Micromod 53SL6000 User Manual

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INSTRUCTION MANUAL

Single Loop Controller 53SL6000

53SL6000 CONTROLLER

PN24991A Rev. 1

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MicroMod Automation, Inc.

The Company

MicroMod Automation is dedicated to improving customer efficiency by providing the most ost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation.

We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support.

The quality, accuracy and performance of the Company's products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology.

Use of Instructions

Ì Warning. An instruction that draws attention to the risk of injury or death.

✎ Note. Clarification of an instruction or additional

information.

❢ Caution. An instruction that draws attention to the risk of

roduct, process or surroundings.

the

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of MicroMod Automation, Inc.

Licensing, Trademarks and Copyrights

MOD 30 and MOD 30ML are trademarks of MicroMod Automation, Inc. MODBUS is a trademark of Modicon Inc.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

The relevant sections of these instructions must be read carefully before proceeding.

1. Warning Labels on containers and packages must be observed.

2. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given or injury or death could result.

3. Normal safety procedures must be taken to avoid the possibility of an accident occurring when operating in conditions of high

4. pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used.

6. When disposing of chemicals, ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual may be obtained from the Company address on the back cover, together with servicing and spares information.

i Information. Further reference for more detailed information or technical details.

All software, including design, appearance, algorithms and source

codes, is copyrighted by MicroMod Automation, inc. and is owned

by MicroMod Automation or its suppliers.

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Table of Contents 53SL6000 Instruction Manual

Safety Summary I

Read First II

1.0 Introduction 1-1

1.1 53SL6000 Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Controller Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.0 Installation and Power-Up Procedures 2-1

2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Site Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3.1 Single Cutout Installation (NEMA4 Compliant) . . . . . . . . . . . . . . . 2-1

2.3.2 Multiple Cutout Installation . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.4 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.4.1 24 V DC Power Connections . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4.2 AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5.1 Analog Inputs AI1 and AI2 . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.5.2 Discrete Outputs DO1 and DO2 . . . . . . . . . . . . . . . . . . . . . 2-4

2.5.3 Discrete Inputs DI1 and DI2 . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.5.4 Analog Output AO1 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Universal Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.6.1 Universal Analog Input Module Backplane Installation . . . . . . . . . . . . 2-5

2.6.2 Universal Analog Input Module Signal Wiring . . . . . . . . . . . . . . . 2-5

2.6.2.1 Thermocouple Connections and Burn-out Detection . . . . . . . . . 2-5

2.7 2DI/2DO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.7.1 2DI/2DO Backplane Installation . . . . . . . . . . . . . . . . . . . . . 2-6

2.7.2 2DI/2DO Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.8 RS-232 and RS-485 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.8.1 RS-232 Plug Connections . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.8.2 RS-485 Plug Connections . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.9 Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.9.1 Power-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3.0 Display Panel 3-1

3.1 Display Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1 Operator Mode Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Auxiliary Operator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Operator Mode Overflow/ Underflow Indication . . . . . . . . . . . . . . . 3-4

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53SL6000 Instruction Manual Table of Contents

3.5 Engineer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5.1 Engineer Mode Display Panel . . . . . . . . . . . . . . . . . . . . . 3-5

3.5.2 Engineer Mode Hierarchical Structure . . . . . . . . . . . . . . . . . . 3-5

3.5.2.1 Editing a Parameter . . . . . . . . . . . . . . . . . . . . . 3-5

3.5.2.2 Deselecting and Scrolling Backward . . . . . . . . . . . . . . 3-6

3.5.2.3 Editing a Numeric Value . . . . . . . . . . . . . . . . . . . 3-6

3.5.2.4 Editing the Tag Parameter . . . . . . . . . . . . . . . . . . 3-7

3.6 Entering a Pass-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6.1 Configuring a Pass-Key . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.7 Offline Display Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.8 Engineer Mode oPEr Selections . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.9 Display Alphanumerics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.10 Engineer Mode Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4.0 Functional Overview 4-1

4.1 Simplified Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Detailed Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5.0 Inputs/Outputs (I/O) 5-1

5.1 I/O Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Universal Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.1 Universal Analog Input Module Parameter Entries . . . . . . . . . . . . . 5-2

5.4 Analog Output 1 (AO1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6 Discrete Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.7 RS-232 and RS-485 Options . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

6.0 Signal Value Modification 6-1

6.1 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Characterizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1. 3SEG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.2 LSEG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.3 PrGM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2.4 DtoA Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 Math Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3.1 ALG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.2 SuMM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.3 PoLY Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.4 PoWr Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.5 LoG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.6 LiM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.7 SEL Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.3.8 Gas Flow Compensation Equations . . . . . . . . . . . . . . . . . . . 6-7

6.3.8.1 Linear Gas Flow Compensation (LFLo) Equation . . . . . . . . . 6-7

6.3.8.2 Square Root Gas Flow Compensation (SFLo) Equation . . . . . . 6-7

6.4 Logic Blocks 1, 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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Table of Contents 53SL6000 Instruction Manual

7.0 Control Scheme Block 7-1

7.1 Control Scheme Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Control Scheme Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3 Control Scheme Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.4 Signal Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes . . . . . . . . . 7-6

7.4.1 Setpoint (SP-PV) Paths for the SnGL, cASc, L.LiM, and h.LiM Control . . . . . 7-6

7.4.2 PID Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes . . . . . . 7-6

7.4.3 OUT Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes . . . . . . 7-6

7.5 Signal Paths for the in.Ld Control Scheme . . . . . . . . . . . . . . . . . . . . . 7-7

7.6 Control Scheme Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.7 Control Loop Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.8 Control Scheme Signal Connector Pin Assignments . . . . . . . . . . . . . . . . 7-28

8.0 Eight Control Strategies 8-1

8.1 Single Loop Control with Remote Setpoint . . . . . . . . . . . . . . . . . . . . 8-1

8.1.1 AI1 - Process Variable Input . . . . . . . . . . . . . . . . . . . . . . 8-2

8.1.2 AI2 - Remote Setpoint Input . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.1.3 DO1 - PV High Alarm Contact Out . . . . . . . . . . . . . . . . . . . . 8-2

8.1.4 DO2 - PV Low Alarm Contact Out . . . . . . . . . . . . . . . . . . . . 8-2

8.1.5 DI1 - Force Control Output Contact Input . . . . . . . . . . . . . . . . . 8-2

8.1.6 DI2 - Remote Enable Contact Input . . . . . . . . . . . . . . . . . . . 8-2

8.1.7 AO1 - Control Output . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.1.8 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.2 Analog Back-Up Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.2.1 AI1 - Process Variable Input . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.2 AI2 - Control Element Feedback . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.3 DO1 - Computer Output Diverter . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.4 DO2 - Backup Output Diverter . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.5 DI1 - Computer Ready . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.6 DI2 - Auto Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.7 A01 - Backup Control Output . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.8 SchM Selection and Path Connections . . . . . . . . . . . . . . . . . . 8-4

8.3 Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.3.1 AI1 - Controlled Variable Input . . . . . . . . . . . . . . . . . . . . . 8-5

8.3.2 AI2 - Wild Variable Input . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.3.3 DO1 - Controlled Variable High Alarm Contact Out . . . . . . . . . . . . . 8-5

8.3.4 DO2 - Controlled Variable Low Alarm Contact Out . . . . . . . . . . . . . 8-5

8.3.5 DI1 - Force Control Output Contact Input . . . . . . . . . . . . . . . . . 8-6

8.3.6 DI2 - Ratio Enable Contact Input . . . . . . . . . . . . . . . . . . . . . 8-6

8.3.7 Control Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.3.8 SPM = K-SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.3.9 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.4 Auto/Manual Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8.4.1 AI1 - Process Variable 1 Input . . . . . . . . . . . . . . . . . . . . . . 8-7

8.4.2 AI2 - Process Variable 2 Input (Auto) . . . . . . . . . . . . . . . . . . . 8-7

8.4.3 DO1 - PV1 High Alarm Contact Out . . . . . . . . . . . . . . . . . . . 8-7

8.4.4 D02 - PV1 Low Alarm Contact Out . . . . . . . . . . . . . . . . . . . . 8-8

8.4.5 DI1 Force Output Contact Input . . . . . . . . . . . . . . . . . . . . . 8-8

8.4.7 A01 - PV2 Re-Transmit (Auto) . . . . . . . . . . . . . . . . . . . . . . 8-8

8.4.8 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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53SL6000 Instruction Manual Table of Contents

8.5 Single Station Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8.5.1 AI1 - Secondary PV Input . . . . . . . . . . . . . . . . . . . . . . . 8-9

8.5.2 AI2 - Primary PV Input . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8.5.3 DO1 - Secondary PV High Alarm Contact Out . . . . . . . . . . . . . . 8-9

8.5.4 DO2 - Secondary PV Low Alarm Contact Out . . . . . . . . . . . . . . 8-10

8.5.5 DI1 - Force Control Output Contact Input . . . . . . . . . . . . . . . . 8-10

8.5.6 DI2 - Cascade Enable Contact Input . . . . . . . . . . . . . . . . . . 8-10

8.5.7 Primary Output (the Setpoint into the Secondary Loop) . . . . . . . . . . . 8-10

8.5.8 AO1 - Control Output . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.5.9 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.6 Single Station Override Control . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.6.1 AI1 - Primary PV Input . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.6.2 AI2 - Limiting PV Input . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.6.3 DO1 - Primary PV High AlarmContact Out . . . . . . . . . . . . . . . . 8-11

8.6.4 DO2 - Primary PV Low Alarm Contact Out . . . . . . . . . . . . . . . . 8-12

8.6.5 DI1 - Force Control Output Contact Input . . . . . . . . . . . . . . . . 8-12

8.6.6 DI2 - Secondary Setpoint Enable . . . . . . . . . . . . . . . . . . . . 8-12

8.6.7 AO1 - Control Output . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.6.8 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.7 Dual Indicator with Re-Transmitted PV . . . . . . . . . . . . . . . . . . . . . 8-13

8.7.1 AI1 - PV1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8.7.2 AI2 - PV2 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8.7.3 DO1 - PV1 High Alarm Contact Out . . . . . . . . . . . . . . . . . . . 8-13

8.7.4 DO2 - PV1 Low Alarm Contact Out . . . . . . . . . . . . . . . . . . . 8-13

8.7.5 A01 - Retransmitted PV1 or PV2 . . . . . . . . . . . . . . . . . . . . 8-13

8.7.6 SchM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8.8 Proportional Speed Floating Control . . . . . . . . . . . . . . . . . . . . . . 8-14

8.8.1 Motorized Valve Connections . . . . . . . . . . . . . . . . . . . . . 8-14

8.8.2 Configuration Requirements . . . . . . . . . . . . . . . . . . . . . . 8-14

8.8.3 Speed Factor Adjusting . . . . . . . . . . . . . . . . . . . . . . . . 8-15

9.0 Commissioning 9-1

9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Proportional Action (Pb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.3 Integral Action (tr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.4 Derivative Action (td) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.5 Trial and Error Tuning Method . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.6 Proportional Cycle Tuning Method . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.7 Step Response Tuning Method (Ziegler-Nichols) . . . . . . . . . . . . . . . . . 9-2

9.8 Easy-Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.8.1 Executing Easy-Tune . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.8.2 Easy-Tune Determined Values . . . . . . . . . . . . . . . . . . . . . 9-7

9.8.3 Easy-Tune Status Responses . . . . . . . . . . . . . . . . . . . . . 9-7

9.8.3.1 out Response . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.2 dout Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.3 dPV Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.4 outX Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.5 StiM Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.6 PtiM Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.7 WtiM Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.8 KtiM Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.9 ttiM Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.10 Abrt Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

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9.8.3.11 PidL Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.12 cM Response . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.13 cASc Response . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.8.3.14 oVr Response . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Appendix A: Glossary A-1

Appendix B: Maintenance and Parts List B-1

B.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B.2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B.3 Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B.4 Controller Confidence Test Procedure . . . . . . . . . . . . . . . . . . . . . . B-3

B.4.1 Jumper Connections for the Controller Confidence Test . . . . . . . . . . . B-3

B.4.2 Starting the Controller Confidence Test via the Faceplate Push Buttons . . . . B-4

B.4.3 Starting the Controller Confidence Test via Datalink . . . . . . . . . . . . B-4

B.4.4 Controller Confidence Test Suite . . . . . . . . . . . . . . . . . . . . B-5

B.4.5 Controller Confidence Test Status . . . . . . . . . . . . . . . . . . . . B-5

B.4.6 Exiting the Controller Confidence Test via the Faceplate Push Buttons . . . . . B-5

B.4.7 Exiting the Controller Confidence Test via Datalink . . . . . . . . . . . . . B-5

B.5 Defaulting the Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

B.6 Analog Input/Output Calibration Values . . . . . . . . . . . . . . . . . . . . . . B-6

B.7 Watchdog LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Appendix C: Datalink Protocol C-1

C.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C.2 Configuring the System Module for Datalink . . . . . . . . . . . . . . . . . . . . C-1

C.3 Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C.3.1 Message Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C.3.2 Transaction Examples . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C.4 Mnemonic-to-Datapoint Cross Reference . . . . . . . . . . . . . . . . . . . . . C-3

C.4.1 Database Starting Addresses . . . . . . . . . . . . . . . . . . . . . . C-3

C.4.2 Controller Memory Address Scheme . . . . . . . . . . . . . . . . . . . C-3

C.4.3 Database Prompt-to-Datapoint Cross Reference . . . . . . . . . . . . . . C-5

C.5 Executing Controller Self Tests via Datalink . . . . . . . . . . . . . . . . . . . . C-8

Appendix D: Prompt List D-1

Photocopy-Ready Pocket Reference Guide Last Sheet

Page 8

53SL6000 Instruction Manual Table of Contents

List of Tables

Table 1-1. 53SL6000 Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table 2-1. Controller Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table 3-1. Operator Mode Display Items . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3-2. Setpoint Up/Down Push Buttons . . . . . . . . . . . . . . . . . . . . . 3-4

Table 3-3. oPEr Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Table 3-4. Operator Enable (oPr) Prompts . . . . . . . . . . . . . . . . . . . . . 3-11

Table 5-1. Analog Input Selections . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-2. Analog Input Registers . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-3. Input Type Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-4. Volt/Millivolt Input Types . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-5. Thermocouple Types . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-6. RTD Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-7. Frequency/Pulse Input Types . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5-8. Calibration Constants . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5-9. Analog Output Selections . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5-10. Analog Output Registers . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5-11. Discrete Input Selections . . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 5-12. Discrete Output Selections . . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 5-13. System (SYS) Prompts . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Table 6-1. Characterizer Parameters . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Table 6-2. Math Function Block Parameters . . . . . . . . . . . . . . . . . . . . . 6-5

Table 6-3. Logic Block Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Table 6-4. Discrete Logic Block Functions . . . . . . . . . . . . . . . . . . . . . . 6-8

Table 7-1. Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . 7-3

Table 7-2. Control Scheme Parameters . . . . . . . . . . . . . . . . . . . . . . . 7-24

Table 7-3. Control Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Table 9-1. ITAE Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Table 9-2. Easy-Tune Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Table 9-3. Easy-Tune Determined Values . . . . . . . . . . . . . . . . . . . . . . 9-7

Table B-1. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Table B-2. Confidence Test Suite . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Table B-3. Factory Subtest Descriptions . . . . . . . . . . . . . . . . . . . . . . B-5

Table C-1. System (SYS) Prompts (Datalink) . . . . . . . . . . . . . . . . . . . . C-1

Table C-2. Datalink Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Table C-3. Datapoint Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Table C-4. Database Starting Addresses . . . . . . . . . . . . . . . . . . . . . . C-3

Table C-5. Datapoint Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Table C-6. Prompt-to-Datapoint Cross Reference . . . . . . . . . . . . . . . . . . . C-5

Page 9

Table of Contents 53SL6000 Instruction Manual

List of Figures

Figure 1-1. 53SL6000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 2-1. Panel Cutout and Installation . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure 2-2. Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-3. 24 V DC Power Connections . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-4. AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-5. Signal Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-6. Signal Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-7. Universal Analog Input Module . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-8. Input Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-9. 2DI/2DO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-10. 2DI Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-11. 2DO Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-12. RS-232 or RS-485 Module . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-13. RS-232 Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-14. RS-485 Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 3-1. Display Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Figure 3-3. Overflow/Underflow Indicators . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-4. Engineer Mode Display Panel . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-5. Editing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3-6. Deselecting and Scrolling Backward . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-7. Editing a Red dro Value . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-8. Moving the Red dro Decimal Point . . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-9. Editing a tAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-10. KEY? Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-11. Offline Display Pattern . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3-12. Display Alphanumerics . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 4-1. Simplified Controller Block Diagram . . . . . . . . . . . . . . . . . . . . 4-1

Figure 4-2. Detailed Functional Controller Block Diagram . . . . . . . . . . . . . . . . 4-5

Figure 7-1. Input Signal Designators by Control Scheme . . . . . . . . . . . . . . . . 7-2

Figure 7-2. Control Signal Logic Paths . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Figure 7-3. SnGL, cASc, L.LiM, and h.LiM Signal Paths . . . . . . . . . . . . . . . . . 7-8

Figure 7-4. Common Setpoint Logic Paths . . . . . . . . . . . . . . . . . . . . . . 7-9

Figure 7-5. Local Standard (Std) Setpoint Path . . . . . . . . . . . . . . . . . . . . 7-9

Figure 7-6. Remote Ratio Setpoint Path . . . . . . . . . . . . . . . . . . . . . . 7-10

Figure 7-7. StV Setpoint Tracking . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Figure 7-8. PVt Setpoint Tracking . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Figure 7-9. cASc Control Scheme Setpoint Path . . . . . . . . . . . . . . . . . . . 7-12

Figure 7-10. Pb, td, and tr PID Paths . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Figure 7-11. Pb, td, tr, and FF PID Paths . . . . . . . . . . . . . . . . . . . . . . 7-14

Figure 7-12. Pb, td, tr, and FF PID Paths with EXrF . . . . . . . . . . . . . . . . . 7-15

Figure 7-13. Output Tracking Path . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Figure 7-14. Auto Output Path . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Figure 7-15. Manual Output Path . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

vii

Page 10

53SL6000 Instruction Manual Table of Contents

Figure 7-16. Auto Digital Output Path . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Figure 7-17. in.Ld Control Scheme Alarmed Variable Input . . . . . . . . . . . . . . . 7-20

Figure 7-18. in.Ld Control Scheme Auto Input with Digital Output . . . . . . . . . . . . 7-21

Figure 7-19. in.Ld Control Scheme Output Tracking . . . . . . . . . . . . . . . . . . 7-22

Figure 7-20. in.Ld Control Scheme Manual Operation . . . . . . . . . . . . . . . . . 7-23

Figure 7-21. Control Schemes Signal Connector Pin Assignments . . . . . . . . . . . . 7-29

Figure 8-1. Single Loop Application . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Figure 8-2. Single Loop Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Figure 8-3. Backup Control Application . . . . . . . . . . . . . . . . . . . . . . . 8-3

Figure 8-4. Output Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Figure 8-5. Backup Control Signals . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Figure 8-6. Ratio Control Application . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Figure 8-7. Ratio Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Figure 8-8. A/M Selector Application . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Figure 8-9. A/M Selector Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Figure 8-10. Single Station Cascade Control Application . . . . . . . . . . . . . . . . 8-9

Figure 8-11. Single Station Cascade Signals . . . . . . . . . . . . . . . . . . . . 8-9

Figure 8-12. Single Station Override Control Application . . . . . . . . . . . . . . . . 8-11

Figure 8-13. Single Station Override Control Signals . . . . . . . . . . . . . . . . . 8-11

Figure 8-14. Dual Indicator Application . . . . . . . . . . . . . . . . . . . . . . . 8-13

Figure 8-15. Dual Indicator Signals . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Figure 8-16. Proportional Speed Floating Control . . . . . . . . . . . . . . . . . . . 8-14

Figure 9-1. Typical Step Response Record . . . . . . . . . . . . . . . . . . . . . 9-3

Figure 9-2. Easy-Tune Process . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Figure 9-3. Preliminary Step Response - Actual Curve . . . . . . . . . . . . . . . . 9-4

Figure 9-4. Preliminary Step Response - Approximated Curve . . . . . . . . . . . . . 9-4

Figure 9-5. Easy-Tune Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Figure B-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . B-1

Figure B-2. Bezel and Lever Tabs . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Figure B-3. Confidence Test Connections . . . . . . . . . . . . . . . . . . . . . . B-4

Figure B-4. Watchdog LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Figure C-1. Floating Point Examples . . . . . . . . . . . . . . . . . . . . . . . . C-4

viii

Page 11

Safety Summary

GENERAL Electric Shock Hazard During Maintenance WARNINGS

GENERAL Equipment Environment CAUTIONS

Disconnect power or take precautions to ensure that contact with energized parts is avoided when servicing.

Input Connector Shock Hazard

Instruments powered from an ac line source may cause input connectors to have power even though the controller is powered off.

Safety Hazard

Substitution of or modification with improper replacement components may impair the safety of this device.

All components, whether in transportation, operation or storage must be in a noncorrosive environment.

SPECIFIC WARNINGS

SPECIFIC CAUTIONS

Special Handling

This unit uses electrostatic sensitive devices.

Instruments that are powered from an ac line service constitute a potential electric shock hazard to the user; therefore, only qualified technicians should install the unit. Make certain that the ac power lines are disconnected from the operating branch circuit before attempting electrical connections. (p. 2-1)

Always remove power before attempting to install, disassemble, or service the controller. Failure to remove power may result in serious personal injury and/or equipment damage. (p. B-2)

Use a grounded wrist strap to prevent damage to integrated circuit devices when handling circuit boards. (p. B-2)

53SL6000 Instruction Manual I

Page 12

53SL6000 INSTRUCTION MANUAL

READ FIRST

WARNING

INSTRUCTION MANUALS

Do not install, maintain, or operate this equipment without reading, understanding and

following the proper MicroMod Automation Inc. instructions and manuals, otherwise

injury or damage may result.

Read these instructions before starting installation;

save these instructions for future reference.

Contacting MicroMod Automation Inc.

Should assistance be required with any MicroMod Automation Inc. product, contact the following:

Telephone:

MicroMod Automation Inc., Rochester NY:

Phone: 1 (585) 321-9200 Fax: 1 (585) 321-9291

MicroMod Automation Inc., Southampton, PA:

Phone: 1 (215) 355-4377 Fax: 1 (215) 355-4378

E-Mail:

support@micmod.com

Page 13

Section 1. Introduction 53SL6000 Instruction Manual

1.0 Introduction

Summation

•

Setpoint Programmer

1.1 53SL6000 Controller Overview

•

The 53SL6000 controller is a functionally robust instrument capable of performing any one of many control strategies. Typical control strategies that can be readily implemented are:

Single Loop Control with Remote Setpoint

•

(PID control)

Analog Back-up Control

•

Ratio Control (PID control)

•

Auto/Manual Selector

•

Single Station Cascade Control (Dual PID

•

control)

Single Station Override Control (Dual PID

•

control)

Dual Indicator with Re-Transmitted Proc-

•

ess Variable (PV)

Proportional Speed Floating Control (re-

•

quires the 2DI/2DO option module)

The complexity of learning software languages or signal interconnection schemes is eliminated, as all parameter entries are a control strategy. Mnemonic prompts appear on the display panel to solicit the necessary responses.

