Super Systems 9010 User Manual
eSPP Recipe Programmer
Series 9010
OPERATIONS MANUAL
Super Systems Inc.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060
800-666-4330
Fax: 513-772-9466
www.supersystems.com
Super Systems Inc. help desk:
1-800-666-4330
Table of Contents
Installation Safety Requirements ......................................................................................................... 5
Chapter 1 - INSTALLATION .................................................................................................................. 8
Overview .................................................................................................................. 8
Mounting .................................................................................................................. 8
Dimensional Drawings .............................................................................................. 9
24V DC Power Supply Dimensions .............................................................................. 9
12” Operator Interface Cutout dimensionsWiring ...................................................... 10
Wiring .................................................................................................................... 11
Pin Out ................................................................................................................... 12
Ancillary Items ....................................................................................................... 12
ETHERNET Connections .......................................................................................... 13
Setup ..................................................................................................................... 13
Chapter 2 - OPERATION .................................................................................................................... 14
Overview ................................................................................................................ 14
Status Display ........................................................................................................ 14
Menu ..................................................................................................................... 14
Chart ..................................................................................................................... 15
Chart Sub Menu ...................................................................................................... 15
Recipe.................................................................................................................... 16
Loops ..................................................................................................................... 18
Chapter 3 - CONFIGURATION ............................................................................................................ 19
Logs ...................................................................................................................... 19
Auxiliary Analog Input ............................................................................................. 19
Manual Event Control .............................................................................................. 20
Shutdown ............................................................................................................... 20
Recipe Edit ............................................................................................................. 20
Load T/C Configuration ........................................................................................... 21
Trend Chart Edit ..................................................................................................... 21
Communications Setup ........................................................................................... 22
Instrument Assignments ......................................................................................... 23
Zone Assignments .................................................................................................. 25
Furnace Setup ........................................................................................................ 25
Security ................................................................................................................. 26
Alarms ................................................................................................................... 27
Event Hold/Reset .................................................................................................... 27
Aux Analog Input Setup ........................................................................................... 28
Configuration ......................................................................................................... 28
T/C Correction Curves ............................................................................................. 30
Generic Instruments ............................................................................................... 31
Aux Input Offset Correction ..................................................................................... 32
Chapter 4 - Series 9010 “Opcodes”..................................................................................................... 33
SSi Manual Series 9010 – eSPP Programmer Page 2
Programmer Description ........................................................................................ 33
Opcodes ................................................................................................................. 33
Wait ....................................................................................................................... 42
Wait Up .................................................................................................................. 43
Wait Down .............................................................................................................. 44
Wait in a Guaranteed Soak ....................................................................................... 45
Guarantee High Assignment .................................................................................... 46
Guarantee Low Assignment ..................................................................................... 47
Chapter 5 - APPLICATIONS INFORMATION ......................................................................................... 48
Standard Event Assignments ................................................................................... 48
Appendix A – Slave Instrument Mapping ............................................................................................. 49
Atmosphere Instruments ........................................................................................ 50
Temperature Instruments ....................................................................................... 53
Events Instruments ................................................................................................. 57
Appendix B – Series 9010 Wiring Diagram .......................................................................................... 60
Appendix C – Using MiniBatch with the 9010 Touchscreen ................................................................... 61
Appendix D – Data and Flash Card Management ................................................................................. 63
Appendix E – Sample Recipe .............................................................................................................. 66
SSi Manual Series 9010 – eSPP Programmer Page 3
WARNINGS !!
Never remove the flashcard when the operator interface is ON. Follow the
shutdown procedure in this manual. After you see the Windows desktop
you can turn the power to the operator interface OFF by sliding the power
switch to the left or disconnecting the 24VDC. This switch is located right
above the connector bringing 24VDC power to the unit. This does not turn
the controllers off.
SSi Manual Series 9010 – eSPP Programmer Page 4
!
!
Installation Safety Requirements
Safety Symbols
Various symbols are used on the instrument; they have the following meaning:
Caution, (refer to the accompanying documents)
Functional earth (ground) terminal!
