Partlow MIC 1460 Operating Manual

MIC 1460

1/4 DIN SETPOINT PROGRAMMER

OPERATORS MANUAL

FORM 3707 EDITION 1 © MAY 1996 PRICE $10.00

CIRCULAR CHART RECORDERS • STRIP CHART RECORDERS • DATA ACQUISITION SYSTEMS

DATALOGGERS • ANALOG AND MICROBASED CONTROLLERS

MECHANICAL RECORDERS AND CONTROLLERS

PARTLOW CORPORATION • 2 CAMPION ROAD • NEW HARTFORD, NY 13413 USA

1-800-866-6659 • 315-797-2222 • FAX 315-797-0403

Information in this installation, wiring, and operation manual is subject to change without notice. One manual is provided with each instrument at the time of shipment. Extra copies are available at the price published on the front cover.

Copyright © May 1996, The Partlow Corporation, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of the Partlow Corporation.

This is the First Edition of the MIC 1460 manual. It was written and produced entirely on a desk-top-publishing system. Disk versions are available by written request to the Partlow Publications Department.

We are glad you decided to open this manual. It is written so that you can take full advantage of the features of your new MIC 1460 setpoint programmer .

NOTE: It is strongly recommended that Partlow equipped applications incorporate a high or low limit protective device which will shut down the equipment at a preset process condition in order to preclude possible damage to property or products.

Table of Contents

Section 1 - General Page

1.1 Product Description 1

Section 2 - Installation & Wiring

2.1 Unpacking Procedure 3

2.2 Panel Mounting 3

2.3 Wiring Guidelines 5

2.4 Input Connections 12

2.5 Output Connections 15

Section 3 - Operation

3.1 Power-up Procedure 20

3.2 Keypad Operation 20

3.3 Indicators 22

3.4 Displays 23

3.5 Alarm Status Indication 23

3.6 Viewing Program and Controller Parameters 24

3.7 Adjusting the Setpoint 24

3.8 Manual Control 25

3.9 Using the Pre-Tune Facility 25

3.10 Using the Self-Tune Facility 26

Section 4 - Configuration

4.1 Entry into Configuration 28

4.2 Hardware Definition Mode 29

4.3 Configuration Mode Parameters 31

4.4 Alarm Inhibit Facility 35

4.5 Exit from Configuration Mode 35

Section 5 - Controller Define Mode

5.1 Controller Parameters 37

5.2 Base Mode Displays 52

5.3 Loop Alarm and Loop Alarm Time 52

5.4 Exiting Controller Define Mode 53

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Section 6 - Program Define Mode

6.1 Entry into Program Define 54

6.2 Paramters Common to All Programs 55

6.3 Parameters which apply to a Specific Program 57

6.4 Parameters in any/each Segment 61

6.5 Using Join, Repeat, and End Segments 64

6.6 Basic Rules to Remember 66

6.7 Exiting Program Define Mode 66

Section 7 - Programs

7.1 Selecting and Running a Program 67

7.2 Changing Timebase 67

7.3 Holding Manually 67

7.4 Jumping to Next Segment 68

7.5 Viewing Program Status 68

7.6 Aborting a Program 69

7.7 End of Progam Indication 69

7.8 Viewing Program/Control Parameters 70

Appendices

A - Input Range Codes 71 B - Board Layout - Jumper positioning 73

Figure B-1 PCB Positions 73 Figure B-2 Output 2/Output 3 Removal 74 Figure B-3 CPU PWA 75 Figure B-4 PSU PWA with Relay or SSR Out.1 76 Figure B-5 PSU PWA with DC Output 1 77

Figure B-6 Option PWA DC Output 2/Output 3 78 C - Specifications 79 D - Model Number Hardware Matrix 87 E - Software Reference Sheet 88

