Red Lion DUAL LOOP CONTROLLER Users Manual

DUAL LOOP CONTROLLER

PROCESS CONTROL EQUIPMENT

US LISTED

3RSD

Bulletin No. DLC-J

Drawing No. LP0495

Released 09/16

 MODULAR BUILDING BLOCK FOR MULTI-ZONE PROCESS CONTROL

 TWO INDEPENDENT PID CONTROL LOOPS

 PID CONTROL WITH REDUCED OVERSHOOT

 UNIVERSAL INPUTS ACCEPT TC, RTD, 0-10 V AND 0/4-20 mA SIGNALS

 TWO DC ANALOG OUTPUTS (OPTIONAL)

 WINDOWS

 RS485 MODBUS™ PROTOCOL

 CHANNEL B CAN BE ASSIGNED AS A SECOND ANALOG INPUT TO

CONFIGURATION SOFTWARE

CHANNEL A FOR REMOTE SETPOINT OPERATION

 SETPOINT CONTROLLER OPTION FOR TIME VS. TEMP./PROCESS

(RAMP/SOAK) AND SPECIAL BATCH/RECIPE APPLICATIONS

 SQUARE ROOT EXTRACTION FOR FLOW SENSOR APPLICATIONS

GENERAL DESCRIPTION

The Model DLC, Dual Loop Controller, is a full featured, DIN rail mounted, dual input PID controller. The DLC is designed as a modular building block for multi-zone process control applications. The controller has two independent “A” & “B” input channels. Each channel’s input can be configured to accept a wide range of thermocouple, RTD, 0-10 V, 0/4-20 mA, or resistive signals. Each channel can also be configured to extract the square root of the input in both process voltage or process current modes for applications such as flow measurement using a differential flow sensor.

Channel B can be assigned as a Remote Setpoint for Channel A. The two time-proportioning or DC Analog outputs can be programmed to control two independent processes. The two alarms per channel can be configured for various alarm modes, or provide a secondary control output for heat/cool applications.

The control and alarm outputs are N channel open drain MOSFETs capable of switching up to 1 Amp DC. For applications requiring larger loads or A/C loads, several DIN rail mount relays are available.

The controller operates in the PID Control Mode for both heating and cooling, with on-demand auto-tune, that establishes the tuning constants. The PID tuning constants may be fine-tuned through the serial interface. The controller employs a unique overshoot suppression feature, which allows the quickest response without excessive overshoot. The controller can be transferred to operate in the Manual Mode, providing the operator with direct control of the output, or the On/Off Control Mode with adjustable hysteresis.

The controller’s high density packaging and DIN rail mounting saves time and panel space. The controller snaps easily onto standard top hat (T) profile DIN rails.

DIMENSIONS In inches (mm)

TBA

ต

POWER: (FULL LOAD)

AC 24V ±10%, 50/60 Hz, 15VA

DC 18-36V, 13W

RTD

FACTORY

JUMPER

SETTINGS

JUMPERS

CH B CH A

INPUTS

INPUT COMMON

3RSD

EQUIPMENT

CONTROL

PROCESS

TBB

1ต32ต4 6

OUTPUT COMMON

DC- / (AC)

DC+ / (AC)

+24VDC OUT

20mA

RTD

10V

INPUTS

0-10V, 0-20mA

INPUT COMMON

TC+ OR RTD

RTD EXC.

435

4.47 (114)

OP1

AL178OP1

CH A CH B

OUTPUTS

DEFAULT SERIAL SETTING

0-10V, 0-20mA

789

AL2/OP2

OUTPUTS

V1+

V1-

I1+

I1-

ANALOG OUTPUT 1

0-10V, 0-20mA

OUT +

OUT -

MODEL DLC

109

AL1

AL2/OP2

V2-

V2+

I2+

I2-

ANALOG OUTPUT 2

0-10V, 0-20mA

OUT +

OUT -

1110

YORK, PA. MADE IN U.S.A.

RED LION CONTROLS

OPTIONAL

4.02

(102)

RED LION CONTROLS

MODEL DLC

PWR/COMM.

CH A OP

BOTH FLASHING

INPUT ERROR

CH A ALM

AUTOTUNE

CH B OP

BOTH FLASHING

INPUT ERROR

ALL FLASHING = CHECKSUM ERROR

CH B ALM

RS485

MODBUS

PROTOCOL

1.97 (50)

SAFETY SUMMARY

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

Do not use the controller to directly command motors, valves, or other actuators not equipped with safeguards. To do so can be potentially harmful to persons or equipment in the event of a fault to the controller. An independent and redundant temperature limit indicator with alarm outputs is strongly recommended.

CAUTION: Risk of Danger.

Read complete instructions prior to

installation and operation of the unit.

ALARMS

The DLC’s two solid-state alarms can be configured independently for absolute high or low acting with balanced or unbalanced hysteresis. They can also be configured for deviation and band alarm. In these modes, the alarm trigger values track the setpoint value. Adjustable alarm trip delays can be used for delaying output response. The alarms can be programmed for Automatic or Latching operation. Latched alarms must be reset with a serial command. A standby feature suppresses the alarm during power-up until the temperature stabilizes outside the alarm region. The outputs can also be manually controlled with Modbus register or coil commands.

