Super Systems 9200 User Manual
Model 9200 Programmable Dual-loop Controller
Super Systems Inc.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060
800-666-4330
Fax: 513-772-9466
www.supersystems.com
Model 9200 Controller
USER’S MANUAL
Super Systems Inc. help desk:
1-800-666-4330
SSi Manual SERIES 9200 1 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Table of Contents
Safety ............................................................................................................................... 4
About This Manual.............................................................................................................. 6
Controller Description ......................................................................................................... 6
Model 9200 Terminals Connections ...................................................................................... 7
Additional Features.............................................................................................................7
Ethernet Connections.......................................................................................................... 7
Mechanical Installation........................................................................................................ 8
Electrical Installation........................................................................................................... 8
Instrument Start-up............................................................................................................ 8
Flash Card & Flash Card Reader........................................................................................... 8
Operator Interface Screen Saver.......................................................................................... 8
Chapter 1 - INSTALLATION ............................................................................................ 9
Mounting ........................................................................................................................... 9
Default Status Screen ......................................................................................................... 9
Display .............................................................................................................................. 9
Loops Display....................................................................................................................10
Menu Display ....................................................................................................................10
Menus ..............................................................................................................................11
Program Display................................................................................................................12
Quench / Zone Instrument Assignments (Read-only)...........................................................13
Chart................................................................................................................................13
Alarm Ack .........................................................................................................................14
Data Logging using Flash Card ...........................................................................................14
Chapter 2 - CONFIGURATION .......................................................................................15
Configuration Menu ...........................................................................................................15
Program Edit.....................................................................................................................15
Factor Entry......................................................................................................................16
Burnoff.............................................................................................................................16
Auxiliary Instruments (Read-only).......................................................................................17
Auxiliary Analog Input (Read-only)......................................................................................17
Shutdown (Display) ...........................................................................................................17
Adjust Date and Time ........................................................................................................17
Slave Communications Status.............................................................................................18
Backup Compressed Data...................................................................................................18
Manual Event Control.........................................................................................................18
Probe Burn off Setup .........................................................................................................18
PID Loop Setup (Includes cycle time and more….) ...............................................................19
Event Run Program Setup ..................................................................................................20
Zone / Load TC Setup........................................................................................................20
Port Setup ........................................................................................................................21
Instrument Setup ..............................................................................................................21
Zone Assignments .............................................................................................................23
Furnace Setup...................................................................................................................24
Default Wait Limits ............................................................................................................24
Furnace Name...................................................................................................................24
Alarm Setup......................................................................................................................25
Relay Assignments ............................................................................................................25
Relay Set Points ................................................................................................................26
Analog Input Setup............................................................................................................27
Analog Output Setup .........................................................................................................27
SSi Manual SERIES 9200 2 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Passcode and Alarm ..........................................................................................................28
IP Address ........................................................................................................................28
Event Control....................................................................................................................29
Valve Setup – USED ONLY IN THE NITRIDING VERSION ......................................................29
Valve Inputs –USED ONLY IN THE NITRIDING VERSION ......................................................30
Programmer Setup ............................................................................................................30
Recipe Transfer.................................................................................................................30
User Calibration.................................................................................................................30
Full Calibration ..................................................................................................................33
Set Menu Security .............................................................................................................33
Read/Write Raw Data ........................................................................................................34
Tuning Assistant................................................................................................................34
Curve Entry.......................................................................................................................36
Alternate PID Setup...........................................................................................................36
Analog Input Board Setup ..................................................................................................36
AI Board Calibration...........................................................................................................36
ADAM Correction ...............................................................................................................36
Aux SP Configuration .........................................................................................................37
Chapter 3 - PROGRAMS .................................................................................................38
Overview ..........................................................................................................................38
Program Editing ................................................................................................................38
Chapter 4 - SERIES 9200 Opcodes................................................................................39
Programmer Description.....................................................................................................39
Opcodes ...........................................................................................................................39
Chapter 5 - APPLICATIONS INFORMATION .................................................................44
9200 MMI Protocol Register Mapping ..................................................................................44
Default Values...................................................................................................................44
Sample Recipe - % Carbon and Temperature (Batch Furnace)...............................................47
Standard Event Assignments ..............................................................................................47
Flash Card Management.....................................................................................................47
SDRecorder Installation......................................................................................................49
Slave Instrument Mapping..................................................................................................51
Revision History.............................................................................................................61
SSi Manual SERIES 9200 3 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Safety
Safety Symbols
•
Functional earth (ground) terminal
The functional earth connection is required for safety purposes and to ground RFI filters.
