Red Lion P48 User Manual

Tel +1 (717) 767-6511 Fax +1 (717) 764-0839 www.redlion.net

MODEL P48 - 1/16 DIN PROCESS CONTROLLER



PID CONTROL WITH REDUCED OVERSHOOT



ACCEPTS 0 to 10 VDC or 0/4 to 20 mA DC INPUTS



OPTIONAL TWO LINEAR DC OUTPUTS (0 to 10 V, 0/4 to 20 mA)



OPTIONAL DUAL ALARM OUTPUTS



OPTIONAL REMOTE SETPOINT INPUT (0/4 to 20 mA)



OPTIONAL RS485 SERIAL COMMUNICATIONS



SECOND SETPOINT SETTING



SETPOINT RAMPING FOR PROCESS STARTUP



PROGRAMMABLE USER INPUT (Digital) FOR ADDED FLEXIBILITY



PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS



MANUAL/AUTOMATIC CONTROL MODES



ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS



DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF

PROCESS AND SETPOINT



STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES



PC SOFTWARE AVAILABLE FOR CONTROLLER CONFIGURATION



NEMA 4X/IP65 BEZEL

Bulletin No. P48-E Drawing No. LP0464 Released 03/11

UL Recognized Component, File # E156876

DESCRIPTION

The P48 Controller accepts either a 0 to 10 VDC or a 0/4 to 20 mA DC signal,

precisely displays the input process signal according to the programmable scaling points, and provides an accurate output control signal (time proportional or linear DC) to maintain the process at the desired control point. The controller’s comprehensive yet simple programming allows it to meet a wide variety of application requirements.

In the PID control mode the controller operates with on-demand auto-tune, which will establish the tuning constants. The PID tuning constants may be finetuned by the operator at any time and then locked out from further modification. The controller employs a unique overshoot suppression feature, which allows the quickest response without excessive overshoot. The unit can be transferred to operate in the manual mode, providing the operator with direct control of the output. The controller may also operate in the ON/OFF control mode with adjustable hysteresis. a second setpoint is available to allow quick selection of a different setpoint setting.

Dual 4-digit displays allow viewing of the process and setpoint simultaneously. Front panel indicators inform the operator of the controller and output status. On some models, the main control output and the alarm outputs are field replaceable.

Optional alarm(s) can be configured to activate according to a variety of actions (Absolute HI or LO, Deviation HI or LO, and Band IN or OUT) with

CAUTION: Risk of Danger.

Read complete instructions prior to

installation and operation of the unit.

CAUTION: Risk of electric shock.

DIMENSIONS In inches (mm)

1.95

(49.5)

A2A1O1MNDV%P

D P

1.95

(49.5)

0.37 (9.4)

4.17 (105.9)

adjustable hysteresis. A standby feature suppresses the alarm during power-up until the process stabilizes outside the alarm region. The second alarm can be configured as a secondary PID output (heat/cool applications).

Optional Main Linear DC output (10 V or 20 mA) can be used for control or process re-transmission purposes. Programmable output update time reduces valve or actuator activity. The output range can be scaled independent of the input range.

Optional Second Linear DC output (10 V or 20 mA) provides an independent process re-transmission, while the main Linear DC output is being used for control. The output range can be scaled independent of the input range.

Optional Remote Setpoint input (0/4 to 20 mA) allows for cascade control loops; and allows for remotely driven setpoint signal from computers or other similar equipment. Straightforward end point scaling with independent filtering and local/remote transfer option expand the controller’s flexibility.

The optional RS485 serial communication interface provides two-way communication between a P48 and other compatible equipment such as a printer, PLC, HMI, or a host computer. In multipoint applications (up to thirty-two), the address number of each P48 on the line can be programmed separately from 0 to

99. Data from the P48 can be interrogated or changed, and alarm output(s) may be reset by sending the proper command code via serial communications. PC software, SFCRM, allows for easy configuration of controller parameters. These settings can be saved to disk for later use or used for multi-controller down loading. On-line help is provided within the software.

The unit is constructed of a lightweight, high impact plastic case with a tinted front panel. The front panel meets NEMA 4X/IP65 specifications when properly installed. Multiple units can be stacked horizontally or vertically. Modern surfacemount technology, extensive testing, plus high immunity to noise interference makes the controller extremely reliable in industrial environments.

