Partlow MIC 6000 Operating Manual

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Form 2854 Edition 10 © December 1993

MIC 6000

Installation, W iring, Operation Manual

Brand

PAGE 2

nformation 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 © December 1993, 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 factory.

This is the Tenth Edition of the Manual. It was written and produced entirely on a desk-top-publishing system. Disk versions are available by written request to the factory Advertising and Publications Department.

NOTE

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 1/4 DIN Profiling Controller.

It is strongly recommended that factory 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 Number

1.1 Product Description 5

SECTION 2 - INSTALLATION & WIRING

2.1 Installation & Wiring 7

2.2 Unpacking 7

2.3 Location 7

2.4 Mounting 7

2.5 Preparation for Wiring 8

2.6 Wiring Connections 13

SECTION 3 - CONFIGURATION

3.1 Configuration 21

3.2 Shipped Configuration/Jumper Positioning 22

3.3 Start up Procedure 22

3.4 Front Panel Operation 23

3.5 Operation Summary 25

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SECTION 4 - OPERATION

4.1 Operation 38

4.2 Alarm Operation 44

4.3 Tune Mode Operation 44

SECTION 5 - SERVICE

5.1 Service 47

5.2 Calibration 47

5.3 Test Mode Procedures 52

5.4 Troubleshooting and Diagnostics 56

APPENDICES

A - Board Layouts

A-1 Power Supply Board 63 A-2 Processor Board 64 A-3 Option Board (Revision D and Below) 65

Option Board (Revision E and Above) 66 B - Glossary 67 C - Order Matrix 70 D - Specifications 71 E - Software Record/Reference Sheet 75 F - Profile Development Sheet 78 Warranty Inside Back Cover

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Figures and Tables

Figure 1-1 Front Panel Display 5 Figure 2-1 Installation View and Dimensions 8 Figure 2-2 Noise Suppression 10 Figure 2-3 Noise Suppression 10 Figure 2-4 Wiring Connection Diagram 13 Figure 2-5 AC Power Input 14 Figure 2-6 Thermocouple Input 14 Figure 2-7 RTD Input 15 Figure 2-8 Volt, Millivolt, milliamp Input 15 Figure 2-9A 24V Transmitter Power Supply 16 Figure 2-9B 24V Power Supply 16 Figure 2-10 Remote Run/Hold Input 17 Figure 2-11 Remote Digital Communications Option 17 Figure 2-12 Alternate Remote Digital Communications 18 Figure 2-13 Relay Output 18 Figure 2-14 SSR Driver Output 19 Figure 2-15 Current Output 20 Figure 2-16 Position Proportioning Control 20 Figure 4-1 Dual Output Control 42 Table 3-1 Program Mode Configuration Procedures 25 Table 3-2 Tune Mode Configuration Procedures 32 Table 3-3 Profile Entry Mode Configuration Procedures 35 Table 3-4 Enable Mode Configuration Procedures 36 Table 4-1 Profile Continue Mode 40 Table 5-1 Calibration Procedures 48 Table 5-2 Test Procedures and Description 53

Flow Charts

Flow - Calibration 47 Flow - Enable Mode 37 Flow - Profile Entry 34 Flow - Profile Continue 39 Flow - Program Mode 26 Flow - Tune Mode 33 Flow - Test 52

Product Description 1.1

1.1.1 GENERAL

This instrument is a microprocessor based profiling controller capable of measuring, displaying, and controlling a process variable from a variety of inputs. Applications include temperature, pressure, level, flow, and others.

Control functions, alarm settings and other parameters are easily entered via the front keypad. All user data can be protected from unauthorized changes by the Enable mode security system, and is protected against loss from AC power failure by battery back-up.

The process input is user configurable to directly connect to either thermocouple, RTD, mVDC, VDC, or mADC inputs. depending on the input type specified. Thermocouple and RTD linearization, as well as thermocouple cold junction compensation, is performed automatically. The instrument's process input is isolated from the rest of the instrument.

The instrument can be ordered to operate on either 115VAC or 230VAC power at 50/ 60Hz. The instrument is housed in an extruded aluminum enclosure suitable for panel mounting.

FIGURE 1-1

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SEG2

MAN

SEG3

Scroll

SEG4 SEG5

OUT1

OUT2

SEG6 RAMP

ALRM

Down

SOAK

°C

°F

Operation Status Indicators

Degrees C, F, or Engineering Units

SEG1

Setpoint Indicator

Minus Sign

RUN

HOLD

Run/Hold

1.1.2 DISPLAYS

Each instrument is provided with a digital display and status indicators as shown in Figure 1-1. The digital display is programmable to display the process value only, process and setpoint, deviation from setpoint only, deviation and setpoint, or setpoint continuously.

Status indication is provided for Alarm , Output 1, Output 2, degree C, degree F, engineering units, Manual operation, Segment 1 thru 6, Ramp, and Soak.

Display resolution is programmable for 0.1 or 1 degree for thermocouple and RTD inputs, and 0.001, 0.01, 0.1, or 1 unit for volt, mV input types.

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1.1.3 CONTROL

Instruments can be programmed for On-Off, Time Proportioning, Current Proportioning, or Position Proportioning control implementations. Selectable direct or reverse control action is also provided. Proportional control implementations are provided with fully programmable PID parameters.

Automatic to Manual switching is easily accomplished via the Standby mode . Switching is bumpless, and while in manual, manipulation of proportional outputs is possible.

Other standard control features include control output limits, setpoint limits, anti-reset windup control, and a unique Automatic Transfer function, which, if configured, allows manual control of the process until setpoint is reached, at which time the unit will automatically transfer from manual to automatic control.

Remote Run-Hold capability can be provided via the Auxiliary Input.

1.1.4 PROGRAMMABLE SETPOINT PROFILES

Up to eight profiles can be programmed on any of these Profile Controllers. Each of the eight profiles can contain up to six segments. Each segment contains a ramp and a soak operation. Profiles can be programmed to run continuously or any number of times up to

9999. A combination of profiles may be combined for back to back execution. This has the affect of acting as a single profile of more than six segments.

Assured Soak is provided with the use of two programmable parameters that will activate an Auto/Hold feature. This feature will place a running profile in the Hold condition and prohibit a Soak operation from starting or completing if an acceptable process value is not reached and then maintained.

Event outputs may also be provided. Up to three events may be assigned and can be turned on or off at the beginning of each ramp and soak.

1.1.5 ALARMS

Alarm settings are fully programmable. Alarm type may be set as Process direct or reverse (High or Low), Deviation direct or reverse (above or below setpoint), or Deviation Band type (closed or open within band).

Alarm outputs can be provided by assigning any specified relays (SPST or SSR driver) to the respective alarm.

1.1.6 DIGITAL COMMUNICATIONS

The instrument can be provided with an RS-422/485 communications port which allows bi-directional multidrop communications with a supervisory computer.

Installation and Wiring 2.1

Read these instructions carefully before proceeding with installation and operation. Electrical code requirements and safety standards should be observed. Installation should be performed by qualified personnel.

CAUTION: The Instrument AC power input is specified in the model number and on the wiring label for either 115VAC or 230VAC. Verfiy the AC power input required by the instrument prior to proceeding with installation.

Unpacking 2.2

Remove the instrument from the carton and inspect it for any damage due to shipment. If any damage is noticed due to transit, report and file a claim with the carrier. Write the model number and serial number of the instrument on the front cover of this Operation Manual for future reference when corresponding with the factory.

Location 2.3

Locate the instrument away from excessive moisture, oil, dust, and vibration. Do not subject the instrument to operating temperatures outside of 0 to 55˚ C (32° to 131° F).

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Mounting 2.4

Figure 2-1 (page 8) shows installation view and physical dimensions for the panel mounted instrument.

The electronics can be removed from the housing for installation, if so desired. To remove, loosen the locking screw centered on the bottom face of the unit. The instrument pulls straight out. When installing, be sure that the verically mounted circuit boards are inserted in the correct grooves in the top and bottom of the housing. Also make sure the screw lock is sufficiently tight. When installing multiple instruments, be sure to reinsert the proper instrument into its correct enclosure by matching the serial number with the number inside the housing. This will insure that the accuracy of the control will be within the published specifications. The ambient compensator on the rear of the enclosure is calibrated to the electronics at the factory.

Cut the panel cutout to the dimensions shown in Figure 2-1 (page 8). Insert the instrument housing into the panel cutout and install the mounting bracket. Place the mounting screws on the back of the housing and tighten until the instrument is rigidly mounted. Do not overtighten.

A surface mounting kit is available - part number 64405801. For installation of the instrument in areas subjected to washdowns, a water tight cover option is available (part # 64417801).

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FIGURE 2-1

4.8 (.188) MAX PANEL THICKNESS

165.9 (6.53)

146.8 (5.78)

96.0 (3.78)

92 + or - 0.8 (3.622 + or - .031)

PANEL CUTOUT SIZE

All dimensions shown in mm and inches. Inches shown in ( ).

96.0 (3.78)

92+ or-.8 (3.622 + or-.031)

Side View

Panel

Top View

90.4 (3.560)

Mounting Bracket

90.4 (3.560)

Mounting screw

Preparation for Wiring 2.5

2.5.1 WIRING GUIDELINES

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.

2.5.1.1 INSTALLATION CONSIDERATIONS

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

• Ignition Transformers

• Arc Welders

• Mechanical contact relay(s)

• Solenoids Before using any instrument near the devices 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 practicies have been followed.

2.5.1.2 AC POWER WIRING

Earth Ground The instrument includes noise suppression components that require an earth ground connection to function. To verify that a good earth ground is being attached, make a resistance check from the instrument chassis to the nearest metal water pipe or proven earth ground. This reading should not exceed 100 ohms.

Neutral (For 115VAC) 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.

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2.5.1.3 WIRE ISOLATION

Four voltage levels of input and output wiring may be used with the unit: * Analog input or output (i.e. thermocouple, RTD, VDC, mVDC or mADC) * SPST Relays * SSR driver outputs * AC power

The only wires that should be 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 the wires. If wires must cross each other, do so at 90 degrees. This will minimize the contact with each other and reduces "cross talk".

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 its source.

2.5.1.4 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 at the sensor, transmitter or transducer.

"Cross talk" is due to the EMF (Electro Magnetic Flux)

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2.5.1.5 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 thta 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 2-2. Additional protection may be provided by adding an RC network across the MOV.

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 2-3.

FIGURE 2-2

FIGURE 2-3

0.5 mfd 1000V

220 ohms

115V 1/4W 230V 1W

MOV

Coil

Inductive Load

2.5.2 SENSOR PLACEMENT (Thermocouple or RTD)

If the temperature probe is to be sufnected to corrosive or abrasive conditions, 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.

THERMOCOUPLE LEAD RESISTANCE

Thermocouple lead length can affect instrument accuracy since the size (gauge) and the length of the wire affect lead resistance.

To determine the temperature error resulting from the lead length resistance, use the following equation:

Terr = TLe * L where; TLe = value from appropriate table below

L = length of leadwire in thousands of feet

TABLE 1 Temperature error in °C per 1000 feet of Leadwire

AWG Thermocouple Type: No. J K T R S E B N C 10 .34 .85 .38 1.02 1.06 .58 7.00 1.47 1.26 12 .54 1.34 .61 1.65 1.65 .91 11.00 2.34 2.03 14 .87 2.15 .97 2.67 2.65 1.46 17.50 3.72 3.19 16 1.37 3.38 1.54 4.15 4.18 2.30 27.75 5.91 5.05 18 2.22 5.50 2.50 6.76 6.82 3.73 44.25 9.40 8.13 20 3.57 8.62 3.92 10.80 10.88 5.89 70.50 14.94 12.91 24 8.78 21.91 9.91 27.16 27.29 14.83 178.25 37.80 32.64

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TABLE 2 Temperature Error in °F per 1000 feet of Leadwire

AWG Thermocouple Type: No. J K T R S E B N C 10 .61 1.54 .69 1.84 1.91 1.04 12.60 2.65 2.27 12 .97 2.41 1.09 2.97 2.96 1.64 19.80 4.21 3.66 14 1.57 3.86 1.75 4.81 4.76 2.63 31.50 6.69 5.74 16 2.47 6.09 2.77 7.47 7.52 4.14 49.95 10.64 9.10 18 4.00 9.90 4.50 12.17 12.28 6.72 79.95 10.64 9.10 20 6.43 15.51 7.06 19.43 19.59 10.61 126.90 26.89 23.24 24 15.80 39.44 17.83 48.89 49.13 26.70 320.85 68.03 58.75

Example: An MIC is to be located in a control room 660 feet away from the process. Using 16 AWG, type J thermocouple, how much error is induced?

Terr = TLe * L

TLe = 2.47 (°F/1000 ft) from Table 2 Terr = 2.47 (°F/1000 ft) * 660 ft Terr = 1.6 °F

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RTD LEAD RESISTANCE

RTD lead length can affect instrument accuracy, since the size (gauge) and length of the wire affect lead resistance.

To determine the temperature error resulting from the lead length resistance, use the following equation:

Terr = TLe * L where; TLe = value from Table 3 if 3 wire RTD or Table 4 if 2 wire RTD

L = length of lead wire in thousands of feet

TABLE 3 - 3 Wire RTD AWG No. Error °C Error °F

10 +/- 0.04 +/- 0.07 12 +/- 0.07 +/- 0.11 14 +/- 0.10 +/- 0.18 16 +/- 0.16 +/- 0.29 18 +/- 0.26 +/- 0.46 20 +/- 0.41 +/- 0.73 24 +/- 0.65 +/- 1.17

TABLE 4 - 2 Wire RTD AWG No. Error °C Error °F

10 +/- 5.32 +/- 9.31 12 +/- 9.31 +/- 14.6 14 +/- 13.3 +/- 23.9 16 +/- 21.3 +/- 38.6 18 +/- 34.6 +/- 61.2 20 +/- 54.5 +/- 97.1 24 +/- 86.5 +/- 155.6

Example: An application uses 2000 feet of 18 AWG copper lead wire for a 3 wire RTD sensor. What is the worst case error due to this leadwire length?

Terr = TLe * L

TLe = +/- .46 (°F/1000 ft) from Table 3 Terr = +/- .46 (°F/1000 ft) * 2000 ft Terr = +/- 0.92°F

Wiring Connections 2.6

All wiring connections are typically made to the instrument with it installed. Terminal connections should be made via the rear panel with 14 gauge wire maximum (see Figure 2-4).

