Precision Digital PD540 User Manual

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DIGITAL CONTROLLER

NOVA PD540 Series

Instruction Manual

PD540 - PD549

PRECISION DIGITAL CORPORATION

89 October Hill Road z Holliston MA 01746 USA Tel (800) 343-1001

Fax (508) 655-8990

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Disclaimer

The information contai ned i n t h i s docu m ent i s su b j ec t t o c h ang e wi t hou t n oti ce. Precision D i g i t al C or p or ati on m akes no repr esentati ons or warranties with res p ect t o t he c on t en ts h ereof , an d s p ecifically disclai m s any i m p l ied warran tie s of merchantability or fitness f or a particular purpose.

Registered Trademarks

MODBUS® is a registered tr ademar k of Sch n eid er A u t omati on I n c. A l l ot h er trademarks men t ion ed i n t hi s doc u men t ar e t h e pr op ert y of their respective owner s.

Nova PD540 Series Model Number Guide

Digital Control l er Size - DIN Cutou t

0, 1 = 1/16 D I N 2, 3 = 1/8 DIN ( H) 4, 5 = 3/16 D I N 6, 7 = 1/8 DIN (V) 8, 9 = 1/4 D I N

Power

6 = 100-240 VAC

Display

R = Red LED

Main Control Ou tp u t

PD540, PD541, PD544, PD545:

A = 1 relay & 1 analog output

PD542, PD543, PD546 to PD549:

B = 1 relay & 2 analog outputs

Visit our Web S i te

http://www.predig.com

0-6RA-00PD5 4

Notes: 0, 2, 4, 6, 8 = Heating or Cooling 1, 3, 5, 7, 9 = Heating & Cooling

Options

00 = None

PD540, PD541

11 = 1 relay & 2 digital inputs 14 = 1 relay & RS-485 31 = 1 analog output & digital input s 34 = 1 analog output & RS-485

PD544, PD545:

04 = RS-485 51 = 2 relays, 1 analog output

& 2 digital inputs

54 = 2 relays, 1 analog output

& RS-485

PD542, PD543:, PD546 to PD 549:

21 = 2 relays & 2 digital inputs 24 = 2 relays & RS-48 5

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Table of Contents

1. Safety Guide and Specifications

1.1 Specifications

2. Front Panel Buttons and LED Indicators

3. Parameter Map

4. Operation Flow Chart

5. Controller Parame t er Se t up

5.1 Input Group (G.IN) 15

5.2 Output Group (G.OUT ) 19

5.3 Control Group (G.CT L ) 22

5.4 SP Group (G. SP) 25

5.5 PID Group (G.PI D )

5.6 Auto-Tuning Group (G.AT) 31

5.7 Alarm Group (G.ALM)

5.8 Retransmission Group (G.RET )

5.9 Communication Group (G.COM)

6. Error Display and Correction

7. Installation

7.1 D imensions and Panel Cutouts

7.2 Panel Mounting

7.3 Power Cable Specifications

7.4 Terminal Specifications

7.5 Terminal Assignment, Connections, and Ratings

5 7

11 12 14 15

33 36 37 39 40 40 45 46 46 47

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.6 Grounding and Power Cable Connection 52

7.7 Signal Input Connection

7.8 Analog Output Connection 53

7.9 Relay Output Connection (RELAY) 54

7.10 Digital Input Connection (DI) 54

7.11 Use of an External Relay 54

7.12 Communication Wiring (RS-485) 55

Appendix

Table of D-Registers 56

Tables and Figures

Table 1: Universal Input Selection 15

Table 2: DI Operation 22

Table 3: Alarm Selection 34

Fig 1: Temperature Bi as 17 Fig 2: Bias Formula Calculation 17 Fig 3: Time-Proportional PID Control Output 20 Fig 4: Output Delay and Timer Functi ons 22 Fig 5: Overshoot Suppression with Fuzzy Logic 27 Fig 6: Heating and Cooling Outputs Using PID Control 29 Fig 7: Heating On/Off and Cooling PID Outputs 29 Fig 8: Heating PID and Cooling On/Off Outputs 30 Fig 9: Auto-Tuning 31 Fig 10: Auto-Tuning Gain 32 Fig 11: Alarm Oper at i on 34

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

1. Safety Guide and Specifications

CAUTION

NOTE

CAUTION

The following safety symbols are used in this manual (1) This symbol notifies the use r o f s pe c i f ic in f o rmatio n r e l a t in g t o t h e sa f e oper ation of the controller.

Information noted with this symbol must be observed to protect the user from injury and to prevent damag e to the product. (A) For User: Be awa re of t h i s ma rking i n t h e manual and refer to the explanation in the manual to

(2) For Installer : Stud y the warning s marked t o p r e vent inju ry and dama g e .

(2) Functional ea rth te rminal : This symbol i n d ic a t e s t h a t t h e t e r mi n a l mu st b e c onnected to ground.

(3) This symbol i ndicates additional information on the features of the product.

(4) This symbol directs the reader to further information on the current topic.

Precautions R eg a rd i ng This Instr ucti o n Ma n ua l

(1) This manual must be kept in the possession of the end user and in a suitable place for the operator to

study and to check the functions of the product. (2)The installer and oper ator should carefully study and understand how to operate this product before use. (3)This manual describes the functions of the product. Precision Digital Corporation does not guarantee

that the functions will suit a particu lar pu r pose . (4) The contents of this manual have been reviewed for accuracy and correctness. However, shou l d a n y

errors or omission s c o me t o t h e at t e n t i o n o f t h e u se r, con t a ct t e c h n ic a l s u pport as listed on the back of this

manual

Safety Procedures and Unauthorized Modification Warning

(1)In order to prote c t t h is p r oduct and the system controlled by it against damage and ensure its safe use,

make certain t h a t a ll o f t h e sa f e t y instructi o n s and pr ecautions in this manual are strictly adhered to. (2)Precision Digital Corporation does not guarantee safety if the products are not handled in accordance

with this instruction manual. (3) If separate prot ec t i o n o r safe t y circ u it s a r e t o b e in s t a ll e d in t h e s y s t e m wh ic h is co n t rolle d b y t h i s p r oduct,

ensure that such circu i t s a re ins t a ll e d e xternal t o t h is p r o d u ct . (4) Do not make modifications or additions internally to the product. It may cause personal injur y to t h e u se r or

damage to the product. (5)Contact tech n ic a l s upport as listed on the back of the manual for warranty and repair issues. (6)Exposure to e xcessive mo i st u re, el e ct rical o verloads, or mechanical vibration may damage the product.

prevent injury and damage.

CAUTION

Limited Liability

Precision Digital Corpo ration a s su me s n o li a b ility t o an y pa rt y fo r any lo ss or d amage, dir ect or in dir ect , caused by the use of or any unpredictable defect of the product.

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Operational Enviro nment Precautions

CAUTION

(1)Only operate the c o nt rolle r when it is properly installed. (2)When inst alling the controller, select a location where:  Rear terminals a re pr o t e ct e d f r o m a c ci d e n t a l c o n t a ct .  Mechanica l vibrati o n s a re minima l .  No corrosive ga s i s p resen t .

 Temperature fluctuation is minimal.  Temperat u r e c a n b e mai n t a in e d between 1 0 and 50 ºC (50 and 110ºF) with 20 to 90% RH.  No direct heat r adiation is present.  High levels of electr oma g n e t i c i n t e r f e r e n c e a r e n o t p r e s e n t  The unit is not exposed to water.  No flammable materials are present.  Dust particles ar e n o t p r e s e n t in t h e a i r .  Expo s u r e t o u l t r a violet r a y s is min i mal .  Openings on t h e r e a r of th e c o n t r o l le r are n o t b lo c ke d .

(3)This unit is suitable fo r inst a ll a t io n i n a n e n viornment c l as s if i e d a s Pollution D e g r e e 2 . (4)This unit is designated as Installation Category I I . (5) If the equipment is used in a manner not specified by the manufacturer, the protection provided by

the equipment may be impair e d .

(6)A switch or circuit -bre a ke r acti n g a s t h e d i sc onnect dev ice shall be included in the application or the

installation.

Contr olle r Mounting Pr ecaut ions

 Keep the input circuit wiring as far a s poss i bl e awa y from po wer a nd ground circuits.

 Keep the u n i t s i n 1 0 t o 5 0 º C ( 5 0 t o 110º F) with 20% to 90% re l a t ive humidit y (RH ).

The controller may need a warm up period to return to operating temperature ranges when below 10ºC.

 To prevent electric sho c k, b e s u r e t o t u r n o f f t h e p o we r sour c e and circuit breaker before wiring.  The po we r requi r e me n t s a r e 1 0 0 t o 2 40 V A C , 5 0 / 6 0 H z , 1 0 V A max. Do not s wit c h p owe r

supplies without first disconnecting the power supply.

 F ollow the operating procedures and precautions in the manual to avoid fire, shock, damage to the unit,

or injury. Follow the operations and mounting directions indicated in this manual.

 Always create a ground connection where indicated, however do not ground to gas pipes,

water pipes, lighten i n g r o d s, o r oth er pot e n t ia l ly haz a r dous metal objects.

 Do not apply power to the unit until all connections have been made.  Do not cov e r t h e venting h o le s in t h e r e a r of t h e u n i t .

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

1.1 SPECIFICATIONS

Except where note d a ll sp e c i f ic a t io n s apply to operation at 23ºC.

General

DISPLAY Dual 4 digits, red LED, -1999 to 9999

FRONT PANEL 1/16 & 1/8 DIN: IP65; 3/16 & 1/4 DIN: IP55 SAMPLING TI ME 250 ms OVERRANGE Ove r r ange PV read s ovR , under range PV reads -ovR PROGRAMMING Four f r ont p anel b ut t on s and Modbus

METHODS PID ZONES 3 programmable PID zone ranges, 1 PID PV deviation zone NOISE FILTER Programmable from 1 t o 1 2 0 CALIBRATION All rang es are calibr at ed at t h e fa ctory PASSW ORD Progr a mma bl e password restr icts mod ifi cati o n of

POWER 100-240 VAC, 50/ 6 0 HZ, 1 0 Watts FUSE Required fuse: UL Recognized, 1 A, 250 V, slow blow ISOLATION 2300 V input-to-output-to-power lin e;

NUMBER OF 4 programmable set poin t s SET POI NTS

ENVIRONMENTAL Operating temperatu re range: 10 º C to 50ºC ( 5 0ºF to 110ºF)

MOUNTING 1/16, 3/16, 1/8, or 1/4 D I N si z e c u t out r eq ui r ed

WARRA NTY Thr ee years p ar t s an d la bor

DIN Sizes PV Display SP Display Weight

mm (inch) mm (inch) g (oz) 1/16 11.3 (0.45) 9.5 (0.37) 198 (7.0) 3/16 14.0 (0.55) 12.0 (0.47) 324 (11.4) 1/8 (H) 19.8 (0.78) 11.5 (0.45) 306 (10.6) 1/8 (V ) 13.6 (0.54) 10.5 (0.41) 304 (10.7) 1/4 20.5 (0.81) 11.0 (0.43) 389 (13.7)

programmed settin g s

4 kV relay output-to-input/output/power line

Relative humid i t y: 2 0 t o 90 % n on - condensing

Two panel mounting b r ac k et assemb l i es p r ovid ed One one-pi ec e bracket provided f or t h e P D 5 4 0

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Process and Temperatu re I nputs

TEMPERATURE DRIFT Refer to accuracy specifications below DECIMAL POINT Up to three decimal places for process inputs:

REAR JUNCTION Automatic or off s ett i n gs f or t emp er atu r e i nputs . N o user COMPENSATION calibrati on r eq ui r ed .