As listed below, a suite of control modifiers and signal conditioners is provided to supplement every control strategy.

prompt-driven

to configure

Every control strategy is also supported with a standard controller I/O complement that includes two 0/4-20 mA inputs, two digital/contact inputs, one 0/4-20 mA output, and two contact outputs.

Also available for every control strategy is additional functionality provided by optional I/O modules that mount externally at the rear of the controller for easy upgrade. Available option modules are as follows:

•

RS-232 Communications Module - provides personal computer communication port connectivity (can not coexist with the RS-485 module).

•

RS-485 Communications Module - provides datalink connectivity capabilities (can not coexist with the RS-232 module).

•

Universal Analog Input Module - provides one or two isolated inputs that accept RTD, thermocouple, millivolt, volt, and frequency inputs. The thermocouple and RTD inputs are automatically linearized.

•

2DI/2DO Module - provides two additional digital inputs and two digital outputs. With this option, a time proportional or three-step output can be applied to the 2DO relays for proportional speed floating control.

Control Modifiers:

External Reset Feedback

•

Additive Feedforward

•

External/Internal (Safety) Output Tracking

•

Output High/Low/Rate-of-Change Limiting

•

Process Variable/Internal (Safety) Set-

•

point Tracking

Setpoint High/Low/Rate-of-Change

•

Limiting

Signal Conditioners:

Twelve Linear Segment Characterizer

•

Five Third Order Segment Characterizer

•

Third Order Polynomial

•

Flow Compensation

•

Exponentiation

•

Algebraic Component Combinations

•

Logarithmic Extraction

•

Contact Duration-to-Analog

•

Power dependent transmitters are provided operating current from a 50 mA (24 V dc) transmitter power supply located in the controller.

Tuning the 53SL6000 controller is automated with EasyTune, the MicroMod algorithm designed to calculate the optimal PID values for precise analog control responses to process deviations.

The 53SL6000 controller is easy to install due to its small size. Installation depth is only 2 7/8 inches (73 mm) without option modules and 4 21/32 inches (118.1 mm) with option modules. A 1 inch (25.4 mm) access space is required for rear terminal plug removal and insertion.

An illustration of the 53SL6000 controller that depicts the front display panel and the option modules is provided in Figure 1-1.

1-1

Page 14

53SL6000 Instruction Manual Section 1. Introduction

1-2

Figure 1-1. 53SL6000 Controller

Page 15

Section 1. Introduction 53SL6000 Instruction Manual

1.2 Controller Model Numbers

The 53SL6000 controller model numbers are described in Table 1-1.

Table 1-1. 53SL6000 Model Numbers

53 SL6

Controllers Design Designator

(includes analog inputs 1 and 2, analog output 1, discrete inputs 1 and 2, discrete outputs 1 and 2)

Power Requirements:

120/240 V ac 0 24 V dc 1

Option Slot A Module:

None 0 Single Universal Analog Input

(analog input 3)

Dual Universal Analog Input

(analog inputs 3 and 4) (Each universal analog input can accept RTD, thermocouple, millivolt, voltage, and frequency inputs. Thermocouple inputs are linearized by this module.)

Option Slot B Module:

None.

♦♦♦A♦♦

SL6

Physical Ch ar a cte r is tic s

Weight

Front Dimension

Overall Length

< 1.5 kg (3 lb 5 oz)

72 x 144 mm (2 53/64 x 5 43/64 in)

With Option Modules - 130.8 mm (5.15 in)

Without Option Modules - 85.7 mm (3 3/8 in)

Panel Insta llat ion

Panel Cutout

Installation Depth

Mounting Position

See Figure 2-1

Allow an additional 25.4 mm (1 inch) for rear plug removal and insertion.

Flush panel mounting ± 60

Degree of Pr ote cti on

Facial

Housing

NEMA4 (IP64)

NEMA1 (IP20)

Safety Classification

CSA

Approved for Class 1, Division 2 (planned).

FM Approved for Class 1, Division 2 (planned)

2 Discrete Input/2 Discrete

Output (discrete inputs 3

and 4, discrete outputs 3

and 4)

Design Level A Communications Mode:

None RS-485 (allows datalink connection) RS-232 (allows connection to a

personal computer or a modem)

Enclosure:

Standard Panel Mount Case

0 1 2

1.3 Product Specifications

The 53SL6000 controller conforms to the following specifications and complies with the following regulatory requirements:

Environmental Limits

Operating Ambient Temperature Limits

Storage/Transport Ambient Temperature Limits

-5 to 50°C (23 to 122° F)

-40 to 85°C (-40 to 185° F)

Relative Humidity Limits

Humidity Limits (operation)

Humidity Limits (storage/transport)

Barometric Pressure (operation)

Barometric Pressure (storage/transport)

Thermal Shock (operation)

5 to 95%

5 to 100%

82.7 to 103.4 kPa

13.8 to 103.4 kPa

20°C/hr ( ± 68° F /hr)

1-3

Page 16

53SL6000 Instruction Manual Section 1. Introduction

Thermal Shock (storage/transport)

Physical Shock (operation)

Physical Shock (storage/transmit)

Vibration point-to-point constant displacement (operation)

Vibration (storage/transport)

Corrosion

ESD

Transient Immunity

EM Emission

EMI Susceptibility

Surge Withstand Capability

66°C/hr ( ± 150.8° F /hr)

15 g 1/2 sine, 11 ms

ASTM D4169, DC1

0.76 mm, 5 to 14 Hz

0.3 g, 14 to 200 Hz

ASTM D999 B 3-100 Hz

0.5 g

ISA S71.04, airborne contaminates G3 for 10 years.

IEC 801-2 8.0 kV

IEC 801-4, power 4 kV direct, signal 2 kV capacitively coupled

CISPR Pub. 11 Class A

SAMA PMC 33.1 - 1978 Class 3 - abc: no effect at 30 V/m, at 27, 146, and 446 MHz; IEC 801-3 10 V/m

ANSI C37.90a - 1974/IEEE Standard 472 - 1974 Ring Wave: 1.5 MHz, 3 kV, 60 pulses/second for 2.0 seconds

Power Consumption (no options installed transmitter supply not in use)

Power Consumption (options installed transmitter supply in use)

Permitted Voltage Dips

8 W

15 W

≤

20 ms

Transmitte r Su pp ly

(referenced to power common)

Voltage Range

Ripple

On-Load Current

Pulsing Short Circuit Current

24 V to 26 V

≤

200 mVp-p

≤

50 mA (short circuit protected)

50 mA

Analog Inputs 1 and 2

(referenced to power common)

Number

Rated Signal Range (for each input)

Control Range

Input Impedance

2, non-isolated

0/4 to 20 mA

0 to 21.5 mA

250 ohm

AC Power

Voltage Range

Frequency Range

Power Consumption (no options Installed, transmitter supply not in use)

Power Consumption (options installed transmitter supply in use)

Permitted Voltage Dips

DC Power

Voltage Range

93.5 to 276 V ac

47 to 63 Hz

8 W/14 VA

20 W/36 VA

≤

20 ms

20 to 30 V dc

Filter Time Constant

Measurement Error

Temperature Effects

50 ms

≤ ±

0.02 mA

≤ ±

0.002 mA/°C

Discrete Inputs 1 and 2

(referenced to power common)

Number

Signal Low Voltage

Signal High Voltage

Input Impedance

Signal Low Contact (closed)

Signal High Contact (open)

2 (dry contacts or power contacts up to 24 V dc)

0 to 1 V dc

4 to 24 V dc

1000 ohm

≤

100 ohms

≥

5000 ohms

1-4

Page 17

Section 1. Introduction 53SL6000 Instruction Manual

Analog Output 1

(referenced to power common)

Number

Rated Signal Range

Control Range

No-Load Voltage

Load Range

Filter Time Constant

Output Measurement Error

Temperature Effects

0/4 to 20 mA

0 to 21.5 mA

≤

24 V

0 to 750 ohms

50 ms

≤ ±

0.02 mA

≤ ±

0.002 mA/°C

Discrete Outpu ts 1 and 2

(open drain tied to power common)

Number

2 (Contact ratings are for resistive

loads; transient suppression is required for reactive loads.)

Input Ranges (cont)

RTD - 3 or 4 wire connection (see list) Thermocouple (see list)

High/Low Level Input Specifications

Low Level Input High Level Input

Input Connection Differential Differential Input Range: Input Resistance: 10 Mohm 800 Kohm Filter - 3db Point: 4.0 Hz no filter Filter Response

(63%): 0.025 sec N/A Normal Mode

Rejection: Common Mode

Rejection: 160 db 160 db Common Mode

Operating: 250 V rms 250 V rms Normal Mode

Maximum: 250 V rms < 25 V Conversion Type: Volts to

Resolution (17 bits plus sign): 2.5618 uV 0.1636 mV

Analog Measurement Error:

83 mV

24 db @ 60 Hz, 22 db @ 50 Hz

frequency

0.1% F.S.

25 ppm/°C

5.3 V

N/A

Volts to frequency

0.1% F.S.

25 ppm/°C

Open (off)

Closed (on)

≤

1 mA leakage

2.0 V dc maximum voltage drop, 50 mA maximum operating current, 30 V dc maximum operating voltage, and 100 mA maximum short circuit current

Universal Analog Input Option Module

(Isolated inputs, see Common Mode Rejection in High/Low Level Input chart on next column)

Number

Update Rate

General Input Types

Input Ranges

Single: 1 input module, Dual: 2 input module

300 msec

Low Level - mV, RTDs, thermocouples High Level - voltage, current, frequency, pulse

1 to 5 V linear 1 to 5 V square root 0 to +5 V square root 0 to ±80 mV Frequency input 8 Hz - 100 kHz Frequency input 2.5 Hz - 100 kHz Frequency input 0.5 Hz - 30 kHz Pulse input (incremental sum) 0-100 kHZ

Frequency Measurement Error

Frequency Input Requirement

Pulse Measurement Error

Thermocouple

CJC Measurement Error

RTD List

Platinum RTDs

0.01%

Pulse, Square Wave: +5 V, 5 usec-minimum Sine, Triangular Wave: 10 V p-p

Internal CJC

±2°

Platinum 100 Ohm RTD

= 0.003850

200° to +850° C

(-320° to 1560° F)

Platinum 100 Ohm RTD

= 0.003926

200° to +870° C

(-320° to 1590° F)

Platinum 100 Ohm RTD

= 0.003911

-200° to +850° C

1-5

Page 18

53SL6000 Instruction Manual Section 1. Introduction

Copper RTDs

Nickel RTDs

Thermocouple List

(-320° to 1560° F)

Copper 10 Ohm RTD

= 0.00427

200° to +260° C

(-320° to 500° F)

Copper 53 Ohm RTD

= 0.00427

-50° to +150° C (-55° to 300° F)

Copper 100 Ohm RTD

= 0.00427

-100° to + 260° C (-150° to 500° F)

Nickel 100 Ohm RTD

= 0.00618

-60° to +180° C (-80° to 350° F)

Nickel 120 Ohm RTD

= 0.00672

-80° to +273° C (-110° to 520° F)

Fe/Cu-Ni

-200° to +1200° C (-325° to 2190° F)

Ni-Chrom/Ni-Al

-200° to +1370° C (-320° to 2490° F)

Cu/Cu-Ni

-250° to +400° C (-418° to 750° F)

Ni-Chrom/Cu-Ni

-260° to +1000° C

(−

436° to 1830° F)

Ni-14%Chrom-1.4%Si/Ni-4.4%Si

-0.1%Mg

-200° to +1300° C (-320° to 2370° F)

Tungsten-5%Rhenium/Tungsten

-26%Rhenium 0° to +2320° C (32° to 4200° F)

Pt-13%Rhodium/Pt 0° to +1765° C (32° to 3200° F)

Pt-10%Rhodium/Pt 0° to +1765° C (32° to 3200° F)

CHE

CHS

PLII

Pt-30%Rhodium/Pt-6%Rhodium +20° to +1820° C (68° to 3300° F)

Fe/Cu-Ni

-200° to +900° C (-320° to 1650° F)

Cu/Cu-Ni

-200° to +600° C (-325° to 1110° F)

Ni-Chrom/Cu-Ni (Chinese E)

-50° to +800° C (-50° to 1470° F)

Pt-10%Rhodium/Pt (Chinese S) 0° to +1600° C (32° to 2900° F)

0° to +1400° C (32° to 2550° F)

Tungsten/Tungsten-26%Rhenium 20° to +2320° C (68° to 4200° F)

Tungsten-3%Rhenium/Tungsten

-25%Rhenium 0° to +2320° C (32° to 4200° F)

Au-Pt-Palladium/Au-Pall (Platinel II)

-100° to +1395° C (-140° to 2540° F)

2DI/2DO Option Module

Discrete Inputs

Signal Low, Voltage

Signal High, Voltage

Input Impedance

Signal Low Contact

Signal High Contact

Discrete Outputs

Contact Load

Life Expentancy

0 to 1 V dc

4 to 24 V dc

1000 ohms

≤

100 ohms

≥

5000 ohms (minimum

recognition 10 ms)

2 (Form C Relays)

250 V switching voltage,

≤

5 A switching current, and

≤

1250 VA-ac,

≤

30 W at 250 V dc, and

≤

100 W at 24 V dc

switching power

20,000,000 mechanical switching operations and 2,000,000 electri-

1-6

Page 19

Section 1. Introduction 53SL6000 Instruction Manual

cal 24 V/4 A ohmic Amp switching operations

Spark Suppressor

Electrical Isolation

CPU Cycle Time

Input Sample Rate

Output Update Rate

Display Update Rate

Control Ranges

Proportional (P)

Integral (I)

Derivative (D)

Display

Element Type

Digital Readouts

In series 5nF/51 ohm with varistor 420 Veff in parallel

1000 V contact coil 1000 V contact-contact 1000 V between relays

50 ms

1000% - 2%

200 min/repeat - 0.02 min/repeat, 0 is off.

8 min - 0.01 min, 0 is off

Red, green, and yellow LEDs

8.9 mm in height

Analog Bar Graphs

LED Indicators

Keypad

two 4 digit, 7 segment digital readouts

one 3 digit, 7 segment digital readouts

two columns of 40 LEDs

80.7 mm in height

4.8 mm in width 0 to 100% range

2.5% bargraph operation resolution red PV LEDs green SP LEDs

twelve LEDs: red, green, yellow

Seven positive tactile-feel keys

1-7

Page 20

Section 2. Installation and Power-Up Procedures 53SL6000 Instruction Manual

2.0 Installation and Power-Up Procedures

rear of the controller so that it butts against the

2.1 Inspection

Inspect the equipment upon arrival for damage that may have occurred during shipment. If damage is such that faulty operation is likely to result, do not install the controller and contact the MM Automation representative if purchased direct, or contact the appropriate supplier for repair/replacement procedures. Inspect the packing material before discarding it to prevent the loss of any additional product literature that may have been included in the shipment. Also inspect the controller data tag to ensure it has the correct power requirements for the intended application (e.g., 120/240 V ac or 24 V dc).

display flange. This step is optional and not required. The applicable option modules can be installed

before each controller is mounted in the panel cutout, or after mounting. If installing the option modules now, see Figure 2-7 to install the universal analog input module, Figure 2-9 to install the 2DI/2DO module, and Figure 2-12 to install the RS-232 or RS-485 module. This step can be skipped if none of these modules were ordered with the controllers. Slide each controller through the mounting col-

lar and panel cutout. Secure each controller in place using the two mounting brackets as shown in Figure 2-1.

2.2 Site Location

The 53SL6000 controller is designed to operate on a plant floor where the controller faceplate might be exposed to occassional wash-downs. See Section

1.3 for the stated environmental specifications of the controller.

2.3 Panel Mounting

Dimensions for single and multi-controller mounting in a single panel cutout are provided in Figure 2-1.

2.3.1 Single Cutout Installation (NEMA4 Compliant)

From the rear of the controller, slide on the

rubber O-ring so that it butts against the display flange. The applicable option modules can be installed

now, before the controller is mounted in the panel cutout, or after mounting. If installing the option modules now, see Figure 2-7 to install the universal analog input module, Figure 2-9 to install the 2DI/2DO module, and Figure 212 to install the RS-232 or RS-485 module. This step can be skipped if none of these modules were ordered with the controller. Slide the controller through the panel cutout

and secure it in place using the two mounting brackets as shown in Figure 2-1.

2.3.2 Multiple Cutout Installation

Multi-controller mounting collar part numbers are provided in Table B-1, Parts List.

2.4 Power Connections

Figure 2-2 illustrates the power plug location on the controller backplane. The power plug is removable and can be pulled straight out from its backplane connector. The plug is scalloped on one side to ensure proper insertion after the power wires are connected.

WARNING:

ac line service constitute a potential electric shock hazard to the user; therefore, only qualified technicians should install the unit. Make certain that the ac power lines are disconnected from the operating branch circuit before attempting electrical connections.

NOTE:

to a high quality, noise-free point of earth reference. Connection should be through a low resistance (less than one ohm) lead wire directly to the installation’s point of earth reference which can be an independent grounding rod or ground grid mesh that penetrates the permanent moisture level below the frost line in accordance with Article 250 of ANSI/NFPA 70, the National Electrical Code, or other code(s) acceptable to the authority having jurisdiction over the installation.

NOTE:

signal wiring. Also, the power wiring should not be routed in close proximity to signal wiring.

NOTE:

to expose 1/4 inch (6.4 mm) conductor.

Instruments that are powered from an

Installations are expected to have access

In electrically noisy locations, use shielded

Each power wire lead should be stripped

If it is desired to cushion the controller from the

collar, then slide on the rubber O-ring from the

2-1

Page 21

2-2

53SL6000 Instruction Manual Section 2. Installation and Power-Up Procedures

Figure 2-1. Panel Cutout and Installation

Page 22

Section 2. Installation and Power-Up Procedures 53SL6000 Instruction Manual

Connect the chassis safety ground lug of the

power plug to the ground wire.

NOTE: DO NOT APPLY POWER TO THE CONTROLLER.

(Applying power is performed in Section 2.9.)

2.4.2 AC Power Connections

Figure 2-2. Power Plug

2.4.1 24 V DC Power Connections

Figure 2-3. 24 V DC Power Connections

Refer to Figure 2-3 to make the following connections:

Connect the positive (+) 24 V input line, via an

SPST switch, to L1 of the power plug. As shown in Figure 2-3, the positive input should come from a distribution strip; do not daisychain the input power from one controller to another. Leave the SPST switch in the OFF position. Connect the negative (-) input line to L2 of the

power plug. As shown in Figure 2-3, the negative input should come from a distribution strip; do not daisy-chain the negative input from one controller to another. The distribution strip should be connected to a noise free earth reference as shown in Figure 2-3.

Figure 2-4. AC Power Connections

Refer to Figure 2-4 to make the following connections:

For 110/120/220 V ac, connect the phase and

neutral inputs to the power plug. For 240 V ac, connect the two phase inputs to the power plug. Connect the chassis safety ground lug of the

power plug to the ground wire (green, greenyellow).

NOTE: DO NOT APPLY POWER TO THE CONTROLLER.

(Applying power is performed in Section 2.9.)

2.5 Signal Connections

Figure 2-5 illustrates the signal plug location on the controller backplane. The signal plug is removable and can be pulled straight out from its backplane connector. The plug is scalloped on one side to ensure proper insertion after the signal wires are connected. Figure 2-6 illustrates the signal wire connections.

Each signal wire lead should be stripped

NOTE:

to expose 1/4 inch (6.4 mm) conductor.

2-3

Page 23

53SL6000 Instruction Manual Section 2. Installation and Power-Up Procedures

2.5.1 Analog Inputs AI1 and AI2

In Figure 2-6, AI1 is connected to a transmitter that requires power from the controller. Both, AI1 and/or AI2 can be connected to transmitters that require controller power provided the total required power does not exceed the specifications stated for the transmitter supply in Section 1.3. The current path for AI1 is from +24V to the + transmitter input, through the transmitter element, out of the transmitter (-), to the AI1 plug connection, across the internal 250 ohm (0.1%) voltage dropping resistor, and down to Common.

In Figure 2-6, AI2 is connected to a transmitter type that has its own power source and does not require power from the controller. This transmitter type can be connected to both AI1 and/or AI2. The current path for AI2 is from the transmitter current out (Io), to the AI2 plug connection, across the internal 250 ohm (0.1%) voltage dropping resistor, out the plug Common connection, to the transmitter

Figure 2-5. Signal Plug

Common connection.

Figure 2-6. Signal Plug Connections

NOTE 1:

be used in electrically noisy locations.

NOTE 2:

exceed the limit specified for the particular transmitter (refer to the applicable technical literature provided with the respective device).

NOTE 3:

connecting remote transmitters to the controller.

Shielded signal cable (two-wire) should

Signal transmission distance must not

Correct polarity must be observed when

Notice in Figure 2-6 that the signal cable shields are connected to the backplane shield stud.

2.5.2 Discrete Outputs DO1 and DO2

Only DO1 is shown connected in Figure 2-6; connections to DO2 are identical. A discrete output resistive load does not require transient suppression; however, reactive loads do to prevent coil ringing or spiking from feeding back into the controller. The required diode shown as the suppression device is circuit dependent (typical: a 24V, 430 ohm, dc coil relay would require a 1N4003 diode).

2.5.3 Discrete Inputs DI1 and DI2

Only DI2 is shown connected in Figure 2-6; connections to DI1 are identical. In the figure, the discrete input solid state circuitry is depicted as a signal contact that opens or closes (logic states) in response to input voltage levels (the discrete inputs also work with dry contacts: ≤ 100 ohms is closed and ≥ 5000 ohms is open).

2.5.4 Analog Output AO1

In Figure 2-6, the control output device is connected across the AO1 and COM lugs. Signal current passes from the AO1 connection, through the device and back to Common. Control output device response to alter process operation is depenedent upon the analog signal amplitude.

2-4

Page 24

Section 2. Installation and Power-Up Procedures 53SL6000 Instruction Manual

2.6 Universal Analog Input Module

This information applies to only those controllers with an optional universal analog input module.

2.6.1 Universal Analog Input Module Backplane Installation

Figure 2-7 illustrates the universal analog input module location on the controller backplane. The universal input module is socket mounted and is secured to the backplane with two screws. Also shown in Figure 2-7 are the signal plugs AI3 (right plug) and AI4 (left plug) that are screw mounted to the universal analog input module (the plug mounting screws are not illustrated). Depending on the option ordered, one (AI3) or both (AI3 and AI4) of these plugs will require installation and input connections. The plugs for AI3 and AI4 are identical; therefore, care should be taken to ensure each plug is installed in its proper location. Each plug, however, is keyed to prevent inverted insertion into its module connector.

2.6.2.1 Thermocouple Connections and Burn-out Detection

To ensure proper cold junction compensation (CJC) operation, the steps to wire a thermocouple to the universal analog input module are as follows:

Prepare the thermocouple leads as shown in

the following illustration:

For dual universal analog input modules that

will have one thermocouple connected, ensure it is installed on AI3 and that the other input is installed on AI4. For dual universal analog input modules that

will have only one terminal plug connected, the other terminal plug must still be installed on the module for proper performance.