FIGURE 2-4

PAGE 13

RELAY C

RELAY B

RELAY A

115 230

VAC

SERIAL A

SERIAL B

INPUT RATINGS: 115/230 VAC 50/60 HZ 15VA MAX

RELAY OUTPUT RATINGS: 115VAC 5.0A RESISTIVE 230VAC 2.5A RESISTIVE 230VAC 1/8 HP 115/230VAC 250VA

MAXIMUM AMBIENT: 55˙C

POS. PROP. WIPER

POS. PROP. HIGH

REMOTE

RUN/ HOLD

OUT2

4-20MA

OUT1

4-20MA

RETURN

SIGNAL +

CJC

SIGNAL -

MADE IN U.S.A.GROUND

2.6.1 INPUT CONNECTIONS WARNING: Avoid electrical shock. AC power wiring must not be connected at the source distribution panel until all wiring connections are completed.

Consult the model code and the wiring label for the appropriate line voltage for the instrument.

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FIGURE 2-5

AC Power Connect 115 VAC hot and neutral to terminals B and A respectively as illustrated below. Connect 230 VAC as described below. Connect Earth ground to the ground screw as shown.

115 VAC INSTRUMENT VOLTAGE

Rear View

.5 AMP* FUSE

L1 L2

GROUND

230 VAC INSTRUMENT VOLTAGE

Rear View

.25 AMP* FUSE

GROUND

*Supplied by the customer

*Supplied by customer

FIGURE 2-6

Thermocouple Input Make thermocouple connections as illustrated below. Connect the positive lead of the thermocouple to terminal 3, and the negative to terminal 1. For industrial environments with comparatively high electrical noise levels, shielded thermocouples and extension wire are recommended. Be sure that the input conditioning jumpers are properly positioned for a thermocouple input. See Appendix A-2 (page 64) and A-3 (page 65 or 66).

THERMOCOUPLE INPUT

Rear view

300 OHMS MAXIMUM LEAD

FIGURE 2-7

RTD Input Connections are shown for 3 wire and 2 wire RTD's. If a three wire device is used, install the common wires to terminals 1 and 5. If a two wire device is used, install a jumper between terminals 1 and 5.

PAGE 15

2 WIRE RTD INPUT

Rear View

JUMPER*

100 OHM* PLATINUM

3 WIRE RTD INPUT

Rear View

100 OHM* PLATINUM

10 FEET LEAD

*Supplied by the customer

MAXIMUM

*Supplied by customer

FIGURE 2-8

Volt, Millivolt and Milliamp Input Make volt, millivolt or milliamp connections as shown below. Terminal 3 is positive and terminal 1 is negative. Milliamp input requires a shunt resistor be installed across the input terminals as shown. 4-20mA input are accommodated by setting up the instrument for either 10 to 50mVDC or 1 to 5VDC input. Make sure that the appropriate resistor value is used. Terminal 3 is positive and terminal 1 is negative. (.1% resistors recommended.) (Continued on next page)

MILLIAMP DC INPUT

Rear View

Shielded Twisted Pair

MILLIAMP DC SOURCE 250 OHM SHUNT RESISTER REQUIRED

MILLIAMP DC INPUT

Rear View

NOTE: Fault detection is not functional for 0-5 V or 0-20 mA inputs.

Shielded Twisted Pair

MILLIAMP DC SOURCE

2.5 OHM SHUNT RESISTER REQUIRED

PAGE 16

MILLIVOLT DC INPUT

Rear View

Shielded Twisted Pair

MILLIVOLT DC SOURCE 50 MILLIVOLT DC MAXIMUM

VOLT DC INPUT

Rear View

Shielded Twisted Pair

VOLT DC SOURCE 5 VOLT DC MAXIMUM

FIGURE 2-9A

24Volt Transmitter Power Supply (XP Option) Make connections as shown below. Terminal 3 is positive (+) and terminal 1 is negative (-). Be sure the input conditioning jumpers are properly positioned for the input type selected. See Figure A-2 Processor Board, page 64 and Figure A-3 Option Board, page 65 or 66.

Note the 250 ohm shunt resistor is

not required.

-1

Two Wire Transmitter

FIGURE 2-9B

24 Volt Power Supply (XA Option) Make connections as shown below. Terminal G is positive (+) and terminal H is negative (-). Be sure the input conditioning jumpers are properly positioned. See Figure A-2 Processor

Board, page 64 and Figure A-3 Option Board, page 65 or 66.

H -

24VDC

G +

FIGURE 2-10

Remote Run/Hold Input If Remote Run/Hold capability has been specified, make connections as shown. Terminal 5 is the ground and terminal 8 is the input.

Shielded Multi-Conductor Cable

Run/

Hold

Out2

4-20mA Out1

4-20mA Return

Remote Dry Contact

FIGURE 2-11

Remote Digital Communications RS-485 Terminals 7 & 8 (Optional) If the communications network continues on to other units, connect the shields together, but not to the instrument. A terminating resistor should be installed at the terminals of the last instrument in the loop. The shield should be grounded at the computer or the convertor box, if used. See the Protocol Manual (Form 2878) for more details on the use of the digital communications option.

PAGE 17

Terminals 7 & 8 are used for communications when the model number is 6XXYX3X or 6XXYX5X where X= any valid number and Y=0, 1, or 2.

DIGITAL COMMUNICATIONS CONNECTIONS - TERMINALS 7 & 8

FROM HOST

Output 2 cannot be DC Current

COMPUTER

TO OTHER INSTRUMENTS

PAGE 18

FIGURE 2-12

Alternate Remote Digital Communications RS-485 Terminals G & H (Optional) If the communications network continues on to other units, connect the shields together, but not to the instrument. A terminating resistor should be installed at the terminals of the last instrument in the loop. The shield should be grounded at the computer or the convertor box, if used. See the Protocol Manual (Form 2878) for more details on the use of the digital communications option.

DIGITAL COMMUNICATIONS

Terminals G & H are used for communications when the model number is 6XXY04X or 6XXY06X where X= any valid number and Y=3, 4, or 5.

CONNECTIONS - TERMINALS G & H

From Host Computer

Output 3 Must Be 0

Rear View

GROUND

INPUT POWER

To Other Instruments

2.6.3 OUTPUT CONNECTIONS

Output connections include SPST relays, SSR drivers, and 4 to 20mADC. Relay outputs may be assigned control, alarm or event functions. Assignment of output function is accomplished via the front keypad and is described in Section 4 (page 38) of this manual.

FIGURE 2-13

Relay Output Connections are made to relay A as illustrated below. Connect relay(s) B & C (if present) in the same manner. Relay contacts are rated at 5 amp resistve at 130 VAC.

INPUT POWER

L2 L1

LOAD

RELAY A

Rear View

GROUND

L2 L1

INPUT POWER

LOAD

RELAY B

Rear View

GROUND

RELAY C

PAGE 19

Rear View

GROUND

INPUT POWER

LOAD

L2 L1

FIGURE 2-14

SSR Driver Output Connections are made to the solid state relay shown. The solid state relay driver is a 5 VDC current sink output type. Connect the solid state relay driver(s) in the Relay B and C position (if present) in the same manner.

SSR DRIVER (RELAY A)

Rear View

SOLID STATE RELAY

INPUT POWER

GROUND

driver

output located in the Relay A position as

SSR DRIVER (RELAY B)

Rear View

SOLID STATE RELAY

INPUT POWER

GROUND

INPUT POWER

SOLID STATE RELAY

SSR DRIVER (RELAY C)

Rear View

GROUND

PAGE 20

FIGURE 2-15

mADC Output Connections are made to current outputs 1 and 2 as shown. Connect the positive lead to terminal 6 for Output 1 or terminal 7 for Output 2, the negative leads connect to terminal 5. Current outputs will operate up to 650 ohms maximum load. The current output(s) can be selected for either 4-20mADC or 0-20mADC (if EO option is present).

DC CURRENT OUTPUT 1

Rear View

Shielded Twisted Pair

LOAD 650 OHMS MAXIMUM

DC CURRENT OUTPUT 2

Rear View

Shielded

Twisted Pair

LOAD 650 OHMS MAXIMUM

FIGURE 2-16

Position Proportioning Control The relay and slidewire feedback connections are made as illustrated below. The relay assigned to Output 1 will be used to drive the motor in the open direction and the relay asssigned to Output 2 will be used to drive the motor in the closed direction. The minimum slidewire feedback resistance is 135 ohms, the maximum resistance is 10K ohms.

RELAY B

RELAY A

OPEN

Modulating Motor

Rear View

POS.PROP.

WIPER

POS.PROP.

HIGH

RETURN

Configuration 3.1

After completing installation of the unit, the configuration procedures contained within this section must be performed to prepare the instrument for operation on the intended application. The procedures include selecting specific parameters, entering data and possible jumper positioning.

Parameter selections and data entry are made via the front keypad. To ease configuration and operation, user entered data has been divided up into several modes. Each mode contains a different type of data or may be used for specific operating functions. These modes are as follows:

PAGE 21

Control (CtrL)

Standby

(Stby)

Test (tESt)

Profile Continue (PCon)

Calibrate (CAL)

Profile Entry (PEnt)

Program (Prog)

P1..P8 Profile Number

Tune (tunE)

OFF

Mode Display Code Function Description

Off oFF Operation Outputs and Alarm Off Control CtrL Operation Operates in automatic

control; Change local setpoint, Alarms are On

Manual Stby Operation Manual control of

proportional outputs

Program Prog Configuration Configures operating

parameters

Tune tunE Configuration & Sets alarm settings &

Operation tunes the controller to

the process

Profile PCon Operation Provides Profile Continue Continue function

Profile PEnt Configuration Configures profile Entry Entry parameters

P1 thru P8 P1 - P8 Operation Executes any of the 8

profiles

Test tESt Service Performs instrument

tests

Calibration CAL Service Performs instrument

calibration

Enable EnAb Configuration Locks out or enables

access to any modes

(Continued on next page)

PAGE 22

Associated with each mode is a series of unique displays which are accessed via the front keypad.

Prior to first time operation of the instrument, the configuration procedures for the Program, Profile Entry and Tune modes must be performed as applicable. The Control, Off, Standby, Profile Continue and Profile execution (P1 thru P8) modes are discussed in Section

4.1 (page 38) of this manual. Calibration and Test modes are not used as part of instrument configuration or operation.

These are used for service and maintenance functions and are discussed in Section 5.2 (page 47) of this manual.

Shipped Configuration/ Jumper Positioning 3.2

All configuration parameters in each mode are set to default values. These defaults are shown in tabular form under the description for each mode. Instrument AC power input is as specified in the instrument model number and as shown on the instrument ratings label.

3.2.1 JUMPER POSITIONING

Jumpers are used in all instruments to provide a security lockout feature and to condition the process input . All jumpers are typically of the three pin type and have two functions. All jumpers are either located on the Options Board or the Processor Board. Board layouts and jumper locations are shown in Appendix A-2 and A-3 (pages 64 and 65 or 66).

Check the actual jumper position in the instrument to be configured and verify the proper position for the intended application. If the current position is not correct, make changes.

Start up Procedures 3.3

Step by step procedures are provided in Tables 3-1 thru 3-4 . These tables provide the display sequence, parameter adjustment and factory setting for each step.

The instrument is provided with a "time out" feature. If the instrument is in any mode and no keypad activity takes place for 30 seconds, the instrument will "time out" and exit the mode automatically. The instrument will display the code for the respective mode. If a mode code is displayed for 5 seconds with no activity it will then "time out" and proceed to either the Control or Off mode, depending upon which operational state the instrument was in last.

3.3.1 POWER UP PROCEDURE

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

If the instrument is being configured for the first time, it may be desirable to disconnect the controller output connections as the instrument may go into the Control mode automatically following the power up sequence. Upon verification, power may be applied.

B. Upon power up, "6XXX" will be displayed (X representing digits), then "XXX-", identifying the seven digit model number as defined in the order matrix. Next, the software revision level will be displayed in the format "rX.XX". Then "tSt1", "tSt2", and "tSt3" will be displayed while Test 1 thru 3 are executed automatically. Upon successful completion of these tests, "Ctrl" (for the Control mode) or "oFF" (for the Off mode) will be displayed for about three seconds. During this time the operator may select another mode prior to the instrument automatically going into the Control mode.

C. If any error messages are displayed, refer to Section 5.4, page 56 for a definition of these error messages and the required action.

D. If the instrument has been configured or operated previously, the mode that the instrument will go into upon power up, depends on what mode the instrument was in on power-down and how it has been programmed.

Front Panel Operation 3.4

3.4.1 DIGITAL DISPLAY AND STATUS LED's

The digital display provided has 4 digits and a decimal point. Each digit has seven segments and is capable of producing numeric characters from 0-9 and certain alpha characters. The digital display is used to provide indication of process variable as well as displaying codes used for configuration and operation of the instrument. The display includes the following Status Indicator LED's:

PAGE 23

Label Color Function

MAN Amber Lights when the Manual StbY mode is on. OUT1 Red Lights when Output 1 is on. OUT2 Amber Lights when Output 2 is on. ALRM Red Lights when either Alarm is on or active. SEG 1 Red Lights to indicate the profile section segment number

thru that is active.

SEG 6 RAMP Red Lights during the Ramp section of any profile segment. SOAK Red Lights during the Soak section of any profile segment. SP Green Indicates that the value displayed is the setpoint. C Red Lights to indicate that the process value is in terms of

degrees C (Celcius)

F Red Lights to indicate that the process value is in terms of

degrees F (Farenheit)

U Red Lights to indicate that the process value is in terms of

engineering units.

- Red Lights to indicate a negative displayed value

PAGE 24

3.4.2 KEYPAD CONTROLS

The keys on the keypad functions include: SCROLL: Used to: 1. Display the enabled modes and programmed profiles.

2. While in a mode, used to sequence the parameter codes and values.

3. Exit some Test and Calibration functions.

4. Work in conjuction with other keys: a. With the UP key to display proportional output % when in the Control mode or while a profile is running. b. With the DOWN key:

1) On power up to alter model #

2) Enter Cal/Test functions

3) While a profile is running to view the ramp/soak time remaining.

UP: Used to: 1. Exit a mode.

2. Turn a mode On in the Enable mode

3. Increases a parameter numerical value.

4. View the setpoint.

5. Increase the setpoint value in the Control mode.

6. Work in conjuction with the other keys: a. With the SCROLL key to display proportional output % b. With the DOWN key:

1) On power up to reset the instrument

2) Lamp test

3) Enter the Enable mode

DOWN: Used for: 1. Enter a mode.

2. Turn a mode Off in the Enable mode.

3. Decrease a parameter numerical value.

4. To start a profile when the profile number is displayed.

5. Decrease the setpoint value in the Control mode.

6. Step display through parameter codes in a mode.

7. Work in conjuction with the other keys: a. With the SCROLL key:

1) On power up to alter the model number displayed.

