Red Lion PCU User Manual

THE PROCESS CONTROL UNIT

MODEL PCU INSTRUCTION MANUAL

INTRODUCTION

US LISTED

The Process Control Unit (PCU) is a multi-purpose series of industrial control products that are field-programmable for solving various applications. This series of products is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements.

The PCU unit, which you have purchased, has the same high quality workmanship and advanced technological capabilities that have made Red Lion Controls the leader in today’s industrial market.

Red Lion Controls has a complete line of industrial indication and control equipment, and we look forward to servicing you now and in the future.

US LISTED

IND. CONT. EQ.

51EB

CAUTION: Read complete

instructions prior to installation

and operation of the unit.

CAUTION: Risk of electric shock.

GENERAL DESCRIPTION ....................................................................1

Safety Summary ............................................................................2

INSTALLATION & CONNECTIONS ...........................................................3

Installation Environment .....................................................................3

Standard Unit Installation ....................................................................3

NEMA 4X/IP65 Unit Installation ..............................................................3

Unit Removal Procedure .....................................................................5

Removing Bezel Assembly ..................................................................5

Installing Bezel Assembly ...................................................................5

Output Modules ............................................................................5

Output Module Restrictions ...............................................................5

Installing Output Modules ................................................................6

Typical Connections .....................................................................6

Select AC Power (115/230 VAC) .............................................................6

EMC Installation Guidelines .................................................................7

Wiring Connections ........................................................................8

Valve Positioner Wiring .................................................................9

Linear DC Output Wiring .................................................................9

Second Analog Input Wiring ..............................................................9

Program Disable Or User Input Wiring ....................................................10

AC Power Wiring ......................................................................10

FRONT PANEL DESCRIPTION ..............................................................11

Button Functions ..........................................................................11

OPERATION OVERVIEW ...................................................................12

Controller Power-up .......................................................................12

Controller Power Down ....................................................................12

Process Start-up ...........................................................................12

Manual (User) & Automatic Operation .......................................................12

Remote And Local Setpoint Operation ........................................................13

Configuration Of Parameters ................................................................14

Parameter Entry ...........................................................................15

Normal Display Mode ......................................................................15

Modifying A Secondary Display Parameter From The Front Panel .................................15

UNPROTECTED PARAMETER MODE .......................................................16

Unprotected Parameter Mode Reference Table .................................................16

PROTECTED PARAMETER MODE ..........................................................18

Protected Parameter Mode Reference Table ....................................................18

FRONT PANEL PROGRAM DISABLE .......................................................19

Models With User Input ....................................................................19

Models With Program Disable ...............................................................19

HIDDEN FUNCTION MODE .................................................................20

Hidden Function Mode Reference Table .......................................................20

CONFIGURATION PARAMETER MODULES .................................................21

Input Module (1- In) .......................................................................21

Input Type (tYPE) ......................................................................21

Square Root Linearization (root) (Optional) ................................................21

Decimal Point Position (dCPt) ............................................................21

Rounding Increment ( rnd) ...............................................................21

Input Signal Filter and Display Update Rate (FLtr) ..........................................22

Scaling Points .........................................................................22

Display Values (dSP1 & dSP2) ...........................................................22

Signal Input Values (INP1 & INP2) .......................................................22

Key-in Method ....................................................................22

Signal Input Method ...............................................................22

Setpoint Limit Values (SPLO & SPHI) ....................................................23

Setpoint Ramp Rate (SPrP) ..............................................................23

Output Module (2-OP) .....................................................................24

Time Proportioning Cycle Time (CYCt) ...................................................24

Output Control Action (OPAC) ...........................................................24

Output Power Limits (OPLO & OPHI) .....................................................25

Input Overdrive Preset Power (OPFL) .....................................................25

Output Power Dampening (OPdP) ........................................................25

ON/OFF Control Hysteresis Band (CHYS) .................................................25

Auto-Tune Dampening Code (tcod) .......................................................26

Linear DC Analog Output (ANAS, ANLO, ANHI, ANdb, ANUt) (Optional) ....................26

Lockouts Module (3-LC) ...................................................................27

Lower Display Lockouts (SP, OP, IN-2, dEv, bdSP) .........................................27

Protected Mode Lockouts (Code, PID, PID2, rtbS & AL) .....................................28

Hidden Mode Lockouts (ALrS, trnF, tUNE and SPSL) .......................................28

Alarm Module (4-AL) (Optional) ............................................................28

Alarm Action (Act1, Act2) ..............................................................28

Second Analog Input Alarm ..............................................................29

Valve Fail Alarm (VFAL) ...............................................................29

Alarm Action Figures ...................................................................30

Alarm Reset (rSt1, rSt2) .................................................................32

Alarm Standby Delay (Stb1, Stb2) ........................................................32

Alarm Value (AL-1, AL-2) ..............................................................32

Alarm Hysteresis (AHYS) ...............................................................33

Secondary Output Module (5-02) (Optional) ...................................................33

Time Proportioning Cycle Time (CYC2) ...................................................33

Relative Gain (GAN2) ..................................................................33

Overlap/Deadband (db-2) ................................................................33

Serial Communications Module (6-SC) (Optional) ..............................................34

Baud Rate (bAUd) ......................................................................34

Parity Bit (PArb) .......................................................................34

Address Number (Addr) .................................................................34

Abbreviated or Full Transmission (Abrv) ...................................................34

Print Rate (PrAt) .......................................................................34

Print Options (PoPt) ....................................................................35

Second Analog Input Module (7-2N) (Optional) ................................................35

Operation mode (OPEr) .................................................................35

Square Root Linearization (root) ..........................................................35

iii

Decimal Point Position (dPt2) ............................................................36

Second Analog Input Scaling Points (dSP1, INP1, dSP2, INP2) ................................36

Display Values (dSP1 & dSP2) ......................................................36

Signal Input Values (INP1 & INP2) .......................................................36

Key-in Method ....................................................................36

Signal Input Method ...............................................................36