PANEL CUT-OUT

1.76

(44.7)

1.76 (44.7)

13 14

1211

1.772

(45 )

1.772 (45 )

+0.024

-0.000

+0.6

-0.0

+0.024

-0.000

+0.6

-0.0

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 P48 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 process limit indicator with alarm outputs is strongly recommended.

SPECIFICATIONS

1. DISPLAY: Dual 4-digit

Upper Process Display: 0.4" (10.2 mm) high red LED

Lower Auxiliary Display: 0.3" (7.6 mm) high green LED

Display Messages:

“OLOL” - Appears when measurement exceeds + input range. “ULUL” - Appears when measurement exceeds - input range. “SENS” - Appears when measurement exceeds controller limits. “...” - Appears when display values exceed + display range. “-..” - Appears when display values exceed - display range.

LED Status Annunciators:

%P - Lower auxiliary display shows power output in (%). MN - Flashing: Controller is in manual mode. On: Local Setpoint (Remote Setpoint option) Off: Remote Setpoint DV - Lower auxiliary display shows deviation (error) from setpoint. O1 - Main control output is active. A1 - Alarm #1 is active (for A1 option). A2 - Alarm #2 is active OR

- Secondary output (02) is active.

2. POWER:

AC Versions: 85 VAC min. to 250 VAC max., 50 to 60 Hz, 8 VA max.

DC Versions:

DC Power: 18 to 36 VDC; 7 W AC Power: 24 VAC 10%; 50 to 60 Hz, 9 VA

3. CONTROLS: Four front panel push buttons for modification and setup of

controller functions and one external user input for parameter lockout or other

functions.

4. MEMORY: Nonvolatile E

and values.

5. RANGE AND ACCURACY:

INPUT

RANGE

10 VDC

(-1 to 11)

20 mA DC

(-2 to 22)

ACCURACY *

(18 to 28°C)

0.10% of reading +0.02 V

0.10% of reading

+0.03 mA

* Accuracies are expressed as percentages after 20 minutes warm-up. The

controller’s accuracy is specified in two ways: accuracy over an 18 to 28°C range at 10 to 75% RH environment; and accuracy over a 0 to 50°C range at 0 to 85% RH (non-condensing) environment. Accuracy over the wide sensor range reflects the coefficient of the internal circuitry.

6. MAIN SIGNAL INPUT:

Sample Period: 100 msec Response Time: Less than 300 msec typ., 400 msec max. (to within 99% of

final value w/step input; typically, response is limited to response time of sensor)

Normal Mode Rejection: 40 dB @ 50/60 Hz (improves with increased

digital filtering.)

Common Mode Rejection: Greater than 120 dB, DC to 60 Hz Protection: Input overload 120 VAC max. for 15 sec. max.

7. USER INPUT: Internally pulled up to +5 VDC (1 M).

= 5.25 VDC; V

IN MAX

= 1μA max.

OFF

Response Time: 120 msec max. Functions:

Program Lock Integral Action Lock Auto/Manual Mode Select Setpoint Ramp Enable Reset Alarms Setpoint 1/Setpoint 2 Select Local/Remote Setpoint Select Serial block print

8. CONTROL AND ALARM OUTPUTS: Relay outputs with Form A contacts:

Contact Rating: 3 A @ 250 VAC or 30 VDC (resistive load)

1/10 HP @ 120 VAC (inductive load)

Life Expectancy: 100,000 cycles at max. load rating.

(Decreasing load and/or increasing cycle time, increases life expectancy.)

PROM retains all programmable parameters

ACCURACY *

(0 to 50°C)

0.30% of reading

+0.03 V

0.30% of

reading

+0.04 mA

= 0.85 V max.; V

IMPEDANCE RESOLUTION

1 M ohm 300 V 10 mV

10 ohm 100 mA 10 μA

MAX

CONTINUOUS

OVERLOAD

= 3.65 V min.;

9. MAIN CONTROL:

Control: PID or ON/OFF Output: Time proportioning or Linear DC Cycle time: Programmable Auto-tune: When selected, sets proportional band, integral time, and

derivative time values.

