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9120
User Manual
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Super Systems 9120 User Manual

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Page 1
9120 Operations Manual
Super Systems Inc.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060 / 800-666-4330
Fax: 513-772-9466
www.supersystems.com
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Table of Contents
General Information .................................................................................................................................................... 3
SSi 9120 Setup ........................................................................................................................................................... 4
Step 1 – Install Configurator 2.0 on the Local Computer ............................................................................................ 4
Step 2 – Connect the SSi 9120 to a Network or Local Computer ................................................................................. 6
Step 3 – Configure Configurator 2.0 on the local computer ......................................................................................... 7
Step 4 – Complete Configurator Step 5 – Complete Configurator Step 6 – Complete Configurator Step 7 – Complete Configurator Step 8 – Complete Configurator
Step 9 – Complete Configurator
SSi 9120 Pinout Diagram ........................................................................................................................................... 20
SSi 9120 Wiring Diagram ........................................................................................................................................... 21
Section 1 – 9120 Configurator Menus ......................................................................................................................... 22
Burnoff ................................................................................................................................................................. 22
Slave Instruments .................................................................................................................................................. 23
Aux Analog Inputs ................................................................................................................................................. 24
Burnoff Setup ........................................................................................................................................................ 24
PID Loop Setup ..................................................................................................................................................... 25
Furnace Setup ....................................................................................................................................................... 27
Communications Setup........................................................................................................................................... 29
Slave Instrument Setup .......................................................................................................................................... 30
Analog Input Setup ................................................................................................................................................ 31
Analog Output Setup.............................................................................................................................................. 32
Alarm Setup .......................................................................................................................................................... 34
Calibration ............................................................................................................................................................. 36
Overview ........................................................................................................................................................... 36
Equipment needed ............................................................................................................................................. 36
Calibration Procedure ......................................................................................................................................... 37
User Calibration .................................................................................................................................................. 37
Full Calibration ................................................................................................................................................... 38
Appendix 1 – Standard Configurations for PVT Types .................................................................................................. 41
Appendix 2 – Accessing the SSi 9120 Web Page ......................................................................................................... 43
Revision History ........................................................................................................................................................ 45
Furnace Setup Analog Input Setup Analog Output Setup Alarm Setup
Menu Option ...................................................................................... 9
Menu Option ............................................................................ 11
Menu Option .......................................................................... 13
Menu Option ....................................................................................... 15
Communications Setup PID Loop Setup
Menu Option .................................................................................. 17
Menu option ........................................................................ 17
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GGeenneerraall IInnffoorrmmaattiioonn
The SSi 9120 is a single or dual loop blind controller/signal conditioning/data concentrating device that can be used in carbon, oxygen, millivolt, SSi redundant probe, simple nitriding and universal dual loop applications. The 9120 is supplied with Ethernet communications capability and has a limited web server for thin client control and supports ModbusTCP host communications. Serial I/O includes two (2) RS-232 ports and three (3) RS-485 ports. As a data concentrator, the 9120 is capable of communication to SSi's analog input modules as well as up to 25 slave serial instruments and supports host communications via Modbus over RS232 or RS485 or ModbusTCP communications.
The SSi 9120 Controller is a single or two loop device that can be configured to be used for control of:
% Carbon Dew Point Oxygen Millivolt Redundant Probe Simple Nitrider Dual Loop Temperature Mode
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SSSSii 99112200 SSeettuupp
This section will explain how to set the SSi 9120 controller up. The steps required to set up the SSi 9120 through a local computer are:
1. Install Configurator 2.0 on the local computer
2. Connect the SSi 9120 to a network or local computer
3. Configure Configurator 2.0 on the local computer
4. Complete Configurator
5. Complete Configurator
6. Complete Configurator
7. Complete Configurator
8. Complete Configurator
9. Complete Configurator
Furnace Setup Analog Input Setup Analog Output Setup Alarm Setup Communications Setup PID Loop Setup
menu option
menu option
menu option
menu option
menu option
menu option
Step 1 – Install Configurator 2.0 on the Local Computer
Configurator 2.0 is a configuration utility developed by SSi that will allow the user to interface with an SSi instrument directly or over a network. The installation file, ConfiguratorSetup.msi, should be included with the installation CD provided by SSi. If this file is not on the CD, contact Super Systems at 513-772-0060.
Double-click on the installation file to begin the installation process. The first page displayed is just for information purposes. Click on the Next > button to move to the next page, or press the Cancel button to cancel the installation.
The second page is a warning about Configurator 2.0. Since Configurator 2.0 is a Microsoft .Net 2.0 product, the local computer will have to have the .Net 2.0 framework installed before Configurator 2.0 can be used. Click on the Next > button to continue or the Cancel button to cancel the installation.
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Page 3 will allow the user to select the location of the installation. The default location is “C:\SSi\”. To change this location, click on the Browse button and select a new location from the dialog box that is displayed. The Disk Usage button is a utility that will display the available hard drive space on the local computer. Click on the Next > button to move to the next page.
Page 4 will allow the user to review the installation settings, if necessary. Click on the Install button to install the software.
Page 5 will display a progress bar as the installation proceeds.
Note: The installation should only take a few minutes
.
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Page 7 is the informational screen about the makers of the installation software. Click on the Finish button to close out this screen.
Page 6 is the finishing screen, which is displayed after the software has been installed. Click on the Next > button to continue.
Step 2 – Connect the SSi 9120 to a Network or Local Computer
To connect the instrument to the network, through a wall port or switch, use a regular Ethernet cable. To connect the instrument directly to a computer, use an Ethernet crossover cable. Contact your IT Department for the necessary cables. Once the SSi 9120 is connected to a network, the Configurator 2.0 software will be able to find it during any searches. Connecting the instrument to your network or directly to a PC is accomplished using the Ethernet port on the instrument. If you are connecting the instrument to your network, you will need an Ethernet cable. The cable is plugged into the instrument Ethernet plug and then other end should be plugged into a network hub. If the IP Address of the instrument needs to be changed, this can be done through the Configurator software (see Step 3 below). If you are not putting the instrument on the network, you should use an Ethernet crossover cable. Ethernet crossover cables are most often used when connecting two Ethernet computers without a hub. An Ethernet crossover cable has its send and receive wires crossed. When using a hub or switch, this is automatically done for you. With a crossover cable, you are forming a network between the computer that you are directly plugged into and the SSi 9120. There will be some network settings on the computer that you will have to configure for the 2 devices to communicate. The SSi 9120 will have the network setting already setup with the following default IP address – 192.168.0.200. This can be modified through the Configurator software. Network settings can be found through the operator will be given a list of the current available connection types. Using the crossover cable will require the “Local
Control Panel
in Microsoft Windows. By selecting
Network Setting
, the
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Area Connection” as seen in the diagram to be modified. The Properties can be changed by highlighting the connection and using the right mouse button to click and select the tab or by highlighting the connection and clicking on Change setting of this connection. Once the screen is displayed, highlight the Internet Protocol (TCP/IP) option. Click the Properties button to display Internet Protocol (TCP/IP) Properties. On the Internet Protocol (TCP/IP) Properties tab, you will need to select the option for Use The Following IP Address. Enter in the following data on these fields: IP Address: 192.168.0.209 Subnet Mask: 255.255.255.0 Default Gateway: 192.168.1.1 Note: These fields are suggestions. Contact your IT department to get a valid IP address, Net Mask, and Gateway for the local computer. To change the network settings on your computer you may need addition information so please refer to the computer manual.
Local Area Connection Properties
Properties
Step 3 – Configure Configurator 2.0 on the local computer
When Configurator starts up for the first time, the user will see the main screen, which will be blank because no instruments have been set up yet. The first step is to set up an instrument in Configurator.
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First, the user will need to log in with administrative rights.