SETPOINT CONTROLLER OPTION

The Setpoint Controller option is suitable for time vs. temperature/process control applications. The controller allows a profile of up to 20 ramp/soak segments. Profile conformity is assured by using the Error Band Mode and Error Band parameter. The Profile Cycle Count allows the profile to run continuously or a fixed number of cycles. Power-on options automatically stop, abort, start, resume, or pause a running profile.

ORDERING INFORMATION

MODEL NO. DESCRIPTION PART NUMBERS

Dual Loop Controller DLC00001

DLC

CBPRO Programming Interface Cable CBPRO007

CBJ Cable RJ11 to RJ11 (6 inch jumper) CBJ11BD5

DRR RJ11 to Terminal Adapter DRRJ11T6

See our RSRLYB, RLY6, and RLY7 literature for details on DIN rail mountable relays.

Dual Loop Controller w/ 2 Analog Outputs DLC01001

Dual Setpoint Controller w/ 2 Analog Outputs DLC11001

SF PC Configuration Software for Windows SFDLC

RS485 to RJ11 Cable CBLRLC00

COMMUNICATIONS

The RS485 serial communications allows the DLC to be multi-dropped, with Baud rates up to 38400. The CBPRO007 programming cable converts the RS232 port of a PC to RS485 and is terminated with an RJ11 connector. The bi-directional capability of the CBPRO007 allows it to be used as a permanent interface cable as well as a programming cable.

SOFTWARE

The DLC is programmed with Windows® based SFDLC software. The software allows configuration and storage of DLC program files, as well as calibration. Additionally, all setup and control parameters can be interrogated and modified through MODBUS™ register and coil commands.

ANALOG OUTPUT OPTION

The optional dual DC Analog Output (10 V or 20 mA) can be independently configured and scaled for control or re-transmission purposes. These outputs can be assigned to separate channels, or both outputs can be assigned to the same channel. Programmable output update time reduces valve or actuator activity.

SPECIFICATIONS

1. POWER:

18 to 36 VDC, 13 W (4 W if +24 VDC Output excitation is unused)

24 VAC, ±10% 50/60 Hz, 15 VA (7 VA if +24 VDC Output excitation is unused)

Must use a Class 2 or SELV rated power supply.

2. +24 VDC OUTPUT POWER: 24 VDC, +15%, -5%, 200 mA max

3. MEMORY: Non-volatile memory retains all programmable parameters.

4. INPUT:

Sample Time: 100 msec (9.5 Hz)

Failed Sensor Response: Open or shorted (RTD only) sensor coils

indication, error code returned in Process Value

Common Mode Rejection: >110 dB, 50/60 Hz

Normal Mode Rejection: >40 dB, 50/60 Hz

Temperature Coefficient: 0.013%/°C

Overvoltage: 50 VDC max

Step Response Time: 300 msec typ., 400 msec max

5. THERMOCOUPLE INPUTS:

Types: T, E, J, K, R, S, B, N, C, linear mV

Input Impedance: 20 MΩ

Lead Resistance Effect: 0.25 µV/Ω

Cold Junction Compensation: Less than ±1°C typical (±1.5°C max) over

0 to 50°C ambient temperature range or less than ±1.5°C typical (2°C max) over -20 to 65°C maximum ambient temperature range.

Resolution: 1° or 0.1° for all types except linear mV (0.1 or 0.01 mV)

TYPE

W5/W6

mV -5 mV to 56 mV N/A N/A

MEASUREMENT

RANGE

-200 to +400°C

-328 to +752°F

-200 to +750°C

-328 to +1382°F

-200 to +760°C

-328 to +1400°F

-200 to +1250°C

-328 to +2282°F 0 to +1768°C

+32 to +3214°F

0 to +1768°C

+32 to +3214°F

+149 to +1820°C +300 to +3308°F

-200 to +1300°C

-328 to +2372°F 0 to +2315°C

+32 to +4199°F

No Standard

No Standard No Standard

6. RTD INPUTS: Type: 2 or 3 wire Excitation: 150 µA Lead Resistance: 15 Ω max Resolution: 1 or 0.1° for all types

TYPE INPUT TYPE RANGE

385 100 Ω platinum, Alpha = .00385

392 100 Ω platinum, Alpha = .003919

672 120 Ω nickel, Alpha = .00672

ohms Linear Resistance 0 to 320 Ω

WIRE COLOR

ANSI BS 1843

(+) Blue

(-) Red

(+) Violet

(-) Red

(+) White

(-) Red

(+) Yellow

(-) Red

(+) Orange

(-) Red

(+) Orange

-200 to +600°C

-328 to +1100°F

-200 to +600°C

-328 to +1100°F

-80 to +215°C

-112 to +419°F

(+) White

(-) Blue

(+) Brown

(-) Blue

(+) Yellow

(-) Blue

(+) Brown

(-) Blue

(+) White

(-) Blue

(+) White

(-) Blue

7. TEMPERATURE INDICATION ACCURACY: ± (0.3% of span, +1°C). Includes NIST conformity, cold junction effect, A/D conversion errors, temperature coefficient and linearization conformity at 23 °C after 20 minute warm up.

