Marathon Computer AACC 2000 User Manual

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Marathon Monitors Inc.
AACC 2000 (Carbon) Monitor / Controller
Installation and Operation Handbook
COPYRIGHT © 1998
MARATHON MONITORS INC
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Marathon Monitors Inc.
COPYRIGHT © 1998 MARATHON MONITORS INC. 3100 East Kemper Road, Cincinnati, Ohio 45241 1-800-322-4444 (513) 772-7788 FAX: (513) 772-7853 No part of this document may be stored or reproduced by any means whatsoever without prior written permission of Marathon Monitors Inc.
All trademarks used in this publication are duly marked and the sole property of their respective owners. No attempt at trademark or copyright infringement is intended or implied.
Marathon Monitors makes no warranties express or implied beyond the written warranty presented at initial purchase. Marathon Monitors Inc. is not responsible for any product, process, damage or injury incurred while using this equipment. Marathon Monitors makes no representations or warranties with respect to the contents hereof and specifically disclaims any warranties of merchantability or fitness for any particular application or purpose.
“This product is covered by one or more of the following US Patents:
5,484,206; Additional patents pending.
REVISION 1.1.1 - 1998-02-26 ADD TYPICAL WIRING DIAGRAM. REVISION 1.1.2 - 1998-04-30 ADD HEADER AND FOOTER TO PAGE 36.
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Table of contents:
SAFETY and EMC INFORMATION................................................................... 4
Installation Safety Requirements ........................................................................... 5
Installation requirements for EMC.................................................................... 7
Technical Specification......................................................................................... 8
Installation ..........................................................................................................11
Introduction.....................................................................................................13
MECHANICAL INSTALLATION ..................................................................13
Wiring of 2-wire EIA-485 serial communications link.....................................21
OPERATION ......................................................................................................23
FRONT PANEL LAYOUTs.............................................................................24
Basic operation ................................................................................................26
Operating modes ..............................................................................................27
Automatic mode...............................................................................................28
MANUAL MODE ...........................................................................................29
PARAMETERS AND HOW TO ACCESS THEM ...........................................30
Parameter names..............................................................................................32
Navigation Diagram.........................................................................................33
PARAMETER TABLES..................................................................................37
Alarms.............................................................................................................44
Diagnostic alarms............................................................................................45
ACCESS LEVELS ..............................................................................................47
Edit level .........................................................................................................50
Setting operator access to a parameter ..............................................................50
TUNING .............................................................................................................53
AUTOMATIC TUNING..................................................................................54
MANUAL TUNING........................................................................................56
Setting the cutback values................................................................................57
motorized valve control....................................................................................59
Gain scheduling...............................................................................................62
CONFIGURATION.............................................................................................63
Selecting configuration level............................................................................64
Changing the passwords ..................................................................................65
User calibration ...................................................................................................85
User Calibration Enable...................................................................................86
Offset calibration .............................................................................................87
Two-point calibration.......................................................................................89
Calibration points and Calibration offsets.........................................................92
Parameter Table (Default)....................................................................................93
INDEX.............................................................................................................. 102
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SAFETY and EMC INFORMATION
Please read this section carefully before installing the controller
This controller is intended for industrial temperature and process control applications where it will meet the requirements of the European Directives on Safety and EMC. Use in other applications, or failure to observe the installation instructions of this handbook may impair the safety or EMC protection provided by the controller. It is the responsibility of the installer to ensure the safety and EMC of any particular installation.
Safety
This controller complies with the European Low Voltage Directive 73/23/EEC, amended by 93/68/EEC, by the application of the safety standard EN 61010.
Electromagnetic compatibility
This controller conforms with the essential protection requirements of the EMC Directive 89/336/EEC, amended by 93/68/EEC, by the application of a Technical Construction File. This instrument satisfies the general requirements of an industrial environment as described by EN 50081-2 and EN 50082-2. For more information on product compliance refer to the Technical Construction File.
SERVICE AND REPAIR
This controller has no user serviceable parts. Contact your nearest MMI Service center (800-322-4444) for repair.
Caution: Charged capacitors
Before removing an instrument from its case, disconnect the supply and wait at least two minutes to allow capacitors to discharge. Failure to observe this precaution will expose capacitors that may be charged with hazardous voltages. In any case, avoid touching the exposed electronics of an instrument when withdrawing it from the case.
Electrostatic discharge precautions
When the controller is removed from its case, some of the exposed electronic components are vulnerable to damage by electrostatic discharge from someone handling the controller. To avoid this, before handling the unplugged controller discharge yourself to ground.
Cleaning
Do not use water or water based products to clean labels or they will become illegible. Isopropyl alcohol may be used to clean labels. A mild soap solution may be used to clean other exterior surfaces of the product.
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Installation Safety Requirements
Safety Symbols
Various symbols are used on the instrument, they have the following meaning:
Caution, (refer to the
!
accompanying documents)
The functional earth connection is not required for safety purposes but to ground RFI filters.
Personnel
Installation must only be carried out by qualified personnel.
Enclosure of live parts
To prevent hands or metal tools touching parts that may be electrically live, the controller must be installed in an enclosure.
Caution: Live sensors
The fixed digital inputs, non-isolated dc, logic and outputs and the logic output of dual output modules, are all electrically connected to the main process variable input. If the temperature sensor is connected directly to an electrical heating element then these non­isolated inputs and outputs will also be live. The controller is designed to operate under these conditions. However you must ensure that this will not damage other equipment connected to these inputs and outputs and that service personnel do not touch connections to these i/o while they are live. With a live sensor, all cables, connectors and switches for connecting the sensor and non-isolated inputs and outputs must be mains rated.
Functional earth (ground) terminal
Wiring
It is important to connect the controller in accordance with the wiring data given in this handbook. Take particular care not to connect AC supplies to the low voltage sensor input or other low level inputs and outputs. Only use copper conductors for connections (except thermocouple inputs) and ensure that the wiring of installations comply with all local wiring regulations. For example in the in the UK use the latest version of the IEE wiring regulations, (BS7671). In the USA use NEC Class 1 wiring methods.
Power Isolation
The installation must include a power isolating switch or circuit breaker. This device should be in close proximity to the controller, within easy reach of the operator and marked as the disconnecting device for the instrument.
Earth leakage current
Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This may affect the design of an installation of multiple controllers protected by Residual Current Device, (RCD) or Ground Fault Detector, (GFD) type circuit breakers.
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Overcurrent protection
To protect the internal PCB tracking within the controller against excess currents, the AC power supply to the controller and power outputs must be wired through the fuse or circuit breaker specified in the technical specification.
Voltage rating
The maximum continuous voltage applied between any of the following terminals must not exceed 264Vac:
line or neutral to any other connection;
relay or triac output to logic, dc or sensor connections;
any connection to ground.
The controller should not be wired to a three phase supply with an unearthed star
connection. Under fault conditions such a supply could rise above 264Vac with respect to ground and the product would not be safe.
Voltage transients across the power supply connections, and between the power supply and
ground, must not exceed 2.5kV. Where occasional voltage transients over 2.5kV are expected or measured, the power installation to both the instrument supply and load circuits should include a transient limiting device.
These units will typically include gas discharge tubes and metal oxide varistors that limit
and control voltage transients on the supply line due to lightning strikes or inductive load switching. Devices are available in a range of energy ratings and should be selected to suit conditions at the installation.
Conductive pollution Electrically conductive pollution must be excluded from the cabinet in which the controller
is mounted. For example, carbon dust is a form of electrically conductive pollution. To secure a suitable atmosphere in conditions of conductive pollution, fit an air filter to the air intake of the cabinet. Where condensation is likely, for example at low temperatures, include a thermostatically controlled heater in the cabinet.
Over-temperature protection When designing any control system it is essential to consider what will happen if any part of
the system should fail. In temperature control applications the primary danger is that the heating will remain constantly on. Apart from spoiling the product, this could damage any process machinery being controlled, or even cause a fire.
Reasons why the heating might remain constantly on include:
the temperature sensor becoming detached from the process;
thermocouple wiring becoming a short circuit;
the controller failing with its heating output constantly on;
an external valve or contactor sticking in the heating condition;
the controller setpoint set too high.
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Where damage or injury is possible, we recommend fitting a separate over-temperature
protection unit, with an independent temperature sensor, which will isolate the heating circuit.
Please note that the alarm relays within the controller will not give protection under all
failure conditions.
Grounding of the temperature sensor shield In some installations it is common practice to replace the temperature sensor while the
controller is still powered up. Under these conditions, as additional protection against electric shock, we recommend that the shield of the temperature sensor is grounded. Do not rely on grounding through the framework of the machine.
Installation requirements for EMC To ensure compliance with the European EMC directive certain installation precautions are
necessary as follows:
For general guidance refer to MMI Controls EMC Installation Guide, HA025464.
When using relay or triac outputs it may be necessary to fit a filter suitable for
suppressing the emissions. The filter requirements will depend on the type of load. For typical applications we recommend Schaffner FN321 or FN612.
If the unit is used in table top equipment which is plugged into a standard power socket,
then it is likely that compliance to the commercial and light industrial emissions standard is required. In this case to meet the conducted emissions requirement, a suitable mains filter should be installed. We recommend Schaffner types FN321 and FN612.
Routing of wires
To minimise the pick-up of electrical noise, the wiring for low voltage dc and particularly the sensor input should be routed away from high-current power cables. Where it is impractical to do this, use shielded cables with the shield grounded at both ends.
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Technical Specification
Environmental ratings
Panel sealing: Instruments are intended to be panel mounted. The
rating of panel sealing is IP65, (EN 60529), or 4X, (NEMA
250). Operating temperature: 0 to 55oC. Ensure the enclosure provides adequate ventilation. Relative humidity: 5 to 95%, non condensing. Atmosphere: The instrument is not suitable for use above 2000m
or in explosive or corrosive atmospheres.
Equipment ratings
Supply voltage: 100 to 240Vac -15%, +10%, or optionally: Supply frequency: 48 to 62Hz. Power consumption: 15 Watts maximum. Relay 2-pin (isolated): Maximum: 264Vac, 2A resistive. Minimum: 12Vdc, 100mA. Relay changeover (isolated): Maximum: 264Vac, 2A resistive. Minimum: 6Vdc, 1mA. Triac outputs (isolated): 30 to 264Vac. Maximum current: 1A resistive. Leakage current: The leakage current through triac and relay contact
suppression components is less than 2mA at 264Vac, 50Hz.
Over current protection: External over current protection devices are required that
match the wiring of the installation. A minimum of 0.5mm2 or 16awg wire is recommended. Use independent fuses for the instrument supply and each relay or triac output. Suitable fuses are T type, (EN 60127 time-lag type) as follows; Instrument supply: 85 to 264Vac, 2A, (T). Relay outputs: 2A (T). Triac outputs: 1A (T).
Low level i/o: All input and output connections other than triac and relay are
intended for low level signals less than 42V.
Single logic output: 18V at 24mA. (Non-isolated.) DC output (Isolated): 0 to 20mA (600 max), 0 to 10V (500 min). DC output (Non isolated): 0 to 20mA (600 max), 0 to 10V (500 min). Fixed digital inputs: Contact closure. (Non isolated.) Triple contact input: Contact closure. (Isolated.) Triple logic input: 11 to 30Vdc. (Isolated.) DC or 2nd PV input: As main input plus 0-1.6Vdc, Impedance, >100MΩ.
(Isolated.)
Potentiometer input: 0.5V excitation, 100 to 1.5k Potentiometer. (Isolated.) Transmitter supply: 24Vdc at 20mA. (isolated.) Strain gauge supply: 10Vdc. Minimum bridge resistance 300. (Isolated.) Digital Communications: EIA-232, 2-wire EIA-485 or 4-wire EIA-485 (All isolated).
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General
Main PV Input range: +100mV, 0 to 10Vdc (auto ranging) and 3 wire Pt100. Calibration accuracy: The greater of +0.2% of reading, +1 LSD or +1oC. Cold junction compensation >30:1 rejection of ambient temperature, (for thermocouple
i/p).
Electrical safety
Standards: EN 61010, Installation category II, pollution degree
2.
CSA C22.2 No.142-M1987.
Installation category II: Voltage transients on any mains power connected to the
instrument must not exceed 2.5kV.
Pollution degree 2: Conductive pollution must be excluded from the
cabinet in which the instrument is mounted.
Isolation: All isolated inputs and outputs have reinforced
insulation to provide protection against electric shock. The fixed digital inputs, non-isolated dc, logic, and the logic output of dual output modules, are all electrically connected to the main process variable input, (thermocouple etc.).