Personnel
Installation must only be carried out by technically qualified personnel.
Enclosure of live parts
To prevent hands or metal tools from touching parts that may be electrically live (powered), the controller
must be installed in an enclosure.
Caution:
The functional earth connection is required for safety purposes and to ground RFI filters.
Live sensors
Do not connect live (powered) sensors to any signal input on the controller. Live sensors are
sensors that must be connected to the main's supply. The controller has transient protection
circuits connected between the inputs and the earth connection that might be damaged by
live (powered) sensors.
SSi Manual Series 9010 – eSPP Programmer Page 5
Wiring
It is important to connect the controller in accordance with the wiring data given in this handbook. Take
particular care not to connect AC supplies to the low voltage power supply input. Use copper wires for
24V DC power supply to the instrument. Ensure that the wiring of installations comply with all local wiring
regulations. For example in the United Kingdom use the latest version of the IEE wiring regulations,
(BS7671). In the USA use NEC Class 1 wiring methods.
Power Isolation
The installation must include a power isolating switch or circuit breaker. This device should be in close
proximity to the controller, within easy reach of the operator and marked as the disconnecting device for
the instrument.
Earth leakage current
Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This may affect the design of an
installation of multiple controllers protected by Residual Current Device, (RCD) or Ground Fault Detector,
(GFD) type circuit breakers.
Over current protection
To protect the internal PCB tracking within the controller against excess currents, the AC power supply to
the controller and power outputs must be wired through a fuse or circuit breaker specified in the
technical specification.
Voltage rating
The maximum continuous voltage applied between any of the following terminals must not exceed 24V DC
relay or triac output to logic, DC or sensor connections;
any connection to ground.
The controller should not be wired to VAC. The 24V DC power supply voltage across the connections and
between the power supply and ground must not exceed 2.5kV. Where occasional voltage over 2.5kV are
expected or measured, the power installation to both the instrument supply and load circuits should
include a transient limiting device.
These units will typically include gas discharge tubes and metal oxide varistors that limit and control
voltage transients on the supply line due to lightning strikes or inductive load switching. Devices are
available in a range of energy ratings and should be selected to suit conditions at the installation.
SSi Manual Series 9010 – eSPP Programmer Page 6
Conductive pollution
Electrically conductive pollution must be excluded from the cabinet in which the controller is mounted.
For example, carbon dust is a form of electrically conductive pollution. To secure a suitable atmosphere
in conditions of conductive pollution, fit an air filter to the air intake of the cabinet. Where condensation is
likely, for example at low temperatures, include a thermostatically controlled heater in the cabinet.
Over-temperature protection
When designing any control system it is essential to consider what will happen if any part of the system
should fail. In temperature control applications the primary danger is that the heating will remain
constantly on. Apart from spoiling the product, this could damage any process machinery being
controlled, or even cause a fire. Reasons why the heating might remain constantly on include:
the temperature sensor becoming detached from the process;
thermocouple wiring becoming a short circuit;
the controller failing with its heating output constantly on;
an external valve or contactor sticking in the heating condition;
the controller set point set too high.
Where damage or injury is possible, we recommend fitting a separate over temperature protection unit
with an independent temperature sensor, which will isolate the heating circuit. Please note that the
alarm relays within the controller will not give protection under all failure conditions.
Installation requirements for EMC
To ensure compliance with the European EMC directive certain installation precautions are necessary as follows:
When using relay or triac outputs it may be necessary to fit a filter suitable for suppressing the emissions.
The filter requirements will depend on the type of load. For typical applications we recommend Schaffner
FN321 or FN612.
Routing of wires
To minimize the pick-up of electrical noise, the wiring for low voltage dc should be routed away from high-current
power cables. Where it is impractical to do this, use shielded cables with the shield grounded at one end.