The user will need to be logged in with at least administrative rights; Supervisor rights will not allow the user to add an instrument
four levels of rights in Configurator are: operator, supervisor, administrator, SSi Special. The lock on the toolbar will let the user know what level is currently logged in. Operators are blue, supervisors are gold, administrators are green, and the SSi Special, which is used for configuration purposes before the unit is shipped, is red. Click on the lock and log in with the following information: username = administrator, password = 2.
Note: The supervisor and administrator passwords can be
Furnace Setup
. The lock should now
screen.
be green. Click on the
Click on the Add button to display the rest of the screen. First, give the instrument a name. The name can be anything the user wants, but it is suggested that the user makes the name descriptive. Next, select the model from the drop-down list. Next, enter the IP address in the “Ethernet” section and make sure the “Ethernet” option is selected. Note: The SSi 9120 is shipped with a default IP address of 192.168.0.200. This is set this way so that it will not interfere with any other instruments/computers on the network.
Options
menu, then select
Settings
. This will display the
changed on the menu page
System Management
Note: even if the local computer is hooked up directly to the instrument through a crossover cable, the IP address will still need to be correct
to find all available SSi instruments by clicking on the search button next to the “Ethernet” IP address box. This will set up Configurator for Ethernet communications. To set it up for serial or SuperData communications, the proper option will need to be selected and filled out. Click on the Save button to save the information. Click on the Done button to close down this screen.
. The user can also scan the network
Note:
. The
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Click on the Connect button on the left of the toolbar to connect to the device. If the connect button has a red square on it, then the device is disconnected. If the button has a green triangle, then the device is connected. Also, the connection status is displayed along the bottom of the screen. Once the device is connected, the user can move on to “Step 4 - Complete Configurator
Furnace Setup
menu option”.
Step 4 – Complete Configurator
Furnace Setup
Note: This menu item is also located later in the manual under the
enter the PV’s name.
Menu Option
Section 1 – 9120 Configurator Menus
The Furnace Setup menu option is an administrative access only option. Do not make any adjustments on this screen without first contacting Super Systems Inc.
Date and Time
This option will display the current date and time on the 9120 controller. From this menu option, the user can change the date/time
controller
Furnace Name
This value will define the name of the furnace. Clicking on the “Value” column will bring up an input box where the user can enter the furnace’s name.
PV1 Name
This value will define the name of the first process variable. Clicking on the “Value” column will bring up an input box where the user can
.
section
on the 9120
.
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PV2 Name
This value will define the name of the second process variable. Clicking on the “Value” column will bring up an input box where the user can enter the PV’s name.
PVT Type
The PVT type is the mode the device runs in (Carbon, Dewpoint, etc.). The mode selected determines the calculations and scaling for the Process Variable.
performs a simple calculation based on that input
defaults to ensure all parameters have been changed to the new Process Variable ( → Set Defaults button or FD Preserve button). Clicking on this value will display an input box with a drop-down list from which the user can select a new PVT Type. The values for the PVT type are:
% Carbon Dew Point Oxygen Millivolt Redundant Probe Simple Nitrider Dual Loop
Temperature Mode
This value determines the specific temperature scale to be used. Clicking on the value will allow the operator to change the value. It can be either Degrees °°°°F or degrees °°°°C.
Level 1 Code
Typically, operations used by a supervisor require a level 1 code for access. When a supervisor is logged in, the lock on the toolbar will be gold, . To change the level 1 passcode, click on the “Level 1 Code” value (range is –32768 to
32767) and an input box will be displayed where the user can select a new value.
Level 2 Code
Typically, operations used by an administrator require a level 2 code for access. When an administrator is logged in, the lock on the toolbar will be green, . To change the level 2 passcode, click on the “Level 2 Code” value (range is –
32768 to 32767) and an input box will be displayed where the user can select a new value.
Web Level 1 Code
This value is the supervisor-level passcode for any web-based operations with the 9120 controller. Clicking on the value will allow the operator to change the value. The range for the passcode is 0 to 9999.
Note: The Simple Nitrider only reads the H2 cell on the female RS232 port and
. Any time this selection is changed it is necessary to reset the factory
Options
menu →
Settings
menu option
Web Level 2 Code
This value is the administrator-level passcode for any web-based operations with the 9120 controller. Clicking on the value will allow the operator to change the value. The range for the passcode is 0 to 9999.
Web Change Enable
This will either enable or disable the web change feature, which will allow changes to be made over the web page for the 9120 controller. Clicking on the value will allow the operator to change the value. Select either a 0 (Web Change Disable) or a 1 (Web Change Enable).
O2 Mode
This value will allow the operator to select the oxygen mode. Clicking on the value will allow the operator to change the value. The options are:
% with control
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Monitor Offset with control. Sample Pump Mode Remote Setpoint Remote Setpoint Hysteresis
Sample Pump Mode This menu option will allow the user to turn the sample pump On or Off. For the HP PVT types (% Carbon, Dewpoint, Oxygen, Millivolt, and Redundant Probe), there is the option to set a minimum temperature in order for the pump to
run. See the “Minimum Temp/Pump Run” description below.
Remote Setpoint
This option will allow the user to select where the remote setpoint will come from. The options are:
None Slave 1 PV Slave 2 PV Slave 1 SP Slave 2 SP Input 3 Value
Remote Setpoint Hysteresis This option will allow the user to enter the remote setpoint hysteresis. The range is 0 to 9999.
Minimum temp/pump run
This option will set the minimum temperature for the pump to run, if that feature is used. A 0 value will disable the minimum temperature feature.
for the pump minimum temperature feature to work
Input 1
This value will display the Input 1 type. This value cannot be changed from this screen.
Input 2
This value will display the Input 2 type. This value cannot be changed from this screen.
Input 3
This value will display the Input 3 type. This value cannot be changed from this screen.
Note: The furnace that is being sampled must have its temperature connected to input 3
.
Loop 1 PV
This value will display the Loop 1 PV type. This value cannot be changed from this screen.
Loop 2 PV
This value will display the Loop 2 PV type. This value cannot be changed from this screen.
Step 5 – Complete Configurator
Setup
Menu Option
Analog Input
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Note: This menu item is also located later in the manual under the
The 9120 controller has two analog inputs. Each of the inputs comes with a factory default configuration dependent on the application (refer to PVT type under the or in the field by a technician or qualified/trained person with the proper security code.
Analog Input Terminals
Analog Input 1 – terminals 31 and 32 Analog Input 2 – terminals 29 and 30
Parameter Definitions Input Type
The thermocouple type for most applications can be modified depending on your specific needs. Please note that in some applications, some of the inputs DO NOT allow the user to modify the Input type.
make sure to set the appropriate jumpers, if necessary
Furnace Setup
.
The jumper will need to be manually changed on the input board
section). It can be modified prior to shipment to your facility
before changing the input type to a 10:1 setting (non-thermocouple types)
input you want to change by selecting it in the pull-down menu just below the main menu list. Clicking on the Value will display an input box, and then you can use the pull-down menu to select the desired parameter. Once selected, click and the displayed Input type under Value will be the current type.
The following is a list of the options:
B S 12.5 volts C T 781.25mv E 2.5 volts 195.3125 mV J 1.25 volts K 78.125 mV N 19.53125 mV NNM 4-20 mA R 25 volts
Filter time
The filter time is a factory applied averaging tool used to help maintain steady control in high EMI environments. The filter time should not be adjusted with consulting SSI. Clicking on this value will display an input box from which the user can select a new value. The range is 0 to 32767.
Initial Scale
This is the initial scale value. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Full scale
This is the full scale value. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Decimal Point Location
This is the decimal point location value. Clicking on this value will display an input box from which the user can select a new value. The range is 0 to 4.
Open TC This is the open TC value. Clicking on this value will toggle between up scale, and down scale.
Input Offset
The input offset value is algebraically added to the input value to adjust the input curve on read-out.
offsets are unscaled
. The range is –5000 to 5000.
Section 1 – 9120 Configurator Menus
Note: Before changing the input type,
. To change the Input type, first select which
Note: The input
section
.