2) Enter Cal/Test functions

b. With the UP key:

1) On power up resets the instrument

2) Lamp test

3) Enter the Enable mode

RUN/HOLD: Used to: 1. To start the profile number being displayed.

2. Change between the profile Run and Hold profile conditions.

Operation Summary 3.5

The configuration and operating modes, the method of moving from one mode to another, and the basic parameter functions are described in each individual section . Data and parameter entry is made by stepping through each mode and making an appropriate response or entry to each step.

3.5.1 MODE SELECTION

If the instrument is in either the Off mode or Control mode, repeated depression of the Scroll key will cause the instrument to display the code corresponding to each mode which is enabled and each profile which has been entered. To enter a mode while its code is displayed, depress the Down key.

To exit the OFF mode, press the SCROLL key until CtrL is displayed, then press the DOWN key.

Entry into any mode except the Control, Tune, Standby, Enable and Profile execution, will cause the instrument's outputs to turn off. Access to the Tune mode is provided while the instrument continues normal operation if in Control or running a Profile.

3.5.2 CONFIGURATION DISPLAYS

During configuration, the display is used to show the parameter codes and values. During normal operation, these displays are used to indicate process values, setpoints, etc. .

PAGE 25

TABLE 3-1 PROGRAM MODE CONFIGURATION PROCEDURE

Press and release the SCROLL key until Prog is displayed. Press the DOWN key to enter the Program mode. Press the SCROLL key to advance the display through the parameter codes and their values. Use the Up and DOWN keys to adjust the values. After adjusting a parameter, press the SCROLL key to proceed to the next parameter. Each time the DOWN key is pressed while a parameter code is being displayed, such as dFF, the next parameter code in the sequence will be displayed.

After all selections have been made, to exit the mode, press the UP key with a parameter in the display (not a setting ). For illustration purposes, all available Program mode parameters have been listed. The parameters that will appear on the specific instrument will depend upon the model number (hardware configuration) of the instrument and on the parameter selections previously made.

For future reference, record the parameter selections for the application in the "Your Setting" column and on the Software Reference Sheet in Appendix E (page 75).

To prevent unauthorized changes to the Program mode, the mode can be disabled (turn off) in the Enable mode.

(Continued on next page)

PAGE 26

PROGRAM MODE FLOW CHART

Prog

inPS

iCor

out1

o1PL

out2

o2PL

rLyC

diSP

dPoS

Euu

EuL

HySt

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

Up Arrow Key

Down Arrow

out3

rLyA

rLyb

SPL

(SPuL EO Option)

SPLL (EO Option)

AtFr

PAGE 27

Com (Optional)

Ptb

PiA

rrH

PFF

dFF

Co1r

PoL

CCon

CbS

CAd

EO Option

Co2r

Pout

Pou

PAGE 28

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

1 Input Selection inPS 0=J T/C degrees C

NOTE: Fault detection is not functional for 0-5 V or 0-20mA inputs.

2 Input Correction iCor -300 to 300 degrees 3 Output 1 out1 1=On-Off - Direct

1=J T/C degrees F 2=K T/C degrees C 3=K T/C degrees F 4=T T/C degrees C 5=T T/C degrees F 6=R T/C degrees C 7=R T/C degrees F 8=S T/C degrees C 9=S T/C degrees F 10=E T/C degrees C 11=E T/C degrees F 12=B T/C degrees C 13=B T/C degrees F 14=N T/C degrees C 15=N T/C degrees F 16=C T/C degrees C 17=C T/C degrees F 20=RTD degrees C 21=RTD degrees F 30=0 to 5VDC/0 to 20mA 31=1 to 5VDC/4 to 20mA 32=0 to 50mVDC 33=10 to 50mVDC 34=0 to 25mVDC

(cooling) 2=On-Off - Reverse (heating) 3=Time Proportioning Direct (cooling) 4=Time Proportioning Reverse (heating) 5=Current Proportioning Direct (cooling) 6=Current Proportioning Reverse (heating) 7=Position Proportioning Open

0 2

4 Output 1Percent Limit o1PL 0 to 100% 5 Output 2 out2 0=None

(Position Prop. Direct - Close) 1=On-Off Direct (cooling) 2=On-Off - Reverse (heating) 3=Time Proportioning Direct (cooling) 4=Time Proportioning Reverse (heating) 5=Current Proportioning Direct (cooling) 6=Current Proportioning Reverse (heating) 7=Position Proportioning Reverse - Close

100 0

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

PAGE 29

6 Output 2 Percent Limit o2PL 0 to 100 % 7 Output 3 out3 0=None

1=Process Alarm Direct 2=Process Alarm Reverse 3=Deviation Alarm Direct 4=Deviaiton Alarm Reverse 5=Deviation Band Alarm Open withing band 6=Deviaiton Band Alarm Closed within band

8 Relay A Assignment rLyA 0=Not Assigned

1=Assigned to Output 1 2=Assigned to Output 2 3=Assigned to Output 3 4=Assigned to Event 1 5=Assigned to Event 2

6=Assigned to Event 3 9 Relay B Assignment rLyb Same selection as Relay A 10 Relay C Assignment rLyC Same selection as Relay A 11 Display Select diSP 1=Process Value

2=Process Value & Setpoint

3=Process Value Deviation

4=Process Value Deviation &

Setpoint

5=Setpoint 12 Decimal Position dPoS 0 or 1 decimal place

(dPoS can be 2, 3, &4 if Euu is selected)

13 Engineering Units Euu -9999 to 9999 units

Upper Value

14 Engineering Units EuL -9999 to 9999 units

Lower Value

100 0

2 3 1

1000

NOTE:

When changing the Decimal position dPoS, the operator MUST ensure that all values previously programmed or tuned are now valid with the entry of a decimal point.

15 Hysteresis HySt 0 to 300 degrees

16 Setpoint Upper Limit SPL -9999 to 9999 degrees

17 Setpoint Lower Limit SPLL -9999 to 9999 degrees

18 Automatic Transfer AtFr 0=No automatic transfer

(SPuL -EO option)

(EO Option)

(width of hysteresis band,

see Page 68)

1=Transfer when

temperature goes

below setpoint

2=Transfer when

temperature goes

above setpoint

1400

PAGE 30

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

19 Profile Time Base Ptb 1=HHH.T - Hours & Tenths

2=HH.MM - Hours & Min. 3=MM.SS - Minutes & Sec. EO Option 4=Units/Hr ramp rate; Hrs. & Tenths soak time 5=Units/Hr ramp rate; Hrs/Mins soak time 6=Units/Hr ramp rate; Mins & Secs soak time

20 Profile Interrupt Action PiA 0=Go to Off mode

1=Continue profile 2=Go into hold condition 3=Restart at the beginning of the profile

21 Remote Run/Hold rrH 0=Not selected

1=Selected. Remote Run/Hold will override controller front panel when placed in hold from remote source 2=Selected. Remote Run/Hold will not override controller front panel when placed in hold from remote source

22 Process Filter Factor PFF 1 to 20 (# of scans aver.)

1=No filtering

23 Display Filter Factor dFF 1 to 20 (# of scans aver.)

1=No filtering

Parameters 24 - 28 are for Extended Option (EO) Only

24 Current Output 1 Range Co1r 0=0 to 20 mA

1=4 to 20 mA

25 Current Output 2 Range Co2r 0=0 to 20 mA

1=4 to 20mA

26 Process Output Pout 0=Not selected

1=Process Assigned to Current Output 1 2=Process Assigned to Current Output 2 3=Setpoint Assigned to Current Output 1 4=Setpoint Assigned to Current Output 2

27 Process/Setpoint Pou -9999 to 9999

Output Upper Value

28 Process/Setpoint PoL -9999 to 9999

Output Lower Value

2000

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

Parameters 29 - 31 are for Communications Option Only

PAGE 31

29 Communications CCon 0=Off

Configuration 1=Monitor only (read only)

2=Normal mode (read and write) 3=Total Access with Limit Checking 4=Total Access without Limit Checking

30 Communication CbS 1=300 bits per second (bps)

Bit Rate Select 2=600 bps

3=1200 bps 4=2400 bps 5=4800 bps 6=9600 bps

31 Communication Address CAd 0 to 99

* Factory setting for Total Access

0, 4*

0, 1*

PAGE 32

TABLE 3-2 TUNE MODE CONFIGURATION PROCEDURE

The Tune mode allows the entry, review or altering of the process control Tune adjustments and the alarm setting.

To enter the Tune mode, press and release the SCROLL key until tunE is displayed, then press the DOWN key. Press the SCROLL key to advance the display through the parameters and their values. Use the UP and DOWN keys to select (adjust) the values. Each time the DOWN key is pressed while a parameter code is being displayed, such as dFF, the next parameter code in the sequence will be displayed.

After selecting a parameter, to exit the mode, press the SCROLL key to proceed to the next parameter. After all selections have been made, press the UP key with a parameter in the display (not a setting).

For illustration purposes, all available Tune mode parameters have been listed. The parameters that will appear on the specific instrument will depend upon the parameter selection previously made in the Program mode.

For future reference, record the parameter selections for the application in the "Your Setting" column and on the Software Reference Sheet in Appendix E (page 75).

To prevent unauthorized changes to the Tune mode, the mode can be disabled (turned off) in the Enable mode.

The Tune mode is adjusted on-line. The instrument will react to changes as they are made.

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

1 Second Output Position SPrd -1000 to 1000 units 2 Process Alarm PAL -9999 to 9999 units* 3 Deviation Alarm dAL -3000 to 3000 units* 4 Deviation Band Alarm dbAL 1 to 3000 units* 5 1st Output Proportional Pb1 1 to 3000 units

Band Width

6 2nd Output Proportional Pb2 1 to 3000 units

Band Width 7 Manual Reset rSEt -1500 to 1500 units 8 Automatic Reset (integral) ArSt 0.0 to 100.0 repeats per

minute 9 Rate (or Derivative) rAtE 0.0 to 10.0 minutes 10 Cycle Time Output 1 Ct1 1 to 240 seconds 11 Cycle Time Output 2 Ct2 1 to 240 seconds 12 Position Proportioning SEnS 0.0 to 50.0%

Sensitivity

0 0 0 1 100

100

0.0

0.0 30 30

1.0

13 First Output Position FoP -1000 to 1000 units * See Section 4.2, page 44 for explaination of setting alarms.

TUNE MODE FLOW CHART

tunE

PAGE 33

SPrd

PAL

dAL

dbAL

Pb1

Pb2

rSEt

Ct1

Ct2

SEnS

FoP

ArSt

rAtE

Key

Actual Display

ON OFF

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

Up Arrow Key

Down Arrow

PAGE 34

PROFILE ENTRY MODE FLOW CHART

PEnt

PLCt

dhru

dhrd

PEnd

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

Up Arrow Key

Down Arrow

TABLE 3-3 PROFILE ENTRY MODE CONFIGURATION PROCEDURE

Depress and release the SCROLL key until PEnt is displayed. Use the DOWN key to enter the Profile Entry mode. Depress the SCROLL key to scroll through the parameters and their values. Use the UP and DOWN keys to adjust the values. After adjusting a parameter, depress the SCROLL key to proceed to the next parameter. After all selections have been made, to exit the mode, depress the UP key with a parameter in the display (not a setting). For assistance in developing the Profile refer to Appendix F (page 78).

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

1 Profile Number Pn 1 to 8

PAGE 35

2 Number of Segments nS 0-6 segments Steps 3-11 are repeated for each segment 3 Ramp Time rt 0 to 9999 units per Ptb 3 *Ramp Rate rr 0 to 9999 units per Ptb 4 Setpoint SP Setpoint at end of Ramp 5 Event Output 1 E1 on or off 6 Event Output 2 E2 on or off 7 Event Output 3 E3 on or off 8 Soak Time St 0 to 9999 units per Ptb 9 Event Output 1 E1 on or off 10 Event Output 2 E2 on or off 11 Event Output 3 E3 on or off

** ** ** ** ** ** ** ** ** **

* Will be displayed instead of Ramp Time rt if Ramp Rate is utilized (see Ptb, EO Option only, page 29).

12 Profile Loop Count PLCt 0 to 9999, 0-continuous 13 Deviation Hold after dhru 0 to 3000 units

Ramp Up 0=no auto hold

** **

14 Deviation Hold after dhrd 0 to 3000 units

Ramp Down 0=no auto hold

15 Profile End control PEnd -1=Hold at last setpoint

0=Abort - all outputs off or at 0% Events off 1=Transfer to profile 1 2=Transfer to profile 2 3=Transfer to profile 3 4=Transfer to profile 4 5=Transfer to profile 5 6=Transfer to profile 6 7=Transfer to profile 7 8=Transfer to profile 8

After selecting the Profile End Control parameter value, press the SCROLL key to advance the display to Pn. Press the UP key with Pn or any parameter code displayed to exit the Profile Entry Mode. (Continued on next page)

PAGE 36

**All values except Profile Loop Count (PLCt) are initialized to zero and all event outputs are initialized to OFF, with the exception of the first profile. Profile Loop Count (PLCt) is set to 1.

The first profile has the number of segments initialized to zero, to turn the profile OFF, but the profile has values stored in it for demonstration purposes. By setting the number of segments to two, the profile can be reviewed and/or executed.

PROFILE 1 VALUES FOR DEMONSTRATION PURPOSES

Code Value rt .10 Ramp Time SP 100 Setpoint E1 on Event 1 on E2 oFF Event 2 off E3 oFF Event 3 off St .10 Soak Time E1 oFF Event 1 off E2 on Event 2 on E3 oFF Event 3 off rt .10 Ramp Time SP 0 Setpoint E1 oFF Event 1 off E2 oFF Event 2 off E3 on Event 3 on St .10 Soak Time E1 oFF Event 1 off E2 oFF Event 2 off E3 oFF Event 3 off PLct 1 Profile Loop Count dhru 0 Deviation Hold after Ramp Up - None dhrd 0 Deviation Hold after Ramp Down - None PEnd 0 Profile End Control - Abort - oFF Mode

TABLE 3-4 ENABLE MODE CONFIGURATION PROCEDURE

To enter the Enable mode, press and hold the UP and DOWN keys while in CtrL or oFF modes. All the display lamps will light. After 10 seconds, the lamps will go out and EnAb will be displayed. Release the keys and the display will change to EtSt. Press and release the DOWN key and each mode to be enabled/disabled will be displayed. With the Enable mode prompt for the desired mode displayed, press the SCROLL key to verify that the displayed mode is either on (enabled) or oFF (disabled). Press the DOWN key to turn off the mode, press the UP key to turn on the mode or press the SCROLL key to advance the display to the next Enable mode prompt. Use the "Your Setting" column in the table to record your programming.