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Installation
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Display screen
Latching ears
Ratchets
AACC 2000 1/4 DIN controller
Case
Figure 1 - 3
Terminal
Label
Panel retaining clips
Panel sealing gasket
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Outline dimensions Model 2000
96mm
3.78in
96mm
3.78in
Panel cut-out
92 x 92 mm
3.62 x 3.62 in
Figure 1-4 Outline dimensions Model 2000 controller
-0
+0.8
-0
+0.03
Recommended minimum spacing of controllers
150mm
5.91in
The electronic assembly of the controller plugs into a rigid plastic case, which in turn fits into the standard DIN size panel cut-out shown in Figures 1-3 and 1-4.
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Introduction
Model AACC 2000’s are high stability, process controllers with self and adaptive tuning. They have a modular hardware construction which accepts up to three plug-in Input/Output modules and two interface modules to satisfy a wide range of control requirements. Two digital inputs and an optional alarm relay are included as part of the standard hardware.
Before proceeding, please read the, Safety and EMC Information.
Controller labels
The labels on the sides of the controller identify the ordering code, the serial number, and the wiring connections.
Appendix A, Understanding the Ordering Code, explains the hardware and software configuration of your particular controller.
MECHANICAL INSTALLATION
To install the controller
1. Prepare the control panel cut-out to the size shown in Figure 1-3, or 1-4.
2. Insert the controller through the panel cut-out.
3. Spring the upper and lower panel retaining clips into place. Secure the controller in
position by holding it level and pushing both retaining clips forward.
Note: If the panel retaining clips subsequently need removing, in order to extract the controller from the control panel, they can be unhooked from the side with either your fingers, or a screwdriver.
Unplugging and plugging-in the controller
If required, the controller can be unplugged from its case by easing the latching ears outwards and pulling it forward out of the case. When plugging the controller back into its case, ensure that the latching ears click into place in order to secure the IP65 sealing.
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All electrical connections are made to the screw terminals at the rear of the controller. If you wish to use crimp connectors, the correct size is AMP part number 349262-1. They accept wire sizes from 0.5 to 1.5 mm2 (16 to 22 AWG). A set of connectors is supplied with the controller. The terminals are protected by a clear plastic hinged cover to prevent hands, or metal, making accidental contact with live wires.
Rear terminal layouts
The rear terminal layouts are shown in Figure 1-6. The right-hand column carries the connections to the power supply, digital inputs 1 and 2, alarm relay and sensor input. The second and third columns from the right carry the connections to the plug-in modules. The connections depend upon the type of module installed, if any. To determine which plug-in modules are fitted, refer to the ordering code and wiring data on the controller side labels.
Model AACC 2000 rear terminal layout
Figure 1-6 Rear terminal layout
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The display below shows a typical wiring diagram for the AACC2000 Carbon Controller:
Typically a series of letters appear after the part number, see chart below.
D – Dual Relay
A – Analog Output
X – Not Installed
C – Communications
I – Analog Input (typically in position 3)
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P V
Sensor input connections
The connections for the various types of sensor input are shown below.
Thermocouple
V1
V+
v-
PLUG-IN MODULE CONNECTIONS
Module 1, 2 and 3
Module positions 1, 2 and 3 are plug-in modules. They can be either two terminal modules of the types shown in Table 1-1, or four terminal modules of the types shown in Table 1-2.
The tables show the connections to each module and the functions that they can perform.
Resistance thermometer
V1
V+
v-
Fig 1-7 Sensor input connections
mA input Volts or mV inputs
V1
V+
v-
2.49 current sense resistor
V1
V+
v-
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Two terminal modules
Note: Module 1 is connected to terminals 1A and 1B
Module 2 is connected to terminals 2A and 2B Module 3 is connected to terminals 3A and 3B.
Terminal identity Module type A B C D Possible functions Relay: 2-pin
(2A, 264 Vac max.)
Logic - non-isolated
(18Vdc at 20mA)
Triac
(1A, 30 to 264Vac)
DC output:
- non-isolated
(10Vdc, 20mA max.)
++
−−
Line Load
++
Table 1-1 Two terminal module connections
Unused Heating, cooling, alarm,
program event, valve raise,
or valve lower
Unused Heating, cooling, mode 1,
mode 2, program event
Unused Heating, cooling, program
event, valve raise, or valve
lower
Unused Heating, or cooling, or
retransmission of PV,
setpoint, or control output
Snubbers
The relay and triac modules have an internal 15nF/100 ‘snubber’ connected across their output, which is used to prolong contact life and to suppress interference when switching inductive loads, such as mechanical contactors and solenoid valves.
WARNING
When the relay contact is open, or the triac is off, the snubber circuit passes 0.6mA at 110Vac and 1.2mA at 240Vac. You must ensure that this current, passing through the snubber, will not hold on low power electrical loads. It is your responsibility as the installer to ensure that this does not happen. If the snubber circuit is not required, it can be removed from the relay module (BUT NOT THE TRIAC) by breaking the PCB track that runs crosswise, adjacent to the edge connectors of the module. This can be done by inserting the blade of a small screwdriver into one of the two slots that bound it, and twisting.
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Four terminal modules
Note: Module 1 is connected to terminals 1A, 1B, 1C and 1D
Module 2 is connected to terminals 2A, 2B, 2C and 2D Module 3 is connected to terminals 3A, 3B, 3C and 3D
Module type Terminal identity Possible functions
A B C D
lay: changeover
(2A, 264 Vac max.)
Heating, cooling,or
alarm,
DC control: Isolated
(10V, 20mA max.)
24Vdc transmitter supply
Potentiometer input
100 to 15K
DC retransmission
DC remote input or
Process Value 2
(Module 3 only)
Dual output modules
Dual relay
(2A, 264 Vac max.)
Dual Triac
(1A, 30 to 264Vac)
Dual logic + relay
(Logic is non-isolated)
Dual Logic + triac
(Logic is non-isolated)
Triple logic input and output modules - see ratings on the next page
Triple contact input Input 1 Input 2 Input 3 Common
++ −−
+
+0.5Vdc
+
0-10Vdc RT source
(Refer to Fig. 1-8)
Line
+
+
Load
±100mV
0-20mA
Line
Line
0V
COM
Load
Load
Heating, or cooling
To power process
inputs
Motorised Valve
Position feedback
Retrans. of setpoint,
or process value Remote Setpoint
Second PV
Heating + cooling
Dual alarms
Valve raise & lower
Heating + cooling
Valve raise & lower
Heating + cooling
Heating + cooling
Triple logic input Input 1 Input 2 Input 3 Common
Table 1-2 Four terminal module connections.
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3D
3D
3D
3D
3D
Connections for Process Value 3 in module position 3
Thermocouple
3A
3B
3C
Resistance thermometer
3A
3B
3C
Figure 1-8 Connections for Process Value 2 (PV2)
mA input
3A
3B
3C
Current
sense
resistor
2.49
+
Volts or mV inputs
3A
3B
3C
0-1.6Vdc
High Impedance
or mVdc
+
The diagrams above show the connections for the various types of input. The input will have been configured in accordance with the ordering code.
10V inputs
+
3A
3B
0-10Vdc
3C
-
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Communication module 1
The Models AACC 2000 will accept a plug-in communications modules. The possible module types are shown in the table below. The serial communications can be configured for either Modbus, or MMI protocol.
Communications module 1 Terminal identity (COMMS 1) Module type HA HB HC HD HE HF 2-wire EIA-485 serial
communications EIA-232 serial communications
Table 1-3 Communication module 1 connections
Common A (-) B (+)
Common Rx Tx
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Com
Note:
All resistors are 220 ohm 1/4W carbon composition.
Local grounds are at equipotential. Where equipotential is not available wire into
separate zones using a galvanic isolator.
Use a repeater (KD845) for more than 32 units.
ABPC
MMI Universial
RXTXCom
ComTXRX
Up to 32 S2000 controllers or
Interface Units may
be included on the network
232
ComBA
ComAB
ComAB
Com
ABLocal Earth
Area 1
ComABEFDLocal
Earth
HE-
HF+HDSeries 2000
Controller
HE-
HF+HDSeries 2000
Controller
For reasons of safety
do
not
connect to
local earth here.
Local
Earth
Local
Earth
Local
Earth
Local
Earth
Local
Earth
HE -
HF+
HD
Series 2000
Controller
Galvanic
Isolation
Barrier
Wiring of 2-wire EIA-485 serial communications link
2-wire EIA-485 is a connection which allows up to 32 controllers to be multi-dropped from a single communications link over a distance of up to 1.2Km. To ensure reliable operation of the communications link, (without data corruption due to noise or line reflections) the connections between the controller should be made using a twisted pair of wires inside a screened cable with the connections terminated with resistors in the manner shown in this diagram.
Converter
Local Ground Zone 1
Local Ground Zone 1
Local Ground Zone 1
Local Ground Zone 1
Local Ground Zone 2
Figure 1-9 EIA-485 wiring
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OPERATION
This chapter has nine topics:
FRONT PANEL LAYOUTS
BASIC OPERATION
OPERATING MODES
AUTOMATIC MODE
MANUAL MODE
PARAMETERS AND HOW TO ACCESS THEM
NAVIGATION DIAGRAM
PARAMETER TABLES
ALARMS
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FRONT PANEL LAYOUTs
Figure 2-1 Model AACC 2000 front panel layout
26.0
20.0
Button Button Button Button
Page Scroll Down Up
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Button or
indicator
OP1
OP2
Marathon Monitors Inc.
Name Explanation
Output 1
Output 2
When lit, it indicates that the output installed in
module position 1 is on. This is normally the heating output on a temperature controller.
When lit, it indicates that the output installed in
module position 2 is on. This is normally the cooling output on a temperature controller.
SP2 Setpoint 2
REM Remote setpoint
Run/Hold button
When lit, this indicates that setpoint 2, (or a
setpoint 3-16) has been selected.
When lit, this indicates that a remote setpoint
input has been selected.
‘REM’ will also flash when communications is
active.
When pressed, this toggles between automatic
and manual mode:
• If the controller is in automatic mode the
Auto/Manual
button
AUTO light will be lit.
• If the controller is in manual mode, the MAN
light will be lit.
The Auto/Manual button can be disabled in
configuration level.
• Press once to start an automatic Probe care
cycle
• This RUN light indicates when ever a probe
care function is in progress
Page button Press to select a new list of parameters.
Scroll button Press to select a new parameter in a list.
Down button Press to decrease a value in the lower readout.
Up button Press to increase a value in lower readout.
Figure 2-3 Controller buttons and indicators
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Basic operation Switch on the power to the controller. It runs through a self-test sequence for about three
seconds and then shows the process value, in the upper readout and the setpoint, in the lower readout. This is called the Home display.
26.0
20.0
Figure 2-4 Home display
You can adjust the setpoint by pressing the or buttons. Two seconds after
releasing either button, the display blinks to show that the controller has accepted the new value.
OP1 will light whenever output 1 is ON. This is normally the heating output when used
as a temperature controller.
OP2 will light whenever output 2 is ON. This is normally the cooling output when used
as a temperature controller.
Note: You can get back to this display at any time by pressing and together.
Alternatively, you will always be returned to this display if no button is pressed for 45 seconds, or whenever the power is turned on.
Process Value (PV) Setpoint
Alarms If the controller detects an alarm condition, it flashes an alarm message in the Home
display. For a list of all the alarm messages, their meaning and what to do about them, see Alarms at the end of this chapter.
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Operating modes The controller has two basic modes of operation:
Automatic mode in which the output is automatically adjusted to maintain the
temperature or process value at the setpoint.
Manual mode in which you can adjust the output independent of the setpoint.
You toggle between the modes by pressing the AUTO/MAN button. The displays which
appear in each of these modes are explained in this chapter.
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Automatic mode You will normally work with the controller in automatic mode. If the MAN light is on,
press the AUTO/MAN button to select automatic mode. The AUTO light comes on
Power on
x 2
The Home display Check that the AUTO light is on. The upper readout shows the measured
temperature.
The lower readout shows the setpoint. To adjust the setpoint up or down, press
or .
(Note: If Setpoint Rate Limit has been enabled, then the lower readout will show the active setpoint. If or is pressed, it will change to show and allow adjustment of, the target setpoint.)
Press once Display units
A single press of will flash the
display units for 0.5 seconds, after which you will be returned to the Home display. Flashing of the display units may have been disabled in configuration in which case a single press will take you straight to the display shown below.