4. Thermocouple Burn-out Detection

shown in Figure 2-8, an open thermocouple detection (OTD) current, which is very small, is provided at pin 3 of each connector plug. If pin 3 is wired to pin 1 and the thermocouple opens, then a positive temperature over range results. If pin 3 is wired to pin 2 and the thermocouple opens, then a negative temperature over range results.

- As

Figure 2-7. Universal Analog Input Module

2.6.2 Universal Analog Input Module Signal Wiring

As shown in Figure 2-7 (e.g., INSERT SCREWDRIVER), the signal wire lug screws are accessed on the side of each plug.

Each analog input (AI3 and AI4) can accept only one device input configuration as illustrated in Figure 2-8.

to another input.

Unused plug lugs can not be dedicated

NOTE: If an upscale or downscale open thermocouple detection (OTD) wire is installed as part of the thermocouple connection, then the wire should be 2 inches (50.8 mm) of 22AWG wire or lighter. Do not use longer or heavier gauge (e.g., 14AWG) wire.

The complete assembly will reach thermal

equilibrium approximately 30 minutes after the controller is powered up (see Section 2.9, Applying Power).

2-5

Page 25

53SL6000 Instruction Manual Section 2. Installation and Power-Up Procedures

2.7 2DI/2DO Module

This information applies to only those controllers with the optional 2DI/2DO module.

2.7.1 2DI/2DO Backplane Installation

Figure 2-9 illustrates the 2DI/2DO module location on the controller backplane. The 2DI/2DO module is socket mounted and is secured to the backplane with two screws. Also shown in Figure 2-9 are the 2DI and 2DO signal plugs that are screw mounted to the module (the plug mounting screws are not illustrated). The two plugs are different in size; therefore, they can not be inadvertently installed in the wrong sockets and each plug is keyed to prevent inverted insertion into its module socket.

Figure 2-8. Input Configurations

Figure 2-9. 2DI/2DO Module

2.7.2 2DI/2DO Signal Wiring

As shown in Figure 2-9 (e.g., INSERT SCREWDRIVER), the lug adjusting screws are accessed on the side of the plug.

Signal input connections for the 2DI four terminal plug are illustrated in Figure 2-10. The functional description for DI3 and DI4 is identical to that described in Section 2.5.3 for DI1 and DI2.

Figure 2-10. 2DI Plug Connections

2-6

Page 26

Section 2. Installation and Power-Up Procedures 53SL6000 Instruction Manual

Signal input connections for the 2DO six terminal plug are illustrated in Figure 2-11. Both, DO1 and DO2 are Form C relays. The contact load capacities are 250 V ac or 250 V dc maximum switching voltage; 5 A switching current; 1250 VA-ac maximum, and 30 W at 250 V-DC maximum or 100 W at 24 V-DC maximum switching power.

The 2DI/2DO module provides line

NOTE:

suppression; appropriate load suppression must be supplied by the user.

Figure 2-11. 2DO Plug Connections

2.8 RS-232 and RS-485 Modules

This information applies to only those controllers with the optional RS-232 module or RS-485 module.

2.8.1 RS-232 Plug Connections

Signal connections to the RS-232 module plug are illustrated in Figure 2-13. Transmitted (TxD) and received (RxD) signals are with respect to the controller.

Figure 2-13. RS-232 Plug Connections

2.8.2 RS-485 Plug Connections

Signal connections to the RS-485 module plug are illustrated in Figure 2-14. In the illustration, the controller is shown wired as a drop on the datalink. Two wires are therefore connected to each lug: one set (T+, T-, R+, R-, SC) that comes from the previous node and another set that is connected to the next datalink node.

Figure 2-12 illustrates the RS-232 module or the RS-485 module location on the controller backplane. The module is socket mounted and is secured to the backplane with a screw. Also shown in Figure 2-12 is the module signal plug, which is keyed to prevent inverted insertion in its socket. As shown in Figure 2-12 (e.g., INSERT SCREWDRIVER AT BASE), the lug adjusting screws are accessed at the bottom of the plug.

Figure 2-12. RS-232 or RS-485 Module

Figure 2-14. RS-485 Plug Connections

Cable shield should be connected to

NOTE:

ground at only one location.

2.9 Applying Power

Verify all controller connections and ensure each connection is mechanically sound before closing the power switch to apply controller power. The

2-7

Page 27

53SL6000 Instruction Manual Section 2. Installation and Power-Up Procedures

controller powers up in the last state it was in before power was removed.

2.9.1 Power-up Sequence

The power-up sequence is as follows:

At power-up, the controller performs a power-

on self test which includes lighting all faceplate LEDs for three seconds to show they are working. After completing the power-on self test, status

information is presented in the dros. During status, both of the vertical bars have five equally spaced LEDs lit.

If the power-on self test is successful, the

2a.

dros will contain option identification codes and the firmware revision level identification for the next three seconds as described in Table 2-1.

Table 2-1. Controller Status Codes

dro Attribute Status Code

Top (red) Option A status

Middle (green)

Bottom (yellow)

code. Option B status

code.

Firmware revision level identifier.

0 = no options. 192 = 2DI/2DO. 193 = Single Universal Analog Input. 194 = Dual Universal Analog Input.

Code must be cross referenced to revision level.

controller confidence tests when it was powereddown. Both vertical bars and all status indicator LEDs, except the WD indicator, will be lit during the controller confidence test execution.

If a power-on self-test database memory

2b.

error occurs, the

error appears in

nrAM

the top (red) dro and the controller halts further operation. Return unit to for service

After a successful power-on self test and

status presentation, the controller enters operator mode, unless it was offline or executing the controller confidence test when it was powered-down.

Offline is indicated by four equally spaced pairs of lit LEDs in the green vertical bar. When offline, no control is being performed and all outputs are held at their values previous to being placed in offline mode. (For more information about operator mode see Section 3.2, Operator Mode; for more information about the offline state, see Section 3.7, Offline Display Pattern.)

Reference Section B.4.6, Exiting the Controller Confidence Test via the Faceplate Push Buttons, if it is suspected that the controller was executing the

2-8

Page 28

Section 3. Display Panel 53SL6000 Instruction Manual

3.0 Display Panel

3.1 Display Panel Overview

As shown in Figure 3-1, the controller display panel contains three digital read-out (dro) fields, two vertical bar indicators, twelve function specific status indicators, and seven push buttons (pbs). The display panel is used to alter controller settings (which in turn affect process operation), to monitor process operation, and to configure controller functionality. (It is also used to commission the controller, which is described in Section 9.) Process operation is altered and monitored with the controller in operator mode; controller functionality is configured with the controller in engineer mode.

The red display area includes the left vertical

Red:

bar, upper dro, and alarm status indicators (A1, A2). This display area is assigned to the process variable input. The red vertical bar indicates the process variable as a percent of control range and the red dro is the process variable in engineering units.

Green:

vertical bar, the dro immediately beneath it, the remote/local pb with its two status indicators, and the setpoint up/down pbs. This display area is usually assigned to setpoint indication and control, although the green vertical bar and dro can be used to indicate a second process variable if the selected control scheme is an indicator. The green vertical bar indicates the setpoint as a percent of control range and the green dro is the value in engineering units.

Yellow:

tom dro, the auto/manual pb with its status indicators, the output pbs, and the two multistate (MS1, MS2) indicators. This display area is primarily assigned to output indication and control. The yellow dro is an output value in percent of the scaled final control element travel range.

The green display area includes the right

The yellow display area includes the bot-

Figure 3-1. Display Panel Overview

3.2 Operator Mode

The colors red, green, and yellow are used to visually partition the display panel into general operating mode functional areas as follows:

red - process variable presentation.

•

green - setpoint presentation and control.

•

yellow - output presentation and control.

•

3.2.1 Operator Mode Panel Functions

The operator mode panel functions are described in Figure 3-2 on the next page. The figure has three major parts: an illustration of the controller with item number call-outs in the upper right, a supporting chart in the upper left that defines the Off/On/Blinking status indicator states, and a summary chart at the bottom that lists the assigned functions of each item call-out by control scheme. The illustration item call-outs are defined in more detail in Table 3-1.

As shown in Figure 3-2, many of the push buttons and status indicators have identical functions in the different control schemes; however, the indicator/loader (in.Ld) control scheme is the most unique.

3-1

Page 29

53SL6000 Instruction Manual Section 3. Display Panel

Item/LED Off On Blink-

8 - R X Remote/Ratio.

9 - L X Local Setpoint.

3 - A1 4 - A2

24 - Watch dog

21 - Loop 1 X Loop 1 selected (cASc,

22 - Loop 2 X Loop 2 selected (cASc,

23 - Easy Tune

14 - Auto X In Auto.

15 - Manual X In Manual.

18, 19 MS1, MS2

X No alarm.

X Normal operation.

X Not running Easy-Tune.

Alternately on/off for time proportioned or three step output.

ing

X Remote requested, but

X Setpoint is tracking the

XAlarm active.

XOut of service.

XFailed Easy-Tune.

X Running Easy-Tune.

X Auto requested but not

X Output is tracking the

Description

not granted (Remote Enable [RE] not true).

SP tracking signal.

L.LiM, h.LiM).

granted - (Auto Enable [AE] not true.)

Force Output signal.

Item SnGL

1 PV dro PV dro PV dro PV dro PV dro PV(1) dro 2 PV bar PV bar PV bar PV bar PV bar PV(1) bar 3 PV Alarm 1 status PV Alarm 1 status PV Alarm 1 status PV Alarm 1 status PV Alarm 1 status PV(1) Alarm 1 4 PV Alarm 2 status PV Alarm 2 status PV Alarm 2 status PV Alarm 2 status PV Alarm 2 status PV(1) Alarm 2 5 Setpoint* dro Setpoint* dro Setpoint dro Setpoint* dro Setpoint dro Auto/PV2 dro 6 Setpoint bar Setpoint bar Setpoint bar Setpoint bar Setpoint bar Auto/PV2 bar 7 R/L pb R/L pb N/A R/L pb N/A N/A 8 Remote LED Remote status N/A Remote status N/A N/A

9 Local LED Local status N/A Local status N/A N/A 10 SP Up pb SP Up pb SP Up pb SP Up pb SP Up pb N/A 11 SP Down pb SP Down pb SP Down pb SP Down pb SP Down pb N/A 12 Out dro Out dro Out dro Out dro Out dro Auto/PV2 Xmt dro 13 Auto/Manual pb Auto/Man. pb Auto/Man. pb Auto/Man. pb Auto/Man. pb Auto/Manual pb 14 Auto LED Auto status Auto status Auto status Auto status Auto status 15 Manual LED Manual status Manual status Manual status Manual status Manual status 16 Decrease Out pb Decr. Out pb Decr. Out pb Decr. Out pb Decr. Out pb Decrease Out pb 17 Increase Out pb Incr. Out pb Incr. Out pb Incr. Out pb Incr. Out pb Increase Out pb 18 Multistate 1 Multistate 1 N/A Multistate 1 N/A Multistate 1 19 Multistate 2 Multistate 2 N/A Multistate 2 N/A Multistate 2 20 Mode pb Mode pb, Loop 1/2 Select pb Mode pb, Loop 1/2 Select pb Mode pb 21 N/A Loop 1 select Loop 1 select N/A 22 N/A Loop 2 select Loop 2 select N/A 23 Easy-Tune status N/A 24 Watchdog condition indicator

Control

Secondary (L1) Primary (L2) Primary (Loop 1) Limiting (Loop 2)

cASc Control L.LiM/h.LiM Control in.Ld

PV(1)=PV/PV1

*Ratio based on conF-cn.1-SPM setting.

Figure 3-2. Operator Mode Display Panel Summary

3-2

Page 30

Section 3. Display Panel 53SL6000 Instruction Manual

Table 3-1. Operator Mode Display Items

Item Call-Out Description

1 PV dro It is the process variable

2 PV bar It indicates the process

3PV Alarm 1

Status

4PV Alarm 2

Status

5 Setpoint dro It is the setpoint value in

6 Setpoint bar It indicates the setpoint

7R/L

Push Button

8Remote

Setpoint Status

9Local

Setpoint Status

10 Setpoint

Up Push Button

value in engineering units.

variable percent of control range.

When active, it indicates alarm 1 of the selected alarm index limits (e.g. high/low alarms; high, highhigh alarms; etc.) was not within tolerable limits. For high/low alarms, an active Alarm 1 LED indicates the the PV exceeded the high alarmed value.

When active, it indicates alarm 2 of the selected alarm index limits (e.g. high/low alarms; low, lowlow alarms; etc.) was not within tolerable limits. For high/low alarms, an active Alarm 2 LED indicates the PV fell below the low alarmed value.

engineering units or a ratio setpoint.

percent of control range. It also produces a striped pattern when the controller is offline.

Generally, it is used to select the setpoint source: remote or local setpoint control. Remote setpoint control requires an active Remote Enable. For ratio control, it is used to select ratio or standard control.

It indicates remote setpoint is selected with the R/L push button. See item 7 above and the LED chart in Figure 3-2.

It indicates the local or tracking setpoint is selected with the R/L push button. See item 7 above and the LED chart in Figure 3-2.

Pressing this push button increases the local setpoint or ratio setpoint value. See Table 3-2 for setpoint mode selections.

Table 3-1. Operator Mode Display Items

Item Call-Out Description

11 Setpoint

Down pb

12 Out dro It is the control output as a

13 A/M

Push Button

14 Auto

Status

15 Manual

Status

16 Decrease Out

Push Button

17 Increase Out

Push Button

Multistate 1 Indicators

Multistate 2 Indicators

Pressing this push button decreases the local setpoint or ratio setpoint value. See Table 3-2 for setpoint mode selections.

percent of control range. It can also be used to display an externally generated signal such as a proportional speed floating control valve position indication.

It is used to select auto or manual control. If auto is selected and Auto Enable is active, then the output is determined by the controller PID algorithm. If manual is selected, the output is determined by the decrease/increase out push buttons.

It indicates auto operation is selected with the A/M push button. See the LED chart in Figure 3-2.

It indicates manual operation is selected with the A/M push button. See the LED chart in Figure 3-2.

When in manual operation, pressing this push button causes the output to decrease.

When in manual operation, pressing this push button causes the output to increase.

These two indicators activate to show the direction of the discrete control output.

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53SL6000 Instruction Manual Section 3. Display Panel

Table 3-1. Operator Mode Display Items

Item Call-Out Description

Select Mode and Loop 1/2 Push Button

Pressing this push button in operator mode with an active two loop control scheme (cASc, L.LiM, or h.LiM) selects the loop under display panel control. It toggles from one loop to the other each time it is pressed. If this push button is held for three seconds, it causes engineer mode to be entered. Pressing it in engineer mode causes a return to operator mode.

Loop 1 Select Indicator

Loop 2 Select Indicator

These indicators are for the two loop control schemes cASc, L.LiM, and h.LiM. Either one of these two indicators will activate to show which loop is under display panel control as selected by the Mode push button.

Easy-Tune Status

This status indicator blinks during Easy-Tune operation. A steadystate-on condition indicates Easy-Tune terminated with an error. It stops blinking when Easy-Tune completes successfully.

Watchdog Condition Indicator

This indicator activates whenever the controller detects an internal processor failure. When active, all outputs are forced to their power-off state. Attempt to restart the controller by cycling power.

Table 3-2. Setpoint Up/Down Push Buttons

Display Panel Action

Alter standard SP value. Y Std No SP control. Y Std Alter standard SP value. Y K-SP Alter ratio SP value. Y K-SP

R/L PB (7)

R LED

(8)

L LED

(9)

SPM*

*SPM settings (Std or K-SP) are made in engineer mode, which is described later in Section 3.

3.3 Auxiliary Operator Access

To facilitate operator access for auxiliary data input and selected parameter modification, an engineer mode oPEr menu is provided. This menu allows display panel entry of logical and analog signal constants, process variable alarm values, high/low output limit values, and PID values. It also provides operator capabilities to execute the EasyTune sequence. Access to menu items is controlled through the conF-oPr enabling parameters. Because the oPEr menu parameters and their corresponding conF-oPr enabling parameters are accessed in engineer mode, they are described in Tables 3-3 and 3-4, which appear later as part of the engineer mode information.

3.4 Operator Mode Overflow/ Underflow Indication

Overflow indicators are plus signs (+) and underflow indicators are negative signs (-). Illustrations of the overflow and underflow conditions are provided in Figure 3-3. They appear in the affected dro and are decimal point sensitive. If these indicators repeatedly appear, the decimal point should be repositioned with the conF-cn.1(cn.2)-dP parameter described in Table 7-3. Adjusting this parameter requires knowledge of engineer mode, which is described next in this section.

3-4

Figure 3-3. Overflow/Underflow Indicators

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Section 3. Display Panel 53SL6000 Instruction Manual

mon parameters such as alarm limits,

3.5 Engineer Mode

The controller parameters and path connections are configured in engineer mode. Engineer mode is also used to initiate the Easy-Tune sequence (see Section 9.8). This mode is entered when the mode push button is held pressed for an extended period of approximately 3 seconds, at which time the oPEr menu prompt appears in the green dro.

3.5.1 Engineer Mode Display Panel

The display panel functions for engineer mode are described in Figure 3-4 as follows:

• Level 2, Module Select - used to select a spe-

• Level 3, Parameter Select - used to select a

• Level 4, Edit - this is where a value is entered

deadband, etc. (This path skips level 2, module described below.) ProG (Program) - is selected to enter reg-

ister values, formula constants, and to make path connections. Parameters entered in this menu will force the controller offline. It is used primarily by engineering personnel. conF (Configure) - is selected to configure

online database parameters; it is used primarily by engineering personnel.

cific controller functional element (e.g., the prompt Ai.1 for analog input 1). The full path name is indicated by menu-module (e.g., conFAi.1). The module selection is skipped in the oPEr menu path.

specific parameter from a list of module parameters (e.g., the parameter prompt SPAn under Ai.1). The full path name is indicated by menu-module-parameter (e.g., conF-Ai.1SPAn).

for the displayed parameter or a selection from a list of values or mnemonics is made.

Figure 3-4. Engineer Mode Display Panel

3.5.2 Engineer Mode Hieracrhical Structure

Engineer mode is a hierarchical structure of nested prompt layers that can be four levels deep; the general order of selection is:

• Level 1, Menu - After engineer mode is accessed with the mode push button, each menu prompt can be displayed sequentially by pressing the scroll forward pb. The menu prompts are three major display panel paths: oPEr, ProG, and conF. The ProG and conF paths can each be protected with their own unique pass-key. The three menu prompts are described as follows:

oPEr (operator) - provides quick access

for operators to display and configure com-

3.5.2.1 Editing a Parameter

Figure 3-5 illustrates the steps to edit a parameter in engineer mode. In the illustration a parameter selection is made; some parameters require a numeric value to be entered. The process to edit a parameter is reiterative:

• When engineer mode is entered, the oPEr menu prompt (level 1) appears in the green dro. The menu prompts are scrolled and one is selected.

• Selecting a menu prompt causes the first module prompt (level 2) to appear in the yellow dro. The module prompts of the selected menu are scrolled and one is selected.

• Selecting a module prompt causes the first parameter prompt (level 3) to appear; it replaces the menu prompt in the green dro. The parameter prompts of the selected module are scrolled and one is selected.

• Selecting a parameter prompt causes the first edit entry prompt (level 4) to appear in the red dro. An edit input list is scrolled and an item is selected or a numeric value is entered.

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53SL6000 Instruction Manual Section 3. Display Panel

NOTE 1:

occurs if a parameter prompt is not selected in engineer mode.

NOTE 2:

affect immediately. If a ProG menu parameter is edited, the controller goes to the offline condition in which no control action is performed.

There is a 12.5 second time-out that

oPEr and conF parameter changes take

3.5.2.2 Deselecting and Scrolling Backward

Figure 3-6 illustrates how to move through the various modules and their parameters by using the deselect and scroll backward push buttons. Figure 3-6 begins with the last level 4 edit select step in Figure 3-5 where the bASE parameter of the Ai.2 module was updated. The object in Figure 3-6 is to exit the Ai.2 module after the bASE parameter has been updated and to access the Ai.1 module where any one of its parameters can be scrolled and selected for updating.

3.5.2.3 Editing a Numeric Value

If a parameter value must be entered in the red dro, different editing steps must be performed than when a selection is made from an item list. Figure 3-7 illustrates these steps; it assumes engineer mode has been entered, and the menu, module, and parameter have been selected. The parameter conF-Ai.1-SPAn will be edited from 100.0 to 275.0. Only the red dro showing the conF-Ai.1-SPAn value appears in the illustration.

Figure 3-5. Editing a Parameter

Figure 3-8 illustrates changing the conF-Ai.1-SPAn value from 100.0 to 10.00 by moving the decimal point. It assumes engineer mode has been entered, and the menu, module, and parameter have been selected.

3-6

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Section 3. Display Panel 53SL6000 Instruction Manual

Figure 3-6. Deselecting and Scrolling

Backward

Figure 3-8. Moving the Red dro Decimal

Point

3.5.2.4 Editing the Tag Parameter

The tAG is one parameter where an alphanumeric, rather than a numeric, can be entered. It occurs when the datalink controller conF-SYS-tAG parameter must be configured. Because four characters maximum can be displayed at any one time in the red dro, using the shift right push button in engineer mode allows the ten character positions to be displayed as follows:

The bold characters are those that can be changed with each four position display.

Characters are selected for each position with the scroll forward/backward push buttons in a manner described in Figure 3-7. The procedure to edit the tag is described in Figure 3-9. It assumes the conF-SYS-tAG parameter is already accessed.

0123

→ 3

456

→ 6

789

Figure 3-7. Editing a Red dro Value

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53SL6000 Instruction Manual Section 3. Display Panel

Press the scroll forward pb until the desired

number for the first digit appears (assumes first digit is not a zero). Press the position select right pb; the second

zero starts blinking. Repeat steps 1 and 2 to enter all four pass-key

digits. Press the enter pb; if the pass-key is correct

engineer mode functions are permitted for that menu.

If the pass-key can not be recalled, then

NOTE:

the database must be defaulted using the procedure described in Section B.5.

Figure 3-9. Editing a tAG

3.6 Entering a Pass-Key

In engineering mode, access to the ProG and conF menus can be selectively restricted, as each menu has its own pass-key capabilities. A pass-key is a four digit number that must be entered when a menu is selected; otherwise, access to module prompts in that menu are prohibited. Figure 3-10 illustrates the key display that appears if a menu is pass-key protected.

3.6.1 Configuring a Pass-Key

To configure a conF (or ProG) pass-key, the following steps must be performed:

Enter engineer mode by pressing and holding

the mode pb until a menu prompt appears in the green dro. Press the scroll forward pb until conF (ProG)

appears in the green dro. Press the enter pb to accept the conF (ProG)

menu. If KEY does not appear in the yellow dro, press

the scroll forward pb until it does. Press the enter pb to select the KEY prompt.

cKEY (PKEY) appears in the green dro.