A Hardware jumper located on the Controller Board (See Appendix A-2, page 64) can be used to lock/unlock the Enable mode. When the jumper is moved to the locked position, entry into the Enable mode is not possible until the jumper is moved to the unlock position.

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

1 Test Mode EtSt on or oFF 2 Calibration Mode ECAL on or oFF

oFF oFF

DISPLAY AVAILABLE FACTORY YOUR

STEP DESCRIPTION CODE SETTINGS SETTING SETTING

3 Program Mode EPro on or oFF

PAGE 37

4 Tune Mode Etun on or oFF 5 Manual (Stby) Mode ESby on or oFF 6 Profile Continue Mode EPC on or oFF 7 Profile Entry Mode EPE on or oFF 8 Setpoint Change ESPC on or oFF

ENABLE MODE FLOW CHART

EnAb

EtSt

ECAL

ON OFF

on on oFF on on

EPro

Etun

ESbY

EPC

EPE

ESPC

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

Up Arrow Key

Down Arrow

PAGE 38

Operation 4.1

4.1.1 OFF MODE

In the Off Mode, the instrument control, process retransmission signal(s) and alarm function(s) are turned off. The Off mode can be entered by pressing and releasing the SCROLL key until the display reads oFF, then pressing the DOWN key. The display will read oFF and then the current process variable at two second intervals. This sequence will repeat to indicate that the instrument is in the Off mode.

4.1.2 CONTROL MODE

In the Control mode, the instrument control function(s) and alarm(s) are actively responding to the process variable as selected in the Program and Tune modes. The control mode allows setpoint changes from local setpoint (standard) adjustment by an operator at the front keypad. Other operations in the Control mode include a lamp test and proportional output % display.

4.1.2.1 DIRECT/REVERSE OPERATION OF OUTPUTS

Direct operation is typically used with cooling applications. On-Off direct output(s) will turn on when the process variable exceeds setpoint. Proportional direct output(s) will increase the precentage of output as the process value increases within the proportional band.

Reverse operation is typically used with heating applications. On-Off reverse output(s) will turn off when the process variable exceeds setpoint. Proportional reverse output(s) will decrease the percentage of output as the process value increases within the proportional band.

4.1.2.2 LOCAL SETPOINT OPERATION

The instrument must be in the Control mode to allow the setpoint value to be adjusted. In the Control mode, to view the setpoint, press and release the UP or DOWN key. The green LED under the SP label will light to indicate that the displayed value is the setpoint. To change the setpoint value, press and hold the appropriate key. Press and hold the UP key to increase the setpoint or press and hold the DOWN key to decrease the setpoint. The setpoint will change slowly at first then faster as the key is held pressed. If the setpoint will not increase, check the Program mode (page 25) to see that you are not trying to increase the setpoint above the setpoint limit SPL. Check that the Setpoint Change mode is on in the Enable mode.

4.1.2.3 PROFILE OPERATION

To start a profile, press and release the SCROLL key to sequence the display to the profile number display code P1, P2, etc. With the desired profile number displayed, press either the DOWN or the RUN/HOLD to start the profile. run will be displayed for about 2 seconds to indicated that the profile is starting. The status lamps will indicate which segment is active and if the profile is in the ramp or soak portion of the segment.

To stop a profile that is running, press the RUN/HOLD key. The display will show hold for about 2 seconds, then the process value for about 2 seconds and then continue to display this sequence. The profile timer will stop but the control, alarm, and event outputs will remain active. The profile can be restarted by pressing the RUN/HOLD key. To exit the profile, go to hold and then press and release the SCROLL key until the display shows oFF or CtrL, then press the DOWN key. Pressing the DOWN key with oFF displayed will cause the control, alarm, and events to be turned off. (Pressing the DOWN key with CtrL displayed will leave the events as they were, and the control and alarm outputs will remain active). The setpoint will be the last setpoint seen in the profile.

While a profile is running, it is possible to display additional profile status information. To activate the Profile Execution Status Display sequence, hold the DOWN key and press the SCROLL key. This will cause the display to sequence through the following series of display codes and values:

Display Code Description Value

Pn Profile Number Actual Profile Number tr Time remaining in current Ramp or Soak Actual time remaining value

(in whatever units were config ured in the program mode for

Ptb) E1, E2, E3 Event 1-3 status (if applicable) on or oFF SP Current Setpoint Actual Setpoint Value ProC Current Process Value Actual Process Value PLCt Profile Loop Count remaining Profile Loop count Value

Each code or value will only be displayed if they are appropriate. Each code or value will be displayed for one second. This sequence will continue until any key is depressed.

To start a profile running at some point within the profile other than start can be accomplished by using the Profile Continue mode. Press and release the SCROLL key until display is PCon, then press the DOWN key. The display will be Pn; adjust the profile parameter values as needed in the Profile Continue Configuration mode, then press the RUN key. The instrument will execute the profile selected as directed by the information entered in the Profile Continue mode. See Table 4-1, page 40. If you are running a profile and it is desired to alter the profile you must go to hold and then scroll to the Off or Control mode before entering Pcon.

Note: Pcon is not available when Profile Time Base (Ptb) in Program mode has been set for Units Ramp Rate (EO Option).

PAGE 39

PROFILE CONTINUE MODE FLOW CHART

PCon

rtr

Str

E1-E3

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

PLCt

Up Arrow Key

Down Arrow

PAGE 40

TABLE 4-1 PROFILE CONTINUE MODE - Not available when Ptb=4, 5, or 6

(EO Option only)

DISPLAY

STEP DESCRIPTION CODE ACTION

1 Profile Number Pn Press the SCROLL key to see the

number of the last active profile.

2 Profile Number Value X If necessary, use the UP or DOWN key

to change the profile number to the desired value, then press the SCROLL key.

3 Segment Number Sn Press the SCROLL key to see the

number of the last active segment.

4 Segment Number Value X If necessary, use the Up or Down key

to change the segment number to the desired value, then press the SCROLL key. DO NOT SET THIS VALUE TO 0 AND ATTEMPT TO RUN THE PROFILE. AN ERROR 19 WILL DISPLAY AND THE PROFILE WILL NOT RUN.

5 Ramp Time Remaining rtr Press the SCROLL key to see the

Ramp Time Remaining value.

6 Ramp Time Remaining X If necessary, use the UP or DOWN key

Value to adjust the Ramp Time Remaining

value, then press the SCROLL key. If the time remaining is set to 0 when the SCROLL key is pressed, the Soak Time Remaining code will be displayed. If the time remaining is greater than 0, then the display will advance to the Profile Loop Count code.

7 Soak Time Remaining Str Press the SCROLL key to see the Soak

Time Remaining value of the last active profile.

8 Soak Time Remaining X If necessary, use the UP or DOWN key

Value to adjust the Soak Time Remaining

value, then press the SCROLL key.

9 Event(s) E1-E3 If any event outputs have been selected

in the Program mode then each event number selected will be displayed in sequence. Press the SCROLL key to see the status of the event(s).

10 Event(s) Status on/oFF If necessary, use the UP key to turn on

an event that is off or the DOWN key to turn off an event that is on. Press the SCROLL key to see the next event number. After the last event status is selected, pressing the SCROLL key will advance the display to be PLCt.

11 Profile Loop Count PLCt Press the SCROLL key to see the

Remaining Profile Loop Count Remaining for the

last active profile.

12 Profile Loop Remaining X If necessary, use the UP and DOWN

key to adjust the Profile Loop Count Remaining value.

To start a profile running, press the RUN/HOLD key while in the Profile Continue mode. If no changes were made to any of the Profile Continue parameters, press the RUN/HOLD key twice. The profile selected will start at the point selected.

4.1.2.4 ON-OFF CONTROL

On-Off control can only be implemented on controllers provided with SPST relay or SSR driver output(s). On-Off operation can be assigned to either or both output 1 and 2. The On-Off control can be selected as direct or reverse acting. Direct action is typically used in cooling applications. The output device will turn on when the process value is greater than the setpoint. Reverse action is typically a heating application. The output device will turn on if the process value is below the setpoint. A hysteresis adjustment is provided for On-Off outputs. This adjustment is in terms of degrees/engineering units and defines the width of the hysteresis bandwidth about the setpoint. This parameter may also be referred to as a dead band. Relay chatter can be eliminated by proper adjustment of this parameter. When operating in On-Off control, the control algorithm will turn the output on or off depending upon the setpoint, the relative position of the process value, and the hysteresis adjustment. The respective OUT1 or OUT2 indicator will illuminate to indicate that the output device is on. The hysteresis will also affect the operation of the alarm output if used.

PAGE 41

4.1.2.5 TIME PROPORTIONING CONTROL

Time Proportioning Control can be implemented on controllers provided with SPST relay or SSR driver output(s). Time proportioning can be programmed for output 1 and/or 2. Time Proportioning control is accomplished by cycling the output on and off when the process value is within the proportional bandwidth selected at a prescribed time period. The time period is selected in the Tune mode by adjusting Ct1 and/or Ct2. The on time is a percentage of the Cycle Time.

Example: Calculated output % = 40%; Cycle Time adjustment = 20 seconds

Output on time = .4 x 20 = 8 seconds Output off time = .6 x 20 = 12 seconds

4.1.2.6 CURRENT PROPORTIONING CONTROL

Current Proportioning control provides a proportional current output in response to process value and setpoint. The current output can be selected for direct or reverse operation. Direct current output control is typically used for cooling applications. The current output will increase as the process value increases within the proportional bandwidth selected. The reverse current output control is typically used in heating applications. The current output will decrease as the process value increases within the proportional bandwidth selected.

The instrument can be programmed to provide 0 to 20mADC or 4 to 20mADC (if EO option is present) current output(s). The output selected is dependent upon the final control element being used in the process. The output 1 and/or output 2 LED will be lighted whenever the Current Proportional outputs are selected.

PAGE 42

4.1.2.7 POSITION PROPORTIONING CONTROL

Position Proportioning control can be implemented on those controllers provided with two SPST relay outputs or two SSR Driver outputs and Slidewire Feedback option.

Positioning proportioning control permits the use of PID control where the final control element is a modulating device such as a motorized valve. In this form, each of the two required relays or SSR Drivers will be used to control the valve. One output is used to open the valve, the other is used to close the valve. The slidewire feedback is used to provide a signal relative to the valve armature position to the instrument.

As with the other proportioning control forms, the process input, tuning parameters and the setpoint are used by the control algorithm to calculate the output % requried to correct for the deviation between setpoint and process.

With Position Proportioning control, it may be necessary to adjust the Sensitivity (SEnS) Tune mode parameter to reduce or eliminate oscillations of the motor around setpoint. If oscillation occurs, increase the SEnS value until the motor stops oscillating. If the differential between the Open and Closed rotation is too large, then decrease the SEnS value. Also, for proper Position Proportioning operation, it is necessary to specify the actuation time of the valve or damper from full open to full closed. If the motor has a stroke duration of 60 seconds, change the value in the Cycle Time parameter Ct1 to 60. This ensures that the controller will move the motor for the proper amount of time when making adjustments.

4.1.2.8 DUAL OUTPUT CONTROL

Dual output control can be performed when two outputs are specified. The outputs may be programmed for On-Off, Time Proportioning, or Current Proportioning, as applicable.

The output action is dependent upon the setpoint, the process value, and Tune mode parameters. If two proporitonal outputs are selected, both output proportional bands will be biased so that 0% of output is seen when the process value equals setpoint. The output(s) can be biased by the use of the Tune mode parameters FOP and SPrd as shown in Figure 4-1 (below).

The first output is programmed as a proportional reverse output and the second as a proportional direct output. (See Glossary, page 67, for definitions of these terms). Dual proportioning outputs are provided with separate proportional bands and cycle time adjustments for each output.

FIGURE 4-1

100% Proportional Output 1

Reverse Actin

Output

Control

Setpoint

Direct Actin

Output

100% Proportional Output 2

Process

First Output Position = X

-X

Second Output Position = Y

Value

4.1.2.9 PROPORTIONAL OUTPUT PERCENTAGE DISPLAY

While in the Control mode, press and hold the UP key and then press the SCROLL key to cause the display to sequence through a series of display codes and values:

Po1 Percent Output 1 (if applicable) Output 1% value Po2 Percent Output 2 (if applicable) Output 2% value Proc Process Value Actual Process Value

Each code and output value will be displayed only if the corresponding proportional output is present. Each code or value will be displayed for 1 second. This sequence of displays will continue until the SCROLL key is pressed, which will then return the display to the normal mode.

4.1.3 MANUAL MODE FOR PROPORTIONAL OUTPUTS

Manual adjustments of the proportional output(s) can be used to test the operation of the output(s), while tuning to establish basic process control, or to provide control of the proportional output(s) during the occurance of certain error conditions.

Note: The proportional output(s) do not change automatically in response to changes in the process while in the Manual mode. Be sure to pay close attention to the process to avoid damage.

To enter the Manual mode, press and release the SCROLL key until you see Stby. Then press the DOWN key . The Manual mode status LED will light to indicate that the Manual mode is in use. Shifting from the Control to the Manual mode is bumpless. The proportional output(s) will stay at the last value(s) calculated by the control algorithm. Po1 will appear on the display if output 1 is a proportional output or Po2 if output 1 is not a proportional control. If no keys are pressed, the display will sequence through the following displays:

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Po1 if output 1 is 3, 4, 5, 6, 7 then the output 1 percentage of output value Po2 if output 2 is 3, 4, 5, 6 then the output 2 percentage of output value. Proc will be displayed, then the current process value.

In order to vary a proportional output percentage value, press and release the SCROLL key until the display code for the output is displayed Po1 or Po2. Press and release the SCROLL key again to see the percentage of output value. Press the UP key to increase the output percentage value. Press the DOWN key to decrease the output percentage value.

To return to the Control mode of operation from the Manual mode, press the SCROLL key until you see Po1 or Po2 then press the UP key. The display will change to Stby. Press the SCROLL key until you see the mode you wish to enter, then press the DOWN key. If the Automatic Transfer feature is selected in the Program mode, the instrument will switch from Manual mode to the Control mode when process value reaches the setpoint value.

4.1.4 PROCESS RE-TRANSMISSION OUTPUT - EO OPTION ONLY

If the instrument is provided with a current output not used for process control, this output may be assigned to provide a linear re-transmission of the process value. This output can be used to provide a process signal to remotely installed recorders, panel meters, or dataloggers. The process output is scaled for the application by using the Program mode parameters process/setpoint value upper Pou and process/setpoint value lower PoL. The current output resolution is @ 200 steps, so for the best re-transmission accuracy, the span between Pou and PoL should be as small as possible. If a current output is used for re-transmisssion, the corresponding control output, out1 or out2, cannot be assigned to it.