Press twice % Output power demand
The % output power demand is displayed
in the lower readout. This is a read-only value. You cannot adjust it.
Press and together to return to the Home display.
Pressing from the Output Power display may access further parameters. These may
be in this scroll list if the ‘Promote’ feature has been used (see Chapter 3, Access Level). When you reach the end of this scroll list, pressing will return you to the Home
display.
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MANUAL MODE If the AUTO light is on, press the AUTO/MAN button to select manual mode.
The MAN light comes on.
Power on
x 2
Pressing from the Output Power display may access further parameters. These may
be in this scroll list if the ‘Promote’ feature has been used (see Chapter 3, Edit Level). When you reach the end of this scroll list, pressing will return you to the Home display.
The Home display Check that the MAN light is on. The upper readout shows the measured
temperature, or process value. The lower readout shows the % output.
To adjust the output, press or . . (Note: If Output Rate Limit has been enabled,
then the lower readout will show the working output. If or . is pressed, it will change to show and allow adjustment of, the target output.)
Press once. Display units A single press of flashes the display units
for 0.5 seconds, after which you are returned to the Home display. Flashing of the display units may have been disabled in configuration, in which case a single press will take you straight to the display shown below.
Press twice. Setpoint
To adjust the setpoint value, press or .
Press .
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PARAMETERS AND HOW TO ACCESS THEM Parameters are settings, that determine how the controller will operate. For
example, alarm setpoints are parameters that set the points at which alarms will occur. For ease of access, the parameters are arranged in lists as shown in the navigation diagram on Pages 2-10 and 2-11. The lists are:
Home list Probe list Care list User list Alarm list
Each list has a ‘List Header’ display. List header displays
Figure 2-5 Typical list header
display
A list header can be recognized by the fact that it always shows ‘LiSt’ in the lower readout. The upper readout is the name of the list. In the above example, ‘AL’ indicates that it is the Alarm list header. List header displays are read­only.
To step through the list headers, press . Depending upon how your controller has been configured, a single press may momentarily flash the display units. If this is the case, a double press will be necessary to take you to the first list header. Keep pressing to step through the list headers, eventually returning you to the Home display.
To step through the parameters within a particular list, press . When you reach the end of the list, you will return to the list header. From within a list you
Autotune list PID list Motor list Setpoint list Input list
List name
Always displays LiST
Output list Communications
list
Information list Access list.
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can return to the current list header at any time can by pressing . To step to the next list header, press once again.
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Parameter names In the navigation diagram, each box shows the display for a selected parameter.
The Operator parameter tables, later in this chapter, list all the parameter names
and their meanings. The navigation diagram shows all the parameters that can, potentially, be
present in the controller. In practice, a limited number of them appear, as a result of the particular configuration.
The shaded boxes in the diagram indicate parameters that are hidden in normal operation. To view all the available parameters, you must select Full access level. For more information about this, see Chapter 3, Access Levels.
Parameter displays Each list has a ‘List Header’ display. Parameter displays
Figure 2-6 Typical parameter display Parameter displays show the controller’s current settings. The layout of
parameter displays is always the same: the upper readout shows the parameter name and the lower readout its value. In the above example, the parameter name is 1FSL (indicating Alarm 1, full scale low), and the parameter value is 10.0.
To change the value of a parameter First, select the required parameter.
To change the value, press either or . During adjustment, single presses
change the value by one digit.
Keeping the button pressed speeds up the rate of change. Two seconds after releasing either button, the display blinks to show that the
controller has accepted the new value.
parameter name
parameter value
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Navigation Diagram (Part A) (THE PARAMETERS THAT APPEAR DEPEND UPON
HOW THE CONTROLLER HAS BEEN CONFIGURED)
Home List
20.0
20.0
OP
100.0
m-A Auto
rEF 1
Probe List
Prob LIST
PF
0.1
OFFS
0.01
H-CO
10.0
Ptc 10
Pmu 10
AIin 10
Care List
CArE LIST
Care
Prt.r
0.0
tmin
0.1
Pti 1OFF
imp.h
10.0
Ptrt
10.0
bot
15.0
bort
10.0
FDE
5.0
t2C
0.0
imP.r
0.0
User List
USEr LIST
n1
0.1
n2
0.1
n3
0.1
n4
0.1
n5
0.1
n15
0.1
Alarm List
AL LIST
1--- 1
2---
1
3--- 1
4---
1
HY 1 1
HY 2
1
HY 3 1
HY 4 1
Lbt
OFF
diAG
no
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Autotune List
Atu n
tunE OFF
Adc mAn
PID List
Pid LiSt
G.SP 500
SEt PID.1
Pb 5
Ti 300
Td
60.0
rES
0.0
Hcb Auto
Lcb Auto
rEL
Pb2 10
Marathon Monitors Inc.
Ti.2 300
Td.2 500
rES.2
0.0
Hcb2 Auto
Lcb2 Auto
rEL.2
1.00
FF.Pb
0.0
FF.du
100.0
Motor List
mtr LiSt
tm
30.0
In.t OFF
bAcT OFF
mP.T Auto
U.br DWn
Setpoint List
SP LiSt
SSEL SP 1
SP 1
20.0
SP 2
0.0
SPL
0.0
SPH
100.0
SP2L
0.0
SP2H
100.0
SPrr OFF
HbtY OFF
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Input List
iP LiSt
FiLT OFF
FLt.2 1P.1
PU.1P OFF
FLT.3 OFF
CAL FACT
ofs1 0F
ofs2 0
mv.1 0
mv.2 0
mv.3 0
cjc1 0
L1.1 0
L1.2 0
L1.3 0
PVSL 1P1
Output List
oP LiSt
OP.Lo
0.0
OP.Hi
100.0
OPrr OFF
FOP
0.0
CYC.1
20.0
hYS.1
1.0
onT.1 Auto
CYC.2
5.0
hYS.2
1.0
onT.2 Auto
db
0.0
Sb.OP
100.0
Comms List
cmS LiSt
Addr 1
Information List
inF o
diSP STD
LoG.L
0.0
LoG.H
100.0
LoG.A
50.0
LoG.T
100.0
LoG.u
0.0
rES.L no
mCT 0
w.OP
0.0
FF.OP 0
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P OP 19
1 OP 10
d OP
1.
Access List
ACCS LiST
codE PASS
GoTo OPEr
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PARAMETER TABLES
Name Description Home list
Home Measured value and Setpoint OPOP SPSP m-Am-A reFreF + Extra parameters, if the ‘Promote’ feature has been used (see Chapter 3, Edit
Level).
Name Description ProbProb
PFPF OFFSOFFS H-COH-CO PTcPTc
PmuPmu AinAin
Name Description CareCare
CareCare PrtrPrtr TminTmin PTiPTi imp.Himp.H PtrtPtrt botbot bortbort FdEFdE t2Ct2C imp.rimp.r
% Output level Target setpoint (if in Manual mode ) Auto-man select Customer defined identification number
Probe list Process Factor Millivolt input OFFSET Hydrogen or CO constant
Probe Temperature Probe millivolts AUX input
Care list Probe care operation selection MMI actual Probe recovery time Minimum temperature for care procedure
Probe care cycle time Maximum probe impedance Impedance test recovery time Burn off time Burn off recovery time Final delay time Time to next care impedance test result
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Name Description UserUser
n1n1 n2n2 n3n3 n4n4 n5-15n5-15
Name Description ALAL
11 -- -- -- 22 -- -- -- 33 -- -- -- 44 -- -- -- In place of dashes, the last three characters indicate the alarm type. See alarm types
table:
HYHY 11 HYHY 22 HYHY 33 HYHY 44 LbLb tt diAGdiAG Enable Diagnostic alarms ‘no’ / ‘YES’
-FSL-FSL
-FSH-FSH
--dEvdEv
--dHidHi
--dLodLo
--LCrLCr
--HCrHCr
-FL2-FL2
-FH2-FH2
-LOP-LOP
-HOP-HOP
-LSP-LSP
-HSP-HSP 4rAt4rAt
AtunAtun
User list user parameter #1 user parameter #2 user parameter #3 user parameter #4
user parameter #5 - 15
Alarm list Alarm 1 setpoint value Alarm 2 setpoint value Alarm 3 setpoint value Alarm 4 setpoint value
Alarm 1 Hysteresis (display units) Alarm 2 Hysteresis (display units) Alarm 3 Hysteresis (display units) Alarm 4 Hysteresis (display units) Loop Break Time in minutes
Alarm types table PV Full scale low alarm PV Full scale high alarm PV Deviation band alarm PV Deviation high alarm PV Deviation low alarm Load Current low alarm Load Current high alarm Input 2 Full Scale low alarm Input 2 Full Scale high alarm Working Output low alarm Working Output high alarm Working Setpoint low alarm Working Setpoint high alarm Rate of change alarm (AL 4 only)
Autotune list
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tunEtunE drAdrA drA.tdrA.t AdcAdc
One-shot autotune enable Adaptive tune enable Adaptive tune trigger level in display units. Range = 1 to 9999 Automatic Droop Compensation (PD control only)
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Name Description PidPid
G.SPG.SP SEtSEt Pid.1’ or ‘Pid.2’ selected
PbPb Proportional Band (SEt 1) titi Integral Time in secs(SEt 1)
tdtd Derivative Time in secs (SEt 1) rESrES Manual Reset (%) (SEt 1) HcbHcb Cutback High (SEt 1) LcbLcb Cutback Low (SEt 1) rEL.CrEL.C Relative Cool Gain (SEt 1) Pb2Pb2 Proportional Band (SEt 2) ti2ti2 Integral Time in secs(SEt 2) td2td2 Derivative Time in secs (SEt 2) rES.2rES.2 Manual Reset (%) (SEt 2) Hcb2Hcb2 Cutback High (SEt 2) Lcb2Lcb2 Cutback Low (SEt 2) rEL.2rEL.2 Relative Cool Gain (SEt 2) The following three parameters are used for cascade control. If this facility is not
being used, then they can be ignored.
FF.PbFF.Pb FF.trFF.tr FF.dvFF.dv PID feedforward limits ± %
mtrmtr tm In.t bAc.t mp.t U.br
PID list If Gain Scheduling has been enabled (see Chapter 4), this parameter sets
the PV below which ‘Pid.1’ is active and above which ‘Pid.2’ is active.
(in display units)
SP, or PV, feedforward propband Feedforward trim %
Motor list - see Table 4-3 Valve travel time in seconds Valve inertia time in secs Valve backlash time in secs Minimum ON time of output pulse Valve sensor break strategy
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Name Description
SPSP SSEL Select SP 1 to SP16, depending on configuration SP 1 SP 2 SP L SP H SP2.L SP2.H SPrr Hb.ty Holdback Type for setpoint rate limit (OFF, Lo, Hi, or bAnd)
iPiP FiLt FLt.2 PV.ip Selects ‘ip.1’ or ‘ip.2’ FLt.3 CAL OFS.1 OFS.2 mV.1 mV.2 mV.3 CJC.1 CJC.2 Li.1 Li.2 Li.3 PV.SL
Setpoint list
Setpoint one value Setpoint two value Setpoint 1 low limit Setpoint 1 high limit Setpoint 2 low limit Setpoint 2 high limit Setpoint Rate Limit
Input list IP1 filter time constant (0.0 - 999.9 seconds). IP2 filter time constant (0.0 - 999.9 seconds).
DC input Filter Time Constant User Calibration Enable simple offset PV2 simple offset ADC Converter millivolts ADC Converter millivolts PV2 Second PV millivolts input IP1 cold junction temp. reading IP2 cold junction temp. reading IP1 linearised value IP2 linearised value DC Input 3 Current Input or Inputs used for PV
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Name Description oPoP
Does not appear if Motorised Valve control configured. OP.Lo OP.Hi OPrr FOP CYC.H hYS.H ont.H
CYC.C hYS.C ont.C
HC.db Sb.OP
cmScmS Addr
inFoinFo
diSP
LoG.L LoG.H LoG.A Log.t Log.v
Output list Low power limit (%)
High power limit (%) Output Rate Limit (% per sec) Forced output level (%) Heat cycle time (0.2S to 999.9S) Heat hysteresis (display units) Heat output min. on-time (secs)
Auto (0.05S), or 0.1 - 999.9S Cool cycle time (0.2S to 999.9S) Cool hysteresis (display units) Cool output min. on-time (secs) Auto (0.05S), or 0.1 - 999.9S Heat/cool deadband (display units) Sensor Break Output Power (%)
Comms list Communications Address
Information list Configure lower readout of Home display to show: VPoS Valve position Std Standard - display setpoint AmPS Load current in amps OP Output Stat Program status PrG.t Program time remaining in hours Li 2 Process value 2 rAt Ratio setpoint PrG Selected program number rSP Remote setpoint PV minimum PV maximum PV mean value Time PV above Threshold level PV Threshold for Timer Log
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Name Description
Information list - continued
inFoinFo
rES.L mCt
w.OP FF.OP VO P OP I OP d OP
codE Goto Goto level - OPEr, FuLL, Edit or conF
ConF
Logging Reset - ‘YES/no’
The following set of parameters is for diagnostic purposes.