Personnel
•
Enclosure of live parts
•
live (powered), the controller must be installed in an enclosure.
Caution: Live sensors
•
!
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, which might be damaged
by live (powered) sensors.
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 sensor input or other lowlevel inputs and outputs. Only use copper conductors for connections (except thermocouple inputs) and
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
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
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
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
not exceed 264VAC:
• line or neutral to any other connection
• relay or triac output to logic, DC or sensor connections
• any connection to ground.
- Various symbols are used on the instrument, they have the following meaning:
Caution (refer to the accompanying documents)
!
- Installation must only be carried out by technically qualified personnel.
- To prevent hands or metal tools from touching parts that may be electrically
- Do not connect live (powered) sensors to any signal input on the controller. Live
- The installation must include a power isolating switch or circuit breaker. This device
- Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This
- To protect the internal PCB tracking within the controller against excess
- The maximum continuous voltage applied between any of the following terminals must
SSi Manual SERIES 9200 4 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
The power supply/controller should not be wired to a three-phase supply with an unearthed star
connection. Under fault conditions such a supply could rise above 264Vac with respect to ground and the
product would not be safe.
Voltage transients across the power supply connections, and between the power supply and ground, must
not exceed 2.5kV. Where occasional voltage transients 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.
Conductive pollution
•
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
•
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.
Grounding of the temperature sensor shield
•
temperature sensor while the controller is still powered up. Under these conditions, as additional
protection against electric shock, we recommend that the shield of the temperature sensor be
grounded. Do not rely on grounding through the framework of the machine.
Installation requirements for EMC
•
installation precautions are necessary. 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
•
particularly the sensor input 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.
- Electrically conductive pollution must be excluded from the cabinet in which the
- When designing any control system it is essential to consider what will
- In some installations it is common practice to replace the
- To ensure compliance with the European EMC directive certain
- To minimize the pick-up of electrical noise, the wiring for low voltage DC and
SSi Manual SERIES 9200 5 Programmable Dual-loop
!
Model 9200 Programmable Dual-loop Controller
About This Manual
This instrument is designed to be custom-configured for each specific application and customer need. The
applications (addendum’s to the general manual) include atmosphere control, vacuum furnace control and
nitriding control (% dissociation). Each addendum is application specific showing the specific screens and
terminal connections.
Controller Description
The Model 9200 is a multi-loop Proportional Integral Derivative (PID) controller that can be custom
configured to control a variety of different applications. General features of this product include:
The Model 9200 is powered by 24 VDC, not LINE Voltage. Please be careful when connecting power to this
controller. Connecting anything other than 24 VDC will cause serious damage.
The variety of input and output combinations allows SSi to configure the Model 9200 to control furnace
atmosphere
gauges), and to control nitriding
occasions where the three analog inputs have been used to control 3-zones of temperature.
(temperature and % carbon), to control vacuum furnaces (temperature and vacuum
Approximate Box Dimensions 2.75" x 4" x 4.5"
Power Requirements 24VDC, 4 Watts
Digital Output Rating
Analog Output Load Rating
Controller Enclosure Rating
Number of RS232 Ports One (1)
Number of Ethernet Ports One (1)
Number of RS485 Host Ports One (1)
Number of RS485 Slave Ports Two (2)
Number of Internal Relays Eight (8)
Number of Analog Inputs Three (3)
Number of Analog Outputs Two (2)
Number of Digital Inputs Four (4)
Number of Control Loops Three (3)
(temperature, % dissociation, and back-pressure). There are special
300VAC / 1 AMP
1000 Ohms (Total)
IP10 – hand protected
SSi Manual SERIES 9200 6 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Model 9200 Terminals Connections
Additional Features
The Operator Interface (touch screen) contains a removable compact Flash Card that can be used to
transfer data from the Model 9200 to a computer. This flash card acts like a removable hard drive,
however it is very small and contains no moving parts to make it very portable. It is located on the back of
the touch screen (see
Flash Card & Flash Card Reader
).
