How it Works
Eurotherm
Loading...
Invensys Mini8
Engineering Manual
310 pgs6.89 Mb0

Eurotherm Invensys Mini8 Engineering Manual

Download
Page 1
Mini8™
Multi-loop Controllers
Engineering Manual
Page 2
© 2009 Eurotherm Limited
All rights are strictly reserved. No part of this document may be reproduced, modified, or transmit­ted in any form by any means, nor may it be stored in a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates, without the prior, written permission of Eurotherm Limited.
Page 3
Mini8 Controller Engineering Handbook
Mini8 controller – Multi-Loop Process Controller
1. CHAPTER 1 INSTALLATION AND OPERATION.......................................................8
1.1 What Instrument Do I Have? ................................................................................................ 8
1.2 Mini8 Controller Ordering Code ........................................................................................... 9
1.3 How to Install the Controller ...............................................................................................10
1.3.1 Dimensions........................................................................................................................................................................................ 10
1.3.2 To Install the Controller................................................................................................................................................................ 10
1.3.3 Environmental Requirements ...................................................................................................................................................... 10
1.4 Electrical Connections .........................................................................................................11
1.4.1 Power Supply.................................................................................................................................................................................... 11
1.4.2 Fixed IO Connections..................................................................................................................................................................... 12
1.4.3 Digital Communications Connections....................................................................................................................................... 12
1.4.4 Configuration Port .......................................................................................................................................................................... 12
1.4.5 Modbus .............................................................................................................................................................................................. 12
1.4.6 DeviceNet / CANopen ................................................................................................................................................................... 14
1.4.7 Enhanced DeviceNet Interface.................................................................................................................................................... 15
1.4.8 Typical DeviceNet / CANopen Wiring Diagram ..................................................................................................................... 16
1.4.9 Profibus DP ....................................................................................................................................................................................... 17
1.4.10 Ethernet (Modbus TCP)........................................................................................................................................................... 18
1.4.11 Thermocouple Input TC4 and TC8 ...................................................................................................................................... 19
1.4.12 RTD / PT100 Input RT4............................................................................................................................................................ 20
1.4.13 Logic Input DI8 .......................................................................................................................................................................... 21
1.4.14 Logic Output DO8..................................................................................................................................................................... 22
1.4.15 Relay Output RL8 ...................................................................................................................................................................... 23
1.4.16 Analogue Output AO4 and AO8........................................................................................................................................... 24
1.4.17 Current Transformer input Module CT3 ............................................................................................................................ 25
1.5 Adding or replacing an IO module. ......................................................................................26
1.6 Mini 8 LED Indicators ...........................................................................................................27
1.6.1 Status Indication for Enhanced DeviceNet.............................................................................................................................. 28
2. CHAPTER 2 USING THE MINI8 CONTROLLER .......................................................29
2.1 iTools ...................................................................................................................................29
2.1.1 iTools OPC Open server ................................................................................................................................................................ 29
2.2 Modbus, single register, SCADA addressing .........................................................................29
2.3 Modbus (Floating Point) ......................................................................................................30
2.4 Fieldbus ...............................................................................................................................30
2.5 Ethernet...............................................................................................................................30
2.6 Mini8 Controller Execution ..................................................................................................30
2.7 The iTools Operator Interface..............................................................................................31
2.7.1 Scanning............................................................................................................................................................................................. 31
2.7.2 Browsing and Changing Parameter Values.............................................................................................................................. 31
2.8 Recipe Editor .......................................................................................................................33
2.8.1 Recipe Menu Commands.............................................................................................................................................................. 33
2.9 OPCScope ............................................................................................................................34
2.9.1 OPC Scope List Window Context Menu ................................................................................................................................... 35
2.9.2 OPC Scope Chart Window............................................................................................................................................................ 35
2.9.3 OPC Server ........................................................................................................................................................................................ 37
3. CHAPTER 3 CONFIGURATION USING ITOOLS ......................................................38
3.1 Configuration.......................................................................................................................38
3.1.1 On-Line/Off-line Configuration................................................................................................................................................... 38
3.2 Connecting a PC to the Mini8 Controller .............................................................................38
3.2.1 Configuration Cable and Clip ...................................................................................................................................................... 38
3.2.2 Scanning............................................................................................................................................................................................. 38
3.3 Cloning ................................................................................................................................39
3.4 Configuring the Mini8 Controller.........................................................................................40
3.4.1 Function Blocks ............................................................................................................................................................................... 40
3.4.2 Soft Wiring ........................................................................................................................................................................................ 41
3.5 Simple Worked Example ......................................................................................................42
3.5.1 The I/O ............................................................................................................................................................................................... 42
Part No HA028581 Issue 7.0 Dec-09 CN25905 1
Page 4
Engineering Handbook Mini8 Controller
3.6 Graphical Wiring Editor....................................................................................................... 48
3.6.1 Graphical Wiring Toolbar ..............................................................................................................................................................49
3.6.2 Function Block..................................................................................................................................................................................49
3.6.3 Wire .....................................................................................................................................................................................................49
3.6.4 Block Execution Order ...................................................................................................................................................................49
3.6.5 Using Function Blocks ....................................................................................................................................................................49
3.6.6 Tooltips ...............................................................................................................................................................................................50
3.6.7 Function Block State.......................................................................................................................................................................51
3.6.8 Using Wires........................................................................................................................................................................................52
3.6.9 Using Comments..............................................................................................................................................................................53
3.6.10 Using Monitors ........................................................................................................................................................................... 54
3.6.11 Downloading ...............................................................................................................................................................................54
3.6.12 Selections .....................................................................................................................................................................................54
3.6.13 Colours..........................................................................................................................................................................................55
3.6.14 Diagram Context Menu............................................................................................................................................................55
3.6.15 Wiring Floats with Status Information.................................................................................................................................56
3.6.16 Edge Wires ................................................................................................................................................................................... 57
4. CHAPTER 4 MINI8 CONTROLLER OVERVIEW ...................................................... 58
4.1 Complete list of Function Blocks. ....................................................................................... 59
5. CHAPTER 5 ACCESS FOLDER.............................................................................. 60
6. CHAPTER 6 INSTRUMENT FOLDER..................................................................... 61
6.1 Instrument / Enables ........................................................................................................... 61
6.2 Instrument Options ............................................................................................................. 62
6.3 Instrument / InstInfo ...........................................................................................................62
6.4 Instrument / Diagnostics ..................................................................................................... 63
7. CHAPTER 7 I/O FOLDER..................................................................................... 65
7.1 Module ID ........................................................................................................................... 65
7.1.1 Modules..............................................................................................................................................................................................65
7.2 Logic Input .......................................................................................................................... 66
7.2.1 Logic Input Parameters ..................................................................................................................................................................66
7.3 Logic Output ....................................................................................................................... 67
7.3.1 Logic Out Parameters ..................................................................................................................................................................... 67
7.3.2 Logic Output Scaling.......................................................................................................................................................................68
7.3.3 Example: To Scale a Proportioning Logic Output .................................................................................................................68
7.4 Relay Output ....................................................................................................................... 69
7.4.1 Relay Parameters..............................................................................................................................................................................69
7.5 Thermocouple Input............................................................................................................ 70
7.5.1 Thermocouple Input Parameters ................................................................................................................................................70
7.5.2 Linearisation Types and Ranges...................................................................................................................................................72
7.5.3 CJC Type .............................................................................................................................................................................................72
7.5.4 Sensor Break Value .........................................................................................................................................................................73
7.5.5 Fallback...............................................................................................................................................................................................73
7.5.6 User Calibration (Two Point)........................................................................................................................................................74
7.5.7 PV Offset (Single Point) .................................................................................................................................................................74
7.5.8 Using TC4 or TC8 channel as a mV input.................................................................................................................................75
7.6 Resistance Thermometer Input ........................................................................................... 76
7.6.1 RT Input Parameters .......................................................................................................................................................................76
7.6.2 Linearisation Types and Ranges...................................................................................................................................................77
7.6.3 Using RT4 as mA input...................................................................................................................................................................77
7.7 Analogue Output.................................................................................................................78
7.7.1 Example – 4 to 20mA Analogue Output...................................................................................................................................78
7.8 Fixed IO............................................................................................................................... 79
7.9 Current Monitor .................................................................................................................. 80
7.9.2 Single Phase Configurations .........................................................................................................................................................81
7.9.3 Three Phase Configuration ...........................................................................................................................................................83
7.9.4 Parameter Configuration ............................................................................................................................................................... 84
7.9.5 Commissioning .................................................................................................................................................................................85
7.9.6 Calibration .........................................................................................................................................................................................87
2 Part No HA028581 Issue 7.0 Dec-09
Page 5
Mini8 Controller Engineering Handbook
8. CHAPTER 8 ALARMS.......................................................................................... 88
8.1 Further Alarm Definitions....................................................................................................88
8.2 Analogue Alarms..................................................................................................................89
8.2.1 Analogue Alarm Types................................................................................................................................................................... 89
8.3 Digital Alarms ......................................................................................................................90
8.3.1 Digital Alarm Types......................................................................................................................................................................... 90
8.4 Alarm Outputs .....................................................................................................................90
8.4.1 How Alarms are Indicated ............................................................................................................................................................ 90
8.4.2 To Acknowledge an Alarm ........................................................................................................................................................... 90
8.5 Alarm Parameters ................................................................................................................91
8.5.1 Example: To Configure Alarm 1................................................................................................................................................. 92
8.6 Digital Alarm Parameters ....................................................................................................93
8.6.1 Example: To Configure DigAlarm 1 .......................................................................................................................................... 93
8.7 Alarm Summary ...................................................................................................................94
8.8 Alarm Log ............................................................................................................................96
9. CHAPTER 9 BCD INPUT....................................................................................... 97
9.1 BCD Parameters ...................................................................................................................97
9.1.1 Example: To wire a BCD Input ................................................................................................................................................... 98
10. CHAPTER 10 DIGITAL COMMUNICATIONS...........................................................99
10.1 Configuration Port...............................................................................................................99
10.1.1 Configuration Communications Parameters ..................................................................................................................... 99
10.2 Field Communications Port................................................................................................100
10.3 Modbus..............................................................................................................................100
10.3.1 Modbus Connections............................................................................................................................................................. 100
10.3.2 Communications Parameters............................................................................................................................................... 101
10.3.3 Communications Identity...................................................................................................................................................... 101
10.3.4 Modbus Address Switch........................................................................................................................................................ 102
10.3.5 Baud Rate .................................................................................................................................................................................. 102
10.3.6 Parity........................................................................................................................................................................................... 102
10.3.7 RX/TX Delay Time ................................................................................................................................................................... 102
10.4 Modbus Broadcast Master Communications......................................................................103
10.4.1 Mini8 Controller Broadcast Master ...................................................................................................................................103
10.4.2 Wiring Connections ................................................................................................................................................................ 104
10.5 DeviceNet .......................................................................................................................... 105
10.6 Enhanced DeviceNet Interface........................................................................................... 105
10.6.1 Address Switch......................................................................................................................................................................... 105
10.6.2 Baud Switch .............................................................................................................................................................................. 105
10.7 Switch Position in iTools....................................................................................................105
10.8 CANopen............................................................................................................................106
10.8.1 Instrument setup..................................................................................................................................................................... 106
10.8.2 Mini8 Controller CANopen Features................................................................................................................................. 106
10.8.3 Communication Interface..................................................................................................................................................... 107
10.8.4 Network Management (NMT) ............................................................................................................................................. 108
10.8.5 Device Profile DS-404 ............................................................................................................................................................ 109
10.8.6 Default PDOs ............................................................................................................................................................................ 109
10.8.7 Enabling and Disabling PDO Communications............................................................................................................... 112
10.8.8 Changing PDO Mapping........................................................................................................................................................ 112
10.8.9 Remapping over the network.............................................................................................................................................. 115
10.8.10 Enabling & Disabling PDO Change of State transmission. .......................................................................................... 117
10.8.11 General Communication Objects ....................................................................................................................................... 117
10.8.12 Device Type Information ...................................................................................................................................................... 117
10.8.13 Error Register ...........................................................................................................................................................................118
10.8.14 Manufacturer Device Name................................................................................................................................................. 118
10.9 Profibus .............................................................................................................................122
10.10 Ethernet.........................................................................................................................123
10.10.1 Instrument setup..................................................................................................................................................................... 123
10.10.2 Unit Identity.............................................................................................................................................................................. 123
10.10.3 Dynamic Host Configuration Protocol (DHCP) Settings .............................................................................................. 123
10.10.4 iTools Setup .............................................................................................................................................................................. 124
10.10.5 Ethernet Parameters............................................................................................................................................................... 125
Part No HA028581 Issue 7.0 Dec-09 3
Page 6
Engineering Handbook Mini8 Controller
11. CHAPTER 11 COUNTERS, TIMERS, TOTALISERS, RT CLOCK ............................. 126
11.1 Counters............................................................................................................................ 126
11.1.1 Counter Parameters ............................................................................................................................................................... 127
11.2 Timers ............................................................................................................................... 128
11.2.1 Timer Types .............................................................................................................................................................................. 128
11.2.2 On Pulse Timer Mode ........................................................................................................................................................... 128
11.2.3 On Delay Timer Mode........................................................................................................................................................... 129
11.2.4 One Shot Timer Mode .......................................................................................................................................................... 130
11.2.5 Minimum On Timer or Compressor Mode ..................................................................................................................... 131
11.2.6 Timer Parameters ................................................................................................................................................................... 132
11.3 Totalisers........................................................................................................................... 133
11.3.1 Totaliser Parameters .............................................................................................................................................................. 134
11.4 Real Time Clock ................................................................................................................ 135
11.4.1 Real Time Clock Parameters................................................................................................................................................ 135
12. CHAPTER 12 APPLICATIONS ............................................................................ 136
12.1 Humidity ........................................................................................................................... 136
12.1.1 Overview.................................................................................................................................................................................... 136
12.1.2 Temperature Control of an Environmental Chamber.................................................................................................. 136
12.1.3 Humidity Control of an Environmental Chamber ......................................................................................................... 136
12.1.4 Humidity Parameters ............................................................................................................................................................. 137
12.2 Zirconia (Carbon Potential) Control.................................................................................. 138
12.2.1 Temperature Control............................................................................................................................................................. 138
12.2.2 Carbon Potential Control ..................................................................................................................................................... 138
12.2.3 Sooting Alarm.......................................................................................................................................................................... 138
12.2.4 Automatic Probe Cleaning ................................................................................................................................................... 138
12.2.5 Endothermic Gas Correction ............................................................................................................................................... 138
12.2.6 Clean Probe .............................................................................................................................................................................. 138
12.2.7 Probe Status ............................................................................................................................................................................. 138
12.2.8 Zirconia Parameters ............................................................................................................................................................... 139
13. CHAPTER 13 INPUT MONITOR......................................................................... 141
13.1 Description........................................................................................................................ 141
13.1.1 Maximum Detect .................................................................................................................................................................... 141
13.1.2 Minimum Detect..................................................................................................................................................................... 141
13.1.3 Time Above Threshold.......................................................................................................................................................... 141
13.2 Input Monitor Parameters................................................................................................. 142
14. CHAPTER 14 LOGIC AND MATHS OPERATORS. ................................................ 143
14.1 Logic Operators................................................................................................................. 143
14.1.1 Logic 8........................................................................................................................................................................................ 143
14.1.2 2 input Logic Operations...................................................................................................................................................... 144
14.1.3 Logic Operator Parameters.................................................................................................................................................. 145
14.2 Eight Input Logic Operators .............................................................................................. 146
14.3 Maths Operators ............................................................................................................... 147
14.3.1 Math Operations..................................................................................................................................................................... 148
14.3.2 Math Operator Parameters.................................................................................................................................................. 149
14.3.3 Sample and Hold Operation................................................................................................................................................ 150
14.4 Multiple Input Operator Block .......................................................................................... 151
14.4.1 Cascaded operation ............................................................................................................................................................... 152
14.4.2 Fallback Strategy..................................................................................................................................................................... 152
14.4.3 Multiple Input Operator Block Parameters .................................................................................................................... 153
14.5 Eight Input Analog Multiplexers........................................................................................ 154
14.5.1 Multiple Input Operator Parameters ................................................................................................................................ 154
14.5.2 Fallback...................................................................................................................................................................................... 154
15. CHAPTER 15 INPUT CHARACTERISATION......................................................... 155
15.1 Input Linearisation ............................................................................................................ 155
15.1.1 Compensation for Sensor Non-Linearities ...................................................................................................................... 156
15.1.2 Input Linearisation Parameters ........................................................................................................................................... 157