Local/Remote Setpoint Transfer Modes (SPtr) ..............................................37

Secondary Output Power Dampening (OPd2) ...............................................37

Valve Positioner Module (8-VP) .............................................................37

Valve Position 1 And Valve Position 2 (VPS1, VPS2) ........................................37

Valve Update Time (VUdt) (Position And Velocity Mode) ....................................38

Valve Position Deadband (VPdb) (Position Mode) ...........................................38

Valve Fail Time Alarm (VFAL) (Position Mode) ............................................38

Valve Motor Open Time And Valve Motor Close Time (VOPt, VCLt) (Velocity mode) ............38

Valve Minimum On Time (VONt)(Velocity Mode) ..........................................38

Factory Service Operations Module (9-FS) ....................................................38

Reference Tables: Configuration Parameter Modules ............................................39

Configure Module 1 - Input Parameters (1-IN) ..............................................39

Configure Module 2 - Output Parameters (2-OP) ............................................40

Configure Module 3 - Lockout Parameters (3-LC) ...........................................41

Configure Module 4 - Alarms (4-AL) .....................................................42

Configure Module 5 - Secondary Output Parameters (5-O2) ...................................43

Configure Module 6 - Serial Communications (6-SC) ........................................44

Configure Module 7 - Second Analog Input (7-2N) ..........................................45

Configure Module 8 - Valve Positioner (8-VP) ..............................................45

Configure Module 9 - Factory Service Operations (9-FS) .....................................46

RS485 SERIAL COMMUNICATIONS INTERFACE ............................................47

Communication Format .....................................................................47

Sending Commands And Data ...............................................................47

Output Status ..........................................................................48

Receiving Data ...........................................................................50

Serial Connections .........................................................................52

Terminal Descriptions ...................................................................52

Connecting To A Host Terminal ..........................................................53

Troubleshooting Serial Communications ......................................................53

VALVE POSITION OPTION .................................................................54

Position Mode Valve Control ................................................................54

Velocity Mode Valve Control ...............................................................55

SECOND ANALOG INPUT OPTION ..........................................................56

Remote Setpoint ...........................................................................56

Flow Ratio Control .....................................................................56

Process Remote Setpoint Slave Control ....................................................56

Cascade Control ..........................................................................56

External Cascade Control ...............................................................57

Internal Cascade Control ................................................................58

PID CONTROL .............................................................................59

Proportional Band .........................................................................59

Integral Time .............................................................................59

Derivative Time ...........................................................................60

Output Power Offset (Manual Reset) .........................................................60

PID Adjustments ..........................................................................60

ON/OFF CONTROL .........................................................................62

AUTO-TUNE ................................................................................64

Initiate Auto-Tune .........................................................................65

Auto-Tune Of Secondary Output (OP2) / Main Output (OP1) Systems .............................65

Auto-Tune Of Internal Cascade Controllers ....................................................65

Auto-Tune Of External Cascade Systems (Remote Setpoint) ......................................66

APPENDIX “A” - APPLICATION EXAMPLES .................................................67

Chemical Mixing Application ...............................................................67

Flow Rate Programming Example ............................................................68

APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS .......................................69

APPENDIX “C” - TROUBLESHOOTING ......................................................73

Output Leakage Current ....................................................................75

APPENDIX “D” - MANUAL TUNING .........................................................76

Open Loop Step Response Method ...........................................................76

Closed Loop Cycling Method ................................................................77

APPENDIX “E” - CALIBRATION ............................................................78

Calibration Check .........................................................................78

Voltage Reading Check .....................................................................78

Current Reading Check .....................................................................78

Linear DC Output Check ...................................................................78

4to20mA ............................................................................78

0to10VDC ...........................................................................78

Second Input Check ........................................................................78

Second Analog Input Check ..............................................................78

Valve Positioner Check .................................................................78

Calibration ...............................................................................79

Configure Step 9 - Factory Service Operations (9-Fs) ........................................79

Voltage Calibration .....................................................................79

Current Calibration .....................................................................79

Analog Output Calibration (ANCL) .......................................................79

4to20mA .......................................................................79

0to10VDC ......................................................................79

Second Analog Input Calibration (2CAL) ..................................................80

Second Analog Input (Remote Setpoint) ...................................................80

Motorized Valve Positioner ..............................................................80

APPENDIX “F”-USER PARAMETER VALUE CHART .........................................81

APPENDIX “G” ORDERING INFORMATION ................................................84

GENERAL DESCRIPTION

The PCU Controlleraccepts eithera0to10VDCora4to20mADCinput signal,precisely scales the process signalaccording to programmablescaling points, and provides an accurate output control signal (time proportional, linear,or valvepositioning) to maintain a process at thedesired controlpoint. Acomprehensiveset ofeasyto use stepsallowsthe controller tosolve various application requirements.

Thecontroller can operateinthe PID controlmode for boththe main output and optional secondary output. On-demand auto-tune establishes the tuning constants. The PID tuning constants may be fine-tuned by the operator at any time and locked out from further modification. The controller employs a unique overshoot suppression feature that 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 can also be programmed to operate in the ON/OFF control mode with adjustable hysteresis.

Dual 4-digit displays allow viewing of the measured value and setpoint simultaneously. Front panel indicators inform the operator of the controller and output status. Replaceable and interchangeable output modules (Relay, SSR Drive, or Triac) can be installed for the main control output, Alarm output(s), Secondary output, and Valve Positioner outputs.

Optionaldual alarms canbe configured toactivate according toa variety of actions (Absolute HI or LO, DeviationHI or LO, Band IN or OUT,and Valve Fail Detect) with adjustable hysteresis. A standby feature suppresses the output during power-up until the process stabilizes outside the alarm region. An optional secondary output is available (for processes requiring cooling, pH balance, etc.) that provides increased control accuracy and response.