Also included is a Utility Software CD that includes SSi’s Super Data (SD) Charting. SD Charting is a utility
program that can be loaded onto any Windows® based computer (operating Windows 98® or higher).
This software will allow the computer to read the data from the Model 9200, and allow it to be charted in a
manner that is similar to a strip chart recorder.
The Operator Interface is normally accessed via the touch-screen, however connections also exist that will
allow the operator to use a traditional mouse and keyboard to enter information.
Ethernet Connections
The Ethernet connection has three distinct uses. The first is should the Operator Interface fail, the Ethernet
connection allows a laptop to be connected to the Series 9200 DIN rail mounted unit. This connection can
act as a LIMITED FUNCTION “operator interface” until the Operator Interface can be repaired or replaced.
The laptop needs to be operating a WINDOWS 98® or higher with Internet Explorer. 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. The second use for the Ethernet port would be for communications to
SSi Manual SERIES 9200 7 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
a SCADA software package. Call us at 800-666-4330 if you are interested in this option. The third use for
the Ethernet Port is the primary communications connection for the Configurator Software.
Mechanical Installation
The Model 9200 Operator Interface is generally flush-mounted, either in an existing enclosure, on a “plate”
that will be retrofitted to an existing enclosure, or on a new enclosure specifically designed for it’s particular
application. Installation begins by securing the new enclosure to the floor or wall, securing the retrofit plate
to the door of the existing enclosure, or flush-mounting the Operator Interface in a cut-out of the existing
enclosure. When tightening the retaining clips on the Operator Interface, it is important to make them snug
but not to over-tighten them. Over-tightening can warp the bezel and cause irreparable damage to the
Operator Interface. The DIN rail mount portion of the controller (the Model 9200 and the 24 VDC power
supply) needs to be located in close proximity to the existing wires that were connected to the older control
unit being replaced. These units should be secured prior to making any electrical connections.
Electrical Installation
The Model 9200 requires 24VDC, 4 Watt, 60 Hz, single-phase power. A 24 VDC power supply is required
and is generally included as part of the Model 9200 system. This power supply has a universal input that
can accept between 60 and 265VAC. Power should be applied in accordance with the electrical drawings
that have been supplied. Since each installation is unique for each site, the customer is responsible for
providing adequate power and making it available to the Model 9200 power supply.
!
SSi requirement:
MOV’s must be wired across the isolation relay coil terminals on all isolation relays that are connected to
solenoids. Further… MOV’s must be connected across the HOT and NEUTRAL wires when the solenoid is
wired to them. IT IS AN ABSOLUTE MUST to have the MOV’s at BOTH LOCATIONS.
Instrument Start-up
On power-up, the Operator Interface will display a logo screen for thirty seconds and then switch to the
default Status screen. The logo display can be terminated early by touching the screen.
Flash Card & Flash Card Reader
Never remove the flash card when the Operator Interface is “ON”.
To properly shut down the Operator Interface, press the Menu button, and select
prompt, press
Windows screen. Sliding the black switch to the OFF position (located directly over the green power
connector, on the back of the Operator Interface) will turn off the power to the Operator Interface.
Once the Operator Interface is turned off, remove the compact flash card cover at the top of the display
unit, exposing the card. Press the black release button and the card will pop out of the slot. To replace
the flash card, simply return the card to the slot making sure that the release button is in it’s UP position,
and replace the flash card cover to its proper position. To restore power to the unit, move the black switch
to the right or ON position.
Operator Interface Screen Saver
The Operator Interface has a default screen saver. It automatically “blanks” the screen after ten (10)
minutes of non-activity. To disengage the screen saver, simply touch the screen and it will re-appear.