Upon an error condition, Process Value output will be set to 0 percent if the 1st output control is direct acting. If the control action is reverse acting, the Process Value output will be set to 100 percent.

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4.1.5 SETPOINT RE-TRANSMISSION OUTPUT - EO OPTION ONLY

If the instrument is provided with a current output not used for process control, this output may be assigned to provide a linear re-transmission of the setpoint value. The setpoint output is scaled for the application by using the Program mode parameters process/setpoint output value upper Pou and process/setpoint output value lower PoL. The current output resolution is @ 200 steps, so for the best re-transmission accuracy, the span between Pou and PoL should be as small as possible. If a current output is used for re-transmission, the corresponding control output, out1 or out2, cannot be assigned to it.

Alarm Operation 4.2

The type of alarm is selected in the Program mode as follows:

1. Process Alarm Direct - the alarm will be on if the process value is greater than the process value selected.

2. Process Alarm Reverse - the alarm will be on if the process value is less then the process value selected.

3. Deviation Alarm Direct - the alarm will be on if the process value is greater than the setpoint plus the deviation value selected.

4. Devation Alarm Reverse - the alarm will be on if the process value is less than the setpoint plus the devation value selected.

5. Deviation Band Alarm Open Within - the alarm will be on if the process value is greater than one half the deviation band alarm values selected above or below the setpoint.

6. Deviation Band Alarm Closed Within - the alarm will be on if the process value is less than one half the deviation band value selected above or below the setpoint.

The alarm will be active while the instrument is in the Control mode or while the profile is running. Relay and solid state relay drivers can be assigned to provide output capability to the alarm function.

The alarm value (Process, deviation or bandwidth) is selected in the Tune mode. Alarm output chatter can be reduced by using the hysteresis parameter in the Program mode

to create a deadband around the alarm point.

Tune Mode Operation 4.3

Proportional output control may require the adjustment (tuning) of the PID and other related parameters. This provides a means for the instrument's control algorithm to be adjusted to meet specific application requirements.

4.3.1 SYSTEMATIC TUNING METHOD

1. Changes in tuning parameters should be made one at a time.

2. After making any changes in tuning parameters, a disturbance should be introduced into the process so that the process reaction may be observed. This process reaction, or recovery, will tell whether the tuning parameters provide the desired control. It is usually easiest to make a step change in setpoint to introduce this disturbance.

3. The change in setpoint, or disturbance, referenced above should be large enough to cause an observable deviation of process from setpoint. However, this change should not be so large that it will cause the controller output to proceed to either extreme limit.

4. Controller tuning for optimal control is not hard and fast, BE PATIENT. The process will take a certain amount of time to react to the setpoint changes during tuning. The amount of time depends upon the specific process, however, a period of 8 to 12 minutes should be allowed between changes. The important point to remember is to allow the process to react completely, do not rush through tuning of the controller. If the complete process reaction is not observed, optimum control may never be achieved.

5. Time Proportioning control output(s) require(s) the cycle time to be adjusted for the application. Short cycle times typically result in the most accurate process control, but will cause the quickest wear out of any mechanical components.

6. Leave all other tuning parameters (except for the alarm settings, if used) at the factory default settings. Obtain the best possible process reaction by adjusting the Proportional Bandwidth parameter. The setting that achieves the best response for the process should be left in the controller programming, and should be noted on the Software Reference Sheet in Appendix E (page 75).

7. If there are to be no setpoint or load changes in the process, the Proportional Band adjustment may be all that is necessary for proper control. If an offset still exists (the process does not settle out at setpoint with the best possible proportional band adjustment) Manual Reset may be added to eliminate this offset.

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8. Auto Reset may be added to eliminate offsets and improve response to setpoint and load changes. Increase Auto Reset from 0 in 0.2 increments. Start with a small amount. Increase this increment if there is no apparent reaction. Remember to allow the process 8 to 12 minutes to react.

9. If necessary, Rate may be added. Rate is a dynamic tuning parameter. Rate may be required to compensate for process lags or to help inhibit reset windup when a large amount of Auto Reset (4 or 5 repeats per minute) is being used.

10. Controller tuning is not hard and fast. It may be necessary to adjust the tuning parameters over a period of time to obtain optimal control of the process.

4.3.2 ZIEGLER NICHOLS TUNING METHOD

This procedure has been determined empirically to yield 1/4 ampitude decay tuning parameters that are determined by watching the system in a sustained oscillation (curve C, page 46) the ultimate proportional band and ultimate time period) and then using these values from this sustained oscillation to calculate ideal parameters.

Determining Ultimate Proportional Band and Ultimate Time Period

1. Set Manual Reset rSet to 0.0, set ArSt to 0.0 and set rAtE to 0.0

2. Enter the Control mode of operation, observe the process reaction.

3. Set the Proportional Band (PB) at 100 and upset the process and observe the response. One easy method for imposing the upset is to move the setpoint for a few seconds and then return it to its original value.

(Continued on next page)

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4. Achieve a response curve similiar to the sustained oscillation (curve C), this is the Ultimate Proportional Band (UPB) and Ultimate Time Period (UTP).

a) If the response curve from step 3 does not damp out, as in Curve A from the drawing, the PB is too low. The PB should be increased and step 3 repeated.

b) If the response in step 3 damps out, the PB is too high. The PB should be decreased and step 3 repeated.

These values obtained for Ultimate Proportional Band (UPB) and Ultimate Time Period (UTP) are used to calculate ideal P, PI, PD, PID tuning parameters using the following ZieglerNichols equations:

Proportional only control (P) -

P(Pb) = 2 x UPB (degrees or units)

Proportional plus automatic reset (PI) -

P (Pb) = 2.2 x UPB (degrees or units) I (ArSt) = 1.2 / UTP (repeats per minute)

Proportional plus derivative (or rate) (PD) -

P (Pb) = 1.7 x UPB (degrees or units) D (rAtE) = UTP / 8 (minutes)

Proportional plus automatic reset plus derivative (PID)

P (Pb) = 1.7 x UPB (degrees or units) I (ArSt) = 2 / UTP (repeats per minute) D (rAtE) = UTP / 8 (minutes)

If an overdamped response is desired, multiply the proportional band by two.

Period

Curve A : unstable Curve B : stable Curve C : continuously cycling, ultimate PB and period

Service 5.1

This section contains Calibration, Test and Trouble-shooting procedures that can be performed by the user. Instruments are calibrated to all input type specified when ordered at the factory prior to shipment. Re-calibration should not be necessary under normal operating conditions.

Calibration 5.2

Caution: Do not attempt any of these calibrations without the proper test equipment with specifications equal to or better than those listed.

Press and release the SCROLL key to sequence the display until CAL appears. If CAL does not appear, refer to Section 3 for instructions on how to enable the Calibration mode. When CAL appears on the display, press the DOWN key. The display will read CAL 1. CAL 1 can be initiated at this time or press the SCROLL key to advance the display to other calibrations available.

CALIBRATION FLOW CHART

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CAL

CAL1

CAL2

CAL3

CAL4

CAL5

CAL6

CAL7

Prog

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

Up Arrow Key

CAL8

Down Arrow

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TABLE 5-1 CALIBRATION PROCEDURES

Calibration Procedure Description

CAL 1 Re-initialization of Program and Tune mode values. CAL 2 Main Calibration used by all inputs. This is the only calibration requried for

voltage and millivolt inputs.

CAL 3 Cold Junction Compensation calibration used to correct for component

variation in CJC circuit.

CAL 4 Cold Junction utility. The temperature of the cold junction is displayed. No

adjustment is made with this procedure.

CAL 5 RTD input calibration used to correct for component differences in the RTD

input circuit. CAL 6 CJC turn on/off. CAL 7 Factory Use Only. CAL 8 Re-initialization of all profile information

5.2.1 CAL 1 PARAMETER INITIALIZATION

This procedure is performed to erase the information that was entered in the Program and Tune modes. All parameters will be reset to default values. Prior to beginning this procedure record the Program and Tune mode parameters so that they can be re-entered. No special test equipment is required.

With CAL 1 displayed, depress and hold the DOWN key, then press the SCROLL key. The display will momentarily go blank. Release the keys. CAL 1 will reappear on the display. This calibration can be done again or another may be selected.

5.2.2 CAL 2 MAIN CALIBRATION

This procedure determines and saves calibration values which correct for component variations relating to the input measuring function of the instrument. This is the only calibration required for the volt and millivolt inputs. Additional calibration procedures are required for thermocouple and RTD inputs.

A 50.00 ± .01 mVDC source is required for calibrating. In addition, make sure that JU1 on the Processor board is in the "non volt" position. See Appendix A-2 (page 64).

Make sure all input wiring is disconnected. Short the input terminals 1 and 3 or apply

0.00 ± mV to the input. With CAL2 displayed, press and hold the DOWN key, then press the SCROLL key. Release both keys and the instrument will display hLd1. Depress the DOWN key; dELy will appear for up to ten seconds, then SCAn will appear for up to ten seconds. If the calibration reference number which appears is not between -50 and +50, proceed per note below. Otherwise, connect a 50.00 ± .01 mV source to the input terminals. Press the DOWN key and dELy will be displayed for ten seconds and the SCAn for ten seconds. Then CAL2 will reappear. If there is a problem, the appropriate error code will be displayed. Restore JU1 to the position necessary for the input type.

NOTE: If the calibration reference number falls outside the -50 to +50 range, depress the SCROLL key and CAL2 will be displayed. Depress the DOWN key and perform the calibration once more. Repeat the calibration until the number falls within the tolerance limits. If the calibration number remains outside these limits, check the connections to the test equipment and try the calibration again. If the number still does not aproach the tolerance limits contact an Applications Service Engineer at the factory or a local representative.

Error Recover - see 5.4 (page 56) for details. However, be sure that the millivolt source is securely connected, functioning properly and the polarity is correct. Press the DOWN key to bring the instrument back to dELy and try the calibration again. The calibration can be exited at anytime. hLd1 or the reference number is displayed by pressing the SCROLL key.

CAL 2 QUICK CALIBRATION

This routine will allow the operator to execute a rough calibration on their unit via the keypad with no other equipment or disturbance to established wiring. It is intended to provide a partial recovery from a calibration corruption where the necessary equipment indicated in Cal 2-5 may not be available. It should be noted that this is not intended as a substitution to the main calibration procedure described earlier and may considerably deter from the accuracy of the instrument.

With CAL2 displayed, press and hold the DOWN ARROW key, then press the SCROLL key. Release both keys and the instrumet will display hLd1. Press and hold the UP ARROW key, then press the SCROLL key. The display will momentarily blank and then CAL1 will be displayed. Release both keys and depress the UP ARROW key. CAL will be displayed.

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5.2.3 CAL 3 COLD JUNCTION COMPENSATION

This procedure determines and saves calibration values which correct for component variations relating to the cold junction compensation. This calibration must be preceded by CAL2 the main calibration, to properly calibrate the instrument. These two calibrations are all that is needed for proper operation with thermocouple inputs.

Test equipment: : one type J thermocouple and one mercury thermometer, accurate to ± .25 degrees C or equivalent are required.

Make sure all input wiring is disconnected and connect the J thermocouple to the input. Place the thermometer next to the thermocouple and allow the controller to warm up for 30 minutes, before proceeding with the calibration.

With CAL3 displayed, press and hold the DOWN key, then press the SCROLL key and the unit will display hoLd. Release both keys. Press the DOWN key and dELy will be displayed for ten seconds, then SCAn for ten seconds. If SCAn remains in the display for much longer than ten seconds, refer to the the note below. The instrument will compute and display the cold junction temperature to the nearest tenth of a degree C. Compare reading with thermometer and use the UP and DOWN keys to correct the reading, if necessary. To end procedure, press the SCROLL key and CAL3 will be displayed again.

NOTE: If the instrument continues to display in SCAn, proceed as follows. With SCAn displayed, press the SCROLL key. The instrument will display hoLd. Press the UP key . The instrument will begin the calibration procedure with a default value and proceed to dELy. Complete calibration as described above.

Error recovery - see section 5.4 (page 56) for details on specific errors. The calibration can be exited at any time. hoLd is displayed by pressing the SCROLL key.

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5.2.4 CAL4 COLD JUNCTION UTILITY

This procedure displays the temperature the cold junction compensator is sensing. No test equipment is required.

With CAL4 displayed, press and hold the DOWN key, then press the SCROLL key. Release both keys and SCAn will be displayed for 10 seconds while the instrument senses the CJC temperature. The result will then be displayed to a tenth of a degree C. The input terminals must be shorted. CAL3 must first be performed.

ambient temperature. It is the temperature of the CJC

and CAL4 will be displayed.

The displayed temperature is not the

. To exit, press the SCROLL key

5.2.5 CAL5 RTD INPUT

This procedure determines and saves calibration values relating to RTD inputs. This calibration must be preceded by CAL2 to properly calibrate the instrument. A decade resistance substitution box with .01% resolution or equivalent is required.

Processor board jumper JU1 is in the non-volt position (Appendix A-2, page 64) and that the Option board jumpers JU2 and JU3 are in the proper positions (Appendix A-3, page 65).

With CAL5 displayed, press and hold the DOWN key and then press the SCROLL key. The display will now be hLd1 to indicate that the instrument is set to calibrate the RTD input. Connect the decade box at 100 ohm setting across the input terminals 1 and 3 and a jumper wire from terminal 1 to 5. Press the DOWN key and dELy will be displayed for 10 seconds, then SCAn for ten seconds. When hLd2 is displayed, change the decade box setting to 277 ohms to the input terminals (do not disturb the wiring) and press the DOWN key. The display will change to dELy for 10 seconds, followed by SCAn for ten more seconds. CAL5 will be displayed after the calibration is completed.

Make sure that the

Error recovery: See section 5.4 (page 56) for details on specific errors.

The calibration can be exited when the instrument displays hLd1 or hLd2 by pressing the SCROLL key.

5.2.6 CAL6 COLD JUNCTION COMPENSATION

This routine provides selection of operating modes for the cold junction compensation used for thermocouple inputs.

With CAL6 displayed, press and hold the DOWN key, then press the SCROLL key. The instrument will display C6 and the number of the mode in effect. Press the UP or DOWN key to change the mode selection, indicated by the number to the right of the C6. Pressing the SCROLL key will exit the calibration with the last number displayed in effect.

The selected mode will remain in effect if power is interrupted. To return the instrument to normal operation, CAL6 must be exited, with mode zero selected, or CAL1 must be executed to initalize all parameters.

Mode 0: Normal operating mode. Mode 1: Cold Junction Compensation temperature will be internally fixed at 0 degrees C by

the software to facilitate linearization testing when using an uncompensated millivolt source to simulate thermocouple millivolt input signal.