Processor utilisation factor Working output Feedforward component of output PID output to motorised valve Proportional component of output Integral component of output Derivative component of output
Access List
ACCSACCS
Access password Configuration password
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Alarms Alarm annunciation
Alarms are flashed as messages in the Home display. A new alarm is displayed as a
double flash followed by a pause, old (acknowledged) alarms as a single flash followed by a pause. If there is more than one alarm condition, the display cycles through all the relevant alarm messages. Table 2-1 and Table 2-2 list all of the possible alarm messages and their meanings.
Alarm acknowledgement and resetting Pressing both and at the same time will acknowledge any new alarms and reset
any latched alarms.
Alarm modes Alarms will have been set up to operate in one of several modes, either:
Non-latching, which means that the alarm will reset automatically when the Process
Value is no longer in the alarm condition.
Latching, which means that the alarm message will continue to flash even if the
alarm condition no longer exists and will only clear when reset.
Blocking, which means that the alarm will only become active after it has first
entered a safe state on power-up.
Alarm types There are two types of alarm: Process alarms and Diagnostic alarms.
Process alarms These warn that there is a problem with the process which the controller is trying to
control.
Alarm
Display
_FSL* _FSH* _dEv* _dHi* _dLo* _LCr*
p.FLt
What it means PV Full Scale Low alarm PV Full Scale High alarm PV Deviation Band alarm PV Deviation High alarm PV Deviation Low alarm Load Current Low alarm Probe impedance test
fault.
* In place of the dash, the first character will indicate the alarm number.
Alarm
Display
_FL2* _FH2* _LOP* _HOP* _LSP*
What it means
Input 2 Full Scale Low
alarm
Input 2 Full Scale High
alarm
Working Output Low
alarm
Working Output High
alarm
Working Setpoint Low
alarm
Table 2-1 Process alarms
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Diagnostic alarms
These indicate that a fault exists in either the controller or the connected devices.
Display
shows
EE.ErEE.Er
S.brS.br
L.brL.br
Hw.ErHw.Er
no.iono.io
rmt.Frmt.F
LLLLLLLL HHHHHHHH Err1Err1 Err2Err2 Err3Err3 Err4Err4
Err5Err5
What it means What to do about it
Electrically Erasable Memory
Error:
The value of an operator, or
configuration, parameter has been corrupted.
Sensor Break: Input sensor is unreliable or
the input signal is out of range.
Loop Break The feedback loop is open
circuit.
Hardware error
This fault will automatically take you into
Configuration level. Check all of the configuration parameters before returning to Operator level. Once in Operator level, check all of the operator parameters before resuming normal operation. If the fault persists, or occurs frequently, contact MMI Controls.
Check that the sensor is correctly
connected.
Check that the heating and cooling
circuits are working properly.
Check that the correct modules are fitted.
Indication that a module is of
the wrong type, missing, or faulty.
No I/O None of the expected I/O
modules is fitted.
Remote input failure. the
remote DC input, is open or short circuit
Out of range low reading Out of range high reading
This error message normally occurs
when pre-configuring a controller without installing any of the required I/O modules.
Check for open, or short circuit wiring on
the remote DC input.
Check the value of the input.
Check the value of the input. Error 1: ROM self-test fail Return the controller for repair. Error 2: RAM self-test fail Return the controller for repair. Error 3: Watchdog fail Return the controller for repair. Error 4: Keyboard failure
Stuck button, or a button was
pressed during power up.
Error 5: Faulty internal
communications.
Switch the power off and then on, without
touching any of the controller buttons.
Check printed circuit board
interconnections. If the fault cannot be
cleared, return the controller for repair.
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Table 2-2b Diagnostic alarms
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ACCESS LEVELS This chapter describes the different levels of access to the operating parameters within
the controller.
There are three topics:
THE DIFFERENT ACCESS LEVELS
SELECTING AN ACCESS LEVEL
EDIT LEVEL
THE DIFFERENT ACCESS LEVELS
There are four access levels:
Operator level, which you will normally use to operate the controller.
Full level, which is used to commission the controller.
Edit level, which is used to set up the parameters that you want an operator to be able
to see and adjust when in Operator level.
Configuration level, which is used to set up the fundamental characteristics of the
controller.
Access
level
Operator
Full
Edit
Configuration
Display
shows
OPEr
FuLL
Edit
conF
What you can do Password
Protection
In this level, operators can view and adjust the
value of parameters defined in Edit level (see below).
In this level, all the parameters relevant to a
particular configuration are visible. All alterable parameters may be adjusted.
In this level, you can determine which parameters
an operator is able to view and adjust in Operator level. You can hide, or reveal, complete lists, individual parameters within each list and you can make parameters read-only or alterable. (See Edit level at the end of this chapter).
This special level allows access to set up the
fundamental characteristics of the controller.
No
Yes
Yes
Yes
Figure 3-1 Access levels
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SELECTING AN ACCESS LEVEL Access to Full, Edit or Configuration levels is protected by a password to prevent
unauthorised access.
If you need to change the password, see Chapter 6, Configuration.
Access list header Press until you reach the access list header
ACCS’.
Press Password entry
The password is entered from the ‘codE’ display. Enter the password using or . Once the
correct password has been entered, there is a two second delay after which the lower readout will change to show PASS indicating that access is now unlocked.
The pass number is set to ‘1’ when the controller is
shipped from the factory.
Note; A special case exists if the password has
been set to 0. In this case access will be permanently unlocked and the lower readout will always show PASS’.
Press to proceed to the ‘Goto’ page.
(If an incorrect password has been entered and the
controller is still ‘locked’ then pressing returns you to the ACCS list header.)
Access to Read-only Configuration From this display, pressing and
together will take you into Read-Only Configuration without entering a password. This will allow you to view all of the configuration parameters, but not adjust them. If no button is pressed for ten seconds, you will be returned to the Home display. Alternatively, pressing and together takes you immediately back to the Home display
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Alternative path if ‘conF’ selected
Level selection The ‘Goto’ display allows you to select the
required access level.
Use and to select from the following
display codes: OPEr: Operator level
FuLL: Full level Edit: Edit level conF: Configuration level
Press
If you selected either ‘OPEr’, ‘FuLL’ or
Edit level you will be returned to theACCS list header in the level that you
chose. If you selected conF, you will get a display showing ConF in the upper readout (see below).
Configuration password When the ‘ConF’ display appears, you must
enter the Configuration password in order to gain access to this level. Do this by repeating the password entry procedure described in the previous section.
The configuration password is set to ‘2
when the controller is shipped from the factory. If you need to change the configuration password, see Chapter 6,
Configuration.
Press Configuration level
The first display of configuration is shown.
See Chapter 6, Configuration, for details of the configuration parameters.
For instructions on leaving configuration
level, see Chapter 6, Configuration.
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Returning to Operator Level To return to operator level from either ‘FuLL’ or ‘Edit’ level, repeat entry of the
password and select OPEr on the Goto display.
In ‘Edit’ level, the controller will automatically return to operator level if no button is
pressed for 45 seconds.
Edit level Edit level is used to set which parameters you can view and adjust in Operator level. It
also gives access to the ‘Promote’ feature, which allows you to select and add (‘Promote’) up to twelve parameters into the Home display list, thereby giving simple access to commonly used parameters.
Setting operator access to a parameter First you must select Edit level, as shown on the previous page.
Once in Edit level, you select a list, or a parameter within a list, in the same way as
you would in Operator, or Full, level that is to say, you move from list header to list header by pressing , and from parameter to parameter within each list using .
However, in Edit level what is displayed is not the value of a selected parameter, but a
code representing that parameter’s availability in Operator level.
When you have selected the required parameter, use and buttons to set its
availability in Operator level.
There are four codes: ALtrALtr Makes a parameter alterable in Operator level. PrOPrO Promotes a parameter into the Home display list. rEAdrEAd Makes a parameter, or list header, read-only (it can be viewed but not altered). HIdEHIdE Hides a parameter, or list header.
For example:
The parameter selected is Alarm 2, Full Scale Low
It will be alterable in Operator level
Hiding or revealing a complete list To hide a complete list of parameters, all you have to do is hide the list header. If a list
header is selected, only two selections are available: rEAd and HIdE.
(It is not possible to hide the ACCS list, which always displays the code: LiSt.)
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Promoting a parameter Scroll through the lists to the required parameter and choose the ‘PrO’ code. The
parameter is then automatically added (promoted) into the Home display list. (The parameter will also be accessible, as normal, from the standard lists.) A maximum of twelve parameters can be promoted. Promoted parameters are automatically ‘alterable’.
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TUNING
Before tuning, please read Chapter 2, Operation, to learn how to select and change a
parameter.
This chapter has five topics:
WHAT IS TUNING?
AUTOMATIC TUNING
MANUAL TUNING
COMMISSIONING OF MOTORISED VALVE CONTROLLERS
GAIN SCHEDULING
WHAT IS TUNING? In tuning, you match the characteristics of the controller to those of the process being
controlled in order to obtain good control. Good control means:
Stable, ‘straight-line’ control of the process variable at setpoint without fluctuation
No overshoot, or undershoot, of the process variable setpoint
Quick response to deviations from the setpoint caused by external disturbances,
thereby rapidly restoring the process variable to the setpoint value.
Tuning involves calculating and setting the value of the parameters listed in Table 4-1.
These parameters appear in the Pid list.
Parameter
Proportional
band
Code
Pb
Meaning or Function
The bandwidth, in display units, over which the output power is
proportioned between minimum and maximum.
Integral time
Derivative time
High Cutback
Low cutback
Relative cool
gain
Hcb
Lcb
rEL
AACC 2000 Carbon Nov. 1, 1997
Determines the time taken by the controller to remove steady-
ti
state error signals.
Determines how strongly the controller will react to the rate-of-
td
change of the measured value.
The number of display units, above setpoint, at which the
controller will increase the output power, in order to prevent undershoot on cool down.
The number of display units, below setpoint, at which the
controller will cutback the output power, in order to prevent overshoot on heat up.
Only present if cooling has been configured and a module is
fitted. Sets the cooling proportional band, which equals the Pb value divided by the rEL value.
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AUTOMATIC TUNING Two automatic tuning methods are provided in the AACC 2000:
A one-shot tuner, which automatically sets up the initial values of the parameters
listed in Table 4-1 on the previous page.
Adaptive tuning, which continuously monitors the error from setpoint and modifies
the PID values, if necessary.
One-shot Tuning
The ‘one-shot’ tuner works by switching the output on and off to induce an oscillation in the measured value. From the amplitude and period of the oscillation, it calculates the tuning parameter values. If the process cannot tolerate full heating or cooling being applied during tuning, then the level of heating or cooling can be restricted by setting the heating and cooling power limits in the oP list. However, the measured value must oscillate to some degree for the tuner to be able to calculate values. A One-shot Tune can be performed at any time, but normally it is performed only once during the initial commissioning of the process. However, if the process under control subsequently becomes unstable (because its characteristics have changed), you can re­tune again for the new conditions. It is best to start tuning with the process at ambient process variable. This allows the tuner to calculate more accurately the low cutback and high cutback values which restrict the amount of overshoot, or undershoot.
How to tune
1. Set the setpoint to the value at which you will normally operate the process.
2. In the Atun list, select tunEand set it toon’.
3. Press the Page and Scroll buttons together to return to the Home display. The display will flash tunE to indicate that tuning is in progress.
4. The controller induces an oscillation in the process variable by first turning the heating on, and then off. The first cycle is not complete until the measured value has reached the required setpoint.
5. After two cycles of oscillation the tuning is completed and the tuner switches itself off.
6. The controller then calculates the tuning parameters listed in Table 4-1 and resumes normal control action.
If you want ‘Proportional only’, ‘PD’, or ‘PI’ control, you should set the ti or td parameters to OFF before commencing the tuning cycle. The tuner will leave them off and will not calculate a value for them.