8. PROCESS INPUT:

INPUT RANGE

10 VDC

(-1 to 11)

20 mA DC

(-2 to 22)

ACCURACY *

(18 to 28°C)

(10 to 75% RH)

0.10% of reading +0.02 V

0.10% of reading

+0.03 mA

IMPEDANCE

1 MΩ 50 V 1 mV

10 Ω 100 mA 1 µA

MAX

CONTINUOUS

OVERLOAD

RESOLUTION

* Accuracies are expressed as ± percentages after 20 minute warm-up.

9. ISOLATION LEVEL: 500 VAC @ 50/60 Hz, for one minute (50 V working) between the following groups:

Ch A Input Ch B Input Control and Alarm Outputs RS485/Analog Output

Power Supply

Note:

RS485 and Analog Outputs are not internally isolated. Their commons

must not be connected together externally for proper unit function (i.e., earth ground).

10. SERIAL COMMUNICATIONS: Type: RS485; RTU and ASCII MODBUS modes Baud: 300, 600, 1200, 2400, 4800, 9600, 19200, and 38400 Format: 7/8 bits, odd, even, and no parity Transmit Delay: Programmable: See Transmit Delay explanation. Transmit Enable (TXEN): (primarily for 20 mA loop converter) open

collector VOH = 10 VDC max, VOL = 0.5 VDC @ 5 mA max current limit

11. A/D CONVERTER: 16 bit resolution

12. CONTROL AND ALARM OUTPUTS:

Type: Non-isolated switched DC, N Channel open drain MOSFET Current Rating: 1 A max V

: 0.3 V @ 1 A

DS ON

: 30 VDC

DS MAX

Offstate Leakage Current: 0.5 mA max

13. MAIN CONTROL: Control: PID or On/Off Output: Time proportioning or DC Analog Cycle Time: Programmable Auto-Tune: When selected, sets proportional band, integral time, derivative

time values, and output dampening time

Probe Break Action: Programmable

14. ALARM: 1 or 2 alarms Modes:

Manual (through register/coil) Absolute High Acting (Balanced or Unbalanced Hysteresis) Absolute Low Acting (Balanced or Unbalanced Hysteresis) Deviation High Acting Deviation Low Acting Inside Band Acting Outside Band Acting

Reset Action: Programmable; automatic or latched Standby Mode: Programmable; enable or disable Hysteresis: Programmable Sensor Fail Response: Upscale

15. COOLING: Software selectable (overrides Alarm 2). Control: PID or On/Off Output: Time proportioning or DC Analog Cycle Time: Programmable Proportional Gain Adjust: Programmable Heat/Cool Deadband Overlap: Programmable

16. ANALOG DC OUTPUTS: (optional) Control or retransmission, programmable update rate from 0.1 sec or 1 to 250 sec Step Response Time: 100 msec

OUTPUT

RANGE**

0 to 10 V

0 to 20 mA

ACCURACY *

(18 to 28°C)

(10 to 75% RH)

0.10% of FS + 1/2 LSD

COMPLIANCE

10 KΩ min 1/18000

500 Ω max 1/18000

RESOLUTION

(TYPICAL)

OUTPUT

RANGE**

4 to 20 mA

ACCURACY *

(18 to 28°C)

(10 to 75% RH)

0.10% of FS + 1/2 LSD

COMPLIANCE

RESOLUTION

(TYPICAL)

500 Ω max 1/14400

* Accuracies are expressed as ± percentages after 20 minute warm-up.

** Outputs are independently jumper selectable for either 10 V or 20 mA.

The output range may be field calibrated to yield approximate 10% overrange and a small underrange (negative) signal.

17. ENVIRONMENTAL CONDITIONS:

Operating Temperature Range: -20 to +65°C Storage Temperature Range: -40 to +85°C Operating and Storage Humidity: 85% max relative humidity,

noncondensing, from -20 to +65°C

Vibration to IEC 68-2-6: Operational 5 to 150 Hz, 2 g Shock to IEC 68-2-27: Operational 30 g Altitude: Up to 2000 meters

18. CERTIFICATIONS AND COMPLIANCE:

CE Approved

EN 61326-1 Immunity to Industrial Locations Emission CISPR 11 Class A

Safety requirements for electrical equipment for measurement, control, and

laboratory use: EN 61010-1: General Requirements EN 61010-2-030: Particular Requirements for Testing and Measuring

Circuits RoHS Compliant UL Listed: File #E179259 IP20 Enclosure rating

19. CONSTRUCTION: Case body is black high impact plastic. Installation Category I, Pollution Degree 2.

20. CONNECTIONS: Wire clamp screw terminals. Removable terminal blocks.

21. MOUNTING: Snaps on to standard DIN style top hat (T) profile mounting rails according to EN50022 -35 x 7.5 and -35 x 15.

22. WEIGHT: 10.5 oz. (298 g.)

INPUT

POWER

24 VDC

OUTPUT

COMM.