15.2 Polynomial ........................................................................................................................ 158
16. CHAPTER 16 LOAD .......................................................................................... 160
16.1 Load Parameters ............................................................................................................... 160
4 Part No HA028581 Issue 7.0 Dec-09
Page 7
Mini8 Controller Engineering Handbook
17. CHAPTER 17 CONTROL LOOP SET UP............................................................... 162
17.1 What is a Control Loop? ....................................................................................................162
17.2 Loop Parameters - Main.....................................................................................................163
17.3 Loop Set up........................................................................................................................163
17.3.1 Types of Control Loop........................................................................................................................................................... 164
17.4 PID Control ........................................................................................................................164
17.4.1 Proportional Term .................................................................................................................................................................. 165
17.4.2 Integral Term............................................................................................................................................................................ 165
17.4.3 Derivative Term ....................................................................................................................................................................... 166
17.4.4 High and Low Cutback ..........................................................................................................................................................167
17.4.5 Integral action and manual reset ....................................................................................................................................... 167
17.4.6 Relative Cool Gain................................................................................................................................................................... 167
17.4.7 Loop Break................................................................................................................................................................................ 168
17.4.8 Cooling Algorithm ..................................................................................................................................................................168
17.4.9 Gain Scheduling....................................................................................................................................................................... 169
17.4.10 PID Parameters ........................................................................................................................................................................170
17.5 Tuning Function Block .......................................................................................................171
17.5.1 Loop Response......................................................................................................................................................................... 171
17.5.2 Initial Settings........................................................................................................................................................................... 171
17.5.3 Multi-zone applications......................................................................................................................................................... 172
17.5.4 Automatic Tuning ................................................................................................................................................................... 173
17.5.5 Tune Parameters ..................................................................................................................................................................... 174
17.5.6 To Auto Tune a Loop - Initial Settings.............................................................................................................................. 174
17.5.7 To Start Autotune ................................................................................................................................................................... 174
17.5.8 Autotune and Sensor Break................................................................................................................................................. 175
17.5.9 Autotune and Inhibit .............................................................................................................................................................175
17.5.10 Autotune and Gain Scheduling ........................................................................................................................................... 175
17.5.11 Autotune from Below SP – Heat/Cool.............................................................................................................................. 176
17.5.12 Autotune From Below SP – Heat Only .............................................................................................................................177
17.5.13 Autotune at Setpoint – Heat/Cool..................................................................................................................................... 178
17.5.14 Failure Modes........................................................................................................................................................................... 179
17.5.15 Manual Tuning ......................................................................................................................................................................... 180
17.5.16 Manually Setting Relative Cool Gain ................................................................................................................................. 180
17.5.17 Manually Setting the Cutback Values ............................................................................................................................... 181
17.6 Setpoint Function Block .................................................................................................... 182
17.6.1 Setpoint Function Block........................................................................................................................................................ 182
17.6.2 SP Tracking................................................................................................................................................................................ 183
17.6.3 Manual Tracking...................................................................................................................................................................... 183
17.6.4 Rate Limit .................................................................................................................................................................................. 183
17.6.5 Setpoint Parameters............................................................................................................................................................... 183
17.6.6 Setpoint Limits ......................................................................................................................................................................... 185
17.6.7 Setpoint Rate Limit ................................................................................................................................................................. 185
17.6.8 Setpoint Tracking .................................................................................................................................................................... 186
17.6.9 Manual Tracking...................................................................................................................................................................... 186
17.7 Output Function Block ......................................................................................................187
17.7.1 Output Limits ...........................................................................................................................................................................189
17.7.2 Output Rate Limit ................................................................................................................................................................... 190
17.7.3 Sensor Break Mode ................................................................................................................................................................ 190
17.7.4 Forced Output ......................................................................................................................................................................... 190
17.7.5 Feedforward ............................................................................................................................................................................. 191
17.7.6 Effect of Control Action, Hysteresis and Deadband ..................................................................................................... 192
18. CHAPTER 18 SETPOINT PROGRAMMER ........................................................... 193
18.1.1 Time to Target Programmer ................................................................................................................................................ 193
18.1.2 Ramp Rate Programmer........................................................................................................................................................ 194
18.2 Mini8 Controller Programmer Block(s) .............................................................................. 194
18.3 Segment Types...................................................................................................................195
18.3.1 Rate ............................................................................................................................................................................................. 195
18.3.2 Dwell........................................................................................................................................................................................... 195
18.3.3 Step ............................................................................................................................................................................................. 195
18.3.4 Time ............................................................................................................................................................................................ 195
18.3.5 GoBack ....................................................................................................................................................................................... 195
18.3.6 Wait............................................................................................................................................................................................. 196
18.3.7 End............................................................................................................................................................................................... 196
Part No HA028581 Issue 7.0 Dec-09 5
Page 8
Engineering Handbook Mini8 Controller
18.4 Output Events ................................................................................................................... 197
18.4.1 Digital Events............................................................................................................................................................................ 197
18.4.2 PV Event & User Value .......................................................................................................................................................... 198
18.4.3 Time Event ................................................................................................................................................................................ 198
18.5 Holdback........................................................................................................................... 201
18.5.1 Guaranteed Soak..................................................................................................................................................................... 201
18.6 PID Select.......................................................................................................................... 202
18.7 Program Cycles ................................................................................................................. 202
18.7.1 Servo........................................................................................................................................................................................... 202
18.8 Power Fail Recovery .......................................................................................................... 203
18.9 To Run, Hold or Reset a Program ...................................................................................... 204
18.9.1 Run.............................................................................................................................................................................................. 204
18.9.2 Reset........................................................................................................................................................................................... 204
18.9.3 Hold ............................................................................................................................................................................................ 204
18.9.4 Skip segment............................................................................................................................................................................ 204
18.9.5 Advance segment ................................................................................................................................................................... 205
18.9.6 Fast.............................................................................................................................................................................................. 205
18.10 PV Start......................................................................................................................... 205
18.11 Configuring the Programmer ........................................................................................ 206
18.12 Programmer Run Status ................................................................................................ 208
18.13 Creating a Program ....................................................................................................... 209
18.14 Program Editor.............................................................................................................. 209
18.14.1 Analog View ............................................................................................................................................................................. 210
18.14.2 Digital View............................................................................................................................................................................... 212
18.14.3 Saving & Loading Programs ................................................................................................................................................. 212
18.14.4 Printing a Program ................................................................................................................................................................. 213
18.15 Wiring the Programmer Function Block........................................................................ 214
19. CHAPTER 19 SWITCH OVER ............................................................................. 216
19.1.1 Example: To Set the Switch Over Levels......................................................................................................................... 216
19.1.2 Switch Over Parameters ....................................................................................................................................................... 217
20. CHAPTER 20 TRANSDUCER SCALING ............................................................... 218
20.1 Auto-Tare Calibration ....................................................................................................... 218
20.2 Load Cell ........................................................................................................................... 219
20.3 Comparison Calibration .................................................................................................... 219
20.4 Transducer Scaling Parameters ......................................................................................... 219
20.4.1 Parameter Notes ..................................................................................................................................................................... 221
20.4.2 Tare Calibration....................................................................................................................................................................... 221
20.4.3 Load Cell.................................................................................................................................................................................... 222
20.4.4 Comparison Calibration ........................................................................................................................................................ 222
21. CHAPTER 21 USER VALUES.............................................................................. 223
21.1 User Value Parameters...................................................................................................... 223
22. CHAPTER 22 CALIBRATION.............................................................................. 224
22.1 TC4 / TC8 User calibration ................................................................................................ 224
22.1.1 Set Up ........................................................................................................................................................................................ 224
22.1.2 Zero Calibration ...................................................................................................................................................................... 224
22.1.3 Voltage Calibration ................................................................................................................................................................ 224
22.1.4 CJC Calibration......................................................................................................................................................................... 224
22.1.5 Sensor-Break Limit Check .................................................................................................................................................... 224
22.2 To Return to TC4/TC8 Factory Calibration ........................................................................ 225
22.3 RT4 User calibration.......................................................................................................... 225
22.3.1 Set Up ........................................................................................................................................................................................ 225
22.3.2 Calibration ................................................................................................................................................................................ 225
22.4 To Return to RT4 Factory Calibration ............................................................................... 225
22.5 Calibration Parameters ..................................................................................................... 226
23. CHAPTER 23 OEM SECURITY............................................................................ 227
23.1 Introduction ...................................................................................................................... 227
23.2 Using OEM Security........................................................................................................... 227
23.3 Step 1 – View iTools OPC Server ....................................................................................... 228
23.4 Step 2 – Create Custom Tags............................................................................................. 229
6 Part No HA028581 Issue 7.0 Dec-09
Page 9
Mini8 Controller Engineering Handbook
23.5 Step 3 – Activate OEM Security ......................................................................................... 231
23.6 Step 4 – Deactivate OEM Security .....................................................................................232
23.7 Erasing Memory .................................................................................................................232
24. APPENDIX A MODBUS SCADA TABLE............................................................... 233
24.1 Comms Table .....................................................................................................................233
24.2 SCADA Table...................................................................................................................... 233
24.2.1 Version 2.xx Programmer Addresses - Decimal............................................................................................................. 257
24.2.2 Version 2.xx Programmer Addresses - Hexadecimal.................................................................................................... 264
25. APPENDIX B DEVICENET PARAMETER TABLES.................................................. 271
25.1 IO Re-Mapping Object .......................................................................................................271
25.2 Application Variables Object .............................................................................................272
25.2.1 Table Modification.................................................................................................................................................................. 276
26. APPENDIX C CANOPEN PARAMETER TABLES ................................................... 277
26.1 Manufacturer Object – Pick List ........................................................................................277
27. APPENDIX D VERSION 1.XX PROGRAMMER...................................................... 281
27.1 Version 1.xx Parameter Tables........................................................................................... 281
27.1.1 Configuring the Programmer (V1.xx)................................................................................................................................ 281
27.1.2 To Select, Run, Hold or Reset a Program (V1.xx).......................................................................................................... 282
27.1.3 Creating a Program (V1.xx) .................................................................................................................................................. 282
27.1.4 To Select, Run, Hold or Reset a Program (Version 1.xx) ........................................................................................... 283
27.2 Version 1.xx Programmer SCADA addresses ......................................................................283
28. APPENDIX E SAFETY AND EMC INFORMATION ................................................ 288
29. APPENDIX F TECHNICAL SPECIFICATION.......................................................... 291
29.1 Environmental Specification.............................................................................................. 291
29.2 Network Communications Support.................................................................................... 291
29.3 Configuration Communications Support ...........................................................................291
29.4 Fixed I/O Resources ........................................................................................................... 292
29.5 TC8 8-Channel and TC4 4-Channel TC Input Card ..............................................................292
29.6 DO8 8-Channel Digital Output Card...................................................................................293
29.7 RL8 8-Channel Relay Output Card...................................................................................... 293
29.8 CT3 3-Channel Current-Transformer Input Card ................................................................293
29.9 Load Failure Detection ......................................................................................................294
29.10 DI8 8-Channel Digital Input Card ................................................................................... 294
29.11 RT4 Resistance Thermometer Input Card ......................................................................294
29.12 AO8 8-Channel and AO4 4-Channel 4-20mA Output Card ..............................................295
29.13 Toolkit Blocks ................................................................................................................296
29.14 PID Control Loop Blocks ................................................................................................ 297
29.15 Process Alarms .............................................................................................................. 297
29.16 Setpoint Programmer .................................................................................................... 297
29.17 Recipes ..........................................................................................................................297
30. PARAMETER INDEX ........................................................................................... 298
Issue Status of This Manual
Issue 6 includes Enhanced Devicenet Communications.
Issue 7 corrects terminal numbers in Example 2 section 7.9.2.1, adds references to iTools in sections 1.4.11 and
1.4.12 and adds to section 10.8 ‘Note: from July 09 CANopen option has been discontinued’.
Part No HA028581 Issue 7.0 Dec-09 7
Page 10
Engineering Handbook Mini8 Controller
Mini8 Multi-Loop Process Controller
1. Chapter 1 Installation and Operation
1.1 What Instrument Do I Have?
Thank you for choosing this Mini 8 Controller.
The Mini8 controller is a compact DIN rail mounting multi-loop PID controller and data acquisition unit. It offers a choice of I/O and a choice of field communications.
The Mini8 controller mounts on 35mm Top Hat DIN Rail. It is intended for permanent installation, for indoor use only, and to be enclosed in an electrical panel or cabinet.
The Mini8 controller is pre-assembled in the factory to give the I/O required for the application as specified in the order code. With standard applications the Mini8 controller is also supplied configured. Alternatively, the Mini8 controller is configured using Eurotherm’s iTools configuration suite running on a personal computer.
All Safety & EMC information is in Appendix E.
The full Technical Specification is in Appendix F.
Whenever the symbol
8 Part No HA028581 Issue 7.0 Dec-09
☺ appears in this handbook it indicates a helpful hint
Page 11
Mini8 Controller Engineering Handbook
1.2 Mini8 Controller Ordering Code
1.
Mini8
controller
11
Application
2.
Loops
12 .
Recipe
3.
Programs
13.
Wires
4.
PSU
14.
Manual
5.
Comms
15.
Config
6.
Units
7.
I/O
Slot1
8.
I/O
Slot2
Slot3
1 7-10 IO Slots 1-4
MINI8
CONTROLLER Mini 8 controller XXX No module fitted
2 Control Loops TC4 4 Channel TC Input
ACQ IO Acquisition only TC8 8 Channel TC Input
4LP 4 Control loops RT4 4 Channel RTD input
8LP 8 Control loops
16LP 16 Control loops
3 Programs
0PRG No Programs 1PRG 1 Profile – 50 programs DO8 8 Channel logic output XPRG Multi-profile – 50 programs CT3 3 Channel CT input
4 PSU RL8 8 Channel relay (slots 2, 3 only)
VL 24Vdc DI8 8 Channel logic input
VH 100 – 264 Vac
5 Communications 11 Application
MODBUS Non Isolated Modbus RTU slave STD No configuration
ISOLMBUS Isolated Modbus RTU slave EC8 8 Loop Extrusion Controller
DEVICENET DeviceNet Slave FC8 8 Loop 4-20mA outputs
PBUSRJ45 Profibus Slave RJ45 12 Wires
PBUS9PIN Profibus Slave 9 pin D type 30 30 User Wires
ENETMBUS Ethernet Modbus TCP IP Slave 60 60 User Wires
CANOPEN CANopen Slave 120 120 User Wires
DNETSEMI DeviceNet Enhanced card 250 250 User Wires
13 Recipes
6 Temperature Units None No Recipes
C Centigrade RCP 8 Recipes
F Fahrenheit 14 Manual
ENG English
GER German
FRA French
SPA Spanish
AO4
AO8
ITA Italian
15 Configuration Software
NONE No CD
ITOOLS
4 Channel 4-20mA output (slot 4 only)
8 Channel 4-20mA output (slot 4 only)
Itools CD & Mini8 controller documentation
9.
I/O
10.
I/O
Slot4
Part No HA028581 Issue 7.0 Dec-09 9
Page 12
Engineering Handbook Mini8 Controller
1.3 How to Install the Controller
This instrument is intended for permanent installation, for indoor use only, and to be enclosed in an electrical panel.
Select a location where minimum vibrations are present and the ambient temperature is within 0 and 50oC (32 and 122
Please read the safety information, Appendix E at the end of this manual, before proceeding and refer to the EMC Booklet part number HA025497 for further information.
1.3.1 Dimensions
A
o
F).
Allow a minimum of 25mm above and below each unit
B
Dimension mm
Allow a minimum of 25mm for terminals and cables
A 108 B 124 C 115
Figure 1-1: Mini8 Controller Dimensions
C
1.3.2 To Install the Controller
1. Use 35mm symmetrical DIN Rail to EN50022-35 x 7.5 or 35 x 15,
2. Mount the DIN Rail horizontally as indicated in Figure 1.1. The Mini8 controller is NOT designed to be mounted in other orientations.
3. Hook the upper edge of the DIN rail clip on the instrument on the top of the DIN rail and push.
4. To remove use a screwdriver to lever down the lower DIN rail clip and lift forward when the clip has released.
5. A second unit on the same DIN rail may be mounted adjacent to the unit.
6. A second unit mounted above or below the unit requires a gap of at least 25mm between the top of the lower one and the bottom of the higher one.
1.3.3 Environmental Requirements
Mini8 controller Minimum Maximum
Temperature 0°C 55°C Humidity (non condensing) 5% RH 95% RH Altitude 2000m
10 Part No HA028581 Issue 7.0 Dec-09
Page 13
Mini8 Controller Engineering Handbook
1.4 Electrical Connections
The Mini8 controller is intended for operation at safe low voltage levels, except the RL8 relay module.
Voltages in excess of 42 volts must not be applied to any terminals other than the RL8 relay module.
A protective earth connection is required.
Do not replace the battery. Return to factory if replacement battery is required.
Communications LEDs
Communications Configuration port
Instrument
LEDs
Power
Supply
Fixed IO
Communications connector
DeviceNet shown
Communications settings
I/O Slots I to 4
Figure 1-2: Terminal Layout for Mini8 Controller
1.4.1 Power Supply
The power supply requires a supply between 17.8 to 28.8 V dc, 15 watts maximum
24V Ø 24 V dc
24V Ø 24 V dc
0V Ø 0 V dc
GND Ø Ground
Connector terminals will accept wire sizes from 0.5 to 2.5, 24 to 12 awg.
Note: If the Min8 is used with the VT505 panel ensure that the power supply connectors cannot be mistakenly changed over. The connectors are physically the same, but the electrical connections are not compatible. Plugging the VT505 connector into the Mini8 controller will short-circuit the 24 volt supply.
Part No HA028581 Issue 7.0 Dec-09 11
User-Terminals
Page 14
Engineering Handbook Mini8 Controller
1.4.2 Fixed IO Connections
These I/O are part of the power supply board and are always fitted.
D1 Ø Digital Input 1
D2 Ø Digital Input 2
C Ø Digital Input common
A1 Ø Relay A n/open
A2 Ø Relay A n/closed
A3 Ø Relay A common
B1 Ø Relay B n/open
B2 Ø Relay B n/closed
B3 Ø Relay B common
Digital Inputs : ON requires > 10.8V with 2mA drive, 30V max.
Relays contacts: 1 amp max, 42Vdc. These contacts are NOT rated for mains operation.
1.4.3 Digital Communications Connections
Two communications connections are fitted – a Modbus Configuration port (RJ11) and a Fieldbus port.
The Fieldbus is either Modbus (2 x RJ45 ), DeviceNet, CANopen, Profibus or Ethernet 10baseT.
1.4.4 Configuration Port
The configuration port (Modbus) is on an RJ11 socket, just to the right of the power supply connections. It is a point to point RS232 connection. Eurotherm supply a standard cable to connect a serial COM port on a computer to the RJ11 socket, part no. SubMin8/cable/config.
1.4.5 Modbus
For a full description of the installation of a communications link, including line matching resistors, see Eurotherm 2000 series communications handbook, part no. HA026230.
RJ45 pin 3 wire 5 wire
8 A RxA
7 B RxB
6 Ground Ground
5
4
3 Ground Ground
9 pin DF to PC
COM port (RS232)
- 6 N/c
RJ11
Pin
Function
Pin 6
3 (Tx) 5 Rx
2 (Rx) 4 Tx
Pin 1
5 (0v) 3 0v (gnd)
2 N/c
1 Reserved
Pin 8
Pin 1
2 A TxA
1 B TxB
12 Part No HA028581 Issue 7.0 Dec-09
Page 15
Mini8 Controller Engineering Handbook
Two RJ45 sockets are provided – one for the incoming connection, the second to loop onto the next instrument or for a line terminator.
For the address switch see section 10.3.4
The RS485 standard allows one or more instruments to be connected (multi dropped) using a two wire connection, with cable length of less than 1200m. 31 instruments and one master may be connected.
To use RS485, buffer the RS232 port of the PC with a suitable RS232/RS485 converter. The Eurotherm Controls KD485 Communications Adapter unit is recommended for this purpose. The use of a RS485 board built into the computer is not recommended since this board may not be isolated, which may cause noise problems or damage to the computer, and the RX terminals may not be biased correctly for this application.
Either cut a patch cable and connect the open end to the KD485 converter or, using twin screened cable, crimp an RJ45 plug on the Mini8 controller end.
The communication line must be daisy chained from device to device and, if the communications line is more than a metre or two long, it must be correctly terminated. A Modbus terminator containing the correct termination resistors is available from Eurotherm, order code:
SubMin8/RESISTOR/MODBUS/RJ45. The Modbus terminator is BLACK.
See also the 2000 series Communications Handbook, part number HA026230, available on
www.eurotherm.co.uk
. for further information on digital communications.
Com Rx Tx
RS232
RxA RxB Com TxA TxB
RS485
220 ohm termination resistor on the Rx of the converter unit
RJ45 Patch cables
Modbus Terminator
Type KD485
converter
Mini8 no. 1
Mini8 no. n
Figure 1-3: RS485 two-wire Connections
For the 4 wire connection the TxA and TxB are not connected to RxA and RxB but connected separately through another twisted pair.
Part No HA028581 Issue 7.0 Dec-09 13
Page 16
Engineering Handbook Mini8 Controller
1.4.6 DeviceNet / CANopen
This instrument supports DeviceNetTM CAN interface, CANopen V4.02 CAN interface and Enhanced DeviceNet
DeviceNet and CANopen both use a 5 way, 5.08mm pitch, connector/screw terminal. The DeviceNet bus is powered (24V) from the system network, not from the instrument. The Mini8 controller requirement is a load of around 100mA. For the address switch see section 10.5.
Mini8 controller Label
V+ Red Network power positive terminal. Connect the red wire of the DeviceNet /
CAN_H White CAN_H data bus terminal. Connect the white wire of the DeviceNet /
SHIELD None Shield/Drain wire connection. Connect the DeviceNet cable shield here. To
CAN_L Blue CAN_L data bus terminal. Connect the blue wire of the DeviceNet / CANopen
V- Black Network power negative terminal. Connect the black wire of the DeviceNet /
The DeviceNet specification states that the bus terminators of 121 ohm should not be included as any part of a master or slave. They are not supplied but should be included in the cabling between CAN_H and CAN_L where required.
The CANopen Cabling and Connector Pin Assignment specification specifies that the minimum termination resistance is 118 ohm with the following guidelines. They are not supplied but should be included in the cabling where required.
Pin Legend Function
5
5 V+ V+ 4 CH CAN HIGH 3 DR DRAIN 2 CL CAN LOW 1 V- V-
1
Colour Description
CANopen cable here. If the network does not supply the power, connect the positive terminal of an external 11-25 Vdc power supply.
CANopen cable here.
prevent ground loops, the network should be grounded in only one location.
cable here.
CANopen cable here. If the DeviceNet network does not supply the power, connect the negative terminal of an external 11-25 Vdc power supply.
Bus length (m) Termination resistance (ohms)
0 – 40 124
40 – 100 150 - 300
TM
.
Network length depends on Baud rate.
Network Length Varies w/speed, up to 4000m possible w/repeaters
Baud Rate 125 250 500 1M (CANopen)
Thin trunk 100m (328ft) 100m (328ft) 100m (328ft) 100m
Max drop 6m (20ft) 6m (20ft) 6m (20ft) 6m(20ft)
Cumulative drop 156m (512ft) 78m (256ft) 39m (128ft) 19m (64ft)
14 Part No HA028581 Issue 7.0 Dec-09
Page 17
Mini8 Controller Engineering Handbook
1.4.7 Enhanced DeviceNet Interface
This version of DeviceNet has been added for use in the Semiconductor industry. Configuration for both versions is the same and is described in the DeviceNet Handbook HA027506 which can be downloaded from www.eurotherm.com
The Enhanced DeviceNet interface uses a different connector, as described below, but cabling, cable specification and termination are the same as described in sections 1.4.6 and 1.4.8.
.
1.4.7.1 Connector
The 5-way connector shown in the previous section is replaced by a ‘Micro-Connect’ circular 5-pin M12 male connector mounted in the module.
Pin Legend Function
5 CAN_L CAN LOW
4 CAN_H CAN HIGH
3 V- V-
2 V+ V+
1 DR DRAIN
1.4.7.2 Switches and LED Indicators
The Enhanced DeviceNet interface also uses different Module and Network Status indicators, address and baud rate switches.
To set the Address and Baud Rate, see section 10.6.
For Module and Network Status indication see section 1.6.1.
2
3
View from front
Plug Key
1
5
4
Part No HA028581 Issue 7.0 Dec-09 15
Page 18
Engineering Handbook Mini8 Controller
1.4.8 Typical DeviceNet / CANopen Wiring Diagram
V- 1
RED
WHT
BLU
BLK
V+ 5
CAN-H 4
Drain 3
CAN-L 2
MASTER
Supply
24Vdc (+/- 1%)
250mV p-p Ripple
max
V+ V-
Gnd
Mini8
Mini8
Mini8
V+
CAN-H
Drain CAN-L
V-
(SLAVE) Address 11
V+
CAN-H
Drain
CAN-L
V-
(SLAVE) Address 12
V+
CAN-H
Drain
CAN-L
V-
(SLAVE) Address N+1
121
Ω*
* CANopen specifies 124 ohms, see section 1.4.6.