Shutdown
Yes
to shut down the Operator Interface. This will bring you to a conventional Microsoft
. At the
SSi Manual SERIES 9200 8 Programmable Dual-loop
Mounting
The Series 9200 Operator Interface mounts into a panel or on a plate by using the enclosed 8
mounting brackets. With the exception of the Operator Interface, these items can be mounted on a
standard DIN rail for mounting inside an electrical enclosure. SSi supplies a 10-foot
communications cord with the two connectors and the piece of DIN rail required for the
components that have been ordered.
Default Status Screen
Display
Model 9200 Programmable Dual-loop Controller
Chapter 1 - INSTALLATION
Operator Interface Cutout: 7.40”W X 5.56”H
The Status Display shows the atmosphere and temperature controller information as well as an
overview of the programmer. There are six active buttons on the Status Display: Loops, Menu,
Program, Quench Zone, Chart and Alarm Ack. One hidden button is located behind the SSi
Logo. By activating this button selected Software and Firmware information will be displayed.
• The Loops button will switch the display to the two control loops, % Carbon on the left and
Temperature on the right.
• The Menu button will switch to the menu. The blue UP and DOWN arrow keys move you from
one selection to another. The Enter button will enter the selected Menu Screen, if access is
authorized.
• The Program button will switch to the Program Display. This is a companion display to the
status screen and is described below.
• The Quench Zone button will switch to the Quench and Zone Display. This is a companion
display to the Status Screen and is described below.
• The Chart button will switch the display to the video recorder display. Use of the Chart Display
is explained below.
• The Alarm Ack button is used to acknowledge an alarm. The alarm is displayed in the lower
left-hand corner of the Status Screen. A red ALM block in the top right corner of the screen
SSi Manual SERIES 9200 9 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
displays an alarm condition. The alarm will either be a flashing number, which indicates a
program operator alarm, or a flashing message, which indicates a program system alarm.
Loops Display
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 Enter key to
make the change. When the Enter key is
pressed the display returns to the Loops Screen.
The other active keys within the Loop Screen
are the two A/M (Auto/Manual) buttons.
Pressing either of those buttons moves you to a
display page asking for a supervisor or
administrative pass code. Pressing the proper
numeric keys and pressing the Enter button
changes the controllers mode from Auto to Manual, or from Manual to Auto depending on which mode it
was in when the A/M key was pressed. If you are in the manual mode, you may press that button on the
Loops Screen and a numeric keypad appears, allowing you to enter a % output to control the “loop” in a
manual mode.
Also displayed are the probe millivolts, the probe temperature, and the COF Factor. The COF 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 default Status Screen or to the Program Screen to
view the program currently running on the Series 9200 Dual Loop controller.
Menu Display
SSi Manual SERIES 9200 10 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
The remaining items on the Menu Display are:
• Instrument Setup
• Zone Assignments
• Furnace Setup
• Default Wait Limits
• Furnace Name
• Alarm Setup
• Relay Assignments
• Relay Setpoints
• Input Setup
• Output Setup
• Passcode and Alarm
• IP Address
• Event Control
• Valve Setup
• Valve Inputs
• Programmer Setup
• Recipe Transfer
• User Calibration
• Full Calibration
• Set Menu Security
• Read/Write Raw Data
• Tuning Assistant
• Curve Entry
• Alternate PID Setup
• Analog Input Board Setup
• AI Board Calibration
• ADAM Correction
• Aux SP Configuration
Menus
There are three levels of menus in the Series 9200.
• The first level is the
handled by the furnace operator. This menu is accessed without the need for a pass code.
• The second level is to be used by a
level 2-pass code.
• The third level is the
As shipped, the level 1 and level 2 codes are set as 1 and 2 respectively. The pass codes can be changed
at the Passcode and Alarm Screen
The menu has five operating buttons located on the right side of the screen. The UP arrow moves the
cursor from bottom to top. The Enter button activates the selection that the operator has chosen, the
DOWN arrow key moves the cursor from top to bottom, the Login key activates another screen that allows
access to the Supervisor Menu and the Configuration Menu, and the Esc key takes you back to the
previous screen without any action being taken.