Note: If the Process Value exceeds 999.9, the leftmost digit will be the letter o with a bar over it. The other digits will be valid.

5.2.7 CAL8 PROFILE REINTIALIZATION

This procedure is used to erase all profiles that have been entered in the instrument. Be sure to record any profile information on the Profile Recording Sheets (Appendix F, pages 78 and

79) so that they can be re-entered. With CAL8 displayed, press and hold the DOWN key, then press the SCROLL key. The

display will blank momentarily and then CAL8 will be displayed.

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Test Mode Procedures 5.3

To enter the Test mode, press and release the SCROLL key until tESt appears on the display, then press the DOWN key. tSt1 will be displayed, press and release the SCROLL key to advance the display to the desired test. Test 1, 2 and 3 are performed as a unit so the display will advance directly to tSt4 from tSt1. Listed below in Table 5-2 are the test procedures available. Test 1, 2 and 3 are performed on start up, periodically during operation, and on entry into the Test mode. Test 4 is executed on entry into and periodically during the Operation mode. These tests can be used as a trouble shooting aid.

TEST MODE FLOW CHART

tESt

tSt1

ON OFF

Key

Actual Display

On/Off Display Use arrow keys to turn on or off

Scroll Key

Numeric Display Use arrow keys to change value

tSt4

tSt5

tSt6

tSt7

tSt8

tSt9

Up Arrow Key

Down Arrow

tStA

TABLE 5-2 TEST PROCEDURES AND DESCRIPTION

Test Description Test 1 Microprocessor internal RAM test. Used to check the processor RAM to

make sure it is functioning correctly. Test 2 External RAM test, used to test the RAM chip for proper function. Test 3 EPROM checksum test, used the check that the EPROM program is

correct. Test 4 External RAM checksum test; instrument test and identifies how many times

Errors 16, 17 and 18 have occured.

Test 5 Verifies that all keys are functional and all LEDs are working. Test 6 Used to verify that all relays and solid state relay driver outputs are working

correctly. Test 7 This procedure will allow operator to adjust the current output value to

check the output and to test the operation of the external device. Test 8 This is the same as Test 7 except it is for Output 2.

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Test 9 Auxiliary Input Test. Allows for the viewing of the optional auxiliary input

voltage level. Test A Communications Hardware Test

5.3.1 TEST 1 INTERNAL RAM TEST

Tests the Random Access Memory internal to the microprocessor. No special test equipment is required.

With tSt1 displayed, press and hold the DOWN key, then press the SCROLL key. tSt1 will be displayed momentarily while the test is in progress. Upon successful completion, the instrument will proceed to Test 2.

5.3.2 TEST 2 EXTERNAL RAM TEST

Tests the battery backed-up RAM external to the microcomputer No special test equipment is required.

After completion of Test 1, tSt2 will be displayed momentarily while the test is in progress. Upon successful completion, the instrument will proceed to Test 3.

5.3.3 TEST 3 PROGRAM EPROM TEST

This is a checksum test to verify data integrity of the stored program. No special test equipment is required.

After completion of Test 2, tSt3 will be displayed momentarily while the test is in progress. Upon successful completion of Test 3, tSt1 will be displayed.

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5.3.4 TEST 4 EXTERNAL RAM CHECKSUM TEST

This is a checksum test to verify the integrity of data stored in RAM and indicate the number of times the instrument has had an Error 16, 17 and 18. The unit may have automatically recovered from these errors. No special test equipment is required.

With tSt4 displayed, press and hold the DOWN key, then press the SCROLL key. The display will blank momentarily, then momentarily display three numbers, and then tSt4 will be displayed. These numbers indicate the number of times Error 16, 17, and 18 have occured respectively. Test 4 can be executed again, or another test may be selected.

5.3.5 TEST 5 KEYPAD/DISPLAY TEST

This test allows the operator to verify that the keys work and that all display elements can be lit. No special test equipment is required.

With tSt5 displayed, press and hold the DOWN key, then press the SCROLL key and then release both keys. The display will go blank. The following code will be displayed while the corresponding key is pressed:

Key Display

SCROLL SCrL UP uAro DOWN dAro RUN/HOLD run UP and DOWN (All LED's and segments lit)

To exit, press the SCROLL and UP key simultaneously, tSt5 will be displayed.

5.3.6 TEST 6 RELAY/SOLID STATE RELAY DRIVER OUTPUT TEST

Allows the operator to verify that the Relay and/or the Solid State Relay Driver output(s) are working. A volt/ohm meter will be required to test the output.

With tSt6 displayed, press and hold the DOWN key, then press the SCROLL key. oFF will be displayed. For SPST Relay outputs, connect the meter across the relay output in the ohm scale. The meter should read continuity with the relay on and infinity when the relay is off. For SSR Driver outputs, connect the meter across the output in the Volt DC scale. The meter should read 5 VDC when the SSR driver is on and 0 VDC when the driver is off. Press and release the DOWN key to advance through the following sequence:

Display Relay On rLYA A Only rLYb B Only rLYC C Only oFF None

To exit, press the SCROLL key and tSt6 will be displayed. The existence of Relay and Solid State Relay Driver output(s) is dependent upon the hardware configuration.

5.3.7 TEST 7 CURRENT 1 OUTPUT TEST

This test allows the operator to verify that the current output(s) are functioning properly or will allow the selection of an output value for testing of associated equipment. A milliamp meter is required for testing.

With tSt7 displayed, press and hold the DOWN key, then press the SCROLL key. The display will indicate 4 milliamps. Use the UP and/or DOWN key to increase or decrease the current output in 1 mADC steps from 4 to 20mADC. The current output reading should be ± 0.5 mADC at any output value. To exit the test, press the SCROLL key and tSt7 will be displayed. The existence of mADC current output is dependent upon the hardware configuration. See Appendix A-3 (page 65 or 66) to make sure hardware is present.

5.3.8 TEST 8 CURRENT OUTPUT 2 TEST

This test is the same as Test 7 except that it is for Output 2.

5.3.9 TEST 9 AUXILIARY INPUT TEST

This test allows the operator to verify that the auxiliary inputs used for motor modulation feedback and remote Run/Hold contact closure are functioning properly. A variable voltage source, 5VDC, is required for testing.

With tSt9 displayed, press and hold the DOWN key, then press the SCROLL key. The Auxiliary input voltage will be displayed to the nearest hundredth of a volt. Connect the +5V source across the Auxiliary input terminals (terminals 8 and 5) and adjust the supply up and down to verify that it changes on the display. The displayed voltage should typically be 0-5VDC +/- 0.3 volts. To terminate the test, press the SCROLL key. The display will show tSt9. Test 9 can be initiated again or another may be selected. The existence of the auxiliary inputs tested in Test 9 depends upon the hardware configuration.

5.3.10 TEST A COMMUNICATION HARDWARE TEST (Communications Option)

This test allows the operator to verfiy that the communications hardware is functioning properly.

PAGE 55

With tStA displayed, press and hold the DOWN key then press the SCROLL key. The display will indicate SEnd. Each time the DOWN key is depressed, the unit will toggle between SEnd and rEC (receive). With the desired function selected, depress the SCROLL key. The unit will perform as described below.

In the SEnd (send or transmit) mode, the unit will repeat the following sequence. First it will enable the transmitter and put a logic 1 on the line for one second. Second, with the transmitter still enabled, it will change the logic level to 0 for one second. Third, it will disable the transmitter for one second. In the rEC mode, the unit will have its transmitter continuously disabled. In either mode, the unit will monitor the line and display rEC1 or rEC0 when it senses a logic 1 or 0 on the line respectively. In the SEnd mode, the unit will display rEC when the transmitter is disabled.

To perform an internal test and verify the basic operation of the hardware, place the unit in the SEnd mode and verify that the display cycles through rEC1, rEC0 and rEC. To verify that the transmitter functions properly, two LED''s, each with a current limiting resistor, can be connected to the communications terminals, with their polarities connected oppositely, and it should be observed that the following states are produced: one LED on, then the other LED on, then both off. Alternately, a load resistor can be placed on the terminals and it can be observed that the voltage generated across the load resistor is as follows : >+3 VDC, then >-3 VDC, and then 0 VDC.

Another method, which would also apply to an applications network, would be to connect one or more units in the Receive mode to a first unit in the Send mode. All of the units in the Receive mode should have their display alternating in sync with the first unit which is in the Send mode. When the sending unit displays rEC, the receiving units should display rEC1. To terminate the test, press the SCROLL key for one second. Upon exit, tStA will be displayed. Test A can now be initiated again or another test selected.

PAGE 56

Trouble-shooting and Diagnostics 5.4

This section consists of two columns. The first column is a list of some possible instrument conditions. The second column is a list of steps that should improve the condition. The steps should be performed in order until the condition improves or all the steps have been completed. If the instrument condition has not improved, contact the nearest representative or factory for assistance.

Trouble-shooting should be performed by qualified personnel using the proper equipment and following all safety precautions. Whenever possible, the trouble-shooting should be accomplished with the electrical power disconnected. The instrument contains static sensitive components so care should be taken to observe anti-static procedures.

Condition Correction Steps

Display is blank 1. Verify that the correct instrument power, as indicated

on the wiring label on the housing, is supplied to terminals A & B. If the voltage is not correct, check the power source.

2. Turn off the instrument power. Wait about 5 seconds then turn the power on again.

3. Turn off the instrument power, loosen the front panel screw and remove the instrument from the housing. Inspect the instrument for poor connections.

a. The white ribbon cable that connects the Processor board (Appendix A-2, page 64) to the Power Supply Board (Appendix A-1, page

63), must be properly aligned and seated. b. The Front Display board pins should be

properly aligned and seated in the sockets on the Processor board (Appendix A-2, page

64) and the Power Supply board (Appendix A-1, page 63).

c. The EPROM and RAM chips, located on the Processor board (Appendix A-2, page 64) must be free from corrosion and firmly seated in the socket. Also check the Display Driver chip U1 loacted on the display board for the same. Reinsert the instrument in the housing, tighten the panel screw, and turn on the power.

4. Turn off the instrument power. Press and hold the UP and DOWN keys. Turn on the power. Hold the keys depressed for about 10 seconds. If the display lights the model number, Program , Tune and Profile mode parameters will need to be re-entered (pages 25 - 35, or the Software Ref. Sheet, pages 75-77, if already filled out).

Model Number Displayed 1. Turn off the instrument power, wait 5 seconds then is incorrect reapply power. Verify that the number displayed

during the power up sequence is the same as indicated on the label affixed to the lower front of the display bezel.

2. Turn off the power to the instrument. Press and hold the UP and DOWN keys and turn on the power. Keep the keys depressed until the model number resets to 6100-000. Release the keys and turn off the power.

3. To enter the correct model number press and hold the SCROLL and DOWN keys and turn on the instrument power, 6100 should be displayed. Wait about 5 seconds and release the SCROLL key first and then release the DOWN key. The display should remain 6100. Use the UP/DOWN keys as necessary to change the displayed number to match the first 4 digits of the model number. After adjusting the first 4 digits to the proper values, press the SCROLL key and the display will change to 000-. Use the UP/DOWN keys to set the last 3 digits of the model number to the correct values. Press the SCROLL key and the power up sequence will complete. The Program , Tune and Profile mode parameters will need to be re-entered (pages 25 - 35, or the Software Ref. Sheet, pages 75 77, if already filled out).

Relay/SSR Driver Output(s) 1. Verify that the Proagram and Tune mode parameters Malfunction are correctly set (pages 25 - 32 or the Software Ref.

Sheet, page 75, if already filled out).

PAGE 57

2. Turn off the power to the instrument. Wait about 5 seconds and turn the power on again. Confirm that the model number displayed during the power up sequence indicates that the output(s) is/are present in the instrument. This number should match the number on the label affixed to the bottom of the front display bezel. If the model # is incorrect, follow the steps for "Model # displayed is incorrect".

3. Turn off the power to the instrument. Loosen the front panel screw and remove the unit from the housing. Inspect the Power Supply board (Appendix A-1, page

63) for the presence of the output device(s). Relay A is located at K1, Relay B at K2, and Relay C at K3. A relay output will appear to be a cube. The SSR Driver will appear as a resistor and a jumper wire. The output will not work if the hardware is not present.

4. Check the output operation by performing Test 6 as described in the Test section (page 54). If the output(s) function(s) in the Test mode, re-examine the Program and Tune mode parameter settings (pages 25- 32, or the Software Ref. Sheet, page 75, if already filled out).

5. If the output appears not to turn off, remove the power to the instrument. Loosen the front panel screw and take the unit out of the housing. Clip the resistor located on the Power Supply board (Appendix A-1, page 63) for the output(s) that seem to stay on. A .01 microfarrad, 1 KV should be connected from the terminal listed below, for the output where the resistor indicated was removed, to the AC ground. (Continued on next page)

PAGE 58

(Continued from page 57)

Relay A R12 Terminal C Relay B R13 Terminal E

Relay C R14 Terminal G Return the instrument to the case and tighten the front panel screw. Turn the power on to the instrument and check the operation of the output(s).

mADC Output(s) 1. Verify that the Program and Tune mode parameters Malfunction are correctly set (page 25 & 32 or the Software Ref.

Sheet, page 75, if already filled out).

2. Turn off the power to the instrument. Wait about 5 seconds and turn the power on again. Confirm that the model number displayed during the power up sequence indicates that the output is present in the instrument. The number should match the model number on the label located on the bottom of the front display bezel. If the model # is incorrect, follow the steps for "Model # displayed is incorrect" (page

57).

3. Verify that the hardware is present on the Option board (Appendix A-3, page 65 or 66).

4. Check the output operation in the Test mode. Use Test 7 for Output 1 and Test 8 for Output 2. If the output works in the Test mode, re-check the Program & Tune mode parameter settings ( pages 25 - 32, or the Software Ref. Sheet, page 75, if already filled out).

Error Code Displayed

SnSr 1. Inspect the sensor for proper operation and Sensor Break or out of range connection to the instrument. Acceptable sensor

ranges for the instrument are listed in the Specifications section of Appendix D (page 71).

2. Verify that the Program mode input selection matches the sensor input connected.

3. Check that the input conditioning jumpers on the Processor board (Appendix A-2, page 64) and the Option Board (Appendix A-3, page 65 or 66) are in the proper position for the sensor input.

4. Perform the calibration procedure(s), as described in the Calibration section (page 47) for the sensor input type.

FbEr 1. Inspect the Slidewire Feedback connections at Slidewire Feedback Error terminals 8, 7 and 5. Be sure that the connections are

the same as shown in the position proportioning illustration (page 20).