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Figures

Figure 1-1 Front Panel 2 Figure 2-1 Panel Cut-Out Dimensions 3 Figure 2-2 Main Dimensions 4 Figure 2-3 Panel Mounting the controller 5 Figure 2-4 Noise Suppression 8 Figure 2-5 Noise Suppression 8 Figure 2-6 Rear Terminal Connections 10 Figure 2-6A Rear Terminal Connections 11 Figure 2-7 Main Supply 12 Figure 2-7A 24V Nominal AC/DC Supply 13 Figure 2-8 Thermocouple (T/C) Input 13 Figure 2-9 RTD Input 14 Figure 2-10 Volt, mV Input 14 Figure 2-11 mA DC Input 14 Figure 2-12 Remote Digital Communications 15 Figure 2-13 Relay Output 1 15 Figure 2-14 SSR Driver Output 1 15 Figure 2-15 mADC Output 1 16 Figure 2-16 Relay Output 2 16 Figure 2-17 SSR Driver Output 2 16 Figure 2-18 mADC Output 2 17 Figure 2-19 Relay Output 3 17 Figure 2-20 SSR Driver Output 3 17 Figure 2-21 mADC Output 3 18 Figure 2-22 End of Program Output 18 Figure 2-23 Event Outputs 18 Figure 2-24 Remote Program Output 19 Figure 5-1 Proportional Band and Deadband/Overlap 48 Figure 5-2 Alarm Operation 49 Figure 5-3 Alarm Hysteresis Operation 51 Figure 6-1 Auto Hold Operation 60

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Section 1 - General

1.1 PRODUCT DESCRIPTION

This instrument is a powerful, easy-to-use 1/4 DIN setpoint programmer with full PID control capability (complete with Self-Tune and Pre-T une facilities).

Its standard features include:

• Up to eight programs of up to 16 free-format (e.i. dwell, ramp, join, or end) segments each.

• Facility to join programs to one another in any sequence (maximum program length 121 segments)

• User can change currently-running program segment.

• Delayed Start of Program facility

• End of Program relay output

• Universal input-thermocouple, RTD (PT100) or DC linear user-selectable.

• Universal power supply (90 -264V AC 50/60 Hz)

• Configurable from front panel

• Comprehensive front panel displays

• Front panel sealing to NEMA 4 standard

• Behind-panel depth only 100mm (3.94 inchs)

Optional features include:

• Remote control and selection of program (plug-in option)

• Up to four Event relay outputs (plug-in option)

• Second control output

• Recorder output (setpoint or process variable)

• RS-485 serial communications

• User-definable program tag names

• Support software (Off-line Configurator, On-line Graphic Program Editor) - operates via RS-485 communications link.

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The Setpoint Programmer has four operating modes:

Base Mode: Day to day PID control operations with no program running. In this mode, a program may be selected to run.

Program Run Mode: A selected program is running, held or waiting for a pre-defined delay before starting. In this mode, the operator can view status and program information.

Program Define Mode:* Used to view/create/edit programs. this mode is entered either from Base Mode (selected program may be edited/ created) or from Program Run Mode (currently-running program may be edited).

Controller Define Mode:** Used to define the controller characteristics. * Entry via Lock Code; also optional Program Lock prevents changing of

program definitions while a program is running. ** Enry via a Lock Code.

FIGURE 1-1

Front Panel

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Section 2 - Installation & Wiring

2.1 UNPACKING PROCEDURE

1. Remove the instrument from its packing. The instrument is supplied with a panel gasket and push-fit strap. Retain the packing for future use, should it be necessary to transport the instrument to a different site or return it to the factory for repair/testing.

2. Examine the delivered items for damage or deficiencies. If any is found, notify the carrier immediately. Check that the model number shown on the label affixed to the instrument housing corresponds to that ordered (see Appendix D).

2.2 PANEL-MOUNTING THE SETPOINT PROGRAMMER

The panel on which the instrument is to be mounted must be rigid and may be up to 6.0 mm (.25 inches ) thick. The cutout required for a single instrument is shown in Figure 2-1.