A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface with actuators, chart recorders, indicators, or other controllers. The type of Linear DC output is determined by the model ordered. (See Ordering Information, page 84, for available models.) The output signal can be digitally scaled and selected to transmit one of the following: % output power,measurement value deviationor setpoint value.For Linear DCcontrol applications,the adjustable outputdemand dampening, outputdeadband, and output update time parameters expand the versatility of the PCU to final control devices.

Theoptional Motorized Valve Positioner directlycontrols theposition of a valve by the use of twin outputs (open and close) to control the direction of motor rotation. The motor position defines the opening position at the valve. Two control modes are possible: position control, which makes use of the slidewirefeedbacksignal supplied withthepositioner and velocitycontrol,in whichno slidewirefeedback signalis used.Parameters areprovided toadjust the operation of the valve. These include:

- Valve activity hysteresis

- Valve update time

- Variable control dampening

- Slidewire signal fail action

- Adjustable valve position limits

The Valve Positioner PCU achieves tight process control; yet minimizes unnecessary valve activity. An alarm event output or display alarm can be programmed under loss of slidewire feedback or under valve fail detection.

The optional Second Analog Input (0 to 20 mA DC) can be configured as a Remote Setpoint signal or as a Secondary Process signal. Configuration of the Second Analog Input as a Remote Setpoint signal allows ratio control, master setpoint/multiple slave operation, and the ability to cascade the PCU with another controller (External Cascade). Configuration of the Second Input as a Secondary Process signal allows operation as a two-process cascade controller within a single unit (Internal Cascade). In either control mode,parameters are providedto scale, configure,communicate and monitor the activity of both analog inputs. A square law linearizer function can be used to linearize signals derived from flow transmitters.

The optional RS485 multi-drop serial communication interface provides two-way communication between a PCU unit and other compatible equipment such as a printer, a programmable controller, or a host computer. In multi-point applications the address number of each unit on the line can be programmed from zero to ninety-nine. Up to thirty-two units can be installed ona single pair of wires.The Setpointvalue, % Output Power, SetpointRamp Rate, etc. can be interrogated or changed, by sending the proper command code via serial communications. Alarm output(s) may also be reset via the serial communications interface option.

-1-

A programmable User Input is available with RS485, Valve Position, and Second Analog Input models. The User Input can be programmed to perform a variety of controller functions.

An optional NEMA 4X/IP65 rated bezel is available for wash down applications and similar environments, when properly installed. Modern surface-mount technology, in-house assembly and testing, and high immunity to noise interference makes the controller extremely reliable in industrial environments.

SAFETY SUMMARY

All safety related regulations, local codes and instructions that appear in themanual or on equipment mustbe observed toensure personalsafety 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.

Donot usethe PCUto directlycommand motors, valves, or other actuators notequipped withsafeguards. Todo so,can bepotentially harmfulto persons orequipment in the event of a faultto the unit. An independent and redundant temperaturelimit indicator withalarm outputsis strongly recommended.Red LionControls offersvarious units (such as an IMP, IMD1, or IMD2)that may be used for this purpose. The indicators should have input sensors and AC power feeds independent from other equipment.

-2-

INST ALLA TION& CONNECTIONS

INSTALLATION ENVIRONMENT

Theunitshould be installedin a locationthatdoes not exceedthemaximum operatingtemperature and providesgood air circulation.Placing the unitnear devices that generate excessive heat should be avoided.

Continuousexposure to directsunlight mayaccelerate the agingprocess of the bezel.

Thebezelshould be cleanedonly with asoftcloth and neutralsoapproduct. Do not use solvents.

Do not use tools of any kind (screwdrivers, pens, pencils, etc.) to operate the keypad of the unit.

STANDARD UNIT INSTALLATION

Prepare the panel cutout to the dimensions shown in Figure 1, Panel Installation & Removal. Remove the panel latch and cardboard sleeve from theunitand discard thecardboardsleeve. The unitshouldbe installed withthe bezel assembly in place. Insert the unit into the panel cutout. While holding the front of the unit in place, push the panel latch over the rear of the unit so that the tabs of the panel latch engage in the slots on the case. The panel latch should be engaged in the farthest forward slots possible. Tighten the screws evenly until the unit is snug in the panel.

NEMA 4X/IP65 UNIT INSTALLATION

Theoptional NEMA4X/IP65 PCUController providesa watertightseal in panelswith aminimum thicknessof 1/8inch. Theunits meet NEMA 4X/IP65 requirements for indoor use, when properly installed. The units are intended to be mounted into an enclosed panel. Prepare the panel cutout to the dimensionsshownin Figure 1,Panel Installation &Removal.Carefully apply the adhesive side of the panel gasket to the panel cutout. Remove the panel latch and cardboard sleeve from the unit. Discard the cardboard sleeve. The unit should be installed with the bezel assembly inplace and the bezel screws tightened slightly. Insert the unit into the panel cutout. While holding the front of the unit in place, push the panel latch over the rear of the unit so that the tabs of the panel latch engage in the slots on the case. The panel latch should be engaged in the farthest forward slot possible. To achieve a proper seal,tighten thelatch screwsevenly untilthe unitis snugin thepanel (Torque to approximately 7 in-lbs [79 N-cm]). Do NOT over-tighten the screws.

Note: The installation location of the controller is important. Be sure to keep it

away from heat sources (ovens, furnaces, etc.), away from direct contact with

caustic vapors, oils, steam, or any other process by-products in which

exposure may affect proper operation. Caution: Prior to applying power to the controller, the internal AC power

selector switch mustbe set. Damage tothe controller may occurif the switch is

set incorrectly.

-3-

Figure 1, Panel Installation & Removal

-4-

UNIT REMOVAL PROCEDURE

Toremove aNEMA 4X/IP65or standardunit fromthe panel,first unscrew andremove the panel latch screws. Insert flat blade screwdriversbetween the latch and the case on the top and bottom of the unit, so that the latches disengage from the grooves in the case. Push the unit through the panel from the rear.