AL2/OP2

BLOCK DIAGRAM

24V

+24V OUT

+5V MAIN DIG

+5V DIG

+5VC DIG

+5VC

-3.6VC

+5VS DIG

+5VS

-3.6VS

+18V

+13.3V

-0.6V

+2.5V

PROCESS

CIRCUITRY

(DO NOT CONNECT AND ) O U

ANNUNCIATORS

E MEMORY

DIP SWITCHES

5V MAIN

DIG

5V MAIN

DIG

ISOLATED

976K

4.99K

A/D

CONV.

5VC

4.02K

10 Ω

ISOLATED

976K

4.99K

A/D

CONV.

5VS

D/A

CONV. (PWM)

D/A

CONV. (PWM)

5VS

4.02K

10 Ω

ISOLATED

25.5 Ω

+18V

5VC

20M

5VS

20M

V+

I+

V-

I-

V+

I+

V-

I-

TBB

INPUT B COMMON

INPUT B

TC+ / RTD

INPUT B

0-10V, 0-20mA

RTD EXC

INPUT A COMMON

INPUT A TC+ / RTD

INPUT A 0-10V, 0-20mA RTD EXC

DEFAULT SERIAL SETTINGS

ANALOG OUT 1 +

0-10V, 0-20mA

ANALOG OUT 1 -

ANALOG OUT 2 + 0-10V, 0-20mA

ANALOG OUT 2 -

TBA

POWER

24VDC

OP1

AL1

OP1

24V

AL1

24V

B-

A+

RS485

GND

TXEN

SUPPLY

24V

5V DIG

MAIN DIG

EMC INSTALLATION GUIDELINES

Although Red Lion Controls products are designed with a high degree of immunity to Electromagnetic Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in each application. The type of the electrical noise, source or coupling method into a unit may be different for various installations. Cable length, routing, and shield termination are very important and can mean the difference between a successful or troublesome installation. Listed are some EMI guidelines for a successful installation in an industrial environment.

1. A unit should be mounted in a metal enclosure, which is properly connected

to protective earth.

2. Use shielded cables for all Signal and Control inputs. The shield connection

should be made as short as possible. The connection point for the shield

depends somewhat upon the application. Listed below are the recommended

methods of connecting the shield, in order of their effectiveness.

a. Connect the shield to earth ground (protective earth) at one end where the

unit is mounted.

b. Connect the shield to earth ground at both ends of the cable, usually when

the noise source frequency is over 1 MHz.

3. Never run Signal or Control cables in the same conduit or raceway with AC

power lines, conductors, feeding motors, solenoids, SCR controls, and

heaters, etc. The cables should be run through metal conduit that is properly

grounded. This is especially useful in applications where cable runs are long

and portable two-way radios are used in close proximity or if the installation

is near a commercial radio transmitter. Also, Signal or Control cables within

an enclosure should be routed as far away as possible from contactors,

control relays, transformers, and other noisy components.

4. Long cable runs are more susceptible to EMI pickup than short cable runs.

5. In extremely high EMI environments, the use of external EMI suppression

devices such as Ferrite Suppression Cores for signal and control cables is

effective. The following EMI suppression devices (or equivalent) are recommended:

Fair-Rite part number 0443167251 (Red Lion Controls #FCOR0000) Line Filters for input power cables:

Schaffner # FN2010-1/07 (Red Lion Controls #LFIL0000)

6. To protect relay contacts that control inductive loads and to minimize radiated and conducted noise (EMI), some type of contact protection network is normally installed across the load, the contacts or both. The most effective location is across the load. a. Using a snubber, which is a resistor-capacitor (RC) network or metal oxide

varistor (MOV) across an AC inductive load is very effective at reducing EMI and increasing relay contact life.

b. If a DC inductive load (such as a DC relay coil) is controlled by a transistor

switch, care must be taken not to exceed the breakdown voltage of the transistor when the load is switched. One of the most effective ways is to place a diode across the inductive load. Most Red Lion products with solid state outputs have internal zener diode protection. However external diode protection at the load is always a good design practice to limit EMI. Although the use of a snubber or varistor could be used. Red Lion part numbers: Snubber: SNUB0000 Varistor: ILS11500 or ILS23000

7. Care should be taken when connecting input and output devices to the instrument. When a separate input and output common is provided, they should not be mixed. Therefore a sensor common should NOT be connected to an output common. This would cause EMI on the sensitive input common, which could affect the instrument’s operation.

Visit http://www.redlion.net/emi for more information on EMI guidelines,

Safety and CE issues as they relate to Red Lion products.

STEP 1 SETTING THE JUMPERS AND DIP SWITCHES

The jumpers are accessible from the bottom of the controller. Needle-nose pliers are needed to remove the jumpers. They should be set prior to installation. To insure proper operation, the jumpers must match the controller software configuration.

Analog Output 2 Jumpers (current) Analog Output 1 Jumpers (current)

Channel A Input Jumpers

(RTD)

Channel B Input Jumpers

(As set from factory)

SERIAL DIP SWITCH SETTINGS

The DLC Serial Communications Settings can be set via DIP Switches or through the serial communications port (software selectable). The software selectable serial settings method using the serial communications port must be set using “RLCPRO” or another software program to write to the DLC Modbus registers (40401-40407). When using the DIP switches to configure the serial settings, the Modbus mode is limited to “RTU” mode only.