SSi Manual SERIES 9200 11 Programmable Dual-loop
operator level
configuration level
.
. These are functions or operations that are typically
supervisor
. This level requires the entry of a level 1 or
. This requires the level 2-pass code ONLY.
Model 9200 Programmable Dual-loop Controller
Pressing the Login key takes you to the numeric keypad Enter Password Screen. Entering the correct
password (the default password is “2”) displays the Supervisor Menu, which includes the entire list of
menus necessary to configure the Series 9200. These are explained in detail in
Program Display
Pressing the Program key displays the default Program Status page.
The Program Status Display shows the last
program loaded into the program run buffer
and its status. If the program is running,
the active step number is highlighted, and
the status is running. A red ALM block in
the top right corner of the screen displays
an alarm condition.
The Program Display has seven active
buttons located on the right side of the
display. Touching the inside of the blocks
activates these. The active buttons are
Soak Adjust, Load, Stop, Hold, Cont,
Alm Ack (Alarm Acknowledge) and Esc.
Chapter 2 – Configuration
.
• The Soak Adjust button allows
you to enter a new value for the
time remaining in the current
soak or ramp cycle. A soak or
ramp cycle must be running for
a change in soak/ramp time to be adjusted.
• 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. You can start the program in any step, simply by moving the highlight down to the step
that that the program needs to be started in, and then pressing the Run key.
While reviewing the program that is about to be run, certain parameters within those steps can
be modified. You can change the set points, the time and the options. You CAN NOT delete a
step, or modify it’s OPT CODE.
• The Stop button stops the recipe program that is currently displayed. Stop means exactly that!
It stops the program. It is NOT a hold button. See hold below. To re-start the program if it has
been stopped you must use the Load button, enter the recipe number, and then highlight the
Run
segment number of the recipe that you want to start with and initiate
• 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 Cont button.
.
• The Cont button re-starts the displayed (active) recipe, where it was placed in hold at.
• The Alm Ack displays the Alarm Screen. From here you can acknowledge the alarm, in most
cases it will be acknowledging
program to go to the next step.
• The Esc button returns you to the default Display Screen.
SSi Manual SERIES 9200 12 Programmable Dual-loop
end of soak
. The alarm must be acknowledged to allow the
Model 9200 Programmable Dual-loop Controller
Quench / Zone Instrument Assignments (Read-only)
The Quench / Zone Instrument Assignments
Display shows two groups of information,
both of which are dependent on
CONFIGURATION or OPT CODE use. The
quench portion will only display if the
quench opcode was executed in a program.
This will then show the total quench time,
the time remaining, and the quench speed.
The zone group will display the process
variables that have been assigned in the
zone assignment configuration.
Chart
The Chart Display shows between 15 minutes and 7 days of process variable data on the screen, and can
be scrolled back to view all of the data stored on the hard drive (72 hours at a time). The vertical timelines
change as the time changes on the screen. A chart is available for the LP1 and LP2 only and a chart is
available for the LP1 and LP2 plus their set points. You can toggle between the two charts by pressing the
PREV and the NEXT keys.
The Prev and Next arrows
change the display from one chart
to another (i.e. from just process
variables to process variables and
set points.)
The blue RIGHT and LEFT
arrows move the displayed chart
along the horizontal axis, going
back and forward in time and
then returning to real time.
The + and – keys change the
time window displayed on the
screen.
The Note key 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 9200 instrumentation. The interface must be the ADVANTECH 5.7-inch with the Flash Card.
SSi Manual SERIES 9200 13 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Pressing the Note key displays an alphanumeric keypad asking for operator ID or initials. Pressing the
appropriate keys and then pressing the <- Enter key displays another alphanumeric keypad and prompts
the operator to enter a note. After pressing the keys on this keypad and then <- Enter key, the next
screen displayed asks you where you want the note written. The default choice is the current time and
date. You can change the parameters and place the note at whatever time and date is required. Pressing
the OK key takes you back to the real time chart page.
Pressing the Realtime key brings the chart display back to the current time.
The View key allows you to look at the NOTES that have been stored with the chart.
!
