected by external BCD inputs from, for example, a
thumbwheel switch.
The appropriate number of digital inputs must be installed in the controller and be configured
for this function - see Chapter 6, Configuration.
To invoke this mode of operation, the parameter ‘bcd’ in ‘inst-Conf’ must be set to
‘PrOg’.

bcd

PrOG

P

ress until you reach ‘bcd’.

Use the

or buttons, to select ‘PrOG’.

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-11

CREATING A NEW PROGRAM, OR MODIFYING AN EXISTING ONE

The only difference between creating a new program, and modifying an existing one, is that a
new program starts with all its segments set to End in the tYPE parameter. The procedure
for both consists of setting up the parameters in the PrOG list of the Operator Navigation
Diagram shown in Chapter 2. As explained earlier under ‘Programmer states’, temporary
changes can be made to these parameters while in the HOLD state but permanent changes (t o
the stored valu es) can only be made when the programmer is in the Reset state. So, before
modifying a stored program first make sure that it is in Reset and then follow the procedure
below.

Program edit list

From the Home display press

until you reach the ProG

LiSt header.

Press

Program number

This display appears only on the multi-program controllers.
Use

or to select the number of the program which you

wish to modify (from 1 to 4, or 1 to 20).

Press

Holdback type
[Only appears when Holdback has been selected for the whole
program.]
Use

or to select:

• OFF: Holdback disabled

• Lo: Deviation Low Holdback

• Hi: Deviation High Ho ldback

• bAnd: Deviation Band Holdback

Press

Holdback value

Note!

The value set in this parameter is always for the whole
program.
Use

or to set the value.

Press

Continued on the next page.

Programmer Operati on Installation and Operat i on Handbook

5-12 2408 and 2404 Controller

Ramp units

Use

or to select:

•

Sec

•

min

•

Hour

Press

Dwell units

Use

or to select:

•

Sec

•

min

•

Hour

Press

Number of program cycles

Use

or to set the number of program cycles required from

1 to 999, or ‘cont’ for continuous cycling.

Press

Segment number

Use

or to select the number, from 1 to 16.

(1 to 8 in 8-segment programmers)
The parameters that follow ‘SEG.n’ set up the characterist i cs of
the individually-selected segment number. By defining the
characteristics of each segment of the program, you define the
whole program.

Press

Continued on the next page.

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-13

Segment type

Select the segment type using

or :

•

rmP.r: Ramp to a new setpoint at a set rate

• rmP.t: Ramp to a new setpoint in a set time

• dwEl: Dwell for a set time

•

StEP: Step to a new setpoint

•

cALL: Call another program as a subroutine

(only available in multi-program controllers)

•

End: Make this segment the end of the program.

Press

The parameters that follow ‘tYPE’ depend on the type of segment selected as
shown in the table below. The function of each parameters follows the table.

Parameter Segment type selected

rmP.r rmP.t dwEl StEP cALL End

EndEnd

End

Hb

! ! ! !

tGt

! !

!

rAtE

!

dur

! !

PrG.n

!

cYc.n

!

outn

! ! ! !

!

SYnc

! ! ! !

End.t

!

Pwr

!

Table 5-3 Parameters t hat follow segment type

Holdback type
Only appears when Holdback per segment has been selected.
Use or to select:

• OFF: Holdback disabled

• Lo: Deviation Low Holdback

• Hi: Deviation High Ho ldback

• bAnd: Deviation Band Holdback

Press

Target setpoint

Target setpoint for ‘rmP.r’, ‘rmP.t’ or ‘StEP’ segments.
Set the target setpoint using or .

Press Continued on the next page.

Programmer Operati on Installation and Operat i on Handbook

5-14 2408 and 2404 Controller

Ramp rate

Ramp rate for ‘rmP.r’ segments
Using

or , set a value for the ramp rate, ranging from 0.0 to

999.9. The units are the ramp units (rmP.U) set earlier in this
sequence.

Press

Duration time

Time for a ‘dwEl’ segment, or time to target for a ‘rmP.t’
segment.
Set the time using

or . You have set the units earlier in

this sequence. [‘dwL.U’ defines the units for ‘dwEl’ segments:
‘rmP.U’ defines the units for ‘rmP.t’ segments.]

Press

Called program number

Only appears for ‘cALL’ segments.

(multi-program controllers only)

Set a called program number from 1 to 4, or from 1 to 20, using

or .

Press

Number of cycles of the cALLed program

Only appears for ‘cALL’ segments.

(multi-program controllers only)

Sets the number of cycles of the cALLed program from 1 to 999,
using

or .

Press

Continued on the next page.

Installation and Operat i on Handbook Programmer Operati on

2408 and 2404 Controller 5-15

Event output 1

(16-segment programmers only)

Appears in all segments, except ‘cALL’ segments.
Use

or to set output 1:

• OFF: Off in the cu rrent segment

• on: On the current segment.

Press

Further event outputs

(16-segment programmers only)

Up to eight (8) event outputs may appear in this list where ‘n’ =
event number.
Pressing

will step through all the remaining event outputs.

Note:

If you are not using all of the event outputs, you can step

immediately to the next segment number by pressing .

Press

Synchronisation event output (only appears if configured)

Use

or to select:

• YES: Synchronisation Enabled

• no: Synchronisation Disabled

Note:

This event output, if used, occupies the position of ‘out8’.

Press

End segment

Use

or to select:

• dwEl: An indefinite dwell

• rSEt: Reset.

• S OP: End Segment Output Power Level

Press

SYnc

YES

Programmer Operati on Installation and Operat i on Handbook

5-16 2408 and 2404 Controller

Power Value [End Segment]

Use

or to set the power value in the range ±100.0%.
This power level is clipped by the parameters ‘OP.Hi’ and
‘OP.Lo’ before being applied to the process.