ANALOG DC OUTPUTS (OPTIONAL)

Analog Output 1 and Analog Output 2 can be configured for voltage (V) or current (I), independent of each other. Both V/I + and V/I - jumpers of the same channel must be set for the same type of output signal.

I2-

V2+

I2-

V2+

I1-

V1+

I1-

V1+

INPUTS

Channel A and Channel B can be configured independent of each other. Jumper position can be ignored for thermocouple and millivolt inputs.

PARITY

BAUD RATE

DEFAULT

PARITY

BAUD RATE

DEFAULT

SWA

X128

SWB: ADDRESS

X64 X32 X16 X8 X4 X2 X1

M2802X

SWA

X128

SWB: ADDRESS

X64 X32

X16 X8 X4 X2 X1

M2802X

10V

20mA

RTD

10V

20mA

RTD

Analog

Output 2

Jumpers

Analog

Output 1

Jumpers

Channel A

Input

Channel B

Input

SWA

SWB

DEFAULT SERIAL

SETTINGS

Use DIP Switch or Software Serial Settings

Use Default Serial Settings

PARITY

None DN DN

None UP

Even UP DN

Odd UP UP

SWITCH POSITION

2 3

SWITCH

POSITION

BAUD RATE

300 DN DN DN

600 DN DN UP

1200 DN UP DN

2400 DN UP UP

4800 UP DN DN

9600 UP DN UP

19200 UP UP DN

38400 UP UP UP

Serial Communication Defaults:

RTUProtocol: 247Address: 9600Baud Rate:

SWITCH POSITION

4 5 6

Stop Bit: Parity: Start Bit

1 none 1

UNIT ADDRESS

Software Selectable

Serial Settings

1 DN DN DN DN DN DN DN UP

2 DN DN DN DN DN DN UP DN

3 DN DN DN DN DN DN UP UP

4 DN DN DN DN DN UP DN DN

5 DN DN DN DN DN UP DN UP

6 DN DN DN DN DN UP UP DN

7 DN DN DN DN DN UP UP UP

8 DN DN DN DN UP DN DN DN

…

247* UP UP UP UP DN UP UP UP

*- Unit will use address 247 for binary switch settings above 247

STEP 2 INSTALLING THE CONTROLLER

INSTALLATION

The controller is designed for attachment to standard DIN style top hat (T) profile mounting rails according to EN50022 -35 x 7.5 and -35 x 15. The controller should be installed in a location that does not exceed the maximum operating temperature and provides good air circulation. Placing the controller near devices that generate excessive heat should be avoided.

SWITCH POSITION / (BIT WEIGHT)

(128)2 (64)3 (32)4 (16)5 (8)6 (4)7 (2)

DN DN DN DN DN DN DN DN

(1)

T Rail Installation

To install the DLC on a “T” style rail, angle the controller so that the top groove of the mounting recess is located over the lip of the top rail. Push the controller toward the rail until it snaps into place. To remove a controller from the rail, insert a screwdriver into the slot on the bottom of the controller, and pry upwards until it releases from the rail.

STEP 3 IDENTIFYING THE LEDs - LED FUNCTIONALITY

On power-up, all LEDs are turned on briefly in an alternating pattern to allow visual check of LED functionality.

CONDITION CH A OP CH A ALM CH B OP CH B ALM PWR/COMMPRIORITY AUTOTUNE

Power Applied ------Communicating ------- ------- ------- -------Flashing1 ------OP1 On (Channel A) ** On ------- ------- --------------4 ------OP1 On (Channel B) ** ------- ------- On --------------4 ------AL1 On (Channel A) * ------- On ------- --------------4 ------AL1 On (Channel B) * ------- ------- ------- On-------4 ------AL2 On (Channel A) * Fast Flashing ------- --------------4 ------AL2 On (Channel B) * ------- ------- ------- Fast Flashing-------4 ------OP2 On [Cool](Channel A) Fast Flashing ------- ------- --------------5 ------OP2 On [Cool](Channel B) ------- ------- Fast Flashing --------------5 ------Auto-Tune On (Channel A) ------- ------- ------- --------------3 On Auto-Tune On (Channel B) ------- ------- ------- --------------3 Fast Flashing Input Error (Channel A) Slow Flashing Slow Flashing ------- --------------3 ------Input Error (Channel B) Calibration Mode

-------3

-------2

------On

Checksum Error Slow Flashing Slow Flashing Slow Flashing Slow Flashing-------1 Slow Flashing

-------

------On

------- -------On1 -------

Slow FlashingOnSlow Flashing

* If AL1 & AL2 outputs are on at the same time, the ALM annunciator will alternate between On and Fast Flashing every ½ second. ** If OP1 and AL2/OP2 (configured for cool) outputs are on at the same time, the annunciator will only show the OP1 state. The OP2 state is only shown when OP1 is off.

STEP 4 WIRING THE CONTROLLER

WIRING CONNECTIONS

All conductors should meet voltage and current ratings for each terminal. Also, cabling should conform to appropriate standards of good installation, local codes and regulations. When wiring the controller, use the numbers on the label to identify the position number with the proper function. Strip the wire, leaving approximately 1/4" (6 mm) of bare wire exposed. Insert the wire into the terminal, and tighten the screw until the wire is clamped tightly. (Pull wire to verify tightness.) Each terminal can accept up to one #14 AWG (2.55 mm), two #18 AWG (1.02 mm), or four #20 AWG (0.61 mm) wires.