SSi Manual Series 9010 – eSPP Programmer Page 7
Chapter 1 - INSTALLATION
Overview
The eSPP/9010 is a programmable instrument that is intended to connect to remote PID controllers via
RS 485. With the use of the 9010 a simple single loop temperature and carbon controller can be used as
a fully programmable control system with ramps, soaks, events and alarms. Additionally the 9010 allows
for zone control for up to five instruments commonly used on continuous furnace applications. The 9010
allows for offsets between zones and includes a digital charting of the process at the touch screen. The
9010 can also serve as a data concentrator for various 485 instrumentation. These instruments can then
be controlled or communicated via Ethernet to a supervisor software package such as SuperData.
The product is available in three different screen sizes. 3.5”, 5.7” and 12”.
Mounting
The Series 9010 Operator Interface mounts into a panel or on a plate by using the enclosed mounting
brackets. A rectangular cutout is required; the size of the cutout is determined by the operator interface
size. These units, along with an optional ADAM module, will mount on a commercially available DIN rail.
This can be mounted on the sub-panel on the side of an enclosure for the convenience of the control
system.
SSi Manual Series 9010 – eSPP Programmer Page 8
Dimensional Drawings
Series 9010 Controller Dimensions
24V DC Power Supply Dimensions
SSi Manual Series 9010 – eSPP Programmer Page 9
3.5” Operator Interface Cutout dimensions
5.7” Operator Interface Cutout dimensions
12” Operator Interface Cutout dimensions
SSi Manual Series 9010 – eSPP Programmer Page 10
Wiring
Wiring to the Series 9010 eSPP’s operator interface can be done using 232 or 485 to two connectors,
comm1 (232) or comm3 (485). The terminal strip on the lower right rear corner of the operator interface
is used to connect 24VDC power. The DB-9 port A connection is used to connect the display via 232 to the
Series 9010 PID controller. The eSPP is connected via RS485 communication to the single-loop
controllers (AC20-Atmosphere and 7EK-Temperature).
Model 9010 eSPP Terminal Assignments
SSi Manual Series 9010 – eSPP Programmer Page 11
Pin Out
9010 Pin Out
A wiring diagram of the Series 9010 controller can be found in Appendix B.
Ancillary Items
The following items can be included with the Series 9010: a flash card, a flash card reader, a touch
screen, an RS-232 cable, a 24V DC DIN rail mount power supply, and a software CD with Configurator, the
Configurator manual, TS Manager, .NET 2.0, and SD Recorder software. The flash card installs the
operator interface and the flash card reader connects to a Windows® based computer. SD Recorder is a
utility program that can be loaded on any current Windows® based computer. Its purpose is to read the
data collected by the flash card and allow that data to be charted, similar to a strip chart recorder.
Further information can be found in Appendix D,
the Installation CD, double-click on the SD_SDRecetup.exe file, and follow the instructions on your screen
The operator interface includes connections for a mouse and a keyboard. These may be connected to the
operator interface via USB, allowing the operators to use a mouse and keyboard instead of the touch
screen.
The following table shows the ancillary items and their part numbers.
Flash Card Management
. To install SD Recorder from
SSi Manual Series 9010 – eSPP Programmer Page 12
Part
Part Number
eSPP controller alone
13354
3.5" Operator Interface
13498
5.7" Operator Interface
13448
12" Operator Interface
13455
SD Recorder/PC
Configurator Software
13339
Flash Card
13335
Flash Card Reader
13333
RS232 Cable
33027
24V DC Din Rail
Mounted Power Supply
31135
ETHERNET Connections
This connection has two distinct uses. First, it allows a laptop to be connected to the Series 9010. This
connection can act as a FULL FUNCTION operator interface using Configurator software. The laptop
needs to be operating a current WINDOWS® based system with Internet Explorer. Secondly, if the
instrument is connected to the customer’s local intranet, then the instrument’s information can be
digitally logged and recorded using SSI software or another SCADA package. The default IP address is
192.168.0.200. If you are experiencing problems please call 800-666-4330 and talk with our computer
communications personnel.
Setup
The Series 9010 setup consists of setting the local time if required. As shipped from the factory the
communications ports are set at 19200 baud in Modbus mode.