REMOVING BEZEL ASSEMBLY

The bezel assembly, shown in Figure 2, must be removed from the case to install or replace output modules, or to set the 115/230 VAC selector switch. Disconnectpower to theunit and tothe output controlcircuits to eliminatethe potential shock hazard when removing the bezel assembly. To remove a standard bezel assembly (without bezel securing screws), press the latch under the lower bezel lip and withdraw the bezel assembly. To remove the sealedNEMA 4X/IP65 bezel assembly, loosen the twobezel securing screws untila slight“click” is felt (the screws are retained in thebezel) andwithdraw the assembly.

Caution: The bezel assembly contains electronic circuits that are damaged by

static electricity. Before removing the assembly, discharge stray static

electricity on yourbody by touching anearth ground point. It isalso important

that the bezel assembly be handled only by the bezel itself. Additionally, if it is

necessary to handle a circuit board, be certain that hands are free from dirt,

oil, etc., to avoid circuit contamination that may lead to malfunction. If it

becomes necessaryto ship the unit for repairs, placethe unit in its case before

shipping it.

Figure 2, Bezel Assembly

INSTALLING BEZEL ASSEMBLY

To install the standard bezel assembly, insert the assembly into the case until the bezel latch snaps into position.

To install the NEMA 4X/IP65 bezel assembly,insert the assemblyinto the case and tighten the bezel screws uniformly until the bezel contacts the case and then turn each screw another half turn to insure a watertight seal (do not over-tighten screws).

Caution: When substituting or replacing a bezel assembly, be certain that it is

done with the same model using the same Output Modules. Damage to the

controller may result if the unit’s output modules are not the same. A NEMA

4X/IP65 and a standard bezel assembly are NOT interchangeable.

OUTPUT MODULES

The main control, optional Alarm, optional Secondary output andoptional Valve Position control output sockets must be fitted with the appropriate output module. Output modules are shipped separately and must be installed by the user.

Output Module Restrictions

Withsome models,the Alarm outputs and ValvePosition outputsshare the same common terminal. When using these models, the same type of output modules should be installed in these positions.

-5-

Installing Output Modules

To install an output module into the controller, remove the bezel assembly from the case (See Removing Bezel Assembly, page 5). Locate the correct output module socket (OP1, AL1, or AL2/OP2, see Figure 6, Hardware, or label outside of case) and plug the output module into the socket. No re-programming is required. If changing an output module type, be sure the appropriate output interface wiring changes are made. Re-install the bezel assembly when complete.

Note: For Valve Positioner models, the circuit board markings have the

following meaning:

AL1 - Open Output

AL2/OP2 - Close Output

OP1 - Alarm #1 Output

OUTPUT MODULE “OUTPUT ON” STATE

Relay Normally open contact is closed Logic/SSR Drive Source is active. Triac Solid state switch is closed.

Typical Connections

Figure 3, Relay Module

Relay:

Type:Form-C(Form A withsomemodels. See OrderingInformation.) Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @

120 VAC (inductive load).

Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing

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

Figure 4, Logic/SSR Drive Module

Logic/SSR Drive:

Type: Non-isolated switched DC, 12 VDC typical Drive: 45 mA Max. Can drive multiple SSR Power Units.

Figure 5, Triac Module

Triac:

Type: Isolated, Zero Crossing Detection. Rating:

Voltage: 120/240 VAC. Max. Load Current: 1 amp @ 35°C

0.75 amp @ 50°C

Min. Load Current: 10 mA Off State Leakage Current: 7 mA maximum @ 60 Hz Operating Frequency: 20 to 400 Hz Protection: Internal Transient Snubber, Fused.

SELECT AC POWER (115/230 VAC)

TheAC power to the unitmust be selectedfor either115 VAC or230 VAC. The selector switch is located inside the case near the rear of the unit on the main circuit board (see Figure 6, Hardware, or label on outside of case). The unit is shipped from the factory with the switch in the 230 VAC position.

Caution: Damage to the controller may occur if the AC selector switch is set

incorrectly.

-6-

Figure 6, Hardware

EMC INSTALLATION GUIDELINES

Although this unit is 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 electrical noise, source or coupling method into the unit may be different for various installations. In extremely high EMI environments, additional measures may be needed. The unit becomes more immune to EMI with fewer I/O connections. Cable length, routing and shield termination are very importantand can mean the difference between a successful or a troublesome installation. Listed below are some EMC guidelines for successful installation in an industrial environment.

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

connected to protective earth.

2.Use shielded (screened) cables forall Signal andControl inputs.The shield

(screen) pigtail 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 only at the panel where the unit is mounted to earth

ground (protective earth).

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

when the noise source frequency is above 1 MHz.

c. Connect the shield to common of the unit and leave the other end of the

shield unconnected and insulated from earth ground.

3.Never runSignal orControl cablesin the same conduit or raceway with AC

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

heaters, etc. The cables should be run in 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.

4.Signalor Control cableswithinan enclosure shouldberouted as farawayas

possible from contactors, control relays, transformers, and other noisy

components.

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

devices, such as ferrite suppression cores, is effective. Install them on

Signal and Control cables as close to the unit as possible. Loop the cable

through the core several times or use multiple cores on each cable for

additionalprotection. Install linefilters onthe power inputcable to theunit

-7-

tosuppress power line interference. Installthem near thepower entrypoint of the enclosure. The following EMI suppression devices (or equivalent) are recommended: Ferrite Suppression Cores for signal and control cables:

Fair-Rite # 0443167251 (RLC #FCOR0000) TDK # ZCAT3035-1330A Steward #28B2029-0A0

Line Filters for input power cables:

Schaffner # FN610-1/07 (RLC #LFIL0000) Schaffner # FN670-1.8/07 Corcom #1VR3

Note: Reference manufacturer’s instructionswhen installinga line filter.

6. Long cable runs are more susceptible to EMI pickup than short cable runs. Therefore, keep cable runs as short as possible.