24 VAC POWER

18 to 36 VDC POWER

CONTROLLER POWER CONNECTIONS

TBA

(AC)

DC-

DC+

TBA

For best results, the power should be relatively “clean” and within the specified limits. Drawing power from heavily loaded circuits or from circuits that also power loads that cycle on and off should be avoided. It is recommended that power supplied to the controller be protected by a fuse or circuit breaker.

INPUT CONNECTIONS

RTD and Resistance *

0-10V, 0-20mA

Exc./ Jumper

Sense

2 Wire Current Signal Requiring DLC Excitation **

TC+ OR RTD

INPUT COMMON

CH A = Terminals 4, 5 & 6

TBB

CH B = Terminals 1, 2 & 3

RTD EXC.

0-10V, 0-20mA

LOAD

+24VDC OUT

(200 mA max)

TBA

CH A = Terminals 4, 5 & 6 CH B = Terminals 1, 2 & 3

* For two wire RTDs, install a copper sense lead of the same gauge and length as the RTD leads. Attach one end of the wire at the probe and the other end to input

common terminal. Complete lead wire compensation is obtained. This is the preferred method. If a sense wire is not used, then use a jumper. A temperature offset

error will exist. The error may be compensated by programming a temperature offset. ** +24 VDC OUT (Terminal 3) shares common with Ch A Inputs & All Control/Alarm Outputs.

TC+ OR RTD

INPUT COMMON

TBB

Thermocouple and Millivolt

0-10V, 0-20mA

TC+

TC-

RTD EXC.

TC+ OR RTD

INPUT COMMON

CH A = Terminals 4, 5 & 6

TBB

CH B = Terminals 1, 2 & 3

RTD EXC.

DC+

DC-

3 Wire Current or Voltage Signal Requiring DLC Excitation **

+24VDC OUT

(200 mA max)

TBA

CH A = Terminals 4, 5 & 6 CH B = Terminals 1, 2 & 3

Voltage or Current

TBB

Out

LOAD

Comm

TBB

0-10V, 0-20mA

RTD EXC.

TC+ OR RTD

INPUT COMMON

CH A = Terminals 4, 5 & 6 CH B = Terminals 1, 2 & 3

0-10V, 0-20mA

INPUT COMMON

RTD EXC.

TC+ OR RTD

CONTROL AND ALARM OUTPUT CONNECTIONS

Load Power from DLC

External Controller Power

CH A = Terminals 5, 6, & 7 CH B = Terminals 8, 9, & 10

Load

AL2/OP2

AL1

OP1

OUTPUT COMMON

(200 mA max)

ต

TBA

+24VDC OUT

DC- / (AC)

DC+ / (AC)

CH A = Terminals 5, 6, & 7 CH B = Terminals 8, 9, & 10

Separate External Power

For Load and Controller

Load

AL2/OP2

AL1

OP1

OUTPUT COMMON

ต

1 2

ต

TBA

+24VDC OUT

DC- / (AC)

DC+ / (AC)

Combined External Power

For Load and Controller

CH A = Terminals 5, 6, & 7 CH B = Terminals 8, 9, & 10

Load

TBA

AL2/OP2

AL1

OP1

OUTPUT COMMON

+24VDC OUT

DC- / (AC)

ต

DC+ / (AC)

1 2

ต

ANALOG DC OUTPUT CONNECTIONS

1110

OUT -

Controller, Recorder

Output 1 = Terminals 8 & 9 Output 2 = Terminals 10 & 11

Note: Analog Outputs & RS485 are not internally isolated and must not

share the same common (i.e., earth ground).

TBB

OUT +

ANALOG OUTPUT

0-10V, 0(4)-20mA

RS485 SERIAL CONNECTIONS

There are two modular connectors located on the front for paralleling communications. The CBPRO007 programming cable converts the RS232 port of a PC to RS485 and is terminated with an RJ11 connector. The bi-directional capability of the CBPRO007 allows it to be used as a permanent interface cable as well as a programming cable.

DEFAULT SERIAL SETTING CONNECTIONS

TBB

DEFAULT SERIAL

SETTING

OUTPUT COMMON

TBA

Defaults:

If using software selectable serial settings and the serial settings are unknown or forgotten, they can be temporarily reset to the defaults by connecting the “Default Serial Setting” terminal 7 to “Output Common” terminal 4 with a jumper.

RTUProtocol: 247Address: 9600Baud Rate:

Data Bits: Parity:

8 none

STEP 5 INSTALLING SFDLC (Software for DLC)

After downloading RLCPro for DLC Series (http://www.redlion.net/

SFDLC) open the ZIP archive and then run dlc207.exe to install the

software.

STEP 6 PROGRAMMING - Getting Started

Run RLCPro by double-clicking the icon, or use the start menu.

You will be prompted to

select the proper device,

Use the FILE pull-down menu

to select a NEW file.

and then the model.

STEP 7 PROGRAMMING THE PID SETTINGS

Note: The register numbers correspond to (Channel A/Channel B).Channel B PID control is not functional when the input is assigned as a Remote Setpoint.