Note: In programmer/controller softw are versions 3.56
onwards this parameter has been replaced by a parameter

End.P

End.PEnd.P

End.P whic h appe ar s at the end of the Output Li st, see

Chapter 2

P

ress to return to the ProG-LiSt header.

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-1

Chapter 6 CONFIGURATION

This chapter consists of six topics:

• SELECTING CONFIGURATION LEVEL

• LEAVING CONFIGURATION LEVEL

• SELECTING A CONFIGURATION PARAMETER

• CHANGING THE PASSWORDS

• NAVIGATION DIAGRAM

• CONFIGURATION PARAMETER TABLES.

In configuration level you set up the fundamental characteristics of the controller.
These are:

• The type of control (e.g. reverse or direct acting)

• The Input type and range

• The Setpoint configuration

• The Alarms configuration

• The Programmer configuration

• The Digital input configuration

• The Alarm Relay configuration

• The Communications configuration

• The Modules 1, 2 & 3 configuration

• Calibration

• The Passwords.

WARNING

Configuration is protected by a password and should only be c a r r ied out by a qualified
person, authorised to do so. Incorrect configuration could result in damage to the
process being controlled and/or personal injury. It is the responsibility of the person
commissioning the process to ensure that the configuration is correct.

Configuration Installation and Operation Handbook

6-2

2

408 and 2404 Controller

SELECTING CONFIGURATION LEVEL

There are two alternative methods of selecting Configuration level:

• If you have already powered up, then follow the access instructi ons given in Chapter 3,

Access levels.

• Alternatively, press

and together when powering up the controller. This will

take you directly to the ‘ConF’ password display.

Password entry

When the ‘ConF’ display appears, you must enter the

Configuration password (which is a number) in order to

gain access to Configu r ation level.

Enter the password using the

or buttons.

The configuration password is set to ‘2’ when the

controller is shipped from the factory.

Once the correct password has been entered, there is a two

second delay, after which the lower readout will change to

‘PASS’ indicati ng that access is now unlocked.

Note: A special case exists if the password has been set to

‘0’. In this situ ation, access is permanently unlocked and

the lower readout will always show ‘PASS’.

Press to enter configuration.

(If an incorrect password has been entered and the

controller is still ‘locked’ then pressing

at this point

will take you to the ‘Exit’ display with ‘no’ in the lower

readout. Simply press to return to the ‘ConF’

display.)

You will obtain the first display of configuration.

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-3

LEAVING CONFIGURATION LEVEL

To leave the Configuration level and return to Operator level Press until the ‘Exit’
display appears.

Alternatively, pressing

and together will take you directly to the ‘Exit’ display.

Use

or to select ‘YES’. After a two-second

delay, the display will blank and revert to the Home
display in Operator level.

SELECTING A CONFIGURATION PARAMETER

The configuration parameters are arranged in lists as shown in the navigation diagram in
Figure 6.1.

To step through the list headers, press the Page

button.

To step through the parameters within a particular list press the Scroll

button.

When you reach the end of the list you will return to the list header.
You can return directly to the list header at any time by pressing the Page

button.

Parameter names

Each box in the navigation diagram shows the display for a particular parameter. The upper
readout shows the name of the parameter and the lower readout its value. For a definition of
each parameter, see the Configurat i on Parameter Tables at the end of th i s chapter. To change

the value of a selected parameter, use the

and buttons.

The navigation diagram shows all the lists headers and parameters that can, potentially, be
present in the controller. In practice, those actually present will vary according to the
particular configuration choices you make.

CHANGING THE PASSWORDS

There are TWO passwords. These are stored in the Password configuration list and can be
selected and changed in the same manner as any other configuration parameter.
The password names are:
‘ACC.P’ which protects access to Full level and Edit level
‘cnF.P’ which protects access to Configuration level.

Configuration Installation and Operation Handbook

6-4

2

408 and 2404 Controller

NAVIGATION DIAGRAM (PART A)

Instrument Process Value Input Setpoi nt Alarms Programmer Logic inputs
Config

Config Config Config Config Config Config

Fig 6.1a Navigation Diagram (P art A)

m-A

diSA

ti.td

SEc

CooL

Lin

Act

rEv

CtrL

Pid

inSt

ConF

rmt

nonE

rmP.U

PSEc

Pr.tr

OFF

m.tr

OFF

rm.tr

OFF

nSP

2

SP

ConF

AL

ConF

AL1

FSH

Ltch

no

bLoc

no

AL2

FSL

Ltch

no

bLoc

no

AL3

OFF

Ltch

no

bLoc

no

AL4

OFF

Ltch

no

bLoc

no

PROG

ConF

PtyP

20

Pwr.F

cont

Srvo

to.PV

out

no

SYnc

no

iP

ConF

id

LoG.i

Func

mAn

LA/b

ConF

inPt

k.tc

CJC

Auto

inp.L

0.0

VaL.H

100.0

VaL.L

0.0

inp.H

50.0

imp

Auto

HbAc

SEG

unit

o

C

dEc.P

nnnn

PV

ConF

rnG.H

1200

rnG.L

0

FOP

no

Sbr.t

b.

Pd.tr

no

Fwd.t

nonE

PwrF

YES

r-h

diSA

GSch

no

bcd

nonE

dtYP

PV

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-5

NAVIGATION DIAGRAM (PART B)

Alarm relay Com ms 1 Comms 2 Module 1 Module 2 Module 3 Module 4

(2)

Custom

(3)

Config

Config Config Config

(1)

Config

(1)

Config

(1)

Config Config

Fig 6.1b Navigation Diagram (P art B)

Note:

1. Additional headers, carrying the suffixes b
and C, will appear if dual-, or triple-, channel
modules have been inst al l ed. The header
denotes the labelling of the terminal to which
the output functi on i s connected.