OK
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Trip Point 1 Setpoint This is the trip point 1 setpoint value. The range is –32768 to 32768.
Trip Point 1 Force Value This is the trip point 1 force value. The range is –32768 to 32768.
Trip Point 1 Direction This is the trip point 1 direction. The options are: input above setpoint or input below setpoint.
Trip Point 2 Setpoint This is the trip point 2 setpoint value. The range is –32768 to 32768.
Trip Point 2 Force Value This is the trip point 2 force value. The range is –32768 to 32768.
Trip Point 2 Direction This is the trip point 2 direction. The options are: input above setpoint or input below setpoint.
High Input Limit Setpoint This is the setpoint for the high input limit. The range for this can be –32768 to 32768.
High Input Limit Hysteresis This is the hysteresis for the high input limit. The range for this can be –32768 to 32768.
Step 6 – Complete Configurator
Analog Output Setup
Menu Option
Note: This menu item is also located later in the manual under the
Configurator Menus The 9120 controller has the option of two analog outputs. The outputs are ranged for a 4 – 20 milliamp signal or a 0 – 20 milliamp signal. Each output comes with a factory default configuration dependent on the application. Each output can be modified prior to shipment to your facility or in the field by a supervisor.
Analog Output Terminals
Analog output 1 – terminals 24 and 25 Analog output 2 – terminals 25 and 26
Assignment
The analog output assignment can be modified depending on your system requirements. To change the Assignment first select which analog output you want to change by selecting it in the pull-down menu just below the main menu list. Clicking on this value will display an input box, and then you can use the pull-down menu to select the desired parameter. Once selected click OK and the displayed assignment under Value will be the current assignment type. The following is a list of the options:
PV 1 retrans Input 1 retrans
Section 1 – 9120
section
.
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Loop 1 inc Input 2 retrans Loop 1 dec Input 3 retrans Loop 1 combo PV1 retrans w/ expo range PV 2 retrans O2 offset log Loop 2 inc SP1 retrans Loop 2 dec SP2 retrans Loop 2 combo DP retrans Disassociation Nit_Pot Hydrogen
Combo example for carbon – 4 – 12 mA Air 12 – 20 mA Gas
Offset
This is the starting point, the Process Variable value at which you get 4 milliamps. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Range
This is a Process Variable value between 4 and 20 milliamps. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Note: The range, although not displayed with a decimal point, contains a decimal point that is dependent on the process variable selected. For example, If the offset is 20 mV for 4 mA, and you want 100 mV to be 20 mA, then your range should be 80. If the process variable is temperature, then the range will be 80, since temperature PVs do not have a decimal. If the PV is % Carbon, then the range will need to include the two decimal points for % Carbon. So, a range of 80 will be entered as 8000
for more examples.
Current Selection
Provides the option of 4-20 mA or 0-20 mA control. Clicking on this value will display an input box with a drop-down list from which the user can select either of the two values listed above.
Offset and Range when assigned to a control loop
Inc -- 0 = 4mA, 100 = 20mA Dec -- 0 = 4mA, -100 = 20mA
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is Temperature Offset = 800 (starting point) Range = 400
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is O2 Offset = 800 (starting point) Range = 4000 (400.0)
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is % Carbon Offset = 800 (starting point) Range = 40000 (400.00)
O2 Exponent Range
This menu option will allow the user to set the Oxygen exponent range. The range is 0 to 10.
The 9120 controller has the option of using eight relay outputs. All of the relays have a positive common terminal and independent negative terminals. All of the relays are configured in a normally closed position except relay number eight, which has both a normally closed (NC) and a normally open (NO) terminal.
. See below
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Note: Relay 1 through Relay 8 are display-only and cannot be modified from this screen
Relay Output Terminals
Relay Output 1 – terminals 7 and 8 Relay Output 2 – terminals 7 and 9 Relay Output 3 – terminals 7 and 10 Relay Output 4 – terminals 7 and 11 Relay Output 5 – terminals 7 and 12 Relay Output 6 – terminals 7 and 13 Relay Output 7 – terminals 7 and 14 Relay Output 8 – terminals 7 and 15 NC Relay Output 8 – terminals 7 and 16 NO
.
Step 7 – Complete Configurator
Alarm Setup
Note: This menu item is also located later in the manual under the
drop-down lists from which the user can select a new value. The values in the first (top) list box are:
PV 1 Value PV 2 Value PV 3 Value Input 1 Value Input 2 Value Input 3 Value PO1 Value PO2 Value PO3 Value
The values in the second (bottom) list box are:
Menu Option
Section 1 – 9120 Configurator Menus
The 9120 controller can be configured to use three different alarms. Each of the alarms consists of an alarm setpoint, alarm type, alarm hysteresis, smart alarm, ON delay time, and a 0 SP blocks alarm value. The alarms come from the factory with a default configuration dependent on the application but also can be modified prior to shipment to your facility or in the field by a supervisor.
Setpoint
This value is the setpoint for the alarm. Clicking on this value will display an input box from which the user can select a new value. The range is from –9999 to 9999.
Alarm Type
This value is the type of alarms used. Clicking on this value will display an input box with two (2)
section
.
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Process High
Process Low Band, Normally Open Band, Normally Closed Deviation, Normally Open Deviation, Normally Closed
Deviation alarm is single sided. i.e. a +10 deviation will alarm when the PV is greater than SP + 10 but not neg. A -10 deviation will alarm when the PV is less than SP -10 but not on the positive side.
When set to deviation, the alarm message shows in Configurator below or above. The actual relay setup with that alarm will only energize depending on the setpoint. For the standard alarms (1, 2, and 3), the user can select if the alarm condition is for above or below. This will dictate when the relay will energize.
Example: alarm 1 set to plus 10F will alarm 11 degrees above setpoint and pull in the relay. It will show alarm 10 degrees below but not pull in the relay.
A Band alarm will activate and energize the relay on both sides (+) and (-).
Note: some alarm types may be fixed at the current value
.
Hysteresis
The hysteresis is in degrees, i.e. 10 hysteresis = 10 degrees. Alarm hysteresis should not have a decimal place. It is in units. If it is a control loop doing on/off control then the decimal place on the reset (hysteresis) should be ignored. The Hysteresis is a set number that works with the alarm to help control a motor or pump longer to reach a set amount to come back into band before it will shut off motor or pump.
Example: Using quench oil as an example, assume the SP is 200F. The alarm is set as a deviation of +10F. At 210 the alarm is active and the pump will run to cool the oil. With a hysteresis of 8 degrees the alarm and pump will turn off at 202F. It will turn back on when it is 10 degrees above setpoint. If the setpoint is still 200 then at 210 it is on again. Clicking on this value will display an input box from which the user can select a new value. The range is from 0 to 9999.
Smart Alarm
This value is a display of the Smart Alarm status. A smart alarm is an alarm that works with a Process Variable and when enabled it will not be active until the process variable is within band of the setpoint.
Example: If the SP is 1700 and the band is 10 degrees the alarm will not be active until the PV reaches 1690. The value can be either disabled or enabled.
ON Delay Time
This value is the ON Delay Time for the Smart Alarm, in seconds. If the timer is utilized the alarm will not be active until in band and the timer has timed out (this is in seconds).
Example: If you select 30, the output will not energize until 30 seconds after the alarm is active. Clicking on this value will display an input box from which the user can select a new value. The range is from 0 to
9999 seconds.
0 SP Blocks Alarm
This value will allow a 0 setpoint to block an alarm. The
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options are either no or yes.
Step 8 – Complete Configurator
Note: This menu item is also located later in the manual under the Communications Setup
666-4330 for more information regarding port setup. It is without technical support from Super Systems Inc. Clicking on any of the values will display an input box that will allow the user to modify the current settings.
is the communications definitions for the controller. Please contact Super Systems Inc. at 800-
Step 9 – Complete Configurator
Communications Setup
Section 1 – 9120 Configurator Menus
strongly recommended
PID Loop Setup
that none of the settings be modified
Menu Option
Menu option
section
.