10. ALARMS: 1 or 2 alarms (optional) Modes:

Absolute high acting Absolute low acting 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 Annunciator: LED backlight for “A1”, “A2”

11. SECONDARY OUTPUT: Software selectable (overrides alarm 2) Control: PID or ON/OFF Output: Time Proportioning Cycle time: Programmable Proportional Gain Adjust: Programmable Deadband /Overlap: Programmable

12. MAIN AND SECOND LINEAR DC OUTPUT: (optional) Main: Control or re-transmission, programmable update rate from 0.1 sec to

250 sec

Second: Re-transmission only, fixed update rate of 0.1 sec

OUTPUT **

RANGE

0 to 10 V

0 to 20 mA

4 to 20 mA

ACCURACY *

(18 to 28°C)

0.10% of FS + 1/2 LSD

ACCURACY *

(0 to 50°C)

0.30% of FS + 1/2 LSD

COMPLIANCE RESOLUTION

10k ohm min. 1/3500

500 ohm max. 1/3500

500 ohm max. 1/2800

* Accuracies are expressed as percentages after 20 minutes warm-up. Output

accuracy is specified in two ways: Accuracy over an 18 to 28°C range at 10 to 75% RH environment; and accuracy over a 0 to 50°C range at 0 to 85% RH (non-condensing) environment. Accuracy over the wide sensor range reflects the coeffecient of the internal circuitry.

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

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

13. REMOTE SETPOINT INPUT: (optional)

Input type: 0/4 to 20 mA Input Resistance: 10 Overrange: -5% to 105% Overload: 100 mA (continuous) Scale Range: -999 to 9999 Resolution: 1 part in 10,000. Accuracy:

At 25

° C: (0.1 % of full scale +½ LSD)

Over 0 to 50

°C range: (0.2% of full scale +½ LSD)

Reading Rate: 10/sec. Setpoint Filtering: Programmable Digital Setpoint Ramping: Programmable, 1 to 9999 units/minute.

14. SERIAL COMMUNICATIONS: (optional) Type: RS485 multipoint, balanced interface Baud Rate: 300 to 9600 Data Format: 7O1, 7E1, 7N2, 8N1 Node Address: 0 to 99, max of 32 units per line Transmit Delay: 2 to 100 msec or 100 to 200 msec Data Encoding: ASCII Isolation w.r.t Main Input Common: 500 Vrms for 1 min. (50 V working)

Not isolated w.r.t. Remote Setpoint or Analog Output common

Note: RS485 and the Analog Output commons are not internally isolated

within the controller. The terminating equipment of these outputs must not share the same common (ie. earth ground).

15. ENVIRONMENTAL CONDITIONS: Operating Range: 0 to 50°C Storage Range: -40 to 80°C Operating and Storage Humidity:

85% max. relative humidity (non-condensing) from 0°C to 50°C.

Vibration According to IEC 68-2-6: Operational 5 to 150 Hz, in X, Y, Z

direction for 1.5 hours, 2 g.

Shock According to IEC 68-2-27: Operational 20 g (10 g relay), 11 msec

in 3 directions.

Altitude: Up to 2000 meters

16. ISOLATION BREAKDOWN RATINGS: AC line with respect to all Inputs and outputs: 250 V working (2300 V for

1 minute).

Main input with respect to Analog Outputs and Remote Setpoint Input:

50 V working (2300 V for 1 minute).

All other inputs and outputs with respect to relay contacts: 2000 VAC Not isolated between Analog Output and Remote Setpoint commons.

17. CERTIFICA TIONS AND COMPLIANCES:

SAFETY

UL Recognized Component, File #E156876, UL873, CSA 22.2 No. 24

Recognized to U.S. and Canadian requirements under the Component Recognition Program of Underwriters Laboratories, Inc.

Type 4X Enclosure rating (Face only), UL50

IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment

for measurement, control, and laboratory use, Part 1.

IP65 Enclosure rating (Face only), IEC 529

ELECTROMAGNETIC COMPATIBILITY

Immunity to EN 50082-2

Level 2; 4 Kv contact EN 61000-4-2Electrostatic discharge Level 3; 8 Kv air

EN 61000-4-3Electromagnetic RF fields

EN 61000-4-6RF conducted interference

EN 61000-4-8Power frequency magnetic fields

Emissions to EN 50081-2

Notes:

1. No loss of performance during EMI disturbance at 10 V/m.

Unit is panel mounted in a metal enclosure (Buckeye SM7013-0 or

equivalent) that provides at least 20 dB shielding effectiveness. Metal panel is connected to earth ground.

Power Line and I/O cables routed in metal conduit connected to earth

ground.

2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:

Analog output may deviate during EMI disturbance.

For operation without loss of performance:

Install power line filter, RLC#LFIL0000 or equivalent. OR Install 2 ferrite cores, RLC#FCOR0000 or equivalent, to AC lines at

unit for frequencies above 5 MHz.

I/O cables routed in metal conduit connected to earth ground.