2.

M

odule 4 is the High Current Switc h Module.

This is only available i n the Model 2404

c

ontroller on controllers manufactured before

Jan-04.

3. 8-point custom linearisation. Only appears
when either‘3a or iP-Conf’ has ‘inpt’ =
‘mV.C’, or ‘mA.C’, or ‘V.C’.

4. The navigation diagram shows typical
parameters, but i s dependant upon the exact
configuration of the i nstrument. The
following sheets show the full l i st of
parameters.

See parameter

t

ables

id

dC.OP

Func

HEAt

VAL.L

0

VAL.H

100

unit

mA

Out.L

4.0

Out.H

20.0

rES

FuLL

Prty

nonE

bAud

9600

Func

mod

id

cmS

in 1

0.0

UAL.1

0.0

in 2

1.0

UAL.2

200.0

in 3

2..0

VAL.H

100

VAL.L

0

Func

SP.oP

id

PdS

id

rELy

Func

dIG

SEnS

nor

2A

ConF

1A

ConF

3A

ConF

HA

ConF

CUSt

ConF

JA

ConF

AA

ConF

See parameter

t

ables

id

dC.iP

Func

SEL

inpt

mU

imp

Auto

inp.L

0.0

inp.H

50.0

VAL.L

0

VAL.H

100

4A

ConF

id

HCS

Func

HEAt

VAL.L

0

VAL.H

100

Out.L

0.0

Out.H

100.0

UAL.3

350.0

in 8

7.0

UAL.8

800.0

deLY

no

SEnS

nor

Configuration Installation and Operation Handbook

6-6

2

408 and 2404 Controller

NAVIGATION DIAGRAM (PART C)

Calibration Password
Config

Config

Fig 6.1c Navigation Diagram (Part C)

ACC.P

1

cnF.P

2

Exit

no

PASS

ConF

cAL

nonE

UCAL

no

pt1.L

0

pt1.H

0

OF1.L

0.0

CAL

ConF

OF1.H

0.0

pt2.L

0

pt2.H

0

OF2.L

0.0

OF2.H

0.0

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-7

CONFIGURATION PARAMETER TABLES

Name Description Values Meaning

inSt

inStinSt

inSt

Instrument configuration

CtrL

Control type

Pid

PID control

On.OF

On/off control

VP

Boundless motorised valve
control - no feedback requi red

VP b

Bounded motorised val ve
control - feedback requi red

Act

Control action

rEv

Reverse acting

dir

Direct acting

CooL

Type of cooling

Lin

Linear

oiL

Oil (50mS m i ni mum on-time)

H2O

Water (non-linear)

FAn

Fan (0.5S minimum on-time)

on.OF

On/off cooling

ti.td

Integral & derivative

SEc

Seconds, OFF to 9999

time units

min

Minutes, OFF to 999.9

dtYP

Derivative type

pV
Err

Operates on rate of change of
PV
Operates on rate of change of
error

m-A

Front panel Auto/Man button

EnAb

Enabled

diSA

Disabled

r-h

Front panel Run/Hold button

EnAb

Enabled

diSA

Disabled

PwrF

Power feedback

on

On

OFF

Off

Fwd.t

Feed forward type

none

None

FEEd

Normal feed forward

SP.FF

Setpoint feed forward

PV.FF

PV feed forward

Pd.tr

Manual/Auto transfer when

no

Non-bumpless transfer

using PD control

YES

Bumpless transfer - (Pre-loads
Manual Reset value)

Sbr.t

Sensor break output

Sb.OP

Go to pre-set value

HoLd

Freeze output

FOP

Forced manual output

no

Bumpless Auto/Manual transfer

trac

Returns to the Manual value that
was set when last in Manual
mode

Step

Steps to forced output level.
Value set in ‘FOP’ of ‘op-List’
in Operator Level

bcd

BCD input function

none
prog
sp

Not used
Select program number
Select setpoint number

gsch

Gain schedule enable

no
yes

Disabled
Enabled

Configuration Installation and Operation Handbook

6-8

2

408 and 2404 Controller

Name Description Values Meaning

pV

pVpV

pV

Process value config

unit

Instrument uni ts

0

C

Celsius

0

F

Fahrenheit

0

k

none

Kelvin
Display units blanked

dec.p

Decimal plac es in the

nnnn

None

displayed value

nnn.n
nn.nn

One
Two

rng.L

Range low

Low range limit. Also setpoint limit for
alarms and programmers

rng.h

Range high

High range limit. Also setpoint lim i t for
alarms and programmers

Notes:

1. Pyrometer Emmisivity

Controllers which are specifically supplied for pyrometer inputs (not Exergen K80), have the

curve downloaded in the Custom Input. The parameter, EmiS, Pyrometer Emmis ivity,
appears in the Input List on page 2-15. This parameter is also now correctly adjusted.

2. Range

If a decimal point was configured, negative display and setpoint ranges were limited to -99.9

in previous software versions. The range has been increased to -199.9 by combining the
negative sign with the figure one. This allows Setpoints, Process Variables, Alarm
Setpoints and Programmers to be set to -199.9.