OFF S ET ADJUS T MENT Four programmable input bias zones SENSOR BREAK Open sensor i n di cated by P V d i s p l ay f l as h i n g S.OPN.

DETECTION All PID control outputs transmit at t h e user pr ogrammed

TRANSMITTER 14 to 18 VDC @ 20 mA; avail ab le at t ermi n al s O UT 2 or SUPPLY OUT3, instead of a retr ansmit t i n g an alog ou t p ut

UNIVERSAL IN PU T TYPE A ND A CCURACY

Input Type

*Performance with i n recomme nded operating conditions (10 to 50°C, 20 to 90% RH) **For a range scale of 0 to 100°C: +0.3°C +1 digit, and for a range scale of -100 to 100°C: +0.5°C +1 digit

9.999, 99.99, 999.9, or 9999

percent of f u l l out p ut sc ale s et i n p ar amet er s Po and Poc . Up or down scale, user selectable; alarm relays will follow the up or down scale select ion.

Temp Temp Range (ºC) Range (ºF) Accuracy*

K1 -200 to 1370 -300 to 2500 K2 -1 9 9 . 9 t o 9 9 9.9 0 to 230 0 > 0°C : ±0.1% F S ± 1 d ig i t J -199.9 to 999.9 -300 to 2300 < 0°C : ±0.2% F S ± 1 d ig i t T -199.9 to 400.0 -300 to 750

B 0 to 1800 32 to 3300 > 400°C : ±0.1 5 % FS ±1 d i g it

Thermocouple S 0 to 1700 32 to 3100

RTD PtC -19.99 to 99.99 -4.0 to 212.0 ±0.2% FS ±1 d ig i t

Process 0 to 10 V

R 0 to 1700 32 to 3100 ±0.15% FS ±1 d i g it

E -199.9 to 999.9 -300 to 1800 > 0°C : ±0.1% F S ±1 d i g it L -199.9 to 900.0 -300 to 1600 < 0°C : ±0.2% F S ± 1 d ig i t U -199.9 to 400 . 0 -300 to 750

N -200 to 1300 -300 to 2400 > 0°C : ±0.1% F S ±1 d i g it

W 0 to 2300 32 to 4200 ±0.2% FS ± 1 d i g it Platinel II 0 to 1390 32 to 2500 ±0.1% FS ± 1 d ig i t PtA -199.9 to 850.0 -300 to 1560 ±0.1% FS ±1 d ig i t * *

PtB -199.9 to 500.0 -199.9 to 999.9

JPtA -199.9 to 500.0 -199.9 to 999. 9 ±0.1% FS ±1 d ig i t * * JPtB -150.0 to 150.0 -199.9 to 300. 0

0.4 t o 2 .0 V ±0.1% FS ± 1 d i g it

1.000 to 5. 0 0 0

-10 to 20 mV 0 to 100 mV

0.400 to 2. 0 0 0

1.000 to 5. 0 0 0

0.00 to 10.00

-10.00 to 20.00

0.0 to 100.0

< 400°C : ±5% FS ± 1 d ig i t

< 0°C : ±0.2 5 % F S ± 1 d ig i t

Display range can be scaled between -1999 and 9999.

4 to 20 mA Inp ut

To accept a 4 to 20 mA signal, select 0.4 to 2.0 VDC input and connect a 100 Ω resistor across the input terminals.

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Relay Outputs

RATINGS Out1: 250 VAC @ 3 A or 30 V DC @ 3 A ( resisti ve load)

ELECTRICAL NOISE A suppressor (s nubber) s hould be connected to each SUPPRESSION rela y contact switching inductive loads, to pr even t

DEADBAND For alarm operati ons, 0 - 100% of full scale, user selectable HIGH OR LOW U s er may program any relay for high or low trip point

ALARM DEVIATION ALARM U ser may pr ogr am an y rel ay f or a hi g h, l ow, or ran ge set

RELAY OPERATION An y r e l ay m ay b e set as an al arm relay or for tim e

TIME DELAY 0 to 99 minutes 59 seconds alarm trip delay user

FAIL-SAFE Programmable OPERATION Independent for each alarm relay

AUTO INITIALIZATION When power is applied to the controller, alarm relays will

Sub1, Sub2: 250 VAC @ 1 A or 30 VD C @ 1 A (r esist ive load)

disru p tion t o the micropr oces sor ' s operati on . Recommended suppressor value: 0.1 μF/470 Ω, 250 VAC (PDX6901)

point deivation alarm.

proportional PID control.

selectable for each alar m . T i m e p roporti on al PID contr ol relay acti vati on t i me d elay of 0 t o 99 mi n u t es 5 9 s econds user selectable.

reflect the state of the input to the controller except standby alarms.

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Analog Outputs

OUTPUT RANGE Continuous PID or retransmitt ing: 4-20 mA (600 Ω maximum)

SCALING RANGE Retransmitting 4-20 mA outpu t s can b e s caled for any

ACCURACY +0.1% of f u ll scal e

Digital Inputs

CONFIGURATION Tw o contacts , t w o op erati ng modes CONTACTS Nor m al l y op en sw i tc h es (extern al exc i t ation n ot req uir e d)

OPE N CIRCUIT App ro ximate ly 5 VDC VOLTAGE

LOGIC LEVELS LO = 0 to 0.8 VDC, HI = 4.7 to 28 VDC OPERATION MODES Mode 1: Control outp ut run/ s t op , select i on of set poi n t 1 or 2

Serial Communications

PROTOCOLS Modbus (ASCII, RTU), PC software,

UNIT ADDRESS 1 to 99 (Max 31 units connected) BAUD RATE 600, 1200, 2400, 4800, 9600, 19200 bps, user selectable RESPONSE TIME 0 to 100 ms delay response time

DATA 7 or 8 bit user selectable PARITY None, even, or od d

Time Proportional PID: 15 VDC pulse (600 Ω minimum, current limited at 3 0 mA) hi g h , less t h an 0 . 1 V D C low, cycle time 1 to 300 seconds, user selectable

display range low and high

or open coll ect or tran sistor

Mode 2: Selec t i on of s et p oin t s 1 to 4

Sync ( m ast er /s l ave SP cont rol)

10 ms inc remen t s user selectab l e

Approvals

UL R E C OGN IZED USA and Canada

Process Control Equipment UL F I L E N UMBER E244207 CE COMP L I A N T

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

2. Front Panel Buttons and LED Indicato rs

Control K ey s

(UP/DOWN)

Key Function

SET/ENT (ENTER)

 / 

 (SHIFT)

Pressing SET/ENT k ey for at lea s t 3 se c onds switches between the operating di sp l a y an d parameter setu p g r oups. This key is used to verify and bypass parameter settings in the parameter setup groups.

Used t o cha n g e t h e v al u e of digits when setting parameters. Used to move between parameter groups.

Used to move to the next digit when setting parameters.

LED Display

LED Function

SP2, SP3, S P 4 EV1, EV2, E V 3

OUT MAN

LEDs activate when corresponding Set Point is selected for use. LEDs a c t ivate when corresponding relays energize. LED activated to display when control output is active. LED on when manual output control mode is selected. LED blinks during auto- tu n i n g setup process.

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

3. Parameter Map

PwD: Lockout Pass word

Use the  arrows to enter the

NOTE

password an d p ress t h e SE T/ENT key. The default password is 0.





G.AT

SET/ENT SE T/E N T SET/ENT SET/ENT

AT-G

G.SP

R-S

SPSL

SP1 SP2 SP3 SP4

SPRH

SPRL

TMU U.SLP D.SLP



G.PID

ARW

C.MOD

FUZY

PID

PID=1

1.P

1.I

1.D

1.MR

1.Pc

1.Ic

1.Dc

1.DB

1.RP

 ENT

PID=2

2.P

2.I

2.D

2.MR

2.Pc

2.Ic

2.Dc

2.DB

2.RP

PID=3

3.P

3.I

3.D

3.MR

3.Pc

3.Ic

3.Dc

3.DB RHY

PWD



4.P

4.I

4.D

4.MR

4.Pc

4.Ic

4.Dc

4.DB RDV

PID=4

G.CTL

S-TM P-TM

A/M US1

US2 LOCK DI. SL OSTS

DSP.H

DSP.L

U.PWD

ONOF

INIT



: Optional feature : Selection in H/C model controllers only (H/C models and ON/OFF mode display HYS)

: This setting is activ e o n ly when i n t e g r a l t ime i s 0 a n d H e a t o r Cool is s el e c t ed .

: Menu only used if OUT2 or OU T3 selecte d f o r Hea t or Coo l c o n t r o l

: OUT3 is an op t i o n f or the PD 540, PD541, PD544, and PD545, and standard on all other models

***

: Option not available on the PD540 or PD541

****

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

    

G.IN

IN-T

IN-U

IN.RH

IN.RL IN.DP IN.SH

IN.SL

IN.FL

BSL

RSL BSP1 BSP2 BSP3

BS0

BS1

BS2

BS3

BS4

SET/ENT

G.OUT

SET/ENT SET/ENT SET/ENT SET/ENT

OUT1 OUT2 HEAT

OUT3

HEAT

***

COOL

SUB1 SUB2

****

O.ACT

CTc

HYS

HYS.H

HYS.L

POc

G.ALM

ALT1

AL-1

AL1.H

AL1.L A1DB A1DY

ALT2

AL-2

AL2.H

AL2.L A2DB A2DY

ALT3

AL-3 AL3.H AL3.L A3DB A3DY

G.RET

RET

RETH

RETL

G.COM

COM.P

BAUD PRTY

SBIT DLEN ADDR

RP.TM

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

4. Operation Fl ow Ch a rt

Power On

Operation D i s p l ay

note 1: note 2:

note 3: note 4:

note 5: note 6: note 7:

Group dis p l ay

When setting co n t roller

PV Displa y

'STOP'

ENT

PV Valu e SP Valu e

ENT

PV Valu e

OUT Value

ENT

PV Valu e

H.OUT Value

ENT

PV Valu e

C.OUT Value

ENT

(note 1)

(note 2)

(note 3)

(note 4)

(note 5)

ENT key for

3 sec o nds or

no keystroke

for 60 sec

ENT 3 sec

G.AT



G.SP

 or 

User Set Display

US1

(note 6)

ENT

US2

(note 7)

parameters, G. IN and G.OUT should be set up prior to any other parameters.

See Page 12 for the Group

and Parameter Map

US1 and US2 are set by the user to display selected parameters in the operation display. The parameters to be displayed are set from parameters US1 and US2 in G.CTL. The Table of D-Registers provides the number to determine what parameter is displayed b y each. Parameters displayed here may be altered in this display as they are normally.