See also the DeviceNet Communications Handbook HA027506
16 Part No HA028581 Issue 7.0 Dec-09
Page 19
Mini8 Controller Engineering Handbook
1.4.9 Profibus DP
Two Profibus communications board options are available for the Mini8 controller.
1. Standard Profibus 3 wire RS485 9 pin D connector intended for installation using standard Profibus cabling. Note that in this arrangement line terminations must be catered for in the cabling.
2. Profibus 3 wire RS485 via 2 paralleled RJ45 sockets. Instruments may be daisy chained using suitable RJ45 cables and an RJ45 termination plug is available to terminate the line.
1.4.9.1 Profibus Interface (D-Type Connector)
Connector: 9-Way D-Type, R/A, Female, 4-40 UNC Studs:
Pin Function
1 Shield (Case)
2 N/C
3 RxD/TxD+ P (B)
4 N/C
5 GND (0V)
6 VP (+5V)
7 N/C
8 RxD/TxD- N (A)
9 N/C
1.4.9.2 Profibus Interface (RJ45 Connector)
Terminations must be included in the cabling.
Connector: Two RJ45, parallel connected (for daisy-chain):
Pin 3-Wire
8 (do not use)
7 (do not use)
6 VP (+5V)
5
4
3 GND
2 RxD/TxD+ P (B)
1 RxD/TxD- N (A)
8
1
One connector may be used to terminate line using SubMini8/Term/Profibus/RJ45
This terminator is grey.
Part No HA028581 Issue 7.0 Dec-09 17
Page 20
Engineering Handbook Mini8 Controller
1.4.10 Ethernet (Modbus TCP)
The Ethernet connection uses standard Cat5E patch cables (RJ45). These would be used with a 10BaseT hub to create a network.
A crossover patch cable may be used ‘point-to-point’ i.e. to connect a single instrument directly to a PC.
Connector: RJ45:
Pin Function
8
7
6 RX-
5
4
3 RX+
2 TX-
1 TX+
Network traffic activity is displayed on indicators built into the connector, yellow indicates network activity and green shows the Mini8 controller is communicating.
8
1
18 Part No HA028581 Issue 7.0 Dec-09
Page 21
Mini8 Controller Engineering Handbook
1.4.11 Thermocouple Input TC4 and TC8
The TC8 thermocouple module takes 8 thermocouples; the TC4 module takes 4 thermocouples. They may be placed in any slot in the Mini8 controller. Up to 4 may be fitted in a Mini8 controller. Each input can be configured to any thermocouple type or a linear mV input.
Note: Configuration of Mini8 Controller is performed using ‘iTools’ configuration suite running on a personal computer. See subsequent chapters in this manual and specifically example 1 given in section 3.5.1 for further information.
The TC4 module offers TC1 to TC4, on terminals A to H
A Ø TC1 +
B Ø TC1 -
C Ø TC2 +
D Ø TC2 -
E Ø TC3 +
F Ø TC3 -
G Ø TC4 +
H Ø TC4 -
I Ø TC5 +
J Ø TC5 -
K Ø TC6 +
L Ø TC6 -
M Ø TC7 +
N Ø TC7 -
O Ø TC8 +
P Ø TC8 -
Part No HA028581 Issue 7.0 Dec-09 19
Page 22
Engineering Handbook Mini8 Controller
1.4.12 RTD / PT100 Input RT4
The RT4 module provides 4 RTD inputs for 2, 3 or 4 wire connections. Up to 4 modules may be fitted in a Mini8 controller and they may be placed in any slot. Each input can be configured for any resistive sensor up to 600 ohms. Standard linearisation is available for PT100.
Note: Configuration of Mini8 Controller is performed using ‘iTools’ configuration suite running on a personal computer. See subsequent chapters in this manual and specifically example 2 given in section 3.5.1 for further information.
A Ø CH1 Current +
B Ø CH1 Sense +
C Ø CH1 Sense ─
D Ø CH1 Current ─
E Ø CH2 Current +
F Ø CH2 Sense +
G Ø CH2 Sense ─
H Ø CH2 Current ─
I Ø CH3 Current +
J Ø CH3 Sense +
K Ø CH3 Sense ─
L Ø CH3 Current ─
M Ø CH4 Current +
N Ø CH4 Sense +
O Ø CH4 Sense ─
P Ø CH4 Current ─
2 3 4
wire connection
☺ Tip:
Spare RT4 input channels may be configured as mA inputs using a 2.49 ohm resistor, order code
SubMini8/resistor/Shunt/249R.1. See section 7.6.3 for configuration.
A Ø CH1 Current +
B Ø CH1 Sense +
C Ø CH1 Sense ─
2.49 ohm
D Ø CH1 Current ─
20 Part No HA028581 Issue 7.0 Dec-09
mA in
mA out
Page 23
Mini8 Controller Engineering Handbook
1.4.13 Logic Input DI8
The DI8 module provides 8 logic inputs. They may be placed in any slot in the Mini8 controller. Up to 4 may be fitted in a Mini8 controller.
A Ø D1 +
B Ø D1 -
C Ø D2 +
D Ø D2 -
E Ø D3 +
F Ø D3 -
G Ø D4 +
H Ø D4 -
+24V 0V
+24V 0V
+24V 0V
+24V 0V
I Ø D5 +
J Ø D5 -
K Ø D6 +
L Ø D6 -
M Ø D7 +
N Ø D7 -
O Ø D8 +
P Ø D8 -
+24V 0V
+24V 0V
+24V 0V
+24V 0V
Digital Inputs : ON requires > 10.8V with 2mA drive, 30V max.
Part No HA028581 Issue 7.0 Dec-09 21
Page 24
Engineering Handbook Mini8 Controller
1.4.14 Logic Output DO8
The DO8 module provides 8 logic outputs. They may be placed in any slot in the Mini8 controller. Up to 4 may be fitted in a Mini8 controller. Each output can be configured to Time Proportioning or On/Off.
24V
0V
A Ø Supply In +
B Ø Supply In +
C Ø OP 1 +
D Ø OP 2 +
E Ø OP 3 +
F Ø OP 4 +
+
–
SSR 1
G Ø Supply & OP -
H Ø Supply & OP -
I Ø Supply In +
J Ø Supply In +
K Ø OP 5 +
L Ø OP 6 +
M Ø OP 7 +
N Ø OP 8 +
O Ø Supply & OP -
P Ø Supply & OP -
+
–
SSRs
2 to 7
SSR 8
Supply In + (A,B,I,J) are all linked internally.
Supply In – (G,H,O,P) are all linked internally.
22 Part No HA028581 Issue 7.0 Dec-09
Page 25
Mini8 Controller Engineering Handbook
1.4.15 Relay Output RL8
The RL8 module provides 8 relay outputs.
Up to 2 modules may be fitted and in slots 2 and/or 3 only
A Ø
B Ø
C Ø
D Ø
E Ø
F Ø
G Ø
H Ø
I Ø
J Ø
K Ø
L Ø
M Ø
N Ø
O Ø
P Ø
RLY1 A
RLY1 B
RLY2 A
RLY2 B
RLY3 A
RLY3 B
RLY4 A
RLY4 B
RLY5 A
RLY5 B
RLY6 A
RLY6 B
RLY7 A
RLY7 B
RLY8 A
RLY8 B
Relay contacts for full contact life:
Maximum 264V ac 2amps with snubber fitted.
Minimum 5V dc, 10mA
Snubbers are used to prolong the life of relay contacts and to reduce interference when switching inductive devices such as contactors or solenoid valves. If the relay is used to switch a device with a high impedance input, no snubber is necessary.
All relay modules are fitted internally with a snubber since these are generally required to switch inductive devices. However, snubbers pass 0.6mA at 110V and 1.2mA at 230Vac, which may be sufficient to hold on high impedance loads. If this type of device is used it will be necessary to remove the snubber from the circuit.
The relay module has to be removed from the instrument. See Section 1.5. The snubber is removed from the relay module by inserting a screwdriver into one of the pair of slots either side of the track of each snubber network. Twist the screwdriver to break out this track between the slots.
This action is not reversible.
Part No HA028581 Issue 7.0 Dec-09 23
Page 26
Engineering Handbook Mini8 Controller
1.4.16 Analogue Output AO4 and AO8
The AO8 modules provides 8 analogue outputs and the AO4 provides 4 analogue outputs. Each output is configurable within 0 to 20 mA , max load 360 ohm.
The AO4 offers OP1 to OP4 on terminals A to H.
Only one module may be fitted and in slot 4 only.
A Ø OP 1 +
B Ø OP 1 -
C Ø OP 2 +
D Ø OP 2 -
E Ø OP 3 +
F Ø OP 3 -
G Ø OP 4 +
H Ø OP 4 -
I Ø OP 5 +
J Ø OP 5 -
K Ø OP 6 +
L Ø OP 6 -
M Ø OP 7 +
N Ø OP 7 -
O Ø OP 8 +
P Ø OP 8 -
☺ Tip:
A 0 to 10 volt output can be obtained by scaling the drive to 0 to 10mA and fitting an external 1kohm resistor (for example). Low load impedance may alter the results but this can be corrected by adjusting the output range accordingly.
24 Part No HA028581 Issue 7.0 Dec-09
Page 27
Mini8 Controller Engineering Handbook
1.4.17 Current Transformer input Module CT3
This provides inputs for 3 current transformers. The heater load cables are threaded through the transformers. Each input is 50mA max into 5 ohms.
A Ø Reserved
B Ø Reserved
C Ø Reserved
D Ø Reserved
E Ø Reserved
F Ø Reserved
G Ø Reserved
H Ø Reserved
I Ø In 1 A
J Ø In 1 B
K Ø no connection
L Ø In 2 A
M Ø In 2 B
N Ø no connection
o Ø In 3 A
P Ø In 3 B
The current transformers provide channel isolation; there is no channel to channel isolation in the module.
It is recommended that the current transformer is fitted with a voltage limiting device such as two back to back zener diodes between 3 and 10 volts, rated for 50mA.
There are 3 CT inputs, one for each phase. Up to a maximum of 16 heaters may be threaded through the CTs but with a further limit of 6 heater wires through each individual CT.
See Chapter 7.9 for typical circuit arrangements.
CT
To CT input on CT3 module
Part No HA028581 Issue 7.0 Dec-09 25
Page 28
Engineering Handbook Mini8 Controller
1.5 Adding or replacing an IO module.
Modules contain static sensitive electronic devices. Take full antistatic protection when replacing
modules by working on an earthed mat with an earthed wrist strap. Avoiding touching components,
keep fingers on the green connectors or the edge of the printed circuit boards.
Remove screw → ← Remove screw
Figure 1-4: Mini8 controller Cover Retaining Screws
1. Remove all connectors.
2. Remove the 2 screws indicated above
3. Remove the cover.
4. If removing a module gently prise it out using the green connectors.
5. Insert the new module carefully using the guides on the side of the case to help to line up the lower connector with its mate on the motherboard. This requires great care as the guides provide mechanical support rather than being plug in guides.
6. Once you are certain the two connectors are lined up, push the module gently into place. Do NOT force.
7. Replace cover and the 2 cover screws.
8. Replace all connectors onto their correct modules.
26 Part No HA028581 Issue 7.0 Dec-09
Page 29
Mini8 Controller Engineering Handbook
1.6 Mini 8 LED Indicators
Two sets of 3 LEDs on the front panel indicate the power, the state of the output relays, the status of the Mini8 controller and communications activity.
Legend P A B
LED Green Red Red
Function Indicates 24V Relay A state Relay B state
OFF No power De-energised De-energised
ON Powered Energised Energised
FC Legend RN CC
Modbus/Profibus DeviceNet/CANopen Ethernet*
LED Green Green Green Green Green
Function Indicates
run mode
OFF Not
Indicates Configuration
Field comms activity
Status Field comms
activity
-- Offline Offline No port traffic
running
Blinking Standby Config traffic Traffic Ready Port traffic
excluding local housekeeping
ON Running -- Connected
* The Ethernet connector itself has two in-built LEDs : Green = network activity
Yellow = Mini8 controller communicating
The Mini8 controller is controlling normally ONLY if the green RN LED is permanently ON.
Note: In iTools the parameter ‘Comms Network Status’ is available enumerated as shown in the following table. The enumerations correspond to the FC indicator as shown in the final column:-
‘Status’ Parameter
Meaning Corresponding FC LED
Enumeration
RUNNING (0) Network connected and running On
INIT (1) Network initialising Off
READY (2) DeviceNet traffic detected but not for this address Blinking
OFFLINE (3) No DeviceNet traffic detected Off
Part No HA028581 Issue 7.0 Dec-09 27
Page 30
Engineering Handbook Mini8 Controller
1.6.1 Status Indication for Enhanced DeviceNet
If an Enhanced DeviceNet module is fitted (section 1.4.7), two bi-colour LEDs are
NET MOD
1.6.1.1 Module Status Indication
The module status LED (MOD) has the functionality shown below:
LED State Device State Description
OFF Off No power applied to DeviceNet network.
Green/Red flashing Self test LED power-up test.
Green ON Operational DeviceNet interface is operational.
Red ON Unrecoverable fault Mini8 Controller not powered.
1.6.1.2 Network Status Indication
used to indicate Module and Network status.
These two LEDs replace the single LED shown as FC on other modules. See previous section.
Interface state machine not entered the cyclic states.
Invalid baud rate switch setting.
Nvol checksum failure.
The network status LED (NET) indicates the status of the DeviceNet communications link as shown in the table below.
Note: The final column shows the enumerated values for the ‘Comms Network Status’ parameter available in iTools.
LED State Network State Description ‘Status’ Parameter
Enumerations
OFF Off Device is not on line
Green flashing On-line, not
connected
Green ON On-line and
connected
Red flashing Connection timed
Device is on line but has no connections established
Device is on line and has connections established
One or more connections have timed out
OFFLINE (10)
READY (11)
ONLINE (12)
IO TIMEOUT (13)
out
Red ON Critical link failure Communication error that has rendered the
LINK FAIL (14)
device incapable of communicating on the network
Green/Red Communications
fault
Communications fault but the device has received an Identify Communication Faulted
COMM FAULT (15)
Request
28 Part No HA028581 Issue 7.0 Dec-09
Page 31
Mini8 Controller Engineering Handbook
2. Chapter 2 Using the Mini8 controller
The Mini8 controller does not have a display. The only means of configuring it, and of interfacing with it during normal operation is via communications.
The auxiliary communications port CC (RJ11) gives a Modbus interface usually connected to iTools for configuration and commissioning.
The main communications port FC offers Modbus, DeviceNet, CANopen, Profibus, or Ethernet normally connected to the system of which the Mini8 controller is part, and is the means by which the Mini8 controller is operated.
Below are ways the Mini8 controller may be used in a system. iTools is the best PC based solution. The Modbus single register addressing is best for Operator panels, PLCs where floating point may not be available or necessary. Some parameters may also be read this way as floats or long integers.
2.1 iTools
iTools offers a pc based solution. The iTools suite allows configuration, commissioning, trend graphs and logging with OPC Scope, Program Editing, Recipes and User pages with View Builder.
2.1.1 iTools OPC Open server
With an OPEN OPC server running on a PC all the Mini8 controller parameters are available to any third party package with an OPC client. The advantage of this is that all the parameters are addressed by name – the iTools OPC server handles all the physical communication addresses. An example would be with Wonderware inTouch using OPCLink. In this situation the user would not have to know any of the parameter addresses, and would just select a parameter by browsing through the namespace.
e.g. Eurotherm.ModbusServer.1.COM1.ID001-Mini8.Loop.1.Main.PV
2.2 Modbus, single register, SCADA addressing
The key parameters of the Mini8 controller are available at a fixed single 16 bit register address, independent of its configuration. These can be used with any device with a serial Modbus master (Modbus function 4). The parameters are listed in full with their addresses in Appendix A.
By default iTools displays the SCADA address of those parameters which are available.
As shown, not all the parameters within the instrument are available. If other parameters are required they can be obtained by using the Commstab folder. This allows up to 250 other parameters to be made available using indirection addressing. This is explained in Appendix A.
Also note that in this area the resolution (number of decimal points) has to be configured and the serial Master has to scale the parameter correctly.
Part No HA028581 Issue 7.0 Dec-09 29
Page 32
Engineering Handbook Mini8 Controller
2.3 Modbus (Floating Point)
If the application requires the extra resolution, the Commstab folder also offers an alternative solution where a parameter can be indirectly addressed and communicated either as a floating point or as a double integer value – its ‘Native’ format. This can be used with any device e.g. PC or plc, with a serial Modbus master, able to decode a double register for floating point numbers (Modbus function 7) and long integers (Modbus function
8). See Appendix A.
2.4 Fieldbus
The Mini8 controller may be ordered with the option of DeviceNet, Profibus or CanOPEN.
DeviceNet comes pre-configured with the key parameters of 8 PID loops and alarms (60 input parameters process variables, alarm status etc and 60 output parameters – setpoints etc.). Loops 9-16 are not included in the DeviceNet tables as there are insufficient attributes for the DeviceNet parameters. See Appendix B.
CANopen offers 4 receive & 4 Transmit PDOs and 1 server SDO with a 200 parameter pick list. See Appendix C
Profibus is set up using a GSD editor included on the iTools CD. The GSD editor sets up the instrument parameters that are required to be communicated with the master.
2.5 Ethernet
The Mini8 controller may be ordered with an Ethernet connection (10baseT) running ModbusTCP as the protocol. An instrument can therefore have a unique identity on the Ethernet network as well as a unique Modbus address for the Modbus master.
2.6 Mini8 Controller Execution
The nominal update of all inputs and function blocks is 110ms. However, in complex applications the Mini8 controller will automatically extend this time in multiples of 110ms.
For example, eight simple heat/cool loops each with two alarms (40 wires) will run at 110ms, while the full EC8 configuration will run at 220ms because of the extra wiring and functionality.
The communications traffic will also have some effect on the update rate.
For example, an application using every function block and all 250 wires will run at 220ms with light communications traffic but may be slowed to 330ms with heavy traffic.
Note that as loading changes, the sample rate may increase or decrease automatically. In order to recover to a faster sample rate, the Mini8 controller must be running consistently with processing power to spare for at least 30s.
30 Part No HA028581 Issue 7.0 Dec-09
Page 33
Mini8 Controller Engineering Handbook
2.7 The iTools Operator Interface
Much of this manual is about configuring the Mini8 controller with iTools. However iTools also provides an excellent commissioning tool and can be used as a long-term operator view if convenient.
First it is necessary to go ‘on-line’ to the Mini8 controller(s). This assumes the communication ports have been wired up to the COM port on the iTools computer (Chapter 10).
2.7.1 Scanning
Open iTools and, with the controller connected, press on the iTools menu bar. iTools will search the communications ports for recognisable instruments. Controllers connected using the RJ11 configuration port or with the configuration clip (CPI), may be found at address 255 (as a single point to point connection) or on a multidrop RS485 or RS422 network will be found at the address configured in the controller.
The iTools handbook, part no. HA026179, provides further step by step instructions on the general operation of iTools. This and the iTools software may be downloaded from www.eurotherm.co.uk
When an instrument is found on the network it will be shown as, for example
‘COM1.ID001-Min8’ which represents <computer com port>.ID<instrument address>-<Instrument type>
Stop the scan once all the instruments have been found.
.
Once an instrument is found on the network a message ‘’sync pending’ or synchronizing’ is displayed next to it whilst iTools extracts the exact configuration from the instrument. Wait until this message disappears.
2.7.2 Browsing and Changing Parameter Values
Once the instrument is synchronized the parameter navigation tree is displayed. The contents of this tree will vary depending on the actual configuration of the instrument.
The folders shown will be some of those which are always present –
e.g Instrument, IO, Comms, Access
as well as the configuration dependent ones-
e.g. Loops, Alarm, Lgc2 etc. which have been configured.
Part No HA028581 Issue 7.0 Dec-09 31
Page 34
Engineering Handbook Mini8 Controller
To view or change a parameter:
1. Highlight the folder
2. Press required folder. Right click in the parameter list to reveal or hide columns.
3. To change the value of a parameter,
a. click the parameter value,
b. write in the new value. Note a pop-up window indicates the current value, and the high and low limits.
c. Hit <Enter> to enter the new value or <Escape> to cancel.
to get the parameter window or open up the parameter list by clicking on the
The ‘Access’ button puts the controller into configuration mode. In this mode the controller can be set up without its outputs being active. Press ‘Access’ again to return to operating level.
To find a parameter use the ‘Find’ tab at the bottom of the folder list.
☺ Tip: In parameter lists: Parameters in BLUE are read only
Parameters in BLACK are read/write.
☺ Tip: Every parameter in the parameter lists has a detailed description in the help file – just click on a
parameter and hit Shift-F1 on the keyboard or right click and select parameter help.