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-9

Name Description Values Meaning

iP

iPiP

iP

Input configuration

inPt

Input type

J.tc

J thermocouple

k.tc

K thermocouple

L.tc

L thermocouple

r.tc

R thermocouple (Pt/Pt13%Rh)

b.tc

B thermocouple (P t30%Rh/Pt6%Rh)

n.tc

N thermocouple

t.tc

T thermocouple

S.tc

S thermocouple (P t/Pt10%Rh)

PL 2

PL 2 thermocouple

C.tc

Custom downloaded t/c (default = type C)

rtd

100Ω platinum resistance thermometer

mV

Linear millivolt

voLt

Linear voltage

mA

Linear milliamps

Sr V

Square root volts

Sr A

Square root milliamps

* see CUST List.

mV.C

8-point millivolt custom linearisation

*

V.C

8-point Voltage custom linearisation

*

mA.C

8-point milliamp cust om linearisation

*

CJC

Cold Junction

Auto

Automatic i nternal compensation

Compensation

0

o

C

0

o

C external reference

45

o

C

45

o

C external reference

50

o

C

50

o

C external reference

OFF

No cold junction compensation

imp

Sensor Break Impedance

Off

Disabled (applies to any i nput)

Caution:
If sensor break is disabled the
controller will not detect open circuit
faults

Auto

Factory set (Default i.e. enabled)

Hi

Impedance of input > 5K Ω

Hi.Hi

Impedance of input > 15K Ω

Linear Input Scaling − The next 4 parameters only appear if a l i near or sq rt input is chosen.
inp.L

Input value low

inp.H

Input value high

VAL.L

Displayed reading low

VAL.H

Displayed reading high

inP.H

inP.L

VAL. H

Displayed Value

VAL. L

Electrical
Input

Configuration Installation and Operation Handbook

6-10

2

408 and 2404 Controller

Name Description Values Meaning

SP

SPSP

SP

Setpoint configuration

nSP

Number of setpoints

2, 4, 16

Select number of setpoints available

rm.tr

Remote Tracking

OFF

Disable

trAc

Local setpoint tracks remote setpoint

m.tr

Manual Track

OFF

Disable

trAc

Local setpoint tracks PV when in manual

Pr.tr

Programmer Track

OFF

Disable

trAc

Local setpoint tracks programmer SP

rmP.U

Setpoint rate limit units

PSEc

Per second

Pmin

Per minute

PHr

Per hour

rmt

Remote setpoint configuration

nonE

Disable

SP

Remote setpoint

Loc.t

Remote setpoint + local trim

rmt.t

Remote trim + local setpoint

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-11

AL

ALAL

AL

Alarm configuration Values

The controller contains four ‘soft’ alarms, which are
configured in this l i st. Once configured, they can be
attached to a physi cal output as described in the al arm
relay configuration l i st, ‘AA Conf’.

AL1

Alarm 1 Type

see Table A

Ltch

Latching

no/YES/Evnt/mAn

*

bLoc

Blocking

no/YES

AL2

Alarm 2 Type

see Table A

Ltch

Latching

no/YES/Evnt/mAn

*

bLoc

Blocking

no/YES

AL3

Alarm 3 Type

see Table A

Ltch

Latching

no/YES/Evnt/mAn

*

bLoc

Blocking

no/YES

AL4

Alarm 4 Type

see Table A

Ltch

Latching

no/YES/Evnt/mAn

*

bLoc

Blocking

(not if ‘AL4’ = ‘rAt’)

no/YES

Sbr.t

Sensor break trip alarm
latching type.

Disable = process al arms
inhibited when in sensor
break

Enable = process alarms
shown when in sensor
break

En Enable
Dis Disable

* Alarm Modes

‘no’ means that the alarm will be non-latching.
‘YES’ means that the alarm will be latched, with automatic
resetting. Automatic resetting means that if a reset is actioned
before the alarm has cleared, then it will automatically reset
when it clears.

Evnt’ means that the alarm is used to trip an external event. If
this option is selected the front panel alarm message will not
appear.
‘mAn’ means that the alarm will be latched, and can only be
reset after it has first cleared (called ‘manual reset mode’).

Table A - Alarm types
Value Alarm t y pe

OFF

No alarm

FSL

PV Full scale low

FSH

PV Full scale high

dEv

PV Deviation band

dHi

PV Deviation high

dLo

PV Deviation low

LCr

Load Current low

HCr

Load Current high

FL2

Input 2 Full Scale low

FH2

Input 2 Full Scale
high

LOP

Working Output low

HOP

Working Output high

LSP

Worki ng S etpoint low

HSP

Working Setpoint high

rAt

PV Rate of change
AL4 only

Ct.OP

CT open circuit

Ct.Sh

CT short circuit

Configuration Installation and Operation Handbook

6-12

2

408 and 2404 Controller

The following parameters apply if the standard 8-segment programmer is to be configured.

PROG

PROGPROG

PROG

Programmer configuration Values Meaning

PtyP

Programmer type

nonE

Programmer disabled (

factory setting)

1

8-segment program mer enabled

HbAc

Holdback

SEG

ProG

Holdback is indivi dual l y selectable in
each segment.
Holdback is applied across the whole
Program.

Pwr.F

Power fail recovery

cont

Continue from las t setpoint (SP)

rmP.b

Ramp from PV to SP at last ramp rate

rSEt

Reset the program

Srvo

Starting setpoint of a

to.PV

From the Process Value (PV)

program (Servo point)

to.SP

From the setpoint

The following parameters apply if a 16-segment programmer is to be configured.

PROG

PROGPROG

PROG

Programmer configuration Values Meaning

PtyP

Programmer type

nonE

Programmer disabled

1

Single program

4

Four programs

20

Twenty programs

HbAc

Holdback

SEG

ProG

Holdback is indivi dual l y selectable in
each segment.
Holdback is applied across the whole
Program.