7. Switching of inductive loads produces high EMI. Use of snubbers across inductive loads suppresses EMI. Snubbers:

RLC #SNUB0000

WIRING CONNECTIONS

After the unit has been mechanically mounted, it is ready to be wired. 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. It is recommendedthat power supplied to the unit (AC or DC) be protected by a fuse or circuit breaker.

Allwiring connectionsare madeon a fixed terminal block. When wiring the unit, use the numbers on the label to identify the position number with the proper function. Strip the wire, leaving approximately 1/4" (6 mm) bare wire exposed (stranded wires should be tinned with solder). Insert the wire into the terminal and tighten the screw until the wire is clamped tightly. Each terminal canacceptup to two,18-gagewires. Wire eachterminalblock in thismanner.

Figure 7, 4-20 mA Connection

Figure 8, 0-10 V Connection

-8-

Valve Positioner Wiring

Units with Valve Positioner option have three output connections for controlling the valve motor and three input connections for slidewire feedback. The valve motor output connects to terminals labeled “Valve Position Outputs”, terminals 1, 2 and 3. See Figure 9, Valve Positioner Wiring for more details. Terminal 1 is the Valve motor supply common. Terminal 2 is the Valve Close or CW output. Terminal 3 is the Valve Open or CCW output. The valve motor must be fused with a suitable value.

Figure 9, Valve Positioner Wiring

Although RC snubbers are employed inside the controller to suppress inductive“kicks” from the motor, itmay be necessaryto takefurther action to reduce noise effects:

1) Use Triac Output Modules wherever possible. The Triac device

significantly reduces radiated EMI (Electromagnetic Interference).

The Triac Output Module also does not suffer from mechanical wear of the contacts.

2) Use RC snubbers directly across the valve motor.

3) Use a separate AC supply for the valve motor. Where possible, the valve motor control outputs and the slidewire

feedback input routing should be physically separated. Noise interference from the outputs could couple into the slidewire feedback inputs, disrupting proper operation.

The slidewire feedback inputs connect to the terminals labeled “Slidewire

Feedback Inputs”. The terminal placement varies with each model, see the controller label for the actual terminals. For Velocity mode valve control the slidewire feedback inputs are not necessary.

In some cases, it may be desirable to have an independent valve position

indicator. Red Lion Controls Model IMD1 can be wired in parallel with the slidewire input’s Wiper and Comm. terminals for this purpose. The approximate0to 0.9V signalcanbe scaled toindicatepercent valve position.

Linear DC Output Wiring

Units with Linear DC output option have two terminals to outputa4to20

mA or 0 to 10 VDCsignal. The type of LinearDC output is determined by the model ordered. (See Ordering Information page 84, for available models.) These terminals are labeled “4-20 mA (or 0-10 VDC) Analog Output Option, Out+ and Out-”. The common of this output is isolated from main input common , but is not isolated from the Second Analog Input Option common. For proper operation always keep these commons isolated.

Second Analog Input Wiring

Unitswith SecondAnalog Input option have two input terminalsto receive

a4to 20 mAsignal.These terminals arelabeled“Second Input, 4-20mA+and 4-20 mA-”.Terminal placement varies with model. See unit label for actual terminals.The commonof thisinput isisolated frommain inputcommon, but is not isolated from the Linear DC Output common. For proper operation always keep these commons isolated.

-9-

Program Disable Or User Input Wiring

Some models have Terminal #7 as the User Input, which is programmable for a variety of functions. Other models have Terminal #7 dedicated to the program disable function. Any form of mechanical switch may be connected to terminal #7. Sinking open collector logic with less than 0.7 V saturation may also be used (no pull-up resistance is necessary).

Note: Do not tie the commons of multiple units to a single switch. Use either a

multiple pole switch for ganged operation or a single switch for each unit.

AC Power Wiring

PrimaryAC power is connected tothe separate twoposition terminalblock labeled AC. To reduce the chance of noise spikes entering the AC line and affecting the controller, an AC feed separate from that of the load should be used to power the controller. Be certain that the AC power to the controller is relatively “clean” and within the -15%, +10% variation limit. Connecting powerfrom heavilyloaded circuits or circuits that also powerloads thatcycle on and off, (contacts, relays, motors, etc.) should be avoided.

-10-

FRONT PANELDESCRIPTION

The front panel bezel material is flame and scratch resistant, tinted plastic. An optional NEMA 4X/IP65 bezel version is available that meets NEMA 4X/IP65 requirements, when properly installed. There are two 4-digit LED displays, a red upper Main Display and a lower green Secondary Display.

There are up to six annunciators depending on options installed, with red backlighting, that illuminate to inform the operator of the controller and output status. See Figure 10, Front Panel for a description of the available annunciators.

Four front panel buttons are used to access different modes and parameters. The following is a description of each button.

BUTTON FUNCTIONS

DSP - In the normal operating

mode, the Display (DSP) button

is used to select one of the

operational parameters in the

secondary display. In the

Configuration Parameter

Modes, pressing this button

causes the unit to exit (escape) to the normal operating mode with no

changes made to the selected parameter. UP, DN - In the normal operating mode, the Up/Down buttons can be used to

directly modify the setpoint value or % output power (manual mode only),

Figure 10, Front Panel

when viewed in the secondary display. Otherwise, the parameter must be called to alter the value.

PAR - The Parameter (PAR) button is used to access, enter the change, and

scroll through the available parameters in any mode.

-11-

OPERA TION OVERVIEW

CONTROLLER POWER-UP

Upon applying power, the controller delays control action and process indication for five seconds to perform several self-diagnostic tests and displaybasic controller information. Initially, the controller illuminatesboth displays and all annunciators to verify that all display elements are functioning. The controller then displays the programmed input type in the main display. Concurrently, it displays the current revision number of the operating system software in the bottom display. The controller checks for correctinternal operationand displays an error message (E-XX) ifan internal fault is detected (see Troubleshooting, page 73, for further information).

Upon completion of this sequence, the controller begins control action by displaying the process value and updating the outputs based upon the PID control calculation.