It is assumed the pass-key was never configured before and that four zeros appear in the red dro:

Press the enter pb; the leftmost number (zero)

in the red dro blinks. Press the scroll forward pb until the desired

number appears (assumes zero will be changed to a different number). Press the shift right pb; the next zero starts

blinking. Repeat steps 7 and 8 until all four pass-key

digits are entered. Press the enter pb to enter the pass-key.

10.

Press the mode pb to exit engineer mode.

11.

Figure 3-10. KEY? Prompt

The correct pass-key must be entered in the red dro with the following procedure:

3-8

3.7 Offline Display Pattern

The controller offline state is indicated by four activated double LED markers along the green vertical bar as shown in Figure 3-11. The remainder of the vertical bar is dark.

Events that can cause the controller to be offline are as follows:

• If a ProG menu parameter is altered in engineer mode , it causes the controller to immediately go offline,

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Section 3. Display Panel 53SL6000 Instruction Manual

• If exiting the conF or ProG menus in engineer mode, the controller goes offline and a blinking oFF prompt appears in the red dro immediately after the mode pb is pressed. To put the controller in operator mode, press the scroll forward pb to change the oFF prompt to the run prompt and press the enter pb.

• The controller may have been powered-down in offline, in which case it will return to offline after the status and power-on self test se-

3.8 Engineer Mode oPEr Selections

This menu provides operator access to selected parameters and auxiliary inputs. Items not enabled from the oPr module of the conF menu will not appear in the oPEr menu. The oPEr parameters and auxiliary inputs are described in Table 3-3 and their enabling parameters are described in Table 3-4 as follows:

quence is complete. To put the controller in operator mode if an offline indication occurs after the power-up sequence, perform the following steps:

press and hold the mode pb until a menu

item (conF, oPEr, or ProG) appears. Use the scroll forward push button to dis-

play the ProG or conF menu prompts and press the select push button. Press the mode pb; the oFF prompt ap-

pears blinking in the red dro. To put the controller in operator mode,

press the scroll forward pb to change the oFF prompt to the run prompt and press the enter pb.

Figure 3-11. Offline Display Pattern

Table 3-3. oPEr Menu Selections

Prompt Description Dft

Discrete Input 7

di7

It provides enumerated selections, StoP and run, that can be used to implement general purpose logic states.

StoP

- 0

run

- 1

(It is enabled with conF-oPr-di7.E.)

Discrete Input 8

di8

It provides enumerated selections, oFF and on, that can be used to implement general purpose logic states.

oFF

- 0

- 1

(It is enabled with conF-oPr-di8.E.)

Setpoint Programmer StEP

StEP

It indicates the step being executed by the programmer . It can also be used to force the setpoint programmer to a new step. The setpoint programmer step sequence execution is from 0 to 12; 13 indicates the program is done. (It is enabled with conF-oPr-StP.E.)

Analog Input 7 Register

Ai7

It provides operator access to analog input register 7. (See Table 5-2.) (It is enabled with conF-oPr-Ai.E.)

Analog Input 8 Register

Ai8

It provides operator access to analog input register 8. (See Table 5-2.) (It is enabled with conF-oPr-Ai.E.)

Process Limit 1

PL1

Specifies the process or deviation value which triggers the alarm associated with PA1 as determined by conF-cn.1(cn.2)-AiX. (It is enabled with conF-oPr-ALM.E.)

Process Limit 2

PL2

Specifies the process or deviation value which triggers the alarm associated with PA2 as determined by conF-cn.1(cn.2)-AiX. (It is enabled with conF-oPr-ALM.E.)

StoP

oFF

100.0

0.0

3-9

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53SL6000 Instruction Manual Section 3. Display Panel

Table 3-3. oPEr Menu Selections

Prompt Description Dft

Alarm Deadband

Adb

Specifies the hystersis (gap) between alarm trigger and reset. This value is used to eliminate repetitive alarm triggering when the process is fluctuating about a process limit. This value should be set slightly larger then the peak-topeak fluctuations (noise) which are normally present in the process variable signal. (It is enabled with conF-oPr-ALM.E.)

Proportional Band (see Section 8.2)

Specifies the percent of process deviation from setpoint over the control range (conF-cn.1[cn.2]-ir) required to generate a full scale output signal. For a detailed discussion on control and tuning, see Section 9. Values should be limited between 2 to 1000%. (It is enabled with conF-oPr-Pid.E.)

Reset Time (see Section 8.3)

Specifies the time in minutes required for additional corrective response (integral action). For a detailed discussion on control and tuning, see Section 9. Values should be limited between 0.02 and 200 minutes /repeat. A value of 0.0 turns integral action off. (It is enabled with conF-oPr-Pid.E.)

Derivative Time (see Section 8.4)

Specifies the time in minutes that control response is advanced over proportional only action. For a detailed discussion on control and tuning, see Section 9. Values should be limited between 0.01 to 8 minutes. A value of 0.0 turns derivative action off. (It is enabled with conF-oPr-Pid.E.)

Manual reset

This value determines the position of the output element (e.g., valve) when the controller is in automatic mode and the error is zero. It is only in effect when tr is zero. (It is enabled with conF-oPr-Pid.E.)

Output High Limit

Specifies in percent the maximum allowable control output during automatic operation. This limit also affects outputs during manual operations when conF-cn.1(cn.2)hML is turned on. (It is enabled with conF-oPr-hLc.E.)

2.000

100.0

50.0

0.0

Table 3-3. oPEr Menu Selections

Prompt Description Dft

Output Low Limit

Specifies in percent the minimum allowable control output during automatic operation. This limit also affects outputs during manual operations when conF-cn.1(cn.2)hML is turned on. (It is enabled with conF-oPr-hLc.E.)

Control Zone

Specifies in engineering units an area around the setpoint where the process variable is considered to be at setpoint (no error). When the process variable is within this area, the control output is held steady at the integrator value as determined by tr and Mr. Control Zone is used to reduce valve wear where process dynamics cause output oscillations (hunting) when the process is near its setpoint. (It is enabled with conF-oPr-hLc.E.)

Execute Easy-Tune

EZ?

Causes Easy-Tune to start execution. During execution, the Easy-Tune LED flashes and tunE appears in the green dro. Upon successful completion, the EasyTune LED stops flashing and the green dro no longer displays the tunE mnemonic. If an error or warning condition occurs during execution, the Easy-Tune LED changes to a steady-state-on condition and a mnemonic is displayed in the green dro that identifies the error or warning. Pressing the mode/select push button clears the display. After taking the appropriate corrective action(s), Easy-Tune can be restarted by selecting YeS at the run? prompt in the EZ menu. (It is enabled with conF-oPr-EZ.E.)

Easy-Tune Proportional Band

EPb

Resultant %PB value calculated by Easy-Tune. (It is enabled with conF-oPr-EZ.E.)

0.0

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Section 3. Display Panel 53SL6000 Instruction Manual

Table 3-3. oPEr Menu Selections

Prompt Description Dft

Easy-Tune Reset Time

Etr

Resultant reset time value calculated by Easy-Tune. (It is enabled with conF-oPr-EZ.E.)

Easy-Tune Derivative Time

Etd

Resultant derivative time value calculated by Easy-Tune. (It is enabled with conF-oPr-EZ.E.)

Table 3-4. Operator Enable (oPr) Prompts

(conF Menu → oPr Module)

Prompt Description (see Datalink prompts) Dft

Discrete Input 7 Enable

di7.E

Selections are as follows:

on:

When selected, di7 appears in

the oPEr menu.

oFF:

When selected, di7 does not

appear in the oPEr menu.

Discrete Input 8 Enable

di8.E

Selections are as follows:

on:

When selected, di8 appears in

the oPEr menu.

oFF:

When selected, di8 does not

appear in the oPEr menu.

StEP

StP.E

Selections are as follows:

on:

When selected, StEP appears

in the oPEr menu.

oFF:

When selected, StEP does not

appear in the oPEr menu.

Analog Inputs Enable

Ai.E

Selections are as follows:

on:

When selected, the Ai7 and Ai8 prompts appear in the oPEr menu.

oFF:

When selected, the Ai7 and Ai8 prompts do not appear in the oPEr menu.

ALM.E

Alarm Indicators Enable

Selections are as follows:

on:

When selected, the PL1, PL2 and Adb prompts appear in the oPEr menu.

oFF:

When selected, the PL1, PL2 and Adb prompts do not appear in the oPEr menu.

Pid (Pb, tr, and td Enables)

Pid.E

Selections are as follows:

on:

When selected, the Pb, tr, td, and Mr prompts appear in the oPEr menu.

oFF:

When selected, the Pb, tr, td, and Mr prompts do not appear in the oPEr menu.

0.0

Table 3-4. Operator Enable (oPr) Prompts

(conF Menu → oPr Module)

Prompt Description (see Datalink prompts) Dft

hLc.E

oh, oL, and cZ Enables

Selections are as follows:

on:

When selected, the oh, oL, and cZ prompts appear in the oPEr menu.

oFF:

When selected, the oh, ol, and cZ prompts do not appear in the oPEr menu.

EZ?, EPb, Etr, and Etd Enables

EZ.E

Selections are as follows:

on:

When selected, the EZ?, EPb, Etr, and Etd prompts appear in the oPEr menu.

oFF:

When selected, the EZ?, EPb, Etr, and Etd prompts do not appear in the oPEr menu.

3.9 Display Alphanumerics

Figure 3-12 illustrates all of the alphanumeric char-

acters that can appear in the display prompts.

Figure 3-12. Display Alphanumerics

3.10 Engineer Mode Summary

To facilitate configuration of the controller parameters and path connections, all of the engineer mode prompt paths are illustrated in Figure 3-13.

3-11

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53SL6000 Instruction Manual Section 3. Display Panel

Figure 3-13. Engineer Mode Prompt Path Summary

Page 40

Section 4. Functional Overview 53SL6000 Instruction Manual

4.0 Functional Overview

4.1 Simplified Block Diagram

As shown in Figure 4-1 below, the internal operations of the 53SL6000 Controller can be classified into nine major functional areas. An overview of these functional areas is provided in this section; additional information is provided in Sections 5 through 7.

Although external analog connections to

NOTE:

the controller are two standard inputs, two optional inputs, and one output, there are in fact eight analog input registers (AI1-8) and three analog output (AO1-3) registers available in the controller database. The discrete digital external connections include two standard inputs, two optional inputs, two standard outputs, and two optional outputs. There are, however, eight discrete input database registers (DI1- DO8) and eight discrete output database registers (DO1DO8). Registers not assigned to standard or optional external I/O functions can be loaded with constant values to simulate known process events or hold process values for access through datalink communications or for display.

Analog Inputs 1-4 (AI1-4) - accept the 0/4- 20

mA input signals. Analog inputs 3 and 4 require the universal analog input module. The signal values are stored in the analog registers. There are eight analog input registers, AI1-AI8. Analog input registers AI5-AI8 do not accept external signals, but can be loaded with constant values.

Discrete Inputs 1-4 (DI1-4) - accept voltages

0-1 V or 4-24 V, which are converted to logic levels 1 and 0 respectively. Digital inputs 3 and 4 require the 2DI/2DO module. There are

eight digital input registers, DI1-DI8. Digital input registers DI5-DI8 do not accept external signals, but can be loaded with logic level values 0 or 1.

Characterizer - provides four operating modes,

three of which are used to modify input signal values before being passed on to the analog math function block or control scheme block; the other operating mode generates a ramp and hold output value. The four operating modes are as follows:

Five third order polynomial segments

•

Twelve segment linearizer

•

Setpoint programmer (ramp and hold)

•

Digital-to-Analog converter

•

Math Function Block - provides nine different

equations for analog input signal augmentation. The equations are as follows:

Algebraic

•

Summation

•

Polynomial

•

Power

•

Logarithmic

•

Limiter

•

Selector

•

Linear Gas Flow Compensation

•

Square Root Gas Flow Compensation

•

Figure 4-1. Simplified Controller Block Diagram

4-1

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53SL6000 Instruction Manual Section 4. Functional Overview

Discrete Input Logic Blocks - two input logic

blocks permit discrete input signals to be event gated with internal controller signals according to any one of eight specified logic functions. The eight logic functions are as follows:

A OR B

•

A AND B

•

A XOR B

•

A OR NOT B

•

A AND NOT B

•

NOT A OR B

•

NOT A AND B

•

NOT A XOR B

•

Control Scheme Block - five selectable control

scheme applications that calculate and produce the necessary control output signal for the process. The five control schemes are as follows:

SnGL - Single Loop

•

cASc - Single Station Cascade

•

L.LiM - Low Limiter (High Override)

•

h.LiM - High Limiter (Low Override)

•

in.Ld - Indicator/Loader

•

Discrete Output Logic Blocks - two output logic

blocks that permit internal controller signals to be event gated according to any one of eight specified logic functions (see item 5, Discrete Input Logic Blocks for functions).

Analog Output - there are three analog output

registers, AO1-AO3. Analog output 1 (AO1) is associated with the standard 0-100 output value that produces a 0/4-20 mA signal to drive the final control element or is applied as input to another controller. Analog output registers AO2 and AO3 do not provide external signals, but serve as a loop-back to the math function block and control scheme block (the loop-back path is not shown in the illustration).

Discrete Outputs 1-4 (DO1-4) - there are eight

digital output registers, DO1-DO8. DO1 and DO2 provide outputs that may be used to activate pumps, alarms, etc. Discrete outputs 3 and 4 require the 2DI/2DO module, which provides relay outputs capable of higher current loads than DO1 and DO2. DO3 and DO4 are generally sufficient as the two driver outputs for time proportional or three step output driv-

ers, which are digital outputs used instead of the continuous 0/4-20 mA signal. Digital output registers DO5-DO8 have no associated hardware, but DO7 and DO8 serve as loopback registers to the math function block or input logic blocks (the loop-back path is not shown in the illustration).

4.2 Detailed Block Diagram

A more detailed functional block diagram of the controller is illustrated in Figure 4-2. The illustration depicts processing as divided into analog control (upper half) and discrete digital control (lower half). The nine major functional areas are presented with an emphasis on the available input path selections. Additional information for each of the nine functional areas is provided in Sections 5 through 7.

Analog Inputs 1-8 (AI1-8) - the two standard

(AI1 and AI2) and two optional inputs (AI3 and AI4) are identified. The push buttons next to AI7 and AI8 represent operator access to these registers via the oPEr menu. Access to these registers must be enabled with the conFoPr-Ai.E parameter; otherwise, they will not appear in the oPEr prompt list.

Discrete Inputs 1-8 (DI1-8) - the two standard

(DI1 and DI2) and two optional inputs (DI3 and DI4) are identified. Each DI register has two outputs; one of the outputs is inverted and is indicated with a slash (/) across the connection T-bar. The push buttons next to DI7 and DI8 represent operator access to these registers via the oPEr menu. Access to these registers must be enabled from the conF-oPr-di7.E and conF-oPr-di8.E parameters; otherwise, they will not appear in the oPEr prompt list.

Characterizer - is depicted as a five pin plug-

able element, which can be inserted into one of the track locations of the math function block or control scheme block. It intercepts the signal value before the math function block or control scheme and augments that value as determined by the selected operating mode (except for the programmer mode, which generates an independent signal based on time and configured data). The characterizer output is applied to the math function block or control scheme block. The intercept selections Fnc.A through cS.F are from the ProG-cS-chrA list. As shown in the illustration, the chr.A Fnc.A - Fnc.d selections are path connections to the math function block inputs A-D and the cS.A - cS.F

4-2

FUNC

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Section 4. Functional Overview 53SL6000 Instruction Manual

selections are path connections to the control scheme block inputs A - F.

The digital signal selections ([1] - /do8) are available to characterizer inputs chr.b and chr.c. These inputs are used by the characterizer for the digital-to-analog (dtoA) and programmer (PrGM) modes.

The chr digital output is an indicator available to all of the elements that follow the characterizer in the digital path.

Math Function Block - has four analog inputs

(A-D) and two digital inputs (E and F). Each of the four analog input parameters (Fnc.A Fnc.d) has the same available connection selections for inputs. If Ao2 or Ao3 is selected from the list, then the analog output register contents are fed back as the input into the math function block.

The digital input selections work in a manner similar to the analog input selections: the two digital input parameters (Fnc.E and Fnc.F) have the same prompt list selections ([1] /do8). Discrete outputs do7 and do8 allow for the looped-back digital inputs to the math function block.

The math function block analog output (Fnc) is available for control scheme inputs (cS.A cS.F). The digital output (Fnc) is available for the control scheme block inputs (cS.h - cS.L) and the logic block inputs (LG1.A, LG1.b, LG2.A, and LG2.b).

Discrete Input Logic Blocks (LG1 and LG2) -

parameter inputs to both logic blocks (LG1.A, LG1.b, LG2.A, and LG2.b) have the same parameter prompt list selections ([1] - chr). The outputs of both logic blocks can be accessed by the control scheme block input parameters (cS.h - cS.L), by the LG3.A, LG3.b, LG4.A, and LG4.b parameters of logic blocks LG3 and LG4, and by the do1.i - do8.i parameters of the discrete output registers DO1 - DO8.

Control Scheme Block - the analog cS.A - cS.F

input parameters each have the same prompt list (0.0 - Fnc) and the cS.h - cS.L digital input parameters each have the same prompt list ([1] - LG2). The Ao3 register contents can be loop-back selected by a control scheme block analog input.

The control scheme block analog outputs are as follows:

out - the calculated PID algorithm output or

•

value generated from the output push buttons.

PV - the process variable received on an

•

analog input (usually cS.A). SP - the remote or local setpoint value.

•

dV - the deviation error as determined

•

from the difference between the setpoint and process variable, scaled by parameter conF-cn.1(cn.2)-ir and biased by 50.

The digital outputs are as follows:

Vup - time proportional or positive three

•

step signal. Vdn - negative three step signal.

•

PA1 - loop 1 process alarm 1.

•

PA2 - loop 1 process alarm 2.

•

SWA - is active when auto is selected with

•

the auto/manual push button. Aut - indicates loop 1 is operating in

•

auto mode (use PID output). SWr - is active when remote is selected

•

with the remote/local push button. rMt - indicates loop 1 remote setpoint is

•

active. oVtS - indicates loop 1 output tracking is

•

active (has priority over Aut). SPtS - indicates loop 1 setpoint tracking is

•

active (has priority over rMt). Aut.2 - indicates loop 2 is operating in auto

•

mode (use PID output). PA1.2 - loop 2 process alarm 1.

•

PA2.2 - loop 2 process alarm 2.

•

It is the selected control scheme mode that determines the operator display presentation assignments and push button assignments. This is denoted with all seven push buttons shown in the control schemes illustration (four in the center and three at the bottom of the illustration).

There are also eleven push buttons next to the control schemes illustration that represent operator access to commonly used control module parameters (loop 1 cn.1 parameters and loop 2 cn.2 parameters). These parameters are accessed via the oPEr menu. However, they must first be enabled from the conF-oPr

4-3

Page 43

53SL6000 Instruction Manual Section 4. Functional Overview

module; otherwise, they will not appear in the oPEr prompt list.

Discrete output logic blocks (Logic 3 and 4) -

parameter inputs to both logic modules (LG3.A, LG3.b, LG3.A, and LG3.b) have the same parameter prompt list selections ([1] LG2). The outputs of both logic modules can be accessed by the do1.i - do8.i parameters of the discrete output registers 1 - 8 (DO1 - DO8).

Analog Outputs (AO1-3) - the one analog out-

put associated with the standard hardware is shown at Ao1. The input prompt list (nc - dV) is identical for the Ao1.i - Ao3.i parameters of the analog output registers 1 - 3 (AO1 - AO3). Values in analog output registers AO2 and AO3 can be looped-back to the math function block and/or control scheme block.

Notice, that the input prompt list includes Ai1 Ai8 path connections for analog input re-transmission.

Discrete Outputs (DO0-8) - digital outputs as-

sociated with the standard and optional hardware are shown as DO1, DO2, DO3, and DO4, respectively. The input prompt list (nc - LG4) is identical for the do1.i - do8.i parameters of the digital output registers (DO1 - DO8). Values in discrete output registers DO7 and DO8 can be looped-back into the characterizer and math function block digital inputs. Only the DO8 value can be looped-back into logic blocks 1 and 2 (LG1 and LG2).

Notice, that the input prompt list (nc - LG4) does not include any discrete input path connections; therefore, to re-transmit a discrete input logic condition, it must first pass through one of the input logic modules (LG1 or LG2) which is connected to a discrete output 1-4. For example, to connect DI1 to LG1 and LG1 to DO1:

Many different process control strategies

NOTE:

can be implemented through the interconnecting path variations, the five control schemes, and the large array of configuration prompt selections that are available in the 53SL6000 controller.

However, to expedite configuration, the eight control stra tegies me ntioned i n Section 1 can each be invoked very quickly by using the factory parameter default values and one of the ProG-cS-SchM parameter selections (for example, the factory default values and the cASc prompt from the SchM menu selects Single Station Cascade Cont rol operation with dual PI D control). These eight control strategies are covered in Section 8.

4-4

LG1.M = A OR B

•

LG1.A = di1 (connects DI1 to LG1 input)

•

LG1.b = 0 (so any input on LG1.A is

•

passed through unaltered) do1.i = LG1 (connects DO1 to LG1)

•

FUNC

Page 44

Section 4. Functional Overview 53SL6000 Instruction Manual

4-5

Figure 4-2. Detailed Functional Controller Block Diagram

Page 45

Section 5. Inputs/Outputs (I/O) 53SL6000 Instruction Manual

5.0 Inputs/Outputs (I/O)

5.1 I/O Overview

This section provides functional descriptions and applicable parameter definitions for all of the controller inputs and outputs to include the following:

• Analog Inputs

• Universal Analog Input Module

• Analog Output

• Discrete Inputs

• Discrete Outputs (and 2DI/2DO Module)

• RS-232 and RS-485 Modules

5.2 Analog Inputs

Standard 0-20 mA or 4-20 mA analog input signals are received by the controller through analog input modules 1 and 2 (Ai.1, Ai.2). The input current range is selectable as are other parameters that can be used to apply conditioning to the signal. The measured input value is in engineering units and is stored in the analog register after all signal conditioning defined by the analog module parameters is applied.

The signal conditioning parameters for analog input modules Ai.1 and Ai.2 are defined in Table 5-1. The parameter set is identical for each of the two analog input modules. Table 5-2 lists the analog input registers; the register actually stores the analog value.

Table 5-1. Analog Input Selections

(conF Menu → Ai.1, Ai.2 Modules)

Prompt Description Dft

SQrt

Square Root Signal

Speciifies whether the analog input signal requires square root characterization (as would be the case for a differential pressure transducer across an orifice plate), or linear interpretation. Selections:

Linear interpretation.

Lin:

Square root characterization.