FIGURE 2-1

Cut-Out Dimensions

92 mm +0.5 - 0.00

(3.62”+.020 - .000)

PANEL CUTOUT SIZE

92 mm + 0.5 - 0.0

(3.62” + .020 - .000)

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The main dimensions of the instrument are shown below.

FIGURE 2-2

Main Dimensions

100 mm (3.94 in.)

96 mm (3.78 in)

Side View

96 mm (3.78 in.)

Max. Panel Thickness 6.0mm (.25 inches)

10 mm (0.39 in.)

To panel-mount the instrument:

1. Insert the rear of the instrument housing through the cutout (from the front of the mounting panel) and hold the instrument lightly in position against the panel. Ensure that the panel gasket is not distorted and that the instrument is positioned squarely against the mounting panel. Apply pressure to the front panel bezel only.

Caution: Do not remove the panel gasket, as this may result in inadequate clamping of the instrument in the panel.

2. Slide the fixing strap in place (Figure 2-3) and push it forward until it is firmly in contact with the rear face of the mounting panel (the tongues on the strap should have engaged in matching rachet positions on the instrument housing and the fixing strap springs should be pushing firmly against the mounting panel rear face).

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Once the instrument is installed in its mounting panel, it may be subsequently removed from its housing, if necessary, as described in Appendix B.

FIGURE 2-3

Panel-Mounting the Instrument

Mounting Clamp

Controller Housing

Tongues on mounting clamp engage in ratchet slots on controller housing

2.3 PREPARATION FOR WIRING

Electrical noise is a phenomenon typical of industrial environments. The following are guidelines that must be followed to minimize the effect of noise upon any instrumentation.

2.3.1 INST ALLATION CONSIDERA TIONS

Listed below are some of the common sources of electrical noise in the industrial environment:

• Ignition T ransformers

• Arc Welders

• Mechanical contact relay(s)

• Solenoids

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Before using any instrument near the device listed, the instructions below should be followed:

1. If the instrument is to be mounted in the same panel as any of the listed devices, separate them by the largest distance possible. For maximum electrical noise reduction, the noise generating devices should be mounted in a separate enclosure.

2. If possible, eliminate mechanical contact relay(s) and replace with solid state relays. If a mechanical relay being powered by an instrument output device cannot be replaced, a solid state relay can be used to isolate the instrument.

3. A separate isolation transformer to feed only instrumentation should be considered. The transformer can isolate the instrument from noise found on the AC power input.

4. If the instrument is being installed on existing equipment, the wiring in the area should be checked to insure that good wiring practices have been followed.

2.3.2 AC POWER WIRING

Neutral (For 1 15 VAC) It is good practice to assure that the AC neutral is at or near ground potential. To verify this, a voltmeter check between neutral and ground should be done. On the AC range, the reading should not be more than 50 millivolts. If it is greater than this amount, the secondary of this AC transformer supplying the instrument should be checked by an electrician. A proper neutral will help ensure maximum performance from the instrument.

2.3.3 WIRE ISOLA TION

Four voltage levels of input and output wiring may be used with the unit:

• Analog input or output (i.e. thermocouple, R TD, VDC, mVDC, or mADC)

• SPDT Relays

• SSR driver outputs

• AC power

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The only wires that should run together are those of the same category. If they need to be run parallel with any of the other lines, maintain a minimum 6 inch space between wires. If wires must cross each other , do so at 90 degrees. This will minimize the contact with each other and reduces "cross talk". "Cross Talk" is due to the EMF (Electro Magnetic Flux) emitted by a wire as current passes through it. This EMF can be picked up by other wires running in the same bundle or conduit.

In applications where a High Voltage Transformer is used (i.e. ignition systems) the secondary of the transformer should be isolated from all other cables.

This instrument has been designed to operate in noisy environments, however , in some cases even with proper wiring it may be necessary to suppress the noise at the source.

2.3.4 USE OF SHIELDED CABLE

Shielded cable helps eliminate electrical noise being induced on the wires. All analog signals should be run with shielded cable. Connection lead length should be kept as short as possible, keeping the wires protected by the shielding. The shield should be grounded at one end only. The preferred grounding location is the sensor, transmitter, or transducer .

2.3.5 NOISE SUPPRESSION AT THE SOURCE

Usually when good wiring practices are followed no further noise protection is necessary. Sometimes in severe electrical environments, the amount of noise is so great that it has to be suppressed at the source. Many manufacturers of relays, contactors, etc. supply "surge suppressors" which mount on the noise source.

For those devices that do not have surge suppressors supplied. RC (resistance-capacitance) networks and/or MOV (metal oxide varistors) may be added.

Inductive Coils - MOV's are recommended for transient suppression in inductive coils connected in parallel and as close as possible to the coil. See Figure 2-4. Additional protection may be provided by adding an RC network across the MOV.

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FIGURE 2-4

0.5 mfd 1000V

220 ohms

115V 1/4W 230V 1W

Coil

Contacts - Arcing may occur across contacts when the contact opens and closes. This results in electrical noise as well as damage to the contacts. Connecting a RC network properly sized can eliminate this arc.

For circuits up to 3 amps, a combination of a 47 ohm resistor and 0.1 microfarad capacitor (1000 volts) is recommended. For circuits from 3 to 5 amps, connect 2 of these in parallel. See Figure 2-5, below.

FIGURE 2-5

MOV

R C

Inductive Coil

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2.3.5 SENSOR PLACEMENT (THERMOCOUPLE OR RTD)

Two wire RTD's should be used only with lead lengths less than 10 feet. If the temperature probe is to be subjected to corrosive or abrasive condi-

tions, it should be protected by the appropriate thermowell. The probe should be positioned to reflect true process temperature:

In liquid media - the most agitated area In air - the best circulated area

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FIGURE 2-6

Rear Terminal Connections

OUTPUT 3

Relay

END OF PROGRAM OUTPUT

INPUT

Linear (mA)

N/O

N/C

RTD

Linear (V/mV)

Thermocouple

N/C

SSR/DC

9 8 7 6 5 4 3

2 1

N/OC

1210

23 22

13 14 15 16

17 18 19

20 21

MAINS (LINE) SUPPLY

24V 24V

AC DC

RS485

COM

SERIAL COMMS.

N/C

SSR/DC

N/O

Relay

OUTPUT 1

SSR/DC

N/O

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Relay

OUTPUT 2

N/C

FIGURE 2-6A

RESET

RUN/HOLD

REMOTE INPUTS

X60 (FAST)

R1 R2

33 32

31 30

29 28 27 26 25

35 36

EVENT OUTPUTS

41 42

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2.4 Input Connections

In general, all wiring connections are made to the instrument after it is installed. Avoid electrical shock. AC power wiring must not be connected to the source distribution panel until all wiring connection procedures are completed.

Caution: This equipment is designed for installation in an enclosure which provide adequate protection against electric shock. Local regulations regarding electrical installation should be rigidly observed. Consideration should be given to prevention of access to the power terminations by unauthorized personnel. Power should be connected via a two pole isolating switch (preferably situated near the equipment) and a 1 A fuse, as shown in Figure 2-7.

FIGURE 2-7

Main Supply The instrument will operate on 90-264V AC 50/60 Hz mains (line) supply. The power consumption is approximately 4 VA. If the instrument has relay outputs in which the contacts are to carry mains (line) voltage, it is recommended that the relay contact mains (line) supply should be switched and fused in a similar manner but should be separate from the instrument mains (line) supply.

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Line

Neutral

FIGURE 2-7A

24V Nominal AC/DC Supply The supply connection for the 24V AC/DC option of the instrument are as shown below . Power should be connected via a two pole isolating switch and a 315 mA slow -blow (anti-surge type T) fuse. With the 24V AC/DC supply option fitted, these terminals will accept the following supply voltage ranges:

24V (nominal) AC 50/60Hz - 20-50V 24V (nominal) DC - 22-65V

24V AC 50/60Hz

24V DC

FIGURE 2-8

Thermocouple (T/C) Input Make the thermocouple connections as illustrated below. Connect the positive leg of the thermocouple to terminal 2 and the negative leg to terminal 3.

Thermocouple

FIGURE 2-9

RTD Input Make RTD connections as illustrated below. For a three wire RTD, connect the resistive leg of the RTD to terminal 1 and the common legs to terminals 2 and 3. For a two wire RTD, connect one leg to terminal 2 and the other leg to terminal 3 as shown below. A jumper wire supplied by the customer must be installed between terminals 2 and 3. (Continued on next page)

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Input conditioning jumper must be positioned correctly (see Appendix B) and Hardware Definition Code must be correct (see Appendix C).

RTD

FIGURE 2-10

V olt, mV Input Make volt and millivolt connections as shown below . Terminal 2 is positive and terminal 3 is negative. Input conditioning jumper must be positioned correctly (see Appendix B) and Hardware Definition Code must be correct (see Appendix C).

Linear (V/mV)

FIGURE 2-11

mADC Input Make mADC connections as shown below. Terminal 4 is positive and terminal 1 is negative Input conditioning jumper must be positioned correctly (see Appendix B) and Hardware Definition Code must be correct (see Appendix C).

Linear (mA)

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FIGURE 2-12

Remote Digital Communications - RS485 Make digital communication connections as illustrated below .

COM

Output Connections 2.5

FIGURE 2-13

Relay Output 1 (Control Output 1) Connections are made to Output 1 relay as illustrated below. The contacts are rated at 2 amp resistive, 120/240 VAC .

N/C

FIGURE 2-14

SSR Driver Output 1 (Control Output 1) Connections are made to Output 1 SSR Driver as illustrated below. The solid state relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.

Relay

N/O

SSR

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FIGURE 2-15

mADC Output 1 (Control Output 1) Make connections for DC Output 1 as illustrated below.

FIGURE 2-16

Relay Output 2 (Control Output 2 OR Alarm 2) Connections are made to Output 2 relay as illustrated below. The contacts are rated at 2 amp resistive, 120/240 VAC.

24 23 22

N/O

FIGURE 2-17

SSR Driver Output 2 (Control Output 2 OR Alarm 2) Connections are made to Output 2 SSR Driver as illustrated below. The solid state relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.

24 23 22

Relay

SSR

N/C

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FIGURE 2-18

mADC Output 2 (Control Output 2) Make connections for DC Output 2 as illustrated below.

24 23 22

FIGURE 2-19

Relay Output 3 (Alarm 1) Connections are made to Output 3 relay as illustrated below. The contacts are rated at 2 amp resistive, 120/240 VAC.

Relay

10 11 12

FIGURE 2-20

SSR Driver Output 3 (Alarm 1) Connections are made to Output 3 SSR Driver as illustrated below. The solid state relay driver is a non-isolated 0-4 VDC nominal signal. Output impedance is 250 ohms.

N/OCN/C

SSR

10 11 12

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FIGURE 2-21

mADC Output 3 (Recorder Output Only) Make connections for DC output 3 as illustrated below.

10 11 12

FIGURE 2-22

End of Program Output Connections are made to End of Program Output as shown below. The contacts are rated at 5 amp resistive, 120/240 V AC.

N/O END OF PROGRAM OUTPUT

N/C

9 8 7

FIGURE 2-23

Event Outputs (optional) If the Event Outputs have been specified, make connections as shown on top of next page. The contacts are rated at 5 amps, 120/240 VAC.

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34 35

36 37

39 40

EVENT OUTPUTS

FIGURE 2-24

Remote Program Inputs (optional) If the Remote Program Control Inputs has been specified, make connections as shown.

RESET

RUN/HOLD

REMOTE INPUTS

28 27

X60 (FAST)

Note: Only one remote connection shown for clarity.