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Typical automatic tuning cycle
Process Variable
Calculation of the cutback values
Low cutback and High cutback are values that restrict the amount of overshoot, or undershoot, that occurs during large step changes in process variable (for example, under start-up conditions). If either low cutback, or high cutback, is set to Auto the values are fixed at three times the proportional band, and are not changed during automatic tuning.
Adaptive tune
Adaptive tuning is a background algorithm, which continuously monitors the error from setpoint and analyses the control response during process disturbances. If the algorithm recognises an oscillatory, or under-damped, response it recalculates the Pb, ti and td values.
Adaptive tune is triggered whenever the error from setpoint exceeds a trigger level. This trigger level is set in the parameter drA.t, which is found in the Autotune list. The value is in display units. It is automatically set by the controller, but can also be manually re-adjusted.
Setpoint
Time
Adaptive tune should be used with:
1. Processes whose characteristics change as a result of changes in the load, or setpoint.
2. Processes that cannot tolerate the oscillation induced by a One-shot tune.
Adaptive tune should not be used:
1. Where the process is subjected to regular external disturbances that could mislead the adaptive tuner.
2. On highly interactive multiloop applications. However, moderately interactive loops, such as multi-zone extruders, should not give a problem.
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MANUAL TUNING
If for any reason automatic tuning gives unsatisfactory results, you can tune the controller manually. There are a number of standard methods for manual tuning. The one described here is the Ziegler-Nichols method.
With the process at its normal running process variable:
1. Set the Integral Time ti and the Derivative Time td to OFF.
2. Set High Cutback and Low Cutback, Hcb and Lcb, to Auto’.
3. Ignore the fact that the process variable may not settle precisely at the setpoint.
4. If the process variable is stable, reduce the proportional band ‘Pb so that the process variable just starts to oscillate. If the process variable is already oscillating, increase the proportional band until it just stops oscillating. Allow enough time between each adjustment for the loop to stabilise. Make a note of the proportional band value ‘B’ and the period of oscillation ‘T’.
5. Set the Pb, ti, td parameter values according to the calculations given in Table 4-2.
Type of control Proportional
band ‘Pb’
Proportional only 2xB OFF OFF
P + I control 2.2xB 0.8xT OFF
P + I + D control 1.7xB 0.5xT 0.12xT
Table 4-2 Tuning values
AACC 2000 Carbon Nov. 1, 1997
Integral time
56
‘ti’
Derivative time
‘td’
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Setting the cutback values
The above procedure sets up the parameters for optimum steady state control. If unacceptable levels of overshoot or undershoot occur during start-up, or for large step changes in process variable, then manually set the cutback parameters Lcb and Hcb’.
Proceed as follows:
1. Set the low and high cutback values to three proportional bandwidths (that is to say, Lcb = Hcb = 3 x Pb).
2. Note the level of overshoot, or undershoot, that occurs for large atmosphere changes (see the diagrams below).
In example (a) increase Lcb by the overshoot value. In example (b) reduce Lcb by the undershoot value.
Example (a)
Atmosphere
Overshoot
Setpoint
Example (b)
Atmosphere
Setpoint
Undershoot
Time
Where the atmosphere approaches setpoint from above, you can set Hcb in a similar manner.
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Integral action and manual reset
In a full three-term controller (that is, a PID controller), the integral term ‘ti’ automatically removes steady state errors from the setpoint. If the controller is set up to work in two-term mode (that is, PD mode), the integral term will be set to ‘OFF’. Under these conditions the measured value may not settle precisely at setpoint. When the integral term is set to ‘OFF’ the parameter manual reset (code rES) appears in the Pid LiSt in FuLL level. This parameter represents the value of the power output that will be delivered when the error is zero. You must set this value manually in order to remove the steady state error.
Automatic droop compensation (Adc)
The steady state error from the setpoint, which occurs when the integral term is set to ‘OFF’ is sometimes referred to as ‘droop’. Adc automatically calculates the manual reset value in order to remove this droop. To use this facility, you must first allow the process variable to stabilise. Then, in the autotune parameter list, you must set Adc to on. The controller will then calculate a new value for manual reset, and switch Adc to OFF’.
Adc can be repeated as often as you require, but between each adjustment you must allow time for the process variable to stabilise.
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Motorized valve control
The AACC 2000 can be configured for motorised valve control as an alternative to the standard PID control algorithm. This algorithm is designed specifically for positioning motorised valves. These are ordered pre-configured as Model numbers:
2000/VC motorised valve controllers
2000/VP motorised valve controllers with a single setpoint programmer
2000/V4 motorised valve controllers storing four setpoint programs.
2000/VM motorised valve controllers storing twenty setpoint programs.
Figure 1-11 in Chapter 1 shows how to connect a motorised valve controller. The control is performed by delivering open, or close, pulses in response to the control demand signal.
The motorised valve algorithm can operate in one of three ways:
1. The so-called boundless mode, which does not require a position feedback potentiometer for control purposes; although one can be connected and used purely to display the valve’s position.
2. Bounded, (or position), control mode, which requires a feedback potentiometer. This is closed-loop control determined by the valve’s position.
The desired control mode is selected in the ‘inst’ list in configuration level. The following parameter list will appear in the navigation diagram shown in Chapter 2, if
your controller is configured for motorised valve control.
Name Description Values
mtrmtr
tm
In.t
bAc.t
mp.t U.br
AACC 2000 Carbon Nov. 1, 1997
Motor list Min Max Default
Valve travel time in seconds. This is the time taken for the valve to travel from its fully closed position to its fully open position.
Valve inertia time in seconds. This is the time taken for the valve to stop moving after the output pulse is switched off.
Valve backlash time in seconds. This is the minimum on-time required to reverse the direction of the valve. i.e. the time to overcome the mechanical backlash.
Output pulse minimum on-time, in seconds. Valve sensor break strategy.
59
0.1 240.0 30.0
OFF 20.0 OFF
OFF 20.0 OFF
Auto 100.0 Auto
rESt, uP, dwn dwn
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COMMISSIONING THE MOTORISED VALVE CONTROLLER
The commissioning procedure is the same for both bounded and boundless control modes, except in bounded mode you must first calibrate the position feedback potentiometer, as described in the section below. Proceed as follows:
1. Measure the time taken for the valve to be raised from its fully closed to its fully
open position and enter this as the value in seconds into the tm parameter.
2. Set all the other parameters to the default values shown in Table 4-3.
The controller can then be tuned using any of the automatic, or manual, tuning procedures described earlier in this chapter. As before, the tuning process, either automatic or manual, involves setting the values of the parameters in Table 4-1. The only difference with boundless control is that the derivative term td’, although present, will have no effect.
Adjusting the minimum on-time ‘mp.tmp.t’
The default value of 0.2 seconds is satisfactory for most processes. If, however, after tuning the process, the valve activity is excessively high, with constant oscillation between raise and lower pulses, the minimum on-time can be increased. The minimum on-time determines how accurately the valve can be positioned and therefore the control accuracy. The shorter the time, the more precise the control. However, if the time is set too short, process noise will cause an excessively busy valve.
Inertia and backlash settings
The default values are satisfactory for most processes, i.e. ‘OFF’. Inertia is the time taken for the valve to stop after the output pulse is turned off. If this causes a control problem, the inertia time needs to be determined and then entered into the parameter, ‘In.t’. The inertia time is subtracted from the raise and lower output pulse times, so that the valve moves the correct distance for each pulse. Backlash is the output pulse time required to reverse the direction of the valve, i.e. the time taken to overcome the mechanical backlash of the linkages. If the backlash is sufficient to cause a control problem, then the backlash time needs to be determined and then entered into the parameter, ‘bac.t’. The above two values are not part of the automatic tuning procedure and must be entered manually.
CALIBRATING THE POSITION FEEDBACK POTENTIOMETER
Before proceeding with the feedback potentiometer calibration, you should ensure, in configuration level, that module position 2 (2a), or 3 (3a), has its ‘id’ indicating ‘Pot.i’, (meaning Potentiometer Input). Continue to scroll down the module
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configuration list. ‘func’ should be set to ‘Vpos’, ‘VAL.L’ must be set to ‘0’ and ‘VAL.H’ to ‘100’. Exit from configuration and you are now ready to calibrate the position feedback potentiometer. Proceed as follows.
1. In Operator level, press the AUTO/MAN button to put the controller in Manual mode.
2. Drive the valve to its fully open position using .
3. Press until you get to ‘ip-List’.
4. Press to get to ‘PCAL-OFF’.
5. Press or to turn ‘PCAL’ to ‘on’.
6. Press and the upper readout indicates ‘Pot’.
7. Press or to get to ‘Pot-3A.Hi’. (Assuming that the Potentiometer Input
Module is in module position 3.)
8. Press to go to ‘GO-no’.
9. Press or to see ‘GO-YES’, which starts the calibration procedure.
10. Calibration is complete when the display returns to ‘GO-no’.
11. Press and together to return directly to the Operator level.
12. The controller should still be in Manual mode.
13. Drive the valve to its fully closed position using .
14. Press until you get to ‘ip-List’.
15. Press to get to ‘PCAL-OFF’.
16. Press or to turn ‘PCAL’ to ‘on’.
17. Press and the upper readout indicates ‘Pot’.
18. Press or to get to ‘Pot-3A.Lo
19. Press to go to ‘GO-no’.
20. Press or to see ‘GO-YES’, which starts the calibration procedure.
21. Calibration is complete when the display returns to ‘GO-no’.
22. Press and together to return directly to the Operator level.
23. Press the AUTO/MAN button to place the controller in AUTO and the calibration of the position feedback potentiometer is now complete.
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Gain scheduling
Gain scheduling is the automatic transfer of control between one set of PID values and another. In the case of the AACC 2000 controllers, this is done at a presettable process value. It is used for the more difficult to control processes which exhibit large changes in their response time or sensitivity at, for example, high and low process variables, or when heating or cooling.
The AACC 2000 has two sets of PID values. You can select the active set from either a digital input, or from a parameter in the PID list, or you can transfer automatically in gain scheduling mode. The transfer is bumpless and will not disturb the process being controlled.
To use gain scheduling, follow the steps below:
Step1: Enable in configuration level
Gsch
Gain scheduling must first be enabled in Configuration level. Goto the Inst Conf list, select the parameter Gsch, and set it to YES.
YES
Step 2: Set the transfer point
G.SP
350
Step 3: Tuning
Once gain scheduling has been enabled, the parameter G.SP will appear at the top of the Pid list in FuLL access level. This sets the value at which transfer occurs. PID1 will be active when the process value is below this setting and PID2 when the process value is above it. The best point of transfer depends on the characteristics of the process. Set a value between the control regions that exhibit the greatest change
You must now set up the two sets of PID values. The values can be manually set, or automatically tuned as described earlier in this chapter. When tuning automatically you must tune twice, once above the switching point G.SP and again below the switching point. When tuning, if the process value is below the transfer point G.SP the calculated values will automatically be inserted into PID1 set and if the process value is above G.SP, the calculated values will automatically be inserted into PID2 set.
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CONFIGURATION
This chapter consists of six topics:
SELECTING CONFIGURATION LEVEL
LEAVING CONFIGURATION LEVEL
SELECTING A CONFIGURATION PARAMETER
CHANGING THE PASSWORDS
NAVIGATION DIAGRAM
CONFIGURATION PARAMETER TABLES.
In configuration level you set up the fundamental characteristics of the controller. These are:
The type of control (e.g. reverse or direct acting)
The Input type and range
The Setpoint configuration
The Alarms configuration
The Programmer configuration
The Digital input configuration
The Alarm Relay configuration
The Communications configuration
The Modules 1, 2 & 3 configuration
Calibration
The Passwords.
WARNING
Configuration is protected by a password and should only be carried out by a
qualified person, authorised to do so. Incorrect configuration could result in damage to the process being controlled and/or personal injury. It is the responsibility of the person commissioning the process to ensure that the configuration is correct.
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Selecting configuration level There are two alternative methods of selecting Configuration level:
If you have already powered up, then follow the access instructions given in Chapter 3, Access levels.
Alternatively, press and together when powering up the controller. This will take you directly to the ConF password display.
Password entry
When the ConF display appears, you must enter the Configuration password (which is a number) in order to gain access to Configuration level.
Enter the password using the or buttons. The configuration password is set to 2 when the controller is shipped from the factory.
Once the correct password has been entered, there is a two second delay, after which the lower readout will change to PASS indicating that access is now unlocked.
Note: A special case exists if the password has been set to 0. In this situation, access is permanently unlocked and the lower readout will always show PASS’.
AACC 2000 Carbon Nov. 1, 1997
Press to enter configuration.