2. Measure the resistance of the Slidewire segment. The minimum resistance must be 135 ohms, the maximum 10 K ohms.

3. Perform the Auxiliary Input Test, Test 9 as described in the Test section (page 55). The voltage indicated should be between 0 and 5 VDC.

4. Turn off the power to the instrument. Loosen the front panel screw and take the instrument out of the housing. Verify that the jumper JU-1 on the Option board (Appendix A-3, page 65) is in the Motor Modulation position.

Hi - Input more than 10% 1. Perform the steps listed for the SnSr error condition Over Span (page 58).

Lo - Input more than 10% 1. Perform the steps listed for the SnSr error condition Under Span (page 58).

o - display overranged 1. If this error code is displayed as a Program or Tune (the "broken 6" appears mode parameter value, perform CAL1 procedure as on the left side of the display) described in the Calibration section (page 48).

PAGE 59

2. If this error code appears as part of the model number during the power up sequence, follow the steps listed for the "Model # is incorrect" condition (page 57).

3. If this error appears in the process reading and dPoS equals 1, then it means the process is greater then

999.9.

Er1 - Microprocessor RAM 1. Turn off the power to the instrument. Failure

2. Loosen the front panel screw and remove the instrument from the housing. Inspect that the microprocessor (U1) is properly seated in the socket located on the Processor board (Appendix A-2, page

64). Return the instrument to the housing and tighten the front panel screw. Turn the power on.

Er2 - External RAM Failure 1. Turn off the power to the instrument. Wait 5 seconds

and turn the power on.

Er3 - EPROM Checksum 1. Perform the steps listed for Er1 except that the Failure EPROM (U2) on the Processor board (Appendix A-2,

page 64) should be inspected.

Er4 - RTD Mismatch Error 1. Check the connections to the instrument for the RTD

Input Calibration procedure (page 50). Repeat the RTD Input Calibration.

PAGE 60

Er5 - No Zero Crossings 1. Turn off the power to the instrument. Wait 5 seconds Detected and turn the power on.

2. Turn off the power to the instrument. Loosen the front panel screw and remove the instrument from the housing. Inspect the white ribbon cable that connects the Processor board to the Power Supply board. Be sure that the cable is properly aligned and seated in the socket on the Power Supply board. Return the instrument to the housing and tighten the front panel screw. Turn the power on to the instrument.

3. Connect the instrument to another AC power source.

Er6 - AC line below 45 HZ 1. Turn off the power to the instrument. Wait 5 seconds

and turn the power on.

3. Connect the instrument to another AC power source.

Er7 - AC line over 65 HZ 1. Turn off the power to the instrument. Wait 5 seconds

and turn the power on.

2. Turn off the instrument power. Loosen the front panel screw and remove the instrument from the housing. Inspect the white ribbon cable that connects the Processor board to the Power Supply board. Be sure that the cable is properly aligned and seated in the socket on the Power Supply board.

3. Connect the instrument to another AC power source.

Er8 - Cal 2 Volt Input Error 1. Check that 50 mVDC is properly connected to the

instrument and is within the tolerance limits as indicated in the CAL2 procedure of the Calibration section (page 48).

2. Loosen the front panel screw and remove the instrument from the housing. Inspect the Processor board (Appendix A-2, page 64) to insure that the input conditioning jumper JU1 is in the non-volt position.

3. Perform the CAL2 procedure as described in the Calibration section (page 48).

Er9 - ADC Reference Number 1. Perform the CAL2 procedure as described in the Error Calibration section (page 48).

Er10 - ADC Reference 1. Perform the CAL2 procedure as described in the Voltage Error Calibration section (page 48).

Er11 - Cold Junction 1. Be sure the Cold Junction Sensor is firmly attached Compensation Error to terminals 2 and 4.

2. Perform the CAL3 procedure as described in the Calibration section (page 49).

Er12 - CAL2 Voltage Error 1. Check that 50mVDC is properly connected to the

instrument and is within the tolerance limits as indicated in the CAL2 procedure of the Calibration section (page 48).

3. Perform the CAL2 procedure as described in the Calibration section (page 48)

PAGE 61

Er13 - RTD CAL5 Input Error 1. Check that the resistance device is of the correct value

and properly connected to the instrument and is within the tolerance limits as indicated in the CAL5 procedure of the Calibration section (page 50).

65) JU2 and JU3 are in the RTD position.

3. Perform the CAL 5 procedure as described in the Calibration section (page 50).

Er14 - Cold Junction 1. Be sure the Cold Junction Sensor is firmly attached Compensation Error to terminals 2 and 4.

2. Perform the CAL3 procedure as described in the Calibration section (page 49).

Er15 - Ground Reference 1. Perform the CAL2 procedure as described in the Tolerance Error Calibration section (page 48).

Er16 - Program/Tune Mode 1. Record all Program and Tune mode parameters. Checksum Error Perform the CAL1 procedure as described in the

Calibration section (page 48). Re-enter the Program and Tune mode parameters.

Er17 - Calibration Checksum 1. Perform the calibration procedures that are needed for Error the input sensors that will be used (page 48).

PAGE 62

Er18 - Profile Data 1. Record all Profile data that was entered. Perform Checksum Error the CAL8 procedure as described in the Calibration

section (page 51). Re-enter the Profile data as needed.

Er19 - Tried to run profile 1. Press the RUN/HOLD key, then press and release the with 0 segments SCROLL key until oFF or CtrL are displayed, then

press the DOWN key. This error occurs if a profile number is selected in a Profile Continue mode for a profile that has not been developed.

Er20 - Setpoint Error 1. Use the UP or DOWN key to change the setpoint

value.

2. Record all Program and Tune mode parameters. Perform the CAL1 procedure as described in the Calibration section (page 48). Re-enter the Program and Tune mode parameters.

Er36 - Incorrect Cystal 1. Turn off the power to the instrument, wait 5 seconds For Digital Comm. then turn the power on.

2. Check the cyrstal for 11 MHZ Y1 (see Appendix A-2, page 64)

Er37 - Incorrect Micro. 1. Turn off the power to the instrument, wait 5 seconds For Digital Comm. then turn the power on.

2. Check to make sure U1 is a 8032 (see Appendix A-2, page 64)

Errors 70 through 73 are communication errors that are briefly displayed when they occur.

Er70 - The Controller was When the unit receives a complete message, the unable to respond within 250 controller has 250 milliseconds to respond to the request. milliseconds If for any reason the controller is unable to respond within

250 milliseconds, the error is posted and the request ignored.

Er71 - A byte was received by While the unit is processing a message, no data should the controller before the response be on the communication link until the unit has was transmitted responded. If the unit receives data before a response is

transmitted, the error is posted and the message aborted.

Er72 - An incorrect Block Check After the complete message has been received, if the character was received Block Check Character (BBC) transmitted does not match

the calculated BCC, the error is posted and the unit will send a Negative Acknowledge (NAK).

Er73 - A byte was received with If incoming data has incorrect Parity, the unit will post the incorrect parity error and ignore the rest ofthe message. The number of

ones in the transmitted byte is expected to be even (Even Parity).

Appendix A Board Layout - Jumper Positioning

FIGURE A-1 - Power Supply Board

TOP

R14

R13

RELAY C

RELAY B

115 VAC JUMPER POSITION

JU6 JU5

PAGE 63

FRONT OF UNIT

R12

RELAY A

COMPONENT SIDE

230 VAC UNITS MAY BE FIELD CONVERTED TO 115 VAC BY MOVING JUMPERS AS SHOWN ABOVE . (115 VAC UNITS CANNOT BE FIELD CONVERTED TO 230 VAC!!)

230 VAC JUMPER POSITION

JU6 JU5

PAGE 64

FIGURE A-2 - Processor Board

TOP

FRONT OF UNIT

JU1

BATTERY

T/C,mV,RTD, CAL2

VOLT

MICRO U1

EPROM U2

RAM U3

COMPONENT SIDE

JU2

ENABLE MODE LOCKED

ENABLE MODE UNLOCKED

JU12

JU1

JU12

IF NO OPTION BOARD

FIGURE A-3 - Option Board - Revision D and below

REV

FRONT OF UNIT

For 2nd 4-20mA, U5 is populated

PAGE 65

TOP

JU1

For 1st 4-20mA, U1 is populated

JU1

2ND 4-20 mADC

MOTOR MODULATION/ POSITION PROPORTIONING POTENTIOMETER REMOTE SETPOINT

DIGITAL COMMUNICATIONS 422/485

COMPONENT SIDE

JU2

JU3

JU2

RTD

T/C, mV, VOLT

JU3

(NON-RTD)

RTD

T/C , mV , VOLT (NON-RTD)

PAGE 66

FIGURE A-3 - Option Board - Revision E and above

2nd 4-20

Position

Prop.

Com

RS-485

JU1

JU3

JU2

T/C, mV, V

RTD

JU2

J15

J16

JU3

JU1

JU13

T/C, mV, V

RTD

REV

JU14

Com &

2nd 4-20

Pos. Prop. &

Alt. Com

RSP &

Com

RRH &

Com

Alt.

Com

XPS

JU13

XPS

J15 - AC Input XPS cable from transformer J16 - XPS to Relay C

XPS

JU14

XPSNo XPS No XPS

Appendix B Glossary

Assured Soak

Assured Soak refers to the ability of the instrument to be programmed to interrupt the Soak segment time down if the process value exceeds a deviation value selected in the Profile Entry mode from the setpoint. The Soak timer will restart from where it was stopped when the process value does not exceed the deviation value selected from setpoint.

Automatic Reset (Integral)

This parameter is used so that the instrument will compensate for process variable deviations from setpoint that occur when the process load characteristics change. Instructions for determining the automatic reset settings are given in Section 4.3 (page 44). Factory default is

0.0. Display code ArSt.

Automatic Transfer

This feature, if configured, allows manual control of the process until setpoint is reached, at which point the controller automatically transfers from manual to automatic control. Factory default value is 0 = no auto transfer. Display code AtFr.

Balanceless Transfer

This feature prevents changes in proportional output when changing from the Manual to Control mode of operation. When transferring from the manual mode to the control mode, the proportional outputs will be "Balanceless" regardless of whether the unit is inside or outside the proportional band. This only holds true if the Auto Reset (ArSt) value is greater than 0.

PAGE 67

Bumpless Transfer

This feature prevents step changes in proportional outputs when changing from

manual control only

Control Algorithm

A pre-programmed series of instructions that are used by the instrument when determining the status of the output(s).

Cycle Time

This Tune mode parameter is used to select the on/off cycle time for time proportioning outputs (Ct1 for Output 1 and/or Ct2 for Output 2).

When using the Position Proportioning option, Ct1 must be selected for the stroke time of the motor.

Display Filter Factor

This parameter is adjustable from 1 to 20 which represents the number of scans of the process variable that are averaged together before updating the displayed value. The factory default value is 1 = no filtering. Display code dFF.

Engineering Units Upper and Engineering Units Lower

These Program mode parameters are used with volt, millivolt, and milliamp inputs. The Engineering Units Upper Euu should be selected as the value to be displayed when the input is at maximum. The Engineering Units Lower EuL should be selected as the value to be displayed when the input is at minimum.

automatic to

First Output Position

This parameter is adjustable from -1000 to 1000 units and represents a shift or offset of the on-off actuation points or proportional band for the first output relative to the normal position. For example, a negative value could be used to offset an expected overshoot. First Output Position also shifts the proportional band with respect to the process value range outside of which integral action is inhibited. Factory default is 0. Display code FoP.

PAGE 68

Hysteresis

This parameter is adjustable from 0 to 300 units representing the width of the band (half above and half below setoint). Used with On-Off or Alarm outputs to reduce cycling. For instance, with a value of 4 and a setpoint of 70, the output will turn On when the process variable drops to 68 and stay On until 72 is reached, then turn Off the output. Factory default is 3. Display code is HySt.

Input Correction

This parameter is used to adjust the process variable value to compensate for sensor errors. This Program mode parameter is selectable from -300 to +300 degrees/units. The factory default is 0. Display code is iCor.

Manual Reset

This parameter is adjustable from -1500 to 1500 units representing a manual shift of proportional band(s) relative to the normal position. Manual reset is intended to be used when automatic reset is not used to allow compensation for deviations from setpoint which remain after the process has stabilized. Factory default is 0. Increasing the value increases the process variable, i.e. if the process variable stabilized too low, increase the manual set. Integral action, and conversely reset-windup inhibit apply over the same process value range regardless of the manual reset value. Display code rSEt.

Position Proportioning Sensitivity A percentage of the first output proportional band width (Pb1).

Process Filter Factor

This Program mode parameter is used to dampen the process value used to calculate output action. The process value is averaged to dampen the control outputs. This parameter is adjustable from 1 to 20. Factory default is 1. Display code PFF.

Process Retransmission Output (EO Software Option)

Allows retransmission of the process variable. Factory default is 0 = not selected. Display code Pout. If selected, must be assigned to a current output and scaled using Process/ Setpoint upper and lower values.

Process/Setpoint Output Upper and Lower Values (Used in conjuction with process or setpoint retransmission output)

These parameters specify the process or setpoint value range over which the assigned current output will vary in a linear manner from 100 % to 0 %. If the process value or setpoint is greater than Pou the output will be 100%. If the process or setpoint value is less than PoL the output will be 0%. Factory default values are 2000 for the upper value and 0 for the lower value. Display codes Pou (upper) and PoL (lower).

Process Variable

The process variable refers to the condition of the process being measured (sensed). The instrument will accept process inputs other than temperature (pressure, level, flow, etc.).

Proportional Band (PB)

This Tune mode parameter selects the span of the proportional output range. This parameter is adjustable from 1 to 3000 degrees/units. Factory default is 100. If Output 1 is selected as a proportional output, a display code of Pb1 will be seen. If Output 2 is selected as a proportional output, the display code will be Pb2.

Ramp

A Ramp is the section of profile segment where the setpoint value is being changed from the initial value to the value selected over the time period selected. The first Ramp of a profile will take the process value at the time the profile was started as the initial setpoint value.

Rate (Derivative)

This parameter is adjustable from 0.0 to 10.0 minutes and specifies how the control action responds to the rate of change in the process variable. For example, if the process variable is rising rapidly to setpoint, power is turned off sooner than it would be if the rise were slow. In effect, derivative action anticipates lags within the system and shifts the proportioning band by an amount determined by the rate of change of the input sensor. Magnitude of the shift is determined by a derivative time constant. If the time constant is, say, .1 minute (6 seconds), for every unit per second rate of change of the process variable at the sensor, the proportioning band is moved 7 units in the direction that helps control. Likewise, if the time constant is 1 minute (60 seconds), for every unit per second rate of change of the process variable at the sensor, the proportioning band is moved 60 units in the direction that helps control. Instructions for determining rate is given in Section 4.3 (page 44). Factory is 0.0. Display code

rAtE.