Pwr.F

Power fail recovery

cont

Continue from las t setpoint (SP)

rmP.b

Ramp from PV to SP at last ramp rate

rSEt

Reset the program

Srvo

Starting setpoint of a

to.PV

From the Process Value (PV)

program (Servo point)

to.SP

From the setpoint

out

Programmable event
outputs

no
YES

Disabled
Enabled

SYNC

Synchronisation of programs
of several programmers

no
YES

Disabled
Enabled

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-13

Name Description Values Meaning

LALB

LALBLALB

LALB

Digital input 1/2 configuration Action on contact closure

id

Identity

LoG.i

Logic input

Func

Function of input

nonE

No function

The function is active

mAn

Manual mode select

when the input has a contact

rmt

Remote setpoint select

closure to the common

SP.2

Setpoint 2 select

terminal - LC

Pid.2

PID set 2 select

ti H

Integral hold

tunE

One-shot self-tune enable

drA

Adaptive tune enable

Ac.AL

Acknowledge alarms

AccS

Select Full access level

Loc.b

Keylock

uP

Simulate pres sing of the

button

dwn

Simulate pres sing of the

button

ScrL

Simulate pres sing of the

button

PAGE

Simulate pres sing of the

button

run

Run program

HoLd

Hold program

r-H

Run program (closed) / Hold (open)

rES
SkiP

Reset program
Skip to End of Current S egment,

without changing the setpoint

HbAc

Program holdback enabl ed

These BCD inputs are used t o

bcd.1

Least significant BCD digit

select either a program number

bcd.2

2nd BCD digit

or the setpoint number

bcd.3

3rd BCD digit

according to the set ting of the

bcd.4

4th BCD digit

parameter ‘bcd’ in the ‘inSt’

bcd.5

5th BCD digit

configuration lis t

bcd.6

Most signific ant BCD digit

rmP.E

Setpoint Rate Limit Enable

SYnc

Program waits at the end of the
current segment

rrES

Program Run (closed) / Reset (open)

rESr

Program Reset (closed) / Run (open)

Stby

Standby - ALL control out puts turned
OFF (alarm Outputs are not af fected)

PV.SL

PV Select:
Closed = PV1 / Open = PV2

AdV

Advance to End of Segment and to
Target Setpoint

PrGn Program number

AmPS

Current – LB only

Configuration Installation and Operation Handbook

6-14

2

408 and 2404 Controller

Name Description Values Meaning

AA

AAAA

AA

Alarm relay configuration

id

Identity

rELy

Relay output

Func

Function

nonE

No function

dIG

Digital output

SEnS

Digital output sense

nor

Normal (output energi ses when
TRUE, e.g. program events)

inv

Inverted (output de-energis es when

TRUE, e.g. alarms)

The following digital events appear after ‘SEnS’. Any one, or more, of the events can be
combined on to the output (see Fig. 6-2) by selecting ‘YES’ in the lower readout.

1 - - -

Alarm 1 acti ve

YES / no (- - -) = alarm type (e.g. FSL).

2 - - -

Alarm 2 acti ve

YES / no

If an alarm has not been confi gured

3 - - -

Alarm 3 acti ve

YES / no in ‘AL ConF’ l i st, then display will

4 - - -

Alarm 4 acti ve

YES / no differ:- e.g. Alarm 1 = ‘AL 1’.

mAn

Controller in manual mode

YES / no

Sbr

Sensor break

YES / no

SPAn

PV out of range

YES / no

Lbr

Loop break

YES / no

Ld.F

Load failure alarm

YES / no

tunE

Tuning in progress

YES / no

dc.F

Voltage output open circuit, or mA
output open circuit

YES / no

rmt.F

PDS module m easurement
connection or remote input open
circuit

YES / no

iP1.F

Input 1 failure

YES / no

nw.AL

New Alarm has occurred

YES / no

End

End of setpoint rat e l i mit, or end
of program

YES / no

SYnc

Program Synchronis ation active

YES / no

PrG.n

Programmer event out put active,
where ‘n’ = event number from 1
to 8. (Not available with
8-segment programmer.)

YES / no

Figure 6-2 Combining several digital events on to one output

dIG

S

EnS

nor

inv

Output

Module

Digital Events

OR

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-15

Name Description Values Meaning

HA

HAHA

HA

Comms 1 module config

id

Identity of the module installed

cmS

EIA-232, or 2-wire EIA-485, or 4-wire
EIA-485 comms

PDS

PDS retransmi ssion

PDS.i

PDS input

dnET

DeviceNet

For ‘id

idid

id’ = ‘cms’ (Digital communications) use this parameter table:

Func

Function

mod

Modbus protocol

EI.bi

Bisynch protocol

bAud

Baud Rate

1200, 2400, 4800, 9600, 19.20(19,200)
125(K), 250(K), 500(K) for Devi ceNet

dELy

Delay - quiet period, required by

no

No delay

some comms adaptors

YES

Delay active - 10mS
The following parameters only appear i f the function chosen is Modbus protocol.
Prty

Comms Parity

nonE

No parity

EvEn

Even parity

Odd

Odd parity
rES

Comms Res o l ut ion

FuLL

Full resolution

Int

Integer resolution

For ‘id

idid

id’ = ‘pds’ (PDS retransmission output) use this parameter table:

Func

Function

nonE

No PDS function

i.e. Retransmitted output

SP.oP

PDS setpoint retransmission

PV.oP

PDS PV retransmission

OP.oP

PDS output power retransmi ssion

Er.OP

PDS error signal retransmission

SP.nH

PDS setpoint retransmission - no
holdback

Output Scaling

VAL.L

Retransmitted value low

VAL.H

Retransmitted Value High

VAL.L

100%

0%

VAL.H

Displayed Value

Retransmitted
Output

Configuration Installation and Operation Handbook

6-16

2

408 and 2404 Controller

Name Description Values Meaning

For ‘id

idid

id’ = ‘Pdsi’ (PDS setpoint input) use this parameter table:

Func

Function

SP.iP

PDS setpoint input

VAL.L

Setpoint Displayed Value - Low

VAL.H

Setpoint Di splayed Value - High

Note: Having configured the module function as remote setpoint you must then specify the type of

remote setpoint in the SP-conf list

JA

JAJA

JA

Comms 2 module config

As per Comm s 1 module configuration

VAL.L

100%

0%

VAL.H

Displayed Value

Electrical Input

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-17

Name Description Values Meaning

1A

1A1A

1A/bbbb/CCCC

(1)

Module 1 configuration

id

Identity of m odul e installed

nonE

Module not fitted

rELy

Relay output

dC.OP

DC output isolated and non­isolated

(1) If a dual-, or triple-, channel

LoG

Logic/PDS output

module is installed then the list

LoG.i

Logic input

headers 1b and 1C also appear

SSr

Triac output

dc.rE

DC retransmission (isolated)

dc.OP

Isolated DC output

SG.SU

Transducer power supply

For ‘id

idid

id’ = ‘rELy’, ‘LoG’, or ‘SSr’ use this parameter table:

Func

Function

nonE

Function disabled

dIG

Digital output func tion

(Only Channels 1A and 1C can be

HEAt

Heating output

Heating, or Cooling)

COOL

Cooling output

up

Open motorised valve

dwn

Close motorised valve

(Only if ‘id’ = ‘LoG’)

SSr.1

PDS mode 1 heating

(Only if ‘id’ = ‘LoG’)

SSr.2

PDS mode 2 heating

VAL.L

% PID demand s i gnal gi vi ng
minimum output − ‘Out.L’

VAL.H

% PID demand s i gnal gi vi ng
maximum output − ‘Out.H’

Out.L

Minimum average power

Out.H

Maximum average power

SEnS

Sense of output

(Only if ‘Func’ = ‘dIG’)

nor

Normal (output energi ses
when TRUE, e.g program
events)

inv

Inverted (output de-energis es

when TRUE, e.g. alarms)

Notes:

1. When ‘SEnS’ appears , then further parameters are available. Thes e are i dentical
to those in the ‘AA ConF’ li st on Page 6-14.

2. If a Tranducer Power Supply is fitted, the

SenS

parameter selects the output

voltage.

nor

= 5V,

inv

= 10V

3. A Transducer Power Supply does not provide any calibration facility and is simply
a 5 or 10V power supply.

4. To invert a PID output, the Val. H can be set below the Val.L

f

VAL.L

Out.H

Out.L

VAL.H

PID Demand Signal

Electrical
Output

Configuration Installation and Operation Handbook

6-18

2

408 and 2404 Controller

Name Description Values Meaning

For ‘id

idid

id’ = ‘dC.OP’, ‘dc.rE’, or ‘dc.OP’ use this parameter table:

Func

Function

nonE

Function disabled

HEAt

Heating output

COOL

Cooling output

PV

Retransmission of PV

wSP

Retransmission of setpoint

Err

Retransmission of error signal

OP

Retransmission of OP power

VAL.L

% PID, or Retrans ’ n Value,

giving minimum output

VAL.H

% PID, or Retrans ’ n Value,

giving maximum output

unit

voLt = Volts, mA = milliamps

Out.L

Minimum elec trical output

Out.H

Maximum electrical output

For ‘id

idid

id’ = ‘LoG.i’ (i.e logic input) use the

LA

LALA

LA Conf’ list on Page 6-13.

2A

2A2A

2A/bbbb/CCCC

Module 2 configuration
As per module 1 conf i guration, but excluding the ‘SSr.1’, ‘SSr.2’ functions.
id

Identity of m odul e installed.
As per module 2 plus :

tPSU

Transmitter power supply

Pot.i

Potentiomet er i nput

For ‘id

idid

id’ = ‘Pot.i (i.e. potentiometer input module) use this parameter table:

Func

Function

nonE

Function disabled

rSP

Remote Setpoint

Fwd.i

Feedforward input

rOP.h

Remote OP power max.

rOP.L

Remote OP power min.

VPoS

Motorised valve position

VAL.L

Displayed value low
equivalent to 0%
potentiometer pos i tion

VAL.H

Displayed value high
equivalent to 100%
potentiometer pos i tion

V

AL.L

Out.H

O

ut.L

VAL.H

Electrical
Output

%PID, or Retransmission Value

V

AL.L

100%

0

%

VAL.H

Displayed value

Potentiometer
position

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-19

3A

3A3A

3A/bbbb/CCCC

Module 3 configuration

As per module 2 configuration, plus ‘id’ = ‘dC.iP’

For ‘id

idid

id’ = ‘dC.iP’ use this parameter table.

THIS INCLUDES THE SECOND PV FUNCTIONS

Func

Function

nonE

Function disabled

rSP

Remote Setpoint

Fwd.i

Feedforward input

rOP.h

Remote OP power max.

rOP.L

Remote OP power min.