ENT

'STOP' appears in the SP display when the controller has stopped output operation due to running time parameters. The Set Point may be changed while in 'Stop' mode. Opera t i o n Display-1 : Initi a l d i s pl a y after power on. A c t ive Set Po in t ma y be se t t h r ough this menu. Opera t i o n Display-2 : Outp u t contr o l d is p la y shows l e vel of out p u t a s % o f f u l l o u t p u t s ca l e . M a y b e set manually if output configured for manual operation. Heating o u t p u t disp la y in Heating/Cooling mo d e ls o nly. Cooling out p u t display in Heating/Cool i ng mo d e l s only . Only displayed when User Screen 1 is set i n U S 1 . Only displayed when User Screen 2 is set i n U S 2 .

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PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5. Controller Parameter Setup

5.1 Input Group (G.IN)

CAUTION

in-t

G.IN

Input group parameters should be established first, as changes to the input type may reset other parameter settings in o t h e r g roup s t o t h e i r d e f a u lt value.

Press SET/ENT key to sel e ct i nput group. Pr e ss pre s s  or  key to cycle t hr ough groups as shown below. (Refer t o p a r a me t e r ma p i n se c t io n 3 .)

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN

This par a me t e r se le c t s t h e type of input s e n so r used . Its de f a u l t setti n g is type TC. K 1 . Refer to the following table showing the type of sensor inputs and select the desired input type.

Table 1: Universal Input S ele c tio n

TYPE

K1 K2

J E T R B S

L N U W

PtA PtB

PtC JPtA JPtB

1 to 5V

Temp.Range(ºC)

-200 to 1370

-199.9 to 999.9

-199.9 to 400.0

-199.9 to 900.0

-200 to 1300

-199.9 to 400.0

-199.9 to 850.0

-199.9 to 500.0

-19.99 to 99.99

-199.9 to 500.0

-150.0 to 150.0

No.

1 2 3 4 5 6 7 8

9 10 11 12

Platinel II

13 14 15 16 17 18

0.4 to 2.0 V

19 20

0 to 10 V

-10 to 20m V

0 to 100mV

4-20 mA Input Selection:

To accept a 4-20 mA signal, select 0.4 to 2.0 VDC input and connect a 100 Ω resistor across the input terminals.

NOTE

  

 



G.COM  G.RET  G.ALM  G.OUT

Temp.Range(ºF)

-300 to 2500 0 to 2300

-300 to 2300

-300 to 1800

0 to 1700 0 to 1800 0 to 1700

0 to 2300

0 to1390

-10.00 to 20.0 0 mV

-300 to 750 32 to 3100 32 to 3300 32 to 3100

-300 to 1600

-300 to 2400

-300 to 750 32 to 4200 32 to 2500

-300 to 1560

-199.9 to 999. 9

-4.0 to 212.0

-199.9 to 999. 9

-199.9 to 300. 0

0.400 to 2. 0 0 0 V

1.000 to 5. 0 0 0 V

0.00 to 10. 0 0 V

0.0 to 100.0mV



display range : -5% to 105%

Group

Thermocouple

RTD

(0.00385)

RTD

(0.00392)

VDC

mVDC



DISP

TC.t1 TC.t2

TC.J TC.E TC.T TC.R TC.B TC.S TC.L TC.N TC.U TC.y

TC.PL

PTA PTB

PTC JPTA JPTB

2v 5v

10v 20Nv 100n

1 1

Page 16

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

IN-U

IN.RH

IN.RL

IN.DP

IN.SH

IN.SL

IN.FL

BSL

RSL

This parameter sets the display temperature unit for ºC or ºF. Its default selection is ºC. Refer to Table 1 when changing th e t e mp e r a t u r e unit for t h e t e mp e rature input range.

This para me t e r s e t s the high l imi t o f t h e t e mpe rature dis p la y ran g e ( ma ximum temper a t ure displayed). F o r mV a n d V i nputs, this sets the value of the high input of the input scale defined in In.SH.

This para me t e r s et s t h e lo w l i mit o f t h e t e mpe rature dis p la y range (minimum temperature displayed). Fo r mV and V inputs, this sets the low input of the input scale defined in In.SL.

This para me t e r sets th e posit io n of the d e c i ma l po i n t for mV o r V i n p u t s. The posi t io n of the decimal point can be set as 9999, 999.9, 99.99, or 9.999. Its default set value is 1.

This para me t e r s e t s the high l imi t of the mV o r V d i sp l a y s ca l e . This value will be displayed when t h e i n pu t i s se t t o t h e h ig h i nput established in In.rH. Its default value is 100.0.

This parameter se t s t h e lo w l imi t o f t h e mV o r V d i sp l a y s ca l e . This value will be display e d when the input is set to the low input established in In.rL. Its default value is 0.0.

This para me t e r s e t s th e PV filter for stabilizatio n f r o m electromagnetic noise and interference. Th is will ef fe ct t he r a te o f change of the PV display v alue. Its default setting is OFF, and ca n b e s e t f r o m 1 to 120 se c o n ds.

This par a me t e r t o es t a b li sh e s P V behavior when an open input sensor is detected. When BSL is set t o U P, the PV operat e s a s i f a t t h e h ig h i nput range. Whe n BSL is set to DOWN, the PV operates as if a t t h e lo w i nput range. Its default setting is UP. In the case of mV o r V inpu t s , the defau l t se t t i n g is OFF. An open sensor check is not performed in 10 V, 20 mV, or 100 mV input settings.

This parame t e r d e t e r mi n e s i f RJC for the rmocouple inputs is used. RJC can be turned on or off. Its default setting is ON.

BSP1

BSP3

BS0

BS4

This para me t e r s e t s where the PV bias poin t s o cc u r . S e e F i g 1 and Fig 2 for fur ther information about input bias operation.

This para me t e r s e t s th e b i as value a t t h e co rresponding bias point input values. These parameters esta blish th e value of the of fset at ea ch of t he d efin ed BSP1 - BSP3 p oint s.

See Fig 1 and Fig 2 for further information about input bias operation.

Page 17

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

0ºC = BS4

-3ºC = BS3

+1ºC = BS2

-2ºC = BS1

0ºC = BS0

Example 1:

Example 2:

Original Temper a t u r e

-2ºC

RL BSP3 RHBSP1 BSP2

The original temperature is shown within the range of 0ºC (Range Low) and 100ºC (Range High). Bias point s h a ve been used to adjust the displayed temperature as shown in the graph in Fig 1.

To establish this bias, the settings are shown below.

0ºC = BS4

50ºC = BS3

10ºC = BS2

10ºC = BS1

0ºC = BS0

Tempe r a t u r e B ia s Value (BS 0 t h r o u g h B S 4 ) = Tempe r a t u re After Bias - Actual Temperat u re Display temperature after bias at 600ºC actual temperature = P

25ºC

Fig 1: Temperature Bias

Temperature Settings to Establish Where the Bias Occurs RL BSP1 BSP2 BSP3 RH 0ºC 25ºC 50ºC 75ºC 100ºC Bias Offset for Each Point BS0 BS1 BS2 BS3 BS4 0ºC -2ºC +1ºC -3ºC 0ºC

+10ºC

BSP1 BSP2 BSP3RL RH

100ºC0ºC 500ºC 800ºC 1000ºC

Fig 2: Bias Formula Calcul a t i on

P = 600 + (600 - BPS2) x

P = 600 + (600 - 500) x

+1ºC

50ºC 100ºC

Temperature After Bias

+10ºC

+PºC

Original

600ºC -

Temp

BS3 - BS2

BSP3 - BSP2

50 - 10

800 - 500

-3ºC

Temperature

After Bias

75ºC0ºC

+50ºC

Original

Temperature

+ BS2

+ 10 = 623ºC Temperature After Bias

BS4

Page 18

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Input Group Parameter Summary

Display Parameter

IN-T

Input Ty p e

IN-U

Display Unit

IN.RH

IN.RL IN.DP IN.SH

IN.SL

IN.FL

RSL BSP1 BSP2 BSP3

NOTE

Max PV

Display Range

Min PV

Display R ange

Decimal Point

Position

Max Input

Value Scal e

Min Input

Value Scale

PV Filter

Open Sensor

BSL

Behavior RJC Operation Reference Bias

Point 1

Reference Bias

Point 2

Reference Bias

Point 3

Bias Value for RL

BS0 BS1 BS2 BS3 BS4

Point

Bias Value at

BSP1

Bias Value at

BSP2

Bias Value at

BSP3

Bias Value

at RH

There are two types o f e n g in e e r i n g u n it s values us e d i n t h e se t t i n g o f p a r a me t e r s , a b so l u t e engineering units (AEU) and general eng inee r i n g u n it s ( GEU) . A n A E U p a r a me t e r i s se t u si n g a n absolute value engineering unit that represents a specific point, such as a specific temperature or voltage level. An GEU parameter is set using engineering units, however it is a general value, and not tied to any input or output level.

For example: When establishing input bias, parameter BSP1 sets the specific PV value where bias point one will occur. This pa r amete r h as a unit de signation of AEU. BS1, the amount of offset at BSP1 is set in engineer in g u n i t s, h o we ver this p a ramete r occurs at wh a t e ver BSP1 is set to, and therefore does not have an absolute setting related to any input or output, it is just the amount of offset at where BSP1 occurs. While one is related to an absolute input value, and the other stand alone value, both are set as engineering units, such as BSP1 set as 100ºC and BS1 set as 3ºC.

Refer to Table 1: Universal Input Selection

Setting Ra n g e

ºC / ºF

Within sensor i n p u t r ange

Refer to Table 1

INRH > INRL

0, 1, 2, or 3

-1999 to 9999

Decimal position determined by IN.DP

INSH > INSL

OFF, 1 to 120

OFF, UP, DOWN

ON, OFF

AEU (0.0 to 100.0%),

RL≤BSP1≤BSP2 ≤BSP3≤RH

AEU (0.0 to 100.0%),

RL≤BSP1≤BSP2 ≤BSP3≤RH

AEU (0.0 to 100.0%),

RL≤BSP1≤BSP2 ≤BSP3≤RH

GEU (-100.0 to 100.0%) GEU (-100.0 to 100.0%) GEU (-100.0 to 100.0%) GEU (-100.0 to 100.0%) GEU (-100.0 to 100.0%)

Unit Default Remark ABS TC.K1 ABS AEU 1370 AEU -200 ABS 1 mV, V

ABS

ABS UP ABS ON AEU AEU AEU GEU 0 GEU 0 GEU 0 GEU 0 GEU 0

ºC

100. 0 mV, V

0.0 mV, V

sec OFF

AEU

(100.0%)

AEU

(100.0%)

AEU

(100.0%)

T/C, RTD

Not Used for

VDC Input

Only Used for

TC Input

Page 19

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.2 Output Group (G.OUT)

G.oUT

oUT1

oUT2

oUT3

HEAT

cooL

sUB1

SUB2

Output Gr oup Menu Pr ogression Example:

The following settings establish relay out put 1 (OUT1) to trigger based on alarm 1, for analog output 2 (OUT2) to

NOTE

operate as a heating temperature controller outputting a voltage pulse, for analog output 3 (OUT 3) to output a retransmitting 4-20 mA signal, and for auxiliary r elay o utp uts SU B1 and SUB2 to trigger with alarm 2 and alarm 3.

oUT1 oUT2

alm1

Press SET/ENT key to sele ct i nput group. ( Refer to par ameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN  



G.COM  G.RET  G.ALM  G.OUT

This par a me t e r se t s t h e t y p e o f operat i o n for output 1. (OU T1: relay out p u t ) Th e o u t p u t can b e s et t o HEAT, COO L , ALM 1 , AL M 2 , ALM 3 , or RUN. Its de f au l t setting is ALM1. (COOL is disp l a yed o n H/C models only. Skip wh e n ON/OFF M ode selected.)

This parame t e r e st a b l is h e s th e t ype o f operation for output 2. (OUT2: 4-20 mA or voltage pulse) Setti n g s c a n b e HEAT , COO L , or RET (retransmitting ). Its de f a u lt sett in g i s HEAT. (COOL is dis pl a yed o n H/C models only.)

This parameter estab l is h e s t h e t ype of oper ation for output 3. (O UT 3: 4- 20 mA or voltage pulse) Settings can be HEAT, COOL, or RET (retransmitting). Its default setting is HEAT. (COOL is displayed on H/C models only.) Valid for models with OUT3 only.

This parameter selects the ty p e o f o u t pu t s i gnal for each analog output (OUT 2 and O UT3) when they are set to HEAT. The outputs can be set to SSR (pulse output) or SCR (4-20 mA). Its default setting is SSR.

This parameter selects the ty p e o f o u t pu t s i gnal for each analog output (OUT 2 and O UT3) when they are set to C OOL. The outp u t s c a n b e s e t t o S SR (puls e o ut p u t ) or S C R ( 4 20mA). Its d ef a u l t se t t i n g i s S SR.

This para me t e r s e t s th e type of oper ation for auxiliary outp ut 1 (SUB1: relay outp ut ) Output can be set to HEAT, COOL, ALM1, ALM2, ALM3, or RUN. Its default setting is ALM2. (COOL is disp l a y ed on H/C models only. Menu appears only on models with t h e SUB1 output option.)

This parameter sets t h e t y p e o f oper ation for aux ilia r y out put 2 ( SU B2: re lay o utp ut ) Output can be set to HEAT, COOL, ALM1, ALM2, ALM3, or RUN. I ts default setting is ALM2. (COOL is displayed on H/C models only. Menu appears only on models with the SUB2 output option.)

  

HEAT



ssr

oUT3

ret

sUB1 SUB2

alm2 Alm3

Page 20

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

o.Act

ctC

HYS

This parame t e r e s t a b li sh e s rev e r s e (REV) or fo r w a r d (FWD) activation of th e c o n t r o l outputs . I n fo r ward ope r atio n, t he cont r ol ou tpu ts will be most a ctive when the PV value is higher than the SP, as th e c on t rolle r a c t s t o l o we r t h e P V. In rev e r s e operation, the control outputs will be most act ive when the PV value is lower than the SP v alue, as the controlle r acts to increase t h e PV . The defa u lt s e t t in g i s REV.

This parameter estab li s h es t h e cycle t i me f o r use wit h t i me - p r opor tional PID relay or voltage pulse control whe n t h e o u t p u t s a re set t o H E AT or COOL. T h e cycle t ime c a n be set f r o m 1 t o 3 00 seconds. It s d e f a u l t se t t i n g i s 2 s e co n d s .

This parameter estab l is h e s t h e c y c le t i me f o r c oo l i n g ou t p u t s if coolin g (COOL) cont r o l is set u p wi t h time-prop o rtion a l PID contr o l i n a H/C model. (Ex ample: OUT1 = Cool, OUT2 or Out3 = Co o l a n d s e t t o SSR, SU B1 or SUB2 = Cool) Th e c ycle ti me ca n b e s e t f r o m 1 to 300 seconds. Its default setting is 2 seconds.

Output at 50%

5 Sec

CT = 10 Sec

Fig 3: Time-Proportional PID Control Output

This para me t e r s e t s a high limit for the le vels of th e c o n t r o l ou t p u t . This limits t h e o u t p u t levels based on a percent ag e o f t h e i r f u l l s ca l e . Its de f a u l t se t t i n g is 100 (% ).

This parameter sets a lo w l imi t f o r t h e l evels of t h e co n t r o l o u t p u t . This prevents th e outputs from droppi n g b e lo w a c e r t a i n le vel based o n a p e rcent age of their full scale. Its default setting is 0 (%). The outp u t s a re limit e d b y b o t h t h e t h e l o w a n d h i g h l imits.

This parameter set s h y s t e r e s is in c a se o f On/O f f c o n t r o l ou t p u t mode in a H/C model.

Output at 70% Output at 30%

7 Sec

CT = 10 Sec CT = 10 Sec

Cycle Time (CT) set t o 1 0 s ec o n d s

3 Sec

7 Sec

HYS.H

HYS.L

This parameter sets t h e hysteresis h i g h li mit f o r on/o f f relay cont r o l mode in normal models (non-Heating/Cooling models).

This parameter se t s t h e h y s t e r e s is lo w l imi t f o r o n / o f f r e l a y c o n t r o l mode in normal models (non-Heating/Cool in g models).

Page 21

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

poC

Output Group Parameter Summary

Display Parameter

OUT1

Select Output

OUT2

Select Output

OUT3

Select Output Select Output

HEAT

Select Output

COOL

SUB1

Select Output

SUB2

Select Output

Reve rse and

O.ACT

HYS.H Hysteresis Hi g h

HYS.L Hysteresis Low

OUT1 Relay

Condition

Forward

Cycle Time 1

CTc Cycle Time 2

High Limit value

of Output

Low Limit val u e

of Output

HYS Hysteresis

Preset Output

POc Preset Output

OFF

SP SP

Note: In H/C models, HYS.H and HYS.L replaced by HYS, and range high and low is 1/2 HYS setting

This parameter establishes the percent output transmitted by the control outputs when the controller is in STOP mode, or when an error condition occurs such as a PID algorithm error, A/D error, or open sensor error is detected.

This parameter e st a b l is h e s t h e p e rcent o u t p u t t r a n s mit t e d b y t h e C OOL c o n t r o l o u t p ut s i n a Heating & Cooling controller model when the controller is in STOP mode, or when an error condition occurs.

Type Type

On Off

Setting Range

HEAT, COOL, A L M 1 , A L M 2 , AL M 3 , RUN

HEAT, COOL , RET HEAT, COOL , RET

SSR, SCR

SSR, SCR HEAT, COOL, A L M 1 , A L M 2 , AL M 3 , RUN HEAT, COOL, A L M 1 , A L M 2 , AL M 3 , RUN

REV, FWD

1 to 300 sec 1 to 300 sec

OL + 1 digit to 105.0%

HC models: 0 to 105.0%, however OH>OL

-5.0% to OH setting

HC Type: 0 to 105.0%, However OH>OL

0.0 to 10.0 % GEU (0.0 t o 10.0% of se n s o r r a n g e ) GEU (0.0 to 10.0% o f se n s o r r ange)

-5.0 to 105.0%

H/C Type : 0.0 to 105.0%

0.0 to 105.0%

HYS.H

HYS.L

On/Off Relay Be h a vior Base d O n H ysteresis S e t t in g s

Unit Default Remark ABS ALM1 ABS HEAT ABS RET ABS SSR ABS SSR ABS ALM2 Option ABS ALM3 Option ABS REV

sec 2 sec sec H/C Models Only

100.0%

H/C:100.0%

GEU

GEU (0.5%)

GEU

GEU (0.5%) % % H/C Models Only

2 sec

0.5%

0.0%

Models with OUT3 Only

When OU T 2,

3, Set for HEAT

When OUT 2,

3, Set for COOL

H/C Models Only,

On/Off Mode Relay Cutoff,

ON/OFF Mo d e

Relay Activation,

ON/OFF Mo d e

Page 22

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.3 Control Group (G.CTL)

g.ctl

s-tm

p-tm

A/m

US1

US2

LoCk

Table 2: DI Operation

Press SET/ENT key to select control group. (Refer to parameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT



This parameter establishes the delay time from power on to when the outputs are activate d . This can be set from 0 to 99.95 (hours.min u t es ) . Its defau l t se t t i n g is OFF. S e e F i g . 4 .

This parameter establishes the running time for the controller outputs. P-TM can be set from to 99.59 (hours.minut e s). I t s d e f a u lt s e t t i ng i s O F F. See Fig 4. N o t e t h a t t h is t ime begins after the S- TM functi o n .

S-TM P-TM

STOP RUN STOP

POWER ON

Fig 4: Output Delay and Timer Functions

This establishes the con t r o l mo d e a s a u t o ma t ic ( A U TO) or manual (MAN). When in manual mode, the output levels can be set by the user from the operation display, and the MAN LED will active on the front panel. The default setting is AUTO.

This parameter estab l is h e s t h e u s e r sc r eens for viewing, confirmation, and setup of commonly used parameters from the operation display. To add the parameter to t h e operation display , e n t er the co rresponding number for the parameter from the Table of DRegisters as either US1 or US2. The de f a u l t se t t i n g s a re OF F.

See page 14 and the Operation Flow Chart for a map of the operation display.

Turning ON this parameter locks all setting s fr om bein g changed. This applies to the operation display f u nc t i o n s, s u ch a s c h anging the set point, as well as setting group parameters. If ON, on l y t h e L OCK pa ramete r may b e changed. The default setting is OFF.

DI.SL DI1 DI2 Operation

OFF - -

off on

off on off on

off SP1 on SP2 off off on SP3 on SP4





DI Disabled

Stop Run

SP1 SP2

Page 23

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

di.sl

osts

dsp.H

dsp.l

U.pwd

CAUTION

onof

NOTE

init

This parameter establishes the operation of the digital input (DI) ex ter nal contacts. The digital input operating configurati on s a r e s h o wn in Table 2: D I Ope r a t i o n . This feat u r e i s only val id f o r mo d e l s wi t h d ig i t a l i nputs.

When this parameter is on , th e o utp ut sett ing s will be disp lay e d in t he ope r atio n d isplay . The settings of parameter s OUT 1 , O UT2 , O U T3, SUB1 , a n d SU B 2 will be sho wn. O nly outputs built into th e mod e l b e in g u s e d will displa y . Its default sett ing is O FF .

This parameter sets t h e h ig h l imi t o f t h e s e n so r inpu t i n t h e P V d is p l ay. T h e P V value will not display higher than this limit, however the control functions will operate based on the actual input value.

This parameter se t s t h e lo w l imi t o f t h e s e n so r inpu t i n th e P V d is p la y. T h e P V value will not display lower than this limit, however the control functions will operate based on the actual input value.

This parameter estab l is h e s t h e p a s swo r d f o r the co n t r o l le r. T h i s p a s swo rd must b e entered at the PWD screen before accessing the control group (G.CTL) or it will not access the settin g gr o u p s a f t e r the P WD p r o mp t . The defau l t se t t i n g i s " 0 " . S e e t h e parameter map in section 3 for the location of the PWD prompt in the group menus.

Be sure not to forget the password once it has been set. If the passwor d i s f o rgott e n , c o n t a ct t e c h n ic a l support as listed on the back of this manual.

The pa r a me t e r t o s e t the cont r o l t y p e f o r On/O f f control mode in a He a t i n g o r C o o l in g standard cont rolle r . Contr o l o u t p u t is set to ou t p u t 1 ( O u t 1 : R e l a y ) when in On/O f f m ode. See hysteresis commands in the output group for operating the relay in On/Off mode.

The onof parameter does not appear in Heating and Cooling controllers. To set up a Heating and Cooling model for O n / Off co n t r o l , e n t e r t h e G.PID (PID Group) and set parameters 1.P and 1.Pc to 0.0.

See page 20 and 21 for more information on setting up On/Off control.

This parameter rese t s mo st p a ramete r s t o t h e ir fact o ry set t i n g s. To reset the co n t rolle r , set this parameter to ON. Afte r res et , i t will r et ur n t o t he O F F set tin g.

CAUTION

Most parameters will be reset to th e ir defa u l t se t t i n g s when the controller is initialized. Note the current settings before this is done so they can easily be restored after controller initialization.

Page 24

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Control Group Parameter Summary

Display Parameter

S-TM Start Time Delay P-TM Process Run Time

A/M Automatic/Manual US1 US2

LOCK

DI. SL

OSTS

DSP.H

DSP.L

U.PWD User Password

ONOF ON/OFF Mode

INIT

User Screen User Screen

Parameter Lock

DI Selection

Output Status

Display

Display High Limit

Display Low Limit

Factory

Initialization

Setting Range Off (0.00 ) t o 99. 5 9 (hours.minutes) Off (0.00) t o 9 9 . 5 9 (hours.minutes)

AUTO, MAN Off, D-Register Number 1 to 1299 Off, D-Register Number 1 t o 1299

OFF, ON OFF, 1, 2

OFF, ON AEU (-5.0 to 105.0%), DSP.L<DSP.H AEU (-5.0 to 105.0%), DSP.L<DSP.H

0 to 9999

ON, OFF

OFF, ON

Unit Default Remark Time OFF Time OFF ABS AUTO ABS OFF ABS OFF ABS OFF ABS OFF DI Option ABS OFF AEU AEU (105.0%) AEU AEU (-5.0%) ABS 0

ABS OFF ABS OFF

Not in

H/C Models

Page 25

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.4 SP Group (G.SP)

g.sp

r-s

spsl

sp1

sp4

sprh

sprl

tmU

U.SLP

D.SLP

Press SET/ENT key to sele ct S P g r oup. ( Refer to par ameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT



This parameter sets the running mode to RUN or STOP. I n ST O P mode, outputs are turned off, and no set point is maintained.

This parameter selects whi c h se t p o in t i s a ct i ve. The r e a re fou r pro g r a mma b le s e t p o in t s , and one for use with SYNC- SLAVE communication. I t can b e set t o RSP, SP1, SP2, SP3, or SP4. Its default setting is SP1.

When using the communication option for Sync-Slave control, the slave

controllers must have SPSL set t o RSP.

NOTE

This parameter sets the value of each of the 4 programmable set points that can be

selected t o r u n . The para me t e r SPSL selects which set poin t to use.

This par a me t e r sets a hig h l imi t o n wh a t th e s e t p o in t s ca n b e p rogr a mmed o r c hanged to. This value may reset if the t y p e o f i nput is changed, or if parameter IN.RH or I N.RL (IN. SH or IN.SL if input type is mV or V) is changed.

This par a me t e r se t s a lo w l imi t o n wha t t h e s e t p oi n t s c a n b e p r o g r a mme d o r changed to. This value may reset if the t y p e o f i nput is changed, or if parameter IN.RH or I N.RL (IN. SH or IN.SL if input type is mV or V) are changed.

This parameter sets the time unit the controller uses for parameters with time components. This can b e s e t t o t h e f o r ma t o f HH.MM (hours.min u t e s) or MM.SS (minute s . se c o n d s). Its de f a u l t setti n g is HH.MM.

This parameter to sets the SP to ascend or descend gradually over time, dependant on t h e new SP se l e ct e d . U.SLP (ra t e o f a sc e n si o n ) a n d D.SLP (ra t e o f d e sc e n t ) ar e t h e r at e of change over ti me ( t i me u n i t s s e t b y p a ramete r TM U ) o f t h e s e t p o in t wh e n t h e se t p o i n t is changed. When U.SLP and D.SLP is set to OFF, the new SP is set instantly. The default setting of U . S L P a n d D . SL P is OFF.

Parameters S-TM and P-TM are n o t li n ke d t o TMU. T h e t i me u n it s e t t in g

of those paramet e rs is al wa y s H H . M M ( hours.minutes).

NOTE





Page 26

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Set Point Group Parameter Summary

Display Parameter

R-S Run/Stop

SPSL

SP1 SP2 Set Point 2 SP3 Set Point 3

SP4 Set Point 4 SPRH SPRL

TMU Time Unit U.SLP D.SLP

SP Select

Set Point 1

Set Point

Range High

Set Point

Range Low

Rate of Chage

for SP I n c r e a s e

Rate of Chage

for SP Decrease

Setting Range

RUN, STOP

RSP, SP1, SP2, SP3, S P4 AEU (0.0 - 100.0% of input range) AEU (0.0 - 100.0% o f i nput range) AEU (0.0 - 100.0% o f i nput range) AEU (0.0 - 100.0% o f i nput range) AEU (0.0 - 100.0% o f i nput range) AEU (0.0 - 100.0% o f i nput range)

HH.MM (hours.minutes),

MM.SS (minut e s . se c onds)

OFF (0), GEU (0.0%+1digit t o 100 . 0 % ) p e r OFF (0), GEU (0.0%+1digit to 100.0%) per

minute or second minute or second

Unit Default Remark ABS RUN ABS SP1

AEU (Input

AEU

Range Low)

AEU (Input

AEU

Range Low)

AEU (Input

AEU

Range Low)

AEU (Input

AEU

Range Low)

AEU (Input

AEU

Range High)

AEU (Input

AEU

Range Low)

ABS HH.MM GEU OFF (0) GEU OFF (0)

Page 27

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.5 PID Group (G.PID)

NOTE

The PID group selection doe s n o t a p p e a r when the controller is operating in On/Off mode

Press SET/ENT key to select PID group. (Refer to parameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT







C.mod

The parameter sets the PV deviation width to prev ent overshoot. When the control output s reach this high limit value, th e y stop o r d i n a r y outp u t a c t io n f o r inte g r a l co n t rol an d u se ARW (Anti-Reset Windu p ) . When the setting is AUTO, this parameter is calculated automatically.

This par a me t e r establishes the c on t rol mode. It can be set to Differential of Deviation Value (d. dv) or Process Variable (d. pv). Dviation Value mode will reduce overshoot. Process Variable mode will more quickly raise and lower the PV. The def au lt setting i s d . d v.

This parameter act i vates the u s e o f f u zzy logic. Fuzzy logic c a n b e e f f e c t ive in suppressing overshoo t a n d reducing PV variation that may occur once the PV has reached the SP. Ref er to F i g 5: Oversh o o t S uppression with Fuzzy Logic.

PV: Fuzzy Logic Off

PV: Fuzzy Logic On

Fig 5: Overshoot Suppression with Fuzzy Logic

This parameter esta b l is h e s t h e n u mb e r o f P ID set t i n g g r oups to be used in control output calculation. Up to 4 user defined groups of proportional, integral, and derivative v alue zones can be established. U se t h i s s e t t i n g t o e n t e r the s e t t in g menus for each PI D group.

This par a me t e r s e t s th e proport i onal operation for PID control. Setting rang e o f 1 . P is 0.1 (H/C mod el: 0.0 ) to 999.9%. Its default setting is 10.0%.

Page 28

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

. . .

This par a me t e r s e t s th e integrati o n t im e for PI D cont rol. Setting range s of 1. I are OFF or 1 to 60 00 seconds. Its default setting is 120 seconds

The parameter to set derivation time for PID control. Setting range s of 1.D ar e OFF or 1 t o 6 0 00 se c onds. Its default setting is 30 seconds.

The p a r a me t e r to set the manual reset in th e PID calcula t i o n . This sett in g o n l y f u n c t i o n s i f the integral time sett in g i s OFF. This sett i n g al wa ys fun ct i o n s for H/C mod els.

The pa r a me t e r t o s e t p roportion a l operation for PID control for the cooling control in H/C models . Setting op t i o n s a r e 0. 0 (whe n using On/Of f control) o r 0 . 1 t o 999.9% . Its default setting is 10.0%.

The p a r a me t e r to set integral ti me for PID control for t h e cooling control in H/C models. Setting op t io n s a r e OFF or 1 t o 60 00 secon ds. Its default setting is 120 seconds.

The pa r a me t e r t o s e t d eri vative t im e for PID control f o r the cooling contr o l in H/C mode ls. Setting options are OFF or 1 to 6000 seconds. Its default setting is 30 seconds.

The parameter to set the dead band, in which there is n o o u t p u t f r o m e it h e r the he a t i n g o r cooling outputs. Refer to F i g 6 , Fig 7, and Fig 8.

Note: The contents of PID Groups 2, 3, and 4 are the same as PID Group 1.

This parameter establ is h e s t h e P V range of each of the 3 main PID zones. The range of PID zone 1 is IN.RL (IN.SL if set for mV or V input) to 1.RP. The r ange of PI D zone 2 is

1.RP to 2.RP. The range of PID zone 3 is 2. R P t o IN.R H ( IN.SH if s e t f o r mV o r V i nput).

This parameter establish e s t h e r a n g e o f e a ch o f t h e 3 ma i n P ID zones . The range of PID zone 1 is IN.RL (IN.SL if set for mV or V input) to 1.RP. T he range of PI D z one 2 is 1.RP to 2.RP. The range of PID zone 3 is 2.RP t o IN.R H (IN . SH i f s e t f o r mV o r V inp u t ) .

This paramete r e st a b l is h e s t h e h ysteresis wi dt h o f t h e P ID zo n e .

This paramet e r sets th e range o f d e viation f o r P ID z one 4. When the difference between the PV and SP is greater than this deviation range, the controller will utilize PID group 4 for PID settings. While t h e P V a n d S P a r e wi t hi n t h i s d e viation d i f f e r e n ce , t h e c o n t r o l le r will utilize whatever zon e would n or mally b e use d ba sed o n th e PV value .

Page 29

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

COOL

(80%)

COOL

100

P/Pc = 4/5

0 0

0 50 100

OL-LIMIT

(-5%)

(90%)

Fig 6: Heating and Cooling Outputs Using PID Control

100

Dead Ban d

(1.DB at 2 0 % )

Output

HYS

Dead Ban d

(1.DB at 2 0 % )

HEAT

100

OH-LIMIT

(100%)

100

(90%)

HEAT

0 0

0 50 100

OL-LIMIT

(-5%)

Fig 7: Heating On/OFF and Cooling PID Outputs

OUTPUT

OH-LIMIT

(100%)

Page 30

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

100

0 0

0 50 100

OL-LIMIT

(0%)

PID Group Parameter Summary

Display Paramete r

ARW

Anti-Reset Wind-Up

C.MOD Control Mode

FUZY

PID

n.P

n.I

n.D

n.MR n.Manual Reset

n.Pc

n.Ic n.Dc n.DB n.Deadband

1.RP Reference Point 1

2.RP Reference Poin t2 RHY RDV

Fuzzy

PID Number

n.Proportional Band

n.Integra l Time

n.D erivative Time

n.Proportional Band

for Cooling Side

n.Integral Time for

Cooling Side

n.Derivative Time for

Cooling Side

Reference Hysteresis Reference

Deviation

COOL HEAT

Fig 8: Heating PID and Cooling On/Off Outputs

HYS

(20%)

OUTPUT

Setting Range

Auto or 50.0 to 200.0%

Differential of Deviati on V a l u e ( d . d V ) o r

Process Variabl e ( d . P V )

OFF, ON

MENU (0), 1, 2, 3, o r 4

0.1 (H/C Models:0 . 0 ) to 999.9% OFF, 1 to 6 0 0 0 s e c onds OFF, 1 to 6 0 0 0 s e c onds

-5.0 to 105.0%

0.0 (ON/OFF Control) o r 0.1 to 9 9 9 .9% OFF, 1 to 6 0 0 0 sec OFF, 1 to 6000 sec

-100.0 to 50.0%

AEU (0.0%), 1 . R P < 2 . R P

1.RP < 2.RP < AEU (100.0%) GEU (0.0 t o 1 0 . 0 % )

GEU (0.0 t o 1 0 0 . 0 % )

100

(90%)

OH-LIMIT

(105%)

Unit Default Remarks

% Auto ABS d. dV ABS OFF ABS MENU

% 10.0%

sec 120 sec sec 30 sec

% 50.0%

% 10.0%

sec 120 sec sec 30 sec

% 3.0% AEU 100.0% PID Zone 1 AEU 100.0% PID Zone 2

GEU 0.3% PID Zone 3 GEU 0.0% PID Zone 4

Used if I =0 ,

or H/C Model

H/C

Models Only

H/C

Models Only

H/C

Models Only

H/C

Models Only

Page 31

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.6 Aut o -Tuning Group (G.A T)

AT group selection does not appear if operating in On/Off mode or when set for manual output control.

NOTE

Press SET/ENT key to select AT group. (Refer to parameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT







Auto-Tuning (AT)

NOTE

The auto-tuning feature is u se d t o l e t t h e co n t r o l l er measu r e p rocess ch a racte r i s t ic s and automatically set the most

appropriate values for the PID para me t e r s . D u r i n g t h e i n i t ia l a u t o - t u n in g p roces s, t h e co n t rol ou t p u t s will f un ction in an On/Off condition, and the controller will use the r esponses to calculate the needed PID values. During this setup process, the M A N L ED on th e c o n t r o l le r will b link.

Start the auto-tuning process after se t t i n g a d es i r e d se t p o i n t . A ut o -tun in g will set the PI D par a meter s for t he PID

zone which the set p o in t i s i n , b a se d o n t h e P ID re f e r e n c e p o in t (RP) e n t e r e d .

The parameter to activate the auto-tuning function. When AT is set to ON, auto-tuning will begin (indicated by the MAN light blinking). This parameter cannot be used if the controller is in STOP mode.

ON OFF ON OFF ONControl Output

Auto-Tu n in g On

(On/Of f Oper a t i o n , MAN LED Blinki n g )

PID Control

Fig 9: Auto-Tuning

2.PID

1.PID

Page 32

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Auto-Tuning the Heat in g / C o o l i n g Outp u t s:

Auto-tuning of the heating/cooling outputs is the same process as the normal outputs. The PID heating/ cooling parameters wil l be cal cu l a t e d . The p a r a me t e r s f o r t h e P ID deriv a t io n t i me ( 1 . D ) will be the same for both the heating and cooling outputs.

Display During Auto-Tuning: The MAN LED on the fr on t pa ne l will blink at a 50 0 ms time inter val.

Changing the Set Point During Auto-Tuning:

If the set point is changed during the auto-tuning process, the original set point will be maintained fo r the duration of the auto-tun i n g p r o c e ss . Af t e r auto -tuni n g i s c o mpl e t e , t h e co n t roller will change to the new set point.

Changing PID Parameters During Auto-Tuning:

The PID values can be change d d u r i ng t h e a u t o -tuni n g p r o c e ss . Af t e r auto -tun in g i s c o mpl e t e , it will t he n use the auto-tune calculate d P ID v a l u e s. V a lu e s ch a nged after auto-tuning will remain set un til au to -t un ing is run again.

Auto-Tuning Interruption s o r E r rors :

The auto-tunin g p r o c e ss will end without effect for any of the following reasons:

- Auto-tuning forced t o end ( Ex ample: Controller power down or stop condition)

- Open sensor (S.OPN) input erro r dete c t e d d u r i n g t h e a u t o -tuni n g p r o c e ss

- Auto-tuning cycle exceeds 24 hours.

- Control changed to manual (MAN) operation during auto-tuning.

Auto-Tuning Group Parameter Summary

Display Parameter

AT-G

This parameter affects the proportional v alue deriv ed by auto-tuning. Reduce the AT -G gain value and the cycle becomes more rapid, but more unstable. Increasing gain slows system react ion time, b ut sy stem sta bility in cr ea ses.

Fig 10: Auto-Tuning Gain

Auto-Tuning

AT Ga i n

Setting Range

OFF, ON

0.1 to 10.0

Gain < 1

Gain = 1

Gain > 1

Unit Default Remark ABS OFF AT Activation ABS 1.0 Gain Value

Page 33

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.7 Alarm Group (G. A L M )

G.alm

alt1

al-1

al1.H

al1.l

a1db

a1dy

. . .

Alarm Types and LED Display

NOTE

AH.FS

Press SET/ENT key to select a l a r m g r oup. ( Refer to par ameter map in section 3.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT



This parameter sets the type of alarm to be set for alarm 1. The t ypes of a la r ms select a b le a re sho wn i n Table 3: Al a r m S e l e ct i o n .

This parameter sets the alarm trigger point for the alarm set in ALT1. This par a me t e r displays if a high, l o w, o r h ig h a n d l o w li mit a l a r m wa s se l e ct e d f o r A L T1.

This establishes the high deviation range to trigger the alarm of deviation. T his parameter displays if a deviation alarm was selected in ALT1.

This establishes the low deviation range to trigger the alarm of deviation. This parameter displays if a deviation alarm was selected in ALT1.

This parameter sets the dead band (Hysteresis) o f a l a r m 1.

This par a me t e r se t s the d e lay time before of a la rm 1 is triggered.

Note: The menus for alarm 2 and 3 are the same as alarm 1.

Alarm Output Settings:

- Forward : Relay energiz e d i n a la rm condition

- Rever se : Failsafe operation. R e la y energiz e d d u r i ng n o rmal operatin g conditions

S indicates standby operation F for forward operation

r for reverse (failsafe) operation

Decimal point always displaye d

H indicates a high alarm L indicates a low alarm o for outside range of deviation band I for inside range of dev iation band

A indicates an absolute value alarm d indicates a deviation alarm

Standb y Operation: The alarm will not trigger if the alarm condition occurs during the fo l l owi n g a ct i vities.. .

- during power-up

- the set point is changed

- the type of alarm is changed





Page 34

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Table 3: Alarm Selection

No.

1 2 3 4 5 6

9 10 11 12 13 14 15 16 17 18 19 20

Alarm Typ e

Absolute V a lu e H i g h L imi t Al a r m Absolute Value Low Limit Alarm High Limit Dev i a t i on A l a r m Low Limit Deviation Alarm High Limit Dev i a t i on A l a r m Low Limit Deviation Alarm High and Low Limit Deviation Alarm7 High and Low L imi t R ange Deviation Alarm8 Absolute V a lu e H i g h L imi t Al a r m Absolute Value Low Limit Alarm Absolute Value High Limit Alarm with Standby Absolute Value Low Limit Alarm with Standby High Limit Deviation Alarm with Standby Low Limit Deviation Alarm with Standby High Limit Deviation Alarm with Standby Low Limit Deviation Alarm with Standby High and Low Limit Deviation Alarm with Standby High and Low Limi t R ange Dev iation Alarmwith Standby Absolute Va lu e H i g h L imi t A l a r m with Standby Absolute Value Low Limit Alarm with Standby

Operation

For

3 3 3 3

3 3

3 3 3 3

3 3

Rev

Standby

3 3 3 3

3 3 3

3 3

Off

3 3 3 3 3 3 3 3 3 3

Display Data

AH.F

AL.F DH.F DL.F

DH.R

DL.R

DO.F

DI.F

AH.R

AL.R

AH.FS

AL.FS

DH.FS

DL.FS

DH.RS

DL.RS

DO.FS

DI.FS

AH.RS

AL.RS

PV High

Limit Alarm

PV Low

Limit Alarm

High and Low

Limit D evi a t i o n

Alarm

High and Low

Limit Range

Deviation

Alarm

DEV

 OFF

 ON

ALM.L

 OFF

 ON

ALM



ON



ALM



OFF

ON



ALM.L

Fig 11: Ala r m Operation

DEV=0



DEV=0



High Limit

Deviation

Alarm

Low Limit Deviation

Alarm

 OFF

 ON

ALM.H

DEV



 OFF

 ON

DEV





- +

ALM.L

ON



ALM.H



OFF

ON



ALM.H

OFF

Page 35

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Alarm Group Parameter Summary

Display Parameter

ALT1

AL-1

AL1.H

AL1.L A1DB A1DY

ALT2

AL-2

AL2.H

AL2.L A2DB A2DY

ALT3

AL-3

AL3.H

AL3.L A3DB A3DY

Setting Range

Alarm Type 1 Refe r to Ta b l e 3: Alar m S e l e ct i o n ABS AH.F

Set Value of

Alarm 1

High Deviation

Limit of Alarm 1

Low Deviatio n

Limit of Alarm 1

Alarm 1 DB

Delay Time of

Alarm 1

Alarm Type 2 Refe r t o Table 3 : A l a r m S e le c t i o n ABS AH.F

Set Value o f

Alarm 2

High Deviation

Limit of Alarm 2

Low Deviatio n

Limit of Alarm 2

Alarm 2 DB

Delay Time of

Alarm 2

Alarm Type 3 Refer to Table 3: A l a r m Se l e ct i o n ABS AH.F

Set Value o f

Alarm 3

High Deviation

Limit of Alarm 3

Low Deviatio n

Limit of Alarm 3

Alarm 3 DB

Delay Time of

Alarm 3

AEU (-100.0 to 00.0%) GEU (-100 . 0 t o 1 0 0 . 0 % ) GEU (-100.0 to 100.0%)

GEU (0.0 t o 1 0 0 . 0 % )

0.00 to 99. 5 9

AEU (-100.0 to 100.0% ) GEU (-100 . 0 t o 1 0 0 . 0 % ) GEU (-100.0 to 100.0%)

GEU (0.0 t o 1 0 0 . 0 % )

0.00 to 99. 5 9

AEU (-100.0 to 100.0% ) GEU (-100 . 0 t o 1 0 0 . 0 % ) GEU (-100.0 to 100.0%)

GEU (0.0 t o 1 0 0 . 0 % )

0.00 to 99. 5 9

Unit Default Remark

AEU AEU (100.0%) GEU GEU (0.0%) GEU GEU (0.0%) GEU GEU (0.5%)

MM.SS 0.00

AEU AEU (100.0%) GEU GEU (0.0%) GEU GEU (0.0%) GEU GEU (0.5%)

MM.SS 0.00

AEU AEU (100.0%) GEU GEU (0.0%) GEU GEU (0.0%) GEU GEU (0.5%)

MM.SS 0.00

Absolut e

Value Alar m

Deviation

Alarm

Deviation

Alarm

Absolut e

Value Alar m

Deviation

Alarm

Deviation

Alarm

Absolut e

Value Alar m

Deviation

Alarm

Deviation

Alarm

Page 36

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.8 Retransmission Group (G.RET)

g.ret

ret

retH

Press SET/ENT key to select retransmission group. (Refer to parameter map.)

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT



This par a me t e r sets the ty p e o f retr a n smi ss io n oper ation to use. Options are PV, SP, MV, and LPS. See notes below for an explanation of the retransmission typ e s . The default setting is PV.

These parameter s a r e u s ed t o s ca l e t h e r e t ransmit t i n g o u t p u t . They s e t t h e h ig h a n d l o w limits for the retr a n smi ss io n o u t p u t s ca l e , a s s h o wn b e lo w. The retransmit t i n g o u t p u t s wi ll transmit 4 mA at the low limit (RETL) and 20 mA at the high limit (RETH) values. These limits are u se d wh e n t h e r e t r a n s mis si o n t y p e i s s e t t o PV o r S P .



retl

PV and SP Ty p e R e tran s miss i o n S c a l e

PV type retransmits based on the input value, SP retransmits based on the set point value.

NOTE

4.0 mA

RETL

MV Type Retransmission Scale

MV type retr a n smi t s b a s e d o n t h e f ul l sc a le o u t p u t and what is currently being transmitted by the control outputs

4.0 mA

0.0%

(No Output )

12.0 mA

20.0 mA

RETH

20.0 mA

100.0%

(Maximum Output)



LPS Type Retransmission

LPS (Loop Power Suppy) retransmitting outputs will transmit a 14-18 VD C @ 2 0 mA power supp ly ou tpu t.

Retransmission Group P a r a mete r S u mmary

Display Parameter

RET

Select Ret Type PV, SP, MV, LPS ABS PV

Ret Sc al e

RETH

High Limit

Ret Sc al e

RETL

Low Limit

Setting Range

T/C, RTD: INRH to INRL

mV, V: INSH to INSL

RETH > RETL

Unit Default Remark

AEU INRH AEU INRL

Only valid

whe n RET

is set to

PV or SP

Page 37

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

5.9 Communication Group (G.COM)

G.com

com.p

baUD

PRTY

SBLT

DLEN

ADDR

RP.Tm

Press SET/ENT key t o s e le c t co mmu n ic a t io n g roup. (Refer to parameter map.)

This parameter selects the type of communication protocol to be used.

This parameter sets the communicatio n spee d (baud rate). The baud rate can be set at 600 to 1920 0 bps (bytes per second). The default setting is for 9600 bps.

This parameter sets the communicatio n parity. This can be set to NONE, EVEN, or ODD. The default setting is NONE.

This parameter sets the communicatio n stop bit. This can be set as 1 or 2. The defaul t se t t i n g is 2 .

This parameter sets the communicatio n data length. This can be set to 7 or 8. The default setting is 8. This parameter is not d is p la yed whe n t h e c o mmun i ca t i o n p r o t o c o l (COM . P ) i s s e t f o r MODBUS ASCIII or RTU.

This par a me t e r s e t s t h e co mmu n ic ati on addres s for the con t r o l l e r . This can be set as 1 to 99 pcs address. Its default setting is 1.

This parameter sets the communicatio n response time. The RP.TM is the delay t o r e t u rn dat a t o t h e u pper lev el dev ice after processing commands received from the upper level device. The setting RP.T M is base d o n t he n u mb e r o f 1 0 ms in t e rva l s t o d e l ay (example: a se t ting of 2 will result in a 20 ms dela y ) . If RP.TM is set t o 0 it will immediate ly r etu r n a r e sponse once the command processing is complete.

    

G.AT  G.SP  G.PID  PWD  G.CTL  G.IN



  G.COM  G.RET  G.ALM  G.OUT







Page 38

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Communication Group Parameter Summary

Display Parameter

Communication

COM.P

BAUD

PRTY

DLEN

ADDR

RP.TM Response Time

Protocol

Baud Rate 600, 1200, 2400, 4800 , 9600, 19200 ABS 9600 Option

Parity

SBIT

Stop Bit

Data Length

Address

1 to 99 (maximum of 31 connected at on c e )

Setting Ra n g e

PCC0, PCC1, Modbus ASCII,

Modbus RTU, Sync-Master ,

Sync-Slave

None, Even, Odd

1, 2

7, 8 (not used when set for MODBUS)

0 to 10 (number of 10ms intervals)

Unit Default Remark

ABS PCC0 Option

ABS None Option ABS 1 Option ABS 8 Option ABS 1 Option ABS 0 Option

Page 39

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

6. Error Display and Correcti o n

Error Message Action Needed

E.SY S Needs Repair

E.RJC Needs Repair

SP Decimal

Flashing

S.OPN Ch eck Se ns or

E.AT Check Process

Auto-Tune Timed Ou t (Over 2 4 H o u r s )

Error In c i dent

EEPROM, Data Loss

RJC Sensor Failure

Communication Failure

Open Sensor Detected

Check Comm Cable

Page 40

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7. Installation

7.1 Dimensions and Panel Cutouts

PD548-PD549

1/4 DIN

(3.78)

(3.78) (0.45)

(4.72)

(3.62)

(4.23)

(3.61x3.61)

(3.92)

(3.62)

(3. 62)

Units:

(3.78XN)

(inch) - for reference on ly

Page 41

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD546-PD547

1/8 (V) DIN

(3.78)

(4.72)

(1.89)

(2.76)

(1.77)

(4.23)

(3.61X1.76)

(0.45) (3.92)

(3.62)

(1.89XN)

Units: m

(inch) - for reference on ly

Page 42

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD544-PD545

3/16 DIN

(2.83)

(3.54)

(2.68)

(2.65X2.65)

(0.45) (3.92)

(2.68)

(2.80XN)

Units: m

(2.68)

(inch) - for reference on ly

Page 43

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD542-PD543

1/8 (H) DIN

(1.89)

44.6X91.6

(1.76X3.61)

(3.78)

(0.45)

99.6

(3.92)

120

(4.72)

(2.76)

+0.6

(1.77)

+0.6

(3.62)

Units: m

(inch) - for reference on ly

Page 44

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD540-PD541

1/16 DIN

(1. 76X1.76)

(1.89)

(2.76)

(1.89)

(2.76)

(1.77)

(2.17)

(0.43) (3.92)

(1.77)

(1.89XN)

Units: m

(inch) - for reference on ly

(1.77)

Page 45

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.2 Panel Mountin g

PD548-PD549 PD544-PD545

PD546-PD547

Mount ing Br ack et

Panel

PD542-PD543

Mo unt ing Bra cket

Panel

Installation Steps

1. Cut the mounting panel. (Refer to 7.1 Dimen s io n s a nd Panel Cutouts) 2 . Insert the controller through the front o f t h e p a n e l r e a r t e rminals f irst.

3. On applicable models, attach the right and left mounting bracket and secure it to the panel.

4. On 1/16 DIN controller models, slide the mounting bracket onto the back of the controller as shown, and slide it forward on the contr o l le r unti l t h e b racke t lo cks in p lace , and the controller is secure.

Do not excessively tighten the mounting bracket screws. Excessive tightening may lead to

CAUTION

controller or p anel damage.

PD540-PD541

Panel

M o unting Br acket

Panel

Mounting Bracket

Page 46

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.3 Power Cable Specification

Make power connections using 0.9 to 2.0 mm2 or 1 6 A WG vinyl insu l a t e d wire. (Voltage rat i n g o f 300 VAC)

7.4 Terminal Specification

Use M3.5 scr e w- c o mp a t ib l e cr i mp o n t e r min a l s wi t h in s u la t i n g sl e e ve as shown b e lo w.

Maxi mu m

Measurement

Use copper conductors only if the terminal is for connection to copper wire only.

Always turn off t h e so u r c e ci r c u it b reake r a n d c h e ck t o e n su r e t h e p o we r is of f t o t h e c o n t r o l le r thr o ugh the use of a tester pr i o r t o wo r k i n g o n t h e wi r i n g t e r min a l s.

CAUTION

z Never touch the terminals in the rear panel when power is supplied to the controller. z Be sure to tu r n o f f th e electric po wer before wiring an y t e rminal s.

Bind the wires conne ct e d t o t h e co n t rolle r t e r mi n a ls se c u r e l y t ogether in order to prevent el e ct r o ma g n e t i c i n t e r f e r e n c e .

5.8 m m

(0.228 in)

Minimum Diameter

3.0 mm

(0.118 in )

Note: Inch e s f o r ref e r e n c e o n l y.

Page 47

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.5 Terminal Assignment, Connec t ion s, and Rating s

PD548-PD549

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

4 - 20 mADC or 15 VDC Voltage Pulse

100 - 240 VAC 50/60 Hz

Open circuit voltage:

approximat e ly 5 VD C

Lo = 0 to 0.8 VDC

Hi = 4.7 t o 28 VD C

NO switches (external excitation not required) or open collector transistor

Logic le v e ls :

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Max: 19200 b p s

Page 48

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD546-PD547

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

4 - 20 mADC or 15 VDC Voltage Pulse

100 - 240 VAC 50/60 Hz

Rating: 25 0 VA C @ 1 A

Open circuit voltage: approximat e ly 5 VD C

Logic le v e ls : Lo = 0 to 0.8 VDC Hi = 4.7 t o 28 VD C

30 VDC @ 1 A

Max: 19200 b p s

NO switches (external excitation not required) or open collector transistor

Page 49

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD544-PD545

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

4 - 20 mADC or

15 VDC Voltage Pulse

100 - 240 VAC 50/60 Hz

NO switches (external excitation not required) or open collector transistor

Open circuit voltage: approximat e ly 5 VD C

Logic le v e ls : Lo = 0 to 0.8 VDC Hi = 4.7 t o 28 VD C

Rating: 25 0 VA C @ 1 A

30 VDC @ 1 A

Rating: 25 0 VA C @ 1 A

30 VDC @ 1 A

Max: 19200 b p s

Page 50

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD542-PD543

100 - 240 VAC 50/60 Hz

4 - 20 mADC or

15 VDC Voltage Pulse

19 18 17 16 15 14 13 12 11

10987654321

Max: 19200 b p s

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

NO switches (exter n a l e xcitatio n n o t r equired) or open collector transistor

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Rating: 250 VAC @ 1 A

Open circuit voltage:

approximat e ly 5 VD C

Lo = 0 to 0.8 VDC

Hi = 4.7 t o 28 VD C

30 VDC @ 1 A

Logic le v e ls :

Page 51

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

PD540-PD541

NO switches (external excitation not required) or open collector transistor

Open circuit voltage: approximat e ly 5 VD C

Logic le v e ls : Lo = 0 to 0.8 VDC Hi = 4.7 t o 28 VD C

Max: 19200 b p s

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

100 - 240 VAC 50/60 Hz

Rating: 25 0 VA C @ 1 A

30 VDC @ 1 A

4 - 20 mADC or

15 VDC Voltage Pulse

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Page 52

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.6 Grounding and Power Cable Connection

 Use a thick g r ounding cable of at least 2 mm2 or 14 AWG and shorter than 20 m (approximately 22 ft) for class-3

grounding or better with a gr o u nd i n g r e s is t a n ce o f l e ss t han 100 Ω .