32 Part No HA028581 Issue 7.0 Dec-09
Page 35
Mini8 Controller Engineering Handbook
2.8 Recipe Editor
Press for this feature. Up to 8 recipes can be stored. They can also be named by the user. Recipes allow the operator to change the operating values of up to 24 parameters in an instrument for different batch items/processes by simply selecting a particular recipe to load. Recipes are important for reducing error in setup and they remove the need for operator instructions fixed to the panel next to the instrument.
Note: Loading a recipe set causes the instrument to enter Standby mode momentarily during which time it does not control.
The Recipe Editor is used during configuration to assign the required parameters and to set up the values to be loaded for each recipe.
2.8.1 Recipe Menu Commands
Command Description
Load Recipe Used to load a recipe file into the instrument Save Used to save the current recipe configuration into a file Edit Parameter Used to assign a parameter to a Tag. Parameters can also be assigned by 'drag and drop' from
the iTools parameter list Delete Parameter Used to delete an assigned parameter from the recipes Edit Parameter Value Used to edit the current value of the assigned parameter Rename Parameter Tag Allows the user to rename the Tag of the associated parameter. This tag is used on the
instrument to identify assigned parameters (default Value1 - Value24) Parameter Properties Used to find the properties and help information of the selected parameter Copy Parameter Used to copy the currently selected parameter Paste Parameter Used to assign a previously copied parameter to the selected Tag Columns Used to hide/show the Description and Comment Columns Load Access Level Used to configure the lowest access level in which the selected recipe is allowed to load Level1 Permitted to load when the instrument is in any of the access levels Config Permitted to load when the instrument is in the Config access level Never Never permitted to load Edit Data Set Value Used to edit the value of the selected assigned parameter within the selected recipe. Values can
also be edited via double left clicking the value itself Clear Data Set Value Used to clear the value of the selected assigned parameter within the selected recipe, thus
disabling it from loading when the recipe is selected to load Rename Data Set Allows the user to rename the selected recipe. This name is used to identify individual recipes
(default Set1 - Set8). Note: Number of recipes dependent upon features Clear Data Set Used to clear all values in the selected recipe, thus disabling all from loading when the recipe is
selected to load
Snapshot Values Copy Data Set Used to copy all values of the selected recipe Paste Data Set Used to paste all values of a previously copied recipe into the selected recipe
Used to copy all of the assigned parameters current values into the selected recipe
Part No HA028581 Issue 7.0 Dec-09 33
Page 36
Engineering Handbook Mini8 Controller
2.9 OPCScope
OPC scope is a standalone OPC client that can be used to attach to the iTools OPCserver. It offers real time trend charts and data logging to disc in a .csv (comma separated variable) format which can easily be opened by a spreadsheet such as Excel.
With iTools open OPC Scope can be started using the icon
But it can also be started on its own using the Windows Start/Programs/Eurotherm iTools/OPC Scope
Select Server/Connect or click the icon display the active ports on the computer. Opening the COM port will show the attached instruments as shown below.
and the OPC server will start up (if it is not running) and will
.
The ‘ID001-Mini8’ folder will contain all the same folders for the instrument that would have been seen in iTools itself.
Expand the folder and double click on the blue item tag to add to the List Window. The List Window shows all the selected parameters and their current value.
Right click on a parameter to get the context menu.
34 Part No HA028581 Issue 7.0 Dec-09
Page 37
Mini8 Controller Engineering Handbook
2.9.1 OPC Scope List Window Context Menu
Command Description
Save Saves the OPC Scope configuration as <filename>.uix See Section 2.9.3 Copy Item DDE link Saves the DDE path to the clipboard.
‘Paste Special’ in an Excel cell and select ‘Paste Link’ and the current parameter
value will be displayed in the cell. Copy/Paste Item Copy & Paste Add Item Add a new variable by name (easier to browse the navigation tree) Remove Item Remove the selected item. Write Value Write a new value (not if the item is Read Only). Item appears on Chart Item Properties Gives the item properties as seen by OPC
The OPC List can contain parameters from any instrument attached to the Modbus network.
If you have iTools Open (not iTools Standard) then OPC Scope can run on a remote networked computer. Enter the name of the server computer (attached to the instruments) the ‘Computer’ window and browse for the ‘Eurotherm.ModbusServer1’.
Up to 8 items can be trended on the Chart Window
2.9.2 OPC Scope Chart Window
Click the Chart tab at the bottom of the display window and select Chart Control Panel.
1. Items. Includes all the items in the list window. Those items ticked (up to 8) will appear on the chart.
2. Axes. Allows time intervals from 1 minute to 1 month. Vertical axes can be ‘auto’ scaled or a fixed range may be entered.
3. General. Allows selection of colours, grid, legends and a data box.
4. Plot. Allows selection of line thickness and printing
5. Review. Allows review of early history charts.
These are also available on the toolbar.
Part No HA028581 Issue 7.0 Dec-09 35
Page 38
Engineering Handbook Mini8 Controller
iTools Trend Graph showing Loop1 SP and PV
The icon allows the chart to occupy all the window space.
36 Part No HA028581 Issue 7.0 Dec-09
Page 39
Mini8 Controller Engineering Handbook
2.9.3 OPC Server
ITools and OPC Scope all use the Eurotherm OPC Server to provide the connection between the instruments and the computer displays. When you ‘scan’ for instruments on iTools it is in fact the OPC Server that is actually doing the work in background (the window is not usually displayed).
OPC Scope can run on its own but for it to find the instruments on the network it is necessary to tell the server where they are.
1. Start OPC Server (Windows Start/Programs/Eurotherm iTools/OPC Server)
2. On the menu go to ‘Network’ and select ‘Start One-Shot Scan’
3. Stop the scan when all the instruments have been found.
4. On the menu go to ‘File’ and select ‘Save As’ and save the file with a suitable name.
5. Once saved you will be asked ‘Would you like to make this file the default start server address file?’ – select ‘Yes’.
6. Close the server.
Now if you double click on an OPC Scope file e.g. Mini8 Project.uix then this file will open OPC Scope and in turn, in background, OPC scope will open the OPC Server with this instrument file loaded. OPC Scope will then be active with live data from the instrument(s).
Part No HA028581 Issue 7.0 Dec-09 37
Page 40
Engineering Handbook Mini8 Controller
3. Chapter 3 Configuration Using ITools
WARNING
Configuration level gives access to a wide range of parameters that match the controller to the process. 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.
In configuration level the controller may not be controlling the process or providing alarm indication. Do not select configuration level on a live process.
3.1 Configuration
The Mini8 controller is supplied unconfigured, unless ordered preconfigured, e.g. EC8. An unconfigured Mini8 controller has to be configured for use in an application. This is performed using iTools.
The iTools handbook, part no. HA026179 provides further step by step instructions on the general operation of iTools. This and the iTools software may be downloaded from www.eurotherm.co.uk
3.1.1 On-Line/Off-line Configuration
If iTools is connected to a real Mini8 controller then all the parameter changes made will be written to the device immediately. Once the Mini8 controller is configured and working as required, its final configuration can be saved to disk as a ‘clone’ file of the format <name>.uic.
Alternatively iTools can be used ‘off-line’ without a real Mini8 controller connected at all. This virtual Mini8 controller can be created in iTools and again saved to disk as a clone file. This file can later be loaded into a real Mini8 controller to create the required real application. See Section 3.3 .
.
3.2 Connecting a PC to the Mini8 Controller
3.2.1 Configuration Cable and Clip
The controller may be connected to the PC running iTools using the Eurotherm cable SubMin8/Cable/Config from the RJ11 port connecting to a serial port on the PC.
Alternatively a Configuration Clip is available from Eurotherm that can be fitted into the rear of the controller.
The benefit of using this arrangement is that it is not necessary to power the controller, since the clip provides the power to the internal memory of the controller.
3.2.2 Scanning
Open iTools and, with the controller connected, press on the iTools menu bar. iTools will search the communications ports and TCP/IP connections for recognisable instruments. Controllers connected using the RJ11 configuration port or with the configuration clip (CPI), will be found at address 255 regardless of the address configured in the controller. These connections only work from iTools to a single controller.
The iTools handbook, part no. HA026179, provides further step by step instructions on the general operation of iTools. This and the iTools software may be downloaded from www.eurotherm.co.uk
In the following pages it is assumed that the user is familiar with iTools and has a general understanding of Windows.
.
38 Part No HA028581 Issue 7.0 Dec-09
Page 41
Mini8 Controller Engineering Handbook
3.3 Cloning
Saving a Clone File
On the iTools menu ‘File – Save to File’ allows the clone file of the attached Mini8 controller to be saved to disc as <user name>.UIC file. This can be loaded into another Mini8 controller.
Note that after synchronization iTools using uses a ‘quick’ save and will only resave parameters that have been changed through iTools itself. If there is any chance that parameters have been changed through the other port then it is necessary to resave all the parameters. On the menu bar under Options – Cloning ensure Reload is selected. The safest option is to keep Ask selected.
Loading a clone file
On the iTools menu ‘File – Load values File’ allows a clone file of the form <user name>.UIC to be loaded into an attached Mini8 controller unit. Whilst loading, the report window will indicate what is happening. It makes a number of attempts to load all the values and may report some errors. This is generally not an issue. If for some reason the load fails iTools will report specifically that the load ‘Failed’
Communications port parameters
A Mini8 controller clone file contains information on both the CC and FC port config settings. Depending on which comms port is used to load a clone file cloning will behave in a different manner.
Loading the clone file through the FC port will cause the CC port settings to be updated Loading the clone file through the CC port will cause the FC port settings to be updated
Part No HA028581 Issue 7.0 Dec-09 39
Page 42
Engineering Handbook Mini8 Controller
3.4 Configuring the Mini8 Controller
Once iTools is successfully connected to a Mini8 controller, it can be configured for the application in hand. Configuration involves selection of the required elements of functionality called ‘function blocks’ and setting their parameters to the correct values. The next stage is to connect all the function blocks together to create the required strategy of control for the application.
3.4.1 Function Blocks
The controller software is constructed from a number of ‘function blocks’. A function block is a software device that performs a particular duty within the controller. It may be represented as a ‘box’ that takes data in at one side (as inputs), manipulates the data internally (using internal parameter values) and ‘outputs’ the results. Some of these internal parameters are available to the user so that they can be adjusted to suit the characteristics of the process that is to be controlled.
A representation of a function block is shown below.
Name – corresponds to Folder
Output Parameters
Input Parameters
Internal Parameters
Figure 3-1: Example of a Function Block
In the controller, parameters are organised in simple lists. The top of the list shows the list header. This corresponds to the name of the function block and is generally presented in alphabetical order. This name describes the generic function of the parameters within the list. For example, the list header ‘AnAlm’ contains parameters that enable you to set up analogue alarm conditions.
40 Part No HA028581 Issue 7.0 Dec-09
Page 43
Mini8 Controller Engineering Handbook
3.4.2 Soft Wiring
Soft Wiring (sometimes known as User Wiring) refers to the connections that are made in software between function blocks. Soft wiring, which will generally be referred to as ‘Wiring’ from now on is created during the instrument configuration using the iTools configuration package.
In general every function block has at least one input and one output. Input parameters are used to specify where a function block reads its incoming data (the ‘Input Source’). The input source is usually wired from the output of a preceding function block. Output parameters are usually wired to the input source of subsequent function blocks.
All parameters shown in the function block diagrams are also shown in the parameter tables, in the relevant chapters, in the order in which they appear in iTools.
Figure 3.2 shows an example of how the thermocouple is wired to the PID Loop input and the PID Loop channel 1 (heat) output is wired to the time proportioning logic output.
PID output to
t/c to PID input
logic output
Figure 3-2: Function Block Wiring
Part No HA028581 Issue 7.0 Dec-09 41
Page 44
Engineering Handbook Mini8 Controller
3.5 Simple Worked Example
Using function blocks and wiring the following sections will show a blank Mini8 controller being configured to have one PID loop.
3.5.1 The I/O
With the Mini8 controller successfully connected to iTools configuration can begin.
☺ Tip: In parameter lists:
Parameters in BLUE are read only
Parameters in BLACK are read/write.
☺ Tip: Every parameter in the parameter lists has a detailed description in the help file – just click on a
parameter and hit Shift-F1 on the keyboard or right click and select parameter help.
The I/O will already have been installed in the Mini8 controller and can be checked in iTools.
Example 1: Thermocouple Input Configuration
In the IO list ModIDs select the type of module. Thermocouple modules may be 4 input modules or 8 input modules.
Figure 3-3: Mini8 controller I/O Modules
This unit has an 8 thermocouple input board in slot 1, a CT3 input card in slot 2, and 2 DO8 output cards in slot 3 and slot 4. Clicking on the ‘Mod’ tab will enable the first channel of the thermocouple card to be configured. Firstly the Mini8 controller has to be put into configuration mode. Go to Device/Access/Configuration or click on the Access button:
42 Part No HA028581 Issue 7.0 Dec-09
Page 45
Mini8 Controller Engineering Handbook
Figure 3-4: Thermocouple Input
Select the I/O type, linearisation, units, resolution etc. required. Parameter details are in Section 7.5.
The other thermocouple channels can be found by using the 2, 3, 4…7, 8 tabs on the top of the parameter window.
Slot 2 in the Mini8 controller has a CT3 input card and this is configured elsewhere so the Tabs 9 to 16 are not shown.
Slot 3 has a DO8 output card and the first channel of this will be on tab 17 (to 24)
Slot 4 has a DO8 output card and the first channel of this will be on tab 25 (to 32)
Figure 3-5: Digital Output Channel
Set this channel up as required, IOType, MinOnTime etc. as required. The parameters are detailed in Section 7.3. The remaining channels on this slot will be found under the tabs 18 to 24. Slot 4 also contains a DO8 output card with outputs under tabs 25 to 32. The fixed I/O is always there and there is nothing that has to be configured. The Current Monitor is covered in Chapter 7.9.
Part No HA028581 Issue 7.0 Dec-09 43
Page 46
Engineering Handbook Mini8 Controller
Example 2: RTD Input Configuration
In the IO list ModIDs select the type of module. RTD modules are 4 input modules [RT4Mod (173)].
Figure 3-6: Mini8 Controller IO Module1 Defined as RTD
RTDs can be defined as 2-wire [RTD2 (32)], 3-wire [RTD3 (33)] or 4-wire [RTD4 (34)] in the module definition list. It is important that the ‘IO Type’ is configured to match the RTD in use so that the correct lead compensation calculation is selected.
Figure 3-7: Module 1 defined as RTD4
44 Part No HA028581 Issue 7.0 Dec-09
Page 47
Mini8 Controller Engineering Handbook
3.5.2 Wiring
The IO that has been configured now needs to be wired to PID loops and other function blocks.
Select
(GWE) to create and edit instrument wiring.
The Graphical Wiring Editor window
To add a function block drag it from the list and drop it on this editor.
To add IO first expand the IO block (click the + ) and then expand the Mod to show the IO channels 1 to 32
Similarly to add a loop first expand the loop block (click the +) to show loops 1 to 8
Figure 3-8: List of Function Blocks & Graphical Wiring Window
The left window now contains a list of the function blocks available.
Part No HA028581 Issue 7.0 Dec-09 45
Page 48
Engineering Handbook Mini8 Controller
Use drag and drop to select the first thermocouple from IOMod 1, the Cool output from IOMod 17 and the Heat output from IOMod 25 and drop them on the wiring window.
Finally take the first PID block from Loop/Loop 1 and drop it on the wiring window. Note that as each block is used it greys out on the list.
There should now be 4 blocks on the window. Those blocks are shown with dotted lines, as they have not been loaded into the Mini8 controller.
First make the following wire connections.
1. Click on IO.Mod1.PV and move the pointer to Loop 1.MainPV and click again. A dotted wire will have connected the two together.
2. Similarly join Loop1.OP.Ch1Out to IOMod 25.PV (heat output)
3. Enable the Cool output by clicking the select arrow to the top of the loop block:
4. Loop1.OP.Ch2Out to IOMod 17.PV (cool output)
click here
and select PID output
Figure 3-9: Wired Blocks before download
5. Right click on the Loop 1 function Block and select ‘Function Block View’. This opens the Loop parameter list on top of the wiring editor.
46 Part No HA028581 Issue 7.0 Dec-09
Page 49
Mini8 Controller Engineering Handbook
Figure 3-10: PID Function Block
This enables the PID function block to be set up to suit the required application. See Chapter 17 for details.
6. Click on the instrument button to download the application:
7. Once downloaded the dotted lines around the function blocks and the wires will become solid to show that the application is now in the Mini8 controller. The upper status line also shows that 3 wires have been used out of those available. Max is 250 but quantity depends on number of wires ordered (30, 60, 120 or 250).
8. Put the Mini8 controller back into Operating mode by clicking the Access button:
9. The Mini8 controller will now control the Loop1 as configured.
Part No HA028581 Issue 7.0 Dec-09 47
Page 50
Engineering Handbook Mini8 Controller
3.6 Graphical Wiring Editor
Select (GWE) to view and edit instrument wiring. You can also add comments and monitor parameter values.
1. Drag and drop required function blocks into the graphical wiring from the list in the left pane
2. Click on parameter to be wired from and drag the wire to the parameter to be wired to (do not hold mouse button down)
3. Right click to edit parameter values
4. Select parameter lists and switch between parameter and wiring editors
5. Download to instrument when wiring completed
6. Add comments and notes
7. Dotted lines around a function block show that the application requires downloading
Add comment and notes
Blocks ‘clear’ when used
Indicates execution order
Right click to edit parameter values
Click this button to wire unshown parameters
48 Part No HA028581 Issue 7.0 Dec-09
Page 51
Mini8 Controller Engineering Handbook
y
3.6.1 Graphical Wiring Toolbar
Download
Grab & Pan
Pan Drawing
Delete, Undo & Redo
IO Setup Paste
Select
Zoom Drawing
Grid on/off
3.6.2 Function Block
A Function Block is an algorithm that may be wired to and from other function blocks to make a control strategy. The Graphical Wiring Editor groups the instrument parameters into function blocks. Examples are: a control loop and a mathematical calculation.
Each function block has inputs and outputs. Any parameter may be wired from, but only parameters that are alterable may we wired to.
A function block includes any parameters that are needed to configure or operate the algorithm.
3.6.3 Wire
A wire transfers a value from one parameter to another. They are executed by the instrument once per control cycle.
Copy a Diagram Fragment to a File
Paste a Diagram Fragment to a FileCut Cop
Create a Compound
Wires are made from an output of a function block to an input of a function block. It is possible to create a wiring loop, in this case there will be a single execution cycle delay at some point in the loop. This point is shown on the diagram By a || symbol and it is possible to choose where that delay will occur.
3.6.4 Block Execution Order
The order in which the blocks are executed by the instrument depends on the way in which they are wired.
The order is automatically worked out so that the blocks execute on the most recent data.
3.6.5 Using Function Blocks
If a function block is not faded in the tree then it can be dragged onto the diagram. The block can be dragged around the diagram using the mouse.
A labelled loop block is shown here. The label at the top is the name of the block.
When the block type information is alterable click on the box with the arrow in it on the right to edit that value.
The inputs and outputs that are considered to be of most use are always shown. In most cases all of these will need to be wired up for the block to perform a useful task. There are exceptions to this and the loop is one of those exceptions.
If you wish to wire from a parameter, which is not shown as a recommended output click on the icon in the bottom right, and a full list of parameters in the block will be shown, click on one of these to start a wire.
To start a wire from a recommended output just click on it.
Click the icon in the bottom right hand corner to wire other function block parameters not shown on the list on the right hand side.
Part No HA028581 Issue 7.0 Dec-09 49
Page 52
Engineering Handbook Mini8 Controller
3.6.5.1 Function Block Context Menu
Right clicking displays the context menu with the following entries.
Function Block View… Re-Route Wires Throw away current wire route and do an auto-route of all wires connected to this block Re-Route Input Wires Only do a re-route on the input wires Re-Route Output Wires Show wires using tags Hide Unwired Connections Cut Cut the selected function block Copy Right click over an input or output and copy will be enabled, this menu item will copy the iTools "url" of
Paste Add a new copy of the function block Delete If the block is downloaded mark it for delete, otherwise delete it immediately Undelete This menu entry is enabled if the block is marked for delete and unmarks it and any wires connected to it
Bring To Front Bring the block to the front of the diagram. Moving a block will also bring it to the front Push To Back Push the block to the back of the diagram. Useful of there is something underneath it Edit Parameter Value This menu entry is enabled when the mouse is over an input or output parameter. When selected it
Parameter Properties Selecting this entry brings up the parameter properties window. The parameter properties window is
Parameter Help Selecting this entry brings up the help window. The help window is updated as the mouse is moved over
Brings up an iTools parameter list which shows all the parameters in the function block. If the block has sub-lists these are shown in tabs
Only do a re-route on the output wires
Shows the beginning and end of each wire with a descriptor showing the source or destination. Used to simplify a diagram with many wires. Hides function block pins that are not used.
the parameter which can then be pasted into a watch window or OPC Scope
for delete
creates a parameter edit dialog so the value of that parameter can be changed
updated as the mouse is moved over the parameters shown on the function block
the parameters shown on the function block. When the mouse is not over a parameter name the help for the block is shown
3.6.6 Tooltips
Hovering over different parts of the block will bring up tooltips describing the part of the block beneath the mouse.
