Marathon Computer UNIPRO V3 User Manual

UNIPRO v3.5

Users Manual

COPYRIGHT © 1998

MARATHON MONITORS INC

Marathon Monitors Inc.

Description and Applications

The Marathon Monitors Inc. UNIPRO Controller/Programmer
represents the latest technology in microprocessor-based process
control instrumentation. Through flexible PID (Proportional,
Integral, Digital) control along with programmable features, even
the most complex, system can be handled. For a thorough
explanation of PID please refer to Zeigler and Nichols; “Optimum
Settings for Automatic Controllers”, Transactions of ASME, Nov.

1942. Or St. Clair, David W.; Controller Tuning and Control Loop
Performance, a Primer; Straight-Line Control Company, Newark
,Delaware 1989.

The UNIPRO's control actions are based upon input from a
Thermocouple, RTD, Voltage or Current source. The
UNIPRO allows Manual, Automatic, or Programmed control
of a single loop. Its built-in RS-422 computer interface
allows it to be completely supervised by a computer, either
on-site or in some remote location within the plant. The
Programmer can be used, and is strongly recommended, to
allow complete control of temperature or other process
cycles.

The following features have been included to allow use of the
instrument in a wide variety of applications:

Fully site-configurable for single point control from one of three
(3) fully isolated analog input sources, each separately configurable
for thermocouple, RTD, voltage, or current.

Powerful process/logic programmer that can store up to
two-hundred (200) programs, each consisting of nineteen (19)
steps, subroutine calls, test and branch capability, and full access to
all instrument parameters.

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Two (2) control output triacs for use in single or dual control
mode.

Two (2) fully isolated analog outputs, each separately configurable
for voltage or current output.

Two (2) configurable alarm triacs, assignable as process Alarms,
deviation alarms, program alarms, or fault alarms.

Four (4) programmer events, assignable in any combination as
either inputs or outputs (expandable to 16 I/O with external event
boards).

Three (3) communication ports for talking with host computers,
controllers, and discrete digital and / or analog event expansion
racks.

This manual provides all of the information required to install,
operate and maintain the MMI UNIPRO.

The manual is divided into parts: Installation, Setup and
Configuration, Operation, Programming, and Maintenance and
Troubleshooting. Installation and Setup and Configuration will be
used initially to get the instrument into use. Operation and
Programming will be used daily. Maintenance and
Troubleshooting will be used for servicing the instrument
periodically or if trouble occurs.

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Installation

Installation Location

The UNIPRO instrument is designed for 1/8 inch panel mounting in
a DIN standard opening of 5.43 inches square (adapter panels
available by special order). Required rear clearance is 10.5 inches
to allow for wiring. As with all solid state equipment, the
controller should be away from excessive heat, humidity, and
vibration (refer to specifications). Since the unit uses red LED
display devices, avoid placing it in direct sunlight to reduce
interference with the display's visibility. The instrument requires
100/120/200/240 VAC (jumper selectable on power interconnect
board inside the rear panel) 50/60 Hz. It should not be on the
same circuit with other noise-producing equipment such as
induction machines, large electrical motors, etc. All instrument
wiring must be run separate from all control wiring.

Panel Mounting/Removal

Because the instrument uses a ventilated enclosure, it is not
dust-tight and should therefore always be mounted in a sealed
control panel. To mount the UNIPRO in a control panel, a hole
must be cut 5.43 inches square in the necessary location on the
panel. The following procedure should be followed to mount the
UNIPRO in the panel.

1. Insert the unit into previously cut out 5.43 inches square
hole in the panel.

2. While supporting the unit, insert one slotted clamping
bracket, with head of the bolt facing to the rear of the unit, into the

0.62 inch by 0.82 inch cutout on the side of the unit.

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3. Repeat step 2 for the opposite side of the unit.

4. With 1/8 inch HEX KEY wrench, alternately tighten bolts
on either side of the instrument to a torque of 4 in-lbs. (See warning
below). Insure rigidity of mounting.

Warning

To prevent warping of the unit's case, do not over tighten the

clamp bolts.

5. To remove the unit, loosen the side clamping brackets and
reverse steps 1 through 3 above.

Note

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On subsequent removals and installations the rear

panel can be removed (4 screws) and the wiring

does not have to be disturbed.

Warning

All connections, rear panel installations and removals; plus

triac board installations and removals must be done with

power removed from TBA and TBB. All PC boards should

only be removed or installed with power off via the switch

mounted on the triac board. Otherwise, serious personal

and/or equipment damage can occur.

Thermocouples and Other Signal Wires

The wiring used to connect the signal wires to the instrument
should be run in a conduit, separate from any AC lines in the area.
This provides noise immunity and physical protection.
Thermocouples should be wired with the appropriate alloy
extension wire with no termination other than at the instrument. As
with all cold-junction compensating instruments, extreme care
should be used when an existing thermocouple is to be used for
both the Controller and another instrument at the same time.

Control Devices

The UNIPRO provides simple ON/OFF as well as Proportional
control through its two contact closure Control Outputs (TBA-7,
TBB-7, TBA-8, and TBB-8) and two Analog Outputs (TBD-13
through TBD-16). Refer to the Section on Control Modes for
more details on the outputs. This allows control through simple
ON/OFF devices or through Proportional control methods.

SIMPLE ON/OFF CONTROL: Set Control Mode for
ON/OFF Control. This provides contact closure at Control Output
#1 to control absolute heat application/removal for such devices as
heating elements, etc.

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Three types of Proportional control are:

1. Time-Proportioning: Referring to the
modulation of the duty cycle. That is,
changing the ratio of On Time versus Off
Time in systems that use such devices as
heating elements, electronically
operated/assisted valves, or servo drives that
use analog command signals for control.

2. Position-Proportioning: Referring to the
adjustment of a variable positioning device
such as a positioning motor with slidewire
feedback.

3. Voltage or Current Output Proportioning:
An Analog output's (voltage or current)
amplitude is varied based on input from
rheostats, thermocouples, ammeters, etc. to
control heat applications.

The UNIPRO provides many ways to use the above control
methods. Setup has details for setting the Control Modes to
determine the method to be used. Some typical applications for the
Proportioning method are:

1. HIGH/LOW or HEAT COOL heat application system: Set
Control Modes for Time-Proportioning. This provides that
CONTROL OUTPUT #1 (TBA-7, TBB-7) and CONTROL
OUTPUT #2 (TBA-8, TBB-8) are in opposite conditions at either
extreme of the control range and are both OFF at the midpoint of
the control range.

2. ANALOG OUTPUT control: Set Control Modes for
Time-Proportioning. This provides a 0 to 5 VDC or 4 to 20 mA
output which is selectable on the ANALOG OUTPUT BOARD
(TBD-13 through TBD-16, see Section 2.14 and Section 8.0 for

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more details). The output control is based on 0 to 99% of the
output device's control range. For example, 50% control would
equal 2.5 VDC out where 5 VDC equals maximum heat output of
the drive. This can be used with servo drives that require a voltage
or current command signal for controlling heat output or servo
positioning.

3. POSITIONING MOTOR with SLIDEWIRE FEEDBACK:
Set Control Modes for Single Position-Proportioning with slidewire
feedback. CONTROL OUTPUT #1 will drive the motor in the
open direction, CONTROL OUTPUT #2 in the close direction.

Remember, the above methods are just examples of the typical
applications of the UNIPRO. Please call your MMI representative
or application engineer for questions concerning your particular
system.

Chart Recorders

If a chart recorder is to be used, it must have input specifications
within the following ranges:

0 to 4 VDC

0 to 45 mA
corresponding to a FRONT PANEL display of 0-2000. The ideal
location of the recorder is adjacent to the instrument but it may be
located remotely if the connecting wires are properly shielded.
Long wiring runs from the chart recorder outputs may require
resistive termination
(2 K ohms or so) at the chart recorder input(s) should be isolated
from ground.

Computer Interface

If you wish to take advantage of the UNIPRO's RS-422 digital
communications capabilities, refer to "Communications" for more
details.

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Alarms

Two user-programmable triac alarm contacts are available for
connection in appropriately-engineered systems.

Programmer

The Programmer can run an entire process, depending on how
thoroughly the capabilities are set up and used. Refer to
"Operation" and "Programming" for further information.

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Electrical Connections

Connections to the unit are made via four terminal blocks, on the
rear panel, labeled TBA, TBB, TBC, and TBD. (Position 1 is at
the top the position 10 (TBA and TBB) or 18 (TBC and TBD) is at
the bottom of the terminal strip.) AC power, event, control, and
alarm connections are made on TBA and TBB. All
communications are on TBC and all analog I/O signals are on TBD.
Refer to the Figure below for a complete layout of the UNIPRO
rear panel connections.

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UNIPRO Rear Panel

UNIPRO Electrical connections
AC Power

The UNIPRO requires 100/120/200/240 VAC at 1 AMP,

Communications

Three communications busses are at TBC and use RS-422 full or
half duplex protocol for all ports. (Refer to "Communications" in
Maintenance and Troubleshooting.) Typically, the HOST port will
connect to a host computer, the AUXILIARY BUSS to other
instruments, and the OPTOMUX PORT to OPTOMUX
I/O devices.

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Analog Inputs

The UNIPRO allows for three analog inputs with their individual
functions determined by "daughter board" located on the analog
input board inside the unit. The standard connection, at TBD, will
have the first input as a thermocouple, the second for the oxygen
probe, and the third optionally used to input voltage or milliamp
signals.

Analog Outputs

Two, separate, isolated analog outputs are provided on TBD and
can be selected as 4-20 mV (for maximum accuracy, see
Specifications for further details) or 0-10 V output through DIP
switch settings on the analog output board. Additionally, outputs
can be calibrated by placing a jumper on the two terminals supplied.

DIP Switch Setup

The user may use the UNIPRO in a multi-instrument system by
giving the instrument a unique HOST address, specified by using
the DIP switches on the Interface Board inside the UNIPRO
To get to the DIP switches, loosen the black knurled knob on the
front panel by turning in a counterclockwise direction. Carefully
remove the front panel but DO NOT remove the ribbon cable
connecting the front panel to the Interface Board. Safely support
the front panel near the instrument. Adjust the DIP switches per
Section 2.16 for the desired operating mode. When switch
adjustment is complete, replace the front panel to prevent
contamination.

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UNIPRO Front Panel Removal

Find the appropriate switches by referring to the figure below.

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UNIPRO Internal Layout
DIP Switch Assignments

Bank 0
Switch # Description
1 Unassigned
2 Unassigned
3 Slide wire Deadband (see the following table)
4 Slide wire Deadband (see the following table)
5 Slide wire Deadband (see the following table)
6 Unassigned
7 Unassigned
8 Service (Must be OFF)

Selectable deadband for slidewire feedback control.

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Slidewire Dead Band Offset
offset Switch 3 Switch 4 Switch 5

0.4% OFF OFF OFF

0.8% ON OFF OFF

1.2% OFF ON OFF

1.6% ON ON OFF

2.0% OFF OFF ON

2.4% ON OFF ON

2.8% OFF ON ON

3.2% ON ON ON

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Each UNIPRO in a multiple instrument system must have a unique
address for proper communications.

HOST address selection switches: Bank 1Address

DEC HEX SW1 SW2 SW3 SW4
0 0 OFF OFF OFF OFF

1 1 ON OFF OFF OFF
2 2 OFF ON OFF OFF
3 3 ON ON OFF OFF
4 4 OFF OFF ON OFF
5 5 ON OFF ON OFF
6 6 OFF ON ON OFF
7 7 ON ON ON OFF
8 8 OFF OFF OFF ON
9 9 ON OFF OFF ON
10 A OFF ON OFF ON
11 B ON ON OFF ON
12 C OFF OFF ON ON
13 D ON OFF ON ON
14 E OFF ON ON ON
15 F ON ON ON ON

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Thermocouple Burnout Jumper Selection

The thermocouple jumper selects either a full upscale or a full down
scale reaction to take place when a thermocouple fails or becomes
open. The jumper can be found on the thermocouple board, and
has two possible settings (see Figure). For full scale upwards, place
the jumper from the + to the C, and for full scale downwards, place
the jumper from the - to the C.

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Setup And Configuration

Front Panel

The front panel of the UNIPRO consists of three main parts, two
display windows and a keyboard. Refer to the figure shown below
for a layout of the front panel. The display windows each contain
four 14-segment digits that are used to display helpful messages
and numerical parameter values.

PROCESS Display

This 4 digit 14-segment display provides the value of the current
process value, along with messages for ease of operator use when
setting up parameters. The PROCESS window displays the step
number and OPCODE when in the Program Editor.

SET Display

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This 4 digit 14-segment display provides the value of the process
setpoint value during Auto and Program operation. In Manual
mode the Time-Proportioning % Output value is displayed. During
operator input procedures this display shows the data being
entered. The SET window displays the corresponding data for the
OPCODES displayed in the PROCESS window when in the
Program Editor.

LEDs

Several small LEDs indicate operations and functions of the
UNIPRO. Ten are on the face and three are in the keys.

Output 1 indicates when the Output 1 Control relay is closed.

Output 2 indicates when the Output 2 Control relay is closed.

Alarm 1 indicates when the process value has closed the relay
based upon trip point and type of alarm.

Alarm 2 indicates when the process value has closed
the relay based upon the trip point and type of alarm. Also, if
Switch 6, Bank 1 is ON the LED indicates the closed control
output relay.

Prog indicates that a program is running and Automatic control is
activated. If flashing, the program is in HOLD. Refer to the
section "The Programmer".

Auto indicates that the UNIPRO is in Automatic control mode. If
flashing, a program is in HOLD.

Manual indicates that no control action is being executed by the
UNIPRO. If flashing, a program is in HOLD.

Power indicates that the UNIPRO's 5 volt power supply is
functioning.

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Fault indicates that an open circuit is detected at the signal input.

Wait indicates that the Programmer is waiting for some condition
to be satisfied before continuing.

Setpt indicates that the Setpt Enter mode has been selected.

Cntrl Parm indicates that the Control Parameter Enter mode has
been selected.

Alarm Set indicates that the Alarm Setup mode has been selected
or one or both alarm values are non-zero.

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Keyboard

The UNIPRO keyboard consists of ten keys for operating and
programming the instrument. There are no "hidden" keys on the
UNIPRO keyboard.

Various operations with the UNIPRO involve dual-key operations
using the [Shift] key in the same way a shift key on a typewriter is
used. When activating a dual-key assignment do not try to press
both keys simultaneously; rather, follow the sequence below:

1. Press and hold the[ Shift] key,

2. Press and release the second key,

3. Release the [Shift] key.

KEY DESCRIPTION

This key selects the operating mode of the
UNIPRO. The mode selected is indicated by
the illuminated LED.

This key selects the Setpoint Enter mode
where the Setpoint, Setpoint Offset and
Reference Number can be accessed and
altered. When used in the dual-key

operation Shift/Setpt it allows the operator

to pull any program into the edit space or
decrease the remaining time of a program step
if a program is currently running.

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This key selects the Control Parameter Enter
mode where the Proportional Band, Reset,
Rate, Cycle Time and Percent Output values
(if in solenoid mode) can be accessed and
altered. When used in the dual-key

operation Shift/Cntrl Parm it selects the
keyboard Lock Level change mode.

This key selects the Alarm Setup mode where
the Alarm 1 and Alarm 2 conditions can be
accessed and altered or Alarm 2 can be used
to determine setpoint for auxiliary control
loop. When used in the dual-key operation
Shift/Alarm Set it selects the Thermocouple
Type, Custom Features, and Events Partition.
After Shift/Alarm Set the Thermocouple Type
is initially displayed, if Enter is pressed the
Custom Feature option is available while the
second press of Enter allows the Events
Partition to be observed and altered if
necessary.

This key has no function by itself. The
function of the Shift key is for all dual-key
operations, Security Sequence and the
start-up sequences.

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usually used to select which digit is to be
modified in a data entry mode. In Manual
mode this key will cause the control output
to go to the full reverse control direction
while the value is displayed in the SET
window. In Automatic mode pressing "left
arrow" causes the % on-time valve position
to be displayed in the SET window.
(positive-Output 1, negative-Output 2). In
the Programmer Status Display it causes the
display to move to a new page.**

usually used to decrease the value of a digit in
the data entry mode or scroll through various
parameter sequences. In Manual mode this
key will cause the control action

to move toward the Output 2 direction.
When used in the dual-key operation
Shift/"down arrow" it accesses the
Programmer Status Display.

usually used to increase the value of a digit in
the data entry mode or scroll through various
parameter sequences. In Manual mode this key will
cause the control action to move in the Output 1
direction. When used in the dual-key operation

Shift/"up arrow" an LED test is activated, where every segment and
decimal point should light in both displays. If any segment or
decimal point does not light a keyboard problem may exist, contact
a qualified MMI representative.

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usually used to select
which digit is to be
modified in a data entry
mode. In Manual mode

this key will cause the
control output to go to the full Output
1 direction. In the Programmer Status
Display mode it causes the display to
move to a new page.

this key is used to enter
data, clear alarms, or
cancel programs.

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