Hi

PV = The highest of iP.1, or iP.2

Lo

PV = The lowest of iP.1, or iP.2

Ftn

Derived function, where
PV = (f.1 x iP1) + (f.2 x iP2).
‘F.1’ and ‘F.2’ are scalars which are found

in ‘ip-List’ of Operator Level

SEL

Select ip.1, or ip.2 via Comms, front
panel buttons, or a digit al i nput

trAn

Transition of control between ip.1 and
ip.2. The transition region i s set by the
values of ‘Lo.Ip’ and ‘Hi.Ip’, whic h are
found in ‘ip-List’ of Operator Level.
PV = ip.1 below ‘Lo.Ip’

PV = ip.2 above ‘Hi.Ip’

inpt

Input type

Refer to ‘ip Conf’ for all types, + the following:
HiIn

High Impedance (range = 0 to 2 vol t)

CJC

Cold Junction

OFF

No cold junction compensation

Compensation

Auto

Automatic i nternal compensation

0

o

C

0

o

C external reference

45

o

C

45

o

C external reference

50

o

C

50

o

C external reference

imp

Sensor Break Impedance

Off

Disabled (applies to any i nput)

Caution:
If sensor break is disabled the controller
will not detect open circuit faults

Auto

Factory set

Hi

Impedance of input > 15K Ω

Hi.Hi

Impedance of input > 30K Ω

Linear Input Scaling − The next four parameters only appear i f a linear input is chosen.
inP.L

Input value low

inP.H

Input value high

VAL.L

Displayed value low

VAL.H

Displayed value high

VAL.L

inP.H

inP.L

VAL.H

Displayed Value

Electrical
Input

Configuration Installation and Operation Handbook

6-20

2

408 and 2404 Controller

Name Description Values Meaning

4A

4A4A

4A

Module 4 configuration

Note: This option is not available on controllers from 01 Jan-04

id

Identity of m odul e installed

HCS

High Current Switch

Func

Function

nonE

Function disabled

dIG

Digital output func tion

HEAt

Heating output

COOL

Cooling output

VAL.L

% PID demand signal giving

minimum output − ‘Out.L’

VAL.H

% PID demand signal giving

maximum output − ‘Out.H’

Out.L

Minimum electrical output

Out.H

Maximum electrical output

SEnS

Sense of output

(Only if ‘Func’ = ‘dIG’)

nor

Normal (output energi ses when
TRUE, e.g. program events)

inv

Inverted (output de-energis es

when TRUE, e.g. alarms)
When ‘SEnS’ appears, then further parameters are available.
These are identical to t hose in the ‘AA ConF’ list on Page 6-14.

Cust

8-point Custom Linearisation

(1)

in 1

Custom input 1

VAL.1

Linearisation Value repres enting in 1

in 8

Custom input 8

VAL.8

Linearisation Value repres enting in 8

VAL.L

Out.H

Out.L

VAL.H

PID Demand Signal

Electrical
Output

Note:

1.

Custom Linearisation is only available when ‘3a-Conf’or iP- ConF list
has ‘inpt’ set to ‘mV.C’, or ‘mA.C’, or ‘V.C’.

2. The values and inputs must be continuously increasing or decreasing

VAL.1

VAL.3

in 8

in 1 in 3

VAL.8

Displayed Value

Electrical
Input

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-21

Name Description Values Meaning

CAL

CALCAL

CAL

Calibration

In this mode you can

1. Calibrate the instrument using a mV source -

rcAL

or ref source

cal.

2. Offset t he calibration to account for errors in actual sensor
measurement and a ref sensor -

UCAL

or user calibration

3. Return to factory set calibration -

FACT

or factory set calibration.

rcAL

Calibration
point

nonE

No calibration

PV

Calibrate main Process Value input.

PV.2

Calibrate DC input, or PV 2.

1A.Hi

Calibrate DC output high - Module 1

1A.Lo

Calibrate DC output low - Module 1

2A.Hi

Calibrate DC output high - Module 2

2A.Lo

Calibrate DC output low - Module 2

3A.Hi

Calibrate DC output high - Module 3

3A.Lo

Calibrate DC output low - Module 3

INPUT CALIBRATION

For ‘CAL’ = ‘PV’, or ‘PV.2’, the following parameters apply .

PV

PV Calibration Value

IdLE

Idle

mv.L

Select 0mV as the calibration point

mv.H

Select 50mV as the calibration point

V 0

Select 0Volt as the calibration point

1. Select calibration value

V 10

Select 10V as t he calibration point

2. Apply specified input

CJC

Select 0

o

C CJC calibration point

3. Press

to step to ‘GO’ rtd

Select 400Ω as the calibration point

HI 0

High impedance: 0V ol t cal’n point

HI 1.0

High impedance: 1. 0 V ol t cal’n point

See Note below.

FACt

Restore factory c a l i bration

GO

Start calibrati on

no

Waiti ng to calibrate PV point

Select ‘YES’ with

or YES

Start calibrati on

Wait for calibration to

buSy

Busy calibrating

complete.

donE

PV input calibrat i on completed

FAIL

Calibration failed

Note. When a DC input module is installed for the first time, or there is a requirement to change one,
then the microprocessor in the controller needs to read the factory calibration data stored in the module.
Select ‘FACt’ as the calibration value. Step to ‘GO’ and start calibration.

Goto User
calibration table­See also chapter 7

Go to input
Calibation table

Go to
DC Output
Calibration
table

Configuration Installation and Operation Handbook

6-22

2

408 and 2404 Controller

DC Output Calibration

The following parameters apply to DC output modules ie for

rcAL = 1A.Hi to 3A.Lo

cAL.H

Output Calibration High

0 0 = Factory set calibration.

Trim value until out put = 9V, or
18mA

cAL.L

Output Calibration Low

0 0 = Factory set calibration.

Trim value until out put = 1V, or
2mA

User calibration

UCAL User calibration enable Yes/no
pt1.L

Low calibration point for Input 1 The factory calibration point at which the l ow

point offset was performed.

pt1.H

High calibration point for Input 1 The factory calibration point at which the high

point offset was performed.

OF1.L

Offset Low for Input 1 Calculated offset, in display uni t s.

OF1.H

Offset High for I nput 1 Calculated offset, in display units.

pt2.L

Low calibration point for Input 2 The factory calibration point at which the l ow

point offset was performed.

pt2.H

High calibration point for Input 2 The factory calibration point at which the high

point offset was performed.