(If an incorrect password has been entered and the controller is still ‘locked’ then pressing at this point will take you
to the Exit display with no in the lower readout. Simply press to return to the ConF display.)
You will obtain the first display of configuration.
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LEAVING CONFIGURATION LEVEL
To leave the Configuration level and return to Operator level Press until the Exit display appears.
Alternatively, pressing and together will take you directly to the Exit display
Use or to select YES. After a two­second delay, the display will blank and revert to the Home display in Operator level.
SELECTING A CONFIGURATION PARAMETER
The configuration parameters are arranged in lists as shown in the navigation diagram in Figure 6.1.
To step through the list headers, press the Page button. To step through the parameters within a particular list press the Scroll button.
When you reach the end of the list you will return to the list header. You can return directly to the list header at any time by pressing the Page button.
Parameter names
Each box in the navigation diagram shows the display for a particular parameter. The upper readout shows the name of the parameter and the lower readout its value. For a definition of each parameter, see the Configuration Parameter Tables at the end of this
chapter. To change the value of a selected parameter, use the and buttons.
The navigation diagram shows all the lists headers and parameters that can, potentially, be present in the controller. In practice, those actually present will vary according to the particular configuration choices you make.
Changing the passwords
There are TWO passwords. These are stored in the Password configuration list and can be selected and changed in the same manner as any other configuration parameter.
The password names are: ACC.Pwhich protects access to Full level and Edit level
cnF.Pwhich protects access to Configuration level.
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NAVIGATION DIAGRAM (PART A)
Instrument List
Process
Value List
Input Config List
Setpoint Config
Alarms Config
inST
LiSt
2rFn
CArB
CTrL
Pid
TYPE
ctrL
AcT
REU
cool
LIN
TiTd
SEc
Fwd.t
none
SbrT
SB.OP
FOP
no
bcd
nonE
GSch
no
PU
ConF
uniT
°C
dEc.p
nnnn
rnGL
0
rnGH
2000
iP
ConF
inPT
htc
CJC
Auto
imP
Auto
SP
ConF
nSP
2
rmTr
OFF
m.Tr
OFF
rmPU
PSEc
rmT
nonE
AL
ConF
AL1
FSH
LTch
on
bLoc
on
AL2
FSH
LTch
on
bLoc
on
dtYP
PU
m-A
D1SA
r-h
ENAB
AL3
FSH
LTch
on
bLoc
on
PwrF
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AL4
FSH
LTch
on
bLoc
on
Logic Config
LAb
ConF
id
LoG
Func
Man
Alarms Config
AA
ConF
id
RELY
Func
nor
SEnS
nor
IFSH
yes
2FSL
no
Comms1 Config
Ha
ConF
id
CMS
Func
bAud
9600
PrTY
nonE
rES
FuLL
Comms2 Config
JA
ConF
id
NONE
Module1 Config
1A
ConF
id
dCrE
Func
OP1
UaL.L
0
UALH
100
uniT
mA
AL3
no
AL4
no
dELY
no
OuTL
4.0
OuTH
20.0
Plus Event Outputs
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Module2 Config
2A
ConF
id
dCrE
Func
OP2
UaL.L
0
UALH
100
uniT
mA
Module3 Config
3A
ConF
id
dCrE
Func
H-CO
inPT
Hr1n
imP
off
inPL
0.0
Module4 Config
4A
ConF
id
rELY
Func
DIG
SEnS
inu
1FSH
YES
2FSL
no
Module Config
4C
ConF
id
rELY
Func
DIG
SEnS
inu
1FSH
no
2FSL
YES
Module Config
5A
ConF
id
rELY
Func
DIG
SEnS
nor
1FSH
no
2FSL
no
Module Config
5C
ConF
id
rELY
Func
DIG
SEnS
nor
1FSH
no
2FSL
no
OuTL
4.0
OuTH
20.0
AACC 2000 Carbon Nov. 1, 1997
inPH
2.0
UALL
0
UALH
2000
AL3
no
AL4
no
68
AL3
no
AL4
no
AL3
no
AL4
no
imp
Yes
burn
yes
UEri
no
PFLT
no
AL3
no
AL4
no
imp
Yes
burn
yes
UEri
no
PFLT
no
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Module Config
6A
ConF
id
rELY
Func
PMV
inPT
HiLn
imP
Auto
inPL
-0.2
Custom Config
CUST
ConF
in1
0.0
UAL1
0.0
in2
1.0
UAL2
200.0
in3
2.0
Calibration Config
CAL
ConF
cAL
nonE
UCAL
NO
Pt1L
Pt1H
OF1L
0.0
Password Config
PASS
ConF
ACCP
cnFP
Exit
Exit
inPH
1.8
UALL
-200
UALH
1800
UAL.3
350.0
OF1H
0.0
Pt2L
Pt2H
in8
7.0
OF2L
0.0
UAL.8
800.0
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OF2H
0.0
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CONFIGURATION PARAMETER TABLES
Name Description Values Meaning
inStinSt
ZrFn CtrL
tYPE Act
CooL
ti.td
m-A
r-h
PwrF
Fwd.t
Sbr.t
FOP
bcd
Instrument configuration
Instrument Function Control type
Instrument USE Control action
Type of cooling
Integral & derivative time units
Front panel Auto/Man button
Front panel Run/Hold button
Power feedback
Feed forward type
Sensor break output
Forced manual output
BCD input function
Carb Pid
On.OF VP
VP b
ctrL Mon
rEv dir
Lin oiL
H2O FAn
ProP on.OF SEc min EnAb diSA EnAb diSA on OFF none FEEd SP.FF PV.FF Sb.OP HoLd no
trac
Step
none prog sp
% Carbon PID control
On/off control Boundless motorised valve control - no feedback
required
Bounded motorised valve control - feedback required
Controller Monitor Reverse acting Direct acting
Linear Oil (50mS minimum on­time) Water (non-linear) Fan (0.5S minimum on­time) Proportional only to error On/off cooling
Seconds, OFF to 9999 Minutes, OFF to 999.9
Enabled Disabled
Enabled Disabled
On Off
None Normal feed forward Setpoint feed forward PV feed forward
Go to pre-set value Freeze output
Bumpless Auto/Manual transfer Returns to the Manual value that was set when last in Manual mode Steps to forced output level. Value set in ‘FOP’ of ‘op-List’ in Operator Level Not used Select program number Select setpoint number
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gsch
pVpV
unit
dec.p
rng.l rng.h
Gain schedule enable
Process value config
Inststrument units
Decimal places in the displayed value
Range low Low range limit. Also setpoint limit for Range high High range limit. Also setpoint limit for
0
C
0
F
0
k none nnnn
nnn.n nn.nn
no yes
Celsius Farenheit Kelvin Display units blanked None One Two
alarms and programmers alarms and programmers
Name Description Values Meaning
iPiP
inPt
Input configuration
Input type
* see “CUST” List.
J.tc k.tc L.tc r.tc b.tc n.tc t.tc S.tc PL 2 C.tc
rtd mV voLt mA Sr V Sr A mV.C
V.C mA.C
J thermocouple K thermocouple L thermocouple R thermocouple (Pt/Pt13%Rh) B thermocouple (Pt30%Rh/Pt6%Rh) N thermocouple T thermocouple S thermocouple (Pt/Pt10%Rh) PL 2 thermocouple Custom downloaded t/c (default = type C) 100 platinum resistance thermometer Linear millivolt Linear voltage Linear milliamps Square root volts Square root milliamps
8-point millivolt custom linearisation* 8-point Voltage custom linearisation* 8-point milliamp custom linearisation*
Disabled Enabled
Name Description Values Meaning
CJC
imp
AACC 2000 Carbon Nov. 1, 1997
Cold Junction Compensation
Sensor Break Impedance
Auto 0oC 45oC 50oC OFF
Off Auto Hi Hi.Hi
71
Automatic internal compensation 0oC external reference 45oC external reference
50oC external reference No cold junction compensation Disabled (only with linear inputs) Factory set Impedance of input > 5K Impedance of input > 15K
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Linear Input Scaling The next 4 parameters only appear if a linear or sq rt input is chosen.
inp.L
inp.H
Displayed Value
VAL. H
Input value low
Input value high
VAL.L
VAL.H
VAL. L
Electrical Input
inP.HinP.L
Displayed reading low
Displayed reading high
Name Description Values Meaning
SPSP
nSP rm.tr
m.tr
rmP.U
rmt
Setpoint configuration
Number of setpoints Remote Tracking
Manual Track
Setpoint rate limit units
Remote setpoint configuration
2, 4, 16 OFF trAc OFF trAc
PSEc Pmin PHr nonE SP Loc.t rmt.t
Select number of setpoints available Disable Local setpoint tracks remote setpoint Disable Local setpoint tracks PV when in
manual Per second Per minute Per hour Disable Remote setpoint Remote setpoint + local trim Remote trim + local setpoint
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Alarm configuration Values
ALAL
The controller contains four ‘soft’ alarms, which are configured in this list. Once configured, they can be attached to a physical output as described in the alarm relay configuration list,
AA Conf’.
Alarm 1 Type
AL1
Latching
Ltch
Blocking
bLoc
Alarm 2 Type
AL2
Latching
Ltch
Blocking
bLoc
Alarm 3 Type
AL3
Latching
Ltch
Blocking
bLoc
Alarm 4 Type
AL4
Latching
Ltch
Blocking (not if ‘AL4’ = ‘rAt’)
bLoc
Table A - Alarm types Value Alarm type
OFF FSL FSH dEv dHi dLo LCr HCr FL2 FH2 LOP HOP LSP HSP rAt
Alarm Modes
no’ means that the alarm will be non-latching. ‘YES’ means that the alarm will be latched, with automatic resetting. Automatic resetting means that if a
reset is actioned before the alarm has cleared, then it will automatically reset when it clears
No alarm PV Full scale low PV Full scale high PV Deviation band PV Deviation high PV Deviation low Load Current low Load Current high Input 2 Full Scale low Input 2 Full Scale high Working Output low Working Output high Working Setpoint low Working Setpoint high PV Rate of change
AL4 only
see Table A
no/YES/Evnt/mAn* no/YES
see Table A
no/YES/Evnt/mAn* no/YES
see Table A
no/YES/Evnt/mAn* no/YES
see Table A
no/YES/Evnt/mAn* no/YES
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Name Description Values Meaning
LALA
id Func
Digital input 1 configuration Action on contact closure
Identity Function of input
The function is active when the input has a contact closure to the common terminal - LC
These BCD inputs are used to
select either a program number
or the setpoint number
according to the setting of the
parameter bcd in the inStbcd.5
configuration list
LoG.i nonE mAn rmt SP.2 Pid.2 ti H tunE drA Ac.AL AccS Loc.b uP
dwn
ScrL
PAGE
bcd.1 bcd.2 bcd.3 bcd.4
bcd.6 Stby
PV.SL
IMP
Logic input No function Manual mode select Remote setpoint select Setpoint 2 select PID set 2 select Integral hold One-shot self-tune enable Adaptive tune enable Acknowledge alarms Select Full access level Keylock Simulate pressing of the
button Simulate pressing of the
button Simulate pressing of the
button Simulate pressing of the
button Least significant BCD digit 2nd BCD digit 3rd BCD digit 4th BCD digit 5th BCD digit Most significant BCD digit Standby - ALL control outputs turned OFF (alarm Outputs are not affected) PV Select: Closed = PV1 / Open = PV2 Initiate Impedance test
Lb Digital input 2 configuration Action on contact closure As per Digital input 1 configuration
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Name Description Values Meaning
AAAA
id Func
SEnS
The following digital events appear after SEnS’. Any one, or more, of the events can be combined on to the output (see Fig. 6-2) by selecting YESin the lower readout.