Note: This menu item is also located later in the manual under the
Configurator Menus PID is the tuning parameters entered for each Process Variable loop. The loop value can be either Loop 1, or Loop 2.
Prop Band (0 for On/Off)
This is the proportional band field. This represents the P in PID. P = Proportional. This is a field in which you want the process variable to stay around the setpoint. Clicking on the value will allow the user to change the value. The range for the proportional band value is 0 – 999.0.
Reset
This is the reset field. This represents the I in PID. I = Integral. This is the actual temperature being monitored over a period of time and then averaged to keep within the Proportional band. The reset is in repeats per minute. This helps to eliminate offset. Clicking on the value will allow the user to change the value. The reset range 0 – 100.00
Rate
This is the rate field. This represents the D in PID. D = Derivative. This is the sudden change or rate in the temperature. This rate is in minutes. This affects the controller output which is proportional to the rate of change of the measurement and will control the amount of output by time restraints. Thus derivative takes action to inhibit more rapid changes of the measurement than proportional action. Derivative is often used to avoid overshoot. Clicking on the value will allow the user to change the value. The range for the rate is 0 – 100.00. The rate is not typically used for heating/carbon
Section 1 – 9120
section
.
Page 18
Mode
This is the mode of the loop. Clicking on the value will allow the user to change the value. The following is an explanation of the dual/single and direct/reverse properties: Dual – This has two output relays which can increase and decrease to achieve your SP. Single – This has one relay which works in only one direction to achieve your SP. Direct - If the PV - SP is a positive number and the output would bring the PV down toward setpoint that is direct. Reverse – If the PV - SP is a negative number and the output would bring the PV up toward setpoint then that is reverse
Example: If a 12 mA output drives a 0 degree F temp. (PV) up to a 1200 degree F temp. (SP) this would be REVERSE and since this would take a SINGLE output from the controller the Mode for the Temperature Loop is Single Reverse.
The mode values can be:
Dual Reverse; gas/air or heat/cool Single Reverse; heat Dual Direct; Dewpoint gas/air Single Direct; cool
Integral Preset
This field provides an offset for the starting point for PID control, also referred to as “Load Line” or “Manual Reset”. Clicking on the value will allow the user to change the value. The range for the integral preset is –100 to 100.
Cycle Time
Clicking on the value will allow the user to change the value. This field is typically set to the valve travel time multiplied by 1.5. The cycle time range can be 0 – 300.
Setpoint Change Limit
This is a smart time feature that allows the Process Loop to use PB only without Reset until the Process Variable drops below the percent output set under this category. It is used to eliminate overshoot. The Output percentage selected under this category furnace at heat. Clicking on the value will allow the user to change the value.
must
be above the normal operating output percentage of the
Example – if the furnace runs at 40% output at heat for the maximum load, the setpoint change limit should be set to
.
60%
The value can be:
OFF 80 % 70 % 60 % 50 % 40 % 30 % 20 %
Low Limit This is the low limit field. Clicking on the value will allow the user to change the value. The range is –100 to 100.
High Limit This is the high limit field. Clicking on the value will allow the user to change the value. The range is –100 to 100.
0 Setpoint Stops Control
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If the Setpoint is zero, then all outputs are turned off. Clicking on the value will allow the user to change the value. The option is either Yes or No.
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SSSSii 99112200 PPiinnoouutt DDiiaaggrraamm
SUPER SYSTEMS INC.
www.supersystems.com
(800) 666-4330
1 - 24VDC (COM)
2 - 24VDC (+)
3 - RS485 RT (-)
4 - RS485 RT (+)
5 - SLAVE 1 RS485 (-)
6 - SLAVE 1 RS485 (+)
7 - RELAY COMMON
8 - RELAY OUT 1
9 - RELAY OUT 2
10 - RELAY OUT 3
11 - RELAY OUT 4
12 - RELAY OUT 5
13 - RELAY OUT 6
14 - RELAY OUT 7
15 - RELAY OUT 8 NC
16 - RELAY OUT 8 NO
17 - DIGITAL IN 1
18 - DIGITAL IN 2
19 - DIGITAL IN 3
20 - DIGITAL IN 4
21 - DIGITAL IN COM
22 - SLAVE 2 RS485 (+)
23 - SLAVE 2 RS485 (-)
24 - 4-20mA OUT 1 (-)
25 - 4-20mA OUT COM (+)
26 - 4-20mA OUT 2 (-)
27 - ANALOG IN 3 (-)
28 - ANALOG IN 3 (+)
29 - ANALOG IN 2 (-)
30 - ANALOG IN 2 (+)
31 - ANALOG IN 1 (-)
32 - ANALOG IN 1 (+)
Page 21
SSSSii 99112200 WWiirriinngg DDiiaaggrraamm
21 3 54
876 1 09 1 31 1 1 2 1 61 51 4
P OR T BP OR T A
M OD E L
S/ N
2 72 42 2 2 3 2 5 2 6 2 8 2 9 3 13 0
3 22 11 7 1 8 2 01 9
Page 22
SSeeccttiioonn 11 –– 99112200 CCoonnffiigguurraattoorr MMeennuuss
Burnoff
When a probe is in a furnace, soot will collect in the end of the probe, which will have a negative effect on the performance of the probe. Burnoffs are used to clean out the built-up carbon by burning it off of the probe. To manually begin a burnoff, click on the “Value” area next to “Burnoff”. To Cancel a burnoff, click on the “Value” area next to “Cancel”.
“Cancel” are the only two interactive fields on this screen; the rest are read-only
Note: “Burnoff” and
.
Burnoff
Clicking on the “Value” area next to this field will user will have to confirm the initiation. Once a probe burnoff, has started, the rest of the fields on the screen will be updated with the current values.
manuall
y initiate a probe burnoff. The
Page 23
Cancel
Clicking on the “Value” area next to this field will user will have to confirm the cancellation.
Next Burnoff In (shown in minutes)
This value is a displayed calculation based on the burnoff time set in the menu option. It displays the number of minutes until the next burnoff will be initiated.
Test Status This value displays the current testing status. The list of possible values are: Burnoff, Burnoff Recovery, or Idle.
Timer (sec)
This value shows the remaining time, in seconds, for the Burnoff / Recoveries.
MV
This value is a display of the current millivolt input value during a burnoff.
TC
This value is a display of the current probe thermocouple input value during a burnoff.
Start mV
This value is a display of the millivolt input value at the beginning of the Burnoff.
Start TC
This value is a display of the probe thermocouple value at the beginning of the burnoff.
Last Burnoff
This value shows the date and time of the last burnoff.
Last Min mV
manually
cancel a probe burnoff. The
Burnoff Setup
This value is a display of the minimum millivolts measured during the last burnoff.
Last Max TC
This value is a display of the maximum measured probe thermocouple input value during the last burnoff.
Slave Instruments
This page is a display of the current process variables of each of the slave instruments communicating with the 9120 controller.
Note – None of these values can be modified on this screen
.
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For set-up of the auxiliary instruments go to the menu item
Aux Analog Inputs
This menu option shows the process variables for the analog inputs of the 9120 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
.
Slave Instrument Setup
.
Burnoff Setup
This menu option allows the user to modify the settings that are associated with the probe burnoff (menu option
Burnoff
).
Page 25
Burnoff Time (sec)
The amount of time from the beginning of the burnoff to the end of the burnoff measured in seconds. Clicking on the value will allow the user to change the value.
Burnoff Recovery Wait Time (sec)
The amount of time allotted to allow the probe measurements to return to a stable, accurate range after the burnoff is complete. This is measured in seconds. The control output is held until this time is elapsed. Clicking on the value will allow the user to change the value.
Burnoff Interval (min)
The amount of time between the beginning of one burnoff and the beginning of the next scheduled burnoff measured in minutes. Clicking on the value will allow the user to change the value.
Burnoff Minimum Millivolts
The minimum measured millivolt tolerance of the probe required to start a burnoff. If the millivolts value is exceeded
burnoff will stop
the user to change the value.
Burnoff Maximum Temperature
The maximum measured temperature allowed during a burnoff. If the temperature value is exceeded
. This is done to help maintain the life and the accuracy of your probe. Clicking on the value will allow the user to
stop
change the value.
. This is done to help maintain the life and the accuracy of your probe. Clicking on the value will allow
the burnoff will
the
PID Loop Setup
PID is the tuning parameters entered for each Process Variable loop. The loop value can be either Loop 1, or Loop 2.
Prop Band (0 for On/Off)
This is the proportional band field. This represents the P in PID. P = Proportional. This is a field in which you want the process variable to stay around the setpoint.
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Clicking on the value will allow the user to change the value. The range for the proportional band value is 0 – 999.0.
Reset
This is the reset field. This represents the I in PID. I = Integral. This is the actual temperature being monitored over a period of time and then averaged to keep within the Proportional band. The reset is in repeats per minute. This helps to eliminate offset. Clicking on the value will allow the user to change the value. The reset range 0 – 100.00
Rate
This is the rate field. This represents the D in PID. D = Derivative. This is the sudden change or rate in the temperature. This rate is in minutes. This affects the controller output which is proportional to the rate of change of the measurement and will control the amount of output by time restraints. Thus derivative takes action to inhibit more rapid changes of the measurement than proportional action. Derivative is often used to avoid overshoot. Clicking on the value will allow the user to change the value. The range for the rate is 0 – 100.00. The rate is not typically used for heating/carbon
Mode
This is the mode of the loop. Clicking on the value will allow the user to change the value. The following is an explanation of the dual/single and direct/reverse properties: Dual – This has two output relays which can increase and decrease to achieve your SP. Single – This has one relay which works in only one direction to achieve your SP. Direct - If the PV - SP is a positive number and the output would bring the PV down toward setpoint that is direct. Reverse – If the PV - SP is a negative number and the output would bring the PV up toward setpoint then that is reverse
Example: If a 12 mA output drives a 0 degree F temp. (PV) up to a 1200 degree F temp. (SP) this would be REVERSE and since this would take a SINGLE output from the controller the Mode for the Temperature Loop is Single Reverse.
The mode values can be:
Dual Reverse; gas/air or heat/cool Single Reverse; heat Dual Direct; Dewpoint gas/air Single Direct; cool
Integral Preset
This field provides an offset for the starting point for PID control, also referred to as “Load Line” or “Manual Reset”. Clicking on the value will allow the user to change the value. The range for the integral preset is –100 to 100.
Cycle Time
Clicking on the value will allow the user to change the value. This field is typically set to the valve travel time multiplied by 1.5. The cycle time range can be 0 – 300.
Setpoint Change Limit
This is a smart time feature that allows the Process Loop to use PB only without Reset until the Process Variable drops below the percent output set under this category. It is used to eliminate overshoot. The Output percentage selected under this category furnace at heat. Clicking on the value will allow the user to change the value.
must
be above the normal operating output percentage of the
Example – if the furnace runs at 40% output at heat for the maximum load, the setpoint change limit should be set to
.
60%
The value can be:
OFF 80 % 70 % 60 %
Page 27
50 % 40 % 30 % 20 %
Low Limit This is the low limit field. Clicking on the value will allow the user to change the value. The range is –100 to 100.
High Limit This is the high limit field. Clicking on the value will allow the user to change the value. The range is –100 to 100.
0 Setpoint Stops Control
If the Setpoint is zero, then all outputs are turned off. Clicking on the value will allow the user to change the value. The option is either Yes or No.
Furnace Setup
The Furnace Setup menu option is an administrative access only option. Do not make any adjustments on this screen without first contacting Super Systems Inc.
Date and Time
This option will display the current date and time on the 9120 controller. From this menu option, the user can change the date/time
Furnace Name
This value will define the name of the furnace. Clicking on the “Value” column will bring up an input box where the user can enter the furnace’s name.
PV1 Name
This value will define the name of the first process variable. Clicking on the “Value” column will bring up an input box where the user can enter the PV’s name.
PV2 Name
This value will define the name of the second process variable. Clicking on the “Value” column will bring up an input box where the user can enter the PV’s name.
PVT Type
The PVT type is the mode the device runs in (Carbon, Dewpoint, etc.). The mode selected determines the calculations and scaling for the Process Variable. Any time this selection is changed it is necessary to reset the factory defaults to ensure all parameters have been changed to the new Process Variable ( Defaults button or FD Preserve button). Clicking on this value will display an input box with a drop-down list from which the user can select a new PVT Type. The values for the PVT type are:
% Carbon Dew Point Oxygen
Options
menu →
on the 9120 controller
Settings
menu option → Set
.
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Millivolt Redundant Probe Simple Nitrider Dual Loop
Temperature Mode
This value determines the specific temperature scale to be used. Clicking on the value will allow the operator to change the value. It can be either Degrees °°°°F or degrees °°°°C.
Level 1 Code
Typically, operations used by a supervisor require a level 1 code for access. When a supervisor is logged in, the lock on the toolbar will be gold, . To change the level 1 passcode, click on the “Level 1 Code” value (range is –32768 to
32767) and an input box will be displayed where the user can select a new value.
Level 2 Code
Typically, operations used by an administrator require a level 2 code for access. When an administrator is logged in, the lock on the toolbar will be green, . To change the level 2 passcode, click on the “Level 2 Code” value (range is –
32768 to 32767) and an input box will be displayed where the user can select a new value.
Web Level 1 Code
This value is the supervisor-level passcode for any web-based operations with the 9120 controller. Clicking on the value will allow the operator to change the value. The range for the passcode is 0 to 9999.
Web Level 2 Code
This value is the administrator-level passcode for any web-based operations with the 9120 controller. Clicking on the value will allow the operator to change the value. The range for the passcode is 0 to 9999.
Web Change Enable
This will either enable or disable the web change feature, which will allow changes to be made over the web page for the 9120 controller. Clicking on the value will allow the operator to change the value. Select either a 0 (Web Change Disable) or a 1 (Web Change Enable).
O2 Mode
This value will allow the operator to select the oxygen mode. Clicking on the value will allow the operator to change the value. The options are:
% with control Monitor Offset with control. Sample Pump Mode Remote Setpoint Remote Setpoint Hysteresis
Sample Pump Mode This menu option will allow the user to turn the sample pump On or Off. For the HP PVT types (% Carbon, Dewpoint, Oxygen, Millivolt, and Redundant Probe), there is the option to set a minimum temperature in order for the pump to
run. See the “Minimum Temp/Pump Run” description below.
Remote Setpoint
This option will allow the user to select where the remote setpoint will come from. The options are:
None Slave 1 PV
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Slave 2 PV Slave 1 SP Slave 2 SP Input 3 Value
Remote Setpoint Hysteresis This option will allow the user to enter the remote setpoint hysteresis. The range is 0 to 9999.
Minimum temp/pump run
This option will set the minimum temperature for the pump to run, if that feature is used. A 0 value will disable the minimum temperature feature.
for the pump minimum temperature feature to work
Input 1
This value will display the Input 1 type. This value cannot be changed from this screen.
Input 2
This value will display the Input 2 type. This value cannot be changed from this screen.
Input 3
This value will display the Input 3 type. This value cannot be changed from this screen.
Note: The furnace that is being sampled must have its temperature connected to input 3
.
Loop 1 PV
This value will display the Loop 1 PV type. This value cannot be changed from this screen.
Loop 2 PV
This value will display the Loop 2 PV type. This value cannot be changed from this screen.
Communications Setup
Communications Setup
666-4330 for more information regarding port setup. It is
is the communications definitions for the controller. Please contact Super Systems Inc. at 800-
strongly recommended
that none of the settings be modified
Page 30
without technical support from Super Systems Inc. Clicking on any of the values will display an input box that will allow the user to modify the current settings.