Refer to the EMC Installation Guidelines section of the manual for additional

information.

18. CONNECTION: Wire clamping screw terminals

19. CONSTRUCTION: Black plastic alloy case and collar style panel latch. Panel latch can be installed for vertical or horizontal instrument stacking. One piece tinted plastic bezel. Bezel assembly with circuit boards can be removed from the case to change the output board without removing the case from the panel or disconnecting wiring. Unit meets NEMA 4X/IP65 requirements for indoor use, when properly installed. Installation Category II, Pollution Degree 2.

20. WEIGHT: 0.38 lbs (0.17 kgs)

Level 3; 10 V/m 80 MHz - 1 GHz Level 4; 2 Kv I/OEN 61000-4-4Fast transients (burst) Level 3; 2 Kv power Level 3; 10 V/rms 150 KHz - 80 MHz Level 4; 30 A/m Level 3; 10 V/mENV 50204Simulation of cordless telephones 900 MHz ± 5 MHz 200 Hz, 50% duty cycle

Enclosure class AEN 55011RF interference Power mains class A

FRONT PANEL FEATURES

In the normal operating mode, the unit displays the process value in the upper

display. One of the following parameters can be viewed in the lower display:

- Setpoint

- % Power Output

- Process Deviation

- Blank Display

The user scrolls through these parameters by pressing the D button. If enabled, the control setpoint or power output (manual mode only) can be directly modified in this mode.

In the normal operating mode, parameters are selected by use of the P button and modified by use of the UP and DOWN buttons. Parameters are then entered by the P button, which advances the user to the next parameter. Pressing the D button immediately returns the controller to the normal operating mode without changing the currently selected parameter.

HARDWARE FEATURES

A fast 100 msec input sampling rate provides quick controller response to a process disturbance, thus providing excellent process control. Measurement accuracy of 0.1% or better, provides close process control conforming to the desired control setpoint value.

Low-drift, highly stable circuitry ensures years of reliable and accurate process control. The recommended two year re-calibration interval is easily accomplished via the programming menu.

REMOTE SETPOINT INPUT

The remote setpoint input facilitates the use of a remote signal to drive the controller’s setpoint. The remote signal can be scaled independent to that of the controller’s range. The controller’s response to local/remote setpoint transfers can be programmed. Also, the remote signal is filtered by use of an adaptive filter. With this filter, relatively large filtering time constants can be used without suffering from long settling times. The time constant and filter disable band are programmable. Additionally, the remote signal can also be velocity limited (or ramped) to slow the controller’s response to changes in setpoint. This results in a steady control response with no overshoot.

LINEAR DC ANALOG OUTPUTS

The Main Linear DC output has independent scaling, programmable output update time and filter (damping) time. These parameters permit flexibility in process configuration. The output can be set for 0 to 10 V, 0 to 20 mA or 4 to 20 mA ranges and can be configured for control or for re-transmission of input or setpoint values.

A Second Linear DC output is dedicated for the re-transmission of the process input signal. The output can be scaled and converted independent of the input signal and Main Linear DC output. This output is isolated from the input.

SETPOINT FEATURES

The controller setpoint can be protected from out of range values by programming the setpoint range limit values. Additionally, safeguards from inadvertent data entry can be programmed.

A second setpoint can be selected by the user input and/or through the front panel.

The setpoint ramp feature can be used to control the setpoint value at start-up or any time a setpoint change is made, at a user programmable rate. This feature reduces shock to the process and helps to minimize overshoot.

INPUT FEATURES

A programmable input filter can be used to stabilize readings from a process with varying or oscillating process characteristics, helping to provide better control.

The programmable user input can be used to control a variety of functions, such as auto/manual transfer of the controller, reset alarm output(s), etc.

BASIC OPERATION

The P48 controls a process by receiving a linear DC signal representing the process value, then calculating a control output power value by use of a modified PID control algorithm. The unit controls the system with the new output power value to keep the process at setpoint. The PID control algorithm incorporates features which provide for high control accuracy and low overshoot from process disturbances.

OUTPUT FEATURES

Programmable output power limits provide protection for processes where excessive power can cause damage. Programmable output cycle time, output hysteresis, and dampening can reduce output activity without degrading control accuracy. The main outputs can operate in PID, ON/OFF, or manual control modes.

CONTROL AND ALARM OUTPUTS

In addition to the Linear DC output, there are up to three relay outputs available. Relay outputs can switch user applied AC or DC voltages for control or alarm purposes.

+ 5 hidden pages