CONTROLLER POWER DOWN

At power down, the steady statecontrol value as well asall parameters and control modes are saved, to provide a quick and predictable process response on the next power-up.

When powering down the process, it is important to power down the controller at the same time. This prevents the reset action of the controller from shifting the proportional band while the process signal is dropping and prevents excessive overshoot on the next process start-up.

PROCESS START-UP

After starting the process, the controller’s PID settings must be initially “tuned” to the process for optimum control. Minimal tuning consists of adjusting the Proportional Band, Integral Time, and Derivative Time parameters to achieve the optimum response to a process disturbance. The controller can be tuned once, but must be re-tuned if the process has been changed significantly. Several options exist for tuning these parameters: A)Usethe controller’s built-inAuto-Tunefeature (see Auto-Tune,page64). B) Use a manual tuning technique (see Manual Tuning, page 76). C) Use a third party tuning software package (generally expensive and not

always precise). D) Use values based on control loop experience, calculated values or values

from a similar process.

If the controller is a replacement, the PID settings from the unit being replaced may be used as good initial values. Be sure to consider any differencesin theunits andthe PIDsettings whenreplacing. ThePID settings maybe fine tunedby using thetechniques outlined inthe PID Controlsection. Aftertuning the controller to theprocess, itis important to power theload and the controller at the same time for best start-up response.

MANUAL (USER) & AUTOMATIC OPERATION

The controller can be transferred between Automatic control (closed loop; PID or ON/OFF control) and Manual control (open loop). In the Hidden Function Mode, the “trnf” parameter allows the operator to select thedesired operatingmode. Toallow frontpanel switching between control modes, program the transfer (trnf) parameter to “Enbl” in the Lockout Module.The user input or RS485 serial interfaceoption may also be used to perform the auto/manual transferfunction, independent of the setting in the Lockout Module.

Manualoperation provides directcontrol of theoutput(s) from 0to +100%, or -100% to +100% if the secondary output is installed. For Valve Positioner models with slidewire feedback, this mode allows manual valve positioning. TheMAN (REM forRemote Setpoint models)annunciator flashes toindicate that the unit is in manual operation.

When transferring the controller mode from/to automatic, the control power output(s) remain constant, exercising true “bumpless” transfer. When transferringfrom manual to automatic, the power initially remains steadybut integral action corrects (if necessary) the closed loop power demand at a rate proportional to the Integral Time. The programmable high and low power limit values are ignored when the unit is in manual operation.

-12-

REMOTE AND LOCAL SETPOINT OPERATION

The controller setpoint mode can be switched between Local Setpoint operation and Remote Setpoint operation. In the Hidden Function Mode, the “SPSL”parameter allowsthe operator to select the desired setpointoperating mode. To allow front panel switching between setpoint modes, program the setpoint select parameter (SPSL) to “Enbl” in the Lockout Module. The user input or RS485 serial interface option may also be used to perform the setpointselectionfunction, independent ofthesetting in theLockoutModule. Front panel annunciator REM is on for Remote setpoint operation and is off for Local setpoint operation. When transferring the controller mode from/to the setpoint modes, various controller response options are available (see SPtr parameter, page 37).

-13-

CONFIGURATION OF PARAMETERS

As supplied from the factory, the controller parameters have been programmed to the values listed in the Programming Quick Reference Tables.Theuser must modifythevalues, if necessary,tosuit the application.

Operation and configuration of the controller is divided into five distinct operational/programming modes to simplify the operation of the controller: Normal Display Mode, Unprotected Parameter Mode, Protected Parameter Mode, Hidden Function Mode, and Configuration Parameter Modules. See Figure 11, Operational/Programming Modes.

Figure 11, Operational/Programming Modes

-14-

PARAMETER ENTRY

The PAR button is used to select the desired parameter. To modify the parameter setting, use the UP and DOWN buttons. Press PAR to enter the new value. The controller progresses to the next parameter. In a Configuration Parameter Module, pressing the DSP button causes the new value to be rejected, the controller displays “End”, and returns to the Normal Display Mode.For those parameters outside the Configuration Parameter Modules, the new value takes effect and is committed into controller memory WHILE the value is keyed in. The following is a list of commonly modified parameters:

Setpoint Output Power Output Power Offset Proportional Band Integral Time Derivative Time Proportional Band #2 Integral Time #2 Derivative Time #2 Directed Setpoint (Cascade) Ratio Bias Alarm 1 Value Alarm 2 Value

Note: While in a Configuration Parameter Module, all new parameters are

rejected and the old ones recalled if power is removed from the controller. If

power is removed while modifying any parameter, be certain to check the

parameter for the proper value.

NORMAL DISPLAY MODE

In the normal display mode, the process value is always displayed in the main display. By successively pressing the DSP button, one of these operational parameters can be viewed in the secondary display (model dependent):

Setpoint % Output Power Second Analog Input (Remote Setpoint) Process Setpoint Deviation

Each of these displays can be independently locked out from appearing or from being modified by the user (see Lockouts Module,page 27). Only from the normal display mode can access be gained to the other modes (Unprotected, Protected, or Hidden).

MODIFYING A SECONDARY DISPLAY PARAMETER FROM THE FRONT PANEL

Thecontroller must be in thenormal displaymode to modify the secondary displayparameters. The Setpointvalueand % outputpower (in manualmode) are the two parameters which may be modified. The other parameters are read-out values only.

Setpoint Value - Use the up and down arrow buttons to modify the setpoint

value when viewed, if not locked. If locked, the setpoint can be changed in

the unprotected mode when “SP” is viewed, independent of viewing in the

secondary display. The setpoint value is confined to the programmable

setpoint limit values (SPLO & SPHI, Input Module 1). %Output Power -The %Output Power canonly bechanged when theunit is

in the manual mode. See Manual (User) and Automatic Operations, page

12. The annunciator % PW lights, and the Manual annunciator flashes

when viewed. Use the up and down arrow buttons to modify the % Output

Power if not locked. If locked, the % output power can be changed in the

unprotected mode when “OP” is viewed, independent of viewing in the

secondarydisplay. The %output power isnot confined totheprogrammable

output power limit values (OPLO & OPHI, Output Module 2).