Slave Instrument Setup
This menu option will allow the user to set up the slave instruments for the 9120. ** All devices on the same slave port must utilize the same protocol ** An address of zero (0) will disable the instrument** Some controllers (AC20, for example) can provide dual functions (atmosphere and events) and must have the same address assigned for both.
Clicking on the “Value” field for any instrument will allow the user to select the slave instrument.
Instrument
This value will allow the user to select the slave instrument type. The following is the list of instruments available as slave instruments: SSi AC20 Eurotherm 2500 (temp) SSi Quad AO2
Yokogawa 750 (atm) Unipro v3.5 SSi Quad AO3 Honeywell UDC3300 (atm) Unipro v3.0 SSi Quad AO4 Dualpro LP1 Modbus (atm) Carbpro v3.5 Slave (temp) Yokogawa UT350 Dualpro LP2 Modbus (atm) Carbpro v3.0 Slave (temp) Yokogawa 750 Lp 2 Dualpro LP1 MMI (atm) 10Pro Yokogawa UP350 Dualpro LP2 MMI (atm) Dualpro IN C Honeywell DCP551 Eurotherm 2404 (atm) 9200 LP1 (temp) Ascon 08 Eurotherm 2500 (atm) 9200 LP2 (temp) SSi AC E Cabpro v3.5 (atm) 9200 LP3 (temp) Yokogawa 750E Cabpro v3.0 (atm) 9100 LP2 Mod Mux CarbPC Eurotherm 2704 LP1 Dualpro E Modbus 9200 LP1 (atm) Eurotherm 2704 LP2 Dualpro E MMI IR Base Eurotherm 2704 LP3 Carbpro E v3.5 MGA VC Base 1 Carbpro E v3.0 SSi 7EK VC Base 2 Eurotherm 2500 Yokogawa 750 (temp) VC Base 3 SSi 8-8 Honeywell UDC3300 (temp) VC Base 4 SSi 9200 E Dualpro LP1 Modbus (temp) AIPC Micrologix PLC Dualpro LP2 Modbus (temp) SSi 7SL MCM Module Dualpro LP1 MMI (temp) AEC Flow Board PLC5 DF1 Dualpro LP2 MMI (temp) UMC800 LP1 SLC DF1 Eurotherm 2404 (temp) SSi Quad AO1
Address
Page 31
This value allows the user to select the address that corresponds with the controller selected, with a range of 0 to 249.
Port
Currently, the option for this field is Slave 1. Slave 1 – terminals 5(-), 6(+) Slave 2 – terminals 22(+), 23(-).
Analog Input Setup
The 9120 controller has two analog inputs. Each of the inputs comes with a factory default configuration dependent on the application (refer to PVT type under the or in the field by a technician or qualified/trained person with the proper security code. Analog Input Terminals Analog Input 1 – terminals 31 and 32 Analog Input 2 – terminals 29 and 30
Parameter Definitions Input Type
The thermocouple type for most applications can be modified depending on your specific needs. Please note that in some applications, some of the inputs DO NOT allow the user to modify the Input type.
Note: Before changing
the input type, make sure to set the
.
appropriate jumpers, if necessary
The jumper will need to be manually changed on the input board before changing the input type to a 10:1 setting (non-thermocouple
. To change the Input type, first select
types)
which input you want to change by selecting it in the pull-down menu just below the main menu list. Clicking on the Value will display an input box, and then you can use the pull-down menu to select the desired parameter. Once selected, click type under Value will be the current type.
The following is a list of the options:
B S 12.5 volts C T 781.25mv E 2.5 volts 195.3125 mV J 1.25 volts K 78.125 mV N 19.53125 mV NNM 4-20 mA R 25 volts
Filter time
The filter time is a factory applied averaging tool used to help maintain steady control in high EMI environments. The filter time should not be adjusted with consulting SSI. Clicking on this value will display an input box from which the user can select a new value. The range is 0 to 32767.
Initial Scale
OK
and the displayed Input
Furnace Setup
section). It can be modified prior to shipment to your facility
Page 32
This is the initial scale value. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Full scale
This is the full scale value. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Decimal Point Location
This is the decimal point location value. Clicking on this value will display an input box from which the user can select a new value. The range is 0 to 4.
Open TC This is the open TC value. Clicking on this value will toggle between up scale, and down scale.
Input Offset
The input offset value is algebraically added to the input value to adjust the input curve on read-out.
offsets are unscaled
Trip Point 1 Setpoint This is the trip point 1 setpoint value. The range is –32768 to 32768.
Trip Point 1 Force Value This is the trip point 1 force value. The range is –32768 to 32768.
Trip Point 1 Direction This is the trip point 1 direction. The options are: input above setpoint or input below setpoint.
Trip Point 2 Setpoint This is the trip point 2 setpoint value. The range is –32768 to 32768.
Trip Point 2 Force Value
This is the trip point 2 force value. The range is –32768 to 32768.
Trip Point 2 Direction
This is the trip point 2 direction. The options are: input above setpoint or
input below setpoint.
High Input Limit Setpoint
This is the setpoint for the high input limit. The range for this can be –
32768 to 32768.
High Input Limit Hysteresis
This is the hysteresis for the high input limit. The range for this can be – 32768 to 32768.
. The range is –5000 to 5000.
Note: The input
Analog Output Setup
The 9120 controller has the option of
Page 33
two analog outputs. The outputs are ranged for a 4 – 20 milliamp signal or a 0 – 20 milliamp signal. Each output comes with a factory default configuration dependent on the application. Each output can be modified prior to shipment to your facility or in the field by a supervisor.
Analog Output Terminals
Analog output 1 – terminals 24 and 25 Analog output 2 – terminals 25 and 26
Assignment
The analog output assignment can be modified depending on your system requirements. To change the Assignment first select which analog output you want to change by selecting it in the pull-down menu just below the main menu list. Clicking on this value will display an input box, and then you can use the pull-down menu to select the desired parameter. Once selected click OK and the displayed assignment under Value will be the current assignment type. The following is a list of the options:
PV 1 retrans Input 1 retrans Loop 1 inc Input 2 retrans Loop 1 dec Input 3 retrans Loop 1 combo PV1 retrans w/ expo range PV 2 retrans O2 offset log Loop 2 inc SP1 retrans Loop 2 dec SP2 retrans Loop 2 combo DP retrans Disassociation Nit_Pot Hydrogen
Combo example for carbon – 4 – 12 mA Air 12 – 20 mA Gas
Offset
This is the starting point, the Process Variable value at which you get 4 milliamps. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Range
This is a Process Variable value between 4 and 20 milliamps. Clicking on this value will display an input box from which the user can select a new value. The range is –32768 to 32767.
Note: The range, although not displayed with a decimal point, contains a decimal point that is dependent on the process variable selected. For example, If the offset is 20 mV for 4 mA, and you want 100 mV to be 20 mA, then your range should be 80. If the process variable is temperature, then the range will be 80, since temperature PVs do not have a decimal. If the PV is % Carbon, then the range will need to include the two decimal points for % Carbon. So, a range of 80 will be entered as 8000
for more examples.
Current Selection
Provides the option of 4-20 mA or 0-20 mA control. Clicking on this value will display an input box with a drop-down list from which the user can select either of the two values listed above.
Offset and Range when assigned to a control loop
Inc -- 0 = 4mA, 100 = 20mA Dec -- 0 = 4mA, -100 = 20mA
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is Temperature Offset = 800 (starting point)
. See below
Page 34
Range = 400
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is O2 Offset = 800 (starting point) Range = 4000 (400.0)
Example: if 4 – 20 mA = 800 mV - 1200 mV and PV is % Carbon Offset = 800 (starting point) Range = 40000 (400.00)
O2 Exponent Range
This menu option will allow the user to set the Oxygen exponent range. The range is 0 to 10.
The 9120 controller has the option of using eight relay outputs. All of the relays have a positive common terminal and independent negative terminals. All of the relays are configured in a normally closed position except relay number eight, which has both a normally closed (NC) and a normally open (NO) terminal.
Note: Relay 1 through Relay 8 are display-only and cannot be modified from this screen
Relay Output Terminals
Relay Output 1 – terminals 7 and 8 Relay Output 2 – terminals 7 and 9 Relay Output 3 – terminals 7 and 10 Relay Output 4 – terminals 7 and 11 Relay Output 5 – terminals 7 and 12 Relay Output 6 – terminals 7 and 13 Relay Output 7 – terminals 7 and 14 Relay Output 8 – terminals 7 and 15 NC Relay Output 8 – terminals 7 and 16 NO
.
Alarm Setup
The 9120 controller can be configured to use three different alarms. Each of the alarms consists of an alarm setpoint, alarm type, alarm hysteresis, smart alarm, ON delay time, and a 0 SP blocks alarm value. The alarms come from the factory with a default configuration dependent on the application but also can be modified prior to shipment to your facility or in the field by a supervisor.
Setpoint
This value is the setpoint for the alarm. Clicking on this value will display an input box from which the user can select a new value. The range is from –9999 to 9999.
Alarm Type
This value is the type of alarms
Page 35
used. Clicking on this value will display an input box with two (2) drop-down lists from which the user can select a new value. The values in the first (top) list box are:
PV 1 Value PV 2 Value PV 3 Value Input 1 Value Input 2 Value Input 3 Value PO1 Value PO2 Value PO3 Value
The values in the second (bottom) list box are: Process High
Process Low Band, Normally Open Band, Normally Closed Deviation, Normally Open Deviation, Normally Closed
Deviation alarm is single sided. i.e. a +10 deviation will alarm when the PV is greater than SP + 10 but not neg. A -10 deviation will alarm when the PV is less than SP -10 but not on the positive side.
When set to deviation, the alarm message shows in Configurator below or above. The actual relay setup with that alarm will only energize depending on the setpoint. For the standard alarms (1, 2, and 3), the user can select if the alarm condition is for above or below. This will dictate when the relay will energize.
Example: alarm 1 set to plus 10F will alarm 11 degrees above setpoint and pull in the relay. It will show alarm 10 degrees below but not pull in the relay.
A Band alarm will activate and energize the relay on both sides (+) and (-).
Note: some alarm types may be fixed at the current value
.
Hysteresis
The hysteresis is in degrees, i.e. 10 hysteresis = 10 degrees. Alarm hysteresis should not have a decimal place. It is in units. If it is a control loop doing on/off control then the decimal place on the reset (hysteresis) should be ignored. The Hysteresis is a set number that works with the alarm to help control a motor or pump longer to reach a set amount to come back into band before it will shut off motor or pump.
Example: Using quench oil as an example, assume the SP is 200F. The alarm is set as a deviation of +10F. At 210 the alarm is active and the pump will run to cool the oil. With a hysteresis of 8 degrees the alarm and pump will turn off at 202F. It will turn back on when it is 10 degrees above setpoint. If the setpoint is still 200 then at 210 it is on again. Clicking on this value will display an input box from which the user can select a new value. The range is from 0 to 9999.
Smart Alarm
This value is a display of the Smart Alarm status. A smart alarm is an alarm that works with a Process Variable and when enabled it will not be active until the process variable is within band of the setpoint.
Example: If the SP is 1700 and the band is 10 degrees the alarm will not be active until the PV reaches 1690. The value can be either disabled or enabled.
ON Delay Time
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This value is the ON Delay Time for the Smart Alarm, in seconds. If the timer is utilized the alarm will not be active until in band and the timer has timed out (this is in seconds).
Example: If you select 30, the output will not energize until 30 seconds after the alarm is active. Clicking on this value will display an input box from which the user can select a new value. The range is from 0 to 9999 seconds.
0 SP Blocks Alarm This value will allow a 0 setpoint to block an alarm. The options are either no or yes.
Calibration
Overview
The series 9120 controller can be calibrated using the operator interface Configurator software, usually supplied with the system. Before performing this procedure on a newly installed controller, the unit needs to be powered on for at least thirty (30) minutes for a warm up period to allow the inputs/outputs to stabilize with the environment. The series 9120 has two analog inputs. Each range has a zero and span calibration value. A cold junction trim value must be calibrated for thermocouple inputs. There are two analog outputs each with a zero and span value. When using the User Calibration procedure this will allow for the user to only calibrate the input ranges being used in the controller for which ever specific PVT is selected under furnace setup. The Full Calibration will calibrate all of the input ranges regardless of what is selected for PVT.
Equipment needed
A certified calibrator(s) with the ability to input and read millivolts, milliamps and thermocouples is required. The appropriate connection leads are also required. A 24VDC 75-watt power supply is required. The operator interface method requires a PC with the Configurator software loaded. An Ethernet crossover cable is required.
Page 37
Calibration Procedure
The calibration procedure for an input or output will be the same regardless of which operation is being performed. Zero Input: Source a zero mV value to the terminals. Press the Calibrate button. Span Input: Source a specific mV value to the terminals and enter the value in the box. Press the Calibrate button. Zero Output: Press the Prep for Zero button, which will set the output to 0%. Measure the current at the terminals and output the measured value. Enter the value in the box. Press the Calibrate button. Span Output: Press the Prep for Span button, which will set the output to 100%. Measure the current at the terminals and output the measured value. Enter the value in the box. Press the Calibrate button.
User Calibration
Cold Junction Offset
Note: The cold junction offset should be performed after the inputs/outputs have been calibrated
If adjusting the input by a preset amount for all temperature points, calibrate the cold junction by entering a new value ­positive or negative – that would be the difference of the value indicated. Wait 120 seconds and verify with a source calibration device with the correct T/C type. In the “Calibrate Cold Junction” section, enter the temperature of the terminals and click on the Calibrate button. This will calibrate the cold junction value.
Zero/Span Input 1 / Range 0
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
value for the input. Press the Back button to return to the previous screen or press the Next button to view the next screen. Press the Done button to close the calibration screen down.
Zero/Span Input 2 / Range 3
(listed above) to calibrate the zero and span
. Perform the
Calibration
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
value for the input. Press the Back button to return to the previous screen or press the Next button to view the next screen. Press the Done button to close the calibration screen down.
Zero/Span Input 3 / Range 3
(listed above) to calibrate the zero and span
. Perform the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. Press the Done button to close the calibration screen down.
Zero/Span Output 1
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. Press the Done button to close the calibration screen down.
Zero/Span Output 2
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. Press the Done button to close the calibration screen down.
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Calibration
. Perform the
. Perform the
. Perform the
.
Calibration
Calibration
Calibration
Page 38
Full Calibration
Cold Junction Offset
Note: The cold junction offset should be performed after the inputs/outputs have been calibrated Note: These steps should only be performed if the User Calibration procedure did not calibrate the inputs and outputs
If adjusting the input by a preset amount for all temperature points, calibrate the cold junction by entering a new value ­positive or negative – that would be the difference of the value indicated. Wait 120 seconds and verify with a source calibration device with the correct T/C type. In the “Calibrate Cold Junction” section, enter the temperature of the terminals and click on the Calibrate button. This will calibrate the cold junction value. The Set Nominal button will set nominal values for the cold junction value.
Zero/Span Input 0 / Range 0
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
value for the input. Press the Back button to return to the previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 0 / Range 1
(listed above) to calibrate the zero and span
. Perform the
Calibration
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
value for the input. Press the Back button to return to the previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 0 / Range 2
(listed above) to calibrate the zero and span
. Perform the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 0 / Range 3
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 1 / Range 0
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 1 / Range 1
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Calibration
. Perform the
. Perform the
. Perform the
. Perform the
.
.
Calibration
Calibration
Calibration
Calibration
Page 39
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 1 / Range 2
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 1 / Range 3
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 2 / Range 0
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 2 / Range 1
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 2 / Range 2
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 2 / Range 3
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 1 Range Jumper
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 2 Range Jumper
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Input 3 Range Jumper
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
. Perform the
. Perform the
. Perform the
. Perform the
. Perform the
. Perform the
. Perform the
. Perform the
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Page 40
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Output 1
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
Zero/Span Output 2
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
Note: The inputs should be zeroed and spanned before adjusting the cold junction offset Procedure
previous screen or press the Next button to view the next screen. The Set Nominal button will set nominal values for the inputs. Press the Done button to close the calibration screen down.
(listed above) to calibrate the zero and span value for the input. Press the Back button to return to the
. Perform the
. Perform the
. Perform the
Calibration
Calibration
Calibration
Page 41
AAppppeennddiixx 11 –– SSttaannddaarrdd CCoonnffiigguurraattiioonnss ffoorr PPVVTT TTyyppeess
PVT Type Standard Configuration
% Carbon Input 1 is sensor millivolts, and is set to 2.5 volts (fixed) Input 2 is HP/sensor temperature and will only allow TC types Input 3 is universal and is set to control loop 2 Control loop 1 PV is %C calculated from inputs 1 and 2 Control loop 2 PV is temperature from input 2
Dew Point Input 1 is sensor millivolts, and is set to 2.5 volts (fixed) Input 2 is HP/sensor temperature and will only allow TC types Input 3 is universal and is set to control loop 2 Control loop 1 PV is Dew Point calculated from inputs 1 and 2 Control loop 2 PV is temperature from input 2
% Oxygen Input 1 is sensor millivolts, and is set to 1.25 volts (fixed) Input 2 is HP/sensor temperature and will only allow TC types Input 3 is universal and is set to control loop 2 Control loop 1 PV is %O2 calculated from inputs 1 and 2 Control loop 2 PV is temperature from input 2
Millivolts Input 1 is sensor millivolts, and is set to 2.5 volts (fixed) Input 2 is HP/sensor temperature and will only allow TC types Input 3 is universal and is set to control loop 2 Control loop 1 PV is millivolts from input 1 Control loop 2 PV is temperature from input 2
Probe Redundancy Input 1 is probe #1 millivolts, and is set to 2.5 volts (fixed) Input 2 is probe #2 millivolts, and is set to 2.5 volts (fixed) Input 3 is universal and is set to control loop 1 Control loop 1 PV is universal from input 3
Simple Nitrider Input 1 is not used Input 2 is not used Input 3 is not used No control loops Analog output 1 is H2 0 – 100% Analog output 2 is DA 0 – 100%
Dual Loop Input 1 is universal and assigned to control loop 1 Input 2 is universal and assigned to control loop 2 Input 3 is universal and is not used Control loop 1 PV is millivolts from input 1 Control loop 2 PV is temperature from input 2
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Note: All of these values can be viewed from the
Furnace Setup
Furnace Setup
Furnace Setup
Furnace Setup
Furnace Setup
Furnace Setup
Furnace Setup
menu option
menu option
menu option
menu option
menu option
menu option
menu option
Page 42
Outputs Analog output 1 defaults as Loop 1 PV retrans except when PVT = Simple Nitrider (output 1 is H2 0 – 100%) Analog output 2 defaults as Loop 1 control except when PVT = Simple Nitrider (output 2 is DA 0 – 100%) Relay 1 is always loop 2 control (HP temperature) Relay 2 is always input 2 high limit Relay 3 is loop 1 control increase (gas) except when PVT = %Oxygen (Relay 3 is loop 1 control decrease) Relay 4 is loop 2 control decrease (air) except when PVT = %Oxygen (Relay 4 is loop 2 control increase) Relay 5 is always sample pump for HP except when PVT = Probe Redundancy (Relay 5 is probe select) Relay 6 is always probe burnoff Relay 7 is selectable alarm output (any combination) Relay 8 is always general alarm output (any alarm)
Alarms Alarm 1 is always process high on input 2 Alarm 2 is fully assignable Alarm 3 is fully assignable
Digital Inputs (Event Inputs) Digital Input 1 (event In 0) selects probe 1 when PVT = Probe Redundancy only Digital Input 2 (event In 2) selects probe 2 when PVT = Probe Redundancy only Digital Input 3 (event In 2) inhibits sample pump for HP only Digital Input 4 (event In 3) starts probe burnoff when PVT = % Carbon, Dew Point, % Oxygen, or Millivolts
Note: Probe burnoff is available only for PVT types: % Carbon, Dew Point, % Oxygen, and Millivolts
.
impedance test.
.
Note: Dew Point is calculated only for PVT types: % Carbon, Dew Point, % Oxygen, and Millivolts
No
Page 43
AAppppeennddiixx 22 –– AAcccceessssiinngg tthhee SSSSii 99112200 WWeebb PPaaggee
Each SSi 9120 comes equipped with a small webpage that can be accessed over a company’s network, or through a local computer hooked up to the 9120 with a crossover cable. To access the web page, enter the IP address of the SSi 9120 instrument into the address bar of any Internet browser.
Note: Viewing the web page requires the Java platform to be installed on the local computer. Also, some security settings in Internet Explorer 7 may cause the website to not be displayed, even if Java is installed
onto a local computer, and the required Internet Explorer 7 settings. Once the IP address of the instrument is entered, press the Enter button on the keyboard, or press the “Go” button next to the address bar. The user can navigate through the web page by using the buttons along the top of the screen, or the buttons along the bottom of the screen. The first page shown is the
Home
page. This page will display the two process variables and the two setpoints. This page is mainly a display­only page. The next page is the Setpoint 2) for either loop as well as set the loops to auto or manual(Auto/Man 1 or Auto/Man 2). If the loops are in manual mode, the user will also be able to set the control percentage as well (Output PWR 1 and Output PWR 2). The Set Value button will set the setpoints and manual control percentages.
. Contact your company’s IT department for more information on downloading Java
Operator
page. This page will allow the user send down a setpoint (Setpoint 1 or
Note: The user will need to be logged in as a
Page 44
supervisor or administrator to make any changes
Configurator’s page is the Also, the user will need to be logged in as an administrator (web level 2 code from Configurator make any changes. From this screen, the user can change the following for each loop: Setpoint, manual control percentage, Proportional Band (P), Reset (I), Rate (D), Cycle time, Integral preset, High limit, and low limit. The next page is the impedance test is in progress. The user will also be able to start a burnoff or impedance test from this page.
Furnace Setup
PID Tuning
Probe
page. This screen will allow the user to view the probe burnoff settings and progress, if a burnoff or
menu option (supervisor = web level 1 code; administrator = web level 2 code). The next
page. This page is similar in function to the
user will need to be logged in as an administrator (web level 2 code from Configurator changes
make even more changes to the instrument.
code from Configurator
for each loop: Setpoint, manual control percentage, CO Factor, Proportional Band (P), Reset (I), Rate (D), Cycle time, Integral preset, High limit, low limit, alarm setpoint, alarm hysteresis, Burnoff interval, burnoff time, burnoff recovery time, burnoff minimum mV, and burnoff maximum TC. This page will also display information about the two loops, alarm information, and input information. The next page is the should help the user to navigate and use the web page. The last page is the auxiliary analog inputs, if any.
. The next page is the
Furnace Setup
Supervisor
menu) to make any changes
page. This page is similar to the PID Tuning page, but it will allow the user to
. The supervisor and administrator passwords can be changed from
Operator
page, but it will entail more information.
Furnace Setup
menu) to
Note: The
Furnace Setup
menu) to make any
Note: The user will need to be logged in as an administrator (web level 2
. From this screen, the user can change the following
Help
page. This page displays some general help topics that
AUX A/I
page. This page will display any
Page 45
RReevviissiioonn HHiissttoorryy
Rev Description Date MCO #
- Initial Release 6/23/2008 N/A
A Updated “Analog Output Setup” section; Added minimum temp pump
8/18/2008 2065
run in “Furnace Setup” section
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