SQrt:

(For SQrt selection, the value of Ai is forced to 0.0 at low in put signal levels [<6.25%] to pre vent large signal oscillations.)

bASE

Base Current

Specifies the signal range corresponding to a 0 - 100% input. Selections:

4-20 mA 0-20 mA

dFLt

Digital Filter

Specifies the time constant in seconds for a first order filter through which the input is processed. The filter dampens the higher frequency signal components usually associated with signal noise. The larger the selected value, the lower the frequency affected and the greater the dampening to the higher frequencies. Selections:

nonE 0.7 12.7 205

0.05 1.5 25.5 410

0.1 3.1 51.1 819

0.3 6.3 102 1638

- 4 mA = 0%, 20 mA = 100%

- 0 mA = 0%, 20 mA = 100%.

Lin

4-20

0.3

Table 5-1. Analog Input Selections

(conF Menu → Ai.1, Ai.2 Modules)

Prompt Description Dft

SPAn

Engineering Span, Engineering Zero

ZEro

These values set the engineering unit representation of the input signal over the input range.

input%



Ai = SPAn

  

100

+ ZEro

 

100.0

0.0

Table 5-2. Analog Input Registers

(ProG Menu → Ai Module)

Prompt Description Dft

Ai1 -

Analog Input Registers 1 - 8

Ai8

Registers Ai1and Ai2 are capable of receiving hardware inputs from modules Ai.1 and Ai.2. All signal shaping (e.g., ZEro, SPAn, SQrt, bASE, dFLt etc.) is performed by the hardware modules before the value is entered into the register. Registers Ai3 - Ai4 can also receive hardware inputs from an installed universal analog input module. Constant values can be entered into registers Ai1 - Ai8 if the span and zero are both set to 0 to prevent overwriting register contents.

5-1

0.0

Page 46

53SL6000 Instruction Manual Section 5. Inputs/Outputs (I/O)

5.3 Universal Analog Input Module

The universal analog input module can process one or two inputs, as determined by the type of option installed. A single channel input module processes one analog input (Ai3) and has one connector. A dual channel input module processes two analog inputs (Ai3 and Ai4) and has two connectors. A module can not be field upgraded from single to dual input.

For proper thermocouple operation in a

NOTE:

dual channel universal input module, both removable connector plugs must be installed in the module.

This option can process high-level, low-level, thermocouple, resistive thermal device (RTD), frequency, and pulse input types. The dual channel version can also accept any mix of these input types at both input connectors. Each input is processed independently, as 160 db isolation is provided . Input signal characterization and shaping are also performed, such as data linearization, cold junction compensation (CJC), first order digital filtering, and engineering unit conversion.

The module plugs into the rear of the controller at the 10 pin option slot A connector. It is secured to the controller case with two screws. (See Figure 2-7.)

An installed universal analog input module loads its status identification code in the conF-SYS-oPtA parameter, as described in Table 5-13 at the end of this book section.

5.3.1 Universal Analog Input Module Parameter Entries

Parameter entries for the module are listed in Tables 5-3 through 5-8. Configuring the module for any of the input types (e.g., Type J thermocouple) requires accessing information from only two of the tables. Table 5-3 is referenced first to correlate the prompt assigned to the input type, followed by one of the remaining five tables for the specific parameters associated with that input type. The prompts that do appear when a universal analog input module is selected in the conF menu of engineer mode represent the last type input that was specified. Selecting the type from Table 5-3 automatically causes the appropriate parameter suite to replace the previous one when the scroll forward/backward push buttons are pressed. (See Section 3 for display panel procedures.)

Table 5-3. Input Type Prompts

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description See

oFF

This selection causes Ani value updating to stop.

1-5V

1 to ± 5 V 0 to 5 V

0-5V 0-80

0 ± 80 mV TC_J

J.tc

K.tc

t.tc

E.tc

r.tc S.tc b.tc

n.tc

c.tc L.tc

u.tc

F.tc

G.tc

d.tc

/E.tc

/S.tc

PL.tc

Pt.85

Pt.91

Pt.92

10.c

53.c

100.c

100.n

120.n

FrQ1 FrQ2 FrQ3

(-200 to +1200°C, -325 to

+2190°F)

TC_K

(-200 to +1370°C, -320 to

+2490°F)

TC_T

(-270 to +400°C, -450 to

+750°F)

TC_E

(-270 to +1000°C, -450 to

+1830°F)

TC_R

(0 to +1765°C, 32 to +3200°F)

TC_S

(0 to +1765°C, 32 to +3200°F)

TC_B

(100 to +1820°C, 215 to

+3300°F)

TC_N

(-200 to +1300°C, -320 to

+2370°F)

TC_C

(0 to +2320°C, 32 to +4200°F)

TC_L

(-200 to +900°C, -320 to

+1650°F)

TC_U

(-200 to +600°C, -325 to

+1110°F)

TC_F

(0 to +1400°C, 32 to +2550°F)

TC_G

(0 to +2320°C, 32 to +4200°F)

TC_D

(0 to +2320°C, 32 to +4200°F)

TC_CHE

+1470°F)

TC_CHS

+2900°F)

TC_PLII

+2540°F)

RTD385, 100 ohm platinum

+850°C, -320 to +1560°F)

RTD3911, 100 ohm platinum

to +850°C, -320 to +1560°F)

RTD3926, 100 ohm platinum

to +870°C, -320 to +1590°F)

RTD4274, 10 ohm coppper

+200°C, -320 to +500°F)

RTD427, 53 ohm copper

+150°C, -55 to +300°F)

RTD427, 100 ohm copper

+260°C, -150 to +500°F)

RTD618, 100 ohm nickel

+180°C, -80 to +350°F)

RTD672, 120 ohm nickel

+273°C, -110 to +520°F)

Frequency Input Frequency Input Frequency Input

(-50 to +800°C, -50 to

(0 to +1600°C, 32 to

(-100 to +1395°C, -140 to

(-50 to

(-100 to

(-60 to

(-80 to

8-100 kHz 5-7

2.5-100 kHz

0.5-30 kHz

(-200 to

(-200

(-200 to

Table

5-8

5-4

5-5

5-6

5-2

Page 47

Section 5. Inputs/Outputs (I/O) 53SL6000 Instruction Manual

Table 5-3. Input Type Prompts

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description See

Delta Pulse Totalize

dtot

incremental sum) 0-100 kHz

r (pulse input,

Table

5-7

Table 5-4. Volt/Millivolt Input Types

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description Dft

Make prompt selection

tYPE

SPAn

ZEro

dFLt

SQrt

5-3. Applicable types are:

0-5V, 1-5V, 0-80 Engineering Span, Engineering Zero

These values set the engineering unit representation of the input signal over the input range.

input

Digital Filter

nonE 4.2 75.0 1200

0.3 9.0 150.0 2400

0.6 18.6 300.0

1.8 37.2 600

Square Root Signal

Lin: SQrt:

(For SQrt selection, the value of Ai is forced to 0.0 at low input signal levels [<6.25%] to prevent large signal oscillations.)



SPAn



100



Linear interpretation.

Square root characterization.

from Table



ZEro

 

1-5V

100.0

0.0

nonE

Lin

Table 5-5. Thermocouple Types

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description Dft

Make prompt selection

tYPE

5-3. Applicable types are: J.tc S.tc V.tc \S.tc K.tc b.tc F.tc PL.tc t.tc n.tc G.tc E.tc c.tc d.tc r.tc L.tc \E.tc

Digital Filter

dFLt

nonE 4.2 75.0 1200

0.3 9.0 150.0 2400

0.6 18.6 300.0

1.8 37.2 600

Temperature Scale

dEG

Input selections are as follows:

Celsius scale.

Fahrenheit scale.

from Table

1-5V

nonE

Table 5-6. RTD Types

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description Dft

Make prompt selection

tYPE

5-3. Applicable types are:

Digital Filter

dFLt

nonE 4.2 75.0 1200

0.3 9.0 150.0 2400

0.6 18.6 300.0

1.8 37.2 600

Temperature Scale

dEG

Input selections are as follows:

c: F:

RTD Termination

rtd

Input selections are as follows:

3.trM:

4.trM:

Pt.85 53.c PT.91 100.c Pt.92 100.n

10.c 120.n

Celsius scale.

Fahrenheit scale.

3 wire.

4 wire.

from Table

1-5V

nonE

3.trM

5-3

Page 48

53SL6000 Instruction Manual Section 5. Inputs/Outputs (I/O)

Table 5-7. Frequency/Pulse Input Types

(conF Menu → Ai.3, Ai.4 Modules)

Prompt Description Dft

Make prompt selection

tYPE

5-3. Applicable types are: FrQ1, FrQ2, FrQ3, dtot.

Engineering Span, Engineering Zero

SPAn

ZEro

These values set the engineering unit representation of the input signal over the input range.

SPAn

(

input

Digital Filter

dFLt

nonE 4.2 75.0 1200

0.3 9.0 150.0 2400

0.6 18.6 300.0

1.8 37.2 600

from Table

ZEro

)

1-5V

100.0

0.0

nonE

Table 5-8. Calibration Constants

If any of these values are accidentally overwritten,

Prompt Description Dft

G.MV

b.cJc

(conF Menu → Ai.3, Ai.4 Modules)

reference the factory calibration sheet provided

with the controller and enter the values again.

The prompt selection

tYPE

Voltage Calibration Constants

biAS

GAin

These two parameters are the zero offset and span constant for the volt input range.

Millivot Calibration Constants

b.MV

These two parameters are the zero offset and span constant for the miilivolt input range.

Cold Junction Compensation Constant

This parameter accounts for the differences between the actual module pin temperature and the temperature measured by the CJC sensor from within the module.

RTD Hardware Compensator

G.rtd

This parameter accounts for the differences in the module’s hardware characteristics between the 3 and 4 wire RTDs.

is cAL. 1-5V

5.4 Analog Output 1 (AO1)

A standard 0-20 mA or 4-20 mA analog signal is transmitted by the controller through analog output 1 (AO1). It is defined as percent output value from 0 to 100.

The single signal conditioning parameter (bASE) for analog output AO1 is defined in Table 5-9. Table 5-10 lists the analog output registers and register input connection paths; the register stores the analog value before it is conditioned (bASE) by hardware and transmitted. Although there are three analog output database locations (AO1 AO3); only the output from AO1 is transmitted externally by the controller. The value contents stored in analog output registers AO2 and AO3 can be looped-back if selected by the input connections of the math function block or control scheme block (only Ao3 for the control scheme block).

Table 5-9. Analog Output Selections

(conF Menu → Ao.1 Module)

Prompt Description Dft

bASE

Table 5-10. Analog Output Registers

Prompt Description Dft

Ao1 -

Ao1.i Ao2.i Ao3.i

Base Current

Specifies the signal range corresponding to a 0 - 100% input. Selections:

4-20 mA 0-20 mA

Analog Output Registers 1 - 3

Ao3

Ao1 is associated with standard output hardware Ao.1. Ao2 and Ao3 provide loop-back to the math function block; Ao2 also provides loop-back to the control scheme block.

Analog Output Connections

Specifies the input connections for the standard analog output Ao1 and analog outputs Ao2 and Ao3. Input selections are as follows:

nc: out: Ai1: Ai2: Ai3: Ai4: Ai5: Ai6: Ai7:

- 4 mA = 0%, 20 mA = 100%

- 0 mA = 0%, 20 mA = 100%.

(ProG Menu → Ao Module)

No connection.

Control scheme out value.

Analog input 1. Analog input 2. Analog input 3. Analog input 4. Analog Input 5.

Analog input 6.

Analog input 7.

4-20

0.0

out

nc nc

5-4

Page 49

Section 5. Inputs/Outputs (I/O) 53SL6000 Instruction Manual

Table 5-10. Analog Output Registers

(ProG Menu → Ao Module)

Prompt Description Dft

Ao1.i Ao2.i Ao3.i

(cont)

Analog Output Connections (cont)

Specifies the input connections for the standard analog output Ao1 and analog outputs Ao2 and Ao3. Input selections are as follows:

Ai8:

Analog input 8.

Fnc:

Function module output.

SP:

Control scheme setpoint

output value

PV:

Control scheme PV output

value

dV:

Control scheme deviation

output value.

out:

Control scheme calculated PID value or manual push button value.

out

nc nc

5.5 Discrete Inputs

There are eight discrete input database locations (di1 - di8). Each of the eight discrete inputs present both, the standard and inverted values. Standard inputs at di1 and di2, and optional inputs di3 and di4 (if the 2DI/2DO option is installed), reflect logic values based on the voltage applied as stated in Table 5-11. Discrete inputs which are not associated with hardware are available for

network or operator input. Discrete inputs di7 and di8 are accessable to the operator via enabled oPEr-oPr-di7 and oPEr-oPr-di8 parameters.

Table 5-11. Discrete Input Selections

(ProG Menu → di Module)

Prompt Description Dft

Discrete Input

di1,

State = 1

di8

voltage (0 to 1 V dc) or closed contact. A low voltage input causes the output to be true (1) and the inverted output (/) to be a 0.

State = 0

voltage (4 to 24 V dc) or open contact. A high voltage input causes the outputs to false (0) and the inverted output (/) to be a 1.

when signal is a low

when signal is a high

5.6 Discrete Outputs

There are eight discrete output database locations (do1 - do8). Standard outputs do1 and do2 and optional outputs do3 and do4 (if the 2DI/2DO option is installed) produce external contact actions in response to the values of the discrete outputs. Discrete outputs not associated with hardware can be accessed by the network. The values stored in dis-

crete outputs d07 and do8 can be looped-back if selected by the path parameters of the characterizer, math function block, or logic blocks 1 and 2 (only do8 for the logic blocks).

If the 2DI/2DO option module is installed, it loads its status identification code in the conF-SYS-oPtb parameter, as described in Table 5-13. The 2DI/2DO module plugs into the rear of the controller at the option slot B connector and is secured to the case with two screws. (See Figure 2-9.)

A typical use of a discrete output is to trigger an annunciator horn at the onset of a process variable alarm.

Table 5-12 lists the parameters contained in the discrete output block.

Table 5-12. Discrete Output Selections

(ProG Menu → do Module)

Prompt Description Dft

Digital Output Connections

do1.i do2.i

Specifies the input connections for

do3.i

digital outputs do1 - do8. Input

do4.i

selections are as follows:

nc:

do5.i do6.i do7.i do8.i

do1-

do8

No connection.

PA1:

cn.1 PL1 active.

PA2:

cn.1 PL2 active.

Vup:

Time proportional, three step

up.

Vdn:

. Three step down.

PA1.2:

cn.2 PL1 active.

PA2.2:

cn.2 PL2 active.

Fnc:

Math function block digital

output.

chr:

Characterizer digital output.

LG1:

Logic block 1 output.

LG2:

Logic block 2 output.

LG3:

Logic block 3 output.

LG4:

Logic block 4 output.

Discrete Output

It is the state value to be applied to the output as specified by inV1- inV8.

PA1 PA2 VuP

Vdn

nc nc nc nc

5-5

Page 50

53SL6000 Instruction Manual Section 5. Inputs/Outputs (I/O)

Table 5-12. Discrete Output Selections

(ProG Menu → do Module)

Prompt Description Dft

inV1 -

Discrete Output Invert 0-on:

inV8

it indicates a value of zero in the corresponding do(1-8) registers and generates an inactive output (typically an open contact).

1-on:

it indicates a value of one in the corresponding do(1-8) registers and generates an active output (typically a closed contact).

1-on

5.7 RS-232 and RS-485 Options

Both, the RS-232 and RS-485 communications options provide network connectivity between a host device, typically a personal computer, and the controller via the Micro-DCI Datalink protocol. Before communications can be established between the host and the controller, both devices must be set for the same data rate and protocol options. Controller communications parameters for network connectivity are provided in the conFSYS module described in Table 5-13. The Micro-DCI Datalink protocol is covered in Appendix C.

The RS-232 or RS-485 communications module plugs into the rear of the controller as shown in Figure 2-12. It is secured to the backplane with a single mounting screw.

Table 5-13. System (SYS) Prompts

(conF Menu → SYS Module)

Prompt Description (see Datalink prompts) Dft

Instrument Addrsss

bAud

It is the address assigned to this controller on the datalink. Valid addresses are from 0 - 31. No two controllers can have the same address on the datalink.

Baud Rate

This value is set to match the data transfer rate of the datalink. Valid menu selections are:

(Datalink)

110 4800 300 9600 600 19.2K 1200 14.4K 2400 28.8K

(Datalink)

9600

Table 5-13. System (SYS) Prompts

(conF Menu → SYS Module)

Prompt Description (see Datalink prompts) Dft

Datalink Enable

dLE

Selections are as follows:

on:

Allows controller datalink

communication.

oFF:

The controller is not permitted to communicate over the datalink.

Datalink Parity

dLP

Selections are as follows:

on:

It indicates parity generation and checking for even parity serial byte protocol is enabled.

oFF:

It indicates no parity protocol.

Datalink Stuffing

dLS

Selections are as follows:

on:

Selects F&P byte stuffing, which inserts a NULL (00) byte after every SOH (7E hex) that is not the beginning of a message. This permits user written communications software to determine the number of bytes to expect in a response message.

oFF:

Disables datalink stuffing.

Not Communications Parameters

Tag Name

tAG

Allows a 10 character tag to be assigned to the controller. Four characters maximum can be displayed at any one time. Using the engineer mode shift right push button, the ten character positions are displayed as follows: 0123 3456 6789 Characters are selected for each position with the scroll forward/backward push buttons.

oPtA Contains an identification code

provided by the module resident in slot A at the rear of the controller case. Codes are as follows:

None.

192:

2DI/2DO module.

193:

Single universal analog input

module.

194:

Dual universal analog input

module.

oPtb Contains an identification code

provided by the module resident in slot B at the rear of the controller case. Codes are the same as for oPtA above.

(Datalink)

b-FP

5-6

Page 51

Section 6. Signal Value Modification 53SL6000 Instruction Bulletin

6.0 Signal Value Modification

6.1 Section Overview

Signal modification includes the altering, adjusting, selecting, or limiting of the analog input signal values and digital input values. Modification affects the numeric value and not the electrical characterisitcs, which are conditioned prior to being loaded into the analog input registers or digital register.

Signal modifications are performed by the characterizer, the math function block, and/or the digital logic blocks. These elements are shown in the detailed controller block diagram, illustrated in Figure 4-2.

6.2 Characterizer

As shown below, the characterizer is depicted as a five pin plugable module. As such, it can be designated with its chr.A path selection parameters to intercept and act upon any one of the four function generator analog inputs (Fnc.A - Fnc.d), or any one of the control scheme’s six analog inputs (cS.A

- cS.F). Two additional digital inputs, selectors chr.b and chr.c, are used in the characterizer to activate or trigger actions based on logic values. Two outputs, one analog and the other digital, produce values based on the mode of operation selected by the chr.M parameter and the K1-K26 constants.

Table 6-1 is a summary of the connection parameters and the assigned applications for constants K1-K26 by operating mode. Detailed descriptions of the characterizer operating modes (third order polynomial, linear segments mode, setpoint programmer, and digital-to-analog converter) are provided in the sections that follow.

Table 6-1. Characterizer Parameters

(ProG Menu → chr Module)

Prompt Description Dft

chr.M

chr.A

chr.b chr.c

Characterizer Mode Select

This parameter is used to select how an analog input is characterized before it is passed-on to the math function block for further augmenting or the control scheme. Characterizer mode selections are as follows:

No characterization

oFF:

performed.

Third order polynomial.

3SEG:

Linear segments mode.

LSEG:

Setpoint programmer.

PGrM:

Digital-to-analog conversion.

dtoA: Characterizer Position Select

Specifies the characterizer connection point at the math function block or control scheme. Selections are as follows:

The characterizer is not used.

oFF:

Function module A input.

Fnc.A:

Function module B input.

Fnc.b:

Function module C input.

Fnc.c:

Function module D input.

Fnc.d:

Control scheme A input.

cS.A:

Control scheme B input.

cS.b:

Control scheme C input.

cS.c:

Control scheme D input.

cS.d:

Control scheme E input.

cS.E:

Control scheme F input.

cS.F: Characterizer b and c Inputs

Specifies connections to the characterizer b and c inputs. Selections are as follows:

Logical one input.

(1):

Logical zero input.

(0):

Discrete input 1 logic value.

di1:

Inverted di1 logic value.

/di1:

Discrete input 2 logic value.

di2:

Inverted di2 logic value.

/di2:

Discrete input 3 logic value.

di3:

Inverted di3 logic value.

/di3:

Discrete input 4 logic value.

di4:

Inverted di4 logic value.

/di4:

Discrete input 5 logic value.

di5:

Inverted di5 logic value.

/di5:

Discrete input 6 logic value.

di6:

Inverted di6 logic value.

/di6:

Discrete input 7 logic value.

di7:

Inverted di7 logic value.

/di7:

Discrete input 8 logic value.

di8:

Inverted di8 logic value.

/di8:

Loop-back do7 register value.

do7:

Inverted loop-back do7

/d07:

Loop-back do8 register value.

d08:

Inverted loop-back do8

/d08:

oFF

(1) (1)

6-1

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Table 6-1. Characterizer Parameters

(ProG Menu → chr Module)

Prompt Description Dft

K01 -

Assignments for K01 through K26 for

K26

the three segment (3SEG) characterizer, linear segment (LSEG) characterizer, the setpoint programmer (PGrM), and the digitalto-analog converter (DtoA) are as follows

3SEG

(executes 5 third order

polynomials):

K01 - K06:

partition the 5 segments.

K07 - K10:

coefficients.

K11 - K14:

coefficients.

K15 - K18:

coefficients.

K19 - K22:

coefficients.

K23 - K26:

coefficients.

LSEG

segments. Each input value must be greater than the previous one):

K01 - K13: K14 - K26:

Ordered segment pairs are K01, K14; K02, K15; etc.

PGrM: K01 - K13:

whole seconds. Negative numbers not permitted.

K14 - K26:

characterizer (per step).

DtoA: K1: K2: K3: K4:

Six endpoints that

Segment 1 (equation 1)

Segment 2 (equation 2)

Segment 3 (equation 3)

Segment 4 (equation 4)

Segment 5 (equation 5)

(13 ordered pairs for 12

input coordinates. output coordinates.

Entered time intervals in

Target analog output from

B input ramp rate (up).

C input ramp rate (down). Lower output limit. Upper output limit.

0.0

6.2.1. 3SEG Mode

The third order polynomial segment characterizer allows the user to define five adjacent segments. Each segment has an independent third order polynomial defining the relationship between the A input value and the analog output value. Whenever the A input value does not fall within any of the five segments, a logical 1 value is produced at the characterizer’s digital output; otherwise, a logical 0 value is present at the digital output. The characterizer analog output value is forced to reflect the value related to the nearest defined segment whenever the A input is outside all defined segments.