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Section 3 - Operation

3.1 POWER UP PROCEDURE

Verify all electrical connections have been properly made before applying power to the instrument.

If the instrument is being powered for the first time, it may be desirable to disconnect the controller output connections. The instrument will be into control following the power up sequence and the output(s) may turn ON . During Power up, a self-test procedure is initiated during which all LED segments in the two front panel displays appear and all LED indicators are ON . When the self-test procedure is complete, the instrument reverts to normal operation.

Note: When power is first applied, a delay of approx. 3 seconds will be seen before the displays light up.

3.2 KEYPAD OPERATION

Mode Key

MODE

Changes mode of instrument.

Scroll Key Displays the next parameter in sequence (indicated by Message display).

Up Key Increments displayed parameter value/cycles through options.

Down Key Decrements displayed parameter value/cycles through options.

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PROF

PROF Key Cycles through Program (profile) numbers.

RUN/HOLD

RUN/HOLD Key Runs, holds or aborts current program (profile).

Selects/de-selects Self-T une and Pre-Tune (when

MODE

PROF

MODE

message display shows appropriate message).

Jumps to next segment, when program is running.

Selects/de-selects Manual Control

Sets a segment to Dwell when defining a program.

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3.3 INDICATORS

Control Status Indicators

AT ALM

OP1 OP2 MAN

RUN HLD x60

A T - ON when Self-Tune is active; flashes when Pre-

Tune is active.

ALM - Flashes when any alarm is active. OP1 - ON when primary control output is active. OP2 - ON when secondary control output (if fitted) is

active.

MAN - ON when Manual Control is selected. Run Status Indicators RUN - ON - Program running or (if HLD ON also) held

Flashing - Program in Delayed state

HLD - ON - Program held

Flashing - Program in Auto-Hold

x60 - OFF - timebase = hours/minutes

ON - timebase = minutes/seconds

EV1 EV2 EV3

EV4

SET PRG

Event Indicators Each indicates the status (active or inactive) of a user-defined

event (OFF = inactive, ON = active)

Mode Indicators SET - ON when Controller Define Mode or Program

Define Mode is entered; flashes when viewing parameters in Controller Define Mode or Program Define Mode after entry from Base Mode.

PRG - ON when Program Define Mode is entered.

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3.4 DISPLAYS

PROGRAM NUMBER

Number of currentlyselected program

UPPER DISPLAY

Process Variable value

LOWER DISPLAY

Setpoint value or value/setting of parameter being viewed/edited.

MESSAGE DISPLAY

CURRENT RAMP STATE

= UP Ramp

= DOWN Ramp BOTH ON = Dwell Both flashing = In Manual Control while program is running

SEGMENT NUMBER

Number of current segment

3.5 ALARM STATUS INDICATION

When any alarm is active, the ALM indicator will flash. To view the main status in the Message Display, press the SCROLL key until a display appears in the form:

Appears only if Alarm 1 is active

Appears only if Alarm 2 is active Appears only if the Loop Alarm is active

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3.6 VIEWING PROGRAM AND CONTROLLER PARAMETERS

In Base Mode (i.e. with no program currently running or held), the MODE key gives "view only" access to Program Define Mode and Controller Define Mode.

VIEW ONLY

CONTROLLER

DEFINE

MODE

BASE

MODE

VIEW ONLY

PROGRAM

DEFINE

MODE

3.7 ADJUSTING THE CONTROLLER SETPOINT

With the Setpoint Programmer in Base Mode (i.e. with the RUN, HLD, SET, and PRG indicators OFF), the two main displays will show the process variable value (upper display) and the setpoint value (lower display - Read Only). To change the setpoint value:

1. Press the SCROLL key, the Message Area will display:

2. Use the UP and DOWN keys to change the setpoint value (in the lower display) as required.

3. When the setpoint value is set as desired, press the SCROLL key again to return to the initial display.

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