If you hover over the parameter values in the block type information a tooltip showing the parameter description, its OPC name, and, if downloaded, its value will be shown.
A similar tool-tip will be shown when hovering over inputs and outputs.
50 Part No HA028581 Issue 7.0 Dec-09
Page 53
Mini8 Controller Engineering Handbook
3.6.7 Function Block State
The blocks are enabled by dragging the block onto the diagram, wiring it up, and downloading it to the instrument
When the block is initially dropped onto the diagram it is drawn with dashed lines.
When in this state the parameter list for the block is enabled but the block itself is not executed by the instrument.
Once the download button is pressed the block is added to the instrument function block execution list and it is drawn with solid lines.
If a block which has been downloaded is deleted, it is shown on the diagram in a ghosted form until the download button is pressed.
This is because it and any wires to/from it are still being executed in the instrument. On download it will be removed from the instrument execution list and the diagram. A ghosted block can be undeleted using the context menu.
When a dashed block is deleted it is removed immediately.
Part No HA028581 Issue 7.0 Dec-09 51
Page 54
Engineering Handbook Mini8 Controller
3.6.8 Using Wires
3.6.8.1 Making A Wire Between Two Blocks
• Drag two blocks onto the diagram from the function block tree.
• Start a wire by either clicking on a recommended output or clicking on the icon at
the bottom right corner of the block to bring up the connection dialog. The connection dialog shows all the connectable parameters for the block, if the block has sub-lists the parameters are shown in a tree. If you wish to wire a parameter which is not currently available click the red button at the bottom of the connection dialog. Recommended connections are shown with a green plug, other parameters which are available are yellow and if you click the red button the unavailable parameters are shown red. To dismiss the connection dialog either press the escape key on the keyboard or click the cross at the bottom left of the dialog.
• Once the wire has started the cursor will change and a dotted wire will be drawn from the output to the current mouse position.
• To make the wire either click on a recommended input to make a wire to that
parameter or click anywhere except on a recommended input to bring up the connection dialog. Choose from the connection dialog as described above.
• The wire will now be auto-routed between the blocks.
New wires are shown dotted until they are downloaded
3.6.8.2 Wire Context Menu
The wire block context menu has the following entries on it.
Force Exec Break If wires form a loop a break point has to be found
where the value which is written to the block input comes from a block which was last executed during the previous instrument execute cycle thus introducing a delay. This option tells the instrument that if it needs to make a break it should be on this wire
Re-Route Wire Throw away wire route and generate an automatic
route from scratch
Use Tags If a wire is between blocks which are a long way
apart, then, rather than drawing the wire, the name of the wired to/from parameter can be shown in a tag next to the block. Draw the wire first then use this menu to toggle this wire between drawing the whole wire and drawing it as tags
Find Start Find the source of the selected wire Find End Find the destination of the selected wire Delete If the wire is downloaded mark it for delete,
otherwise delete it immediately
Undelete This menu entry is enabled if the wire is marked for
delete and unmarks it for delete
Bring To Front Bring the wire to the front of the diagram. Moving a
wire will also bring it to the front
Push To Back Push the wire to the back of the diagram
52 Part No HA028581 Issue 7.0 Dec-09
Page 55
Mini8 Controller Engineering Handbook
3.6.8.3 Wire Colours
Wires can be the following colours:
Black Normal functioning wire. Red The wire is connected to an input which is not alterable when the instrument is in operator mode and so
values which travel along that wire will be rejected by the receiving block
Blue The mouse is hovering over the wire, or the block to which it is connected it selected. Useful for tracing
densely packed wires
Purple The mouse is hovering over a 'red' wire
3.6.8.4 Routing Wires
When a wire is placed it is auto-routed. The auto routing algorithm searches for a clear path between the two blocks. A wire can be auto-routed again using the context menus or by double clicking the wire.
If you click on a wire segment you can drag it to manually route it. Once you have done this it is marked as a manually routed wire and will retain it's current shape. If you move the block to which it is connected the end of the wire will be moved but as much of the path as possible of the wire will be preserved.
If you select a wire by clicking on it, it will be drawn with small boxes on it's corners.
3.6.8.5 Tooltips
Hover the mouse over a wire and a tooltip showing the names of the parameters which are wired and, if downloaded, their current values will also be shown.
3.6.9 Using Comments
Drag a comment onto the diagram and the comment edit dialog will appear.
Type in a comment. Use new lines to control the width of the comment, it is shown on the diagram as typed into the dialog. Click OK and the comment text will appear on the diagram. There are no restrictions on the size of a comment. Comments are saved to the instrument along with the diagram layout information.
Comments can be linked to function blocks and wires. Hover the mouse over the bottom right of the comment and a chain icon will appear, click on that icon and then on a block or a wire. A dotted wire will be drawn to the top of the block or the selected wire segment.
3.6.9.1 Comment Context Menu
The comment context menu has the following entries on it.
Edit Open the comment edit dialog to edit this comment Unlink If the comment is linked to a block or wire this will unlink
it Cut Remove the comment Copy To make a copy of the comment Paste To Paste a new copy of the comment Delete If the comment is downloaded mark it for delete,
otherwise delete it immediately Undelete This menu entry is enabled if the comment is marked for
delete and unmarks it for delete Bring To Front Bring the comment to the front of the diagram. Moving a
comment will also bring it to the front Push To Back Push the comment to the back of the diagram. Useful if
there is something underneath it
Part No HA028581 Issue 7.0 Dec-09 53
Page 56
Engineering Handbook Mini8 Controller
3.6.10 Using Monitors
Drag a monitor onto the diagram and connect it to a block input or output or a wire as described in ‘Using Comments’.
The current value (updated at the iTools parameter list update rate) will be shown in the monitor. By default the name of the parameter is shown, double click or use the context menu to not show the parameter name.
3.6.10.1 Monitor Context Menu
The monitor context menu has the following entries on it.
Show Names Show parameter names as well as values Unlink If the monitor is linked to a block or wire this will unlink it Cut Remove the monitor Copy Make a copy of the monitor Paste Paste the copy of the monitor Delete If the monitor is downloaded mark it for delete, otherwise delete it
immediately
Undelete This menu entry is enabled if the monitor is marked for delete and
unmarks it for delete
Bring To Front Bring the monitor to the front of the diagram. Moving a monitor
will also bring it to the front
Push To Back Push the monitor to the back of the diagram. Useful if there is
something underneath it
3.6.11 Downloading
The wires have to be downloaded to the instrument together. When the wiring editor is opened the current wiring and diagram layout is read from the instrument. No changes are made to the instrument function block execution or wiring until the download button is pressed.
When a block is dropped on the diagram instrument parameters are changed to make the parameters for that block available. If you make changes and close the editor without saving them there will be a delay while the editor clears these parameters.
When you download, the wiring is written to the instrument that then calculates the block execution order and starts executing the blocks. The diagram layout including comments and monitors is then written into instrument flash memory along with the current editor settings. When you reopen the editor the diagram will be shown positioned the same as when you last downloaded.
3.6.12 Selections
Wires are shown with small blocks at their corners when selected. All other items have a dotted line drawn round them when they are selected.
3.6.12.1 Selecting Individual Items
Clicking on an item on the drawing will select it.
3.6.12.2 Multiple Selection
Control click an unselected item to add it to the selection, doing the same on a selected item unselects it.
Alternatively, hold the mouse down on the background and wipe it to create a rubber band, anything which isn't a wire inside the rubber band will be selected.
Selecting two function blocks also selects any wires which join them. This means that if you select more than one function block using the rubber band method any wires between them will also be selected.
Pressing Ctrl-A selects all blocks and wires.
54 Part No HA028581 Issue 7.0 Dec-09
Page 57
Mini8 Controller Engineering Handbook
3.6.13 Colours
Items on the diagram are coloured as follows:
Red Function blocks, comments and monitors which partially obscure or are partially obscured by other items are
drawn red. If a large function block like the loop is covering a small one like a math2 the loop will be drawn red to show that it is covering another function block. Wires are drawn red when they are connected to an input which is currently unalterable. Parameters in function blocks are coloured red if they are unalterable and the mouse pointer is over them
Blue Function blocks, comments and monitors which are not coloured red are coloured blue when the mouse pointer
is over them. Wires are coloured blue when a block to which the wire is connected is selected or the mouse pointer is over it. Parameters in function blocks are coloured blue if they are alterable and the mouse pointer is over them
Purple A wire which is connected to an input which is currently unalterable and a block to which the wire is connected is
selected or the mouse pointer is over it is coloured purple (red + blue)
3.6.14 Diagram Context Menu
Highlight an area of the graphical wiring by left clicking the mouse button and dragging around the required area. Right click in the area to show the Diagram Context Menu. The diagram context menu has the following entries:-
Cut To delete the selected area Copy To make a copy of the selected area Paste To paste the selected area Re-Route Wires
Align Tops Line up the tops of all the selected items except wires Align Lefts Line up the left hand side of all the selected items except
Space Evenly This will space the selected items such that their top left
Delete Marks all selected items for deletion (will be deleted on next
Undelete This menu entry is enabled if any of the selected items are
Select All To select the complete graphical wiring Create Compound Rename To customise the Compound name. Copy Graphic If there is a selection it is copied to the clipboard as a
Save Graphic Same as Copy Graphic but saves to a metafile rather than
Copy Fragment to File Paste Fragment from File Center To place the selected area in the centre of the graphical
Throw away current wire route and do an auto-route of all selected wires. If no wires are selected this is done to all wires on the diagram
wires
corners are evenly spaced. Select the first item, then select the rest by control-clicking them in the order you wish them to be spaced, then choose this menu entry
download).
marked for deletion and unmarks them when selected
Create a new tab (Compund 1, 2, etc) of the selected area
Windows metafile, if there is no selection the whole diagram is copied to the clipboard as a Windows metafile. Paste into your favourite documentation tool to document your application. Some programs render metafiles better than others, the diagram may look messy on screen but it should print well
putting it on the clipboard To make a copy of the selected area and save it to file
To paste the selected area from file
wiring view.
Part No HA028581 Issue 7.0 Dec-09 55
Page 58
Engineering Handbook Mini8 Controller
3.6.15 Wiring Floats with Status Information
There is a subset of float values which may be derived from an input which may become faulty for some reason, e.g. sensor break, over-range, etc. These values have been provided with an associated status which is automatically inherited through the wiring. The list of parameters which have associated status is as follows:-
Block Input Parameters Output Parameters
Loop.Main PV PV Loop.SP TrackPV Math2
Programmer.Setup PVIn Poly In Out
Lin16 In Out Txdr InVal OutVal IPMonitor In Out
Total In Mux8 In1 to 8 Out Multi-oper In1 to 8 SumOut, MaxOut,
UsrVal Val Val Humidity
IO.MOD 1.PV to 32.PV 1.PV to 32.PV
Parameters appear in both lists where they can be used as inputs or outputs depending on configuration. The action of the block on detection of a ‘Bad’ input is dependent upon the block. For example, the loop treats a ‘Bad’ input as a sensor break and takes appropriate action; the Mux8 simply passes on the status from the selected input to the output, etc.
In1 Out In2
PVOut1 Load PVOut2
In1 SwitchOver In2
MinOut, AverageOut In1 Lgc2 In2
WetTemp RelHumid DryTemp DewPoint PsychroConst Pressure
The Poly, Lin16, SwitchOver, Multi-Operator, Mux8, IO.Mod.n.PV blocks can be configured to act on bad status in varying ways. The options available are as follows:-
0: Clip Bad
The measurement is clipped to the limit it has exceeded and its status is set to ‘BAD’, such that any function block using this measurement can operate its own fallback strategy. For example, control loop may hold its output to the current value.
1: Clip Good
The measurement is clipped to the limit it has exceeded and its status is set to ‘GOOD’, such that any function block using this measurement may continue to calculate and not employ its own fallback strategy.
2: Fallback Bad
The measurement will adopt the configured fallback value that has been set by the user. In addition the status of the measured value will be set to ‘BAD’, such that any function block using this measurement can operate its own fallback strategy. For example, control loop may hold its output to the current value.
3: Fallback Good
The measurement will adopt the configured fallback value that has been set by the user. In addition the status of the measured value will be set to ‘GOOD’, such that any function block using this measurement may continue to calculate and not employ its own fallback strategy
56 Part No HA028581 Issue 7.0 Dec-09
Page 59
Mini8 Controller Engineering Handbook
4: Up Scale
The measurement will be forced to adopt its high limit. This is like having a resistive pull up on an input circuit. In addition the status of the measured value will be set to ‘BAD’, such that any function block using this measurement can operate its own fallback strategy. For example, the control loop may hold its output to the current value.
5: Down Scale
The measurement will be forced to adopt its low limit. This is like having a resistive pull down on an input circuit. In addition the status of the measured value will be set to ‘BAD’, such that any function block using this measurement can operate its own fallback strategy. For example, the control loop may hold its output to the current value.
3.6.16 Edge Wires
If the Loop.Main.AutoMan parameter were wired from a logic input in the conventional manner it would be impossible to put the instrument into manual via communications. Other parameters need to be controlled by wiring but also need to be able to change under other circumstances, e.g. Alarm Acknowledgements. for this reason some Boolean parameters are wired in an alternative way. These are listed as follows:-
SET DOMINANT
When the wired in value is 1 the parameter is always updated. This will have the effect of overriding any changes through digital communications. When the wired in value changes to 0 the parameter is initially changed to 0 but is not continuously updated. This permits the value to be changed through digital communications.
Loop.Main.AutoMan Programmer.Setup.ProgHold Access.StandBy
RISING EDGE
When the wired in value changes from 0 to 1, a 1 is written to the parameter. At all other times the wire does not update the parameter. This type of wiring is used for parameters that start an action and when once completed the block clears the parameter. When wired to, these parameters can still be operated via digital communications.
Loop.Tune.AutotuneEnable Txdr.ClearCal Alarm.Ack Txdr.StartCal DigAlarm.Ack Programmer.Setup.ProgRun Txdr.StartHighCal AlmSummary.GlobalAck Programmer.Setup.AdvSeg Txdr.StartTare Programmer.Setup.SkipSeg Instrument.Diagnostics.
ClearStats
IPMonitor.Reset
BOTH EDGE
This type of edge is used for parameters which may need to be controlled by wiring or but should also be able to be controlled through digital communications. If the wired in value changes then the new value is written to the parameter by the wire. At all other times the parameter is free to be edited through digital communications.
Loop.SP.RateDisable Loop.OP.RateDisable
Part No HA028581 Issue 7.0 Dec-09 57
Page 60
Engineering Handbook Mini8 Controller
4. Chapter 4 Mini8 controller Overview
Input and output parameters of function blocks are wired together using software wiring to form a particular control strategy within the Mini8 controller. An overview of all the available functions and where to get more detail is shown below.
Thermocouples
Dig Inputs
Current Transformers
Inputs Control Processes
Mod.1 to Mod.32
T/C, RTD, mA, mV
Chapter 7.5, 7.6
Setpoint
Loop/SP folder Folder
Chapter 17.6
Input Linearisation
Lin 16 Folder
Chapter 15
Polynomial
Poly Folder
Chapter 15
FixedIO / IO
Logic Input
Chap. 7.8, 7.2
BCD Input
BCD In Folder
Chapter 9
Switchover
SwOver
Folder
Chapter 19
Transducer Scaling
Txdr Folder
Chapter 20
User Values
UsrVal Folder
Chapter 21
Current I/p
IO.Current Monitor
Folder
Chapter 7.9
Figure 4-1: Controller Example
Loops 1 to 16
Loop Folder
Chapter 17
Programmer
Prog Folder
Chapter 18
Application specific
Humidity Zirconia
Chapter 12
Alarm(s)
Alarm Folder
Chapter 8
Digital Alarms
Dig Alm Folder
Chapter 8.3
Alarm Summary
Alarm Summary
Folder
Chapter 8.7
Maths
Math2 & Mux8
Folder
Chapter 14
Maths
Lgc2 & Lgc8
Folder
Chapter 14
Timer/Clock/
Counter/Totaliser
Comms/FC Folder
Chapter 11
Field Comms
Chapter 10
Outputs
Mod.1 to
Mod.32
Logic Output
Chapter 7.3
Mod.25 to
Mod.32
Analogue OP
Chapter 7.7
FixedIO /IO
Relay O/P
Chap. 7.8, 7.4
To plant devices
PC, plc
Mini8 controllers are supplied unconfigured, and with those blocks included in the order code. Option EC8 is supplied with function blocks pre-wired to give an 8 loop heat/cool controller suitable for Extrusion. See data sheet HA028519.
The purpose of the PID control blocks is to reduce the difference between SP and PV (the error signal) to zero by providing a compensating output to the plant via the output driver blocks.
The timer, programmer and alarms blocks may be made to operate on a number of parameters within the controller, and digital communications provides an interface to data collection and control.
The controller can be customised to suit a particular process by ‘soft wiring’ between function blocks.
58 Part No HA028581 Issue 7.0 Dec-09
Page 61
Mini8 Controller Engineering Handbook
4.1 Complete list of Function Blocks.
The list opposite represents an unconfigured Mini8 that has been ordered with all features enabled.
If a particular block or blocks do not appear in your instrument then the option has not been ordered. Check the order code of your instrument and contact Eurotherm.
Examples of features that may not have been enabled are:
Loops
Programmer
Recipe
Humidity
Once a block is dragged and dropped onto the graphical wiring window, the block icon in the block list opposite will be greyed out. At the same time a folder containing the blocks parameters will have been created in the Browse List.
Part No HA028581 Issue 7.0 Dec-09 59
Page 62
Engineering Handbook Mini8 Controller
5. Chapter 5 Access Folder
Folder: Access Sub-folder: none
Name
ClearMemory Cold start the
CustomerID Customer
Standby Set Instrument to
Parameter Description
instrument
Identifier
standby
Value
No App
LinTables InitComms Wires AllMemory Programs
Reference number for customer use
No / Yes
Disabled Mini8 controller memory reset but comms and linearisation tables retained Custom Linearisation tables are deleted Comms ports reset to default configurations Clear all wiring All instrument memory is set to default values All Programs cleared
Default Access
Level
No Conf
0 Oper
No Oper
60 Part No HA028581 Issue 7.0 Dec-09
Page 63
Mini8 Controller Engineering Handbook
6. Chapter 6 Instrument Folder
6.1 Instrument / Enables
The following table lists the options that can be enabled in the instrument.
Enable flags are one bit for each item – i.e.Bit (0=1) enables item 1, Bit 1 (=2) item 2, Bit(3=4) item 3 and so on to Bit7(=128) enables Item 8. All 8 items enabled adds up to 255.
☺ Tip: Features are not normally enabled this way. Dragging and dropping a function block onto
the graphical wiring window automatically sets the required enable flag.
Folder: Instrument Sub-folder: Enables
Name
AlarmEn1 Analogue alarms Enable Flags Alarms 1 to 8 0 (none) to 255 (all 8) 0 Conf
AlarmEn2 Analogue alarms Enable Flags Alarms 9 to 16 0 (none) to 255 (all 8) 0 Conf
AlarmEn3 Analogue alarms Enable Flags Alarms 17 to 24 0 (none) to 255 (all 8) 0 Conf
AlarmEn4 Analogue alarms Enable Flags Alarms 25 to 32 0 (none) to 255 (all 8) 0 Conf
BCDInEn BCD switch input Enable
CounterEn Counters Enable Flags Counters1 and 2 0 (none) to 3 (both) 0 Conf
CurrentMon
(Only if CT3 module fitted)
DigAlmEn1 Digital alarms Enable Flags Dig Alarms 1 to 8 0 (none) to 255 (all 8) 0 Conf
DigAlmEn2 Digital alarms Enable Flags Dig Alarms 9 to 16 0 (none) to 255 (all 8) 0 Conf
DigAlmEn3 Digital alarms Enable Flags Dig Alarms 17 to 24 0 (none) to 255 (all 8) 0 Conf
DigAlmEn4 Digital alarms Enable Flags Dig Alarms 25 to 32 0 (none) to 255 (all 8) 0 Conf
HumidityEn Humidity control Enable Flag 0 = off 1 = On 0 Conf
IP Mon En Input monitor Enable Flags Input Monitor 1 and 2 0 (none) to 3 (both) 0 Conf
Lgc2 En1 Logic operators Enable Flags Logic operators 1 to 8 0 (none) to 255 (all 8) 0 Conf
Lgc2 En2 Logic operators Enable Flags Logic operators 9 to 16 0 (none) to 255 (all 8) 0 Conf
Lgc2 En3 Logic operators Enable Flags Logic operators 17 to 24 0 (none) to 255 (all 8) 0 Conf
Lgc8 En Logic 8 operator Enable Flags 8 input Logic operators 1 & 2 0 (none) to 3 (both) 0 Conf
Lin16Pt En Input linearisation 16 point Input Linearisation 1 and 2 0 (none) to 3 (both) 0 Conf
Load En Load Enable Flags Loads 1 to 8 0 (none) to 255 (all 8) As order
Load En2 Load Enable Flags Loads 9 to 16 0 (none) to 255 (all 8) As order
Loop En Loop Enable Flags Loops 1 to 8 0 (none) to 255 (all 8) As order
Loop En2 Loop Enable Flags Loops 9 to 16 0 (none) to 255 (all 8) As order
Math2 En1 Analogue (Maths) Operators
Math2 En2 Analogue (Maths) Operators
Math2 En3 Analogue (Maths) Operators
MultiOperEn Analogue Multi- Operator
Mux8 En Multiplexor Enable Flags 8 input multiplexor 1 and 2 0 (none) to 3 (both) 0 Conf
Parameter Description Value
BCD input 1 and 2 0 (none) to 3 (both) 0 Conf
Flags
Current Monitor Enable Flag 0 = Off 1 = On 0 Conf
Analogue operators 0 to 8 0 (none) to 255 (all 8) 0 Conf
Enable Flags
Analogue operators 9 to 16 0 (none) to 255 (all 8) 0 Conf
Enable Flags
Analogue operators 17 to 24 0 (none) to 255 (all
Enable Flags
Enable Flags
8)
Multi-operators 0 to 4 0 (none) to 15 (all 4) 0 Conf
Default Access
Level
Conf
code
Conf
code
Conf
code
Conf
code
0 Conf
Part No HA028581 Issue 7.0 Dec-09 61
Page 64
Engineering Handbook Mini8 Controller
Folder: Instrument Sub-folder: Enables
Name
Poly En Polynomial linearisation
Prog En Programmer Enable Flags 0 = off, 1 to 8 0 (none) to 255 (all 8) 0 Conf
RTClock En Real time clock Enable Flags 0 = off 1 = On 0 Conf
SwOver En Switch over block Enable
Timer En Timers Enable Flags Timers 1 to 4 0 = none to 15 = 4 0 Conf
Totalise En Totalisers Enable Flags Totalisers 1 & 2 0 (none) to 3 (both) 0 Conf
TrScale En Transducer scaling Enable
UsrVal En1 User values Enable Flags User Values 1 to 8 0 (none) to 255 (all 8) 0 Conf
UsrVal En2 User values Enable Flags User Values 9 to 16 0 (none) to 255 (all 8) 0 Conf
UsrVal En3 User values Enable Flags User Values 17 to 24 0 (none) to 255 (all 8) 0 Conf
UsrVal En4 User values Enable Flags User Values 25 to 32 0 (none) to 255 (all 8) 0 Conf
Zirconia En Zirconia Input Functions 0 = off 1 = On 0 Conf
Parameter Description Value
Poly Linearisation 1 and 2 0 (none) to 3 (both) 0 Conf
block Enable Flags
0 = off 1 = On 0 Conf
Flags
Transducer scalers 1 and 2 0 (none) to 3 (both) 0 Conf
Flags
Default Access
Level
6.2 Instrument Options
Folder: Instrument Sub-folder: Options
Name
Units Units °C,°F or Kelvin scale for all temperature parameters DegC Oper
ProgPVstart To enable PV start No, Yes – see section 18 No Conf
Parameter Description Value
Default Access
Level
6.3 Instrument / InstInfo
Folder: Instrument Sub-folder: InstInfo
Name
InstType Instrument Type
Version Version Identifier
Serial No Serial Number
Passcode1 Passcode1
Passcode2 Passcode2
Passcode3 Passcode3
CompanyID CompanyID
Parameter Description
Value
0 to 65535
0 to 65535
0 to 65535
Default Access
Level
MINI8 NONE
- NONE
NONE
Oper
Oper
Oper
1280 NONE
62 Part No HA028581 Issue 7.0 Dec-09
Page 65
Mini8 Controller Engineering Handbook
6.4 Instrument / Diagnostics
This list provides fault finding diagnostic information as follows:-
Folder: Instrument
Name Parameter Description
CPUFree This is the amount of free CPU Time left. It shows the percentage of the tasks ticks that are idle. MinCPUFree A benchmark of the lowest reached value of the CPU free percentage. CtrlTicks This is the number of ticks that have elapsed while the instrument was performing the control
Max Con Tick A benchmark of the maximum number of ticks that have elapsed while the instrument was
Clear Stats Resets the instrument performance benchmarks. ErrCount The number of errors logged since the last Clear Log. Note: If an error occurs multiple times only
Err1 The first
Err2 The second
Err3 The third
Err4 The fourth
Err5 The fifth
Err6 The sixth
Err7 The seventh
Err8 The eight
Clear Log Clears the error log entries and count. UserStringCount Number of User Strings Defined UserStringCharSpace Space Available For User Strings.
Sub-folder: Diagnostics
Task.
performing the control Task
the first occurrence will be logged each event will increment the count.
0 There is no error
error to occur
error to occur
error to occur
error to occur
error to occur
error to occur
error to occur
error to occur
1 Bad or unrecognised module ident. A module has been inserted and has a bad or unrecognised ident. Either the module is damaged or the module is unsupported. 3 Factory calibration data bad. The factory calibration data has been read from an I/O module and has not passed the checksum test. Either the module is damaged or has not been initialised. 4 Module changed for one of a different type. A module has been changed for one of a different type. The configuration may now be incorrect 10 Calibration data write error. An error has occurred when attempting to write calibration data back to an I/O module's EE. 11 Calibration data read error. An error occurred when trying to read calibration data back from the EE on an I/O module. 18 Checksum error. The checksum of the NVol Ram has failed. The NVol is considered corrupt and there the instrument configuration may be incorrect. 20 Resistive identifier error. An error occurred when reading the resistive identifier from an i/o module. The module may be damaged. 43 Invalid custom linearisation table. One of the custom linearisation tables is invalid. Either it has failed checksum tests or the table downloaded to the instrument is invalid. 55 The Instrument wiring is either invalid or corrupt. 56 Non-vol write to volatile. An attempt was made to perform a checksummed write to a non-checksummed area 58 Recipe load failure. The selected recipe failed to load 59 Bad User CT calibration data. Corrupted or invalid user calibration data for the current monitor 60 Bad Factory CT calibration data. Corrupted or invalid factory calibration data for the current monitor 62 to 65 Slot1 card DFC1 to DFC4 error 66 to 69 Slot2 card DFC1 to DFC4 error 70 to 73 Slot3 card DFC1 to DFC4 error 74 to 77 Slot4 card DFC1 to DFC4 error
The generic I/O DFC chip will not communicate. This could indicate a build fault.
Segments Left Number of Available Program Segments
Gives the number of unused program segments. Each time a segment is allocated to a program, this value is reduced by one.
CtrlStack Control Stack Free Space (words)
The number of words of un-used stack for the control task
Part No HA028581 Issue 7.0 Dec-09 63
Page 66
Engineering Handbook Mini8 Controller
Folder:
Sub-folder: Diagnostics
Instrument
Name Parameter Description
CommsStack Comms Stack Free Space (words)
The number of words of un-used stack for the comms task
IdleStack Idle Stack Free Space (words)
The number of words of un-used stack for the idle (background) task. Max segments Max number of setpoint programmer segments available MaxSegsPerProg Specifies the maximum number of segments that can be configured for a single program CntrlOverrun Indicates the amount of control overrun. PSUident Shows type of PSU fitted 0 = Mains 1= 24V dc PwrFailCount Counts the number of times the instrument power has been switched off. Cust1Name Name for custom linearisation table 1 Cust2Name Name for custom linearisation table 2 Cust3Name Name for custom linearisation table 3
64 Part No HA028581 Issue 7.0 Dec-09
Page 67
Mini8 Controller Engineering Handbook
7. Chapter 7 I/O Folder
This lists the modules fitted into the instruments, all the IO channels, the fixed IO and the current monitoring.
The IO folder lists all the channels of each of the IO boards in the 4 available slots. Each board has up to 8 inputs or outputs making a maximum of 32 channels. The channels are listed under Mod1 to Mod32.
Slot Channels
1 IO.Mod.1 to IO.Mod.8
2 IO.Mod.9 to IO.Mod.16
3 IO.Mod.17 to IO.Mod.24
4 IO.Mod.25 to IO.Mod.32
Note that the current transformer input, CT3, is not included in this arrangement. There is a separate folder for current monitoring under IO.CurrentMonitor. If this board is fitted into slot 2 the IO.Mod.9 to Mod.16 would not exist.
7.1 Module ID
Folder: IO Sub-folder: ModIDs
Name
Module1 Module1Ident 0 Read
Module2 Module2Ident 0 Read
Module3 Module3Ident 0 Read
Module4 Module4Ident
7.1.1 Modules
Parameter Description
Value
0 NoMod – No Module
24 DO8Mod – 8 logic outputs
18 RL8Mod – 8 relay outputs
60 DI8 – 8 logic inputs
90 CT3Mod – 3 current transformer inputs
131 TC8Mod – 8 thermocouple/mV inputs
133 TC4Mod – 4 thermocouple/mV inputs
173 RT4 – 4 PT100 inputs
201 AO8Mod – 8 0-20 mA outputs (Slot 4 only)
203 AO4Mod – 4 0-20 mA outputs (Slot 4 only)
Default Access
Level
Only
Only
Only
0 Read
Only
The content of the Mod folders depends on the type of IO module fitted in each slot. These will be covered in the following sections.
Part No HA028581 Issue 7.0 Dec-09 65
Page 68
Engineering Handbook Mini8 Controller
7.2 Logic Input
Each DI8 card provides 8 logic input channels (voltage controlled) to the system. These can be wired to provide digital inputs to any function block within the system.
7.2.1 Logic Input Parameters
Folder – IO Sub-folder Mod.1 to .32
Name
Ident Channel Identity LogicIn Read
IOType IO Type OnOff On off input Conf
Parameter Description Value
Default
Access
Level
Only
Invert Sets the sense of the logic input No
Yes
Measured Val Measured Value On/Off Value seen at the terminals Off Read
PV Process Variable On/Off Value after allowing for
No inversion
Inverted
Invert
No Conf
Only
Off Read
Only
66 Part No HA028581 Issue 7.0 Dec-09
Page 69
Mini8 Controller Engineering Handbook
7.3 Logic Output
If a slot is fitted with a DO8 board then 8 channels will be available to be configured and connected to Loop outputs, alarms or other logic signals.
7.3.1 Logic Out Parameters
Folder – IO Sub-folder Mod.1 to .32
Name
Ident Channel Identity LogicOut Read Only
Invert Sets the sense of the logic input or
SbyAct Action taken by output when
The next five parameters are only shown when ‘IO Type’ = ‘Time Prop’ outputs
MinOnTime
DisplayHigh The maximum displayable reading 0.00 to 100.00 100.00 Oper
DisplayLow The minimum displayable reading 0.00 to 100.00 0.00 Oper
RangeHigh The maximum (electrical) input/output
RangeLow The minimum (electrical) input/output
Always displayed
MeasuredVal The current value of the output
PV This is the desired output value, before
Parameter Description Value
OnOff On off output IOType IO Type
Time Prop Time proportioning output
No
output
instrument goes into Standby Mode
Minimum output on/off time.
Prevents relays from switching too rapidly
level
level
demand signal to the hardware including the effect of the Invert parameter.
the Invert parameter is applied
Yes
Off, On
Continue
Auto
0.01 to 150.00 seconds
0.00 to 100.00 100 Oper
0.00 to 100.00 0 Oper
0
1
0 to 100
or
0 to 1 (OnOff)
Default
Conf
No inversion
Inverted
Switches On/Off
Remains in its last state
Auto = 20ms. This is the fastest allowable update rate for the output
Off
On
Oper
No Conf
Off Conf
Auto Oper
Read only
Access
Level
PV can be wired from the output of a function block. For example if it is used for control it may be wired from the control loop output (Ch1 Output).
Part No HA028581 Issue 7.0 Dec-09 67
Page 70
Engineering Handbook Mini8 Controller
7.3.2 Logic Output Scaling
If the output is configured for time proportioning control, it can be scaled such that a lower and upper level of PID demand signal can limit the operation of the output value.
By default, the output will be fully off for 0% power demand, fully on for 100% power demand and equal on/off times at 50% power demand. You can change these limits to suit the process. It is important to note, however, that these limits are set to safe values for the process. For example, for a heating process it may be required to maintain a minimum level of temperature. This can be achieved by applying an offset at 0% power demand which will maintain the output on for a period of time. Care must be taken to ensure that this minimum on period does not cause the process to overheat.
If Range Hi is set to a value <100% the time proportioning output will switch at a rate depending on the value - it will not switch fully on.
Similarly, if Range Lo is set to a value >0% it will not switch fully off.
PID Demand signal
Disp Hi eg 100%
Disp Lo eg 0%
Range Lo = 0%
Output permanently off
Output state
Range Hi = 100%
Output permanently on
Figure 7-1: Time Proportioning Output
7.3.3 Example: To Scale a Proportioning Logic Output
Access level must be configuration.
In this example the output will switch on for 8% of the time when the PID demand wired to ‘PV’ signal is at 0%.
Similarly, it will remain on for 90% of the time when the demand signal is at 100%
68 Part No HA028581 Issue 7.0 Dec-09
Page 71
Mini8 Controller Engineering Handbook
7.4 Relay Output
If slot 2 and/or 3 is fitted with a RL8 board then 8 channels will be available to be configured and connected to Loop outputs, alarms or other logic signals.
7.4.1 Relay Parameters
Folder – IO Sub-folder Mod.9 to .24
Name
Ident Channel Identity Relay Read
Invert Sets the sense of the logic input or
SbyAct Action taken by output when
The next five parameters are only shown when ‘IO Type’ = ‘Time Prop’ outputs
MinOnTime
DisplayHigh The maximum displayable reading 0.00 to 100.00 100.00 Oper
DisplayLow The minimum displayable reading 0.00 to 100.00 0.00 Oper
RangeHigh The maximum (electrical) input/output
RangeLow The minimum (electrical) input/output
Always displayed
MeasuredVal The current value of the output
PV This is the desired output value, before
Parameter Description Value
OnOff On off output IOType IO Type
Time Prop Time proportioning output
No
output
instrument goes into Standby Mode
Minimum output on/off time.
Prevents relays from switching too rapidly
level
level
demand signal to the hardware including the effect of the Invert parameter.
the Invert parameter is applied
Yes
Off, On
Continue
Auto
0.01 to 150.00 seconds
0.00 to 100.00 100 Oper
0.00 to 100.00 0 Oper
0
1
0 to 100
or
0 to 1 (OnOff)
Default
Conf
No inversion
Inverted
Switches On/Off
Remains in its last state
Auto = 220ms. This is the fastest allowable update rate for the output
Off
On
Oper
No Conf
Off Conf
Auto Oper
Read
Access
Level
Only
only
Part No HA028581 Issue 7.0 Dec-09 69
Page 72
Engineering Handbook Mini8 Controller
7.5 Thermocouple Input
A TC4 offers 4 channels and the TC8 board offers 8 channels which may be configured as thermocouple inputs or mV inputs.
7.5.1 Thermocouple Input Parameters
Folder – IO Sub-headers: Mod .1 to .32
Name
Ident Channel Ident TCinput Read Only
IO Type IO Type Thermocouple
Lin Type Input linearisation see section
Units Display units used for units
Resolution Resolution XXXXX to
CJC Type To select the cold junction
SBrk Type Sensor break type
SBrk Alarm Sets the alarm action when
AlarmAck Sensor Break alarm
DisplayHigh The maximum display
DisplayLow The minimum display value
RangeHigh The maximum (electrical)
RangeLow The minimum (electrical)
Fallback Fallback Strategy
Parameter Description Value
mV
7.5.2
see section
conversion
compensation method
a sensor break condition is detected
acknowledge
value in engineering units
in engineering units
input mV
input mV
See also section 7.5..5.
15.1.2
X.XXXX
Internal
o
C
0
o
C
45
o
C
50
External
Off
Low Sensor break will be detected when its
High Sensor break will be detected when its
Off No sensor break
ManLatch Manual latching
NonLatch No latching
Off No sensor break alarm
No
Yes
-99999 to 99999 100 Oper
-99999 to 99999 0 Oper
RangeLow to 70 70 Oper
-70 to RangeHigh
Downscale Meas Value = Input range lo - 5%
Upscale Meas Value = Input range Hi + 5%
Fall Good Meas Value = Fallback PV
Fall Bad Meas Value = Fallback PV
Clip Good Meas Value = Input range Hi/lo +/- 5%
Clip Bad Meas Value = Input range Hi/lo +/- 5%
Default Access
Level
For direct t/c connection
For mV inputs, usually linear, scaled to engineering units.
Conf
Conf
Sets scaling for digital communications using the SCADA table
See description in section 7.5.3. for further details
impedance is greater than a ‘low’ value
impedance is greater than a ‘high’ value
see also the alarm Chapter 8 Alarms
No Oper
For IO Type mV only
Limits apply to Linear and SqRoot linearisation.
See 7.3.7
Conf
Conf
Internal Conf
Conf
Oper
0 Oper
Conf
70 Part No HA028581 Issue 7.0 Dec-09
Page 73
Mini8 Controller Engineering Handbook
Folder – IO Sub-headers: Mod .1 to .32
Name
Fallback PV Fallback value
Filter Time Constant
Measured Val The current electrical value of the PV
PV The current value of the PV input after
LoPoint Low Point 0.0 Oper
LoOffset Low Offset 0.0 Oper
HiPoint High Point 0.0 Oper
HiOffset High Offset
Offset Used to add a constant offset to the PV
CJC Temp Reads the temperature of the rear
SBrk Value Sensor break Value
Cal State Calibration State.
Status PV Status
SbrkOutput Sensor Break Output Off /On R/O
Parameter Description Value
See also section 7.5.5.
Input filter time.
An input filter provides damping of the input signal. This may be necessary to prevent the effects of excessive noise on the PV input.
input
linearisation
see section 7.5.7
terminals at the thermocouple connection
Used for diagnostics only, and displays the sensor break trip value
Idle Conf Calibration of the PV Input is described in section 22.5
0 - OK
The current status of the PV.
1 - Startup
2 - SensorBreak
4 – Out of range
6 - Saturated
8 – Not Calibrated
25 – No Module
Default Access
Level
Instrument range Conf
Off to 500:00 (hhh:mm)
s:ms to hhh:mm
R/O
Instrument range R/O
Lower cal point (See 7.5.6)
Offset at lower point
Higher cal point
Offset at Higher point
Instrument range 0.0 Oper
R/O
R/O
Normal operation
Initial startup mode
Input in sensor break
PV outside operating limits
Saturated input
Uncalibrated channel
No Module
1s600ms Oper
0.0 Oper
R/O
Part No HA028581 Issue 7.0 Dec-09 71
Page 74
Engineering Handbook Mini8 Controller
7.5.2 Linearisation Types and Ranges
Input Type Min Range Max Range Units Min Range Max Range Units J Thermocouple type J -210 1200 K Thermocouple type K -200 1372 L Thermocouple type L -200 900 R Thermocouple type R -50 1700 B Thermocouple type B 0 1820 N Thermocouple type N -200 1300 T Thermocouple type T -200 400 S Thermocouple type S -50 1768 PL2 Thermocouple Platinel II 0 1369 C Custom Linear mV linear input -70 70 mV SqRoot Square root Custom Customised linearisation
tables
o
C -238 2192 oF
o
C -238 2498 oF
o
C -238 1652 oF
o
C -58 3124 oF
o
C 32 3308 oF
o
C -238 2372 oF
o
C -238 752 oF
o
C -58 3214 oF
oC
32 2466 oF
7.5.3 CJC Type
A thermocouple measures the temperature difference between the measuring junction and the reference junction. The reference junction, therefore, must either be held at a fixed known temperature or accurate compensation be used for any temperature variations of the junction.
7.5.3.1 Internal Compensation
The controller is provided with a temperature sensing device which senses the temperature at the point where the thermocouple is joined to the copper wiring of the instrument and applies a corrective signal.
Reference
junction
Measuring
junction
Where very high accuracy is needed and to accommodate multi-thermocouple installations, larger reference units are used which can achieve an accuracy of ±0.1°C or better. These units also allow the cables to the instrumentation to be run in copper. The reference units are contained basically under three techniques, Ice­Point, Hot Box and Isothermal.
7.5.3.2 The Ice-Point
There are usually two methods of feeding the EMF from the thermocouple to the measuring instrumentation via the ice-point reference, the bellows type and the temperature sensor type.
The bellows type utilises the precise volumetric increase which occurs when a known quantity of ultra pure water changes state from liquid to solid. A precision cylinder actuates expansion bellows which control power to a thermoelectric cooling device. The temperature sensor type uses a metal block of high thermal conductance and mass, which is thermally insulated from ambient temperatures. The block temperature is lowered to 0°C by a cooling element, and maintained there by a temperature sensing device.