Rate of Change (EO Software Option)

This parameter is used to provide ramp changes based upon a selectable rate of change. Degrees per hours, minutes, seconds.

Second Output Position

This parameter is adjustable from -1000 to 1000 units and represents a shift or offset of the on-off actuation points or proportional band for the second output relative to the normal position. A positive value creates a gap where no control outputs are on, a negative value creates an overlap of control outputs (if the first output position is at the normal position). Second Output Position also shifts the proportional band with respect to the process value range outside of which integral action is highlighted (reset-windup inhibit). Factory default is

0. Display code Sprd.

PAGE 69

Segment

A segment refers to a part of a profile. A segment consists of a Ramp and a Soak section.

Setpoint Re-Transmission Output (EO Software Option)

Allows for re-transmission of the setpoint value. Factory default is 0 = not selected. Display code Pout. If selected, must be assigned to a current output and scaled using Process/ Setpoint upper and lower values.

Soak

A Soak is the section of a profile segment where the setpoint value is at a constant value for the time period selected.

PAGE 70

Appendix C - Order Matrix

Input

1 T/C or mV 2 Volts/mA 3 RTD 4 All Inputs

Output Group 1 Control Output 1 and/or Event

1 Relay 2 SSR Driver 3 4-20 mA & Relay 4 4-20 mA & SSR Driver

Output Group 2 Control Output 2 and/or Event

0 None 1 Relay 2 SSR Driver 3 4-20 mA 4 4-20 mA & Relay 5 4-20 mA & SSR Driver

Output Group 3 Alarm or Event

0 None 1 Relay 2 SSR Driver

Remote

0 None 1 Position Prop.* 2 Remote Run/Hold 3 RS-485 Std. Com.** 4 RS-485 Std. Com.*** 5 RS-485 Total Access Com.** 6 RS-485 Total Access Com.***

Voltage

1 115VAC Input & Relays 2 230VAC Input & Relays 3 115VAC Input & 230VAC Relays

Option Suffix

(Blank) None EO Extended Features Software Option XP 24VDC Transmitter Power Supply XA 24VDC Power Supply

* Output Group 2 cannot be 0 or 3. ** Cannot be included when Output Group 2 selections 3, 4, or 5. ***Cannot be included when Output Group 3 selection is 1 or 2.

Appendix D Product Specifications

Measurement Error Limit • Type J, K, T, E, N, C, T/C's and RTD +/-.25% of reading

plus 1 degree @ 25 degrees C

• Type R, S, B T/C's +/- .25% of span @ 25 degrees C

• mA, mV and VDC +/- .25% of scaled span plus 1 Least

Significant Digit @ 25 degrees C Ambient Temperature Error 0.01% of span per degree C deviation from 25 degrees C Scan Rate 1 scan/second Display Resolution 0 to 3 decimal places (depending upon input type

selected) Noise Rejection Normal mode, 85 dB minimum at 60 Hz or greater.

Common mode, 90 dB minimum, 115 VAC maximum. Line Voltage 115/230 VAC +/- 10% 50/60 Hz

PAGE 71

Power Consumption 15VA maximum Operating Temperature 0 to 55 degrees C

32 to 131 degrees F Storage Temperature -40 to 65 degrees C

-40 to 149 degrees F Humidity 0 to 90% RH, non condensing Dimensions 1/4 DIN front panel (96mm x 96mm) and 5.8 inches deep Weight 3 pounds maximum Vibration 0.5 to 100 Hz @ 0.5g Agency Approvals UL and CSA Warranty 3 years, see inside back page.

PAGE 72

THERMOCOUPLE

TYPE RANGE TYPE RANGE J -130 to 760°C E 0 to 750°C

-200 to 1400°F 0 to 1400°F

K -130 to 1370°C B 200 to 1800°C

-200 to 2500°F 400 to 3300°F

T -200 to 400°C N 0 to 1300°C

-330 to 750°F 0 to 2370°F

R 200 to 1650°C C 200 to 2300°C

400 to 3000°F 390 to 4170°F

S 200 to 1650°C

400 to 3000°F

RTD VOLTS MILLIVOLTS

100 OHM 0 to 5VDC 0 to 25mVDC

-140 to 440°C 1 to 5VDC 0 to 50mVDC

-220 to 750°F 10 to 50mVDC 0 to 25mVDC

MILLIAMPS

4-20mA input is accommodated via 10-50mV or 1-5V with the addition of the appropriate external shunt resistor

SENSOR FAULT DETECTION

Displays Hi or Lo process input for thermocouple or RTD inputs (10% above or below range) and sensor break, SnSr. On/Off outputs and events go off, proportional outputs go to 0% output. Sensor fault detection is not functional for 0 to 5 VDC.

CONTROL ADJUSTMENTS

On/Off Hysteresis 0 to 300 units Proportional Band 1 to 3000 units Manual Reset -1500 to 1500 units Auto Reset 0.0 to 100 repeats/min. Rate 0.0 to 10.0 min. Cycle Time 1 to 240 sec. Position Proportioning 0.0 to 50.0%

Sensitivity First Output Position -1000 to 1000 units Spread -1000 to 1000 units

(Second Output Position)

ALARM ADJUSTMENTS

Process Alarm -9999 to 9999 units Deviation Alarm -3000 to 3000 units Deviation Band Alarm 1 to 3000 units

CONTROL OUTPUTS

Relay SPST

115VAC: 5.0A Resistive; 1/8HP or 250VA 230VAC: 2.5A Resistive; 1/8HP or 250VA

SSR Driver Open collector output

Short circuit protected @ 100mA maximum. 4VDC at 20mA or 3VDC at 40mA.

Current 4-20mADC into 650 ohms maximum

ALARM OUTPUT

Relay SPST

115VAC: 5.0A Resistive; 1/8HP or 250VA 230VAC: 2.5A Resistive; 1/8HP or 250VA

PAGE 73

SSR Driver Open collector output

Short circuit protected @ 100mA maximum 4VDC at 20mA or 3VDC at 40mA

DISPLAY

Digital Display Four (4) .56 inch high, 7 segment LED's Status Indicators LED indicators for Setpoint, Output 1, Output 2, Manual,

Alarm, Degrees C, Degrees F, U (engineering units), Seg1 thru Seg 6, Ramp and Soak

DIGITAL COMMUNICATIONS

Type RS-485 serial communications port. Half duplex

bi-directional communications Character Format ASCII Protocol Per ANSI X3.28 subcategories 2.5 and A4 Configuration User configurable to Monitor (read only) or Normal (read

and write) Bit Rate User configurable to 300, 600, 1200, 2400, 4800, or 9600

bits per second Address User configurable 0 to 99

PAGE 74

PROFILE PARAMETERS

Programmable Profiles 8 user programmable profiles Segments 1 to 6 segments per profile Ramp and Soak 1 ramp and soak per segment Profile Time Base Selectable:

HHH.T (hours and tenths) HH.MM (hours and minutes) MM.SS (minutes and seconds)

EO Option: Units per hour ramp rate, HHH.T soak time Units per hour ramp rate, HH.MM soak time Units per minute ramp rate, MM.SS soak time

Profile Interrupt Action Upon return of AC power either:

Go to OFF mode Continue profile Go into HOLD

Restart profile at beginning Profile Loop Count 1 to 9999, 0=continuous Profile End Control Selectable:

Hold at last setpoint

Abort (all outputs off or 0%)

Transfer to another profile Assured Soak Deviation Hold after Ramp Up;

1 to 3000 units, 0=no auto hold

Deviation Hold after Ramp Down;

1 to 3000 units, 0=no auto hold Remote Run/Hold Selectable:

Override RUN/HOLD key

Allow RUN/HOLD key to function Event Outputs 3 possible event outputs. Each event can be set on or off

for each ramp and soak.

Appendix E Software Reference/Record Sheet

PROGRAM MODE TUNE MODE

PAGE 75

InPs Icor out 1 o1PL out 2 o2PL out 3 rLyA rLyb rLyC dISP

Standard Software

dPOS Euu EuL HySt SPL SPuL

SPLL AtFr Ptb

PIA rrH PFF dFF

SPrd PAL dAL dbAL Pb 1 Pb 2 rSET ArSt rAtE Ct 1 Ct 2 SEns FoP

ENABLE MODE

ENAB

EtSt ECAL EPro Etun ESby EPC EPE ESPC

OFF

Co1r Co2r Pout

Pou PoL CCon Cbs CAd

Comm

PAGE 76

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

PAGE 77

Pn nS Seg 1 2 3 4 5 6

rt rr SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

EO EO

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

Pn nS Seg 1 2 3 4 5 6

rt rr

SP E1 E2 E3 St E1 E2 E3 PLCt dhru dhrd PEnd

PAGE 78

Appendix F Profile Development Sheet

The Profile Development Worksheet is intended to assist the Profile Controller customers. By filling in the worksheet with the application requirements, profile information can easily be obtained for entry into the instrument. The worksheet is a convenient record of the profile for future use.

A profile is a programmed sequence of setpoint changes over a period of time (or at a rate of change with the EO option) (Ramp) and a constant setpoint (Soak). A sequence of a ramp and a soak is referred to as a Segment. A profile can contain from 1 to 6 segments. The instrument can store in memory up to 8 profiles.

The profile controllers can provide timed output relay action while running a profile, this is called an Event. Events may be selected as on or off as needed during each Ramp and/or Soak segment of the profile.

The first step to completing the worksheet is to determine the range of the setpoints necessary for the application. Fill out the setpoint scale along the left side of the worksheet. Remember that the profile ramp will start at the process value indicated when the profile is initiated.

The next step is to sketch the profile outline on the worksheet. Use the setpoint scale to determine the setpoint level. Be sure to fill in the time periods for each part of the segment in the boxes provided at the top of each column. The Ramp and Soak time boxes are located at the top of each column below the setpoint box for the segment. There are boxes at the bottom of each column to indicate the status of events, if used. If more than six segments are needed for the profile, individual profiles can be linked to preform sequentially. Linked profiles operate like one long profile.

Profile program information is easily determined by completing the Profile Developmental Worksheet (page 78) for the application. The information derived within the worksheet is directly related to the profile entry parameters of the profile controller.

Profile Worksheet

Profile Number Number of Segments

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Segments

Setpoint Scale

123456

SP SP SP SP SP SP Ramp Soak Ramp Soak Ramp Soak Ramp Soak Ramp Soak Ramp Soak

Time Time Time Time Time Time Time Time Time Time Time Time

Event 1 Event 2 Event 3

Profile End Action Profile Loop Count Deviation Hold After Ramp Up Deviation Hold After Ramp Down Profile Time Base Profile Interrupt Action

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Sample Profile

The following is a sample profile intended to assist in understanding how the profile controller functions. Be sure to disconnect all control outputs before running this profile.

Press and release the SCROLL key until Prog appears on the display then press the DOWN key. Press and release the DOWN key until diSp appears then press the SCROLL key. Press and hold the UP key until the display shows a 5 then press the SCROLL key. Press and release the Down key until Ptb appears then press the SCROLL key. Press and hold the UP key until a 3 appears then press the SCROLL key. Press the UP key and Prog will appear. Press and release the SCROLL key until PEnt appears then press the DOWN key. Perform the following keystrokes:

Display Keystroke

Pn SCROLL X DOWN 1 SCROLL nS SCROLL X UP 6 SCROLL rt SCROLL X UP/DOWN

0.10 SCROLL SP SCROLL X UP/Down 100 SCROLL St SCROLL X UP/DOWN

0.10 SCROLL rt SCROLL X UP/DOWN

0.10 SCROLL SP SCROLL X UP/DOWN 150 SCROLL St SCROLL X UP/DOWN rt SCROLL X UP/DOWN

0.10 SCROLL SP SCROLL X UP/DOWN 300 SCROLL St SCROLL X UP/DOWN

0.10 SCROLL rt SCROLL X UP/DOWN

0.10 SCROLL SP SCROLL X UP/DOWN 200 SCROLL St SCROLL X UP/DOWN

0.10 SCROLL rt SCROLL X UP/DOWN

0.10 SCROLL SP SCROLL X UP/DOWN 100 SCROLL

St SCROLL X UP/DOWN

0.10 SCROLL rt SCROLL X UPDOWN

0.10 SCROLL SP SCROLL X UP/DOWN 50 SCROLL St SCROLL X UP/DOWN

0.10 SCROLL PLct SCROLL X UP/DOWN 2 SCROLL dhru SCROLL X UP/DOWN 0 SCROLL dhrd SCROLL X UP/DOWN 0 SCROLL PEnd SCROLL X UP/DOWN 0 SCROLL Pn UP PEnt

With PEnt on the display, press and release the SCROLL key until P 1 appears in the display then press RUN/ HOLD key. The display will show run, then display the ramping setpoint of the profile. This is to demonstrate how the profile controller functions.

Warranty and Return Statement

These products are sold by the factory under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to a purchase of these products, as new merchandise, directly from the factory or from a factory distributor, representative or reseller, and are extended only to the first buyer thereof who purchases them other than for the purpose of resale.

Warranty

These products are warranted to be free from functional defects in materials and workmanship at the time the products leave the factory and to conform at that time to the specifications set forth in the relevant instruction manual or manuals, sheet or sheets, for such products for a period of three years.

THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE WARRANTIES HEREIN AND ABOVE SET FORTH. THE FACTORY MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE PRODUCTS.

Limitations

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The factory shall not be liable for any incidental damages, consequential damages, special damages, or any other damages, costs or expenses excepting only the cost or expense of repair or replacement as described above.

Products must be installed and maintained in accordance with factory instructions. Users are responsible for the suitability of the products to their application. There is no warranty against damage resulting from corrosion, misapplication, improper specifications or other operating condition beyond our control. Claims against carriers for damage in transit must be filed by the buyer.

This warranty is void if the purchaser uses non-factory approved replacement parts and supplies or if the purchaser attempts to repair the product themselves or through a third party without factory authorization.

Returns

Factory’s sole and exclusive obligation and buyer’s sole and exclusive remedy under the above warranty is limited to repairing or replacing (at Factory’s option), free of charge, the products which are reported in writing to the factory at its main office indicated below.

The factory is to be advised of return requests during normal business hours and such returns are to include a statement of the observed deficiency. The buyer shall pre-pay shipping charges for products returned and the factory or its representative shall pay for the return of the products to the buyer.

Approved returns should be sent to: 2 CAMPION ROAD

NEW HARTFORD, NY 13413 USA

THE PARTLOW-WEST COMPANY

2 CAMPION ROAD • NEW HARTFORD, NY 13413 USA

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

Partlow MIC 6000 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual