Prosensor N480D Operating Manual

MICROPROCESSOR BASED TEMPERATURE CONTROLLER

N480D

OPERATING MANUAL

1. SAFETY SUMMARY

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

CAUTION or WARNING:

Read complete instructions prior to installation

and operation of the unit.

CAUTION or WARNING:

Electrical Shock Hazard

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

2. INSTALLATION

The controller should be installed in a panel cut out as specified in item 2. First remove the mounting cl amp
and insert the controller into th e panel cut out. Place the unit into the panel cut-out and slide the mounting
clamps from the rear to a firm grip at the panel.

The internal circuitry can be fully removed from the ho using without disconnecting any wiring. Grab firmly the
front panel and pull out the circuitry from the housing.

2.1 ELECTRICAL CO NNECTIONS

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

The installation must include a power isolatin g switch or circuit breaker that disconnects all c urrent carrying
conductors. T he device s hould be m ounted close to the controller, within easy reach of the operator and
marked as the disconnecting device for the instrument.

Figure 1 shows the electrical terminals of the controller.

Figure 1 - Back panel terminals

3. SPECIFICATIONS

• Dimensions: 48 x 48 x 110 mm (1/16 DIN). Panel cut-out: 45,5 x 45,5 mm. Weight: 160 g (max);

• Power: 100 to 240 Vac/dc (±10 %), 50/60 Hz or 24 Vdc/ac (±10 %); Max. Consumption: 9 VA;

• Pt100: α= 385. 3-wire connection. Excitation current: 0.170 mA;

• Accuracy: 0.2 % of full scale for Pt100 and 0.25 % of full scale ±1 °C for T /C

• Thermocouple input impedance: 10 MΩ

• A/D converter resolution: 15000 steps

• Sampling rate: 10 measurements per second

• Environmental conditions: 5 to 50 °C; Relative humidity (maximum): 80 % up to 30 ºC. For temperatures

above 30 ºC, decrease 3 % per ºC. Installation category II. Pollution degree 2. Altitude < 2000 m.

• Front Panel: Polycarbonate UL94 V-2; Back Panel: ABS + PC UL94 V-0

• EMC: EN 61326-1:1997 and EN 61326-1/A1:1998

• SAFETY: EN61010-1:1993 and EN61010-1/A2:1995

3.1 TEMPERATURE SENSOR INPUT

Thermocouples are connected to terminals 10 and 11 with positive in terminal 11. Pt100 sensors are
connected to terminals 10, 11 and 12, as indicated in figure 1. For full compensation of cable resistance only
cables with equ al wire electrical resist ance should be used. Table 1 shows the sensor types accepted and
their respective codes.

TIPO CÓDIGO FAIXA

J

0000

-50 to 760 °C (-58 to 1400 °F)

K 1111 -90 to 1370 °C (-130 to 2498 °F)

S

2222

0 to 1760 °C (32 to 3200 °F)

Pt100 (Resolution 0,1°C)

3333

-199.9 to 530.0 °C (-199.9 to 986.0 °F)

Pt100 (Resolution 1°C)

4444

-200 to 530 °C (-328 to 986 °F)

T

5555

-100 to 400 °C (-148 to 752 °F)

E 6666 -30 to 720 °C (-22 to 1328 °F)

N

7777

-90 to 1300 °C (-130 to 2372 °F)

R

8888

0 to 1760 °C (32 to 3200 °F)

Table 1 - Sensor types, codes and ranges

3.2 POWER

Mains p ower is connected to terminals 1 and 2. Check the up per side of t he housing for proper power
indication.

3.3 CONTROL AND ALARM OUTPUTS

Up to 4 outputs can be co nfigured for control or alarm. The availabl e outputs are identified on the rear panel
as OUTA, OUTB, OUTC or OUTD. Electrical characteristics of each output are:

OUTA: SPST Relay, 1,5 A / 250 Vac (3 A / 30 Vdc); Resistive load; 100 k cycles;

OUTB: Voltage Pulse, 5 Vdc / 20 mA;

OUTC: SPST Relay, 1,5 A / 250 Vac (3 A / 30 Vdc); Resistive load; 100 k cycles;

OUTD: SPDT Relay, 3 A / 250 Vac (3 A / 30 Vdc); Resistive load; 6 k cycles;

or 4-20 mA output. With 80 count resolution, precision: 0,25 mA, maximum load: 500 Ohms.

The output function is defined on controller configuration, parameters IO A

IO AIO A

IO A, IO B

IO BIO B

IO B, IO (

IO (IO (

IO ( and IO d.

IO d.IO d.

IO d.

Control Output is used to control the process variable using PID algorithm. More than one output can be
selected as control output. When O UTD is configured as Analog Control Output, all other outputs selected
as Control Output will not operate.

Control Outputs are turned off when a sensor error is detected (display “ Erro

ErroErro

Erro”).

Alarm Outputs are used to signal abnormal PV values, sensor error or end of program. The alarm function
must be selected for each alarm output. (Refer to chapter 9).

4. CONFIGURATION AND OPERATION

Prior t o first operation the controller should be fully configured. The user must set basic parameters as
temperature type (“TYPE

TYPETYPE

TYPE”), the desired control set point (“ SP

SPSP

SP “), the alarms set points (“SPA1

SPA1SPA1

SPA1” and

“SPA2

SPA2SPA2

SPA2”), etc.

4.1 PARAMET ERS FLOW CHART

The programming parameters are organized in 4 different sets or levels

Operation level / Alarms and tuning level / Configuration level / Cal ibration level

At power up the controller displays a prompt a t the Operation Level and remains in this level while under
normal operation.

The other levels are on ly accessed when a change of parameters is necessary (except for Set Point
change). To reach these other parameters the user must keep the PROG Key (

P

) pressed for about

three seconds. After this time the controller will show the first parameter of the next level. By keeping the

P

key pressed for another 3 seconds the next level will be accessed.

Release the

P

key when the desired level is reached. Press once the

P

to go to the next prompt in the
same level. When a parameter is shown the display will alternate its name and value. The value can t hen be
changed by pressing the

or

key.

After the last parameter in one level is reached the controller returns to operation level and the display will
indicate the measured temperature.

The display will also go back to the measured temperature w henever the display is inactive for 20 seconds
or more. When a parameter value is chan ged via keyboard the controller will only accept the new value af ter
the user presses the

P

key to go to next prompt or if the keyboard is left inactive for 20 seconds.

4.2 PROGRAM SE CURITY

To avoid t ampering, parameter “P rot

ProtProt

Prot” and a hardware j umper can be us ed to disable access to

programming parameters.
With the jumper in the O FF position, all program levels are unprotected. The “Prot

ProtProt

Prot” parameter can only b e

changed with the jumper in the OFF position.
With the jumper in the ON position or removed, the protection level is defined by the current value of t he

“Prot

ProtProt

Prot” parameter:

0000 No protection. All parameters can be accessed;

1111 No access to the calibration level;

2222 No access to calibration and configuration levels;

3333 No access to calibration, configuration and tuning and alarms levels;

4444 No access to calibration, configuration, tuning and alarms and operation (except SP) levels;

5555 Fully blocked.

OFF

ON

Figure 2 – Protection Disabled Figure 3 – Protection Enabled

4.3 OPERATIO N LEVEL

TEMPERATURE

INDICATION

END

SP

TEMPERATURE measured by the sensor. At power up, the upper display shows the
process temperature value. It also shows the messages described in chapter 5 of this
manual. The lower displays shows the set point value which is the temperature value
desired for the process.

rAte

TEMPERATURE RATE

OF RISE: The user defines the rate of temperature rise from the

starting temperature to the value set in “ SP

SPSP

SP ”. Rate is defined in °C / minute.

T Sp

TIME FOR SOAK: Time in minutes which the temperature will remain at the selected “

SP

SPSP

SP “. Refer to item 4.

Rvn

run

RUN: At this prompt the user sets the control output and alarms t o active or to inactive.

0000 - inactive outputs; 1111 - active outputs;

4.4 TUNING AND ALARMS LEVEL

Atvn

AUTO-TUNE: Activates the auto-tuning of PID parameters.

0000 - Auto-tune is off; 1111 - Auto-tune is on;

Pb

Proportional band

PROPORTIONAL BAND: percentage of maximum input span.

When set to zero (0), control action is ON/OFF.

Ir

integral rate

INTEGRAL RATE: Integral time constant in repetitions per m inute (Reset). This
constant is not used when controller is set to ON/OFF action (Pb=0).

Dt

derivative time

DERIVATIVE TIME: Derivative time constant in seconds. This constant is not used
when controller is set to ON/OFF action (Pb=0).

(t

Cycle time

CYCLE TIME: Pulse Width Modulation (PWM) period in seconds. T his term is not
used when controller is set to ON/OFF action (Pb=0).

KySt

HYSteresis

CONTROL HYS TERESIS: Is the hysteresis for O N/OFF control (set in temperature
units). This parameter is only used when the controller is in ON/OF F mode (Pb=0).

A1SP
A2SP

SP Alarm

SETPOINT for Alarm 1/2: Triping point for alarm 1/2.

4.5 CO NFIGURATION LEVEL

Type

tYPE

INPUT TYPE: Selects the input sensor type to be connected to the cont roller. This is

the first parameter to be set.

0000 - Thermocouple type J; 5555 - Thermocouple type T;
1111 - Thermocouple type K; 6666 - Thermocouple type E;
2222 – Thermocouple type S; 7777 - Thermocouple type N;
3333 - Pt100 with 0,1° resolution; 8888 - Thermocouple type R;
4444 - Pt100 with 1° resolution;

Vnit

unit

TEMPERATURE UNIT: Selects display indication for degrees Celsius or Fahrenheit.

0000 - degrees Celsius ( °C ); 1111 - degrees Fahrenheit ( °F );

A(t

ACtion

CONTROL ACTION: 0000 - reverse action. Generally used for heating.

1111 - direct action. Generally used for cooling.

Io A

Out A

OUTA FUNCTION: 0000 - OUTA is control output.

1111 - OUTA is Alarm 1 output.

2222 - OUTA is Alarm 2 output.

Io b

Out B

OUTB FUNCTION: 0000 - OUTB is control output.

1111 - OUTB is Alarm 1 output.

2222 - OUTB is Alarm 2 output.

Io (

Out C

OUTC FUNCTION: 0000 - OUTC is control output.

1111 - OUTC is Alarm 1 output.

2222 - OUTC is Alarm 2 output.

Io d

Out D

OUTD FUNCTION: 0000 - OUTD is control output.

1111 - OUTD is Alarm 1 output.

2222 - OUTD is Alarm 2 output.

3333 - OUTD is Analog Control Output (4-20mA).

spll

SP Low Limit

SET POINT LOW LIMIT: sets the lower range for SV.

spKl

SP High Limit

SET POINT HIGH LIMIT: Sets the upper range for SV.

0ffs

OFF Set

SENSOR OFFSET: Offset value to be added to the PV to compensate sensor error.

Default value: zero.

A1fv
A2fv

Alarm 1 Function

FUNCTION OF ALARM 1/2

: Refer to table 2 for funct ion description and respective

codes to set at this prompt.

Aiky
A2ky

Alarm HYsteresis

ALARM 1 AND ALARM 2 HYSTERESIS: Defines the differential range between the

PV value at which the alarm is turned on and the value at which it is turned off .

Prot

Protection

PROGRAM SECURI TY: Defines the level of parameters protection from tampering.

Refer the chapter 4.2.

4.6 CALIBRATI ON LEVEL

These par ameters are used to calibrate the temperature measurement and should only be dealt with by
experienced and well equipped personnel.

Inl(

Input Low Calibration

SENSOR OFFSET CALIBRATION. Set s the temperatur e sensor low calibration

(offset). The display sh ows only the corrected temperature and not the offset
added. A s ignal simulator should be used to inject a low value signal to properly
adjust the offset.

InK(

Input High Calibration

INPUT HIGH CALIBRATION. Sets the sensor input circuit gain or high

calibration. A signal simulator should be used to inject a high value signal to
properly adjust the offset.

(j L

Cold Junction Low

Calibration

COLD JUNCTION OFFSET CALIBRATION: Sets the cold junction of fset

calibration. A good thermometer or a temperature simulator should be used to
properly adjust this parameter.

Ovl(

output Low Calibration

OFFSET CALIBRATION OF ANALOG OUTPUT: Offset (zero) calibration of the
analog control output (4-20 mA).

OvK(

output High Calibration

GAIN CALIBRATION OF ANALOG OUTPUT: Gain (span) calibration of the

analog control output (4-20 mA).

5. RAMP TO SOAK FUNCTION CHARACTERISTICS

This function makes the process temperature rise gradually from the starting point (present PV) to the
temperature value set in “ SP

SPSP

SP “ (Ramp). The user defines the rate of rise in degrees per minute at the “rAtE

rAtErAtE

rAtE”

prompt. When SP is reached the temperature is leveled at this point for 1 to 9999 minutes as programmed at the
“ t SP

t SPt SP

t SP ” prompt. Setting 0 (zero) at “ t SP

t SPt SP

t SP ” defines an infinite length soak profile.

Soak

Temperature

PV

Ramp

Time

SP

Figure 2 - Ramp to Soak Function

To disable the ramp function Set 0.0 at the “rAtE

rAtErAtE

rAtE” prompt. To disable the s oak function set 1 at the “ t SP

t SPt SP

t SP

” prompt (thus making a 1 m inute soak) and the control output will go off in 1 minute. To restart control s et 1
at the “ rvn

rvnrvn

rvn ” prompt.

After a power failure the controller will resume r amp to soak execution at the equivalent previous ramp point.
If the process temperature is th e same as th e SP (no t emperature drop) the controller will repeat the soak
segment.

6. PID AUTO TUNE

During auto tune the temperature is controlled in ON/OF F mode at the programmed Set Point (SV).
Depending on the process ch aracteristics large oscillations above and below SV may occur and a uto tuning
may take several minutes to be concluded.