NOTE: See Warnings with respect to removing the Flash Card.
Alarm Ack
The Alarm Ack button displays the Active Alarm Screen. From which you can acknowledge any alarms that
have been configured, or that have been made part of the recipes that run on the Series 9200. If a recipe
has an alarm as a step, the alarm must be acknowledged before the recipe will continue to the next step.
Data Logging using Flash Card
The Advantech TPC-642S/642-SE touch screen Operator Interface utilizing a Compact Flash Card allows the
unit to data log the parameters setup by a qualified SSi technician. Should a customer not take his data
offline in a timely manner, the data will be over-written, the oldest data being that which is over-written
first. Here is how it works:
1. When the ADVANTECH Operator Interface detects that there is less than 5% disk space left on the
compact flash card, an alarm will be displayed on the main interface screen stating "x% disk space
remaining (overwrite at 3%)". In the upper right corner, an ALM is indicated, but because it is not a
communications alarm or a 9200 device alarm, the background remains green. This alarm will remain
active until more than 5% of disk space is available for writing data log files.
2. If the user does not copy the log data from the disk, it will eventually fall to 2% disk space. At this
point, the touch screen will select the oldest compressed file and delete it. It then checks to see if 3%
remains. It repeats this procedure until 3% disk space remains. At this point the alarm message changes
to "Overwriting data log data!” Because this allows the system to seesaw between 2% and 3%, it will
continue to display "Overwriting data log data!" until somebody offloads the files.
Technical concerns and details:
1. If there are not enough compressed files to bring the free space up to 3%, the system will hunt down
and kill hourly files. This should only happen if compression would not be running for some reason.
2. If all compressed files and hourly files have been removed and there is still not enough disk space
(perhaps a problem with the compact flash card), the data logger will not write to the disk until the
condition is remedied. (Alarms continue to display).
3. The data log data alarm is the lowest priority. The alarm priorities are touch screen communications,
then 9200 controller/programmer, then disk space.
SSi Manual SERIES 9200 14 Programmable Dual-loop
Configuration Menu
Program Edit
Model 9200 Programmable Dual-loop Controller
Chapter 2 - CONFIGURATION
The Configuration Menu is entered through the Menu
key that is part of the 7 buttons running down the
right side of the Default Display Screen. Pressing the
Login key that is below the blue up and down arrow
keys displays a numeric keypad. Enter the correct
passcode for the configuration level and press the
Enter key. This displays the following configuration
options:
Selecting this Program Edit button pops up another screen which asks the operator to enter a program
number to be edited. Enter 0 to edit a blank program. To ERASE/DELETE an existing recipe/program you
need to SAVE it as program Zero (0). Program 0 is a NO-OPT program.
When you enter a number for a stored program and push the Enter key the program steps are displayed.
Using the up and down arrow keys you select the step in the existing program that you wish to edit. Move
the cursor to that step and press the Enter key. The next screen to pop up will show the step’s parameter
and it’s value.
NOTE: A list of OPCODES appears in the Appendix of this manual.
Example:
Parameter equals OPCODE, Value equals SOAK.
Parameter equals TIME, Value equals 3:45.
Highlighting the opcode and soak and pressing the Enter key brings up a screen that shows all of the
possible opcodes. Selecting the opcode that you want to use for the program step that you are editing and
pressing the Enter key.
If you desire to change the time highlight the time and press the Enter key. The next screen is the Time
Edit Screen. To change the hour, press the Hour key in the upper right-hand corner. If you want to change
the minutes press the Min key. The next screen that pops up in both cases is a numeric keypad. Enter the
time that you wish to permanently change the recipe to and press the Enter key. If you DO NOT wish to
make any changes press the Esc key. Note, if you wish to only change the minutes, you must enter the
desired hour(s), if other than 0.