OF2.L

Offset Low for Input 2 Calculated offset, in display uni t s.

OF2.H

Offset High for I nput 2 Calculated offset, in display units.

Name Description Values Meaning

PASS

PASSPASS

PASS

Password configuration

ACC.P

FuLL or Edit level password

cnF.P

Configuration level
password

Note:- When passwords are changed pl ease make a note of the new numbers

Exit

ExitExit

Exit

Exit configuration

no/YES

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-23

CONFIGURATION EXAMPLES

Transducer Power Supply

To configure the choic e of output voltage:-

Do This The Display You Should

See

Additional Notes

1. Press as many
times as necessary to
select the sl ot position in
which the transducer
power supply is fitted

The transducer power supply

can be fitted in sl ot positions
1 and 2.

The display will show 1A or
1b accordingly

2. Press to read the
identity of the module

This is read only where:

SG.SU = Transducer Power
Supply

3. Press (twice) to
read ‘Sens’

4. Press

and to

select ‘inv’ or ‘nor’

inv = 10Vdc nor = 5Vdc

The Transducer Power
supply uses existing software
written for digital m odul es. A
list of param et ers follow
which are not applicable to
this module.

1A

ConF

id

SG.SU

SEnS

inv

Configuration Installation and Operation Handbook

6-24

2

408 and 2404 Controller

DeviceNet

To configure Function, Baud Rate, Resolution and Node Address:-

Do This The Display You Should

See

Additional Notes

1. Press as many
times as necessary to
select ‘HA’

This is the position in which

the DeviceNet modul e is
fitted

2. Press to read ‘id’

If the module is present

id = ‘cms’ (digital
communications) or ‘none’ if
the module is not present

3. Press to read
‘Func’

If the DeviceNet module is

fitted ‘Func’ = ‘dnEt’ and
will be read only

4. Press to read
‘bAud’

5. Press

and to

select the baud rate

Baud rate can be set to

125(K), 250(K) or 500(K)

6. Press to read
‘rES’

7. Press

and to

select ‘FuLL’ or ‘int’

FuLL - the decimal point

position is implied, eg 100.1
is transmi t ted as 1001.

‘int’ - rounded to the
nearest integer value

HA

ConF

id

cms

Func

dnEt

bAud

500

res

FuLL

Installation and Operat i on Handbook Configuration

2408 and 2404 Controller 6-25

Node Address is set up in Operator or Full Access l evel . Select either of these l evel s, then:-

8. Press as many
times as necessary to
select ‘cms’

9. Press to read
‘Addr’

10. Press

and to

select the address

Valid addresses are f rom 0 ­63

11. Press to read
‘nw.St’

Indicates the net work s tatus:­‘run’ = network connected

and operational
‘rdy’ = network connected

but not operational
‘OFF.L’ = network not

connected

cms

List

Addr

5

nw.St

run

Configuration Installation and Operation Handbook

6-26

2

408 and 2404 Controller

Installation and Operation Handbook User Calibration

2408 and 2404 Controller 7-

1

Chapter 7 USER CALIBRATION

This chapter has five topics:

• WHAT IS THE PURPOSE OF USER CALIBRATION?

• USER CALIBRATION ENABLE

• OFFSET CALIBRATION

• TWO POINT CALIBRATION

• CALIBRATION POINTS AND CALIBRATION OFFSETS

To understand how to select and change parameters in this chapter you will need to have read
Chapter 2 - Operation, Chapter 3- Access Levels and Chapter 6 - Configuration.

WHAT IS THE PURPOSE OF USER CALIBRATION?

The basic calibration of the controller is highly stable and set for life. User calibration allows
you to offset the ‘permanent’ factory calibration to either:

1. Calibrate the controller to the your reference standards.

2. Match the calibration of the controller to that of a particular transducer or sensor input.

3. Calibrate the controller to suit the characteristics of a particular installation.

4. Remove long term drift in the factory set calibration.

User calibration works by introducing a single point, or two-point, offset onto the factory set
calibration.

User Calibration Installation and Operation Handbook

7-2 2408 and 2404 Controller

USER CALIBRATION ENABLE

The User calibration facility must first be enabled in configuration level by setting the
parameter ‘UCAL' in the input conf list to 'YES'. This will make the User calibration
parameters visible in Operator ‘FuLL’ level.
Select configuration level as shown in Chapter 6, Configuration.

+

The Calibration Configuration List

Press

until you reach the ‘CAL-Conf’ list.

Press until you reach ‘UCAL’.

User Calibration Enable

Use or to select:

•

YES: Calibration enable

• no: Calibration disabled

Press

and together to go to the Exit display.

Exit configuration

Use

or to select ‘YES’ to return to Operator level.

CAL

UCAL

no

Installation and Operation Handbook User Calibration

2408 and 2404 Controller 7-

3

OFFSET CALIBRATION

Offset calibration is used to apply a single fixed offset over the full display range of the
controller.

To calibrate, pro ceed as follows:

1. Connect the input of the controller to the source device to which you wish to calibrate.

2. Set the source to the desired calibration value.

3. The controller will display the current measurement of the value.

4. If the displayed value is correct, then the controller is correctly calibrated and no further

action is necessary. If it is incorrect, then follow the steps shown below.

Select ‘FuLL’ access level, as describ ed in Chapter 3.

x 3

Input list header

Press

until you reach the input list header.

Press until you reach the ‘CAL’ display.

Calibration type

•

FACt: Factory Calibration

• USEr: User Calibration
Use

or to select ‘FACt’.

Selecting ‘FACt’ reinstates the factory calibration and allows the
application of a single fixed offset.

Press

continued
on the next page

Displayed Value

Input

Factory Cali brati on

Fixed Of fset

CAL

FACt