NOVUS N1100 User Manual

Controller N1100

UNIVERSAL PROCESS CONTROLLER – INSTRUCTIONS MANUAL V2.1x

PRESENTATION

The N1100 is a process controller incorporating a PID algorithm and universal inputs (sensor and standard signals) and outputs (logical, relay and analog outputs). It holds in one single instrument all de main features that are needed for the vast majority of industrial processes.

SAFETY SUMMARY

The symbols below are used on the equipment and throughout this document to draw the user’s attention to important operational and safety information.

CAUTION or WARNING:
Read complete instructions prior	CAUTION or WARNING:
to installation and operation of the	Electrical Shock Hazard
unit.

All safety related instructions that appear in the manual must be observed to ensure personal safety and to prevent damage to either the instrument or the system. If the instrument is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

OVER-TEMPERATURE PROTECTION

When designing any control system it is essential to consider what will happen if any part of the system should fail. In temperature control applications the primary danger is one in which the heating remains constantly on. In any application where physical injury or destruction of equipment might occur, it is recommend to install an independent protection equipment, with a separate temperature sensor, to disable the heating circuit in case of overheating. Please note that the alarm relays within the controller will not give protection under all failure conditions.

INSTALLATION

Insert the unit into the panel cut-out and slide the mounting clamp from the rear to a firm grip at the panel.

ELECTRICAL CONNECTIONS

All electrical connections are made to the screw terminals at the rear of the controller. They accept wire sizes from 0.5 to 1.5 mm2 (16 to 22 AWG). The terminals should be tightened to a torque of 0.4 Nm (3.5 lb in).

To minimize the pick-up of electrical noise, the low voltage DC connections and the sensor input wiring should be routed away from high-current power conductors. If this is impractical, use shielded cables. In general, keep cable lengths to a minimum.

Figure 1 - Backpannel terminals

∙Power Wiring

If high voltage is applied to a low voltage input, irreversible damage will occur

Figure 2 – High and Low Voltage AC power wiring

∙Thermocouple and Voltage (Volts and mV) input connect as in

Figure 3.
T/C, 0-50mV, 0-5V	Pt100
Figure 3 – T/C and Voltage wiring	Figure 4 - RTD input wiring

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∙RTD (Pt100)

Figure 4 shows the Pt100 wiring, for 3 conductors. Terminals 10, 11 and 12 must have the same wire resistance for proper cable length compensation. For 2 wire Pt100, short circuit terminals 11 and 12.

	100R 4-20mA
4-20mA
Figure 5 – Current wiring	Figure 6 – Remote SP input

∙4-20 mA

Refer to Figure 5. (The controller provides an internal electronic shunt for the input current. No changes in the circuit are necessary).

∙Remote setpoint

Input available at terminals 9 and 10. The user must connect a 100 Ω resistor shunt as indicated in Figure 6.

∙Digital Input

I/O3 and I/O4 can be used as digital inputs, accepting either dry contact or NPN open collector signals. Figure 7a shows a switch driving the I/O3 digital input. I/O4 can be used analogously. The digital input at I/O5 is driven only by dry contact signals. Figure 7b shows a typical digital input wiring for I/O5.

	Figure 7a – Digital input at I/O3	Figure 7b – Digital input at I/O5

∙Digital Output

I/O3, I/O4 and I/O5 can also be configured as digital outputs (I/O3 and I/O4 provide a 5 Vdc output signal whereas I/O5 a 12 Vdc signal). An example of usage is shown in Figure 8 for the I/O3 and in Figure 9 for the I/O5. I/O5 is electrically isolated from the sensor input.

	Figure 8 – I/O3 driving a SSR.	Figure 9 – I/O5 digital output wiring.

OPERATION

The front panel is shown in Figure 10.

Figure 10 - Front panel parts

Status display/PV: shows the value of PV (Process Variable). When in programming mode, shows the parameter name.

Parameter display/SV: shows the SV (Setpoint Variable) value and the value of other parameters of the controller.

Controller N1100

COM Indicator: Flashes when communication messages are sent by the controller.