-15-

UNPROTECTED PARAMETERMODE

The Unprotected Parameter Mode is accessed by pressing the PAR button from the normal display mode with program disable inactive. In this mode, the operator has access to the list of the most commonly modified controller parameters. At the end of the list, a configuration “access point” allows the operator to enter the configuration parameter modules. These modules allow access to the fundamental set-up parameters of the controller. When the program list has been scrolled through, the controller displays “End” and returns to the normal display mode. The unit automatically returns to the normal display mode if no action is taken.

UNPROTECTED PARAMETER MODE REFERENCE TABLE

Display Parameter

SP Setpoint Confined to

OPOF %Output

Power Offset

OP Output

Power

Prop Proportional

Band

Intt Integral

Time

dErt Derivative

Time

Pb-2 Proportional

Band #2 (Secondary)

It-2 Integral

Time #2 (Secondary)

Range and Units (Factory Setting Value)

range of limits SPLO, SPHI, (0)

-99.9% to

100.0% (0.0)

-99.9% to

100.0% (0.0)

0.0 to 999.9% of scaled input range (4.0)

0 to 9999 sec. (120)

0 to 9999 sec. (30)

0.0 to 999.9% of Scaled input range (4.0)

0 to 9999 sec (0)

Appears only if setpoint value is locked (LOC) or read only (rEd).

Appears only if integral time (Intt) = 0 and controller is in automatic mode.

Appears only if controller is in user (manual) mode and % output power is locked (LOC) or read only (rEd). This parameter is not limited to output power limits (OPLO & OPHI).

0.0% is ON/OFF control. If using ON/OFF mode, set control hysteresis appropriately.

0 is off. This parameter does not appear if proportional band =

0.0%. 0 is off. This parameter does not

appear if proportional band =

0.0%.

0.0% is ON/OFF control. Second Analog Input models only.

0 is off. This parameter does not appear if proportional band #2 =

0.0%. Second Analog Input models only.

Description/

Comments

-16-

Display Parameter

dt-2 Derivative

Time #2 (Secondary)

SP-2 Internal

Cascade Directed Setpoint

rtio Remote

Setpoint ratio multiplier

bIAS Remote

Setpoint bias offset

AL-1 Alarm 1

Value

AL-2 Alarm 2

Value

CNFP Configuration

Access Point

End Unit returns

to Normal Display Mode

Range and Units (Factory Setting Value)

0 to 9999 sec (0)

-999 to 9999 (N/A)

0.001 to 9.999 (1.000)

-999 to 9999 (0)

____ Brief display message.

0 is off. This parameter does not appear if proportional band #2 = 0.0%. Second Analog Input models only.

Second Analog Input models only. Read only parameter.

Second Analog Input models.

Alarm option models only.

This parameter does not appear if the alarm option is not specified, the secondary output option is installed, or if locked (LOC).

Return to normal display mode. Enter Configuration modules.

1-IN

Configure input parameters.

2-OP

Configure output parameters.

3-LC

Configure parameter lockouts.

4-AL

Configure alarm parameters (opt.)

5-02

Configure secondary output (opt.)

6-SC

Configure serial communication parameters (optional). Configure second analog input

7-2N

parameters (optional) Configure valve positioner

8-VP

parameters (optional)

Factory service operations (Qualified

9-FS

technicians only)

Description/

Comments

-17-

PROTECTED PARAMETERMODE

The Protected Parameter Mode is accessed from the normal display mode by pressing the PAR button with program disable active. In this mode, the operator has access to the list of the most commonly modified controller parameters that have been “unlocked” in the configuration parameter lockouts module. Depending on the code number entered in the lockout

PROTECTED PARAMETER MODE REFERENCE TABLE

Display Parameter

Prop Proportional

Band

Intt Integral

Time

dErt Derivative

Time

Pb-2 Proportional

Band #2 (Secondary)

It-2 Integral

Time #2 (Secondary)

dt-2 Derivative

Time #2 (Secondary)

SP-2 Internal

Cascade Directed Setpoint

Range and units (Factory Setting Value)

0.0 to 999.9% of scaled input range (4.0)

0 to 9999 sec. (120)

0 to 9999 sec. (30)

0.0 to 999.9% of scaled input range (4.0)

0 to 9999 sec. (0)

-999 to 9999

(N/A)

Description/Comments

0.0% is ON/OFF control. If using ON/OFF mode, set control hysteresis appropriately. This parameter does not appear if locked (LOC).

0 is off. This parameter does not appear if proportional band = 0.0% or locked (LOC).

0.0% is ON/OFF control. Second Analog Input models only.

0 is off. This parameter does not appear if proportional band #2=

0.0%, or if locked (LOC). Second Analog Input models only.

0 is off. This parameter does not appear if proportional band #2=

0.0%, or if locked (LOC). Second Analog Input models only.

Second Analog Input models only. Read only parameter.

module, access to the unprotected parameter mode and hence, the configuration parameter modules is possible. The controller returns to the normal display mode if the unprotected mode and configuration modules cannotbeaccessed. This modecannot be accessedifall parameters arelocked out in Configuration Module 3.

Display Parameter

rtio Remote

setpoint ratio multiplier

bIAS Remote

setpoint bias offset

AL-1 Alarm 1

value

AL-2 Alarm 2

value

Code Access

code to unprotected mode

End Unit returns

to normal display mode.

Range and units (Factory Setting Value)

0.001 to 9.999 (1.000)

-999 to 9999 (0)

0to250 (0)

Description/Comments

Second Analog Input models only.

Alarm option models only.

This parameter does not appear if the alarm option is not specified, the secondary output option is installed, or if locked (LOC).

To gain access to unprotected mode, enter the same value for Code as entered in parameter lockouts. This parameter does not appear if zero is entered in code parameter lockout.