Special thermometers are obtainable for checking the 0°C reference units and alarm circuits that detect any movement from the zero position can be fitted.
7.5.3.3 The Hot Box
Thermocouples are calibrated in terms of EMF generated by the measuring junctions relative to the reference junction at 0°C. Different reference points can produce different characteristics of thermocouples, therefore referencing at another temperature does present problems. However, the ability of the hot box to work at very high ambient temperatures, plus a good reliability factor has led to an increase in its usage. The unit can consist of a thermally insulated solid aluminium block in which the reference junctions are embedded.
The block temperature is controlled by a closed loop system, and a heater is used as a booster when initially switching on. This booster drops out before the reference temperature, usually between 55°C and 65°C, is reached, but the stability of the hot box temperature is now important. Measurements cannot be taken until the hot box reaches the correct temperature.
72 Part No HA028581 Issue 7.0 Dec-09
Page 75
Mini8 Controller Engineering Handbook
7.5.3.4 Isothermal Systems
The thermocouple junctions being referenced are contained in a block which is heavily thermally insulated. The junctions are allowed to follow the mean ambient temperature, which varies slowly. This variation is accurately sensed by electronic means, and a signal is produced for the associated instrumentation. The high reliability factor of this method has favoured its use for long term monitoring.
7.5.3.5 CJC Options in Mini8 Controller Series
0 – Internal CJC measurement at instrument terminals 1 – 0C CJC based on external junctions kept at 0C (Ice Point) 2 – 45C CJC based on external junctions kept at 45C (Hot Box) 3 – 50C CJC based on external junctions kept at 50C (Hot Box) 4 – External CJC based on independent external measurement 5 – Off CJC switched off
7.5.4 Sensor Break Value
The controller continuously monitors the impedance of a transducer or sensor connected to any analogue input. This impedance, expressed as a % of the impedance which causes the sensor break flag to trip, is a parameter called ‘SBrkValue’. The table below shows the typical impedance which causes sensor break to trip for various types of input and high and low SBrk Impedance readings. The impedance values are only approximate (±25%) as they are not factory calibrated.
TC4/TC8 Input
Range -77 to +77mV
SBrk Impedance – High
SBrk Impedance – Low
~ 12KΩ
~ 3KΩ
7.5.5 Fallback
A Fallback strategy may be used to configure the default value for the PV in case of an error condition. The error may be due an out of range value, a sensor break, lack of calibration or a saturated input. The Status parameter would indicate the error condition and could be used to diagnose the problem. Fallback has several modes and may be associated with the Fallback PV parameter The Fallback PV may be used to configure the value assigned to the PV in case of an error condition. The Fallback parameter should be configured accordingly. The fallback parameter may be configured so as to force a Good or Bad status when in operation. This in turn allows the user to choose to override or allow error conditions to affect the process.
Part No HA028581 Issue 7.0 Dec-09 73
Page 76
Engineering Handbook Mini8 Controller
7.5.6 User Calibration (Two Point)
All ranges of the controller have been calibrated against traceable reference standards. However in a particular application it may be necessary to adjust the displayed reading to overcome other effects within the process. A two point calibration is offered allowing offset and slope adjustment. This is most useful where the setpoints used in a process cover a wide range. The Low and High points should be set on or near the extremities of the range.
Display Reading
Low offset
(e.g. 1.1°)
High offset
(e.g. 2.9°)
Factory calibration
7.5.7 PV Offset (Single Point)
All ranges of the controller have been calibrated against traceable reference standards. This means that if the input type is changed it is not necessary to calibrate the controller. There may be occasions, however, when you wish to apply an offset to the standard calibration to take account of known errors within the process, for example, a known sensor error or a known error due to the positioning of the sensor. In these instances it is not advisable to change the reference calibration, but to apply a user defined offset. A single point offset is most useful where the process setpoint remains at nominally the same value.
PV Offset applies a single offset over the full display range of the controller and can be adjusted in Operator Mode. It has the effect of moving the curve up a down about a central point as shown in the example below:-
Display Reading
Fixed offset
(e.g. 2.1°)
Low point
(e.g. 50°)
Factory calibration
High point (e.g. 500°)
Measured Reading
Measured Reading
7.5.7.1 Example: To Apply an Offset:-
• Connect the input of the controller to the source device which you wish to calibrate to
• Set the source to the desired calibration value
• The controller will show the current measurement of the value
• If the value is correct, the controller is correctly calibrated and no further action is necessary. If you wish to
offset the reading use the Offset parameter where
Corrected value (PV) = input value + Offset.
74 Part No HA028581 Issue 7.0 Dec-09
Page 77
Mini8 Controller Engineering Handbook
7.5.8 Using TC4 or TC8 channel as a mV input
Example – a pressure sensor provides 0 to 33mV for 0 to 200 bar.
1. Set IO type as mV
2. Set the Linearisation Type as Linear
3. Set DisplayHigh to 200 (bar)
4. Set DisplayLow to 0 (bar)
5. Set RangeHigh to 33 mV
6. Set RangeLow to 0 mV
Note maximum input range is ± 70 mV
Part No HA028581 Issue 7.0 Dec-09 75
Page 78
Engineering Handbook Mini8 Controller
7.6 Resistance Thermometer Input
The RT4 module offers 4 resistance inputs which can be linear or PT100.
7.6.1 RT Input Parameters
Folder – IO Sub-headers: Mod .1 to .32
Name
Ident Channel Ident RTinput Read Only
IO Type IO Type RTD2
Lin Type Linearisation Type See
Units Display units used for units
Resolution Resolution XXXXX to
SBrk Type Sensor break type
SBrk Alarm Sets the alarm action when
AlarmAck Sensor Break alarm
Fallback Fallback Strategy
Fallback PV Fallback value
Filter Time Constant
Measured Val The current electrical value of the PV
PV The current value of the PV input after
LoPoint Low Point 0.0 Oper
LoOffset Low Offset 0.0 Oper
HiPoint High Point 0.0 Oper
HiOffset High Offset
Parameter Description Value
RTD3
RTD4
section
7.6.2
See
conversion
a sensor break condition is detected
acknowledge
See also section 7.5.5.
See also section 7.5.5.
Input filter time.
An input filter provides damping of the input signal. This may be necessary to prevent the effects of excessive noise on the PV input.
input
linearisation
section
15.1.2
X.XXXX
Low Sensor break will be detected when its
High Sensor break will be detected when its
Off No sensor break
ManLatch Manual latching
NonLatch No latching
Off No sensor break alarm
No
Yes
Downscale Meas Value = Input range lo - 5%
Upscale Meas Value = Input range Hi + 5%
Fall Good Meas Value = Fallback PV
Fall Bad Meas Value = Fallback PV
Clip Good Meas Value = Input range Hi/lo +/- 5%
Clip Bad Meas Value = Input range Hi/lo +/- 5%
Default Access
Level
For 2 wire, 3 wire or 4 wire connections. Conf
Conf
Conf
Sets scaling for digital communications using the SCADA table
impedance is greater than a ‘low’ value
impedance is greater than a ‘high’ value
see also the alarm Chapter 8 Alarms
No Oper
Instrument range Conf
Off to 500:00 (hhh:mm)
s:ms to hhh:mm
R/O
Instrument range R/O
Lower cal point (See section 7.5.6)
Offset at lower cal point
Higher cal point
Offset at Higher cal point
Conf
Conf
Oper
Conf
1s600ms Oper
0.0 Oper
76 Part No HA028581 Issue 7.0 Dec-09
Page 79
Mini8 Controller Engineering Handbook
Folder – IO Sub-headers: Mod .1 to .32
Name
Offset Used to add a constant offset to the PV
SBrk Value Sensor break Value
Cal State Calibration State.
Status PV Status
SbrkOutput Sensor Break Output Off /On R/O
Parameter Description Value
see section 7.5.7
Used for diagnostics only, and displays the sensor break trip value
Idle Conf Calibration of the PV Input is described in Chapter
22.5
0 - OK
The current status of the PV.
1 - Startup
2 - SensorBreak
4 – Out of range
6 - Saturated
8 – Not Calibrated
25 – No Module
Default Access
Level
Instrument range 0.0 Oper
R/O
Normal operation
Initial startup mode
Input in sensor break
PV outside operating limits
Saturated input
Uncalibrated channel
No Module
R/O
7.6.2 Linearisation Types and Ranges
Input Type Min Range Max Range Units Min Range Max
Range
PT100 100 ohm platinum bulb
Linear Linear 50 450
-200 850
o
C -328 1562 oF
ohms
Units
7.6.3 Using RT4 as mA input
Wire the input with a 2.49 ohm resistor as shown in 1.4.12.
The PV is mapped from the input using User Cal – see section 7.5.6
Approximate Values for 4-20mA input with 2.49 ohm resistor.
PV range 4 to 20 0 to 100 LoPoint 35.4 35.4 LoOffset -31.4 -35.4 HiPoint 169.5 169.5 HiOffset -149.5 -69.5
For best accuracy the input should be calibrated against a reference.
Resistor values up to 5 ohms may be used.
Part No HA028581 Issue 7.0 Dec-09 77
Page 80
Engineering Handbook Mini8 Controller
7.7 Analogue Output
The AO4 offers 4 channels and the AO8 module 8 channels which maybe configured as mA outputs. An AO4 or AO8 may only be fitted in Slot 4.
Folder – IO Sub-folder: Mod.25 to Mod.32
Name
Ident Channel ident mAout R/O
IO Type To configure the output
Resolution Display resolution XXXXX to
Disp Hi Display high reading 100 Oper
Disp Lo Display low reading
Range Hi Electrical high input level 20 Oper
Range Lo Electrical low input level
Meas Value The current output value R/O
PV Oper
Status PV Status
Parameter Description Value
mA milli-amps dc Conf
drive signal
X.XXXX
-99999 to 99999 decimal points depend on resolution
0 to 20
0 - OK
The current status of the PV.
1 - Startup
2 - SensorBreak
4 – Out of range
6 - Saturated
8 – Not Calibrated
25 – No Module
Determines scaling for SCADA communications
Normal operation
Initial startup mode
Input in sensor break
PV outside operating limits
Saturated input
Uncalibrated channel
No Module
Default Access
Level
Conf
0 Oper
4 Oper
R/O
7.7.1 Example – 4 to 20mA Analogue Output
In this example 0% (=Display Low) to 100% (=Display High) from a Loop PID Output is wired to this output channel PV input which will give a 4mA (=Range Low) to 20mA (=Range High) control signal.
Here the PID demand is 50% giving a MeasuredVal output of 12mA.
78 Part No HA028581 Issue 7.0 Dec-09
Page 81
Mini8 Controller Engineering Handbook
7.8 Fixed IO
There are two digital inputs, designated D1 and D2.
Folder: IO Sub-folder: Fixed IO.D1 and .D2
Name
Ident Channel Ident LogicIn LogicIn Read
IO Type IO Type Input Input Read
Invert Invert No/Yes – input sense is inverted No Conf
Measured Val Measured Value On/Off Value seen at the terminals Off Read
PV Process Variable On/Off Value after allowing for Invert Off Read
There are two fixed relay outputs, designated A and B
Folder: IO Sub-folder: Fixed IO.A and .B
Name
Ident Channel Ident
IO Type IO Type OnOff OnOff Read
Invert Invert No/Yes = output sense is inverted. No Conf
Measured Val Measured Value On/Off Value seen at the terminals
PV Process Variable On/Off Requested output before
SbyAct Action taken by output when
Parameter Description
Parameter Description Value
instrument goes into Standby Mode
Value
Relay
Off, On
Continue
Default Access
Level
Only
Only
Only
Only
Default Access
Level
after allowing for Invert.
Invert
Switches On/Off
Remains in its last state
Relay Read
Only
Only
Off Read
Only
Off Oper
Off Conf
Part No HA028581 Issue 7.0 Dec-09 79
Page 82
Engineering Handbook Mini8 Controller
7.9 Current Monitor
The Mini8 controller, with a CT3 card, has the capability of detecting failures of up to 16 heater loads by measuring the current flowing through them via 3 current transformer inputs. The failures that can be detected are:
SSR Fault
If current is detected flowing through the heater when the controller is requesting it to be off then this indicates that the SSR has a short circuit fault. If current is not detected when the controller is requesting the heater to be on it indicates that the SSR has an open circuit fault.
Partial Load Fault (PLF)
If less current is detected flowing through the heater than the PLF threshold, which has been set for that channel, then this indicates that the heater has a fault; in applications that use multiple heater elements in parallel then it indicates that one or more of the elements has an open circuit fault.
Over Current Fault (OCF)
If more current is detected flowing through the heater than the OCF threshold then this indicates that the heater has a fault; in applications that use multiple heater elements in parallel then it indicates that one or more of the elements has lower than expected resistance value.
It should be noted that if the loop associated with a CT monitored output is inhibited, then that output will be excluded from the CT measurements and fault detection.
Heater failures are indicated via individual load status parameters and via four status words. In addition, a global alarm parameter will indicate when a new CT alarm has been detected, which, will also be registered in the alarm log.
7.9.1.1 Current Measurement
Individual LoadCurrent parameters indicate the current measured for each heater. The Current Monitor function block utilises a cycling algorithm to measure the current flowing through one heater per measurement interval (default 10s, user alterable). Compensation within the control loop minimises the disturbance to the PV when current through a load is being measured.
The interval between successive measurements is dependent upon the average output power required to maintain SP. The recommended absolute minimum interval can be calculated as follows:
Minimum interval (s) > 0.25 * (100/average output power to maintain SP).
For example, if average output power to maintain SP is 10%, using the above rule, the recommended minimum interval is 2.5 seconds. The interval may need to be adjusted depending upon the response of the heaters being used.
80 Part No HA028581 Issue 7.0 Dec-09
Page 83
Mini8 Controller Engineering Handbook
N
N
t
7.9.2 Single Phase Configurations
7.9.2.1 Single SSR triggering
With this configuration, failures of individual heater loads can be detected. For example, if the current detected flowing through Heater 3 is less than its PLF threshold then this will be indicated as Load3PLF
Example1 – Using one CT input
L
CT1
MINI8 controller
OP1
OP2
OP3
OP4
OP5
H1
H2
H3
All time proportioning outputs assigned to a single CT input
H4
H5
H6
ote: Maximum of 6 Heaters can be connected to one CT inpu
OP6
Example2 – Using three CT inputs
MINI8 controller
CT1
CT2
CT3
OP1
OP2
OP3
OP4
OP5
OP6
H1
H2
H3
H4
L
This configuration also identifies individual heater failures
H5
H6
Part No HA028581 Issue 7.0 Dec-09 81
Page 84
Engineering Handbook Mini8 Controller
N
H
H
7.9.2.2 Multiple SSR triggering
With this configuration, failure of a set of heater loads can be detected. For example, if the current detected flowing through Heater Set 1 is less than Load1’s PLF threshold then this will be indicated as Load1PLF. Further investigation will then be required to determine which heater within Set 1 has failed.
MINI8 controller
7.9.2.3 Split Time Proportioning Outputs
This is where a single power demand is split and applied to two time proportioning outputs, that have been scaled, allowing the loads to switch on incrementally as the output power increases. For example, Heater1 will deliver any demand from 0-50%, and Heater2 will deliver any demand from 50-100% (with Heater1 fully on).
CT1
OP1
OP2
L
H1
H2
H3
H4
H5
H6
eater Set 1
eater Set 2
CurrentMonitor
CT1
L
Mod.17
Loop
Ch1Out
50
PV
0
100
Pre-Scaling
0 100
Mod.18
H1
H2
MINI8 controller
As the Mini8 controller has the capability of detecting faults with up to 16 heater loads it can handle this type of application even if all 8 loops have split time proportioning outputs.
PV
50
Pre-Scaling
0 100
82 Part No HA028581 Issue 7.0 Dec-09
Page 85
Mini8 Controller Engineering Handbook
N
t
7.9.3 Three Phase Configuration
Configuration for Three Phase supply applications is similar to that for Single phase using three CT inputs.
MINI8 controller
CT1
CT2
CT3
OP1
OP2
OP3
OP4
OP5
Ph1 Ph2 Ph3
H1
H2
H3
N/Ph2
H4
H5
N/Ph3
All currents passed through an individual CT must come from the same phase
Star with neutral or delta connection is possible
H6
OP6
N/Ph1
ote: Maximum of 6 Heaters can be connected to one CT inpu
Part No HA028581 Issue 7.0 Dec-09 83
Page 86
Engineering Handbook Mini8 Controller
7.9.4 Parameter Configuration
If Current Monitor is enabled in the folder Instrument/Options/Current Monitor then the current monitor configuration folder appears as a subfolder in IO.
Folder: IO Sub-folder: CurrentMonitor/Config
Name
Commission Commission CT
CommissionStatus Commission Status
Interval Measurement
Inhibit Inhibit
MaxLeakPh1 Max Leakage
MaxLeakPh2 Max Leakage
MaxLeakPh3 Max Leakage
CT1Range* CT input 1 range
CT2Range* CT input 2 range
CT3Range* CT input 3 range
CalibrateCT1 Calibrate CT1
CalibrateCT2 Calibrate CT2
CalibrateCT3 Calibrate CT3
Parameter Description
Interval
Current Phase 1
Current Phase 2
Current Phase 3
Value
No See section 7.9.5 Auto Manual Accept Abort Not commissioned Commissioning NoDO8orRL8cards
NoloopTPouts
SSRfault
MaxLoadsCT1/2/3
NotAccepted Passed ManuallyConfigured 1s to 1m
No – current is measured Yes –current measurement is inhibited
0.25 to 1 amp
0.25 to 1 amp
0.25 to 1 amp
10 to 1000 amps (Ratio to 50mA)
10 to 1000 amps (Ratio to 50mA)
10 to 1000 amps (Ratio to 50mA)
Idle See section 22.5 0mA
-70mA LoadFactorCal SaveUserCal As CT1
As CT1
Not commissioned Commissioning in progress There are no DO8/RL8 cards installed in the instrument. The digital outputs are either not configured as time proportioning or are not wired from loop heater channels. Either a SSR short circuit or open circuit fault is present. More than 6 heaters have been connected to CT input 1or 2 or 3. Commissioning failed Successfully auto commissioned Configured manually
Default Access
Level
No Oper
0 Read
Only
10s Oper
No Oper
0.25 Oper
0.25 Oper
0.25 Oper
10 Oper
10 Oper
10 Oper
Idle Oper
Idle Oper
Idle Oper
• The current rating of the CT used for each of the CT input channels should cover only the single largest load current proposed for its group of heaters. e.g. if CT1 has heaters of 15A, 15A & 25A it would need a CT capable of at least 25A.
84 Part No HA028581 Issue 7.0 Dec-09
Page 87
Mini8 Controller Engineering Handbook
7.9.5 Commissioning
7.9.5.1 Auto Commission
Auto commissioning of the Current Monitor is a feature that automatically detects which time proportioning outputs drive individual heaters (or heater sets), detects which CT input individual heaters are associated with and determines the Partial Load and Over Current thresholds using a 1:8 ratio. If auto commissioning fails, a status parameter indicates the reason why.
Note: In order for the auto commissioning to operate successfully the process must be enabled for full operation of the heating circuit with the digital outputs configured as Time Proportioning and ‘soft’ wired to the appropriate loop heater channels. During auto commissioning digital outputs will switch on and off.
.How to Auto Commission
1. Put instrument into Operator Mode.
2. Set Commission to Auto and CommissionStatus will display ‘Commissioning’.
3. If successful, CommissionStatus will display Passed and configured load parameters will become available. If unsuccessful, CommissionStatus displays the offending fault.
If unsuccessful, CommissionStatus displays the offending fault:
NoDO8orRL8Cards Indicates that there are no DO8 or RL8 cards installed in the instrument.
NoLoopTPOuts Indicates that the digital outputs are either not configured as time
proportioning or are not wired from loop heater channels.
SSRFault Indicates that either a SSR short circuit or open circuit fault is present.
MaxLoadsCT1
(or 2,3)
Part No HA028581 Issue 7.0 Dec-09 85
Indicates that more than 6 heaters have been connected to CT input 1
(or 2,3)
Page 88
Engineering Handbook Mini8 Controller
7.9.5.2 Manual Commission
Manual Commissioning is also available and is intended for those users who want to commission the Current Monitor off-line or do not want to accept auto commissioned settings.
How to Manual Commission
1. Set Commission to Manual. CommissionStatus will display Commissioning and Load1 configuration parameters will become available
2. Set Load1DrivenBy to the IO Module that is connected to the heater load.
3. Set Load1CTInput to the CT input number that is connected to the heater load.
4. Set Load1PLFthreshold and Load1OCFthreshold to appropriate values for the heater load.
5. Repeat for other loads.
6. To use the commissioned settings set Commission to ‘Accept’. CommissionStatus will display ManuallyConfigured.
7. To stop manual commissioning set Commission to ‘Abort’. CommissionStatus will display NotCommissioned.
86 Part No HA028581 Issue 7.0 Dec-09
Page 89
Mini8 Controller Engineering Handbook
7.9.6 Calibration
A Mini8 controller supplied from factory with the CT3 card already installed the CT inputs will have been factory calibrated. If the CT3 card is installed at a later date then default calibration values are automatically loaded into the instrument. However, three calibration parameters, one for each CT input, are provided to allow the inputs to be calibrated in the field.