1 - - ­2 - - -
3 - - -
4 - - -
mAn Sbr SPAn Lbr Ld.F tunE dc.F
rmt.F iP1.F IMP burn VERi VFLT PFLT nw.AL End
SYnc
Alarm relay configuration
Identity Function
Digital output sense
Alarm 1 active Alarm 2 active
Alarm 3 active
Alarm 4 active Controller in manual mode Sensor break PV out of range Loop break Load failure alarm Tuning in progress Voltage output open circuit, or mA
output open circuit module connection open circuit Input 1 Failure Impedance test in progress Probe burn off in progress Probe verification in progress Verification Fault Probe Fault New Alarm has occurred End of setpoint rate limit, or end of
program Program Synchronisation active
rELy nonE dIG nor
inv
YES / no (- - -) = alarm type (e.g. FSL). YES / no
YES / no in AL ConFlist, then display
YES / no differ:- e.g. Alarm 1 = ‘AL 1’. YES / no YES / no YES / no YES / no YES / no YES / no YES / no
YES / no
YES / no YES / no
YES / no
Relay output No function Digital output Normal (output energises when
TRUE, e.g. program events) Inverted (output de-energises
when TRUE, e.g. alarms)
If an alarm has not been configured
will
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SEnS
Digital Events
OR
Figure 6-2 Combining several digital events on to one output
dIG
nor
inv
Output
Module
Name Description Values Meaning
HAHA
id
Comms 1 module config
Identity of the module installed
cmS
2-wire EIA-485
For ‘idid’ = ‘cms’ (Digital communications) use this parameter table:
Func
bAud
dELy
Prty
The following parameters only appear if the function chosen is Modbus protocol.
rES
Function
Baud Rate
Delay - quiet period, required by
some comms
adaptors Comms Parity
Comms Resolution
mod mAr 1200, 2400, 4800, 9600,
19.20(19,200) no YES
nonE EvEn Odd
FuLL Int
Modbus protocol Marathon Monitors protocol
No delay Delay active - 10mS
No parity Even parity Odd parity
Full resolution Integer resolution
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JAJA
module config
NO configuration required
Name Description Values Meaning
(1)
1A1A/bb/CC
id
Module 1 configuration
Identity of module installed
(1) If a dual-, or triple-, channel module is installed then the list headers 1b and 1C also appear
nonE rELy dC.OP LoG LoG.i SSr dc.rE
Module not fitted Relay output Non-isolated DC output Logic/ output Logic input Triac output DC retransmission (isolated)
dc.OP
Isolated DC output
For ‘idid’ = ‘rELy’, ‘LoG’, or ‘SSr’ use this parameter table:
Func
VAL.L
VAL.H
Function
nonE
dIG
(Only Channels 1A and 1C can be HEAt
Heating, or Cooling)
COOL
up
dwn
(Only if id’ = ‘LoG’) SSr.1 (Only if id’ = ‘LoG’) SSr.2
Displayed Value
VAL.H
VAL.L
100%0%
Retransmitted Output
Function disabled Digital output function Heating output Cooling output Open motorised valve Close motorised valve mode 1 heating mode 2 heating
% PID demand signal giving minimum output Out.L
% PID demand signal giving maximum output Out.H
Out.L Out.H SEnS
Sense of output
(Only if ‘Func’ = ‘dIG’)
nor
Minimum average power Maximum average power
Normal (output energises
when TRUE, e.g program events)
inv
Inverted (output de­energises when TRUE, e.g. alarms)
Notes:
1. When SEnS appears, then further parameters are available. These are identical to those in the AA ConF list on Page 6-12.
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Out.L
2. To invert a PID output, the Val. H can be set below the Val.L
Name Description Values Meaning
For ‘idid’ = ‘dC.OP’, ‘dc.rE’, or ‘dc.OP’ use this parameter table:
Func
Function
nonE HEAt COOL PV wSP Err OP
VAL.L
%PID, or Retransmission Value
VAL.H
VAL.H
Out.H
Electrical Output
unit voLt = Volts, mA = milliamps Out.L
VAL.L
Out.H
For ‘idid’ = ‘LoG.i’ (i.e logic input) use the LA LA Conf’ list on Page 6-11.
Function disabled Heating output Cooling output Retransmission of PV Retransmission of setpoint Retransmission of error signal Retransmission of OP power
% PID, or Retrans’n Value, giving minimum output
% PID, or Retrans’n Value, giving maximum output
Minimum electrical output Maximum electrical output
2A2A/bb/CC
Module 2 configuration
As per module 1 configuration, but excluding the ‘SSr.1’, ‘SSr.2’ functions. id
Identity of module installed. As per module 2 plus:
tPSU
Transmitter power supply
Pot.i
Potentiometer input
Continued on next page
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For ‘idid’ = ‘Pot.i (i.e. potentiometer input module) use this parameter table:
Func
VAL.L VAL.H
Function
Displayed Value
VAL.H
VAL.L
nonE
rSP
Fwd.i
rOP.h
rOP.L
VPoS
Electrical Input
inP.HinP.L
Function disabled Remote Setpoint Feedforward input Remote OP power max. Remote OP power min. Motorised valve position
Displayed value low equivalent to 0% potentiometer position
Displayed value high equivalent to 100% potentiometer position
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3A3A/bb/CC
As per module 2 configuration, plus ‘id’ = ‘dC.iP’
Module 3 configuration
For ‘idid’ = ‘dC.iP’ use this parameter table. THIS INCLUDES THE SECOND PV FUNCTIONS
Func
inpt
CJC
imp
Function
Input type
Cold Junction Compensation
Sensor Break Impedance
nonE rSP Fwd.i rOP.h rOP.L Hi Lo Ftn
SEL
trAn
Refer to ‘ip Conf’ for all types, + the following: HiIn
OFF Auto 0oC 45oC 50oC
Off Auto Hi Hi.Hi
Function disabled Remote Setpoint Feedforward input Remote OP power max. Remote OP power min. PV = The highest of iP.1, or iP.2 PV = The lowest of iP.1, or iP.2 Derived function, where PV = (f.1 x iP1) + (f.2 x iP2).F.1’ and ‘F.2’ are scalars which are
found in ‘ip-List’ of Operator Level Select ip.1, or ip.2 via Comms, front
panel buttons, or a digital input Transition of control between ip.1
and ip.2. The transition region is set by the values of ‘Lo.Ip’ and ‘Hi.Ip’, which are found in ‘ip-List’ of Operator Level. PV = ip.1 below ‘Lo.Ip
PV = ip.2 above ‘Hi.Ip’
High Impedance (range = 0 to 2 volt)
No cold junction compensation Automatic internal compensation 0oC external reference 45oC external reference 50oC external reference
Disabled (only with linear inputs) Factory set Impedance of input > 15K Impedance of input > 30K
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Linear Input Scaling The next four parameters only appear if a linear input is chosen.
inP.L
inP.H
Displayed value
VAL.H
Input value low
Input value high
VAL.L
VAL.H
VAL.L
0%
100%
Potentiometer position
Displayed value low
Displayed value high
Name Description Values Meaning
4 A4 A /CC
As per module AA configuration
5 A5 A /CC
As per module AA configuration
Module configuration
Module configuration
Name Description Values Meaning
6A6A
id Func inPT
inP.L
inP.H
VAL.L
VAL.H
Module configuration
Identity of module DC input Function Input type
Displayed Value
VAL.H
VAL.L
inP.HinP.L
rELy nonE HiIn
Electrical Input
DC input Pin v probe mv input High Impedance (range = 0 to 2 volt)
Input value low
Input value high
Displayed value low
Displayed value high
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Cust in 1
VAL.1
in 8 VAL.8
8-point Custom Linearisation
Displayed Value
VAL.8
VAL.3 VAL.1
(1)
Custom input 1
Linearisation Value representing in 1
Custom input 8
Electrical
Linearisation Value representing
Input
in 8in 1 in 3
in 8
Note:
1. Custom Linearisation is only available when ‘3a-Conf’or iP- ConF list
has ‘inpt’ set to ‘mV.C’, or ‘mA.C’, or ‘V.C’.
1. The values and inputs must be continuously increasing or decreasing
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Name Description Values Meaning
CALCAL
In this mode you can
1. Calibrate the instrument using a mV source - rcAL or ref source cal.
2. Offset the calibration to account for errors in actual sensor
3. Return to factory set calibration - FACT or factory set calibration.
rcAL
Calibration
measurement and a ref sensor - UCAL or user calibration
Calibration point
nonE
PV PV.2
1A.Hi 1A.Lo 2A.Hi 2A.Lo 3A.Hi 3A.Lo
No calibration
Calibrate main Process Value input. Calibrate DC input, or PV 2.
Calibrate DC output high - Module 1 Calibrate DC output low - Module 1 Calibrate DC output high - Module 2 Calibrate DC output low - Module 2 Calibrate DC output high - Module 3 Calibrate DC output low - Module 3
INPUT CALIBRATION
ForCAL=PV’, or ‘PV.2’, the following parameters apply.
PV
GO
PV Calibration Value
1. Select calibration value
2. Apply specified input
3. Press to step to GO
See Note below.
Start calibration
IdLE mv.L
mv.H
V 0
V 10 CJC
rtd
HI 0
HI 1.0
FACt no
Idle Select 0mV as the calibration
point Select 50mV as the calibration
point Select 0Volt as the calibration
point
Select 10V as the calibration
point
o
Select 0
Select 400 as the calibration point
High impedance: 0Volt cal’n point
High impedance: 1.0 Volt cal’n point
Restore factory calibration Waiting to calibrate PV point
C CJC calibration point
Goto User calibration table-See also chapter 7
Go to input Calibation table
Go to DC Output Calibration table
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Select ‘YES’ with or Wait for calibration to complete.
Note. When a DC input module is installed for the first time, or there is a requirement to change one, then the microprocessor in the controller needs to read the factory calibration data stored in the module. Select ‘FACt’ as the calibration value. Step to ‘GO’ and start calibration.
YES buSy
donE FAIL
Start calibration Busy calibrating
PV input calibration completed Calibration failed
DC Output Calibration
The following parameters apply to DC output modules ie for rcAL = 1A.Hi to 3A.Lo
cAL.H
cAL.L
Output Calibration High
Output Calibration Low
0 0 = Factory set calibration.
Trim value until output = 9V, or 18mA
0 0 = Factory set calibration.
Trim value until output = 1V, or 2mA
User calibration
UCAL User calibration enable Yes/no
pt1.L
pt1.H
OF1.L OF1.H pt2.L
pt2.H
OF2.L OF2.H
Low calibration point for Input 1 The factory calibration point at which the
low point offset was performed.
High calibration point for Input 1 The factory calibration point at which the
high point offset was performed. Offset Low for Input 1 Calculated offset, in display units. Offset High for Input 1 Calculated offset, in display units. Low calibration point for Input 2 The factory calibration point at which the
low point offset was performed. High calibration point for Input 2 The factory calibration point at which the
high point offset was performed. Offset Low for Input 2 Calculated offset, in display units. Offset High for Input 2 Calculated offset, in display units.
Name Description Values Meaning
PASSPASS
ACC.P cnF.P
ExitExit
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Password configuration
FuLL or Edit level password Configuration level password
Exit configuration
no/YES
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User calibration
This chapter has five topics:
WHAT IS THE PURPOSE OF USER CALIBRATION?
USER CALIBRATION ENABLE
OFFSET CALIBRATION
TWO POINT CALIBRATION
CALIBRATION POINTS AND CALIBRATION OFFSETS
To understand how to select and change parameters in this chapter you will need to have
read Chapter 2 - Operation, Chapter 3- Access Levels and Chapter 6 - Configuration.
WHAT IS THE PURPOSE OF USER CALIBRATION? The basic calibration of the controller is highly stable and set for life. User calibration
allows you to offset the ‘permanent’ factory calibration to either:
1. Calibrate the controller to the your reference standards.
2. Match the calibration of the controller to that of a particular transducer or sensor
input.
3. Calibrate the controller to suit the characteristics of a particular installation.
4. Remove long term drift in the factory set calibration.
User calibration works by introducing a single point, or two-point, offset
onto the factory set calibration.
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User Calibration Enable
The User calibration facility must first be enabled in configuration level by setting the
parameter ‘UCAL' in the input conf list to 'YES'. This will make the User calibration parameters visible in Operator ‘FuLL’ level.
Select configuration level as shown in Chapter 5, Configuration.
The Calibration Configuration List Press until you reach the ‘CAL-Conf’ list.
Press until you reachUCAL’. User Calibration Enable
Use or to select:
YES: Calibration enable
no: Calibration disabled
Press and together to go to the Exit
+
display.
Exit configuration Use or to select ‘YES’ to return to Operator
level.
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Offset calibration Offset calibration is used to apply a single fixed offset over the full display range of the
controller.
Displayed Value
Factory Calibration
Fixed Offset
Input
To calibrate, proceed as follows:
1. Connect the input of the controller to the source device to which you wish to calibrate.
2. Set the source to the desired calibration value.
3. The controller will display the current measurement of the value.
4. If the displayed value is correct, then the controller is correctly calibrated and no
further action is necessary. If it is incorrect, then follow the steps shown below.
Select ‘FuLL’ access level, as described in Chapter 3.
Input list header
Press until you reach the input list header.
x 3
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Press until you reach the CAL display. Calibration type
FACt: Factory Calibration
USEr: User Calibration
Use or to select ‘FACt’. Selecting ‘FACt’ reinstates the factory
calibration and allows the application of a single fixed offset.
Press continued on the next page
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Set Offset 1
Use or to set the offset value of Process Value 1 (PV1).
The offset value is in display units Press
Set Offset 2
Use or to set the offset value of Process Value 2 (PV2), if configured. The offset value is in display units.
Press
The table below shows the parameters which appear after ‘OFS.2’. These are all read only
values and are for information. Press to step through them.
See table on
the right for
additional
parameters.
mV.1 mV.2
CJC.1 CJC.2 Li.1 Li.2 PV.SL
IP1 measured value (at terminals) IP2 measured value (at terminals), if DC
input in Module 3 position IP1 Cold Junction Compensation IP2 Cold Junction Compensation IP1 Linearised Value IP2 Linearised Value Shows the currently selected input
If you do not want to look at these parameters, then press and this returns you to the ‘iP-
LiSt’ header. To protect the calibration against unauthorised adjustment, return to Operator level and make sure that the calibration parameters are hidden. Parameters are hidden using the ‘Edit’ facility described in Chapter 3, Access Levels
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Two-point calibration
The previous section described how to apply a offset, or trim, calibration, which applies a fixed offset over the full display range of the controller. A two-point calibration is used to calibrate the controller at two points and applies a straight line between them. Any readings above, or below, the two calibration points will be an extension of this straight line. For this reason it is best to calibrate with the two points as far apart as possible.
Displayed Value
Calibration high-point value
High-point calibration
Low-point calibration
Calibration low-point value
Proceed as follows:
1. Decide upon the low and high points at which you wish to calibrate.
2. Perform a two point calibration in the manner described below
Input list header
Press until you reach the input list header, ‘ip LiSt’.
Press until you reach the CAL display.
x 3
Calibration type
FACt: Factory Calibration
USEr: User Calibration
Offset introduced
Offset introduced
User Calibration
Factory Calibration
Use or to select ‘USEr’. Selecting ‘USEr’ enables two-point calibration.
[If two-point calibration is unsatisfactory, select ‘FACt’ to
return to the factory set calibration.]
Press
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Select Low-point Calibration This is the Calibration Status display. This display shows
that no input is selected for calibration.
nonE: No selection
ip1.L: Input 1 (PV1) calibration low-point
selected
ip1.H: Input 1 (PV1) calibration high-point
selected
ip2.L: Input 2 (PV2) calibration low-point
selected
ip2.H: Input 2 (PV2) calibration high-point
selected
Use / to select the parameter for the Low Calibration point of Input 1, ‘ip1.L’.
Press
Adjust low-point calibration
This is the display for adjusting the Low Calibration point of Input 1. The lower readout is a live reading of the process value, which changes as the input changes. Make sure that the calibration source is connected to the terminals of Input 1, switched on and feeding a signal to the controller. It should be set to the desired low-point calibration value. If the lower readout does not show this value, then use / to adjust the reading to the required value.
Press to return to the ‘ip-List’ header.
To perform the High-point Calibration, repeat the above procedure, selecting ‘ip1.H’ in the ‘CAL.S’ display for
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adjustment. Press three times.
Calibration type
USEr’ was selected for the Low-point Calibration, and has remained selected.
Press
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Select High-point Calibration
This is the Calibration Status display, again.
Use / to select the parameter for the High-point Calibration of Input 1, ‘ip1.H’.
Press
Adjust High-point Calibration
This is the display for adjusting the High Calibration point of Input 1. The lower readout is a live reading of the process value, which changes as the input changes.
Feed the desired high-point calibration signal to the controller, from the calibration source. If the lower readout does not show this value, then use / to adjust the reading to the required value.
Press to return to the ‘ip-List’ header.
To protect the calibration against unauthorised adjustment return to Operator level and make sure that the calibration parameters are hidden. Parameters are hidden using the ‘Edit’ facility described in Chapter 3.
To perform a User Calibration on Input 2, proceed as with Input 1 above, except that when ‘CAL.S-nonE’ appears, press / until ‘CAL.S-iP2.L’ is obtained, then proceed as with Input 1. Repeat the procedure for ‘iP2.H’
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Calibration points and Calibration offsets
If you wish to see the points at which the User calibration was performed and the value of the offsets introduced, then these are shown in Configuration, in ‘CAL- Conf’. The parameters are:
Name Parameter description Meaning
pt1.L
pt1.H
OF1.L OF1.H pt2.L
pt2.H
OF2.L OF2.H
Low calibration point for Input 1 The factory calibration point at which the
low point offset was performed.
High calibration point for Input 1 The factory calibration point at which the
high point offset was performed.
Offset Low for Input 1 Calculated offset, in display units. Offset High for Input 1 Calculated offset, in display units. Low calibration point for Input 2 The factory calibration point at which the
low point offset was performed.
High calibration point for Input 2 The factory calibration point at which the
high point offset was performed.
Offset Low for Input 2 Calculated offset, in display units. Offset High for Input 2 Calculated offset, in display units.
Note: The value of each of the parameters in the above table may also be altered by using the / buttons.
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Parameter Table (Default)
Home list Process Variable Target Setpoint Output power OP Auto/Manual Mode M-a Reference Number rEF
Probe List Process Factor PF Milivolt Offset OFFS H-CO Compensation H-CO Probe Temperature Ptc Probe Millivolts Pmv Auxilliary Input Axin
Care List
Care CArE Measured Recovery Time prt.r Temperature Minimum tmin Verification Test Result VrF.r Probe Test Interval Pti Maximum Impedance imPH Probe Test Recovery Time Ptrt Burn Off Time bot Burn Off Recovery Time bort Final Delay FdE Time Of Average 2 tA2 Probe Impedance Result imp.r
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User List Number 1 n1 Number 2 n2 Number 3 n3 Number 4 n4 Number 5 n5 Number 6 n6 Number 7 n7 Number 8 n8 Number 9 n9 Number 10 n10 Number 11 n11 Number 12 n12 Number 13 n13 Number 14 n14 Number 15 n15
Alarm List Alarm 1 Setpoint 1--­ Alarm 2 Setpoint 2--­ Alarm 3 Setpoint 3--­ Alarm 4 Setpoint 4--­ Alarm 1 Hysteresis HY1 Alarm 2 Hysteresis HY2 Alarm 3 Hysteresis HY3 Alarm 4 Hysteresis HY4 Loop Break Time Lbt Enable Diagnostic Messages diAG
Autotune List Autotune Enable tunE Automatic manual Reset Calculation Adc
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PID List Gain Scheduler Setpoint G.SP Current PID Set Set Proportional Band PID1 Pb Intergal Time PID1 ti Derivative Time PID1 td Manual Reset rES Cutback High Hcb Cutback Low PID1 Lcb Relative Cool Gain PID1 rEL.C Proportional Band PID2 Pb2 Intergal Time PID2 ti2 Derivative Time PID2 td2 Manual Reset PID2 rES2 Cutback High PID2 Hcb2 Cutback Low PID2 Lcb2 Relative Cool Gain PID2 rEL2 FeedForward Proportional Band FF.Pb
FeedForward Trim Limit FF.du
Motor List Valve Travel Time tm Valve Inertia Time Int Valve Backlash Time bAct Minimum On Time MP.t Valve Sensor Break Strategy U.br
Setpoint List Setpoint Select SSEL Setpoint 1 SP1 Setpoint 2 Sp2 Setpoint 1 Low Limit SPL Setpoint 1 High Limit SPH Setpoint 2 Low Limit SP2L Setpoint 2 High Limit SP2H Local Setpoint trim Hbty
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Input List Filter 1 FiLt Filter 2 FLt2 Filter 3 FLT3 Calibration CAL CJC Temperature CJC
Output List Low Power Limit OP.Lo High Power Limit OP.Hi Output Rate Limit Oprr Forced Output Power FOP Cycle time OP1 CYC.1 Hysteresis OP1 hYS.1 OP1 Minimum On Time ont.1 Cycle time OP2 CYC.2 Hysteresis OP1 hYS.2 OP2 Minimum On time ont.2 Deadband db Sensor Break Output Power Sb.OP
Comms List Comms Address Addr
Info List Custom Display Type diSP SPC Minimum PV LoG.L SPC Maximum PV Log.H SPC Mean PV LoG.A SPC Time above TIME Trigger LoG.t PV Threshold for Timer Log LoG SPC Reset rES Control task execution time high water mark mCt Working Output w.OP Feedforward Output FF.OP Proportional Output Pop Intergral Output IOP Derivative Output dOP Continued on next page…..
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Configuration Mode Parameters
Inst Conf Function: O2, %C, Dewpoint, Redox Zr.Fn Control Type CtrL Instrument type: Monitor/Controller tYPE Control Action Act Control Time Units ti.td Manual Key Enable m-A dtYP dtYP Feedforward Type Fwd.t Bumpless PD Control Pd.tr Sensor Break Action Sbr.t Forced Manual Availability FOP BCD Input Function bcd Gain Scheduling Gsch
PV Conf Instrument Units unit Display Resolution dEc.P Exponent ExP Setpoint Minimum rnG.L Setpoint maximum rnG.H
IP Conf Linearisation type inPt CJC Type CJC Sensor break Impedance imP
SP Conf Number of Setpoints nSP Remote Tracking Configuration rm.tr manual track Configuration m.tr SRL rate units rmP.U Remote Setpoint Configuration rmt Continued on next page…..
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Alarm Conf Alarm 1 Type AL1 Alarm 1 Latch Ltch Alarm 1 Block bLoc Alarm 2 Type AL2 Alarm 2 Latch Ltch Alarm 2 Block bLoc Alarm 3 Type AL3 Alarm 3 Latch Ltch Alarm 3 Block bLoc Alarm 4 Type AL4 Alarm 4 Latch Ltch Alarm 4 Block bLoc
LA/B Conf Logic Input A Ident id Logic Input A Slot Function Func Logic Input B Ident id Logic Input B Slot Function Func
Module AA Conf Fixed Module AA Ident id Fixed Module AA Slot Function Func Summary OP AA invert Sens Summary OP AA Conf
Module H Conf Interface Module H Ident id Interface Module H Slot Function Func Baud Rate bAud Comms Parity Prty Comms Resolution rES Comms Delay dELY
Module 1A Conf Module 1A Ident id Module 1A Slot Function Func Module 1A Low Value VAL.L Module 1A High Value VAL.H Output 1A units unit Module 1A Low Output Range Out.L Module 1A High Output Range Out.H Continued on next page…..
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Module 2A Conf Module 2A Ident id Module 2A Slot Function Func Module 2A Low Value VAL.L Module 2A High Value VAL.H Output 2A units unit Module 2A Low Output Range Out.L Module 2A High Output Range Out.H
Module 3A Conf Module 3A Ident id Module 3A Slot Function Func Module 3A Input Type inPt Module 3A Sensor break Impedance iMP Module 3A Input Value Low inP.L Module 3A Input Value High inP.H Module 3A Displayed Value Low VAL.L Module 3A Displayed Value High VAL.H
Module 4A Conf Module 4A Ident id Module 4A Slot Function Func Summary OP 4A Invert SEnS Summary OP 4A configuration
Module 4C Conf Module 4C Ident id Module 4C Slot Function Func Summary OP 4C Invert SEnS Summary OP 4C configuration
Module 5A Conf Module 5A Ident id Module 5A Slot Function Func Summary OP 5A Invert SEnS Summary OP 5A configuration
Module 5C Conf Module 5C Ident id Module 5C Slot Function Func Summary OP 5C Invert SEnS Summary OP 5C configuration Continued on next page…..
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Module 6A Conf Module 6A Ident id Module 6A Slot Function Func Module 6A Input Type inPt Module 6A Sensor break Impedance iMP Module 6A Input Value Low inP.L Module 6A Input Value High inP.H Module 6A Displayed Value Low VAL.L Module 6A Displayed Value High VAL.H
CUST Conf Input 1 in 1 Value 1 VAL.1 Input 2 in 2 Value 2 VAL.2 Input 3 in 3 Value 3 VAL.3 Input 4 in 4 Value 4 VAL.4 Input 5 in 5 Value 5 VAL.5 Input 6 in 6 Value 6 VAL.6 Input 7 in 7 Value 7 VAL.7 Input 8 in 8 Value 8 VAL.8
CAL Conf
PASS Conf Access Mode User Password ACC.P Configuration Mode User Password cnF.P Continued on next page…..
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