Time will be set for local time in Cincinnati, Ohio (EST /EDT) or time zone of location of city and state on
sales order. For instruction on adjusting these values, please see
Chapter 3 - Configuration
.
SSi Manual Series 9010 – eSPP Programmer Page 13
Overview
The Series 9010 eSPP Operator Interface is either a 3.5”, 5.7”, or 12.1” color, touch-screen
display.
On power-up, the Series 9010 will display a logo screen for sixty seconds and then switch to
the default Status Screen.
The active menu buttons on the status display are located at the bottom of the display.
Status Display
The Status display shows the
atmosphere and temperature controller
information as well as an overview of
the programmer. There are four active
buttons at the bottom of the Status
Display: Menu, Chart, Recipe, and
Loops.
Chapter 2 - OPERATION
Menu
There are three levels of menus in the Series
9010.
The first level is the
are functions or operations that are
typically handled by the furnace operator.
This menu is accessed without the need
for a pass code.
The second level is the
This level requires the entry of a level 1 or
a level 2-pass code.
The third level is the
This requires the level 2-pass code ONLY.
operator level
. These
supervisor level
administrator level
.
.
As shipped, the
level codes are set as 1 and 2 respectively. The pass codes can be changed at the Passcode and Alarm
Screen.
Note: Any level can access a lower level screen. For instance, the Administrator level passcode
can access all of the Supervisor and Operator level screens
The menu items are explained in detail in
SSi Manual Series 9010 – eSPP Programmer Page 14
supervisor
and
administrator
.
Chapter 3 – Configuration.
Chart
The Chart Display shows between 1 hour and 24 hours of process variable data on the screen and can be
scrolled back to view all of the data stored on the hard drive. The vertical timelines change as the time
changes on the screen. Any trend charts that have been created through the Configuration menu are
accessible here. See the
charts.
The function buttons run along the bottom of the screen.
The Trend Lines button - - will allow the user to select or de-select the trend lines on the trend
chart to display. If the checkbox next to each trend line is checked, then that trend line will be displayed.
The Datagrid View button - - will display a screen with the trend data in a grid format instead of
with trend lines. The trend data is shown in 1-minute intervals. Clicking on the OK button on this screen
will close the screen down and return to the Chart Display screen.
The Refresh button - - will refresh the screen’s trend data if the screen is not in real-time mode.
Chapter 2 – Configuration
section for more information on creating trend
The left-pointing green arrow button - - will move the chart’s view backward in time by the
specified chart interval.
The chart interval button - - will determine the number of hours displayed on the trend chart. The
options are: 1 Hour, 2 Hours, 4 Hours, 8 Hours, 12 Hours, or 24 Hours.
The right-pointing green arrow button - - will move the chart’s view forward in time by the
specified chart interval.
The right-pointing arrow with the vertical line next to it button - - will put the chart into real-time
mode if it is not in real-time mode, or take the chart out of real-time mode if it is. When in real-time
mode, the chart will automatically be updated once a minute.
Chart Sub Menu
There is a sub-menu available by putting a finger
or a stylus anywhere on the chart and holding it
there for a couple of seconds. The sub-menu will
have the following options available: Zoom,
Restore, Add Note, Data, and Exit.
SSi Manual Series 9010 – eSPP Programmer Page 15
The Zoom option will allow the user to zoom in on a
particular part of the screen. Once this has been selected,
the user can take a stylus or a finger and create a box
around the desired data. Once the user releases the stylus
or finger, a zoom is no longer possible, and the user will
need to re-select the option from the sub-menu to zoom in
again.
The Restore option will back out of any zoom options that
have been performed and display the chart screen as it
initially was.
The Add Note option allows the operator to enter a note on
the chart, similar to writing on a paper chart. The note shows up when the chart is printed out using the
utility software included with the Series 9010 instrumentation. Pressing the Add Note option displays a
screen where the operator can enter the operator ID or initials and a note. The user has the option to
enter a note using the operator interface keyboard, where he or she will be able to type in the note; or the
user can use the Signature mode, which will allow them to write a note using a stylus.
The Data option will show the trend data as a data grid instead of the trend lines on a chart. This
functionality is exactly the same as if the user pressed the Datagrid View button - - from the chart
screen.
Exit will close out the sub-menu without selecting an item.
Pressing the red ‘X’ in the top right-hand corner of the screen will take the user back to the status
screen.
Recipe
Pressing the Recipe button on the main status screen
displays the recipe screen, which will allow the user
to load up an existing recipe and start it or see the
recipe that is currently running.
The recipe screen shows the last program loaded into
the program run buffer and its status. If the program
is running, the active step number is highlighted
green. When the step is highlighted green, then the
recipe is running on that step. When a step is
highlighted yellow, the recipe is in hold on that step.
A red Acknowledge button in the bottom left corner of
the screen displays an alarm condition.
Acknowledge button is only visible when an alarm condition is present. Once the condition is
acknowledged, the Acknowledge button will become invisible again
show the recipe running status as well as run time and remaining time for the current step and the entire
recipe.
The recipe screen has a total of seven buttons that will allow the user to load a recipe, control the recipe
and acknowledge an alarm.
. The main status screen will also
Note – The
The Advance button will advance the recipe to the next step in the recipe. The user will need
to confirm the advance command.
SSi Manual Series 9010 – eSPP Programmer Page 16
The Hold button places the displayed recipe program in hold. Once a decision is made that
affects the recipe, it may be continued by pressing the Resume button.
Note – When a recipe
is put into hold status, the text on the Hold button will change to “Resume”. When the step is
started up again, the text on the button will change back to “Hold”
hold status, the step will be highlighted yellow. The user will need to confirm the hold or
resume command.
The Stop button stops the recipe program that is currently running. Stop means exactly that!
It stops the program. It is NOT a hold button. See the description for the hold button above. To
re-start the program if it has been stopped you must use the Load button, enter the recipe
number, and then highlight the segment number of the recipe that you want to start with and
start the recipe again. The user will need to confirm the stop command.
The Soak button allows you to enter a new value for the time remaining in the current soak or
ramp cycle only – future soak or ramp cycle times cannot be modified. The step must be a
soak or ramp cycle for a change in soak/ramp time to be adjusted.
The Acknowledge button will acknowledge the alarm. In most cases, it will be acknowledging
end of soak
. The alarm must be acknowledged to allow the program to go to the next step.
. When a recipe step is in a
Note – The Acknowledge button is only visible when an alarm condition is present. Once the
condition is acknowledged, the Acknowledge button will become invisible again
The Load button allows the operator to enter the recipe number to be run and to view the
recipe before pushing the Run button. Pushing the Run button starts the recipe. If a recipe
program is running and the operator enters a new recipe program it can be viewed and
modified. The recipe does not become active until the Run button is pushed. Pressing Run
places the program currently being viewed in the active memory and will begin to run the
new recipe. To select the recipe to
view or edit, click on the recipe
number button in the top left corner of
the screen. This will display a screen
where the user will be able to load up
a valid recipe (range 1 – 300). The
.
program can be started in any step by clicking on
the step number button next to the “Step” text and
entering the new step number (range 1 – 24), and
then pressing the Run key.
While reviewing the program that is about to be
run, each step can be modified. Highlight a step number and click on the Edit button. The
opcode can be changed with the drop down list at the top. This list can be sorted
alphabetically by click on the “Alphabetical” checkbox. The parameters of the opcode can be
modified on this screen as well. See the
about each opcode. Click on the OK button to accept the changes; click on the Cancel button
to ignore the changes.
Note – Any change to the recipe is a one-time edit, and will not affect
the recipe that is saved on the 9010 controller
screen to cancel loading a recipe and return to the main recipe screen.
The Return button returns you to the main status screen.
SSi Manual Series 9010 – eSPP Programmer Page 17
Chapter 4 – SERIES 9010 Opcodes
. Click on the Cancel button on the Load Recipe
section for details
Loops
The current process variable is displayed at the top,
with each loop set point displayed beneath the
process variable. The operator can change the
process set point by touching the screen area below
the large process variable numbers. When pressing
the Temperature or % Carbon set point a numeric
keypad is displayed, showing the current value and
allowing you to enter a new set point by simply
pressing on the appropriate numeric keys. Once the
correct set point has been entered, press the OK key
to make the change. When the OK key is pressed the
display returns to the Loops Screen.
Also displayed are the probe millivolts, the probe temperature, and the CO Factor. The CO Factor can
also be adjusted from this screen. After pushing the COF button a numeric screen pad pops up and allows
the authorized personnel to make the appropriate change.
The Loops Screen also allows you to move back to the Status Screen or to the Recipe Screen by pressing
the Recipe button to view the program currently running on the Series 9010 controller.
SSi Manual Series 9010 – eSPP Programmer Page 18
Chapter 3 - CONFIGURATION
The following options allow the user to customize and monitor the operation of the Series 9010 controller.
Logs
The Logs screen will allow the user to view three
different types of logs – System, Alarms, and Cycle.
Clicking on the button that displays the log type (System
Log, Alarm Log, or Cycle Log) will allow the user to
select the type of log file to view.
The green directional arrows will display the previous
items in the log or the next items in the log, if the log
items are longer than one screen. The drop down list in
between the directional arrows will allow the user to
select the date of the log items to view.
The Return button will return the user to the menu
screen.
Slave Communications Status
This page is a display of the current process variables of
each of the auxiliary instruments communicating with the
controller. These values are display-only, and cannot be
modified from this screen.
There are five possible messages that can occur to
describe the instrument communications status.
N/A – No instrument is connected
Bad – No communications exist
??? – Communications exist, but there are
frequent errors
?OK – Communications exist, but there are
occasional errors
OK – Communication is established and
working properly
For set-up of the auxiliary instruments go to the menu
item “
Slave Instrument Setup
The Return button will return the user to the menu
screen.
”
Auxiliary Analog Input
This menu option shows the process variables for the 3
analog inputs of the 9010 dual loop controller. It also
shows the input types and any information from attached
slave analog input modules.
can be modified on this screen
Note – None of these values
.
SSi Manual Series 9010 – eSPP Programmer Page 19
Manual Event Control
The Manual Event Control menu option shows the user
all of the events (0 – 15) and their current status. It also
allows the user to manually control the status of any
event by clicking on the value. To change the status,
highlight the specific event and click on the Edit button.
The user will be able to select either an On value or an
Off value. Clicking on the OK button will set the value,
while clicking on the Cancel button will cancel the
action. The Return button will return the user to the
menu screen.
Shutdown
The Shutdown selection will display a screen asking whether or not to shutdown the interface of the
Series 9010. When the operator interface is shutdown, the SERIES 9010 controller is still functioning. IT
can be monitored by connecting the ETHERNET connection to a laptop computer, using Internet Explorer,
and assigning a legitimate IP address. Choosing Yes displays a typical computer desktop screen with the
Start button in the bottom left-hand corner. The power to the operator interface can now be turned off
without upsetting any of the settings. Choosing No displays the initial Status Screen.
down the Operator Interface does not shutdown the Series 9010 Controller
.
Note -Shutting
Recipe Edit
This option will allow the user to edit a recipe that
is stored on the controller.
The Load button will allow the user to select which
recipe to load. Once the recipe has been selected,
the recipe will be displayed on the screen.
The higher recipe steps can be viewed by holding a
finger or stylus on the screen and scrolling up or
down.
To edit a specific step, highlight that step and press
the Edit button. This will allow the user to select a
different Opcode to use, or to change the
information entered for the current Opcode. See
the
Chapter 4 – SERIES 9010 Opcodes
more information on each Opcode and their
purpose.
To insert a step into the program, highlight the step number for the step, and press the Insert button.
The user will have to confirm the insert. Once this has been confirmed, the user will be able to select the
Opcode to use.
be lost
.
Note – Inserting a step will push every step after down one, so an Opcode at step 24 will
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