Note: DC Current Source, capable of outputting a –70mA signal, is required to calibrate the inputs.
The 3 CT inputs are calibrated individually.
How to Calibrate
1. Apply the stimulus (0mA or –70mA) from the DC current source to the CT input to be calibrated.
2. Set CalibrateCT1, to reflect the stimulus being applied to the input.
3. CalibrateCT1 displays ‘Confirm’. Select ‘Go’ to proceed with the calibration process.
4. After selecting Go, CalibrateCT1 displays ‘Calibrating’.
5. If calibration was successful, CalibrateCT1 displays ‘Passed’. Select ‘Accept’ to keep the calibration values.
6. If calibration was unsuccessful, CalibrateCT1 displays ‘Failed’. Select ‘Abort’ to reject the calibration.
7. Select ‘SaveUserCal’ to save the calibration values into non-volatile memory.
8. Select ‘LoadFactCal’ to restore calibration values to the factory calibrated or default settings.
9. Note: It is possible to stop the calibration process at anytime by selecting ‘Abort’.
Follow the same procedure for CT2 and CT3.
Part No HA028581 Issue 7.0 Dec-09 87
Page 90
Engineering Handbook Mini8 Controller
8. Chapter 8 Alarms
Alarms are used to alert the system when a pre-set level has been exceeded or a particular condition has
changed state. As the Mini8 controller has no display to show alarms the alarm flags are all available over communications in status words See Alarm Summary (Section 8.7). They may also be wired directly or via logic to an output such as a relay.
Alarms can be divided into two main types. These are:-
Analogue alarms - operate by monitoring an analogue variable such as the process variable and comparing it with a set threshold.
Digital alarms – operate when the state of a boolean variable changes, for example, sensor break.
Number of Alarms - up to 32 analogue and 32 digital alarms may be configured.
8.1 Further Alarm Definitions
Hysteresis is the difference between the point at which the alarm switches ‘ON’ and the point at which
it switches ‘OFF’. It is used to provide a definite indication of the alarm condition and to prevent alarm relay chatter.
Latch used to hold the alarm condition once an alarm has been detected. It may be configured
as:-
None Non
latching
Auto Automatic An auto latching alarm requires acknowledgement before it is
Manual Manual The alarm continues to be active until both the alarm condition is
Event Event Alarm output will activate.
Block The alarm may be masked during start up. Blocking prevents the alarm from being activated
until the process has first achieved a safe state. It is used, for example, to ignore start up conditions which are not representative of running conditions. A blocking alarm is re­initiated after a setpoint change.
Delay A short time can be set for each alarm which prevents the output from going into the alarm
state. The alarm is still detected as soon as it occurs, but if it cancels before the end of the delay period then no output is triggered. The timer for the delay is then reset. It is also reset if an alarm is changed from being inhibited to uninhibited.
A non latching alarm will reset itself when the alarm condition is removed
reset. The acknowledgement can occur BEFORE the condition causing the alarm is removed.
removed AND the alarm is acknowledged. The acknowledgement can only occur AFTER the condition causing the alarm is removed.
88 Part No HA028581 Issue 7.0 Dec-09
Page 91
Mini8 Controller Engineering Handbook
8.2 Analogue Alarms
Analogue alarms operate on variables such as PV, output levels, etc. They can be soft wired to these variables to suit the process.
8.2.1 Analogue Alarm Types
Absolute High - an alarm occurs when the PV exceeds a set high threshold.
Absolute Low - an alarm occurs when the PV exceeds a set low threshold.
Deviation High - an alarm occurs when the PV is higher than the setpoint by a set threshold
Deviation Low - an alarm occurs when the PV is lower than the setpoint by a set threshold
Deviation Band - an alarm occurs when the PV is higher or lower than the setpoint by a set threshold
These are shown graphically below for changes in PV plotted against time. (Hysteresis set to zero)
Alarm Type
Abs High
Dev High
Setpoint (SP)
Dev Low
Abs Low
PV
Process Variable (PV)
Dev Bnd
Output State
Time
Abs Low On
On
Dev Low
On On
Dev High
On
Dev Bnd
On On On
Abs High
On
Part No HA028581 Issue 7.0 Dec-09 89
Page 92
Engineering Handbook Mini8 Controller
8.3 Digital Alarms
Digital alarms operate on Boolean variables. They can be soft wired to any suitable Boolean parameter such as digital inputs or outputs.
8.3.1 Digital Alarm Types
Pos Edge The alarm will trigger when the input changes from a low to high condition Neg Edge The alarm will trigger when the input changes from a high to low condition Edge The alarm will trigger on any change of state of the input signal High The alarm will trigger when the input signal is high Low The alarm will trigger when the input signal is low
8.4 Alarm Outputs
Alarms can operate a specific output (usually a relay). Any individual alarm can operate an individual output or any combination of alarms can operate an individual output. They are wired as required in configuration level
Each source may be chosen from:-
Analogue Alarms 1 to 32 Digital Alarms 1 to 32 Any alarms New alarm/ New CT Alarm Loop break alarms
OR
Invert
No
Output
Yes
.
8.4.1 How Alarms are Indicated
Alarm states are all embedded in 16 bit status words. See Alarm Summary in Section 8.7
8.4.2 To Acknowledge an Alarm
Set the appropriate alarm acknowledge flag to acknowledge that particular alarm. Alternatively the GlobalAck in the AlmSummary folder can be used to acknowledge ALL alarms that require acknowledging in the instrument.
The action, which now takes place, will depend on the type of latching, which has been configured
8.4.2.1 Non Latched Alarms
If the alarm condition is present when the alarm is acknowledged, the alarm output will be continuously active. This state will continue for as long as the alarm condition remains. When the alarm condition clears the output will go off. If the alarm condition clears before it is acknowledged the alarm output goes off as soon as the condition disappears.
8.4.2.2 Automatic Latched Alarms
The alarm continues to be active until both the alarm condition is removed AND the alarm is acknowledged. The acknowledgement can occur BEFORE the condition causing the alarm is removed.
8.4.2.3 Manual Latched Alarms
The alarm continues to be active until both the alarm condition is removed AND the alarm is acknowledged. The acknowledgement can only occur
AFTER the condition causing the alarm is removed.
90 Part No HA028581 Issue 7.0 Dec-09
Page 93
Mini8 Controller Engineering Handbook
8.5 Alarm Parameters
Four groups of eight analogue alarms are available. The following table shows the parameters to set up and configure alarms.
Folder: Alarm Sub-folders: 1 to 32
Name
Type Selects the type of alarm None
In This is the parameter that will be monitored and
Reference The reference value is used in deviation alarms and
Threshold The threshold is the value that the input is compared
Out The output indicates whether the alarm is on or off
Inhibit Inhibit is an input to the Alarm function. It allows the
Hysteresis Hysteresis is used to prevent signal noise from
Latch Determine the type of latching the alarm will use, if
Ack Used in conjunction with the latching parameter. It is
Block Alarm Blocking is used to prevent alarms from
Delay This is a small delay between sensing the alarm
Parameter Description Value
Abs Hi Abs Lo Dev Hi Dev Lo Dv Bnd
Instrument range Oper compared against the threshold value to see if an alarm condition has occurred
Instrument range Oper the threshold is measured from this reference and not from its absolute value.
Instrument range Oper against to determine if an alarm has occurred.
Off depending on: the alarm condition, latching and acknowledge, inhibiting and blocking.
alarm to be switched OFF. Typically the Inhibit is connected to a digital input or event so that during a phase of the process alarms do not activate. For Example, if the door to a furnace is opened the alarms may be inhibited until the door is closed again.
causing the Alarm output to oscillate. Alarm outputs become active as soon as the PV exceeds the Alarm Setpoint. They return to inactive after the PV has returned to the safe region by more than the hysteresis value. Typically the Alarm hysteresis is set to a value that is greater than the oscillations seen on the instrument display
any. Auto latching allows acknowledgement while the alarm condition is still active, whereas manual latching needs the condition to revert back to safe before the alarm can be acknowledged. See also the description at the beginning of this chapter
set when the user responds to an alarm.
activating during start-up. In some applications, the measurement at start-up is in an alarm condition until the system has come under control. Blocking causes the alarms to be ignored until the system is under control (in the safe state), after this any deviations trigger the alarm
condition and displaying it. If in the time between the two, the alarm goes safe, then no alarm is shown and the delay timer is reset. It can be used on systems that are prone to noise.
On
No
Yes
Instrument range Oper
None
Auto
Manual
Event
No
Yes
No
Yes
0:00.0 to 500
mm:ss.s
hh:mm:ss
hhh:mm
Alarm not configured Full Scale High Full Scale Low Deviation High Deviation Low Deviation band
Alarm output deactivated Alarm output activated
Alarm not inhibited Inhibit function active
No latching is used Automatic Manual Event
Not acknowledged Acknowledged No blocking Blocking
Default Access
Level
Conf
R/O
Oper
Oper
Oper
Oper
0:00.0 Oper
Part No HA028581 Issue 7.0 Dec-09 91
Page 94
Engineering Handbook Mini8 Controller
8.5.1 Example: To Configure Alarm 1
Change Access level to configuration.
In this example the high alarm will be detected when the measured value exceeds 100.00.
The current measured value is 27.79 as measured by the ‘Input’ parameter. This parameter will normally be wired to an internal source such as a thermocouple input. In this example the alarm will set when the measured value exceeds the threshold 100.0 and will clear when the input decreases 0.50 units below the threshold level (i.e. at 99.5 units).
92 Part No HA028581 Issue 7.0 Dec-09
Page 95
Mini8 Controller Engineering Handbook
8.6 Digital Alarm Parameters
Four groups of eight digital alarms are available. The following table shows the parameters to set up and configure alarms.
Folder: DigAlarm Sub-folders: 1 to 32
Name
Type Selects the type of alarm None
In This is the parameter that will be monitored and
Out The output indicates whether the alarm is on or
Inhibit Inhibit is an input to the Alarm function. It allows
Latch Determine the type of latching the alarm will use,
Ack Used in conjunction with the latching parameter.
Block Alarm Blocking is used to prevent alarms from
Delay This is a small delay between sensing the alarm
8.6.1 Example: To Configure DigAlarm 1
Parameter Description Value
PosEdge NegEdge Edge High Low
0 to 1 Oper checked according to the AlarmType to see if an alarm condition has occurred
Off off depending on: the alarm condition, latching and acknowledge, inhibiting and blocking.
the alarm to be switched OFF. Typically the Inhibit is connected to a digital input or event so that during a phase of the process alarms do not activate. For Example, if the door to a furnace is opened the alarms may be inhibited until the door is closed again.
if any. Auto latching allows acknowledgement while the alarm condition is still active, whereas manual latching needs the condition to revert back to safe before the alarm can be acknowledged. See also the description at the beginning of this chapter
It is set when the user responds to an alarm.
activating during start-up. In some applications, the measurement at start-up is in an alarm condition until the system has come under control. Blocking causes the alarms to be ignored until the system is under control (in the safe state), after this any deviations trigger the alarm
condition and displaying it. If in the time between the two, the alarm goes safe, then no alarm is shown and the delay timer is reset. It can be used on systems that are prone to noise.
On
No
Yes
None
Auto
Manual
Event
No
Yes
No
Yes
0:00.0 to 500
mm:ss.s
hh:mm:ss
hhh:mm
Alarm not configured On rising edge On falling edge On change High (1) Low (0)
Alarm output deactivated Alarm output activated
Alarm not inhibited Inhibit function active
No latching is used Automatic Manual Event
Not acknowledged Acknowledged No blocking Blocking
Default Access
Level
Conf
R/O
Oper
Oper
Oper
Oper
0:00.0 Oper
Change Access level to configuration.
In this example the digital alarm will come on if Timer 1 expires.
Timer.1.Out is wired to the alarm input. The DigAlarm.1.Out will turn on if the timer expires.
Part No HA028581 Issue 7.0 Dec-09 93
Page 96
Engineering Handbook Mini8 Controller
8.7 Alarm Summary
This is a summary of all the alarms in the Mini8 controller. It provides global alarm and acknowledge flags as well as 16 bit status words which can be read over communications by the supervisory system.
Folder: AlmSummary Sub-folders: General
Name
NewAlarm A new alarm has occurred since the last
RstNewAlarm Resets the NewAlarm flag Yes / No No Oper NewCTAlarm A new Current alarm has occurred since
RstNewCTAlarm Resets the NewCTAlarm flag Yes / No No Oper AnyAlarm Any new alarm since the last reset Off/On R/O GlobalAck Acknowledges every alarm in the Mini8
AnAlarmStatus1 16 bit word for analogue alarms 1 to 8 Bit 0
AnAlarmStatus2 16 bit word for analogue alarms 9 to 16 Same format as above R/O AnAlarmStatus3 16 bit word for analogue alarms 17 to 24 Same format as above R/O AnAlarmStatus4 16 bit word for analogue alarms 25 to 32 Same format as above R/O
Parameter Description Value
Off/On R/O
reset (excludes CT alarms)
Off/On R/O
the last reset
No controller requiring acknowledgement. Also resets NewAlarm and NewCTAlarm flags.
Yes
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Not acknowledged Acknowledged
Alarm 1 active Alarm 1 not ack’d Alarm 2 active Alarm 2 not ack’d Alarm 3 active Alarm 3 not ack’d Alarm 4 active Alarm 4 not ack’d Alarm 5 active Alarm 5 not ack’d Alarm 6 active Alarm 6 not ack’d Alarm 7 active Alarm 7 not ack’d Alarm 8 active Alarm 8 not ack’d
Default Access
Level
Oper
R/O
94 Part No HA028581 Issue 7.0 Dec-09
Page 97
Mini8 Controller Engineering Handbook
Folder: AlmSummary Sub-folders: General
Name
DigAlarmStatus1 16 bit word for digital alarms 1 to 8 Bit 0
Parameter Description Value
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15
Alarm 1 active Alarm 1 not ack’d Alarm 2 active Alarm 2 not ack’d Alarm 3 active Alarm 3 not ack’d Alarm 4 active Alarm 4 not ack’d Alarm 5 active Alarm 5 not ack’d Alarm 6 active Alarm 6 not ack’d Alarm 7 active Alarm 7 not ack’d Alarm 8 active Alarm 8 not ack’d
Default Access
Level
R/O
DigAlarmStatus2 16 bit word for digital alarms 9 to 16 Same format as above R/O DigAlarmStatus3 16 bit word for digital alarms 17 to 24 Same format as above R/O DigAlarmStatus4 16 bit word for digital alarms 25 to 32 Same format as above R/O SBrkAlarmStatus1 16 bit word for IO channels Mod.1 to 8 Bit 0
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15
Mod.1 fault Alarm 1 not ack’d Mod.2 fault Alarm 2 not ack’d Mod.3 fault Alarm 3 not ack’d Mod.4 fault Alarm 4 not ack’d Mod.5 fault Alarm 5 not ack’d Mod.6 fault Alarm 6 not ack’d Mod.7 fault Alarm 7 not ack’d Mod.8 fault Alarm 8 not ack’d
R/O
SbrkAlarmStatus2 16 bit word for IO channels Mod.9 to 16 Same format as above R/O SbrkAlarmStatus3 16 bit word for IO channels Mod.17 to 24 Same format as above R/O SbrkAlarmStatus4 16 bit word for IO channels Mod.25 to 32 Same format as above R/O CTAlarmStatus1 16 bit word for CT alarms 1 to 5 Bit 0
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15
Load1 SSR fail Load1 PLF Load1 OCF Load2 SSR fail Load2 PLF Load2 OCF Load3 SSR fail Load3 PLF Load3 OCF Load4 SSR fail Load4 PLF Load4 OCF Load5 SSR fail Load5 PLF Load5 OCF
-
R/O
Part No HA028581 Issue 7.0 Dec-09 95
Page 98
Engineering Handbook Mini8 Controller
Folder: AlmSummary Sub-folders: General
Name
CTAlarmStatus2 16 bit word for CT alarms 6 to 10 Bit 0
CTAlarmStatus3 16 bit word for CT alarms 11 to 15 Same format as CTAlarmStatus1 R/O CTAlarmStatus4 16 bit word for CT alarm 16 Same format as CTAlarmStatus1 R/O
Parameter Description Value
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Load6 SSR fail Load6 PLF Load6 OCF Load7 SSR fail Load7 PLF Load7 OCF Load8 SSR fail Load8 PLF Load8 OCF Load9 SSR fail Load9 PLF Load9 OCF Load10 SSR fail Load10 PLF Load10 OCF
-
Default Access
Level
R/O
8.8 Alarm Log
A list of the last 32 alarms to have occurred is maintained in an Alarm Log.
Folder: AlmSummary Sub-folder: AlmLog
Name
ClearLog Clear Alarm Log Yes/No No Oper Entry1Ident Most recent alarm activation All analogue alarms
Entry1Day The day the first entry activated NoEntry, Monday/Tuesday…Sunday. NoEntry R/O Entry1Time The time the first entry activated hh:mm:ss 0 R/O Entry2Ident 2nd most recent alarm activation All analogue alarms
Entry2Day The day the second entry activated NoEntry, Monday/Tuesday…Sunday. NoEntry R/O Entry2Time The time the second entry activated hh:mm:ss 0 R/O …etc Entry32Ident 32nd most recent alarm activation All analogue alarms
Entry32Day The day the 32nd entry activated NoEntry, Monday/Tuesday…Sunday. NoEntry R/O Entry32Time The time the 32nd entry activated hh:mm:ss 0 R/O
Parameter Description Value
All digital alarms
All sensor break alarms
All current alarms
All digital alarms
All sensor break alarms
All current alarms
All digital alarms
All sensor break alarms
All current alarms
Default Access
Level
NoEntry R/O
NoEntry R/O
NoEntry R/O
Note that EntryDay and EntryTime parameters require the Real Time Clock to be set up (Section 11.4) to record meaningful values.
96 Part No HA028581 Issue 7.0 Dec-09
Page 99
Mini8 Controller Engineering Handbook
9. Chapter 9 BCD Input
The Binary Coded Decimal (BCD) input function block uses a number of digital inputs and combines them to make a numeric value. A very common use for this feature is to select a setpoint program number from panel mounted BCD decade switches.
The block uses 4 bits to generate a single digit.
Two groups of four bits are used to generate a two digit value (0 to 99)
The block outputs four results
1. Units Value: The BCD value taken from the first four bits (range 0 – 9)
2. Tens Value: The BCD value taken from the second four bits (range 0 – 9)
3. BCD Value: The combined BCD value taken from all 8 bits (range 0 – 99)
4. Decimal Value: The decimal numeric equivalent of Hexadecimal bits (range 0 – 255)
The following table shows how the input bits combine to make the output values.
Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8
Units value ( 0 – 9)
Tens value ( 0 – 9)
BCD value (0 – 99)
Since the inputs cannot all be guaranteed to change simultaneously, the output will only update after all the inputs have been stable for two samples.
Decimal value (0 – 255)
9.1 BCD Parameters
Folder – BCDInput Sub-Folders: 1 and 2
Name
In 1 Digital Input 1 On or Off Off Oper
In 2 Digital Input 2 On or Off Off Oper
In 3 Digital Input 3 On or Off Off Oper
In 4 Digital Input 4 On or Off Off Oper
In 5 Digital Input 5 On or Off Off Oper
In 6 Digital Input 6 On or Off Off Oper
In 7 Digital Input 7 On or Off Off Oper
In 8 Digital Input 8 On or Off
Dec Value Decimal value of the inputs 0 – 255 See examples below R/O
BCD Value Reads the value (in BCD) of the
Units Units value of the first switch 0 – 9 See examples below R/O
Tens Units value of the second
Parameter Description Value
0 – 99 See examples below switch as it appears on the digital inputs
0 – 9 See examples below R/O switch
Default Access
Level
Alterable from the operator interface if not wired
Off Oper
Part No HA028581 Issue 7.0 Dec-09 97
Page 100
Engineering Handbook Mini8 Controller
In 1 In 2 In 3 In 4 In 5 In 6 In 7 In 8 Dec BCD Units Tens 1 0 0 0 0 0 0 0 1 1 1 0 1 1 1 1 0 0 0 0 15 9 9 0 0 0 0 0 1 1 1 1 240 90 0 9 1 1 1 1 1 1 1 1 255 99 9 9
9.1.1 Example: To wire a BCD Input
The BCD digital input parameters may be wired to digital input terminals of the controller. A DI8 module may be used and there are also two standard digital input terminals in FixedIO, D1 and D2.
This example shows a BCD switch selecting one of eight values, In1 to In8 on the Mux8.
98 Part No HA028581 Issue 7.0 Dec-09
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use