If you have made a change, pressing the Enter key takes you back to the Time Edit Screen. If you wish to
make the change, press the Set key on the right-hand side of the screen. The next screen to pop up
verifies the time has been changed to the number of minutes that you have selected. Pressing the Cancel
key takes you back to the full Program Screen. If you are sure that you want the change to be permanent
press the Set key. This takes you back to the screen that shows you the entire program. Notice that the
time has been changed on the program segment that you were editing. If you wish to save this change
press the Save key. You will notice that a numeric keypad pops up and asks you to enter the number of
SSi Manual SERIES 9200 15 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
the program that you wish to save. You must enter the desired program number you wish to save these
changes to.
NOTE: See the APPENDIX section of this manual for a sample program
.
The Insert button will insert a step into the recipe.
The Delete button will delete a step from the recipe.
The Esc button takes you back to the Default Menu.
Factor Entry
Highlighting the Factor Entry and pressing Enter pops up the Factor Entry Screen, showing the
parameter as CO Factor or H Factor and Value as is currently in the Series 9200. To make an adjustment,
press the Enter key. A numeric keypad will be displayed. Using the keypad, enter the number that you
wish the CO Factor to be and press the Enter key. This returns you to the original Factor Entry Screen,
which now shows the new CO Factor that you have entered. If you do not wish to make the change simply
press the Esc key which takes you back to the Factor Entry Screen with NO change being made to the CO
Factor.
The COF factor allows you to make adjustments that will allow the controller to match the results obtained
when measuring shim stock. If the controller set point and the process variable are the same, but you are
not attaining the desired surface Carbon, you can make the adjustment with the COF Factor to increase the
amount of surface Carbon available to the parts. If you lower the COF factor, it immediately lowers the %
Carbon process variable. This will cause the controller to add more enriching gas--- raising the process
variable until once again the process variable and the set point match. Conversely, raising the COF Factor
will cause the process variable to read higher, shutting down the enriching gas solenoid (possibly turning
on the air dilution solenoid) causing the % Carbon process variable to begin to lower (NOT ADDING
ENRICHING GAS) until the set point and process variable match.
Pressing the Esc button takes you back to the Menu Screen.
Burnoff
NOTE: All timer functions are in SECONDS
The Burnout Display shows the following
information:
Burnout, impedance test, when the next
automated burnout is scheduled, the test status,
the countdown timer, the probe mV’s, the probe
T/C, the last burnout date, the last impedance
test date, and the time that it took for the probe
to recover.
This screen will allow personnel to start a probe
burn off or impedance test, by highlighting the
desired test and pressing the Enter button.
SSi Manual SERIES 9200 16 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Auxiliary Instruments (Read-only)
Auxiliary Analog Input (Read-only)
The Auxiliary Analog Input Display shows the
information from any attached analog input
modules such as: load T/C’s, flows from WaukeeTronic flow meters, etc.
Shutdown (Display)
The Auxiliary Instruments Display shows the
following information:
The instruments slaved to the Series 9200 and their
process variables.
The Shutdown selection pops up another screen asking whether or not you wish to shutdown the interface
with the Series 9200. Two responses are possible Yes or No.
When you shutdown the ADVANTECH interface, the SERIES 9200 controller is still functioning. You can
monitor it by connecting the ETHERNET connection to a laptop computer, using Internet Explorer, and
assigning a legitimate IP address.
“Yes” shows you a typical computer screen with the Start button in the bottom left-hand corner. You can
now turn the power off to the operator interface without upsetting any of the settings. The “No” response
returns you to the initial Status Screen.
9200 Controller
.
Shutting down the Operator Interface does not shutdown the Series
Adjust Date and Time
Pressing Enter moves you to screen Clock setup.
Highlighting the date and pressing Enter moves you to a screen Date Edit.
The current date in the Series 9200 is displayed as well as the date on a scroll type display. Touching the
individual parts of the date [day (Monday, Tuesday, etc.), month, and year] will highlight that portion of
the date, and using the little up and down arrow keys will allow you to adjust the highlighted value.
SSi Manual SERIES 9200 17 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Pressing the Set button makes the change permanent.
If you desire to change the time highlight the time and press the Enter key. The next screen is the Time
Edit Screen. To enter the hour, press the Hour key in the upper right-hand corner. If you want to change
the minutes press the Min key. The next screen that pops up in both cases is a numeric keypad. Enter the
time that you wish to change the time to and press the Set key. If you DO NOT wish to make any changes
press the Cancel key. Note, if you wish to only change the minutes, you must also enter the hour in 24hour (Military) format.