TUNE Indicator: Lights during the execution of PID automatic tunning.

MAN Indicator: Lights when the controller is in manual.

RUN Indicator: Lights when the controller is active, with control and alarm outputs enabled.

OUT Indicator: For relay or pulse control output, reflects the actual state of the output. If an analog output is assigned for control, lights continuously.

A1, A2, A3 and A4 Indicators: Status of the alarms.

P - PROG key: used to walk through the menu cycles

- BACK key: go back to the previous displayed parameter

- INCREASE and - DECREASE keys: Used to change parameter values

When the controller is turned on, its firmware version is displayed for 3 seconds, after which the controller starts normal operation. The values of PV and SV are displayed and the outputs are enabled.

Before the controller is ready to be used in a given process, it requires some basic configuration, such as:

∙input type (T/C, Pt100, 4-20 mA,...) at the “tYPE” prompt, according to Table 1.

∙output type at “I/O 1”, “I/O 2”,... “I/O 5” prompts (see Table 2).

∙setpoint variable SV. Set the remaining parameters.

∙PID parameters (or hysteresis for ON / OFF control).

Other functions, including alarms, ramp and soak, timer, digital input, etc., may be useful for a better system performance. The parameters are grouped in 7 cycles.

	CYCLE	ACCESS
	1- Operation	Free access parameters *
	2- Tuning
	3- R&S Program
	4- Alarms	Reserved access parameters **
	5- Input Configuration
	6- I/Os
	7- Calibration

* These parameters can be viewed but not changed if the cycle is protected.

** Requires a key combination to access the cycle.

Press P to advance and to go back in the menu cycle.

Keep pressing the P or key to move fast forward or backward.

Press and P simultaneously to move from one cycle to the next one.

At the end of each cycle the controller returns to the operation cycle.

PROGRAM SECURITY

Each menu cycle can be locked (protected) by pressing and simultaneously for 3 seconds. Press and for 3 seconds to unlock. A short blink of the display confirms the lock/unlock change. This will alternately lock or unlock the and keys to avoid tampering.

For further protection, the unlock operation through the keypad may be disabled by changing the position of an internal strap inside the controller:

When PROT is OFF, the user is allowed to lock and unlock the cycles using the keypad as explained above. If PROT is ON, the cycles lock / unlock operation is disable.

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CONFIGURATION

INPUT TYPE SELECTION

Select the input type (in parameter “tYPE”) from Table 1 below.

TYPE	CODE	CHARACTERISTICS
J	0	Range: -50 to 760 °C (-58 to 1400 ºF)
K	1	Range: -90 to 1370 °C (-130 to 2498 ºF)
T	2	Range: -100 to 400 °C (-148 to 752 ºF)
N	3	Range: -90 a 1300 °C (-130 a 2372 ºF)
R	4	Range: 0 a 1760 °C (32 a 3200 ºF)
S	5	Range: 0 to 1760 °C (32 to 3200 ºF)
Pt100	6	Range: -199.9 to 530.0 °C (-328.0 to 986.0 ºF)
Pt100	7	Range: -200 to 530 °C (-328 to 986 ºF)
4-20 mA	8	J linearization. Programmable range: -110 to 760 °C
4-20 mA	9	K linearization. Programmable range: -150 to 1370 °C
4-20 mA	10	T linearization. Programmable range: -160 to 400 °C
4-20 mA	11	N Linearization. Programmable range: -90 a 1370 °C
4-20 mA	12	R Linearization. Programmable range: 0 a 1760 °C
4-20 mA	13	S linearization. Programmable range: 0 to 1760 °C
4-20 mA	14	Pt100 linearization. Prog. Range:-200.0 to 530.0 °C
4-20 mA	15	Pt100 linearization Prog. Range:-200 to 530 °C
0-50 mV	16	Linear. Programmable indication -1999 to 9999
4-20 mA	17	Linear. Programmable indication -1999 to 9999
0-5 Vdc	18	Linear. Programmable indication -1999 to 9999
4-20 mA	19	Square Root Extraction

Table 1 - Input Types

OUTPUTS, ALARMS AND DIGITAL INPUTS CONFIGURATION

The controller input/output channels can assume multiple functions, depending on configuration: control output, alarm output, digital output, digital input, and PV or SV analog retransmission. These channels are identified as I/O1, I/O2, I/O3, I/O4 and I/O 5.