The recommended procedure is as follows:

• Program a new SP close to the desired final temperature other than the present measured temperature.

• Enable the auto tune at the “Atvn

AtvnAtvn

Atvn” prompt by selecting 1.

• Set 1 at the “rvn

rvnrvn

rvn” prompt. The TUNE message will be signaled in the display.

During auto tune large oscillations will be induced around the set point. Make sure the proces s can accept
these oscillations. If auto tuning results are not satisfactory refer to t able 3 for manual fine tuning procedure.

PARAMETER RESPONSE SOLUTION

Slow Response Decrease

Proportional

Band

Large Oscillation Increase

Slow Response Increase

Integral

Rate

Large Oscillation Decrease

Slow Response or Instability Decrease

Derivative

Time

Large Oscillation Increase

Table 3 - Suggestions for manual tuning of PID parameters

7. ALARM FUNCTIONS

Low and high alarms are used to signal minimum and maximum temperature values as pro grammed in the
“SPA1

SPA1SPA1

SPA1” and “SPA2

SPA2SPA2

SPA2” prompts.

Differential alarms are used t o indicate deviations from the desired set point (SP) temperature. These
deviations are programmed at the “SPA1

SPA1SPA1

SPA1” and “SPA2

SPA2SPA2

SPA2” prompts. Error alarm shows sensor defects or not

properly connected. Table 2 shows each alarm function operation wit h their respective code. Alarm 1 is used
as an example.

7.1 ALARM INITIA L BLOCKING

The initial blocking option inhibits the alarm from being r ecognized if an alarm condition is present when the
controller is first energized. The alarm will actuate only after the occurrence of a non alarm condition
followed by a new occurrence for the alarm.

TYPE CODE ACTION

LOW

0000

SPA1

Alarm ON

TEMPERATURE

HIGH

1111

SPA1

Alarm ON

TEMPERATURE

SPA1

SPA1SPA1

SPA1

Negative

SP + SPA1 SP

Alarm

ON

TEMPERATURE

LOW

differential

2222

SPA1

SPA1SPA1

SPA1

Positive

SP + SPA1

SP

Alarm ON

TEMPERATURE

SPA1

SPA1SPA1

SPA1

Negative

SP + SPA1 SP

Alarm ON

TEMPERATURE

HIGH

differential

3333

SPA1

SPA1SPA1

SPA1

Positive

SP + SPA1

SP

Alarm

ON

TEMPERATURE

SPA1

SPA1SPA1

SPA1

Negative

SP - SPA1

SP + SPA1 SP

Alarm ON

TEMPERATURE

differential

or deviation

4444

SPA1

SPA1SPA1

SPA1

Positive

SP + SPA1

SP - SPA1 SP

Alarm

ON

Alarm

ON

TEMPERATURE

Input sensor

error or

heater
break

detection

5555

Alarm is ON whenever:

• Temperature is below/above sel ected range;

• Thermocouple or Pt 100 is broken;

• Pt100 is shorted; badly connecte d or wire impedance is too high;

• The heater resistance is broken

End of

Program

6666

Activated when the programme d soak time is run out. Refer to item 4 of this
manual.

7777

Low limit alarm disabled at power-up

8888

High limit alarm disabled at power-up

9999

Differential low limit alarm disabled at power-up

10

1010

10

Differential high limit alarm disabled at power-up

Alarm

Functions

With alarm

inhibition at

power-up

11

1111

11

Differential alarm disabled at power-up

Table 2 - Alarm functions and their identification codes

8. PROBLEMS WITH THE CONTROLLER

Connection and configuration errors state for most of the problems in using the contr oller. A final revision of
parameters will save time and further losses.

Error messages are displayed to help the user to identify possible problems.

: Process temperature is below the selected sensor range.

: Process temperature is above the selected sensor range

: Controller or sensor error. Example: Broken thermocouple or Pt 100, Pt 100 badly

connected, short-circuited or high cable resistance.

5.1 GETTING THE INSTRUMENT SERIAL NUMBER

Upon power-on, the controller displays its firmware version for 3 s econds. The serial number is accessed
when the controller is powered while holding the key

pressed.

9. PRODUCT IDENTIFICATION

The label attached to the controller case identifies the model an d the optional present in the product, as
described below:

MODEL: N480D – A – B, where:

A: Outputs: RP (OUT A = Relay, OUT B = Pulse)

RPR (OUT A = Relay, OUT B = Pulse, OUT D = Relay)
RRR (OUT A = Relay, OUT C = Relay, OUT D = Relay);
RAR (OUT A = Relay, OUT C = Relay, OUT D = 4-20 mA )

B. Voltage rating: blank (100-240 Vac/dc) or 24V (24 Vac/dc);