Pressing the Cancel key takes you back to the Clock Setup Screen.
Slave Communications Status
Pressing the Enter key displays the auxiliary instruments and their status, if any.
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
This is a display only screen.
Backup Compressed Data
Pressing Enter displays the Backup Datalog Data.
This screen is NOT functional at this time.
Manual Event Control
Pressing Enter displays the Manual Event Control Screen.
Highlighting a specific event and pressing the
Enter key changes the displayed status of the
highlighted event. This will activate or deactivate whatever digital contact is connected to
that particular event.
Pressing the Esc key returns you to the original
Menu Screen.
Probe Burn off Setup
SSi Manual SERIES 9200 18 Programmable Dual-loop
Model 9200 Programmable Dual-loop Controller
Pressing the Enter key moves you to the Burn off Setup Screen. This screen shows the parameters and
values associated with a probe burn off.
NOTE: All timer functions are in SECONDS
Burn off Time (sec), Burn off Recovery Wait Time (sec), Burn off Interval (min), Minimum Burn off
Millivolts, and Maximum Burn off Temperature, Digital IN 3 starts burn off. If the burn off does not force
the oxygen probe to read below 800 mV’s then it does not record the burn off, and if the maximum
temperature reaches a value greater than the value indicated it will shutdown the burn off procedure to
prevent damage to the probe. Signal input at Digital Input 3 could be used to initiate probe burn off.
Highlighting any of the parameters and pressing the Enter key displays a numeric keypad that allows the
operator/supervisor to change the current value. Pressing the Enter button after pressing the keypad to
change the value moves you back to the Burn off Setup Screen.
Pressing the Enter button or the Esc button at this point takes you back to the Menu Screen.
PID Loop Setup (Includes cycle time and more….)
Pressing the Enter key moves you to the PID Screen, showing you Loop 1 and it’s control parameter (i.e.
% Carbon, etc.) and Loop 2 and it’s parameter (i.e. temperature)
The TOP two blue arrows move you from one loop to the other. Pressing the down top arrow moves you
from Loop 1 to Loop 2. Below each of the loops are shown the PID parameters as they exist in the Series
9200 at that particular moment.
Highlighting the loop and pressing the Enter key activates the lower two up and down blue arrow keys,
separated by the Enter key. Using the lower up and down arrow keys allows the operator/supervisor to
highlight the parameters shown in the lower portion of the screen. These editable parameters include
Proportional Band, Reset and Rate, Set point, Pct Out (when in Manual Mode), Mode, Integral Preset, Cycle
Time, SP Change Limit, Control Mode, Low Limit, High Limit, 0 SP stops ctrl. Some of the parameters are
view only, such as Probe Millivolts, Process Variable, Pct Out (while in Auto Mode), SP Lower Limit, and SP
Upper Limit. Pressing the Enter key when the parameter is highlighted can change all of the other
parameters. This will move you to a numeric keypad that will allow you to change the specific parameter.
In some cases the keypad is non-active. You are given a menu of choices. Highlight your choice and press
the Enter key to make the appropriate selection.
Change set point overshoot protection:
When the Change Set point is set to any value other than OFF, the PID control operates normally until
there is a set point change. When a set point change occurs, the PID algorithm uses PB only (i.e. it ignores
the (I) Reset and (D) Rate) until the % output from the specified loop falls below the value specified. At
this time it begins calculating Reset and Rate and returns to normal operation.
Example: Change set point is set at 80%.
Current set point is 1500.
New set point is 1700 - % output rapidly goes to 100%, PID ignores Reset and Rate.
Temperature gets within PB, % output starts to drop.
When % output drops below 80%, PID operation returns to normal with Reset and Rate applied.
Normally overshoot is caused by a buildup of the Reset error term, by ignoring this term until the
temperature is with PB; the Reset term is minimized thus reducing the overshoot error. You should be
SSi Manual SERIES 9200 19 Programmable Dual-loop
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