The basic controller model comes loaded with:

∙I/O1 - relay output

∙I/O2 - relay output

∙I/O5 - analog output (0-20 or 4-20mA), pulse 10V max, digital I/O

The options available are:

∙I/O3 - 3rd relay (option 1)

∙I/O3 and I/O4 - 2 digital input/output (option 2)

∙Heater break protection (option 3).

The function code of each I/O can be selected among the options on Table 2. Only valid function codes are displayed for each I/O (for example, I/O1, which is a relay, can be configured with functions 0 to 5 only; on the other hand, I/05 can perform all 16 functions).

The description for the functions follows:

∙CODE 0 - No function. The I/O channel programmed with code 0 will not be used by the controller. It is available to be used by serial communication as digital output.

∙CODES 1 to 4 - Alarm output - Available for all I/O channels. The selected channel can be used as output to Alarms 1 to 4.

∙CODE 5 - PWM control output - Available for all I/O channels.

∙CODE 6 - Digital input - Standard for I/O5 and optional for I/O3 and I/O4.

Closed : Manual control

Opened: Automatic control

Controller N1100

∙CODE 7 - Digital input - Standard for I/O5 and optional for I/O3 and I/O4. Start/Stop input (“rvn” : YES / no).

Closed : outputs enabled

Opened: outputs disabled

∙CODE 8 - Digital input - Standard for I/O5 and optional for I/O3 and I/O4.

Closed: remote SP (4-20 mA in remote SP input) Opened: main SP (internal programmed SV)

CODE	I/O TYPE	I/O FUNCTION
0	Digital Output	Digital Output to be set by the serial comm.
1	Digital Output	Alarm 1 Output
2	Digital Output	Alarm 2 Output
3	Digital Output	Alarm 3 Output
4	Digital Output	Alarm 4 Output
5	Digital Output	PWM Control Output
6	Digital Input	Automatic/Manual mode change
7	Digital Input	Run/Stop mode change
8	Digital Input	Select Remote Set Point Input
9	Digital Input	Executes/Holds selected ramp and soak profile
10	Digital Input	Enable/Disable R&S profile 1 selection
11	Analog Output	0 to 20mA Analog control output
12	Analog Output	4 to 20mA Analog control output
13	Analog Output	0 to 20mA PV retransmission
14	Analog Output	4 to 20mA PV retransmission
15	Analog Output	0 to 20mA SP retransmission
16	Analog Output	4 to 20mA SP retransmission

Table 2 - I/O channel functions

∙CODE 9 - Digital input - Standard for I/O5 and optional for I/O3 and I/O4.

Opened: enables R&S program

Closed: holds R&S program (the program resumes when the contact is opened again)

∙CODE 10 - Digital input - Standard for I/O5 and optional for I/O3 and I/O4. Selects R&S program 1. Used to alternate between the main Setpoint and a second Setpoint defined by the R&S program 1.

Closed : selects program 1

Opened: uses main Setpoint

∙CODE 11 - Analog control output - I/O5 only. 0-20 mA control output.

∙CODE 12 - Analog control output - I/O5 only. 4-20 mA control output.

∙CODES 13 to 16 - Analog retransmission. I/O5 only. Configures I/O5 to output a 0-20 mA or 4-20 mA analog signal proportional to PV or SP.

ALARM FUNCTIONS

The controller has 4 independent alarms. They can be programmed to operate with nine different functions, represented in Table 3.

∙Open sensor

It is activated whenever the input sensor is broken or disconnected.

∙Event alarm

It activates alarm(s) in specific segments of the program.

∙Resistance fail

Detects a heater broken condition, by monitoring the load current when the control output is activated. This alarm function requires an optional device (option 3). Details of the "resistance fail" option can be found in a specific documentation that is sent with the product when the option is purchased.

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