Brief display message display mode.

-18-

FRONT PANELPROGRAM DISABLE

There are several ways to limit the programming of parameters from the frontpanel buttons. Thesettings of theparametersin the LockoutModule, the code number entered, and the state and/or function programmed for the User Input (Terminal #7) affect front panel access.

It is possible to have the program disable function on versions with the User Input, even if the User Input is not programmed for program disable (PLOC),by the useofa code number.Versions that donothave the UserInput are dedicated to the program disable function.

The following charts describe the possible program disable settings depending on your model.

MODELS WITH USER INPUT

User Input State Code Number Description

Inactive or User Input not programmed for PLOC

Active with User Input programmed for PLOC

OR User Input not programmed for PLOC

Note: A universal code number 222 can be entered to gain access to the

unprotected mode and configuration modules, independent of the programmed code number.

0 Full access to all modes and

0 Access to protected parameter

Any # between

1 & 250

parameter modules.

mode only. Code number does not appear.

Access to protected parameter mode. Correct programmed code number allows access to unprotected parameter mode and configuration modules.

MODELS WITH PROGRAM DISABLE

Program Disable Code Number Description

Inactive 0 Full access to all modes and

Active 0 Access to protected parameter

Active Any # between

1 & 250

Note: A universal code number 222 can be entered to gain access to the

unprotected mode and configuration modules, independent of the programmed code number.

parameter modules.

mode only. Code number does not appear.

Access to protected parameter mode. Correct programmed code number allows access to unprotected parameter mode and configuration modules.

-19-

HIDDEN FUNCTION MODE

The Hidden Function Mode is only accessible from the normal display mode by pressing and holding the PAR button for three seconds. These functions must be unlocked in ConfigurationModule #3. Factory settings are locked. In this mode, these controller functions can be performed.

Local/Remote Setpoint Selection Automatic/Manual Transfer Initiate/Cancel Auto-tune Reset Alarm Events

Each function may be “locked out” in the Configuration parameter lockoutsmodule. The PAR button is used toscroll to the desired function and the up and down buttons are used to select the operation. Pressing the PAR button while the function is displayed executes the function, and returns the unitto the normaldisplay mode.Pressing the DSPbutton exitsthis mode with no action taken. The unit automatically returns to the normal display mode if no action is taken.

HIDDEN FUNCTION MODE REFERENCE TABLE

Display Parameter

SPSL Select

Local or Remote Setpoint

trnF Transfer

mode of operation

tUNE Auto-tune

invocation

ALrS Alarm reset UP key resets Alarm 1

Range and Units

(Factory Setting Value)

LOC - Local Setpoint rE_t - Remote Setpoint (LOC)

Auto - Automatic control User - Manual control (Auto)

Yes: starts the

auto-tune sequence.

No: terminates the

auto-tune sequence.

Prl - tune primary

(Cascade)

SEC - tune secondary

(Cascade)

(NO)

DOWN key resets

Alarm 2

Description/Comments

Appears only for models with Second Analog Input. “SPtr” determines nature of controller response.

This step does not appear if locked (LOC). Exits to normal display mode if executed.

This step does not appear if locked (LOC) or exits to normal display mode if executed. These parameters appear only if Second Analog Input Internal Cascade is selected.

This step does not appear if alarm option not installed, if locked (LOC) or previous step performed.

-20-

CONFIGURA TION PARAMETER MODULES

Accessible from the unprotected parameter mode, the configuration parameter modules allow the operator access to the controller’s fundamental set-up parameters. There are nine possible configuration stages that can be accessed. At the configuration stage access point “CNFP”, the operator uses the UP & DOWNarrow buttons to select the desired configuration parameter module. Press the PAR button to enter the module where the settings can be viewed or modified. The PAR button is used to scroll through the parameters and the UP and DOWN buttons are used to modify the parameter value. The PAR button enters the desired choice, advancing to the next parameter. The operator can press the DSP button to exit (escape) without modifying the parameter. The unit returns to the normal display mode. After the parameters in a module are viewed or modified, the unit returns to the configuration access point, allowing access to other modules.

INPUT MODULE (1- IN)

The controller has several input set-up parameters that must be programmed prior to setting any other controller parameters.

Input Type (tYPE)

Select the signal input type Voltage (VOLt), or Current (Curr). The appropriate signal input terminal for voltage is #8 and for current is #9.

Square Root Linearization (root) (Optional)

The main input can be linearized by use of the square root function. See Square Root Linearization, page 35, for a complete description of the square root function.

The“root” parameter inProgram Module1 applies tothe maininput, and the “root” parameter in Program Module 7 applies to the Second Analog Input.

Decimal Point Position (dCPt)

Select the desired decimal point position for the scaled display. The selected decimal point position appears in the following parameters; rnd, dSP1, dSP2, SPLO, SPHI, SP, AL1, AL2, db-2, AHYS, and CHYS.

0.0

0.00

0.000

Rounding Increment ( rnd)

Rounding values other than “1” causes the scaled number to ‘round’ to the nearest rounding increment selected (ie. rounding of‘5’ cause ‘122’to round to ‘120’ and ‘123’ to round to ‘125’). If the process is inherently jittery, the display value may be rounded to a higher value than “1”. If the range of the process exceeds the required resolution, (ex. 0-1000 PSI, but only 10 PSI resolution required), a rounding increment of 10 will effectively make the display more stable.

This programming step is usually used in conjunction with programmable digital filtering to help stabilize display readings (If display stability appears to be a problem and the sacrifice in display resolution is unacceptable, program higher levels of digital filtering or increase the level of process dampening). Rounding increments of 10, 20, 50, and 100 may also be used to add “dummy zeroes” to the scaled readings, as desired.

1 2 5 10 20 50 100

The rounding increment is for the controller’s display only and does not affect (degrade) the control accuracy of the unit.

-21-

+ 67 hidden pages

Red Lion PCU User Manual

Table of Contents