The five segments are defined by the constants K1 through K6. The values assigned to these constants must be monotonically increasing, going from K1 to K6, to ensure the segments are adjacent. Constants K7 through K26 are divided into five groups, each with four constants. The group acts as a set of coefficients for an individual segment’s polynomial as given by the equation and table below:

Output = WA

Equation Segment

1 K1-K2 K7 K8 K9 K10 2 K2-K3 K11 K12 K13 K14 3 K3-K4 K15 K16 K17 K18 4 K4-K5 K19 K20 K21 K22 5 K5-K6 K23 K24 K25 K26

+ XA 2 + YA + Z

WX Y Z

This characterizer mode provides the capability to linearize complex curves (e.g., thermocouple curves). A linearization example of an E-type thermocouple (operating range -115° to 1000° C) with the characterizer A input provided in millivolts is as follows:

Eq. Segment

1 K1: -5.90

K2: 0.0

2 K2: 0.0

K3: 13.42

3 K3: 7.0

K4: 36.99

4 K4: 36.99

K5: 61.02

5 K5: 61.02

K6: 76.40

WXYZ

K7:

0.03947 K11:

0.004269 K15:

0.0007227 K19:

0.0002274 K23:

0.0001247

K8:

0.1575 K12:

0.2143 K16:

0.0769 K20:

0.02488 K24:

0.004976

K9:

17.20 K13:

17.01 K17:

15.12 K21:

13.26 K25:

11.95

K10:

0.04199 K14:

0.02144 K18:

9.264 K22:

32.13 K26:

60.8

Note: many of the values shown in this example can not be entered directly at the front display panel due to the limited size of the data entry display; however, the values given are easily loadable via the communications network datalink interface (requires the RS-485 option module).

6.2.2 LSEG Mode

The linear segment characterizer allows the user to define a relationship between the A input and the analog output value via a piecewise linear approximation. The approximation is made up of twelve adjacent line segments. Each line segment endpoints are defined by two pairs of coordinates, requiring thirteen coordinate pairs in all. The coordinate values are stored in characterizer constants K1-K26.

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Section 6. Signal Value Modification 53SL6000 Instruction Bulletin

To ensure the piecewise approximation specifies a realizable function, the values for the coordinate inputs, which are stored in characterizer constants K1 through K13, must be monotonically increasing (each coordinate value is larger than the preceding one). There is no such dependency for the output coordinate values K14 through K26.

Whenever the A input value falls outside all of the line segments, the characterizer’s digital output value is set to a logical 1; otherwise, the digital output value is always a logical 0. The corresponding output value for an A input outside all of the line segments can be determined by extending either the first or the last segment, as required.

An example of coordinate pair constant assignments is illustrated in the following table and figure:

Pair A Input Analog Output

1 K1 = 0.0 K14 = 0.0 2 K2 = 1.0 K15 = 1.0 3 K3 = 2.0 K16 = 4.0 4 K4 = 3.0 K17 = 9.0 5 K5 = 4.0 K18 = 16.0 6 K6 = 5.0 K19 = 25.0 7 K7 = 6.0 K20 = 36.0 8 K8 = 7.0 K21 = 49.0

9 K9 = 8.0 K22 = 64.0 10 K10 = 9.0 K23 = 81.0 11 K11 = 10.0 K24 = 100.0 12 K12 = 11.0 K25 = 121.0 13 K13 = 12.0 K26 = 144.0

6.2.3 PrGM Mode

The characterizer programmer mode allows the user to define an analog output which depends on the oPEr-StEP parameter value, the elapsed time since the current step was entered, the target value of the StEP, and the target value of the previous StEP. A typical application for programmer mode is a setpoint ramp and hold sequence generator.

Thirteen steps can be defined with the characterizer constants K1 through K26. Constants K1 through K13 are configured with the time interval (0-9999 seconds) required for the target value to be reached at each step and constants K14 through K26 are configured with the target analog output values for each of the steps. During each step the characterizer’s analog output ramps from the target value of the previous step to the target value of the current step. The current step target value is reached just as the time interval for that step expires. One exception is the first step, which has no previous target, and therefore, outputs the target value for the entire interval.

The characterizer’s digital output is a logical zero value throughout the execution of the step sequence. At completion of the last (thirteenth) step, the digital value is set to a logical one to indicate completion of the sequence.

The A input is not used in this mode. The two digital inputs, B and C, are used as follows:

The C input forces both the StEP and interval

•

timer values to zero whenever it is a logical zero value.

The B input value specifies whether the inter-

•

val timer is running (B input = logical 1) or stopped (B input = logical 0).

The parameter oPEr-StEP allows the operator to view the current step value and to manually advance or return to any step in the sequence.

A setpoint programmer ramp and hold sequence, followed by a summary table and illustration, follows:

Load K1-K13 with the time duration intervals

•

and load K14-K26 with the desired setpoint value at each interval.

Access chr.M of the chr module and set it to

•

PGrM.

Access chr.A of the chr module and ensure it is

•

set to cS.b.

6-3

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53SL6000 Controller

When engineer mode is exited and run is se-

•

lected, the setpoint will move to the assigned value for the duration of its corresponding time interval.

To view the stepped sequence manually, ac-

•

cess the StEP parameter in the oPEr menu in engineer mode.

After StEP is selected, the current time interval

•

number flashes in the red dro.

Use the scroll forward/backward push buttons

•

to select a new time interval.

After pressing the enter push button, the set-

•

point will jump to a new value corresponding to the time interval number entered.

Time Interval Time Duration Setpoint Value

1 1.0 52.0 2 2.0 70.0 3 1.0 70.0 4 3.0 50.0 5 1.0 30.0 6 3.0 100.0 7 2.0 90.0 8 2.0 90.0

9 3.0 65.0 10 2.0 35.0 11 3.0 25.0 12 2.0 25.0 13 4.0 10.0

output value will ramp down at the rate set by K2 in units/second. The analog output value is kept between the lower and upper limits set in K3 and K4 respectively. Whenever the analog output value is being limited, the digital output will be a logical one; otherwise, it is a logical zero.

The figure below illustrates the relationship between the digital inputs and resulting analog output. The logic output limiting indicator is also shown in the figure.

6.3 Math Function Block

The math function block (shown below) allows the user to choose one of nine algebraic equations with the ProG-Fnc-Fnc.M parameter. These equations are provided to meet a wide range of application requirements. Depending on the equation selected, up to four analog inputs (A - D), two digital inputs (E and F), and six constants (K1 - K6) are used to generate the analog and digital outputs. The path connection parameters (Fnc.A - Fnc.F) allow the user to choose inputs from a variety of analog and digital sources, and align them as required in the fixed equation positions to obtain the desired outputs.

6.2.4 DtoA Mode

In digital-to-analog mode, the logical values of digital inputs B and C are converted into a representative analog output value. The analog value is based on the duration of a logical one value on either input and constants K1 through K4.

When the B input value is a logical one, the characterizer’s analog output value will ramp up at the rate set by K1 in units/second. When the C input value is a logical one, the characterizer’s analog

6-4

Table 6-2 summarizes the ProG-Fnc module parameter selections for the math function block. The equations with brief descriptions follow the table.

Page 55

Section 6. Signal Value Modification 53SL6000 Instruction Bulletin

Table 6-2. Math Function Block Parameters

(ProG Menu → Fnc Module)

Prompt Description Dft

Fnc.M

Fnc.A Fnc.b Fnc.c Fnc.d

Math Function Block Mode Select

This mode parameter is used to select the function to be performed on the inputs of the math function block. Function selections are as follows:

oFF:

No functions selected.

ALG: SuMM: PoLY PoWr LoG: LiM: SEL: LFLo: SFLo:

Math Function Block Analog Inputs A-D

Specifies a connection to the analog A - D inputs of the math function block. Selections are as follows:

1.0:

0.0: Ai1:

value or a constant value previously loaded into the Ai1 register.

Ai2:

value or a constant value previously loaded into the Ai2 register.

Ai3:

value or a constant value previously loaded into the Ai3 register.

Ai4:

value or a constant value previously loaded into the Ai4 register.

Ai5:

loaded into this register.

Ai6:

loaded into this register.

Ai7:

loaded into this register.

Ai8:

loaded into this register.

Ao2: Ao3:

Algebraic. Summation. Polynomial. Exponential.

Logarithmic. Limiting. Four Signal Selector.

Linear Flow.

Square Root Flow.

A constant value input of 1.0. A constant value input of 0.0.

The standard analog input 1

The standard analog input 2

The optional analog input 3

The optional analog input 4

A constant value previously

Loop-back Ao2 register value. Loop-back Ao3 register value.

oFF

1.0

Table 6-2. Math Function Block Parameters

(ProG Menu → Fnc Module)

Prompt Description Dft

Fnc.E

Math Function Block Digital Inputs E and F

Fnc.F

Specifies connections to the digital inputs E and F of the math function block. Selections are as follows:

[1]:

Logical one input.

[0]:

Logical zero input.

di1:

Discrete input 1 logic value.

/di1:

Inverted di1 logic value.

di2:

Discrete input 2 logic value.

/di2:

Inverted di2 logic value.

di3:

Discrete input 3 logic value.

/di3:

Inverted di3 logic value.

di4:

Discrete input 4 logic value.

/di4:

Inverted di4 logic value.

di5:

Discrete input 5 logic value.

/di5:

Inverted di5 logic value.

di6:

Discrete input 6 logic value.

/di6:

Inverted di6 logic value.

di7:

Discrete input 7 logic value.

/di7:

Inverted di7 logic value.

di8:

Discrete input 8 logic value.

/di8:

Inverted di8 logic value.

do7:

Loop-back do7 register value.

/d07:

Inverted loop-back do7

d08:

Loop-back do8 register value.

/d08:

Inverted loop-back do8

K01 -

K01 through K06 are the formula

K06

constants of the math function block. Valid input values for K01 through K06 are -999 to 9999.

[1] [1]

0.0

6.3.1 ALG Mode

The basic algebraic functions (additon, subtraction, multiplication, and division), as well as limited combinations of them, are provided by this equation. The constants K1 through K6 provide a means of scaling the four analog inputs if required.

X =

K1) (B + K

(A +

)

K4 + K5 D + K6

6.3.2 SuMM Mode

The summer allows up to three inputs to be combined into a single multi-component value which may be further modified (multiplicative) by the fourth input. The constants K1 through K6 allow the individual inputs to be scaled to the proper relationship for combining.

X = (K1 A + K2 B + K3 C +

4) (K5 D + K6

)

6-5

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53SL6000 Controller

6.3.3 PoLY Mode

This is a third order polynomial equation which operates on an algebraic combination of the four analog inputs. The constants K1 through K4 are the coefficients for the equation. The constants K5 and K6 allow for some limited scaling of the four analog inputs.

= K4

+ K5



(

)







+ K3

 

  

(

C + K6



+ K2

 

AB + K5



(



C + K6



)



 

)

6.3.4 PoWr Mode

This mode provides a general purpose exponential (power) equation with the four analog inputs assigned in the exponent, base, multiplier, and bias. The constants K1 through K6 provide scaling for all four except the bias term.

(

X = K5C

K1A + K2

[

]

An important use of the exponential equation is calculating flow values using weirs and Parshall flumes as measuring elements. The table below gives the required assignments for three types of weirs: rectangular, cipolletti, and triangular based on the weirs dimensions (Length - feet, height inches, and x - degrees). Analog output is in gallons per minute (gpm).

)

B + K

Power Equation Constants by Weir Type

Constant Rectangular Cipolletti Triangular

Fnc.A hhh Fnc.b 000 Fnc.c h 0 0 Fnc.d 000 K1 111 K2 000

K3 000 K4 1.5 1.5 2.47 K5 -0.6 0 0 K6 3L 3.037L see K6

below

K6 for triangular weirs is as follows:

K6 = 2.42.9

tan

(

[

) ]

0.992

6.3.5 LoG Mode

The logarithm equation produces a base 2 logarithmic value of the algebraic function of the four analog inputs. The constants K1 through K5 provide scaling for the input values. Constant K5 is a multiplier which can be used to convert the base of the logarithm. For example:

Log

= 0.301 Log

(x)

(x) = 0.6932 Log 2 (x

1) (B

(A +

K5 Log 2

 

C + K



2 (x

)

K4 + D



 

6-6

6.3.6 LiM Mode

The limiter generates both an analog and a digital output value. The analog output reflects the scaled A input as long as it does not exceed the scaled B input (upper limit) or fall below the scaled C input (lower limit). If either is exceeded, the digital output will be a logical one value; otherwise, it is a logical 0 value.

if K1A +

else if K

else

≥ K3B = K4 then X = K3B + K4, Y = 1

C + K6 ≥ K1A + K2 then X = K5C + K6, Y = 1

X = A Y = 0

Page 57

Section 6. Signal Value Modification 53SL6000 Instruction Bulletin

6.3.7 SEL Mode

The selector allows one of four analog input values to be passed to the analog output based on the values of the two digital inputs (E and F). Three of the analog inputs (B, C, and D) can be scaled by the constants K1 through K6. The switching diagram below the equation shows how the digital inputs control the value passed to the analog output.

if E = 1 and F = 1, then X = K5D + K6

if E = 1 and F = 0, then X = K3C + K4

if E = 0 and F = 1, then X = K1B + K2

if E = 0 F

0, then X =

K2 Input if Acoustic Ratio is Very Low

K2 0

(Y = 1.0)

6.3.8.1 Linear Gas Flow Compensation (LFLo) Equation

−

X = K1A [ K3

A is actual CFM volumetric flow B is absolute pressure C is temperature (in R or K)

C + K5

+ K6

]

6.3.8.2 Square Root Gas Flow Compensation (SFLo) Equation

X = K1 [ 1 − K2

A is measured differential pressure B is absolute pressure C is temperature (in R or K)

√



A [ K

]

B − K4

C + K5

]

6.3.8 Gas Flow Compensation Equations

Pressure and temperature compensated gas flow equations for both linear and square root flow elements are provided to compute the mass flow or "standard volume" flow of a gas. The equations handle both perfect and imperfect gases. Three inputs representing A - flow (differential pressure), B - absolute pressure, and C - absolute temperature are converted to a flow output signal based on a set on parameters K1 through K6.

Imperfect Gases in Operating Zone

K1 Overall meter coefficient K2 Slope of Y factor line (negative) K3 Coefficient in density equation K4 Pressure bias in density equation K5 Temperature bias in density equation K6 Density bias in density equation

K3-K6 Inputs for Gas that Behaves as

Perfect Gas in Operating Zone

K3 Molecular weight/Universal Gas

Constant, R K4 0 K5

460° R or 273° K K6 0

6.4 Logic Blocks 1, 2, 3, and 4

As shown in the figures below, each logic block 1,2,3, and 4 can perform a selected mode of operation on two input variables A and B to produce an output at LG(1-4). Inputs A and B, as well as the output, are all logic values (0/1). The applicable modes of operation and the selectable inputs for all four logic blocks are provided in Table 6-3 and the outputs produced by the various operating modes are summarized in Table 6-4.

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Table 6-3. Logic Block Parameters

(ProG Menu → LG Module)

Prompt Description Dft

LG1.M LG2.M LG3.M LG4.M

LG1.A LG1.b LG2.A LG2.b

Logic Blocks 1 - 4 Mode Select

These mode parameters are used to select the logical operation to be performed on the inputs of the logic blocks. Function selections for each block are as follows:

oFF:

No logical operation

performed.

or:

A OR B.

/or:

NOT A OR B.

And:

A AND B.

/And:

NOT A AND B.

Xor

: A EXCLUSIVE OR B.

/Xor:

NOT A EXCLUSIVE OR B.

or/:

A OR NOT B.

And/:

A AND NOT B.

A and B Inputs for Logic Blocks 1 and 2

Specifies the connections for the A and B inputs of logic blocks 1 and 2. Input selections are as follows:

[1]:

Logical one input.

[0]

: Logical zero input.

di1:

Discrete input 1 logic value.

/di1:

Inverted di1 logic value.

di2:

Discrete input 2 logic value.

/di2:

Inverted di2 logic value.

di3:

Discrete input 3 logic value.

/di3:

Inverted di3 logic value.

di4:

Discrete input 4 logic value.

/di4:

Inverted di4 logic value.

di5:

Discrete input 5 logic value.

/di5:

Inverted di5 logic value.

di6:

Discrete input 6 logic value.

/di6:

Inverted di6 logic value.

di7:

Discrete input 7 logic value.

/di7:

Inverted di7 logic value.

di8:

Discrete input 8 logic value.

/di8:

Inverted di8 logic value.

do7:

Loop-back do7 register value.

/d07:

Inverted loop-back do7

d08:

Loop-back do8 register value.

/d08:

Inverted loop-back do8

Fnc:

Math function block digital

output.

chr:

Characterizer output.

oFF oFF oFF oFF

[1] [1] [1] [1]

Table 6-3. Logic Block Parameters

(ProG Menu → LG Module)

Prompt Description Dft

LG3.A LG3.b LG4.A LG4.b

A and B Inputs for Logic Blocks 3 and 4

Specifies the connections for the A and B inputs of logic blocks 3 and 4. Input selections are as follows:

[1]:

Logical 1 input.

[0]:

Logical 0 input.

PA1:

cn.1 AL1 active.

PA2:

cn.1 AL2 active.

Vup:

Floating control valve up.

Vdn:

Floating control valve down.

SWA:

Auto switch.

SWr:

Remote switch.

Aut:

Loop 1 is in auto control.

rMt:

Remote.

oVtS:

Output track status.

SPtS:

Setpoint track status.

PA1.2:

cn.2 AL1 active.

PA2.2:

cn.2 AL2 active.

Aut.2:

Loop 2 is in auto control.

Fnc:

Math function block digital

output.

chr:

Characterizer output.

LG1:

Logic block 1 output.

LG2:

Logic block 2 output.

[1] [1] [1] [1]

Table 6-4. Discrete Logic Block Functions

A OR B (or) A AND NOT B (And/)

ABLG1-4ABLG1-4

011010 111110 000000 101101

A AND B (And) NOT A OR B (/or)

ABLG1-4ABLG1-4

010010 111110 000001 100100

A XOR B (Xor) NOT A AND B (/And)

ABLG1-4ABLG1-4

011011 110110 000001 101101

A OR NOT B (or/) NOT A XOR B (/Xor)

ABLG1-4ABLG1-4

010010 111111 001001 101100

6-8

Page 59

Section 7. Control Scheme Block 53SL6000 Instruction Manual

7.0 Control Scheme Block

7.1 Control Scheme Block

The control scheme block, which is the primary functional element of the controller, provides the capability to select and implement any one of five control schemes. Each control scheme is the basic building block for many control strategies. The five control schemes are described as follows:

• SnGl - For control strategies requiring single loop standard PID functional capabilities.

• cASc - For control strategies requiring tighter control of processes using dual PID loops in a cascade configuration.

• L.LiM - For control strategies with two interdependent loops where one of the two variables must not exceed a safe low limit.

• h.LiM - For control strategies with two interdependent loops where one of the two variables must not exceed a safe high limit.

• in.Ld - For applications that require an auto/manual selector, or a manual loader, or a two/three variable indicator with process variable re-transmission capabilities

Also covered are all control scheme related parameters and input selections.

7.2 Control Scheme Inputs

The five control schemes with their inputs are illustrated in Figure 7-1. In the figure, the L.LiM and h.LiM control schemes are shown in the same illustration, as these two control schemes have the same inputs. Each control module (cn.1, cn.2) is also identified in the figure by loop number.

The A-F inputs loaded via the cS.A - cS.F input selectors for all five of the control schemes are dedicated to analog signals. These analog signals can come from the analog inputs or the math function block and may be modified with the characterizer block. The h-L inputs loaded via the cS.h cS.L input selectors are the control signal enables that cause the control schemes to perform specific functions (e.g., AE for auto enable, RE for remote enable, etc.). The control signals are digital logic values which can come from the discrete inputs, the math function block, or the logic blocks.

When used in conjunction with the path selections, configuration parameters, characterizer block, math function block, discrete logic blocks 1-4, and I/O blocks, the five control schemes are able to address most standard control applications. Each of the control schemes, with the exception of the indicator/loader (in.Ld), have a setpoint generator with deviation calculator, a PID algorithm, and an auto/manual output selector. The in.Ld control scheme does not implement the setpoint generator or the PID algorithm, as its primary functions are signal display, selection, signal re-transmission, and manual output control.

Control scheme information presented in this section covers the cS.A - cS.L input signal selectors for each of the control schemes, the control scheme logic, the three major parts (SP generator, PID, A/M selector) of a control scheme with SnGL, cASc, L.LiM, and h.LiM exceptions noted, and the in.LD control scheme.

7.3 Control Scheme Control Signals

Table 7-1 describes the operations for the logic control signals contained in control modules cn.1 and cn.2. These signals are derived from both, digital input logic values and push button. They control analog signal switches which in turn affect the operations and thus the outputs of the control modules. Also provided, is Figure 7-2, which illustrates the interrelationships between digital inputs, push buttons entries, control scheme switches, and other control signals. As shown in the figure, the control signal priorities are oVtS having precedence over Aut, and SPtS having precedence over rMt. The control signals are depicted in hexagons. Other analog signal switches are controlled by the conF-cn.1(cn.2) module parameters, which are depicted as circled inputs; and the ProG-cS module parameters, which are depicted as diamond inputs.

7-1

Page 60

7-2

53SL6000 Instruction Manual Section 7. Control Scheme Block

Figure 7-1. Input Signal Designators by Control Scheme

Page 61

Section 7. Control Scheme Block 53SL6000 Instruction Manual

Table 7-1. Control Signal Descriptions

Signal Description

Aut

Auto Status

For SnGL, cASc, L.LiM, and h.LiM control schemes, Aut selects the PID algorithm result instead of the output push buttons to be directed to the control scheme’s primary output (out).

In the in.Ld scheme, the B input scaled by conF-cn.1(cn.2)-K1 and conF-cn.1(cn.2)b1 is used in place of the PID algorithm result as the primary output (out).

For the Aut signal to become active, the H input must be a logical one value and the A/M push button activated. When the Aut signal is active, the automatic indicator LED lights and the manual indicator LED is off.

When the H input is not a logical one, and the A/M push button is activated, the automatic indicator LED will flash while the manual indicator LED will remain lit.

Aut.2

oVtS

Auto Status (Loop 2)

For cASc, L.LiM, and h.LiM control schemes, Aut.2 selects the loop 2 PID algorithm result instead of the loop 2 output push buttons to be used as the loop 2 output which is applied to loop 1.

The Aut.2 signal is available as a digital output from the control scheme block.

The Aut.2 signal is activated by the loop 2 A/M push button. When Aut.2 is active, the loop 2 automatic indicator LED and the manual indicator LED is off.

Output Track Status

For all control schemes, oVtS selects the D input value to be directed to the control scheme’s primary analog output (out), thus bypassing the PID and output push button values.

Table 7-1. Control Signal Descriptions

Signal Description

oVtS.2

Output Track Status (Loop 2)

For the cASc control scheme, oVtS.2 forces the loop 2 (primary) output to match the loop 1 (secondary) setpoint whenever loop 2 is not controlling the setpoint of loop 1. This provides for bumpless transfer from local or setpoint tracking to remote setpoint (cascade) operation.

When the oVtS.2 signal is active, it is indicated with a flashing loop 2 manual LED.

oVtS.2 does not apply to other control schemes and is forced to an inactive value.

rMt

Remote Setpoint Status

Remote setpoint status selects the setpoint from a source other than the setpoint push buttons. For the SnGL control scheme, this source is the B input. For the cASc control scheme, the source is the output of loop 2. For the L.Lim and h.LiM control schemes, the source is the conF-cn.1-bi parameter (conF-cn.1-K1 =

0.0), which can be thought of as a fixed secondary setpoint.

The rMt signal is available as a digital output from the control scheme block. For the rMt signal to become active, the J input must be a logical one value and the R/L push button activated (in remote R). When the rMt signal is active, the remote indicator LED lights and the local indicator LED is off.

When the J input is not a logical one and the A/M push button is activated, the remote indicator LED will flash and the manual indicator will remain lit.

The output slew rate (oSr), and when hard manual limiting is selected (hML), the output high (oh) and output low (oL) limit parameters are applied.

When the oVtS signal is active, it is indicated with a flashing manual LED.

The oVtS signal is also available as a digital output from the control scheme block. The oVtS signal is simply the inverse value of the control scheme K input.

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53SL6000 Instruction Manual Section 7. Control Scheme Block

Table 7-1. Control Signal Descriptions

Signal Description

SPtS

Setpoint Track Status

For the SnGL, cASc, L.LiM, and h.LiM control schemes, SPtS selects the StV value to be used for the setpoint, thus bypassing the remote setpoint and setpoint push button values.

The value of StV follows the A input when process variable tracking (PVt) is selected; otherwise, it is a fixed configurable value.

The setpoint slew rate (SSr) and the setpoint high and low limit (sh, sL) paramerters are applied.

When the SPtS signal is active, it is indicated with a flashing local LED.

The SPtS signal is also available as a digital output from the control scheme block. The SPtS signal is simply the inverse value of the L input when there is no process variable track.

SPtS.2

When process variable tracking is selected, SPtS is active whenever oVtS is active or when Aut is not active.

Septoint Track Status (Loop 2)

For cASc, L.LiM, and h.LiM control schemes when process variable tracking (PVt.2) is selected for the primary (cASc) or limiting (L/h.LiM) loop (loop 2), SPtS.2 selects the B input as the setpoint value for the primary/limiting loop instead of the loop 2 setpoint push buttons.

SPtS.2 is simply the inverse of Aut.2 with the L.Lim and h.LiM control schemes.

For the cASc control scheme, SPtS.2 is active whenever the primary loop is not controlling the setpoint of the secondary loop (loop 1), or whenever the primary loop is not in automatic operating mode.

When the SPtS.2 signal is active, it is indicated with a flashing loop 2 local LED.

SPtS.2 does not apply to the SnGL or the in.Ld control schemes or when process variable tracking (PVt.2) is not active in loop 2, in which case it is forced to an inactive value.

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Figure 7-2. Control Signal Logic Paths

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53SL6000 Instruction Manual Section 7. Control Scheme Block

7.4 Signal Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes

Figure 7-3 is a graphical representation of the control scheme block as it applies to the SnGL, cASc, L.LiM, and h.LiM control schemes. The hexagons in the figure are the control signal outputs from Figure 7-2. They enable analog signal switch paths that affect operation of the control scheme. Other analog signal switches are controlled by the conF-cn.1(cn.2) module parameters, which are depicted as circled inputs; and the ProG-cS module parameters, which are depicted as diamond inputs.

Figure 7-3 contains both, the cn.1 and cn.2 control loop modules. The upper half of the diagram is for cn.2 and the lower half is for cn.1. Each half contains three distinct functional areas:

Setpoint Generator with Deviation Calculator

(SP-PV) - It controls setpoint selection (local push buttons, remote setpoint [cn.1 only], or setpoint tracking) and applies the setpoint high/low limits and setpoint slew rate. It calculates the deviation (SP-PV) to determine the error value that is passed on to the PID after control zone modification. It generates process or deviation alarms, and also drives the setpoint display bar, setpoint dro, PV display bar, and PV dro.

PID - It uses the deviation and process vari-

able values as determined by direct or reverse control action to apply the proportional, integral, and derivative actions; and augments the result with any additive feed forward (input). The integral term allows both, internal and external E input feedback paths. Finally, it applies the output high/low limits to the result.

Auto/Manual Output Selector (OUT) - It allows

the control output (out) to be selected from one of the three sources: PID result, output push buttons, or output tracking (D input). It also applies the output high/low limits when indicated by the conF-cn.1(cn.2)-hML parameter to the final result. Both, an analog (out) and dual digital (VuP, Vdn) output are provided.

The cn.1 and cn.2 modules are very similar; however, cn.1 also has the conF-cn.1-SPM (setpoint mode) path enable parameter. Its purpose is to select between the ratio (K-SP) and standard (Std) setpoints.

7.4.1 Setpoint (SP-PV) Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes

The control scheme setpoint (SP-PV) paths are depicted in Figures 7-4 through 7-9. These figures are partials of Figure 7-3. Unless specifically required by the example (e.g., SPM = K-SP, for the remote ratio setpoint example in Figure 7-6), the parameter path settings are arbitrary (e.g., SPM can be set for standard [Std] or ratio [K-SP] setpoint in the other examples). The control scheme setpoint path figures are as follows:

• Figure 7-4. Common Setpoint Path Logic

• Figure 7-5. Local Standard (Std) Setpoint

Path

• Figure 7-6. Remote Ratio Setpoint Path

• Figure 7-7. STV Setpoint Tracking

• Figure 7-8. PVT Setpoint Tracking

• Figure 7-9. cASc Control Scheme Setpoint

Path

7.4.2 PID Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes

The control scheme PID paths are depicted in Figures 7-10 through 7-12. These figures are partials of Figure 7-3. Unless specifically required by the example, the parameter path settings are arbitrary (e.g., rSW can be set for direct [dir] or reverse [rEV]). The control scheme PID path figures are as follows:

• Figure 7-10. Pb, td, and tr PID Paths

• Figure 7-11. Pb, td, tr, and FF PID Paths

• Figure 7-12. Pb, td, tr, and FF PID Paths with

EXrF

7.4.3 OUT Paths for the SnGL, cASc, L.LiM, and h.LiM Control Schemes

The control scheme OUT paths are depicted in Figures 7-13 through 7-16. These figures are partials of Figure 7-3. Unless specifically required by the example, the parameter path settings are arbitrary (e.g., rSV can be set for direct [dir] or reverse [rEV]). The control scheme OUT path figures are as follows:

• Figure 7-13. Output Tracking Path

• Figure 7-14. Auto Output Path

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

• Figure 7-15. Manual Output Path

• Figure 7-16. Auto Digital Output Path

7.5 Signal Paths for the in.Ld

Control Scheme

The indicator/loader (in.Ld) control scheme paths are depicted in Figures 7-17 through 7-20. The hexagons in the figures are the control signal outputs from Figure 7-2. They enable analog signal switch paths that affect operation of the control scheme. Other analog signal switches are controlled by the conF-cn.1 module parameters, which are depicted as circled inputs; and the ProG-cS module parameters, which are depicted as diamond inputs. Unless specifically required by the example, the parameter path settings are arbitrary (e.g., rSV can be set for direct [dir] or reverse [rEV]). The in.Ld control scheme path figures are as follows:

• Figure 7-17. in.Ld Control Scheme Alarmed Variable Input

• Figure 7-18. in.Ld Control Scheme Auto Input with Digital Output

• Figure 7-19. in.Ld Control Scheme Output Tracking

• Figure 7-20. in.Ld Control Scheme Manual Output

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53SL6000 Instruction Manual Section 7. Control Scheme Block

Figure 7-3. SnGL, cASc, L.LiM, and h.LiM Signal Paths

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-4. Common Setpoint Logic Paths

Figure 7-5. Local Standard (Std) Setpoint Path

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53SL6000 Instruction Manual Section 7. Control Scheme Block

Figure 7-6. Remote Ratio Setpoint Path

7-10

Figure 7-7. StV Setpoint Tracking

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-8. PVt Setpoint Tracking

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53SL6000 Instruction Manual Section 7. Control Scheme Block

7-12

Figure 7-9. cASc Control Scheme Setpoint Path

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-10. Pb, td, and tr PID Paths

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53SL6000 Instruction Manual Section 7. Control Scheme Block

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Figure 7-11. Pb, td, tr, and FF PID Paths

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-12. Pb, td, tr, and FF PID Paths with EXrF

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53SL6000 Instruction Manual Section 7. Control Scheme Block

7-16

Figure 7-13. Output Tracking Path

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-14. Auto Output Path

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53SL6000 Instruction Manual Section 7. Control Scheme Block

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Figure 7-15. Manual Output Path

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-16. Auto Digital Output Path

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53SL6000 Instruction Manual Section 7. Control Scheme Block

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Figure 7-17. in.Ld Control Scheme Alarmed Variable Input

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-18. in.Ld Control Scheme Auto Input with Digital Output

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53SL6000 Instruction Manual Section 7. Control Scheme Block

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Figure 7-19. in.Ld Control Scheme Output Tracking

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Figure 7-20. in.Ld Control Scheme Manual Operation

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53SL6000 Instruction Manual Section 7. Control Scheme Block

7.6 Control Scheme Parameters

Table 7-2 provides the control scheme ProG-cS module parameters. These parameters set the basic operation of the control scheme block and determine the input signal sources. Whenever these parameters are edited, control operation is turned off as when any other ProG menu parameter is edited.

Table 7-2. Control Scheme Parameters

(ProG Menu → cS Module)

Prompt Description Dft

SchM

cS.A cS.b cS.c cS.d cS.E

cS.F

Control Scheme

This is a mode switch used to select the control scheme. Control scheme selections are as follows:

Single loop control.

SnGL:

Cascade control.

cASc:

Low limiter (high override)

L.LiM:

control.

High limiter (low override)

h.LiM:

control.

Indicator/Loader operation.

in.Ld: Control Scheme cS.A - cS.F Input

Specifies connections to the cS.A cS.F inputs of the control scheme. Input selections are as follows:

A constant value input of 0.0.

The standard analog input 1

Ai1:

value or a constant value previously loaded into the Ai1 register.

The standard analog input 2

Ai2:

value or a constant value previously loaded into the Ai2 register.

The optional analog input 3

Ai3:

value or a constant value previously loaded into the Ai3 register.

The optional analog input 4

Ai4:

value or a constant value previously loaded into the Ai4 register.

A constant value previously

Ai5:

loaded into this register.

A constant value previously

Ai6:

loaded into this register.

A constant value previously

Ai7:

loaded into this register.

A constant value previously

Ai8:

loaded into this register.

Looped-back value from A03

A03:

The function generator

Fnc:

analog output.

SnGL

Ai1 Ai2

0.0

Ai7

0.0

Table 7-2. Control Scheme Parameters

(ProG Menu → cS Module)

Prompt Description Dft

PVt

Process Variable Tracking

Specifies whether the setpoint should be forced to match the current process variable cS.A input when loop 1 is not in automatic control. When PVt is set to YES, the setpoint automatically tracks the process variable whenever loop 1 is in manual or forced output operating mode (output tracking). Process variable tracking eliminates process bumps when switching to automatic from manual or forced output (output tracking) operation.

doFb

PVt.2

Digital Output Feedback

When set to YES, it enables the valve position value from the slide wire to be displayed in the yellow dro. This parameter is applicable for proportional speed floating control output.

EXrF

External Reset Feedback

When set to YES, the PID reset value comes from an external source via the control scheme cS.E input. When set to no, the PID reset value is feedback from the control scheme output.

Process Variable Tracking 2

Specifies whether the setpoint should be forced to match the current process variable cS.b input when loop 2 is not in automatic control. When PVt.2 is set to YES, the setpoint automatically tracks the process variable whenever loop 2 is in manual or forced output operating mode (output tracking). Process variable tracking eliminates process bumps when switching to automatic from manual or forced output (output tracking) operation.

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Table 7-2. Control Scheme Parameters

(ProG Menu → cS Module)

Prompt Description Dft

cS.h

Control scheme cS.h - cS.L Digital

cS.J

Inputs

Specifies path connections to the

cS.K cS.L

cS.h - cS.L control scheme digital inputs. Selections are as follows:

Logical one input.

(1):

Logical zero input.

(0):

Discrete input 1 logic value.

di1:

Inverted di1 logic value.

/di1:

Discrete input 2 logic value.

di2:

Inverted di2 logic value.

/di2:

Discrete input 3 logic value.

di3:

Inverted di3 logic value.

/di3:

Discrete input 4 logic value.

di4:

Inverted di4 logic value.

/di4:

Discrete input 5 logic value.

di5:

Inverted di5 logic value.

/di5:

Discrete input 6 logic value.

di6:

Inverted di6 logic value.

/di6:

Discrete input 7 logic value.

di7:

Inverted di7 logic value.

/di7:

Discrete input 8 logic value.

di8:

Inverted di8 logic value.

/di8:

Function generator output.

Fnc:

Characterizer output.

chr:

Logic 1 module output.

LG1:

Logic 2 module output.

LG2:

FiX

Function Index

This parameter contains a 001 when the controller is running and a 000 when it is stoppped. Before configuring the controller, the database can be defaulted to the factory settings by entering a 098 into this parameter.

(1) di2

/di1

(1)

000

7.7 Control Loop Parameters

Table 7-3 lists the conF-cn.1(cn.2) configuration parameters for both control loop modules. Some parameters are not applicable to cn.2 and are so noted.

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

AiX

Alarm Index

Selects the type of process alarm monitoring to be performed in the control loop. Limit trip points are set in PL1 and PL2 and alarm conditions are signaled by PA1 and PA2 respectively. Selections:

h/L:

oFF: h/- :

-/L:

h/hh:

L/LL:

dEV:

PL1

Process Limit 1

Specifies the process or deviation value which triggers the alarm associated with PA1 as determined by AiX.

PL2

Process Limit 2

Specifies the process or deviation value which triggers the alarm associated with PA2 as determined by AiX.

Adb

Alarm Deadband

Proportional Band (see Section 9.2)

Specifies the percent of process deviation from setpoint over the control range (ir) required to generate a full scale output signal. For a detailed discussion on control and tuning, see Section 9. Values should be limited between 2 to 1000%.

high/low alarms (PA1 active when PV > PL1; PA2 active when PV < PL2). no alarming performed. high alarm only (PA1 active when PV < PL1. low alarm only (PA2 active when PV < PL2).

high/high-high alarms (PA1 active when PV > PL1; PA2 active when PV > PL2). low/low-low alarms (PA1 active when PV < PL1; PA2 active when PV < PL2. PA1 active when PV-SP>PL1 PA2 active when PV-SP<PL2)

cn.1,

oFF

cn.2

100.0

2.000

100.0

h/L for

for

0.0

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53SL6000 Instruction Manual Section 7. Control Scheme Block

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

Reset Time (see Section 9.3)

Specifies the time in minutes required for additional corrective response equivalent to the proportional response (integral action). For a detailed discussion on control and tuning, see Section

9. Values should be limited between 0.02 and 200 minutes /repeat. A value of 0.0 turns integral action off.

Derivative Time (see Section 9.4)

Manual Reset

This value determines the position of the output element (e.g., valve) when the controller is in automatic mode and the error is zero. It is only in effect when tr is zero.

Output High Limit

Specifies in percent the maximum allowable control output during automatic operation. This limit also affects outputs during manual operations when hard manual limits are turned on.

Output Low Limit

Specifies in percent the minimum allowable control output during automatic operation. This limit also affects outputs during manual operations when hard manual limits are turned on.

oSr

Output Slew Rate

Specifies in percent per second the maximum allowable rate of control output change during automatic operation. A value of 0.0 indicates that the control output rate of change is not limited. Slew values less than 2.0 may experience decreased timing accuracy.

hML

Hard Manual Limits

Specifies whether the output high/low limits affect the output during manual operations. Selections:

: control output is not limited

oFF

on:

during manual operations. control output is limited between output high limit and output low limit during manual operations.

50.00

100.0

0.0

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

MFd

Manual Fallback Disable

Selections are as follows:

On allows the controller auto/

on:

manual selector to remain un changed if power is removed.

If oFF, the controller always

oFF:

powers up with the selector in the manual position.

Instrument Range,

iLr

Instrument Lower Range

These values, given in engineering units, define the vertical bar displays end points and establish the width of the proportional control band. This allows the control range to be set independent of the process variable range.



(

iLr

%PV = 100

%SP = 100

(For the in.Ld control scheme, the ir and iLr values scale the PV1 bar.)

Setpoint High Limit

Specifies the maximum allowable control setpoint in engineering units. It is applied to all setpoint sources; therefore, affecting remote setpoint, local setpoint, and tracking (safety) setpoint. (For the in.Ld control scheme, the Sh value is the instrument range - ir, for the PV2 bar.) (See ir/iLr above.)

Setpoint Low Limit

Specifies the minimum allowable control setpoint in engineering units. It is applied to all setpoint sources; therefore, affecting remote setpoint, local setpoint, and tracking (safety) setpoint. (For the in.Ld control scheme, the SL value is the instrument lower range iLr, for the PV2 bar.) (See ir/iLr above.)

−







(

 

−

iLr

)



)

 

  

oFF

100.0

0.0

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

SSr

Setpoint Slew Rate

Specifies in engineering units per second the maximum allowable rate of setpoint change (or PV2 rate of change for the in.Ld control scheme). When employed, the green bar represents the setpoint as it is applied to control (slew limited), while the green dro represents the target setpoint value. A value of 0.0 indicates that the setpoint rate of change is not limited. Slew values less than 2.0 may experience decreased timing accuracy.

StV

Setpoint Track Value

Specifies in engineering units the desired setpoint when the cS.L input (SWSt) is 0 and the PVt (Process Variable Tracking) path enable is set to no. Using cS.L as the selector control allows the setpoint track value to be treated as either a safety value or a fixed secondary setpoint value. When PVT is set to YES and the controller is not operating in auto (PID output), the setpoint track value is automatically loaded with the current process variable on the cS.A input (cS.b input for loop 2). This provides bumpless transfer from manual to auto operation or from output tracking to auto operation because the setpoint is forced to match the PV before the switch to auto is made.

SPM (cn.1 only)

Setpoint Mode Select

Determines the operation of the setpoint push buttons when remote setpoint operation is selected. Selections:

Std:

with the R/L push button..

K-SP:

Remote Setpoint Ratio

This parameter and Remote Setpoint Bias (b1) allow the remote setpoint input to be modified prior to input at the setpoint generator.

setpoint push buttons have no affect when R is selected

setpoint push buttons modify K1( ratio) value when R R is selected with the R/L push button.

)

(

RSP

0.0

Std

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

Remote Setpoint Bias

This parameter and Remote Setpoint Ratio (K1) allow the remote setpoint to be modified prior to input at the setpoint generator.

(

)

RSP

Control Zone

Specifies in engineering units an area around the setpoint where the process variable is considered to be at setpoint (no error). When the process variable is within this area, the control output is held steady at the integral value as determined by tr and Mr. Control Zone is used to reduce valve wear where process dynamics cause output oscillations (hunting) when the process is near its setpoint.

rSW

Reverse Control Action

Specifies the output response required to correct for process error. Selections:

dir:

reV:

Decimal Point Location

Fixes the location of the decimal point in each dro for the operator display. Selections:

PPPP:

PPP.d:

PP.dd:

P.ddd:

output must increase to eliminate a positive error (PV-SP). output must decrease to eliminate a positive error (PV-SP).

values between -999 and

9999. values between -99.9 and

999.9. values between -9.99 and

99.99. values between -.999 and

9.999.

PPP.d

0.0

rEV

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53SL6000 Instruction Manual Section 7. Control Scheme Block

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

rSv

Reverse Valve

(cn.1

Specifies whether 100% output should be displayed in the output

only)

(yellow) dro as 100% or 0%. This allows the output dro to be set to correspond to a preferred valve representation of output. Selections:

dir:

rEV

MMt

Minimum Manual Jog Time

(cn.1

Designates the mode of manual

only)

operation associated with the VuP and Vdn logic signals. When MMt = 0, VuP and Vdn are always a pulse width modulated (PWM) representation of the control OUT signal. The PWM period is determined by the dcP parameter. When MMt = non-zero, VuP and Vdn are PWM representations in automatic operation; however, in manual operation, they are only active when either of the output push buttons is pressed. A non-zero value entered for MMt represents in percent the minimum duty cycle period the logic values VuP and Vdn will be a 1 whenever the output push buttons are momentarily depressed or when a networked device generates an associated push button operation.

100% control output = 100% displayed.

: 100% control output = 0%

displayed.

dir

0.0

Table 7-3. Control Selections

(conF Menu → cn.1, cn.2 Modules)

Prompt Description Dft

dcP

(cn.1

Duty Cycle Period

Specifies in seconds, the length of the cycle period over which the

only)

digital outputs VuP and Vdn are calculated. This time must be set based on the characteristics of the final control element and the amount of cycling permitted. For minimum cycling of the final control element, the period should be set to match the end-to-end travel time of the element. To operate the digital outputs in a time proportioning manner, much shorter cycle times are required. Because each cycle period is divided into 0.05 second pieces, the resolution of the output is determined by the length of the cycle period. For example: If dcP is 10 seconds, then the period will contain 200 pieces (10/0.05 = 200), each being 0.5% of the 10 second period. If the controller output (OUT) value is 27.65 (%) at the start of the period, then the VuP logic will remain a "1" for 2.8 seconds (27.65% rounded to the closest 0.5% = 28.1 or 28%; 0.28 x 10 seconds = 2.8 seconds). 2.8 seconds is equivalent to 56 pieces. The cycle period will be a "0" for the remainder of the period, which is 7.2 seconds (144 pieces).

0.0

Non-zero operation:

OUT PB

VuP

dcP

Sec.

0 1 2 3 4 25 26 27 28 29 30

dcP = 30 seconds

MMt (MMt = 5% dcP)

7-28

7.8 Control Scheme Signal Connector Pin Assignments

Any one of six control strategies can be configured very quickly from a defaulted controller (ProG-cSFiX = 98) by selecting the appropriate control scheme and setting several parameters. The signal connector pin assignments vary for these control strategies as illustrated in Figure 7-21. The six control strategies are covered as part of the information provided in Section 8. The six control strategies are as follows:

• Single Loop Controller with Remote Setpoint

• Single Loop Ratio Controller

• Dual Loop Cascade Controller

• Dual Loop High Limited Controller

• Dual Loop Low Limited Controller

• Auto/Manual Station

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Section 7. Control Scheme Block 53SL6000 Instruction Manual

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Figure 7-21. Control Schemes Signal Connector Pin Assignments

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Section 8. Eight Control Strategies 53SL6000 Instruction Manual

8.0 Eight Control Strategies

This section provides information to implement eight commonly used control strategies:

Single Loop Control with Remote Setpoint.

•

Analog Back-up Control.

•

Ratio Control.

•

Auto/Manual Selector.

•

Single Station Cascade Control.

•

Single Station Override Control.

•

Dual Indicator with Re-Transmitted PV.

•

Proportional Speed Floating Control

•

Information for each strategy is presented in the same order. There is a brief overview of the control strategy operation with a process illustration and an illustration of the signal connector pin assignments, which is followed by descriptive sections of the connector signals. The applicable parameters that may require configuring are also included in these sections.

Many signal paths can be altered in the controller. To simplify the presentation, it is assumed the path configuration selections are left at the factory settings unless specified otherwise in the example.

The output can also be set manually at the controller, whereby the PID algorithm calculation is not used. The setpoint can be set locally at the controller or it can originate from a remote source (AI2). If the alarm limits are configured, the controller will activate an annunciator whenever the PV exceeds the configured tolerable limits of change.

Figure 8-1. Single Loop Application

The signal connector is illustrated in Figure 8-2 and the connector pin assignment descriptions are provied in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

Also provided, is a description of time proportional output, which can be applied to any of the control strategies presented in this section.

8.1 Single Loop Control with Remote Setpoint

Single loop control with remote setpoint is the controller standard factory set functionality (controller default settings and the SnGL control scheme).

A single loop control strategy with remote setpoint is illustrated in Figure 8-1. In single loop control, a continuous output is calculated from the difference between the process variable (AI1) feedback signal sent from a field transmitter (e.g., flow meter) and a setpoint (SP) value. The output is calculated with the controller PID algorithm, which has proportional, integral, and derivative terms. The effect these terms have on the output calculation depends on the PID configuration selections (Pb, tr, and td). As the output (AO1) is determined, it is applied to a final control element (e.g., valve) to restore the process to the setpoint value.

Figure 8-2. Single Loop Signals

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53SL6000 Instruction Manual Section 8. Eight Control Strategies

8.1.1 AI1 - Process Variable Input

This analog input signal value is compared to the control setpoint to determine the control output value.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For PV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

8.1.2 AI2 - Remote Setpoint Input

This analog input signal value is used as the control setpoint when remote (R) operation is selected with the display panel push button and remote setpoint is enabled (closed) by DI2.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt). Section 7.7, conF-cn.1-(Sh, SL, SSr).

8.1.3 DO1 - PV High Alarm Contact Out

D01 is closed (on) when the process variable value is not within the alarm limit 1 (PL1) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

8.1.4 DO2 - PV Low Alarm Contact Out

D02 is closed (on) when the process variable value is not within the alarm limit 2 (PL2) setting.

8.1.6 DI2 - Remote Enable Contact Input

This is a low active signal (0-1 V dc). When a 0-1 V dc signal is present on this input, the operator can select the Remote Setpoint input at AI2 as the setpoint value with the R/L push button. The Remote LED flashes if the R/L push button is pressed and this signal is not low to enable remote setpoint control.

Applicable parameter that may require configuration change: None.

8.1.7 AO1 - Control Output

This is the 4-20 mA signal that drives the final control element.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.1-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.1-(Pb, tr, td).

8.1.8 SchM Selection

Single loop control is implemented with the controller default settings and SnGL (single loop) selected from the SchM prompt of the cS module.

Applicable parameter that may require configuration changes: Section 7.6, ProG-cS-SchM.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.1.5 DI1 - Force Control Output Contact Input

This is a closed contact or low active signal (0-1 V dc). When a closed contact or 0-1 V dc signal is present on this input, the control output value is applied to the value of Ai7 (the control scheme D input accepts the force control value and cS.d is defaulted to select Ai7).

Applicable parameters that may require configuration changes:

To enter a Force Output value in register Ai7:

Section 5.2, ProG-Ai-Ai.7 or oPEr-Ai7.

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8.2 Analog Back-Up Control

The direct digital control/analog back-up strategy is used in operations where a remote computer is normally controlling the final element directly. It is implemented with the controller default settings, the SnGL control scheme, and the path connections provided on the next page in Section 8.2.8.

A control/analog back-up strategy is illustrated in Figure 8-3.

With this control strategy, the controller functions as a signal selector and automatic back-up unit to the computer host. The controller assumes process control in the event of a signaled computer failure. The analog back-up controller operates as a single loop controller when driving the process final element (e.g., output valve).

While in back-up and automatic, the controller continually adjusts its output to match the AI2 control element feedback signal so that transfer to online operation is bumpless in the event of computer failure. Selection of the computer or back-up controller signals to the process final element is performed by the controller’s DO1 and DO2 modules in conjunction with blocking diodes (see circuit diagram in Figure 8-4). The computer drives the final process element when remote operation is selected with the controller R/L push button and digital input DI1 is closed (0-1 V dc); otherwise, the computer’s control signal is diverted and the output from the controller is the active signal to the process final element. Unless DI2 input is open (4-24 V dc signal), the controller is not permitted to operate in automatic mode.

The signal connector is illustrated in Figure 8-5 and the connector pin assignment descriptions are provided in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

Figure 8-3. Backup Control Application

Figure 8-4. Output Selector

Figure 8-5. Backup Control Signals

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8.2.1 AI1 - Process Variable Input

This analog input signal value is compared to the control setpoint to determine the control output value.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For PV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

8.2.2 AI2 - Control Element Feedback

This is a feedback signal from the diverter circuit to the controller that indicates the position of the final element (e.g., valve) so that if operation transfer to the controller becomes necessary, it will be bumpless.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt).

8.2.3 DO1 - Computer Output Diverter

When open, the computer output path is through the diverter circuit diode to the final element (e.g., valve).

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

push button is pressed and this signal is not 4-24 V dc to enable auto control.

Applicable parameter that may require configuration change: None.

8.2.7 A01 - Backup Control Output

This is the 4-20 mA output signal that drives the final control element if operation is transferred from the computer to the controller.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.1-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.1-(Pb, tr, td).

8.2.8 SchM Selection and Path Connections

Analog control is implemented with the controller default settings, control scheme 1, and SnGL (single loop control) selected from the SchM prompt of the cS module.

Applicable parameter that may require configuration changes: Section 7.6, ProG-cS-SchM.

Applicable path connections that are required:

8.2.4 DO2 - Backup Output Diverter

When open, the controller output path is through the diverter circuit diode to the final element (e.g., valve).

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.2.5 DI1 - Computer Ready

This is a low active signal (0-1 V dc) that enables the computer to drive the final element when R is selected with the R/L push button.

Applicable parameter that may require configuration change: None.

8.2.6 DI2 - Auto Enable

This is a high active signal (4-24 V dc) that enables the controller to drive the final element when L is selected with the R/L push button and the controller is in automatic. The Auto LED flashes if the A/M

ProG-cS-cS.b = Ao3. ProG-cS-cS.d = Ai2. ProG-cS-cS.h = di2¤ (inverted). ProG-cS-cS.J = di1. ProG-cS-cS.K = LG1. ProG-LG-LG1.A = do8. ProG-LG-LG1.M = Xor. ProG-LG-LG3.A = rMt. ProG-LG-LG3.M = And. ProG-Ao-Ao3.i = SP. ProG-do-do1.i = LG3. ProG-do-do2.i = LG3. ProG-do-inV1 = 0-on. ProG-do-do8.i = LG3.

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8.3 Ratio Control

Ratio control is used where one variable, called the controlled variable, must be automatically maintained in definite proportion to another variable, called the wild variable. Ratio control is implemented with the controller default settings, the SnGL control scheme, and the ratio setpoint K-SP selected from the setpoint mode (ConF-cn.1-SPM) parameter. A ratio control strategy is illustrated in Figure 8-6. Field transmitters (e.g, flow meters) must be installed in each variable line. Signals from the controlled and wild variable transmitters (AI1 and AI2 respectively) are received by the controller which compares them and calculates the required correction that is applied as an output signal (AO1) to a final control element (e.g., valve) in the controlled variable line. The final element in the controlled variable line is moved to alter line throughput so that the predetermined ratio between the two lines is maintained. The predetermined ratio is set at the controller with the ratio/local (R/L) push button in R. While in ratio control, the setpoint push buttons are used to set the desired ratio value; when the R/L push button is in local control, the setpoint push buttons modify only the setpoint value. In local control, the controlled variable line functions in single loop control mode.

Figure 8-7. Ratio Control Signals

8.3.1 AI1 - Controlled Variable Input

This is the controlled line analog input signal value that must be maintained in proportion to the wild variable input value.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For CV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

Figure 8-6. Ratio Control Application

The signal connector is illustrated in Figure 8-7 and the connector pin assignment descriptions are provided in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

8.3.2 AI2 - Wild Variable Input

This is the wild variable analog input signal value that determines the required controlled variable input as specified by the ratio setting.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt). Section 7.7, conF-cn.1-(Sh, SL, SSr, B1).

8.3.3 DO1 - Controlled Variable High Alarm Contact Out

D01 is closed (on) when the controlled variable value is not within the process alarm limit 1 (PL1) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

8.3.4 DO2 - Controlled Variable Low Alarm Contact Out

D02 is closed (on) when the controlled variable value is not within the process alarm limit 2 (PL2) setting.

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Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.3.5 DI1 - Force Control Output Contact Input

Applicable parameters that may require configuration changes:

To enter a Force Output value in register Ai7:

Section 5.2, ProG-Ai-Ai.7 or oPEr-Ai7.

8.3.6 DI2 - Ratio Enable Contact Input

This is a low active signal (0-1 V dc). When a 0-1 V dc signal is present on this input, the operator can select ratio operation with the R/L push button. The R LED flashes if the R/L push button is pressed and this signal is not low to enable ratio control.

Applicable parameter that may require configuration change: None.

Applicable parameter that may require configuration changes: Section 7.6, ProG-cS-SchM.

8.3.7 Control Output

This is the 4-20 mA signal that drives the final control element.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.1-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.1-(Pb, tr, td).

8.3.8 SPM = K-SP

Ratio control is implemented with the controller default settings, control scheme 1, and K-SP selected from the SPM prompt of the cn.1 menu.

Applicable parameter that requires configuration change: Section 7.7, conF-cn.1-SPM.

8.3.9 SchM Selection

Ratio control is implemented with the controller default settings and SnGL (single loop) selected from the SchM prompt of the cS module.

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The signal connector is illustrated in Figure 8-9 and

8.4 Auto/Manual Selector

An auto/manual selector application is illustrated in Figure 8-8. This application is implemented with the controller default settings and the in.Ld control scheme. The auto/manual selector default settings allow auto-throughput when Auto is selected with the A/M push button. In automatic, the signal on AI2 is passed through to the station’s output (AO1). Manual operation occurs when M is selected with the A/M push button. In manual, the station output is controlled with the output push buttons. Transfer from automatic to manual is bumpless. There is no PID control performed by the automatic/manual selector; however, the station monitors AI1 for alarmed conditions, which are signaled with DO1 and DO2. If DI1 is closed, the force output signal appears at A01.

the connector pin assignment descriptions are provided in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

Figure 8-9. A/M Selector Signals

8.4.1 AI1 - Process Variable 1 Input

This analog signal is the designated input variable that is checked to be within acceptable process limits.

Figure 8-8. A/M Selector Application

The force output signal can be applied to an analog input (e.g., universal analog input module AI3 or AI4) from an external source, or it can be a constant value entered into one of the controller analog input registers. AI7 is shown in Figure 8-8 in parenthesis to indicate the controller does not have any optional AI inputs and that this value is a constant that was entered into AI7.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For PV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

8.4.2 AI2 - Process Variable 2 Input (Auto)

This analog signal is gated through as the AO1 selector output if force output is not active and auto is selected with the A/M push button.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt).

8.4.3 DO1 - PV1 High Alarm Contact Out

D01 is closed (on) when the alarmed process variable value, PV1, is not within the process alarm limit 1 (PL1) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

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8.4.4 D02 - PV1 Low Alarm Contact Out

D02 is closed (on) when the alarmed process variable value, PV1, is not within the process alarm limit 2 (PL2) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.4.5 DI1 Force Output Contact Input

Applicable parameters that may require configuration changes:

To enter a Force Output value in register Ai7:

Section 5.2, ProG-Ai-Ai.7 or oPEr-Ai7.

8.4.7 A01 - PV2 Re-Transmit (Auto)

This is the selected analog 4-20 mA output signal that is sent to the final control element.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.1-(ir, iLr).

8.4.8 SchM Selection

The auto/manual selector is implemented with the controller default settings and in.Ld (indicator/loader) selected from the SchM prompt of the cS module.

Applicable parameter that may require configuration changes: Section 7.6, ProG-cS-SchM.

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8.5 Single Station Cascade Control

A single station cascade control strategy is illustrated in Figure 8-10. This control strategy is implemented with the controller default settings and cASc control scheme. With single station cascade control, two standard PID control loops function together as a primary (loop 2) and secondary (loop

1). The output of the primary control loop, based on its setpoint and process variable, becomes the setpoint input to the secondary control loop. This controller setup is suited to process applications where the primary loop is usually slower than the secondary loop. The cascade action overcomes the slower process time lags of the primary loop by providing more immediate response to changes in the faster secondary loop, which in turn reduces disturbances to the primary loop. Transfer between local and cascade control is bumpless because the primary control’s output is forced to match the secondary control’s setpoint when the secondary control is in local mode (this is indicated by a blinking loop 2 manual LED). In the illustrated application below, the temperature (primary variable) of a liquid in a tank is maintained by regulating cold water flow to adjust tank jacket temperature (secondary variable).

Figure 8-11. Single Station Cascade

Signals

8.5.1 AI1 - Secondary PV Input

This is the secondary process loop analog input signal value that is compared to the primary control output (setpoint in) to determine the control output.

Applicable menu prompts that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For PV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

Figure 8-10. Single Station Cascade

Control Application

The signal connector is illustrated in Figure 8-11 and the connector pin assignment descriptions are provided in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

8.5.2 AI2 - Primary PV Input

This is the primary process loop analog input signal value that is compared to the primary control setpoint to determine the output (setpoint) value fed into the secondary process loop.

Applicable menu prompts that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt).

8.5.3 DO1 - Secondary PV High Alarm Contact Out

D01 is closed (on) when the secondary process variable value is not within the loop 1 process alarm limit 1 (PL1) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

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8.5.4 DO2 - Secondary PV Low Alarm Contact Out

D02 is closed (on) when the secondary process variable value is not within the loop 1 process alarm limit 2 (PL2) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.5.5 DI1 - Force Control Output Contact Input

Applicable parameters that may require configuration changes:

To enter a Force Output value in register Ai7:

Section 5.2, ProG-Ai-Ai.7 or oPEr-Ai7.

8.5.6 DI2 - Cascade Enable Contact Input

When a low signal (0-1 V dc) is present on this input and R (Remote) is selected with the R/L push button, it enables cascade operation. The R LED flashes if the R/L push button is pressed and this signal is not low to enable cascade control.

8.5.8 AO1 - Control Output

This is the 4-20 mA signal that drives the final control element.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.1-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.1-(Pb, tr, td).

8.5.9 SchM Selection

Cascade control is implemented with the controller default settings and cASc (cascade control) selected from the SchM prompt of the cS module.

Applicable parameter that may require configuration changes: Section 7.6, ProG-cS-SchM.

Applicable parameter that may require configuration change: None.

8.5.7 Primary Output (the Setpoint into the Secondary Loop)

The output of the primary loop is internally fed into the secondary loop as the setpoint for that loop; therefore, there is no signal connector designator.

Applicable parameters that may require configuration changes: Section 7.7, conF-cn.2-(oh, oL, hML, oSr, rSW, rSV).

For control related prompts:

Section 7.7, conF-cn.2-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.2-(Pb, tr, td).

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provided in the sections that follow. These sec-

8.6 Single Station Override Control

With Single Station Override Control, two standard PID control loops function as two interdependent variables, primary and limiting, to control a single final element (e.g., valve). Neither variable may exceed a safe limit. This control strategy is implemented with the controller default settings and the h.LiM or L.LiM (high or low limiting) control schemes. The limiting control schemes are defaulted to use a value entered into cn.1-b1 parameter as the second loop setpoint.

The primary loop of this control strategy is always in control unless the output tries to exceed the high (or low) limit imposed by the limiting loop. As a high limit controller, the lowest output value is selected to drive the final element via AO1. As a low limit (high override) controller, the highest output is selected to drive the final control element via AO1.

A typical high limit controller process application is illustrated in Figure 8-12. In this application the valve is normally adjusted in response to primary variable (flow) disturbances unless the limiting variable (pressure) loop has the highest output. When this happens, the valve is closed to reduce pressure. Pressure is the limiting variable because it is the more critical value.

tions also contain the applicable display prompts that may require configuration changes.

Figure 8-13. Single Station Override

Control Signals

8.6.1 AI1 - Primary PV Input

This is the primary loop analog input signal value that is compared to the primary loop setpoint to determine the required primary output. The primary output is used as the 4-20 mA drive signal for the final control element if the selector determines the primary loop should have process control.

Figure 8-12. Single Station Override

Control Application

The signal connector is illustrated in Figure 8-13 and the connector pin assignment descriptions are

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

For PV alarms:

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

8.6.2 AI2 - Limiting PV Input

This is the limiting loop analog input signal value that is compared to the limiting loop setpoint. The output drives the high/low limiter, which affects the primary output 4-20 mA final control element signal.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt).

8.6.3 DO1 - Primary PV High Alarm Contact Out

D01 is closed (on) when the primary process variable value is not within the loop 1 (cn.1) process alarm limit 1 (PL1) setting.

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Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV1.

8.6.4 DO2 - Primary PV Low Alarm Contact Out

D02 is closed (on) when the primary process variable value is not within the loop 1 (cn.1) process alarm limit 2 (PL2) setting.

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.6.5 DI1 - Force Control Output Contact Input

Applicable parameters that may require configuration changes:

To enter a Force Output value in register Ai7:

Section 5.2, ProG-Ai-Ai.7 or oPEr-Ai7.

Primary: Section 7.7, conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

For control related parameters:

Section 7.7, conF-cn.1-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3 and 9.4, conF-cn.1-(Pb, tr, td).

Limiting: Section 7.7, conF-cn.2-(oh, oL, hML, oSr, rSW, rSV). For control related prompts: Section 7.7, conF-cn.2-(ir, iLr, Mr). Sections 7.7, 9.2, 9.3, and 9.4, conF-cn.2-(Pb, tr, td).

8.6.8 SchM Selection

This control strategy is implemented with the controller default settings and hLiM or LLiM (high or low limiting, as applicable) selected from the SchM prompt of the cS module.

Applicable parameter that requires configuration change: Section 7.6 - ProG-cS-(SchM = h.LiM or L.LiM, as applicable).

If hard manual limiting

NOTE:

(conF-cn.1[cn.2]-hmL) is active, all output sources including forced control output, will be controlled by oh/oL (output high/output low). When using forced control output as a safety output, do NOT apply hard manual limiting, as it will override the forced control output signal in manual (deactivating hmL does not eliminate oh/oL in automatic operation).

8.6.6 DI2 - Secondary Setpoint Enable

When a low signal (0-1 V dc) is present on this input, it allows a value previously entered into the conF-cn.1-b1 parameter to become the fixed setpoint. Factory default settings are assumed for this control strategy; otherwise, the setpoint value may not be determined only by the conF-cn.1-b1 parameter.

Applicable parameter that may require configuration changes: Section 7.7, conF-cn.1-b1

8.6.7 AO1 - Control Output

This is the 4-20 mA signal that drives the final control element.

Applicable parameters that may require configuration changes:

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For PV alarms:

8.7 Dual Indicator with Re-Transmitted PV

The Dual Indicator allows two process variables to be displayed and either one to be selected as the output at AO1. The process variables are input into AI1 and AI2. A dual indicator application is illustrated in Figure 8-14.

This application is implemented with the controller default settings and the in.Ld control scheme.

Section 7.7, conF-cn.1-(AiX, PL1, PL2, Adb).

8.7.2 AI2 - PV2 Input

Process Variable 2 is a displayed analog signal that can be re-transmitted as the selected controller output.

Applicable parameters that may require configuration changes: Section 5.2, conF-Ai.2-(SPan, ZEro, SQrt, bASE, dFLt).

8.7.3 DO1 - PV1 High Alarm Contact Out

D01 is closed (on) when the process variable 1 value is not within the cn.1 process alarm limit 1 (PL1) setting.

Applicable parameter that may require configuration change:

Figure 8-14. Dual Indicator Application

Section 5.6, ProG-do-inV1.

8.7.4 DO2 - PV1 Low Alarm Contact

The signal connector is illustrated in Figure 8-15 and the connector pin assignment descriptions are provided in the sections that follow. These sections also contain the applicable display prompts that may require configuration changes.

Out

D02 is closed (on) when the process variable 1 value is not within the cn.1 process alarm limit 2 (PL2) setting.

Figure 8-15. Dual Indicator Signals

8.7.1 AI1 - PV1 Input

Process Variable 1 is the analog signal that is checked to be within acceptable process limits. It can be re-transmitted as the selected controller output.

Applicable parameters that may require configuration changes: Section 5.2, conF- Ai.1-(SPan, ZEro, SQrt, bASE, dFLt).

Applicable parameter that may require configuration change: Section 5.6, ProG-do-inV2.

8.7.5 A01 - Retransmitted PV1 or PV2

This is a re-transmitted output of either the PV1 or PV2 input, depending on the Ao1.i path connection (to Ai1 or Ai2).

Applicable parameters that may require configuration changes: Section 5.4, ProG-Ao-Ao1.i. Section 7.7 - conF-cn.1-(oh, oL, hML, oSr, rSW, rSV).

8.7.6 SchM Selection

The dual indicator is implemented with the controller default settings and in.Ld (indicator/loader) selected from the SchM prompt of the cS module.

Applicable parameter that requires configuration change: Section 7.6, ProG-cS-SchM.

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Micromod 53SL6000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Safety Summary

READ FIRST

1.0 Introduction

1.1 53SL6000 Controller Overview

1.2 Controller Model Numbers

1.3 Product Specifications

2.1 Inspection

2.2 Site Location

2.3 Panel Mounting

2.4 Power Connections

2.5 Signal Connections

2.6 Universal Analog Input Module

2.7 2DI/2DO Module

2.9 Applying Power

3.0 Display Panel

3.1 Display Panel Overview

3.3 Auxiliary Operator Access

3.4 Operator Mode Overflow/ Underflow Indication

3.5 Engineer Mode

3.6 Entering a Pass-Key

3.7 Offline Display Pattern

3.8 Engineer Mode oPEr Selections

3.9 Display Alphanumerics

3.10 Engineer Mode Summary

4.0 Functional Overview

4.1 Simplified Block Diagram

4.2 Detailed Block Diagram

5.0 Inputs/Outputs (I/O)

5.1 I/O Overview

5.2 Analog Inputs

5.3 Universal Analog Input Module

5.4 Analog Output 1 (AO1)

5.5 Discrete Inputs

5.6 Discrete Outputs

6.0 Signal Value Modification

6.1 Section Overview

6.2 Characterizer

6.3 Math Function Block

7.0 Control Scheme Block

7.1 Control Scheme Block

7.2 Control Scheme Inputs

7.3 Control Scheme Control Signals

7.6 Control Scheme Parameters

7.7 Control Loop Parameters

7.8 Control Scheme Signal Connector Pin Assignments

8.0 Eight Control Strategies

8.1 Single Loop Control with Remote Setpoint

8.2 Analog Back-Up Control

8.3 Ratio Control

8.4 Auto/Manual Selector

8.5 Single Station Cascade Control

8.6 Single Station Override Control

8.7 Dual Indicator with Re-Transmitted PV