The Auto-Tune procedure of the controller sets the Proportional Band, Integral Time, Derivative Time, Digital Filter, Control Ouput Dampening Time, and Relative Gain (Heat/Cool) values appropriate to the characteristics of the process.

Proportional Band (40007/40023): Proportional band, entered as percent of full input range, is the band from

the setpoint where the controller adjusts the percent output power based on how close the process value is to the setpoint. For temperature inputs, the input range is fixed per the entered thermocouple or RTD type. For process inputs, the input range is the difference between the entered Process Low Scaling Value and the Process High Scaling Value. The proportional band should be set to obtain the best response to a process disturbance while minimizing overshoot. A proportional band of 0.0% forces the controller into On/Off Control with its characteristic cycling at setpoint.

Integral Time (40008/40024): Integral time is defined as the time, in seconds, it takes the output power due to integral action alone to equal

the output power due to proportional action alone during a constant process error. As long as the error exists, integral action repeats the proportional action each integral time. Integral action shifts the center point position of the proportional band to eliminate error in the steady state. The higher the integral time, the slower the response. The optimal integral time is best determined during PID Tuning. If time is set to zero, the previous Integral output power value is maintained. Offset Power can be used to provide Manual Reset. Integral Action can be disabled by writing a ‘1’ to the Disable Intergral Action register (40044/40052).

Derivative Time (40009/40025): Derivative time, entered as seconds per repeat, is the time that the controller looks ahead at the ramping

error to see what the proportional contribution will be and it matches that value every Derivative time. As long as the ramping error exists, the Derivative action is repeated by Proportional action every derivative time. Increasing the derivative time helps to stabilize the response, but too high of a derivative time, coupled with noisy signal processes, may cause the output to fluctuate too greatly, yielding poor control. Setting the time to zero disables Derivative Action.

Control Mode (40041/40049): In Automatic Mode, the percentage of Output Power is automatically determined by PID or On/Off Control.

In Manual Mode, the percentage of Output Power is entered manually. For more information, see Control Mode Explanations Section.

Output Power (40005/40021): This parameter can only be changed by direct entry in Manual Mode. For more details on this parameter, see

the Control Mode Explanations Section.

Offset Power (Manual Reset) (40010/40026): If the Integral Time is set to zero (Automatic Reset is off), it may be necessary to modify the

output power to eliminate errors in the steady state. The offset power is used to shift the proportional band to compensate for errors in the steady state. If Integral Action is later invoked, the controller will re-calculate the internal integral value to provide “bumpless” transfer.

Auto-Tune Code (40013/40029): Prior to starting Auto-Tune, this code should be set to achieve the necessary dampening level under PID

Control. When set to zero, it yields the fastest process response with possible overshoot. A setting of 2 yields the slowest response with the least amount of overshoot. If the Auto-Tune Code is changed, Auto-Tune needs to be reinitiated for the changes to affect the PID settings. Auto-tune is initiated by writing a ‘1’ to the Auto-Tune start register (40011/40027). The Auto-Tune phase will be shown in register (40012/40028). For more information, see PID Tuning Explanations Section.

STEP 8 PROGRAMMING THE INPUT SETUP

Input Type (40101/40201): Select the proper input type from the pull down menu. Make sure the input

jumpers are set to match the input signal selection.

Scale (40102/40202): Select either degrees Fahrenheit or Celsius. For mV, resistance, voltage or current types,

this has no effect. If changed, check all temperature related values, as the DLC does not automatically convert these values.

Resolution (40103/40203): For all temperature and ohms Input Types low (x1) resolution selects whole units

of measure. In these same modes, high (x10) resolution selects tenth of units of measure. For mV mode, low selects tenths of mV and high selects hundredths of mV. If changed, be sure to check all parameters because the controller does not automatically convert related parameter values. For voltage or current types, this has no effect.

Rounding (40104/40204): Rounding selections other than 1 cause the process value to round to the nearest

rounding increment selected. (For example, rounding of 5 causes 122 to round to 120 and 123 to round to

125.) Rounding starts at the least significant digit of the process value. If the signal is inherently jittery, the process value may be rounded to a value higher than 1. If the range of the signal exceeds the required resolution (for example, 0-1000 psi, but only 10 psi resolution is required), a rounding increment of 10 will effectively make the reading more stable.

Digital Filtering (40105/40205): The filter is an adaptive digital filter that discriminates between measurement

noise and actual process changes. If the signal is varying too greatly due to measurement noise, increase the filter value. If the fastest controller response is needed, decrease the filter value.

Span Correction (40106/40206): This value is the correction slope. A span of 1.0000 applies no correction.

Span only applies to temperature sensor, millivolt, and ohms inputs.

Offset Correction (40107/40207): This value offsets the temperature value by the entered amount. Offset only

applies to temperature sensor, millivolt, and ohms inputs

Channel B Assignment (40198): This is used to configure Channel B to operate as a Remote Setpoint to

Channel A. Channel B PID control is not functional when the input is assigned as a Remote Setpoint.

Local/Remote Setpoint Transfer Mode (40199): When cycling from/to Local or Remote Setpoint (register 40046), the response of the controller can be

programmed to act in a variety of ways. The table summarizes the responses for Setpoint transfer options.

