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
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 pollutionElectrically 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 protectionWhen 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 shieldIn 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 EMCTo 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 (600Ω max), 0 to 10V (500Ω min).
DC output (Non isolated):0 to 20mA (600Ω max), 0 to 10V (500Ω 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, 100Ω to 1.5kΩ Potentiometer. (Isolated.)
Transmitter supply:24Vdc at 20mA. (isolated.)
Strain gauge supply:10Vdc. Minimum bridge resistance 300Ω. (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
Marathon Monitors Inc.
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 inputVolts or mV inputs
V1
V+
v-
2.49Ω
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.
The relay and triac modules have an internal 15nF/100Ω ‘snubber’ connected across their
output, which is used to prolong contact life and to suppress interference when switching
inductive loads, such as mechanical contactors and solenoid valves.
WARNING
When the relay contact is open, or the 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 typeTerminal identityPossible functions
ABCD
lay: changeover
(2A, 264 Vac max.)
Heating, cooling,or
alarm,
DC control: Isolated
(10V, 20mA max.)
24Vdc transmitter supply
Potentiometer input
100Ω to 15KΩ
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 inputInput 1Input 2Input 3Common
++−−
+−
+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 inputInput 1Input 2Input 3Common
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
2.49Ω
+
−
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.
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.
NameExplanation
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.
SP2Setpoint 2
REMRemote 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 buttonPress to select a new list of parameters.
Scroll buttonPress to select a new parameter in a list.
Down buttonPress to decrease a value in the lower readout.
Up buttonPress to increase a value in lower readout.
Figure 2-3 Controller buttons and indicators
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Basic operationSwitch 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
AlarmsIf 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 modesThe 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 modeYou 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 displayCheck 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 onceDisplay 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 MODEIf 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 displayCheck 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 unitsA 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 THEMParameters 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 listProbe listCare listUser listAlarm 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 listMotor listSetpoint listInput list
List name
Always displays LiST
Output list Communications
list
Information listAccess list.
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