 Be sure to ground from the grounding terminal to an independent grounding point. (1 point grounding)  Use 0.9 to 2.0 mm2 or 1 6 A WG vinyl insu l a t e d wire (Voltage rating 300VAC) or thicker for power cable connection.

CAUTION

7.7 Signal Inpu t Connection

(1) RTD Input (2) DC Voltage In p ut

RTD

L N GND

CAUTION

To prevent electric shock, b e su r e t o t u rn off p o we r to t he c o n t r o l le r and the source circuit breaker before wiring.

 Be sure to connect to correct polarities. Connecting to a wrong polarity may cause damage or malfunction.  Use shielded wires and ground the shielding to an independent grounding point.  Keep the input signal and output wiring as far as possible away from the power and ground circuit.  Use a wire with low conductive resistance and no three-wire resistance differential.

SHIELD

A b

INPUT

NOVA

Be sure to connect L (Hot), N (neutral), and GND (gr ound) as indicated.

Failure to wire th e po we r and ground as indicated could result in damage to the controller.

SHIELD

INPUT

NOVA

(3) DC Current I np ut

SHIELD

DCmA

To accept a 4-20 mA s ignal, select 0.4 to 2.0 VDC input and

connect a 100 Ω resistor across th e i nput terminals as shown.

INPUT

NOVA

Page 53

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.8 Analog Outp ut Connec t ion

To prevent electric shock, b e su r e t o t u rn off p o we r to t he Nov a C o n t r o l le r and the source circuit breaker

CAUTION

(1) Voltage Pulse Output (SSR) / C u r r e n t Output (SCR)

Control Device

CAUTION

(2) Retransmitti n g Output (RE T)

4 to 20 mADC, 600 Ω max or 14-18 VDC @ 20 mA max

Receiver

(Recorder, et c )

before wir i n g .

 Be sure to connect to correct polaritie s . Conn e ct i n g t o a wr o n g pola r i t y ma y cause a cont r o ll e r ma l f u n ct i o n .

 Use shie ld e d wir e s for t h e wiring and c o n n e ct independently to ground (1 point grounding).

SCR : 4 to 20 mADC, 600 Ω maxi mum

SHIELD

OUT2,3 +

OUT2,3 -

NOVA

To prevent electric shock, b e su r e t o t u rn off p o we r to t h e Nov a C o n t r o l le r and t he s o u r c e ci r c u it b reake r

before wir i n g .

SHIELD

RET+

RET-

NOVA

SSR : 12 VDC min, 600 Ω minimu m

CAUTION

To prevent electric shock, b e su r e t o t u rn off p o we r to t he Nov a C o n t r o l le r and the source circuit breaker before wir i n g .

Page 54

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

7.9 Relay Output Connection (RELAY)

CAUTION

7.10 Digital Input Connection (DI)

 Use a no-voltage contact switch such as relay.  The controller supplies the needed voltage (approx . 5 VDC) and current ( approx. 1 mA) to trigger the input.  Whe n using an Open Collector (TR) as a trigger, use one with a 2 V or lower vo l t a g e rating when "on " a n d

100 μA or less leakage current w hen it is OFF.

 Relay Contact Connection

CAUTION

7.11 Use of an External Relay

Switching Inductive Loads When using switching in ductive loa d s , t h e u se o f R C n e t wo rks (snubber s) for AC loads or diodes for DC loads is

recommended to prevent disrupting the microprocessor's operation. The suppressors also prolong the life of the relay contacts. Suppression can be obtained with resistor-capacitor (RC) networks or diodes assembled by the user or purchased as complete assemblies. For AC loads, choose R and C as follows: R: 0.5 to 1 Ω for each volt across the contact C: 0.5 to 1 μF for each amp through closed contacts

Notes: 1 . Use capacitor s rated f o r 250 VAC.

2. RC networks may affect load release time of solenoid loads. Check to confirm proper operation. 3 . RC networks are availa b l e f r o m P r e c is io n D i g it a l and should be applied to each relay contact switching an

inductive load. Part number: PDX6901.

Relay: NO - Normal l y Open Conne c t io n

COM

Relay: NC - Normal ly Clos e d C o n n e ct i o n

NOVA

To prevent electric shock, b e su r e t o t u rn off p o we r to t h e Nov a C o n t r o l le r and the source circuit breaker before wir i n g .

DI_1 DI_2 DI_COM

NOVA

To prevent electric shock, b e su r e t o t u rn off p o we r to t h e Nov a C o n t r o l le r and the source circuit breaker before wir i n g .

 Transistor Cont a c t C onnection

+5V

DI_1 DI_2

DI_COM

NOVA

CAUTION

If the load inductance is over the controller specifications, the output may need a R C filter (snubber) or diode to properly handle frequent relay switching operations.

Page 55

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

(1) DC External Relay

Controller

CAUTION

(2) AC External Relay

Controller

CAUTION

External DC

power

Relay (Verify relay coil ratings are l e s s t h a n t h e voltage a n d c u r rent ratin g s o f t h e relay contacts of th e c o n t r o l le r)

External AC

Powe r

Relay (Verify relay coil ratings are l e s s t h a n t h e voltage and curr ent ratings of the relay contacts of th e c o n t r o l le r)

7.12 Communication Wiring (RS-485)

Master Station NOVA Controll e r

RTX+

Terminatin g Resisto r

RTX- RTX- RTX-

CAUTION

Diode (Connect directly to the relay coil t e r mi n a ls )

CAUTION

RC Network (snubber) (Connect directly to t h e relay c o i l t e r mi n a ls )

RTX+

NOVA Controll e r

RTX+

Terminatin g Resisto r

SHIELD

 Up to 31 slave controllers ( N o va series controllers equipped with the RS-485 serial communication option) can be connected.  Be sure to connect terminating resistors (22 0 Ω, 1/4 W) t o sl a ve and ma st e r controlle r s at communication channel ends as shown above.

To prevent electric shock, b e su r e t o t u rn off p o we r to t h e Nov a C o n t r o l le r and the source circuit

CAUTION

breaker be f o re wiri n g .

Page 56

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

Table of D-Registers:

The following data re g i st e r s a r e u s e d t o d irect t h e U S 1 an d U S 2 c o mmands or for Modbus communication.

NO.

PROC_TIME20

PROCESS FUNCTION SET POINT SIGNAL ALARM PID IN/OUT

0 100 200 300 400 500 600

SPSL0

R-S,STOP/RUN

NPV

SP1 ALT1 ARW IN-T1

NSP SP2 ALT2 FUZZY INT-U2

SP3 ALT3 C.MOD IN.RH3 SP4 IN.RL4

SPSL A/M IN.DP5

HOUT

H.OUT(MVOUT)

C.OUT(MVOUTc)

AL-1 IN.SH6 AL-2 IN.SL7

MVOUT

COUT AL-3 IN.FL8 PIDNO BSL9

NOWSTS RSL10

SPRH A1DB 1.P BSP111 SPRL A2DB 1.I BSP212

A3DB 1.D BSP313

ALSTS TMU 1.MR14

1.Pc BS015 U.SLP A1DY 1.Ic BS116 D.SLP A2DY 1.Dc BS217

A3DY 1.DB BS318

ERROR RP1 BS419

AT AL1.H 2.P OUT121

AT-G AL2.H 2.I OUT222

AL3.H 2.D OUT323

2.MR24

2.Pc SUB125

AL1.L 2.Ic SUB226 AL2.L 2.Dc27 AL3.L 2.DB28

RP229

S-TM 3.P HEAT231 P-TM 3.I COOL232

3.D HEAT333

ONOF 3.MR COOL334

US1 3.Pc35 US2 3.Ic37

LOCK 3.Dc O.ACT36

DI. SL 3.DB CT38

DSP.H RHY CTc39

DSP.L40

4.P OH41

4.I OL42

4.D43

Page 57

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

NO.

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87

PROCESS FUNCTION SET POINT SIGNAL ALARM PID IN/OUT

0 100 200 300 400 500 600

U RETL53

s54 e55 r56

A58

r59 e60 a61

4.MR HYS44

4.Pc45

4.Ic PO46

4.Dc POc47

4.DB HYS.H48 RDV HYS.L49

RET51

RETH52

COM.P

BAUD PRTY

SBIT

DLEN

ADDR

RP.TM

Page 58

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

NO.

88 89 90 91 92 93 94 95 96 97 98 99

PROCESS FUNCTION SET POINT SIGNAL ALARM PID IN/OUT

0 100 200 300 400 500 600

NOTE

Read Only Location

Page 59

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

NOTE

Notes

Warranty and Retu rn I n f orm a t i o n

Precision Digita l wa r rants t h is p r o d u c t t o b e f ree f r o m mat e rial d e f e ct s and workmanship under normal use and service fo r t h ree y e a r s .

Please contact Precision Digita l Technical Su p p o rt at (800) 610-5239 or e-mail at [email protected] prior to any product return. When Technical Support determines a product should be returned, a Return Material Authorization (RMA) # whic h mus t b e in c luded on the r eturn shipping label. Please also include the reason for return, da t e o f p u r c ha s e , co n t a c t n a me , an d h o w t o c o n t a ct . P r o d u c t s returned f o r rea s on s o t h e r t han r epair may be subject to a restock i ng f e e . A n y ret u r n s u nd e r a war r a n t y claim s h o ul d b e r e t u rned f reigh t p r epaid. Upon warranty confirmation Precision Digital will repair o r r e place and return the unit at no charge via UPS Ground. Other shipping is ava il a b le u p o n request and at customer expense. All product returns should be shipped to: Return Authorization # ___________ Precision Digital, 89 October Hill Road Ste 5, H ollist on, MA 01746 USA Attention: Technical Support

Precision Digital Technical Support is trained and eager to serve y ou. We have found most start-up problems to be the result of incorrect signal connectio n s a n d / o r pro g r a mmin g . M o s t o f t e n P recisi o n Digit a l Technical Support ca n q u ic kl y c o r rect t h e se i ss u e s o ver the t e lephone.

Page 60

PD540 Series Nova Digital Process and Temperature Controller Instruction Manual

How to Contact Precision Digital

For Technical Support Call: (800) 610-5239 or (508) 655-7300 Fax: (508) 655-8990 Email: [email protected]

For Sales Support o r t o p la c e a n o r de r p le a s e Call: (800) 343-1001 or (508) 655-7300 Fax: (508) 655-8990 Email: [email protected]

For the latest version of this manual, please visit

www.predig.com

LIM540_C

06/0 9