LOCAL/REMOTE SETPOINT

TRANSFER MODE

0 - Normal Output may bump. Output may bump.

1 - Auto No output bump. Process error eliminated

at rate of integral action. Ramping disabled during transfer.

2 - Track Output may bump. Local Setpoint (40002) assumes value

Note: In situations where an output bump may occur, the Setpoint ramp function can be used to reduce or eliminate bumping when switching Setpoint modes.

The setpoint ramp feature ramps the setpoint from the old setpoint to the new Setpoint.

Remote Setpoint Ratio Multiplier (40206): This value is used for channel B when it is assigned as a Remote Setpoint Input. The Ratio Multiplier applies to

all input types (0-15).

Remote Setpoint Bias Offset (40207): This value is used for channel B when it is assigned as a Remote Setpoint Input. Scaling Points (40111-40114/40211-40214): Low and high scaling points are necessary to scale the controller for process voltage and current inputs. Each scaling

point has a coordinate pair of input and process value entries. The process value will be linear between and continue past the entries up to the limit of the input range. Reverse acting measurement can be accomplished by reversing the Input or Process entries, but not both. (Do not reverse the input wires to change the action.) To scale a 4-20 mA Input signal to provide process values of 0 to 100.00 (% in hundredths), the Input Low (40113/40213) and Input High (40114/40214) values would be 4000 and 20000 (0.001 mA resolution), and the Process Low (40111/40211) and Process High (40112/40212) values would be 0 and 10000.

Process Decimal Point (Dec Pt) (40115/40215): The decimal point position is used to enable SFDLC display in desired engineering units for voltage and current

Process values. It is not used internally by the DLC.

LOCAL TO REMOTE REMOTE TO LOCAL

No output bump. Process error eliminated at rate of integral action. Ramping disabled during transfer.

of Remote Setpoint (tracks). No output bump.

STEP 9 PROGRAMMING THE SETPOINTS

Setpoint (40002/40018): Enter the setpoint value. Deviation of Process Value (40001/40017) from

setpoint value can be viewed in the Setpoint Deviation register (40006/40022).

Low Limit (40108/40208); High Limit (40109/40209): The controller has programmable high and low

setpoint limit values to restrict the setting range of the setpoint. Set the limits so that the setpoint value cannot be set outside the safe operating area of the process.

Ramp Rate (40110/40210): The setpoint ramp rate can reduce sudden shock to the process and reduce

overshoot on startup or after setpoint changes, by ramping the setpoint at a controlled rate. The ramp rate is 0.1° for input types 0-11, 0.1 Ω for input type 12, 0.01 for input type 13, and 0.1 unit for input types 14-15 per minute. Writing a ‘0’ disables setpoint ramping. The Disable Setpoint Ramping register (40042/40050) can also be used to disable ramping. The Setpoint Ramping In-Process register (40043/40051) will be a ‘1’ during setpoint ramping. While ramping is enabled, the Ramping Setpoint can be viewed in register (40045/40053). The Ramp Rate for CHB is not functional when it is assigned as a Remote Setpoint Input.

Once the ramping setpoint reaches the target setpoint, the setpoint ramp rate disengages until the setpoint is changed again. If the ramp value is changed during ramping, the new ramp rate takes effect. If the setpoint is ramping prior to starting Auto-Tune, the ramping is suspended during Auto-Tune and then resumed afterward using the present Process value as a starting value. Deviation and band alarms are relative to the target setpoint, not the ramping setpoint. A slow process may not track the programmed setpoint rate. At power-up, the ramping setpoint is initialized to the starting process value. Remote/Local Setpoint Select (40046): Channel A setpoint mode can be switched between Local Setpoint operation and Remote Setpoint operation. The

Channel B input must be assigned as a remote setpoint (register 40198).

STEP 10 PROGRAMMING PROFILE SETUP (Optional)

Profile Power Cycle Mode (40321/40421): Upon controller power-on several profile operating modes

exist. Stop: If the Profile was running when powered down, upon power-up, "Stop" places the profile into the

stop or off mode, regardless of the mode prior to the power-down. The active Setpoint is the setpoint of the last segment that ran before power-down.

Abort: If the Profile status was running, paused, or in Error Delay when powered down, upon power-up,

"Abort" will place the controller in manual mode at 0% Output Power. The Setpoint and Ramp Rate are the values they were prior to running the profile. If the Setpoint Controller was 'paused,' they will be set to the values that they were at power-down.

Start: The Start power cycle mode causes the controller to automatically start the profile at Power-up.

This will occur if the unit was in manual or automatic control mode. During maintenance or at other times when this action is not desired, the Profile Power Cycle mode should be changed appropriately.

Resume: At Power-up, Resume causes the profile to continue from the point and phase when power was

removed. If the unit was in ramp phase, the ramping setpoint will start ramping from the initial process value at power-up.

Pause: Upon Power-up, the controller pauses and maintains control at the initial process value (on

power-up), at the phase where the controller was powered down. The user can then determine how to proceed based on the process that is being controlled.

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Red Lion DUAL LOOP CONTROLLER Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual