Super Systems 9205 User Manual

PROGRAMMABLE

ATMOSPHERE AND TEMPERATURE CONTROLLER

Series 9205

OPERATIONS MANUAL

Super Systems Inc.

7205 Edington Drive

Cincinnati, OH 45249

513-772-0060

Fax: 513-772-9466

www.supersystems.com

Super Systems Inc.

Super Systems Europe

Super Systems México

Super Systems China

USA Office

Corporate Headquarters

7205 Edington Drive

Cincinnati, OH 45249

Phone: (513) 772-0060

http://www.supersystems.com

Sistemas Superiores Integrales S de RL de CV

Calle 3 Int.: 11.

Zona Ind. Benito Juarez

Querétaro, Qro. Méx.

C.P.: 76120

Phone: +52 (442) 210 2459

http://www.supersystems.com.mx

Units 3 & 4, 17 Reddicap Trading Estate,

Sutton Coldfield, West Midlands

B75 7BU

UNITED KINGDOM

Phone: +44 (0) 121 329 2627

http://www.supersystemseurope.com

No. 335 XianXia Road

Room 308

Shanghai, CHINA

200336

Phone: +86 21 5206 5701/2

http://www.supersystems.com

Series 9205 Operations Manual Rev A 1

Table of Contents

INSTALLATION SAFETY REQUIREMENTS ---------------------------------------------------------------------------------------------------- 5

CHAPTER 1 - OVERVIEW ------------------------------------------------------------------------------------------------------------------------- 8

MOUNTING ----------------------------------------------------------------------------------------------------------------------------------------- 9 DIMENSIONAL DRAWINGS ----------------------------------------------------------------------------------------------------------------------- 10 WIRING ------------------------------------------------------------------------------------------------------------------------------------------- 12 ELECTRICAL INSTALLATION ----------------------------------------------------------------------------------------------------------------------- 12 PIN OUT ------------------------------------------------------------------------------------------------------------------------------------------ 13 ANCILLARY ITEMS --------------------------------------------------------------------------------------------------------------------------------- 13 SETUP --------------------------------------------------------------------------------------------------------------------------------------------- 14 ADDITIONAL FEATURES --------------------------------------------------------------------------------------------------------------------------- 14 ETHERNET CONNECTIONS ------------------------------------------------------------------------------------------------------------------------ 14 INSTRUMENT START-UP -------------------------------------------------------------------------------------------------------------------------- 15 FLASH CARD & FLASH CARD READER ------------------------------------------------------------------------------------------------------------ 15 OPERATOR INTERFACE SCREEN SAVER ----------------------------------------------------------------------------------------------------------- 15 DEFAULT STATUS SCREEN ------------------------------------------------------------------------------------------------------------------------ 15 MENU --------------------------------------------------------------------------------------------------------------------------------------------- 16 CHART --------------------------------------------------------------------------------------------------------------------------------------------- 16 CHART SUB MENU ------------------------------------------------------------------------------------------------------------------------------- 18 RECIPE -------------------------------------------------------------------------------------------------------------------------------------------- 19 LOOPS --------------------------------------------------------------------------------------------------------------------------------------------- 20 ACK (ALARM ACKNOWLEDGE) ------------------------------------------------------------------------------------------------------------------- 20 DATA LOGGING USING FLASH CARD ------------------------------------------------------------------------------------------------------------- 21

CHAPTER 2 - CONFIGURATION --------------------------------------------------------------------------------------------------------------- 22

MENU (CONFIGURATION) ----------------------------------------------------------------------------------------------------------------------- 22

About ----------------------------------------------------------------------------------------------------------------------------------------- 24 Maintenance ------------------------------------------------------------------------------------------------------------------------------- 24 Logs ------------------------------------------------------------------------------------------------------------------------------------------- 24 Probe Manager ---------------------------------------------------------------------------------------------------------------------------- 25 Slave Communications Status ---------------------------------------------------------------------------------------------------------- 26 Load TC/Auxiliary Analog Input -------------------------------------------------------------------------------------------------------- 26 Manual Event Control -------------------------------------------------------------------------------------------------------------------- 26 Shutdown ------------------------------------------------------------------------------------------------------------------------------------ 27 Probe Burnoff Setup ---------------------------------------------------------------------------------------------------------------------- 27 PID Loop Setup ----------------------------------------------------------------------------------------------------------------------------- 28 Recipe Edit ---------------------------------------------------------------------------------------------------------------------------------- 33 Load T/C Configuration ------------------------------------------------------------------------------------------------------------------ 34 Trend Chart Edit --------------------------------------------------------------------------------------------------------------------------- 34 Communications Setup ------------------------------------------------------------------------------------------------------------------ 36 Slave Instrument Setup ------------------------------------------------------------------------------------------------------------------ 38 Zone Assignments ------------------------------------------------------------------------------------------------------------------------ 41 Furnace Setup ------------------------------------------------------------------------------------------------------------------------------ 42 Default Wait Limits ----------------------------------------------------------------------------------------------------------------------- 46 Alarm Setup --------------------------------------------------------------------------------------------------------------------------------- 46 Thermocouple Check --------------------------------------------------------------------------------------------------------------------- 48 Relay Assignments ------------------------------------------------------------------------------------------------------------------------ 48 Analog Input Setup ------------------------------------------------------------------------------------------------------------------------ 49 Analog Output Setup --------------------------------------------------------------------------------------------------------------------- 51 Alarm Polarity ------------------------------------------------------------------------------------------------------------------------------ 52 Redundant TC Setup ---------------------------------------------------------------------------------------------------------------------- 53

Series 9205 Operations Manual Rev A 2

Event Hold/Reset -------------------------------------------------------------------------------------------------------------------------- 53 Security -------------------------------------------------------------------------------------------------------------------------------------- 55 Curve Entry ---------------------------------------------------------------------------------------------------------------------------------- 56 Alternate PID Setup ----------------------------------------------------------------------------------------------------------------------- 57 Aux Analog Input Setup ------------------------------------------------------------------------------------------------------------------ 58 TC Type mV Range Chart ---------------------------------------------------------------------------------------------------------------- 59 Calibration ---------------------------------------------------------------------------------------------------------------------------------- 59 Configuration ------------------------------------------------------------------------------------------------------------------------------- 61 A/I Module Offset Correction ----------------------------------------------------------------------------------------------------------- 71 Aux Setpoint Configuration ------------------------------------------------------------------------------------------------------------- 71 T/C Extension Correction Curves ------------------------------------------------------------------------------------------------------- 71 Generic Instrument Setup --------------------------------------------------------------------------------------------------------------- 72 DF1 Configuration ------------------------------------------------------------------------------------------------------------------------- 73 Tuning Assistant --------------------------------------------------------------------------------------------------------------------------- 74 PLC Data Mapping ------------------------------------------------------------------------------------------------------------------------ 75 Analog Input Correction Curves -------------------------------------------------------------------------------------------------------- 76 Instrument Calculation ------------------------------------------------------------------------------------------------------------------- 76

CHAPTER 3 – CONFIGURATOR 2.0 MENUS ----------------------------------------------------------------------------------------------- 79

BURNOFF ----------------------------------------------------------------------------------------------------------------------------------------- 79 SLAVE INSTRUMENTS ----------------------------------------------------------------------------------------------------------------------------- 81 AUXILIARY ANALOG INPUT ----------------------------------------------------------------------------------------------------------------------- 81 MANUAL EVENT CONTROL ----------------------------------------------------------------------------------------------------------------------- 82 PROBE BURNOFF SETUP -------------------------------------------------------------------------------------------------------------------------- 83 PID LOOP SETUP --------------------------------------------------------------------------------------------------------------------------------- 85 EVENT RUN PROGRAM SETUP ------------------------------------------------------------------------------------------------------------------- 90 LOAD T/C CONFIGURATION --------------------------------------------------------------------------------------------------------------------- 90 PORT SETUP -------------------------------------------------------------------------------------------------------------------------------------- 91 SLAVE INSTRUMENT SETUP ---------------------------------------------------------------------------------------------------------------------- 94 ZONE ASSIGNMENTS ----------------------------------------------------------------------------------------------------------------------------- 95 FURNACE SETUP ---------------------------------------------------------------------------------------------------------------------------------- 97 DEFAULT WAIT LIMITS ------------------------------------------------------------------------------------------------------------------------- 102 ALARM SETUP ---------------------------------------------------------------------------------------------------------------------------------- 103 THERMOCOUPLE CHECK ------------------------------------------------------------------------------------------------------------------------ 104 RELAY ASSIGNMENTS --------------------------------------------------------------------------------------------------------------------------- 105 RELAY SETPOINTS ------------------------------------------------------------------------------------------------------------------------------- 107 ANALOG INPUT SETUP ------------------------------------------------------------------------------------------------------------------------- 108 ANALOG OUTPUT SETUP ----------------------------------------------------------------------------------------------------------------------- 110 PASSCODE AND ALARM ------------------------------------------------------------------------------------------------------------------------ 111 IP ADDRESS ------------------------------------------------------------------------------------------------------------------------------------- 113 REDUNDANT TC SETUP ------------------------------------------------------------------------------------------------------------------------ 113 EVENT CONTROL -------------------------------------------------------------------------------------------------------------------------------- 114 SET MENU SECURITY --------------------------------------------------------------------------------------------------------------------------- 115 CURVE ENTRY ----------------------------------------------------------------------------------------------------------------------------------- 115 ALTERNATE PID SETUP ------------------------------------------------------------------------------------------------------------------------- 116 SSI ANALOG INPUT SETUP --------------------------------------------------------------------------------------------------------------------- 117 SSI CONFIGURATION AND CALIBRATION------------------------------------------------------------------------------------------------------- 118

Overview ---------------------------------------------------------------------------------------------------------------------------------- 118 Equipment needed ---------------------------------------------------------------------------------------------------------------------- 118 Notes --------------------------------------------------------------------------------------------------------------------------------------- 118 User Calibration ------------------------------------------------------------------------------------------------------------------------- 118 Full Calibration --------------------------------------------------------------------------------------------------------------------------- 120 TC Type mV Range Chart -------------------------------------------------------------------------------------------------------------- 121

Series 9205 Operations Manual Rev A 3

A

UXILIARY INPUT OFFSET CORRECTION ------------------------------------------------------------------------------------------------------- 122

AUX SETPOINT CONFIGURATION --------------------------------------------------------------------------------------------------------------- 123 TC EXTENSION CORRECTION CURVES --------------------------------------------------------------------------------------------------------- 123 GENERIC INSTRUMENT SETUPS ---------------------------------------------------------------------------------------------------------------- 124

Configure Generic Instruments ------------------------------------------------------------------------------------------------------- 124 Configure IP Addresses ----------------------------------------------------------------------------------------------------------------- 125 Configure Block Writes ----------------------------------------------------------------------------------------------------------------- 125

DF1 CONFIGURATION -------------------------------------------------------------------------------------------------------------------------- 125 TUNING ASSISTANT ----------------------------------------------------------------------------------------------------------------------------- 126 PLC DATA MAPPING --------------------------------------------------------------------------------------------------------------------------- 128 ANALOG INPUT CORRECTION CURVES --------------------------------------------------------------------------------------------------------- 128 INSTRUMENT CALCULATION -------------------------------------------------------------------------------------------------------------------- 128 PROGRAMMER DESCRIPTION ------------------------------------------------------------------------------------------------------------------ 131 WAIT -------------------------------------------------------------------------------------------------------------------------------------------- 131 WAIT UP ---------------------------------------------------------------------------------------------------------------------------------------- 132 WAIT DOWN ----------------------------------------------------------------------------------------------------------------------------------- 132 WAIT IN A GUARANTEED SOAK ---------------------------------------------------------------------------------------------------------------- 134 GUARANTEE HIGH ASSIGNMENT--------------------------------------------------------------------------------------------------------------- 135 SAMPLE EVENT ASSIGNMENTS ----------------------------------------------------------------------------------------------------------------- 136 FLASH CARD MANAGEMENT ------------------------------------------------------------------------------------------------------------------- 136 SLAVE INSTRUMENT MAPPING----------------------------------------------------------------------------------------------------------------- 140

Atmosphere Instruments -------------------------------------------------------------------------------------------------------------- 140 Temperature Instruments ------------------------------------------------------------------------------------------------------------- 143 Events Instruments ---------------------------------------------------------------------------------------------------------------------- 148

9205 ANALOG INPUT BOARD JUMPER SETTINGS --------------------------------------------------------------------------------------------- 151

CHAPTER 4 – OPCODES ---------------------------------------------------------------------------------------------------------------------- 153

WARRANTY ------------------------------------------------------------------------------------------------------------------------------------- 168

APPENDIX A – WIRING DIAGRAM OF SERIES 9205 ----------------------------------------------------------------------------------- 169

APPENDIX B – GUIDE TO BUILDING A RECIPE ------------------------------------------------------------------------------------------ 171

APPENDIX C – SETUP FOR CARBON / DUAL TEMPERATURE FOR QUENCH CONTROL -------------------------------------- 179

APPENDIX D – 9205 INSTRUMENT ALARMS ------------------------------------------------------------------------------------------- 181

APPENDIX E – FACTORY DEFAULT SETTINGS FOR THE 9205 CONTROLLER ---------------------------------------------------- 183

REVISION HISTORY ---------------------------------------------------------------------------------------------------------------------------- 234

Series 9205 Operations Manual Rev A 4

!

Installation Safety Requirements

Safety Symbols

Various symbols are used on the instrument; they have the following meaning:

Caution, (refer to the accompanying documents)

Functional earth (ground) terminal!

The functional earth connection is required for safety purposes and to ground RFI filters.

Personnel

Installation must only be carried out by technically qualified personnel.

Enclosure of live parts

To prevent hands or metal tools from touching parts that may be electrically live (powered), the controller must be installed in an enclosure.

Caution:

Live sensors

Do not connect live (powered) sensors to any signal input on the controller. Live sensors are sensors that must be connected to the main's supply. The controller has transient protection circuits connected between the inputs and the earth connection that might be damaged by live (powered) sensors.

Series 9205 Operations Manual Rev A 5

Wiring

It is important to connect the controller in accordance with the wiring data given in this handbook. Take particular care not to connect AC supplies to the low voltage power supply input. Use copper wires for 24V DC power supply to the instrument. Ensure that the wiring of installations comply with all local wiring regulations. For example in the United Kingdom use the latest version of the IEE wiring regulations, (BS7671). In the USA use NEC Class 1 wiring methods.

Power Isolation

The installation must include a power isolating switch or circuit breaker. This device should be in close proximity to the controller, within easy reach of the operator and marked as the disconnecting device for the instrument.

Earth leakage current

Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This may affect the design of an installation of multiple controllers protected by Residual Current Device, (RCD) or Ground Fault Detector, (GFD) type circuit breakers.

Over current protection

To protect the internal PCB tracking within the controller against excess currents, the AC power supply to the controller and power outputs must be wired through a fuse or circuit breaker specified in the technical specification.

Voltage rating

The maximum continuous voltage applied between any of the following terminals must not exceed 24V DC

• relay or triac output to logic, DC or sensor connections;

• any connection to ground.

The controller should not be wired to VAC. The 24V DC power supply voltage across the connections and between the power supply and ground must not exceed 2.5kV. Where occasional voltage over 2.5kV are expected or measured, the power installation to both the instrument supply and load circuits should include a transient limiting device. These units will typically include gas discharge tubes and metal oxide varistors that limit and control voltage transients on the supply line due to lightning strikes or inductive load switching. Devices are available in a range of energy ratings and should be selected to suit conditions at the installation.

Series 9205 Operations Manual Rev A 6

Conductive pollution

Electrically conductive pollution must be excluded from the cabinet in which the controller is mounted. For example, carbon dust is a form of electrically conductive pollution. To secure a suitable atmosphere in conditions of conductive pollution, fit an air filter to the air intake of the cabinet. Where condensation is likely, for example at low temperatures, include a thermostatically controlled heater in the cabinet.

Over-temperature protection

When designing any control system it is essential to consider what will happen if any part of the system should fail In temperature control applications the primary danger is that the heating will remain constantly on. Apart from spoiling the product, this could damage any process machinery being controlled, or even cause a fire. Reasons why the heating might remain constantly on include:

• the temperature sensor becoming detached from the process;

• thermocouple wiring becoming a short circuit;

• the controller failing with its heating output constantly on;

• an external valve or contactor sticking in the heating condition;

• the controller set point set too high.

Where damage or injury is possible, we recommend fitting a separate over temperature protection unit with an independent temperature sensor, which will isolate the heating circuit. Please note that the alarm relays within the controller will not give protection under all failure conditions.

Installation requirements for EMC

To ensure compliance with the European EMC directive certain installation precautions are necessary as follows:

• When using relay or triac outputs it may be necessary to fit a filter suitable for suppressing the emissions. The filter requirements will depend on the type of load. For typical applications we recommend Schaffner FN321 or FN612.

Routing of wires

To minimize the pick-up of electrical noise, the wiring for low voltage dc should be routed away from high-current power cables. Where it is impractical to do this, use shielded cables with the shield grounded at one end.

Series 9205 Operations Manual Rev A 7

Chapter 1 - Overview

The 9205 is SSi’s versatile atmosphere programmable controller with Ethernet, RS485 Modbus, and DF1 communications to various slave devices such as temperature controllers, flow meters, and PLCs. This instrument can be used to address many thermal processing applications where temperature and carbon control along with event I/O management are necessary. The 9205 has math block capability allowing custom calculations and custom Modbus mapping for communications

The 9205 recipe programmer includes 24 independent steps per recipe with operational codes (opcodes) to enable effective process control. The 9205 also supports multiple user interface screens for more flexibility. Screen sizes include 3.5”, 5.7” and 12.1”. Functionality added to the screens include “stylus” notes entry, user defined data points and trend charts for paperless chart recording, zoom and pan touch screen control on the charting screen, and remote data retrieval through Ethernet.

Series 9205 Operations Manual Rev A 8

Approximate Box Dimensions

2.75" x 4" x 4.5"

Power Requirements

24VDC, 4 Watts

Digital Output Rating

300VAC / 1 AMP

Analog Output Load Rating

1000 Ohms (Total)

Controller Enclosure Rating

IP10 – hand protected

Number of RS232 Ports

Two (2)

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)

!

The Model 9205 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 9205 to control temperature and atmosphere.

The product is available in three different screen sizes. 3.5”, 5.7” and 12”.

Mounting

The Series 9205 Operator Interface mounts into a panel or on a plate by using the enclosed mounting brackets. A rectangular cutout is required; the size of the cutout is determined by the operator interface size. These units, along with an optional SSi SR3, 6, or 9 analog input board, will mount on a commercially available DIN rail. This can be mounted on the sub-panel on the side of an enclosure for the convenience of the control system.

Series 9205 Operations Manual Rev A 9

Dimensional Drawings

Series 9205 Controller Dimensions

24V DC Power Supply Dimensions

Series 9205 Operations Manual Rev A 10

3.5” Operator Interface Cutout dimensions

5.7” Operator Interface Cutout dimensions

12” Operator Interface Cutout dimensions

Series 9205 Operations Manual Rev A 11

Wiring

Wiring to the Series 9205 operator interface can be done using 232 or 485 to two connectors, comm1 (232) or comm3 (485). The terminal strip on the lower right rear corner of the operator interface is used to connect 24VDC power. The DB-9 port A connection is used to connect the display via 232 to the Series 9205 PID controller. The controller is connected via RS485 communication to the single-loop controllers.

Electrical Installation

The Model 9205 requires 24VDC, 4 Watt, single-phase power. A 24 VDC power supply is required and is generally included as part of the Model 9205 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 to the site, the customer is responsible for providing adequate power and making it available to the Model 9205 power supply.

SSi requirement:

MOV’s must be wired across the isolation relay coil terminals on all isolation relays that are connected to solenoids. when the solenoid is wired to them.

Further… MOVs must be connected across the HOT and NEUTRAL wires

IT IS AN ABSOLUTE MUST to have the MOVs at BOTH

LOCATIONS.

Series 9205 Operations Manual Rev A 12

Pin Out

9205 Pin Out

A wiring diagram of the Series 9205 controller can be found in Appendix B.

Ancillary Items

The following items can be included with the Series 9205: a flash card, a flash card reader, a touch screen, an RS232 cable, an RS485 cable, a 24V DC DIN rail mount power supply, and a software CD with Configurator, the Configurator manual, TS Manager, and .NET 2.0. The flash card is installed in the operator interface and the flash card reader connects to a Windows® based computer.

The operator interface includes a connection for a mouse and a keyboard. These may be connected to the operator interface via USB, allowing the operators to use a mouse and keyboard instead of the touch screen.

Series 9205 Operations Manual Rev A 13

Part

Part Number

31135 or

31137

The following table shows the ancillary items and their part numbers.

3.5" Operator Interface 31296

5.7" Operator Interface 31297

12" Operator Interface 31299

TS Manager/PC Configurator Software 13339

RS485 comms cable for 12.1” and 5.7 “ 20576

RS485 comms cable for 3.5” 20635

Flash Card 31604

Flash Card Reader 13333

RS232 Cable 33027

24V DC Din Rail Mounted Power Supply

9205 Controller 13443

Setup

The Series 9205 setup consists of setting the local time if required. As shipped from the factory the communications ports are set at 19200 baud in Modbus mode.

Time will be set for local time in Cincinnati, Ohio (EST /EDT) or time zone of location of city and state on sales order. For instruction on adjusting these values, please see

Configuration

.

Chapter 3 -

Additional Features

The Operator Interface (touch screen) contains a removable compact Flash or SD Card that can be used to transfer data from the Model 9205 to a computer. It is located on the back of the touch screen (see

Flash Card & Flash Card Reader section for more details).

Also included is a Utility Software CD that includes SSi’s TS Manager. TS Manager is a utility program that can be loaded onto any Windows® based computer (operating Windows XP or higher). This software will allow the computer to read the data from the TS Flashcard, and allow it to be viewed in a manner that is similar to a strip chart recorder.

Ethernet Connections

The Ethernet connection has three distinct uses. First, should the Operator Interface fail, the Ethernet connection allows a laptop to be connected via a crossover cable to the Series 9205 DIN rail mounted unit using Internet Explorer Browser. This connection can act as a LIMITED

Series 9205 Operations Manual Rev A 14

!

FUNCTION “operator interface” until the Operator Interface can be repaired or replaced. The laptop needs to be operating a Windows XP or higher with Internet Explorer. The default IP address is

192.168.0.200. If you are experiencing problems please call (513) 772-0060 and talk with our computer communications personnel. Secondly, the Ethernet port can be used for communications to a SCADA software package. Call us at (513) 772-0060

if you are interested in this option. The third use for the Ethernet Port is the primary communications connection for the Configurator 2.0 Software.

Instrument Start-up On power-up, the Operator Interface will display a Microsoft Windows desktop screen for a few seconds and then switch to the default Status 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 on the default status screen. Once the menu has been displayed, select the to shut down the Operator Interface. See the

Chapter 2 - CONFIGURATION

Shutdown

option. At the prompt, press Yes

section for information on navigating and using the menu system. This will display a conventional Microsoft Windows screen. Sliding the black switch to the OFF position (located directly over the green power connector, on the back of the Operator Interface) or removing the 24VDC plug 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 or side of the display unit, exposing the card. Press the black release button or press card in to eject, 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 its 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 or connect plug.

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 reappear.

Default Status Screen

The Status Display shows the temperature controller information as well as any auxiliary analog inputs, the status of the timer, and an overview of the programmer. There are five active buttons on the Status Display: Menu, Chart, Recipe, Loops, and Ack.

• The Menu button will display the configuration menu.

Series 9205 Operations Manual Rev A 15

• The Chart button will display the video recorder screen. Use of the Chart Display is explained below.

• The Recipe button will switch to the Program Display. This is a companion display to the status

screen and is described below.

• The Loops button will display the main control loop, Temperature, as well as the timer status

and any auxiliary analog inputs.

• The Ack (Alarm Acknowledge) button is used to acknowledge an alarm. The alarm message is

displayed directly under the recipe display. Is this only present when an alarm is going off. This button only acknowledges 9205 alarms and does not acknowledge any PLC alarms.

When the quench timer is running, the ACK button is replaced with a quench button. This quench button is used to adjust the quench timer time remaining. In the purple status bar, the quench time remaining is displayed.

Chart

The Chart Display shows between 1 hour and 24 hours of process variable data on the screen and can be scrolled back to view all of the data stored on the hard drive. The vertical timelines change as the time changes on the screen. Any trend charts that have been created through the Configuration menu are accessible here. See the Chapter 2 - CONFIGURATION information on creating trend charts.

section for more

.

The function buttons run along the bottom of the screen.

Series 9205 Operations Manual Rev A 16

The folder button - -

The Trend Lines button - - will allow the user to select or de-select the trend lines on the trend chart to display. If the checkbox next to each trend line is checked, then that trend line will be displayed.

`

The Datagrid View button - - will display a screen with the trend data in a grid format instead of with trend lines. The trend data is shown in 1-minute intervals. Clicking on the

OK button on this screen will close the screen down and return to the Chart Display screen.

The Refresh button - - will refresh the screen’s trend data if the screen is not in real-time mode.

The left-pointing green arrow button - - will move the chart’s view backward in time by the specified chart interval.

The chart interval button - - will determine the number of hours displayed on the trend chart. The options are:

1 Hour, 2 Hours, 4 Hours, 8 Hours, 12 Hours, or 24 Hours.

The right-pointing green arrow button - - will move the chart’s view forward in time by the specified chart interval.

The right-pointing arrow with the vertical line next to it button - - will put the chart into real-time mode if it is not in real-time mode, or take the chart out of real-time mode if it is. When in real-time mode, the chart will automatically be updated once a minute.

Series 9205 Operations Manual Rev A 17

Chart Sub Menu

There is a sub-menu available by putting a finger or a stylus anywhere on the chart and holding it there for a couple of seconds. The sub-menu will have the following options available: Exit.

to zoom in again.

Zoom, Restore, Add Note, Data, and

The Zoom option will allow the user to zoom in on a particular part of the screen. Once this has been selected, the user can take a stylus or a finger and create a box around the desired data. Once the user releases the stylus or finger, a zoom is no longer possible, and the user will need to re-select the option from the sub-menu

The Restore option will back out of any zoom options that have been performed and display the chart screen as it initially was.

The Add Note option allows the operator to enter a note on the chart, similar to writing on a paper chart. The note shows up when the chart is printed out using the utility software included with the Series 9205 instrumentation. Pressing the

Add Note option displays a screen where the operator can enter the operator ID or initials and a note. The user has the option to enter a note using the operator interface keyboard, where he or she will be able to type in the note; or the user can use the Signature mode, which will allow them to write a note using a stylus.

The Data option will show the trend data as a data grid instead of the trend lines on a chart. This

functionality is exactly the same as if the user pressed the Datagrid View button - - from the chart screen.

Exit will close out the sub-menu without selecting an item.

Pressing the red ‘X’ in the top right-hand corner of the screen will take the user back to the status screen.

Series 9205 Operations Manual Rev A 18

Recipe

Pressing the Recipe button on the main status screen displays the recipe screen, which will allow the user to load up an existing recipe and start it, or see the currently running recipe.

The recipe screen shows the last program loaded into the program run buffer and its status. If the program is running, the active step number is highlighted green. When the step is highlighted green, then the recipe is running on that step. When a step is highlighted yellow, the recipe is in hold on that step. A red the bottom left corner of the screen displays an alarm condition.

Note – the main status screen

Acknowledge button in

will also show the recipe running status, as well as run time and remaining time for the step as well as the entire recipe

The recipe screen has a total of seven buttons that will allow the user to load up a recipe, as well as control the recipe and acknowledge an alarm.

.

• The Advance button will advance the recipe to the next step in the recipe. The user will need to confirm the advance command.

• 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

put into hold status, the text on the

Hold button will change to “Resume”. When the step is

Resume button.

started up again, the text on the button will change back to “Hold”

hold status, the step will be highlighted yellow. The user will need to confirm the hold or resume command.

• The Stop button stops the recipe program that is currently running. Stop means exactly that! It stops the program. It is NOT a hold button. See the description for the hold button above. To restart the program if it has been stopped you must use the number, and then highlight the segment number of the recipe that you want to start with and start the recipe again. The user will need to confirm the stop command.

• The Soak button allows you to enter a new value for the time remaining in the current soak or ramp cycle only – future soak or ramp cycle times cannot be modified. The step must be a soak or ramp cycle for a change in soak/ramp time to be adjusted.

• The Acknowledge button will acknowledge the alarm. In most cases, it will be acknowledging alarm must be acknowledged to allow the program to go to the next step.

Note – The Acknowledge button is only

end of soak

. The

Load button, enter the recipe

Note – When a recipe is

. When a recipe step is in a

visible when an alarm condition is present. Once the condition is acknowledged, the become invisible again

.

Acknowledge button will

• The Load button allows the operator to enter the recipe number to be run and to view the recipe before pushing

Run button. Pushing the Run button starts the recipe.

the 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 places the program currently being viewed in the active memory and will begin to run the new

Series 9205 Operations Manual Rev A 19

Run button is pushed. Pressing Run

recipe. To select the recipe to view or edit, click on the recipe number button in the top left corner of the screen. This will display a screen where the user will be able to load up a valid recipe (range button next to the “Step” text and entering the new step number (range pressing the

While reviewing the program that is about to be run, each step can be modified. Highlight a

1 – 300). The program can be started in any step by clicking on the step number

1 – 24), and then

Run key.

step number and click on the changed with the drop down list at the top. This list can be sorted alphabetically by click on the “Alphabetical” checkbox. The parameters of the opcode can be modified on this screen as well. See the Click on the button to ignore the changes.

Chapter 4 – OPCODES section for details about each opcode.

OK button to accept the changes; click on the Cancel

Edit button. The opcode can be

Note – Any change to the recipe is a one-time edit, and will not affect the recipe that is saved on the 9205 controller

cancel loading a recipe and return to the main recipe screen.

screen.

. Click on the Cancel button on the Load Recipe screen to

• The Return button returns you to the main status

Loops

This screen will display the program loops for the

9205. Up to three loops can be displayed. 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 set point, a numeric keypad is displayed, showing the current value and allowing the operator to enter a new set point by simply pressing on the appropriate numeric keys. Once the correct set point has been entered, press the key is pressed the display returns to the Screen. Another active key within the button toggles the controller’s mode between Auto and Manual. In the manual mode, pressing the percent output button on the output to control the “loop” in a manual mode to be entered. If a timer is running, the status will be displayed at the top right of the screen. Any load T/Cs that are actively communicating will be listed in the box to the right of the setpoint/percent output values. If an alarm condition is present, the alarm text will be displayed below the loop information. If the alarm needs acknowledging, then the be displayed in the bottom left corner. If the alarm is part of a recipe step, the alarm will need to be acknowledged before the recipe can move to the next step. The Loops Screen also allows you to move back to the default Status Screen by pressing the Return.

OK key to make the change. When the OK

Loops

Screen is the Auto/Man (Auto/Manual) button. Pressing that

Loops

Screen (next to the Auto/Man button) displays a numeric keypad, allowing a %

Alarm Ack button will

Ack (Alarm Acknowledge)

The Ack (Alarm Acknowledge) button will allow the user to acknowledge any alarms that have been configured, or that have been made part of the recipes that run on the Series 9205. If a recipe has an alarm as a step, the alarm must be acknowledged before the recipe will continue to the next step.

Series 9205 Operations Manual Rev A 20

!

Data Logging using Flash Card

NOTE: See Warnings with respect to removing the 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 set up by a qualified SSi technician. Should a customer not take the data offline in a timely manner, the data will be over-written, the oldest data being over-written first. Here is how it works:

1. When the 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 9205 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 9205 controller/programmer, then disk space.

See the Flash Card Management Section for more information.

Series 9205 Operations Manual Rev A 21

Chapter 2 - CONFIGURATION

Menu (Configuration)

The Configuration Menu is entered through the Menu key that is part of the four buttons running along the bottom of the Default Display Screen. Pressing the Login key at the bottom of the screen will allow the user to enter a login user and password.

through the Security menu option in this menu

User names and passwords are case sensitive. There are three levels of security for the menu system: Pressing the enter a user name and password to log in. When the menu screen is first displayed, the operatorlevel menu options are visible. The list of the operator-level menu options is:

The list of supervisor-level menu options is:

The list of administrator-level menu options is:

Operator, Supervisor, and Administrator.

• About

• Maintenance

• Logs

• Probe Manager

• Slave Communications Status

• Load TC/Auxiliary Analog Input

• Manual Event Control

• Shutdown

• About

• Maintenance

• Logs

• Probe Manager

• Slave Communications Status

• Load TC/Auxiliary Analog Input

• Manual Event Control

• Shutdown

• Probe Burnoff Setup

• PID Loop Setup

• Recipe Edit

• Load T/C Configuration

• Trend Chart Edit

• About

• Maintenance

• Logs

• Probe Manager

• Slave Communications Status

• Load TC/Auxiliary Analog Input

• Manual Event Control

• Shutdown

Note – users can be set up

.

Login button will allow the user to

Series 9205 Operations Manual Rev A 22

• Probe Burnoff Setup

• PID Loop Setup

• Recipe Edit

• Load T/C Configuration

• Trend Chart Edit

• Communications Setup

• Slave Instrument Setup

• Zone Assignments

• Furnace Setup

• Default Wait Limits

• Alarm Setup

• Thermocouple Check

• Relay Assignments

• Analog Input Setup

• Analog Output Setup

• Alarm Polarity

• Redundant TC Setup

• Event Hold/Reset

• Security

• Curve Entry

• Alternate PID Setup

• Aux Analog Input Setup

• Calibration

• Configuration

• A/I Module Offset Correction

• Aux Setpoint Configuration

• T/C Extension Correction Curves

• Generic Instrument Setup

• DF1 Configuration

• Tuning Assistant

• PLC Data Matching

• Analog Input Correction Curves

• Instrument Calculation

The SSi code of the day can also be used to log in to the menu system. No user name will need to be entered when entering this code. Currently, the menu list is identical to the administrator-level list. The SSi code of the day is typically used for in-house configuration prior to shipment. The code can only be provided by Super Systems at (513) 772-0060.

To select any of the menu options, highlight that item by clicking on it, and click on the Detail button. The Return button will return the user to the default display screen.

Series 9205 Operations Manual Rev A 23

About

The About screen displays important information on the 9205 controller that the touch screen is communicating with. The firmware version of the controller itself.

SSi 9205 field shows the

Serial Number shows the serial number of the controller. Interface Revision shows the current version of the touch screen interface.

The remaining fields show versions of various DLL (dynamic link library) files that the touch screen software uses to operate. These fields may be needed for troubleshooting if you need to contact SSi for technical support.

Maintenance From the Maintenance Status menu, you can view a list of scheduled and completed maintenance items. Maintenance items are added from the Configuration -> Maintenance menu. See the

Configuration section

on page 61 for more information.

Logs

The Logs screen will allow the user to view three different types of logs –

System, Alarms, and

Cycle.

Clicking on the button that displays the log type

System Log, Alarm Log, or Cycle Log) will allow

( the user to select the type of log file to view.

The green directional arrows will display the previous items in the log or the next items in the log, if the log items are longer than one screen. The drop down list in between the directional arrows will allow the user to select the date of the log items to view.

The Return button will return the user to the menu screen.

Series 9205 Operations Manual Rev A 24

Log Types

The System Log tracks the startup and shutdown activity of the touch screen as well as when communications to the controller are established.

The Alarm Log tracks all alarms—those that are internal to the controller and those that are generated by the PLC. This log tracks the alarm generated, its start time, and its end time. This log can be useful for helping build an alarm history.

The Cycle Log keeps track of charged loads and completed recipes. Specifically, it displays the start time and date, completed time and date, and recipe number executed. A Utilization button can be pressed to open a page with information on utilization based a selected date and on the amount of time that the 9205 controller has run a recipe compared to the amount of time it has not run a recipe.

Probe Manager This option allows the user to register a probe within the 9205 by entering its serial number. Doing so starts a tracking history of probe burn-offs, impedance tests, recovery time, and other probe parameters. Trends can be monitored this way, and the impedance of the probe can be traced to help estimate its life expectancy.

To install a new probe, tap Install New Probe. You will be asked for the probe serial number. Enter it and tap

OK.

When Burnoff Report is selected, a list showing when a burnoff took place will appear, along with probe mV, temperature, and temperature change during the burnoff. When a burnoff event is selected, a chart will show temperature changes during the burnoff event.

When Probe Test Report is selected, a list will appear showing test parameters for the selected probe: time: Impedance kΩ, Recovery Time, Start Temperature, Test mV, and Test Temperature. When a test event is selected, a chart will show temperature changes during the test.

Tap Return to return to the main menu.

Series 9205 Operations Manual Rev A 25

Slave Communications Status This page is a display of the current process variables of each of the slave instruments communicating with the 9205 controller. These values are display-only, and cannot be modified from this screen. There are five possible messages that can occur to describe the instrument communications status.

• N/A – No instrument is connected

• Bad – No communications exist

• ??? – Communications exist, but there

are frequent errors

• ?OK – Communications exist, but there are occasional errors

• OK – Communication is established and working properly

For set-up of the auxiliary instruments go to the menu item “ The Return button will return the user to the menu screen.

Load TC/Auxiliary Analog Input The Load TC/Auxiliary Analog Input screen will show the values for the load TCs and the auxiliary analog inputs. These values are display-only, and cannot be modified from this screen.

Manual Event Control Events are assignable outputs, used in recipes/programs. Typically, they are used to signal the recipe is complete, to turn process gases off and on, and tell the equipment to do a variety of tasks. The Manual Event Control submenu allows the user to force the events off or on.

The Manual Event Control menu option shows the user all of the events (

0 – 47) and their current status. It also allows the user to manually control the status of any event by clicking on the value. To change the status, highlight the specific event and click on the The user will be able to select either an

Edit button.

On value or an Off

value.

Slave Instrument Setup

”

Series 9205 Operations Manual Rev A 26

WARNING!

Before assigning or changing events, be certain that you are familiar with the function of the event whose status you are going to change. Changing the status of an event without knowledge of the result can lead to hazardous situations.

Clicking on the OK button will set the value, while clicking on the Cancel button will cancel the action. The Return button will return the user to the menu screen.

Shutdown The Shutdown selection will display a screen asking whether or not to shut down the interface of the Series

9205. When the operator interface is shutdown, the Series 9205 controller is still functioning. IT can be monitored by connecting the Ethernet connection to a laptop computer, using Internet Explorer, and assigning a legitimate IP address. Choosing

Yes displays a typical computer desktop screen with the Start button in the bottom left-hand corner. The power to the operator interface can now be turned off without upsetting any of the settings. Choosing

No displays the initial Status Screen.

Operator Interface does not shutdown the Series 9205 Controller

.

Note - Shutting down the

Probe Burnoff Setup 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.

Burnoff Time: This is the duration of the burnoff measured in seconds. SSi recommends a 90 second burnoff, and this will be the default value. However, it can be adjusted by the operator. Click

OK button to set the new value, or click on

on the

Cancel button to cancel.

the

Rec Wait Time: 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.

Interval: This is the amount of time between the beginning of one burnoff and the beginning of the next scheduled burnoff, in minutes. Default time for the instrument is 720 minutes (12 hours). However, the amount of time between burnoffs should be determined by the application.

Minimum Millivolts: The minimum measured millivolt tolerance of the probe required to start a burnoff. Clicking on the value will allow the user to change the value. SSi recommends the millivolt value gets down to 200 mV.

Maximum Temperature: The maximum measured temperature allowed during a burnoff. If the temperature value is exceeded

the burnoff will stop. This is done to help maintain the life and the accuracy of your probe. SSi recommends a value of 1800 degrees. Clicking on the value will allow the user to change the value.

Series 9205 Operations Manual Rev A 27

Digital IN 4 Assignment: The value for the digital input 4 assignment. Clicking on the value will allow the user to change

the value, which can be either event or Start Burnoff.

Burnoff Minimum Millivolts Alarm Setpoint: The minimum millivolt value that must be reached in order for the “Insufficient mV drop during BO” alarm not to be generated. If the millivolt value does not drop below the minimum, the alarm will be generated.

Burnoff Maximum Temperature Rise Limit: The maximum number of degrees that the temperature is allowed to increase before the “Excessive TC rise during BO” alarm is generated.

PID Loop Setup PID is the tuning parameters entered for each Process Variable loop.

Prop Band (0 for On/Off) Proportional Band determines the response to the current error. The Proportional Band is the percent of the range of the process variable that will produce 100% output and is the inverse of the proportional gain. A low Proportional Band value results in a larger change in output for a given error. Conversely, a high Proportional Band value results in a smaller change in output for a given error. If the Proportional Band is too small, control may oscillate or be otherwise unstable. If the Proportional Band is too large the control action may be too sluggish in response to changes within the system. Note: If the Proportional Band is set to 0.0, only on/off control is performed. The range

0 –

3276.0.

Reset Reset determines the influence of past errors. The Reset, or integral action (expressed in repeats per minute), sums the error between the process variable and setpoint over time and adds this accumulated output to the proportional output. A “proportional only” controller generally operates with steady-state error because some error is required to produce control output. The goal of integral action is to drive the steady-state error to zero and eliminate this droop.

The range 0 – 327.67.

Rate Rate adjusts the response to future errors. The Rate, or derivative action (expressed in minutes), is used to predict system behavior and has a dampening effect. The more the controller tries to change the process variable the harder the derivative will work to counter that effort. This dampening effect can be valuable in reducing overshoot but is most often useful when trying to improve control on systems with significant and predicable lag.

Control Mode This is the mode of the loop. The values are: Dual Reverse, Single Reverse, Dual Direct, or Single Direct. Dual – This has two output relays which can increase and decrease to achieve the SP. Single – This has one relay which works in only one direction to achieve the SP. Direct - If the PV - SP equals a positive number and the output would bring the PV down toward setpoint that is direct. Reverse – If the PV - SP equals a negative number and the output would bring the PV up toward setpoint then that is reverse

The range 0 – 327.67. NOTE: The rate is not typically used for carbon control.

Series 9205 Operations Manual Rev A 28

Example: If a 12 mA output drives a 0 degree F temperature (PV) UP to a 1200 degree F temperature (SP), this would be Temperature Loop is

Integral Preset This field provides an offset for the starting point for PID control, also referred to as “Load Line” or “Manual Reset”. The range is

Cycle Time This field is typically set to the valve travel time multiplied by 1.5. The range is 0 – 500.

Setpoint Change Limit

This is a smart time feature that allows 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 of the furnace at heat. The options are: OFF, 80%, 70%, 60%, 50%, 40%, 30%, or 20%. Example: If the furnace runs at 40% output at heat for the maximum load, the setpoint change limit should be set to 60%.

Control Low Limit This is the low limit for the loop. The range is –100 to 100.

Control High Limit This is the high limit for the loop. The range is –100 to 100.

0 Setpoint Stops Control If the Setpoint is zero, then all outputs are turned off. The option is either Yes or No.

IN1 high limit shuts down ctrl If input 1’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

REVERSE

, and since this would take a

Single Reverse.

–100 to 100.

SINGLE

must

output from the controller, the Mode for the

be above the normal operating output percentage

IN2 high limit shuts down ctrl If input 2’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

IN3 high limit shuts down ctrl If input 3’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

PID Auto Switch This is the PID auto switch field. The value can either be Yes or No.

PID auto switch is a feature within the instrument that allows multiple PID Loops to be used for various temperature ranges. This feature can be extremely helpful when a single PID Loop is not accurate across a wide temperature range. The most common indication that PID auto switching may improve furnace ability is failure to pass Temperature Uniformity Surveys (TUS). In many examples, a certain PID Loop may prevent under- or over-shoot at normal operating temperatures; but produce unacceptable overshoot at lower temperature.

This feature allows the user to utilize (up to) three distinct loops to obtain more accurate heating curves. In most applications, it is helpful to use the built-in Tuning Assistant feature to determine appropriate PID

Series 9205 Operations Manual Rev A 29

Parameter

Value

PID Loop Setup -> Loop 1 -> PID Auto Switch

Yes

PID Loop Setup -> Loop 1 -> Switch Point PID 1-2

800

PID Loop Setup -> Loop 1 -> Switch Point PID 2-3

1500

Alternate PID Setup -> LP1 set 1 -> Prop Band

1.0

Alternate PID Setup -> LP1 set 1 -> Reset

2.0

Alternate PID Setup -> LP1 set 1 -> Rate

3.0

Alternate PID Setup -> LP1 set 2 -> Prop Band

1.3

Alternate PID Setup -> LP1 set 2 -> Reset

2.3

Alternate PID Setup -> LP1 set 2 -> Rate

3.3

Alternate PID Setup -> LP1 set 3 -> Prop Band

1.6

Alternate PID Setup -> LP1 set 3 -> Reset

2.6

Alternate PID Setup -> LP1 set 3 -> Rate

3.6

values. These values can be recorded and manually entered as described below. The chart below demonstrates this feature.

In the example above, proper use of the Tuning Assistant allows the user to find the following optimal PID settings for the following temperature ranges:

• 0-800F -> PID Group 1 (P = 1.0, I = 2.0, D = 3.0)

• 801-1500F -> PID Group 2 (P = 1.3, I = 2.3, D = 2.3)

• 1501F+ -> PID Group 3 (P = 1.6, I = 2.6, D = 3.6)

The following settings must be made via the touch screen:

PID 1 -> 2 Switch Point This is the PID Switch Point field. This is used in conjunction with the PID Auto Switching feature. See the

PID Auto Switch

PID 2 -> 3 Switch Point This is the PID Switch Point field. This is used in conjunction with the PID Auto Switching feature. See the

PID Auto Switch

section for more information. The range is –300 to 4000.

Setpoint Lower Limit This is the lower limit of the setpoint. The range is –300 to 9999.

Series 9205 Operations Manual Rev A 30

Output (in %)

Second Passed

100.0

1

99.0

2

99.0

3

98.0

4

97.0

5

Setpoint Upper Limit This is the upper limit for the setpoint. The range is –300 to 9999.

Cascade SP Lower Limit This is the cascade setpoint low limit. The 9205 uses the difference between the cascade SP lower limit and the cascade SP upper limit and multiplies that value by the % output of the load loop. It then offsets this value by the cascade SP lower limit and feeds the furnace loop this value as a setpoint.

Cascade SP Upper Limit This is the cascade setpoint upper limit. The 9205 uses the difference between the cascade SP lower limit and the cascade SP upper limit and multiplies that value by the % output of the load loop. It then offsets this value by the cascade SP lower limit and feeds the furnace loop this value as a setpoint.

Example: Cascade SP Lower Limit: 0 Cascade SP Upper Limit: 2000 The load has a setpoint of 1700 and it is at 37 % output. The furnace setpoint will be calculated as follows: (2000 – 0) * 0.37 + 0 = 740.

PV Source The options for PV Source are either Internal or External. If External is selected, the loop’s PV must be written by an external source (an example would be a 7EK controller, PLC, etc.). Selecting Internal will continue normal operation where the source is determined by the PID loop and the PV type.

Minimum Forward On Time (sec) This setting specifies the minimum number of seconds for which output must be positive (heating) before the control is turned off. The maximum value for this setting is 100.

Minimum Forward Off Time (sec) This setting specifies the minimum number of seconds for which the control must be off after heat is applied. The maximum value for this setting is 100.

Minimum Reverse On Time (sec) This setting specifies the minimum number of seconds for which output must be negative (cooling) before the control is turned off. The maximum value for this setting is 100.

Minimum Reverse Off Time (sec) This setting specifies the minimum number of seconds for which the control must be off after cooling is applied. The maximum value for this setting is 100.

Positive Output Accumulator The Positive Output Accumulator is the sum of the positive outputs (given in percentages up to one decimal place) measured each second. Therefore, if the following outputs are recorded over five seconds:

Series 9205 Operations Manual Rev A 31

Output (in %)

Seconds Passed

-20.0

1

-20.0

2

-21.0

3

-21.0

4

-22.0

5

Then the value for the Positive Output Accumulator after five seconds will be (100.0 + 99.0 + 99.0 + 98.0 +

97.0) or 493.0.

To reset the Positive Output Accumulator, simply click Edit while the Positive Output Accumulator is highlighted and confirm the reset. This will cause the Positive Output Accumulator to be reset to zero and start accumulating values again from that point.

Negative Output Accumulator The Negative Output Accumulator is the sum of the negative outputs (given in percentages up to one decimal place) measured each second. The sum of the negative values is expressed as a positive value. This means that, if an output of -50% is recorded after one second, a value of 50 will be added to the Negative Output Accumulator. Similarly, if the following outputs are recorded over five seconds:

Then the value for the Negative Output Accumulator after five se

conds will be (20.0 + 20.0 + 21.0 + 21.0 +

22.0) or 104.

To reset the Negative Output Accumulator, simply click Edit while the Negative Output Accumulator is highlighted and confirm the reset. This will cause the Negative Output Accumulator to be reset to zero and start accumulating values again from that point.

Overshoot Control Logic Overshoot control logic is activated when a large setpoint change occurs. If the logic is active and a large

t

point occurs, it sets a working setpoint at an appropriate distance from the desired setpoint to prevent

se the PV from overshooting the desired final setpoint. When the PV reaches or crosses this working setpoint, then the logic exponentially ramps the working setpoint to the desired final setpoint.

Ramp Detect Logic The Ramp Detect logic works in conjunction with the instrument recipe programmer. If the control loop is

e temperature loop for the recipe programmer, and the OPCODE is a ramp, then the control loop does

th some special checks. If the Overshoot Control Logic is active, then the final setpoint of the ramp is used to determine the working setpoint band. However, the ramp setpoint is used until the band is reached. Also, once the band is reached, if the ramp is faster than the overshoot logic exponential ramp, then the program is temporarily put on hold as needed to sync the two ramps.

Ramp Level 1 Control and Ramp Level 2 Control Ramp Level 1 and 2 Control are only active if the Ramp Detect logic is active.

Ramp Level 1 Control provides mild overshoot protection during a recipe ramp.

R

amp Level 2 Control is only active if the Ramp Level 1 control is active.

Ramp Level 2 Control provides enhanced overshoot protection during a recipe ramp.

Series 9205 Operations Manual Rev A 32

Output rate change This option causes the 9205 controller to limit the rate at which the output changes in the furnace. For example, if the output rate change limit is 5% per second, the controller will increase the output at a rate no greater than 5% each second until the output reaches the level needed to reach setpoint. This limit can be useful in cases where (for example) a heating element should not (for operational and safety reasons) heat up to a high output immediately. If the output needs to reach 100% to achieve setpoint, the Output Rate Change Limit will apply the output incrementally, rather than allowing the output to climb to 100% as soon as the heat is turned on.

PID Switch Variable This is the parameter that triggers the PID switch. The options are Process variable and Setpoint. Note that PID Auto Switch must be set to Yes in order to use PID Switching.

Recipe Edit This option will allow the user to edit a recipe that is stored on the 9205 controller. The Select Recipe button will allow the user to select which recipe to load ( been selected, the recipe will be displayed on the screen. The higher recipe steps can be viewed by holding a finger or stylus on the screen and scrolling up or down. To edit a specific step, highlight that step and press

Edit button. This will allow the user to select a

the different Opcode to use, or to change the information entered for the current Opcode. See OPCODES for more information on each Opcode and its purpose. To insert a step into the program, highlight the step number for the step, and press the been confirmed, the user will be able to select the Opcode to use.

step after down one, so an Opcode at step 24 will be lost

To remove a step from the recipe, highlight the step number to remove, and press the Delete button. The user will have to confirm the delete. Once the delete has been confirmed, the step will be deleted and every step after will be moved up one step. Blank step numbers will be replaced with a NO-OP Opcode. Press the Save button to save the changes that have been made. The recipe can be saved as any valid recipe number ( confirm the save before the old recipe will be overwritten. If the user wishes to delete an entire recipe, they have one of two options. First, they could load up the desired recipe and change every step to the NO-OP Opcode and save those changes; Or, they could save the 24-step “blank” (NO-OP) program that is loaded up when the desired program number. This will save the “blank” recipe to the desired recipe number location. The Return button will return the user to the menu screen.

1 – 300). Once the recipe has

Chapter 4 –

Insert button. The user will have to confirm the insert. Once this has

.

1 – 300). If the desired recipe number already contains a recipe, the user will have to

Note: Inserting a step will push every

Recipe Edit

screen is first displayed as the

Series 9205 Operations Manual Rev A 33

IMPORTANT!

enough.

Load T/C Configuration

Configuration of any Load TCs must be completed under this menu item.

It should also be noted that not all analog inputs on SRs to a 9205 will be load thermocouples. They are often used as a means to capture other data. Care MUST be taken with selecting which is a Load TC and which is not, as improperly selecting something that is not a Load TC may cause the program to run excessively long or not run long

Load TC Enable This value will manually toggle between on, on + alarms, and off. On – T/C Enabled On + Alarms – T/C Enabled, Programmer alarm114 provided if out of band (Default wait limits) Off – T/C not enabled

Control TC This value allows the user to set the TC to be part of the group of Load TCs that can hold the program if it is out of band. The values are

active or not active (shown as blank).

TC 1 – 27 This value allows the user to manually turn the T/C from active to not active to be part of the group of TCs that can hold the program if it is out of band.

Input 1 – 3 This value allows the user to assign analog inputs 1, 2, and 3 as Load TCs by selecting the active state for each input. (

Not active means that the input is not set up as a Load TC.)

Load T/C Alm On Delay (Sec) This option will allow the user to set a delay time, in seconds, before the load T/C alarm is activated. The range is

0 – 32767.

The Return button will return the user to the menu screen.

Trend Chart Edit This menu option will allow the user to add, modify, or delete trend lines in a trend chart file, as well as the trend chart files themselves. The trend lines are the number of variables displayed on one screen. For example this could be a control, overtemp, or load thermocouple on a batch furnace. Or it could be one thermocouple from eight temper furnaces. There is not a maximum for template selections, but the number of variables displayed on one screen must be a consideration in this process. The buttons across the top of the screen –

Open, New, Delete, Save, and Save

Series 9205 Operations Manual Rev A 34

As – deal with the trend chart files themselves, not the individual trend lines. Open will allow the user to select a trend chart file to open up to edit. New will create a new trend chart file to begin adding trend lines to. Delete will delete a specified trend chart file. Save will save all changes to the current trend chart file that have been made. Save As will allow the user to save the current trend chart file as a new file with a different name.

Once a new trench chart file has been created, or one has been opened, trend lines can be added, modified, or deleted. specific trend line.

Add will add a new trend line to the file. Edit will allow the user to edit the information for a

Delete Line will delete the specified line from the chart file. Adding or editing a trend line will involve the following parameters: Name – the name of the input, for example “Temp ACT” which would be the actual temperature of the input. It is a good idea to shorten the names so that they still make sense, but do not take up as much space. Data – This will determine where the data is coming from. The user can click on the box to select from the list of data logged points in the 9205. Some of the points have a name, such as “Temperature” or “Temperature SP”, but others will just show the register in the 9205 that has been logged. Note that certain parameters are already setup and logged. For anything needed beyond this, you will need to contact SSi at (513) 772-0060 to get the register information. This register will need to be added to the Datalogging Setup in the

Configuration menu.

Min – the minimum displayed scale value on a chart. Max – the maximum displayed scale value on a chart. Expression – every input requires an expression to be calculated and displayed correctly. This is because the registers in the 9205 hold only integer values, so any value that requires a decimal point needs to be set up properly for the display. For example an expression for temperature would be x (1750 = 1750). For a value such as carbon or millivolts, the expression would be x * 0.01 (150 = 1.50) or x * 0.1 (805 = 80.5). Format – the value displayed on the chart display of the operator interface. A short custom description can be added here. For example, to display one (1) decimal point, enter a value of “#0.0”. For carbon values, enter a value of “#0.00” for 2 decimals. This would display a value like “0.81”. Entering “#.00” would display a value of “.81”. #0 or 0 will display integer values. Color – The box next to the format box will allow the user to apply a color to the trend line to differentiate it from other trend lines on the chart. Units – The type of units used for the trend. Line Width – a numeric value for the thickness of the trend line. A 1 is a thin line; A higher value = thicker line width. Sample – a number is entered here to test the expression and verify that formatting is correct. Test – Press the test button to calculate the expression with the value entered in the sample parameter. For example with an expression of x*.1 and a value of 250 entered in the sample parameter will display a

25.0. The Set button will save the values entered. The Cancel button will cancel the information and make no changes.

The OK button will close the screen and prompt the user to save any changes if changes have been made.

The Cancel button will close the screen and return to the menu screen.

Series 9205 Operations Manual Rev A 35

Communications Setup

Warning: Changes to this screen should not be made without consulting SSi at 513-772-0060. This screen will show the Ethernet and RS-232/RS-485 communications information for the 9205 controller.

Note about ADAM module support: Communications with ADAM analog input modules manufactured by Advantech are not supported as of 9205 firmware revision 2.34. To determine the firmware version of your 9205 instrument, use the

option in the main menu.

About

IP Address This will identify the IP address of the controller. Please

consult your Systems Administrator before changing this value as it can affect communications to the 9205 controller, communications between the controller and the PLC, communications between the controller and other devices on the network, or to data collection systems. This is necessary if the Touchscreen will be communicating to the 9205 over Ethernet communications. The IP address must be in the “xxx.xxx.xxx.xxx” format.

NOTE: The IP address is not typically used for communications from the touch screen to the controller, but for communications between the controller to SuperDATA modules, PLCs, etc.

IP Mask This will identify the Subnet mask of the controller. The Subnet mask must be in the “xxx.xxx.xxx.xxx” format.

IP Gateway This will identify the IP gateway of the controller. The IP gateway must be in the “xxx.xxx.xxx.xxx” format.

RS-232B Baud This will set the baud rate for RS-232 communications. This is necessary if the Touchscreen will be communicating through the Com ports. The list of options is: 1200 14400 57600 460800 2400 19200 76800 921600 4800 28800 115200 9600 38400 230400

RS-232B Mode This will set the mode for RS-232 communications. This is necessary if the Touchscreen will be communicating through the Com ports. The list of options is: Modbus/no PLC Modbus master/PLC

Host 485 (3,4) Baud This will set the baud rate for RS-485 communications. This is necessary if the Touchscreen will be communicating through the Com ports. The list of options is: 1200 14400 57600 460800 2400 19200 76800 921600 4800 28800 115200 9600 38400 230400

Series 9205 Operations Manual Rev A 36

Host 485 (3,4) Mode This will set the mode for RS-485 communications. This is necessary if the Touchscreen will be communicating through the Com ports. This setting is fixed at

Modbus.

Host 485 Address This will set the address for RS-485 communications. This is necessary if the Touchscreen will be communicating through the Com ports. The range is

1 – 247.

Slave 1 485 (5,6) Baud This will set the baud rate for Slave 1 communications. The list of options is: 1200 14400 57600 460800 2400 19200 76800 921600 4800 28800 115200 9600 38400 230400

Slave 1 485 (5,6) Mode This will set the mode for Slave 1 communications. This list of options is: Modbus Yokogawa Modbus Host

Slave 2 485 (22,23) Baud This will set the baud rate for Slave 2 communications. The list of options is: 1200 14400 57600 460800 2400 19200 76800 921600 4800 28800 115200 9600 38400 230400

Slave 2 485 (22,23) Mode This will set the mode for Slave 2 communications. This list of options is: Modbus SSi Analog Input Board Yokogawa

PLC Type The list of options is: Micrologix Modbus MCMmodule Modbus DF1 PLC5 DF1 Slik Passive

Host 232A Baud This will set the baud rate for RS-232 communications. This is necessary if the Touchscreen will be communicating through the Com ports. The list of options is: 1200 14400 57600 460800 2400 19200 76800 921600 4800 28800 115200 9600 38400 230400

Host 232A Mode This will set the mode rate for RS-232 communications. This is necessary if the Touchscreen will be communicating through the Com ports. This setting is fixed at

Modbus.

Series 9205 Operations Manual Rev A 37

The Return button will return the user to the menu screen.

Slave Instrument Setup WARNING: This screen should not be changed without consulting SSi at 513-772-0060.

This screen will allow the user to configure up to eighteen (18) slave instruments through the 9205 controller (7 are reserved). To set up a slave instrument, highlight the instrument number and click on the

Edit button.

The list of available slave instruments will be shown on the screen. The list is color coded by type – Blue for Atmosphere, Red for Temperature, Yellow for Events, and White for User-Selected Instrument. Highlight an instrument to select it as the instrument to use.

The list of controllers includes the following Atmosphere Controllers:

• SSi AC20

• Yokogawa 750

• Honeywell UDC3300

• Dualpro LP1 Modbus

• Dualpro LP2 Modbus

• Dualpro LP1 MMI

• Dualpro LP2 MMI

• Eurotherm 2402

• Eurotherm 2500

• Carbpro v3.5

• Carbpro v3.0

• CarbPC

• 9200 LP1

• IR Base

• MGA

This list of controllers includes the following Temperature Controllers:

• SSi 7EK

• Yokogawa 750

• Honeywell UDC3300

• Dualpro LP1 Modbus

• Dualpro LP2 Modbus

• Dualpro LP1 MMI

• Dualpro LP2 MMI

• Eurotherm 2402

• Eurotherm 2500

• Unipro v3.5

• Unipro v3.0

• Carbpro v3.5 Slave

• Carbpro v3.0 Slave

• 10Pro

• DualPro IN C

Series 9205 Operations Manual Rev A 38

• 9200 LP1

• 9200 LP2

• 9200 LP3

• 9100 LP2

• Eurotherm 2704 LP1

• Eurotherm 2704 LP2

• Eurotherm 2704 LP3

• VC BASE 1

• VC BASE 2

• VC BASE 3

• VC BASE 4

• AIPC

• SSi 7SL

• AEC FurnaceMeter

• UMC800 LP1

• SSi Quad AO1

• SSi Quad AO2

• SSi Quad AO3

• SSi Quad AO4

• Yokogawa UT350

• Yokogawa 750 Lp 2

• Yokogawa UP350

• Honeywell DCP551

• Ascon 08

• SSi X5

• SSi M4L

• SSi X5/timer

• SSi SPUD

• SSi AIB3

• SSi H2 cell

• Flow Meter Short

• SSi O2 remote

• SSi Dual Motor Board

• SSi Smart AIB3

• O2 Block

• Waukee Valvetronic +

This list of controllers includes the following Event Controllers:

• SSi AC E

• Yokogawa 750E

• Mod Mux

• Dualpro E Modbus

• Dualpro E MMI

• Carbpro E v3.5

• Carbpro E v3.0

• Eurotherm 2500

• SSi 8-8

• SSi 9200E

• Micrologix PLC

• MCM Module

• PLC5 DF1

• SLC DF1

Series 9205 Operations Manual Rev A 39

User devices User 1 – 15 can also be selected.

The number below the list is the address for the slave instrument. The range is 0 – 25.

** 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.

The slave port is next to the address. The Slave port option can be: Slave 1, Slave 2, or RS-232.

Some instruments may not be shown in the list of instruments. User Instruments 1 through 16 are used to set up a non-listed instrument as a slave instrument using the Generic Instrument Setup menu.

The OK button will set the slave instrument, and the Cancel button will cancel the setup.

The Return button will return the user to the menu screen.

Series 9205 Operations Manual Rev A 40

Step

Opcode

Temperature

Option 1

ZONE_OFF

25

Zone 1

2

ZONE_OFF

50

Zone 3

3

SETPT

1750

Zone Assignments

WARNING: This screen should not be changed without consulting SSi at (513) 772-0060.

*Slave Instrument Setup must be configured prior to Zone Assignment setup

The zone assignment feature allows the Series 9205 program to change set points on all instruments of a multi-zone furnace. The Series 9205 has up to five temperature and atmosphere zone assignments available ( Typically, the first zone is configured to the programmer’s atmosphere or temperature instrument. That is the master set point that will be propagated to the other configured zone instrument set points on set point change. For example, the user may want to set 4 temperature zones from a recipe where the programmer temperature instrument is loop 2. In this case, zone 1 would be configured as loop

2. Subsequent zones would be configured as previously configured slave temperature controllers.

If the zone instrument would have the offset added. For example, a 3-zone pit furnace, where the bottom zone usually has a higher set point. The middle zone and the top zone usually have a lower set point. The bottom zone temperature controller is assigned to zone 1, the middle temperature controllers to zone 2, and the top zone controller to zone 3.

If the first three steps of a program are as shown below, then the bottom zone set point is 1775, the middle zone is 1750, and the top zone is 1800.

Zone Assignment 1 – Zone Assignment 5).

ZONE_OFF

(Zone Offset) opcode had been used in the program, the set point sent to the specified

The first step sets the offset for zone 1 to 25 degrees; therefore, the bottom zone controller would be sent a set point of 1775 when step 3 is executed. Likewise step 2 sets the offset for zone 3 to 50 degrees. The top zone then receives a set point of 1800. The middle zone controller would receive the 1750. The temperature controller displayed on the Status Display is instrument #2. If instrument #2 were the top zone controller then the Status Display would show the 1800-degree set point.

When using the multi-zone offset feature, the temperature controller assigned as instruments 1 and 2 should be in zones that will not be offset.

Atm Source This will allow the user to set the atmosphere instrument for the zone assignment. The options are

Loop 1 Instrument 5 Instrument 12 Instrument 19 Loop 2 Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Series 9205 Operations Manual Rev A 41

Atm Zone Number This option will allow the user to set the zone number for the assignment. The range is 0 – 5.

Atm Zone Offset This option will allow the user to enter an offset for the assignment. The range is -4000 – 4000.

Temp Source This will allow the user to set the temperature instrument for the zone assignment. The options are:

Loop 1 Instrument 5 Instrument 12 Instrument 19 Loop 2 Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Temp Zone Number This option will allow the user to set the zone number for the assignment. The range is 0 – 5.

Zone Offset, Temp This option will allow the user to enter an offset for the assignment. The range is -4000 – 4000.

Furnace Setup

The Furnace Setup menu option is an administrative access only option. Do not make any adjustments on the screen without first contacting Super Systems, Inc. at (513) 772-

0060.

PVT Type There are nine PVT choices for the 9205:

%Carbon Cascade Dew Point % Carbon + Redundant TC Millivolts Dew Point + Redundant TC Multiloop Millivolts + Redundant TC % Carbon + Dual Temp

%Carbon: Process variable will calculate for carbon potential along with a temperature loop. Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals 29, 30 probe TC). These two inputs together constitute loop 1. Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

Cascade: Three loops of temperature control work together in a cascade setting.

Dew Point: Control will be for dew point along with a temperature loop. Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals 29, 30 probe TC). These two inputs together constitute loop 1. Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

%Carbon + Redundant TC: This functions the same way as the %Carbon option with an additional thermocouple for Loop 3. The two thermocouples are used to control carbon, and the operator can choose the setting that will be used.

Series 9205 Operations Manual Rev A 42

Millivolts: Control is based off of what the millivolt reading is and also reads temperature.

Dew Point + Redundant TC: This functions the same way as the Dew Point option with an additional thermocouple for Loop 3. The two thermocouples are used to control dew point, and the operator can choose the setting that will be used.

Multiloop: Three loops of control can be assigned as selected.

Millivolts + Redundant TC: Control is based off of the millivolt reading and also reads temperature. Loop 3 is another thermocouple.

%Carbon + Dual Temp: This functions similarly to %Carbon. Input 2 is the control TC. IT is not used to calculate carbon potential with input one and to control furnace temperature. Input 3 in the third loop and is another TC.

IMPORTANT:

If the 9205 is controlling % Carbon or Dew Point, control will be disabled if either or both of

the following are true:

• Millivolts registered by probe are below 500 mV or above 1300 mV.

• Temperature registered by probe is below 900°F or above 2100°F.

Temperature Mode

This allows the operator to choose either degrees Fahrenheit or degrees Celsius for the temperature. The options are

°C or °F. Pressing OK will set the choice.

Loop 1 Instrument

Loop 1 (typical) Instrument 5 Instrument 12 Instrument 19 Loop 2 Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Loop 2 Instrument

Loop 1 Instrument 5 Instrument 12 Instrument 19 Loop 2 (typical) Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Event Instrument Allows for a slave instrument (or internal) to be the defined event control device. The types of instruments

Internal, Instrument 1 – Instrument 25. Internal is typical.

are:

Quench Instrument Allows for slave instrument (or internal) to be the defined quench control device. This is setup in the configurator furnace setup submenu. It will send the setpoint out to whatever instrument is configured for quench. The types of instruments are:

Loop 1 – Loop 3, Instrument 1 – Instrument 25.

Series 9205 Operations Manual Rev A 43

End of Quench Event Tells the programmer which event to signal end of quench (related to which relay it is assigned). The default event for this is Event 7, but it can be changed in the furnace setup menu. This event turns on for one (1) minute when the quench timer is complete. The list of possible values is:

Quench Speed Event Tells the programmer which event will signal the quench speed. The default event for this is event 6. This event will remain off if quench speed is set to low. It will turn on if quench timer is timing and quench speed is set to high with the QUENCH opcode. The list of possible values is:

Quench Run Event Tells the programmer which event will signal quench run. The default event for this is 0. This event will stay on when the quench timer is timing. The list of possible values is:

Date and Time This value is the current date and time on the 9205 controller only (not the local computer or the touch screen, if applicable). The time on the controller is displayed in the 24-hour format, so 8 = 8 AM, and 14 = 2

Note: The date and time of the touch screen can be changed (if necessary) by selecting the date and

PM.

0 – 15.

time in the lower right corner on the touch screen, once the screen software has been shut down and the Windows™ desktop is visible. Then, at the CE screen the date and time can be changed by double taping the time in the bottom right corner and setting it, then select “apply”. For this to take effect the screen needs to be rebooted; on the older TPC 642 displays the registry needs to be saved under TPC Configuration icon, the Misc Tab and then reboot the touch screen. The date and time that is recorded on the flash card

(and therefore the datalog data) is the date and time of the Advantech display, not the controller

.

Default Hold Time This value is the default holding time for the furnace. The range is 0 to 10000.

Deviation Alarm Delay This value is the delay for the alarm if a deviation alarm is detected. The range is 0 to 10000.

Name This will allow the user to give the controller a display name.

PV1 Name This will allow the user to give the first process variable a display name.

PV2 Name This will allow the user to give the second process variable a display name

PV3 Name This will allow the user to give the third process variable a display name

Clear events/end of recipe This switch will allow the user to clear the events out at the end of a recipe. The options are either no or yes.

Start Quench This option will determine what event starts the quench cycle. It determines whether the quench timer starts immediately after it sees the quench opcode or if it waits for an input event If this option is set to start on an opcode, when the recipe reaches the step, it will preload the timer and start timing immediately.

Series 9205 Operations Manual Rev A 44

If it is set for an input, it will preload the timer but wait until it sees the input configured go high before it starts timing. The options are:

Quench Hold Event This option will determine which event will hold the quench cycle. It is used to hold the quench timer with an external device. If the input that is configured turns on then the quench timer will go into a hold mode. The list of possible values is:

Quench Transfer Time Configuration This option will allow the user to set what will trigger the transfer from the quench cycle. The options are: Event 2 Active Time, or Event 1 Active to Event 2 Active.

Cascade Inhibit

On Recipe Opcode (

0 – 15.

Note: This field is only applicable if the controller is in Cascade mode

off. When inhibit = enabled, the 9205 functions as a multi-loop controller with three control loops. The options are:

PV Difference Cutback

enabled or disabled.

Note: This field is only applicable if the controller is in Cascade Mode

Range EOPV and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop. This will turn the PV difference cutback feature on or off. The options are:

Cascade Lower Range EOPV

Note: This field is only applicable if the controller is in Cascade Mode

of PV difference. This is used with the PV Difference Cutback and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop. Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop. The range is

Cascade Upper Range EOPV

-300 to 10000.

Note: This field is only applicable if the controller is in Cascade Mode

of PV difference. This is used with the Cascade Lower Range EOPV and PV Difference Cutback to limit the absolute % output of the furnace loop. Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop. The range is

Example: With the Lower EOPV set to 10 and the Upper EOPV set to 110, if the load PV is 1700 and the furnace PV is 1710, the full 100% output is available. If the load PV is 1600 and the furnace PV is 1710, the furnace output will not go above 0%. If the load PV is 1655 and the furnace PV is 1710, the maximum output for the furnace loop will be limited to 55%: (1710 – 1655)/(110-10) * (1.0).

Multiloop Display

-300 to 10000.

QUENCH

Opcode), Input 1 – Input 31.

. This will turn cascade control on or

. This is used with the Cascade Lower

enabled or disabled.

. This is the cascade lower range end

. This is the cascade upper range end

This option allows the user to decide which combination of loops will be displayed on the default status screen. The choices are: No display Loop 1, Loop 2 Loop 2, Loop 3 Loop 1 Loop 3 Loop 1, Loop 2, Loop 3 Loop 2 Loop 1, Loop 3

The Return button will return the user to the menu screen.

Series 9205 Operations Manual Rev A 45

Default Wait Limits The 9205 controller uses default wait limits in conjunction with recipe programs using the wait, wait up, or wait down feature, or guaranteed soaks, atmospheres, etc. The wait limits are in place to help make sure a recipe will not continue to the next step until the process variable is within the specified range. The wait limits are both plus and minus the value of the setpoint specified in the recipe.

Temp Wait Limit This is the specific wait limit for the temperature PV. The range

0 to 4000.

is:

Atm Wait Limit This is the specific wait limit for the atmosphere PV. Range is 0-40.

The Return button will return the user to the menu screen.

Alarm Setup

The 9205 controller can be configured to use three (3) different alarms. Each of the alarms consists of an alarm setpoint, alarm source, 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. See the section Appendix E – Factory Default Settings for the 9205 Controller default settings for the alarms.

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 –32767 to 32767.

Alarm Source This option will indicate the source of the alarm. The options are: PV 1 Value PV 2 Value PV 3 Value Input 1 Value Input 2 Value Input 3 Value Output 1 Value Output 2 Value Output 3 Value

Alarm Type This value is the type of alarm used. Options are: Process High Process Low Band, Normally Open

Series 9205 Operations Manual Rev A 46

for more information on factory

Band, Normally Closed Deviation, Normally Open Deviation, Normally Closed

Band alarm works by looking at a value above and below setpoint. Deviation alarm works by looking at a value either above or below (based upon the setpoint value the user has entered). A few examples would probably be best to explain how to set these up properly.

Hysteresis This value is the Hysteresis value. 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, suppose the SP is 200 °F. The alarm is set as a deviation of +10 °F. At 210 °F, the alarm is active and the pump will run to cool the oil. With a hysteresis of 8 °F, the alarm and pump will turn off at 202 °F. It will turn back on when it is 10 °F above setpoint. If the setpoint is still 200 °F, then at 210 °F, it will turn on again.

Clicking on this value will display an input box from which the user can select a new value. The range is

-32767 to 32767.

from

Smart Alarm This value is a display of the Smart Alarm status. A smart alarm is an alarm that works with a Process Variable (PV), and, when enabled, it will not be active until the PV is within band of the setpoint. The alarm sounding - if active - will be disabled until within the SP band. When it is in band, the alarm will go active unless on delay time is set.

Example: If the SP is 1700 °F and the band is 10 °F, the alarm will not be active until the PV reaches 1690 °F. The value can be either

disabled or enabled.

ON Delay Time This value is the On Delay Time 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

0 Setpoint Blocks Alarm This value will allow a 0 setpoint to block an alarm. The options are either No or Yes.

BO/Impedance inhibits alarm If BO/Impedance inhibits alarm is turned to Yes, no alarm will sound if the carbon percentage drops because of a burnoff.

Inhibit Source Alarms can be inhibited in order to prevent false or unnecessary alarm notifications. The Inhibit Source option will allow the user to set the source of the inhibit signal. The options are: Soak timer inactive (The alarm will not happen if the furnace is in a soak if this option is selected), and . Input 6 – Input 15.

Disable on open input An alarm can be disabled when an input the open in order to avoid false or unnecessary alarms. This option will allow the user to specify if the alarm is disabled when the input is open. The options are either yes.

The Return button will return the user to the menu screen.

-32767 to 32767.

None, Input 1 – Input 4,

no or

Series 9205 Operations Manual Rev A 47

Thermocouple Check This menu option allows the values between up to three thermocouples to be compared to one another. If the thermocouples go out of band, it is possible to set up an alarm that will alert the operators of this error.

Source 1 This assigns the first thermocouple that will be compared. The options are: Not used Instrument 1-27 Input 1 - 3

Source 2 This assigns the second thermocouple that will be compared. The options are: Not used Instrument 1-27 Input 1 – 3

Source 3 This assigns the third thermocouple that will be compared. The options are: Not used Instrument 1-27 Input 1 – 3

Tolerance Band This allows the operator to set the tolerance band between the thermocouples being compared. The range is

-9999 to 9999.

Source 2 Offset This allows for an offset to be assigned to the second thermocouple and taken into account when the comparison between values is made. The range is

-9999 to 9999.

Source 3 Offset This allows for an offset to be assigned to the third thermocouple and taken into account when the comparison between values is made. The range is

-9999 to 9999.

Relay Assignments

The 9205 controller has eight relay outputs, as well as eight relay outputs for four additional modules. 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. These relays can be configured to work with events, alarms, loops, burnoff and alarm combinations.

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

Series 9205 Operations Manual Rev A 48

Loop 1 fwd

IN1 Relay SP A

Loop 1 rev

IN1 Relay SP B

Loop 2 fwd

IN1 Relay SP C

Loop 2 rev

IN2 Relay SP A

Loop 3 fwd

IN2 Relay SP B

Loop 3 rev

IN2 Relay SP C

Programmer alarm

IN3 Relay SP A

Alarm 1 – 3

IN3 Relay SP B

Event 0 – 15

IN3 Relay SP C

Burnoff

IR sample solenoid

0 – 47 Programmer 1

0 – 47 Programmer 2

nothing

Relay Output 8 – terminals 7 and 15 NC Relay Output 8 – terminals 7 and 16 NO

Relay Output Choices

The “Alarm Combination” option will allow the user to select the specific combination of alarms to use. The options are: Programmer, Alarm 1, Alarm 2, Alarm 3, Invert State for Relay, and one of three options in a drop-down box:

TC Chk (Thermocouple Check), EOQ (End of Quench), or Programmer 2.

The Return button will return the user to the menu screen.

Analog Input Setup The 9205 controller has three analog inputs. Each of the inputs comes with a factory default configuration dependent on the application. It can be modified prior to shipment to your facility or in the field by a technician or qualified/trained person with the proper security code. Before connecting your input source to the terminals, please verify that the input type is set up correctly. If the Input Type is not correct, do not connect the input source to the terminals, as damage can occur. Please consult SSi by calling (513) 772-0060 before making any changes.

Analog Input Terminals Analog Input 1 – terminals 31 and 32 Analog Input 2 – terminals 29 and 30 Analog Input 3 – terminals 27 and 28

Input Type The thermocouple type for most applications can be modified depending on your specific needs.

some of the inputs DO NOT allow the user to modify the Input type

. To change the Input type, first select

Note -

which input you want to change by selecting it in the pull-down at the top of the screen. 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

Series 9205 Operations Manual Rev A 49

TRIP POINT EXPLANATION:

Trip Point Setpoint

Trip Point Force Value,

Trip Point Direction

NNM 4-20 mA ** R 25 volts **

** - When the specified input type is selected, a jumper located inside the case will need to be placed on that specific input for reading this selection. If jumper is not placed on input, then damage could occur to the board. Please consult SSI before making any changes.

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 without consulting SSI. Clicking on this value will display an input box from which the user can select a new value. The range is

Initial Scale This is the initial scale value. This could also be referred to as the starting value. For example, the initial value is the value when 0 volts is on the selected input; or on a 4-20 mA input, it would be the value at the selected input of 4 mA. Clicking on this value will display an input box from which the user can select a new value. The range is

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

Decimal Point Location This is the decimal point location value. This will affect the PV value and the location of the decimal when it is displayed. Clicking on this value will display an input box from which the user can select a new value. The range is

Open TC behavior This is the open TC value. The options are: up scale, down scale, one trip point, and two trip points.

Input Offset The input offset value is algebraically added to the input value to adjust the input curve on read-out. The range is

0 to 4.

–32768 to 32767.

0 to 32767.

to a certain value as assigned by the operator. Once the begin reading the value as the furnace. The when the trip point is either above or below the setpoint.

Trip Point 1 Setpoint This is the trip point 1 setpoint value. The range is –32768 to 32767.

Trip Point 1 Force Value This is the trip point 1 force value. The range is –32768 to 32767.

Trip Point 1 Direction This is the trip point 1 direction. The options are: input above setpoint or input below setpoint.

Series 9205 Operations Manual Rev A 50

Setting a trip point will force the value that the controller uses for calculations

is reached, the controller will

regardless of what the actual value is inside the

allows the operator to choose whether the controller will alter its reading

PV 1 retrans

Loop 2 inc

Not assigned

Programmer ID number

Programmer DAC 5

Programmer 2 DAC 3

Trip Point 2 Setpoint This is the trip point 2 setpoint value. The range is –32768 to 32767.

Trip Point 2 Force Value This is the trip point 2 force value. The range is –32768 to 32767.

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 is –32768 to 32767.

High Input Limit Hysteresis This is the hysteresis for the high input limit. The range is –32768 to 32767.

Custom Curve This will allow the user to set the custom curve to use. The curves are set up through the C menu option. The options are:

T/C Correction Curve This will allow the user to set the T/C correction curve to use. The curves are set up through the

Correction Curves

The Return button will return the user to the menu screen.

Analog Output Setup

Port Setup menu to configure communication parameters.

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 at the top of the screen. The following is a list of the options:

menu option. The options are: None, Curve 1 – Curve 3.

None, Curve 1 – Curve 3.

The 9205 controller has the option of six 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 Analog outputs 3, 4, 5, and 6 are enabled by use of an SSi QuadDAC board that connects to two RS485 terminals on the 9205 (terminals 5 and 6 for Slave 1, terminals 22 and 23 for Slave 2). Use the

urve Entry

T/C

Loop 1 inc Loop 1 dec Loop 1 combo PV 2 retrans

Series 9205 Operations Manual Rev A 51

O2 offset log SP1 retrans SP2 retrans SP3 retrans

Programmer DAC 6 Prog 2 Quench speed (0-1000=0-100%) Programmer 2 DAC 1 Programmer 2 DAC 2

Loop 2 dec

Programmer Valve 1 SP

Programmer 2 DAC 4

Loop 3 combo PV 3 retrans Loop 3 inc Loop 3 dec Loop 3 combo Input 1 retrans Input 2 retrans Input 3 retrans

Offset This is the starting point, the Process Variable value at which you get 4 milliamps if the output is set up as 4-20mA (or 0 milliamps if output is set up as 0-20mA). Clicking on this value will display an input box from which the user can select a new value. The range is

Range This is a Process Variable value between 4 and 20 milliamps (or 0 and 20 milliamps, depending on setup). 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.

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 Offset = 800 (starting point) Range = 400

The Return button will return the user to the menu screen.

Alarm Polarity This option will allow the user to set up the polarity of the alarms, or determine whether the Normally Closed option or the Normally Open option makes the alarm active. The alarms to configure are: Programmer Alarm, Alarm 1, Alarm 2, and Alarm 3. The options for each alarm are: Normally Open or Normally Closed.

The Return button will return the user to the menu screen.

Programmer Valve 2 SP Programmer Valve 3 SP Programmer Valve 4 SP Prog 1 Quench speed (0-1000=0-100%) Programmer DAC 1 Programmer DAC 2 Programmer DAC 3 Programmer DAC 4

–32768 to 32767.

Programmer 2 DAC 5 Programmer 2 DAC 6 Programmer 2 ID number Programmer 2 Valve 1 SP Programmer 2 Valve 2 SP Programmer 2 Valve 3 SP Programmer 2 Valve 4 SP Disabled

See below for more examples

.

Series 9205 Operations Manual Rev A 52

Redundant TC Setup

This option allows the operator to choose which TC to control in a redundant TC setup. The redundant TC setup allows for two thermocouples to be used and measured from. This option can be configured so that the higher or lower is automatically selected or in manual mode so that the operator can choose which TC to use.

Band The Band lets the user set how far apart the values of the TCs in the redundant setup can be before an alarm is activated. The alarm can be assigned under the Relay Assignment menu option. The range for this is -4000 to 4000.

Delay Time This is the time in seconds that will pass once the TCs go out of band before an alarm is activated to prevent excessive, unnecessary alarming. The range is

TC Selection To change this option from TC 1, the select mode must be in manual.

Select Mode This allows the operator to choose whether the highest or lowest TC will automatically be chosen, or whether it will be manually chosen by the operator. The options are

NOTE: If the 9205 has redundant TC active, then digital inputs 2 and 3 can manually override the system and force the selected TC to be TC 1 if input 1 is active or TC 2 if TC 2 is active. If both input 1 and input 2 are active, input 1 will take precedence and make TC 1 active.

Event Hold/Reset

0 to 3200 seconds.

highest, lowest, and manual.

The Event Hold/Reset menu option provides the user manual control of actual event outputs. This is useful when testing wiring and field devices.

Hold Instrument Number Clicking on this value will display an input box from which the user can select a new value. The range is

0 to 25.

Hold Minimum PV Clicking on this value will display an input box from which the user can select a new value. The range is

-32768 to 32767.

Hold Maximum PV Clicking on this value will display an input box from which the user can select a new value. The range is 32768 to 32767.

Event for Program Run Clicking on this value will display an input box from which the user can select a new value. The range is –1 (Disable) to

15.

Series 9205 Operations Manual Rev A 53

Event for Program Reset Clicking on this value will display an input box from which the user can select a new value. The range is –1 (Disable) to

15.

Program Number to Run This is the recipe number to run. The range is: 0 – 300.

Input Event 0 - 15 The input box for these events has two drop-down lists. The top list contains active and inactive, and the bottom list contains

closed and open.

The Return button will return the user to the menu screen.

Series 9205 Operations Manual Rev A 54

Security This screen will allow the user to set up the security protocols for the system, as well as set up users for the system.

view will hide the

Users button and only the Level

1 and Level 2 code will be accepted

There are four levels of menus in the 9205 controller - Operator, Supervisor, Administrator, and SSi Special.

Operator Level These are functions typically handled by a furnace operator and do not require a passcode.

Supervisor Level These are functions typically used by a supervisor and require a level 1 passcode. The user name for the Level 1 code for Touchscreen is “Supervisor”. The “Level 1 Code” range and the “Web Level 1 Code” rage

-32768 – 32767.

is

Administrator These are functions typically used by an administrator and require a level 2 passcode. The user name for the Level 2 code for Touchscreen is “Administrator”. The “Level 2 Code” range and the “Web Level 2 Code” rage is

Web Change Enable This option will determine if changes can be made over the 9205’s web page. The options for this are: Enable or Disable.

Minimum Program Control Level This option will allow the user to determine which security level will be the minimum level for program (recipe) control. The options are: Example: If Supervisor is selected, then only a supervisor-level or higher can control the program.

Minimum Alarm Acknowledge Level This option will allow the user to determine which security level will be the minimum level for alarm acknowledgement. The options are: Example: If Supervisor is selected, then only a supervisor-level or higher can acknowledge an alarm.

Minimum Setpoint Level This option will allow the user to determine which security level will be the minimum level for sending a setpoint down. The options are: Example: If Supervisor is selected, then only a supervisor-level or higher can send a setpoint.

Minimum COF/HF Level This option will allow the user to determine which security level will be the minimum level for modifying the Carbon Factor or the Hydrogen Factor. The options are: Example: If Supervisor is selected, then only a supervisor-level or higher can modifying CO Factor or H Factor.

Minimum Automan Level This setting determines which security level will be the minimum level for changing the output mode to Auto or Manual. The options are: Operator, Supervisor, or Administrator.

-32768 – 32767.

Note – The “Classic”

.

Operator, Supervisor, or Administrator.

Series 9205 Operations Manual Rev A 55

Example: If Supervisor is selected, then only a supervisor-level or higher can enable Auto/Manual toggling of the outputs.

Clicking on the will have access to. Clicking on the Supervisor button will allow the user to modify which menu options the supervisor-level users will have access to. Clicking on the Administrator button will allow the user to modify which menu options the administratorlevel users will have access to.

Operator button will allow the user to modify which menu options the operator-level users

If the “Advanced” option is selected, then clicking on the Users button will allow the user to create or modify user information for the Touchscreen.

Note – Once the “Advanced” option is selected, a user name will need to be entered when logging into the menu system. A user name will need to be provided even if the Level 1 or Level 2 code is being used

The New button will allow the user to create a new user for the Touchscreen. A name, password, security level, and email address can be entered.

Note

.

– The password and email address field

can be left blank, if desired

that user active. An inactive user cannot log into the Touchscreen. The Edit button will allow the user to edit the information for a specific user. The Done button will return the user to the screen.

The Return button will return the user to the menu screen.

Curve Entry

five separate curves can be edited. Selecting one of 1-5 and pressing Edit will display the screen where new curves can be assigned. The type can be toggled between Linear and None.

Thirty-two points can be assigned by selecting one of the points and pressing change the

Series 9205 Operations Manual Rev A 56

Millivolts and the corresponding Value by

Edit. This allows the operator to

. The “Active” checkbox will keep

Security

menu

Most types of inputs that are used in SSi controllers are already setup with a curve built for most every type of thermocouple available, certain vacuum sensors, etc. However, if an application calls for an input without a standard curve, the curve can be built using this option. Voltages can be paired with corresponding values to create a sensor curve based off of a provided equation or data. This allows the controller to make appropriate readings from the sensor.

The first screen shows that

Curve

IMPORTANT!

recipe Opcode PID control.

clicking on each option. Pressing OK will save the point. Note that all 32 points do not need to be entered; however, the more points that are entered, the more precise the calculated value will be. Any values that are not entered should be set to values beyond (above or below) the ranges entered.

The Return button will return the user to the menu screen.

Alternate PID Setup

PID Auto Switching must be enabled in the PID Loop Setup menu before Alternate PID Setup settings will be applied. This applies only to the Loop 1 – Loop 3 Set1-Set 3 menu options. All other menu options are for

The Alternate PID Setup menu option allows for up to 16 sets of PID values to be used on the first loop via the programmer. This is frequently used if a different PID would be more suitable once a furnace reaches a certain temperature.

There is a choice of PID 1 – 16, and Loop 1 Set 1 -3, Loop 2 Set 1 – 3, and Loop 3 Set 1 – 3.

Prop Band (0 for On/Off) Proportional Band determines the response to the current error. The Proportional Band is the percent of the range of the process variable that will produce

100% output and is the inverse of the proportional gain. A low Proportional Band value results in a larger change in output for a given error. Conversely, a high Proportional Band value results in a smaller change in output for a given error. If the Proportional Band is too small, control may oscillate or be otherwise unstable. If the Proportional Band is too large the control action may be too sluggish in response to changes within the system. Note: If the Proportional Band is set to 0.0, only on/off control is performed. The range is

Reset Reset determines the influence of past errors. The Reset, or integral action (expressed in repeats per minute), sums the error between the process variable and setpoint over time and adds this accumulated output to the proportional output. A “proportional only” controller generally operates with steady-state error because some error is required to produce control output. The goal of integral action is to drive the steady-state error to zero and eliminate this droop. The range is

Rate Rate adjusts the response to future errors. The Rate, or derivative action (expressed in minutes), is used to

predict system behavior and has a dampening effect. The more the controller tries to change the process variable the harder the derivative will work to counter that effort. This dampening effect can be valuable in reducing overshoot but is most often useful when trying to improve control on systems with significant and predicable lag.

The range is 0.00 through 10.00. NOTE: The rate is not typically used for carbon control.

–1.0 to 999.0.

0.00 through 10.00.

Series 9205 Operations Manual Rev A 57

Integral Preset This is the integral preset value. This field provides an offset for the starting point for PID control, also referred to as “Load Line” or “Manual Reset”. The range is

–100 to 100.

High Limit This is the high limit value. The range is –100 to 100.

Low Limit This is the low limit value. The range is –100 to 100.

Aux Analog Input Setup The Auxiliary Analog Input Setup menu option allows the user an input selection of three inputs per board, three input corrections per board, and three input open T/Cs per board. There are eight (8) boards available. It is configurable for voltage of T/C (universal input), and it is typically used for Load T/Cs, motor speed feedback, current speed devices, and Auxiliary Flow Meters.

Before connecting your input source to the terminals, please verify that the input type is set up correctly. If the Input Type is not correct, do not connect the input source to the terminals, as damage can occur. Please consult SSi by calling (513) 772-0060 before making any changes.

Input 1 – Input 3 This will select the input types for the board. The options are: T/C B 160 mV 40 mV T/C C T/C R 20 mV T/C E T/C S 4-20 mA/124Ω T/C J T/C T 4-20 mA/62Ω T/C K 2.5 volts 25 volts T/C N 1.25 volts 12.5 volts T/C NNM 80 mV

Input 1 Correction – Input 3 Correction This option will set a correction curve for the input. The options for the input corrections are: not used, Curve 1 – Curve 3.

Input 1 Open T/C – Input 3 Open T/C This option will allow the user to set the direction of the open T/C for each input. The options are: Up Scale

Down Scale.

or

Calibration (Auxiliary Analog Inputs) The user will need a calibrator capable of outputting a temperature, voltage, and millivolt signal to calibrate the zero, span or cold junction value. The user will need to connect the calibrator to one of the inputs on the data logger for the channel that will be calibrated. It is recommended to let everything (calibrator and data logger) sit for approximately thirty minutes to allow the temperature to achieve equilibrium. Set up the calibrator for the specific thermocouple type, i.e. type K, type J, etc. Then, source a specific temperature, like 1000°F, or millivolt to the connected input. It is recommended that the actual temperature used be similar to an appropriate process temperature. For example, if your equipment normally operates at 1700°F, then perform the cold junction calibration using a 1700 °F signal. It is important to note that when performing a zero or span calibration,

do not use

regular thermocouple wiring.

Series 9205 Operations Manual Rev A 58

Instead, use any kind of regular sensor wire, or even regular copper wire. To perform the calibrations, the user will need a calibrator that is capable of outputting volts, millivolts, and temperature.

The “Zero/Span” tab will allow the user to perform a zero and span calibration on the selected board.

The help button - - next to the “Range” drop-down list will allow the user to select a range based upon an input type if the range is not known.

Select the input type and click on the OK button. The correct millivolt range will be displayed in the dropdown list. Click on the

Below is a listing of the suggested ranges for the various TC types. TC Type mV Range Chart TC Type Range in mV B 17.5 C 65 E 65 J 65 K 65 N 65 NNM 65 R 65 S 17.5 T 65

Calibration For calibration videos involving the touch screen, visit

http://www.supersystems.com/tech-videos

Cancel button to cancel this action.

.

Overview

The series 9205 can be calibrated using the Touchscreen interface. Before performing this procedure on a newly installed controller, the unit needs to be powered on for at least 30 minutes for a warm up period. The series 9205 has three 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. To calibrate an input or output, select the desired option and continue.

Note – Even though the “Cold Junction” option is listed first, the inputs and outputs should have the zero and span calibration performed BEFORE performing a cold junction calibration

.

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.

Notes

Input 1 – terminals 31 and 32 Input 2 – terminals 29 and 30 Input 3 – terminals 27 and 28 Output 1 – terminals 24 and 25 Output 2 – terminals 25 and 26

Series 9205 Operations Manual Rev A 59

Zero Calibration - Inputs To perform a zero calibration, click on the “Zero” option

- The circle will be filled in with a dot for the selected option. For a zero calibration, the recommended value to source is

0 mV. Click on the Calibrate button to begin the calibration. A progress bar will be displayed along the bottom of the screen giving the progress of the calibration.

Span Calibration - Inputs To perform a span calibration, click on the “Span” option - The circle will be filled in with a dot for the selected option. For a span calibration, the recommended value is 90 % of the full range. For example, if the range is 80 mV, then the span should be

72 mV. The recommended value can be changed by clicking on the value, and entering the new value that way. Click on the Calibrate button to begin the calibration. A progress bar will be displayed along the bottom of the screen giving the progress of the calibration.

Zero Calibration - Outputs To perform a zero calibration, click on the “Zero” option - The circle will be filled in with a dot for the selected option. When ready to start the calibration, click on the

Ready button. The user will then have to measure the current at the appropriate output terminals and enter that value on the button next to

Ready button by clicking on that value button and

the entering the value. Click on the Calibrate button to begin the calibration. A progress bar will be displayed along the bottom of the screen giving the progress of the calibration.

Span Calibration - Outputs To perform a span calibration, click on the “Span” option - The circle will be filled in with a dot for the selected option. When ready to start the calibration, click on the

Ready button. The user will then have to measure the current at the appropriate output terminals and enter that value on the button next to the Ready button by clicking on that value button and entering the value. Click on the Calibrate button to begin the calibration. A progress bar will be displayed along the bottom of the screen giving the progress of the calibration.

Cold Junction Calibration The “Cold Junction” option will allow the user to perform a cold junction trim on the selected board. To determine if a cold junction adjustment is needed, hook up the calibrator with the appropriate T/C wire attached, and source a temperature to the input. It is recommended to use an operating temperature to source. For example, if the furnace typically runs at 1700 °F, then 1700 °F should be sourced to the input. If the displayed value does not equal the value being sourced, then a cold junction adjust would be necessary. The “Offset” will be the amount of change desired. For example, if 1700°F is being sourced, and the “Value” is showing 1696.4 °F, then the “Offset”

Series 9205 Operations Manual Rev A 60

would be set to 3.6. If 1700 °F is being sourced, and the “Value” is showing 1702.3 °F, then the “Offset” would be set to Click on the Calibrate button to begin the calibration. Wait 120 seconds and verify with a source calibration device with the correct T/C type.

-2.3.

Note: During a normal calibration procedure, the user should zero and span all of the inputs first and then perform a cold junction calibration, if necessary

It is recommended after each Cold Junction calibration to source a value in and check what the displayed temperature reading is.

Click on the Return button to close down the screen.

Configuration This option will allow the user to set some general configuration settings. The list of configurable items is:

• Log Maintenance

• Programmer Alarm Text

• Event Text

• Compact Database

• Screen

• Datalogging Setup

• Repair Database

• Device Configuration

• Recipe Configuration

• Product Activation

• Alarm Text

• Time Synchronization

• Probe Management

• Maintenance

• Read/Write Data

Log Maintenance This option will allow the user to purge, or delete, log files, starting from a specific date. All log files from on or before the selected date will be purged. The user can purge log files from the

NOTE: The touch screen may require a login to access this menu.

Alarm Log, Event Log, or System Log.

.

Series 9205 Operations Manual Rev A 61

IMPORTANT!

Cabling changes may be required.

Programmer Alarm Text This option will allow the user to modify the text for

Programmer Alarm 1 – Programmer Alarm 99. Programmer alarms are internal, non-modifiable alarms that are triggered with the Alarm opcode in a recipe. Each alarm is initially labeled by the text “User Alarm #.” However, these labels can be changed to the operator’s preference. To change the text displayed for an alarm, open the Configurator program, open the Settings, and select the controller to edit. Under Alarm Text, double click any alarm number, enter the new text to be displayed, and hit Ok. User Alarm 0 is not an alarm; it is used to turn off a user alarm. It functions the same way as the acknowledge button.

Event Text This menu option will allow the user to configure the text for the input and output events for the 9205. Select whether to edit the Input events or the Output Events.

Note – The list of events can take a few seconds to load

The screen will refresh after the list has been loaded. There are a total of 31 input events, and 47 output events. Highlight the event to be changed and click on the button. This action will display the on-screen keyboard, which will allow the user to modify the event text. To save the changes to the event text, click on the Clicking on the changes made.

close the Edit Event Text screen

performed before switching from the input events to the outputs events, and vice versa. It is also recommended that after you return to the main overview screen, you perform a shutdown using the 9205 menu, and then restart the screen. This will save the registry correctly.

Compact Database Compacting the database will free up extra space, which will speed up the amount of time it takes the software to communicate with the database. This should be done as needed. Please consult SSi (513-772-

0060) for details.

Screen

Return button will not save any of the

Note – Clicking on the Save button will not

. A save must be

Save button.

.

Edit

Series 9205 Operations Manual Rev A 62

The touch screen will is configured by SSi prior to first use. Consult SSi before making changes to these settings.

This menu option will allow the user to determine how the Touchscreen will communicate with the 9205 instrument. The Media option will be the type of connection the Touchscreen is using to connect to the 9205. The options

are:

• COM1

• COM2

• COM3

• COM4

• Ethernet

If COM1 through COM4 is selected, the user will have to set the Address and the Baud rate as well. If Ethernet is selected, then user will have to enter the IP address of the 9205 instrument. The Address option is the slave address of the 9205 instrument for the COM port communications, or the Ethernet IP address for Ethernet communications. For the COM port communications, the address will range from format, or it will not be accepted. The Baud option is the baud rate for the COM port communications. The options are:

• 1200

• 2400

• 4800

• 9600

• 14400

• 19200

• 28800

• 38400

• 57600

• 76800

• 115200

Datalogging Setup

1 to 250. For Ethernet communications, the address must be supplied in a 999.999.999.999

Note – Contact Super Systems before making any changes on this screen, since any changes made can have an adverse effect on the data being displayed

This menu option will allow the user to modify which registers in the 9205 will be used as datalog data.

example from the image, the data values added would be: 850, 851, 852, 853, and 854. Clicking on the button will save the new data value registers.

changes to the datalog data, including resetting the configuration

the action. Clicking on the

Reset button will reset the values to the original configuration.

.

This list of data values is shown at the top of the screen. Click on

Add

the button to add a new set of data values, or click on the button to edit an existing set of data values. Click on the Delete button to delete a set of values. To add or edit data values, enter the initial offset of the register, as well as the number of sequential registers to read for. Using the

Note – The Save button must be clicked on to save any

. Clicking on the Cancel button will cancel

Edit

Save

Note – any

changes made to the data values will need a restart of the application before those changes will take effect

Clicking on the

Descriptions button will display any descriptions for the data values. The default description

.

Series 9205 Operations Manual Rev A 63

for a data value is the data value’s register. So the default description for data value 25007 is “25007”. Changing this to “Temperature”, for example, would make it more descriptive. Register 25007 holds the actual temperature value for the 9205.

To add a new description, click on the Add button. To insert a new description, click on the Insert button. To delete a description, click on the

Delete button. To edit an existing description, click on the Edit button. The Add or Insert feature will only create valid descriptions if there are existing data values without descriptions. Click on the

OK button to save the description changes. Click on the Return button to cancel

any changes and return to the previous screen.

Repair Database This feature will make attempted repairs on all SQL databases associated with the screen. Clicking the Repair Database button will display a timer icon while the repair is taking place.

Device Configuration This option allows the user to customize the text that will display with each loop (

Custom Look 1, 2, 3 Text fields). In order to do this, click on the blue box next to the corresponding Loop number. A keypad will be displayed, and the appropriate text can be written in. Press

enter to

save.

The Programmers option allows you to change the number of programmers managed by the 9205. The possible selections are 1 and 2.

The Recipe Quick View allows you to set an option, RemainingTime, that (when a recipe is running) will cause the current recipe number, step number, and time remaining to be displayed on the 9205 touch screen’s main screen.

Recipe Configuration

Using this screen, operators can give names to recipes for easy access. The operator must first choose “Recipes on device access by name” from the drop down menu. Next, select the

Maintain Recipes button. This screen will allow the operator to Edit and name recipes. Recipes can then be found by name under Recipe Edit.

Each recipe name must be set up with a recipe number in order to be viewable in SSi Configurator. If recipes are set up by name only in Recipe Configuration, you will not be able to view these recipes in SSi Configurator.

Series 9205 Operations Manual Rev A 64

Maintenance items are added from the

Add

Edit

Maintenance Items

Delete

The Compact Database button will compact the mb.sdf database file that is located on the Touchscreen. When records are added, space is reserved in the database table for the maximum amount of characters, regardless of the actual number of characters in the record. Once the record is added, this space is not released. Instead, it will still be associated with the record, thereby adding to the total disk space and slowing down the communication time with the database. Compacting the database will free up this extra space, which will speed up the amount of time it takes the software to communicate with the database.

Product Activation This feature is not yet available on the 9205.

Alarm Text

This menu option will allow the user to configure the text for the three main alarms on the 9205 as well as the PLC alarms. Highlight the alarm to be changed and click on

Edit button. This action will display the on-screen

the keyboard, which will allow the user to modify the alarm text. To save the changes to the alarm text, click on the OK button. Clicking on the Cancel button will forgo saving any of the changes made.

Time Synchronization This option allows the user to set up the touch screen to sync the system time with an Internet-based time server.

Probe Management This option allows the user to register a probe within the 9205 by entering its serial number. Doing so creates a tracking history of the probe burnoffs and impedance tests associated with it. Trends can be monitored this way and the impedance of the probe can be traced to help estimate its life expectancy.

Maintenance

Configuration -> Maintenance menu. To add a maintenance item, first tap the selections to determine the type of maintenance item and corresponding details to add.

Use the

button from the

menu to edit an existing maintenance item. Use the

button to delete an item.

Series 9205 Operations Manual Rev A 65

button. Use the

Types of Maintenance Items

Timed Event, Conditional Timer

Conditional Counter

Totalizer.

Interval

Weeks

message

Register

greater

than

Target

Expression

than

The following types of maintenance items can be programmed:

• Timed Event. A timed event is a maintenance event

that is based on intervals of time. For example, assume a plant has burners that need to be inspected once per week. The Timed Event can be programmed to remind operators to perform this maintenance check. In the example shown, a Timed Event called “Burners” has been created. The and the number of item will remain active is 20. The appear on the main 9205 touch screen is “Check condition of burners”.

• Conditional Timer. The conditional timer maintenance

event is based on the status of a selected controller register over a defined period of time. For example, a maintenance task may need to be performed when a register value is above a certain threshold for 1 hour. If the register value is above that threshold for 1 hour, a maintenance message will be displayed on the main 9205 screen.

In the example shown, when the value for 25007 (Temperature PV) is

field) for 5 minutes (

( message will be displayed on the main screen for the 9205 touch screen.

The value that will be compared to the value entered in

field. In the example shown at right, the

the value of the register will be multiplied by 0.1 (scaled to 10% of the original value) before it is compared to the value in the

, and

is Weekly,

for which the maintenance

that will

(>) than 500.00

), a “Check Alloy”

option allows you to program a scaled

column.

,

Series 9205 Operations Manual Rev A 66

Register

Bit

Target

Bit

Target

Register

Target

Expression

Value of Selected Register at:

First Minute

Second

Minute

Third Minute

Fourth Minute

Fifth Minute

Totalized

Value

5

20 6 5

11

47

Value of Selected Register at:

First Minute

Second

Minute

Third Minute

Fourth Minute

Fifth Minute

Totalized

Value

5

20 6 5

11

Scaled Value with Expression of *.1 applied:

0.5

2.0

0.6

0.5

1.1

Totalizer function with Expression applied

• Conditional Counter. The conditional counter is used

to generate a Maintenance alert based on a register bit value changing a defined number of times. The

is the register number that will be evaluated for changes. The first The need to take place before the Maintenance alert is triggered. The second that will increase the Target count: On, Off, or Change. “Change” is any change from a previous state; therefore, a change from On to Off and a change from Off to On would cause the Target count to increase.

In the example shown, register location 25009, bit 8 will be evaluated for a state change. After the state changes to On (second

• Totalizer. The totalizer works as an accumulator that adds the value of a register to previously summed values. The Totalizer will add the register value to the accumulated value each minute. This feature be useful for monitoring repeated changes that result in the need for maintenance or inspection. One example may be a furnace door opening and closing as loads are charged and removed from the furnace.

In the example shown, the value of will be monitored and added to previously summed values of the register every minute. After the Totalizer reaches 100 ( “Check furnace door” will be displayed on the main 9205 screen.

The value. For example, if be multiplied by 0.1; the scaled value will then be added to the existing sum.

The figures below illustrate how the Totalizer works with and without an Expression applied.

is the number of times that a change will

option allows you to program a scaled value that will be applied to the accumulated

setting is the bit number.

setting defines the change

setting) 5 times (

25029

), a maintenance alert

* .1

is entered as the Expression, the register value recorded each minute will

), the maintenance alert will be triggered.

Totalizer function without Expression applied

Series 9205 Operations Manual Rev A 67

4.7

From the Maintenance menu (accessible from the

Status Maintenance Report

Edit Current Records

Edit Security Settings

main menu), you can view a list of scheduled and completed maintenance items.

Operator level access allows the user to monitor the

of maintenance items and to use the

functions.

Supervisor level access provides all of the above functionality and the ability to Administrator level access provides all of the above, as well as the ability to maintenance menu.

Status

The Maintenance Status screen provides the ability to view the status of maintenance items, mark items complete, and change the status condition format. If a maintenance item is not due, it will appear in black lettering. If the item is due, it will appear in red lettering. The

Show Due Only checkbox, when checked, will cause only those items that need to be completed (“Due”) to be displayed. When a maintenance line item is selected, the button allows you to mark a maintenance item complete. The

Condition: button allows you to change

the status from Total Complete to Percent to Total.

Maintenance Report

The Maintenance Report window provides a log of maintenance items completed on a daily, weekly, or monthly basis beginning at a defined date.

.

for the

Complete

Series 9205 Operations Manual Rev A 68

Edit Current Records With this option, you can edit existing maintenance records. The screen will display maintenance condition in a way similar to the Maintenance Status menu, except that red lettering is not used for items that are due; the condition types can be changed in the same way as on the Maintenance Status screen.

To edit an item, select the item and tap Edit. The Edit Record screen will appear, allowing you to change parameters of the record (such as start date) based on the type of maintenance item.

Edit Security Settings Using this menu, you can change security settings for completing maintenance items and editing maintenance records. By default, both operators and supervisors can complete maintenance items, and only supervisors can edit records. (Of course, an administrator can do all of these. Administrator access is required to edit security settings.

To change a security setting, select the item in the Allowed Item list. Tap Toggle Operator to change the Operator value between True and False. Tap Toggle Supervisor to change the Supervisor value between True and False. If a value is true, it means that the corresponding access level is allowed to perform that function. If a value is false, it means that the corresponding access level is not allowed to perform that function.

Series 9205 Operations Manual Rev A 69

Tap Save when finished updating settings.

Read/Write Data This menu option is protected by the SSi special passcode. Contact SSi at (513) 772-0060 to obtain this passcode before making any changes. This menu option is used mainly for technical support reasons. It will read the registers from the 9205 and display those registers on the screen. The user will be able to read from and write to the 9205’s registers. When the screen is first displayed, it will read the first 100 registers from the 9205 and display them in a column format. The top of the list will show “0”, “10”, “20”, etc. These are the column headers. Each value in the column will be a logical increment of the header, where the first value in the column equals the header value. For instance, column “0” will start with register 0, which in the picture has a value of “101”. The next value down is register 1, which has a value of “5”. The next value down is register 2, which has a value of “1”, etc. So, column “40”, 4 values down is register is register 43, which has a value of “9999”. The number box in the top left of the screen is the beginning register to read from. This will default to 0 when the screen starts. To read registers 100 – 199, edit the value to read “100”.

value will automatically begin the read process. This process could take a few seconds to complete

The “Write offset” value will allow the user to write a specific value listed in the “Write value” box to the register listed in the “Write offset” box. Click on the

Return button to return to the

the

Configuration

Write button to write the value to the register. Click on

menu.

Note – changing the

.

Series 9205 Operations Manual Rev A 70

A/I Module Offset Correction The Analog Input module offset correction menu option gives the user the ability to offset any input on any A/I module for up to forty (40) inputs. Input correction curves can also be applied to inputs 1 through 40. The offset can be in degrees + or -, and it is typically used to compensate for incorrect T/C wires.

Enable Offsets for Aux AIB This option will determine if the offsets entered will be applied on the inputs. The options are:

Input 1 – Input 40 This will be the offset for the specified input. The range of the offsets is

Input 1 Correction – Input 40 Correction This will allow the user to enter a correction curve, if desired, to inputs 1 through 40. The options are: Not Used, Curve 1 – Curve 7.

–50.0 to 50.0.

Yes or No.

Aux Setpoint Configuration Aux Setpoint Configuration is an automatic setpoint retransmission with a corresponding custom offset and delay to one or more of the first 3 configured slave instruments. The delay is in minutes and is only active when the setpoint is dropped. This feature would most commonly be used to keep the alarm setpoint of an overtemp tracking the furnace's main setpoint (with offset). The delay allows the furnace time to cool below the level specified so that there is no overtemp alarm when the furnace is cooling.

Note: If the setpoint is 0, then the retransmission is blocked

T/C Extension Correction Curves

.

This menu option will allow the user to set up to three TC correction curves for the 9205 controller, as well as three auxiliary correction curves (extension curves). Clicking on the desired curve will display the curve edit form.

“Error” value are both zero, then the curve will not be set

combinations.

The range for the “Temperature” field is –32768 to

32767.

The range for the “Error” field is –32768.000 to

32767.000.

Series 9205 Operations Manual Rev A 71

Note: If the first “Temp” value and the first

. The user can enter up to ten “Temp”/“Error”

Generic Instrument Setup The generic instrument’s data will be stored in certain registers on the host instrument, such as the 9205 controller. Each instrument is allotted a certain set of registers, starting with register 1000. To determine the beginning register, use the following calculation: (100 * generic instrument’s number (1 –

16)) + 900. Therefore, instrument 1 would begin at register 1000: (100 * 1) + 900. Instrument 7 would begin at register 1600: (100 * 7) + 900. Each instrument is allotted 100 registers, therefore, instrument 1’s allotment is from register 1000 to 1099 on the 9205 controller, instrument 2’s allotment is from register 1100 to 1199 on the 9205 controller, etc. The

Generic Instrument Setups

menu is split into two parts: Coms, and Data. The screen lists the generic instruments from Instrument 1 to Instrument 16. Select the desired instrument to configure, then choose

Coms or Data.

Coms The three reads can be set up on this screen.

Read 1 Register, Read 2 Register, Read 3 Register The Read X Register field will be the register in the 9205 controller that the instrument will read from. The range is

0 – 32767.

Read 1 Count, Read 2 Count, Read 3 Count The Read X Count field will be the number of successive registers to read. The range is 0 – 100.

Read 1 Storage Offset, Read 2 Storage Offset, Read 3 Storage Offset The Read X Storage Offset field will be the offset in the generic instruments registers (1000 – 1099 for Instrument 1, 1100 to 1199 for Instrument 2, etc). The range is

0 – 100.

Data

The Process Variable (PV), Setpoint (SP), and Output (Out) can be set up from this screen. Select the desired option from the drop-down list to configure those settings.

Offset The Offset field is the instrument’s register offset. The range is

0 – 32767.

Instrument Register The Instrument Register field is the register in the 9205 controller. The range is

0 – 32767.

Input Type The Input Type field will determine what kind of type the

value will be. The options are:

Integer, Big Endian, Big Endian Byte Swap, Little Endian, or Little Endian

Byte Swap.

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Exponential The Exponential field will determine if there is an exponent value. For “Integer” Input Types, exponents do not apply, so this field is not modifiable. If the Input Type is not “Integer”, the options for the exponential

Yes or No. This will cause the Scaler to be a power of 10.

are:

Input Scaler The Input Scaler field will determine the input scaler range. The Scaler is a power of ten in the range -30 to

30.

+

Output Type The Output Type will determine what kind of the output value will be. The options are: Integer, Big Endian, Big Endian Byte Swap, Little Endian, or Little Endian Byte Swap.

Exponential The Exponential field will determine if there is an exponent value. For “Integer” Input Types, exponents do not apply, so this field is not modifiable. If the Input Type is not “Integer”, the options for the exponential

Yes or No. This will cause the Scaler to be a power of 10.

are:

Output Scaler The Output Scaler field will determine the Output Scaler range. The Scaler is a power of ten in the range 31 to +31.

DF1 Configuration This option allows the information data from the 9205 to be sent to the PLC DF1 Register map.

My Node: This option will allow the user to select the node. This node must not exist anywhere else on the computer’s network. The range is

0 to 30000.

PLC node: This option will allow the user to select the PLC node. This must be the node address of a PLC. The range is

0 to

30000.

PLC read table: This option will allow the user to select the PLC read table. The range is 8 to 255.

PLC write table: This option will allow the user to select the PLC write table. The range is 8 to 255.

PLC intermessage delay: This is the delay time (in milliseconds) between requests sent to the PLC from the 9205 controller. The request can be for any read or write transaction between the PLC and the 9205. The range is 51 - 5000.

Series 9205 Operations Manual Rev A 73

Tuning Assistant

The Tuning Assistant menu option will allow the user to automatically generate the PID loop settings for the

temperature control loops in the 9205 controller. Select the loop to tune and click on the auto tune that loop.

Edit button to

Note: The four buttons at the bottom of the screen: Use UD (Under Damped), Use CD (Critically Damped), Use OD (Over Damped), and Use PI will be inaccessible until some PID settings are loaded into the PID settings list above the buttons

right of the screen will display the previous screen.

The “Conservative” option will allow the user to minimize, if not remove, the possibility for an overshoot of the setpoint. If a small overshoot is acceptable, leave the “Conservative” checkbox unchecked. If, however, no overshoot is desired, then checking the “Conservative” checkbox will accomplish this.

The “Max Output” checkbox allows you to set a maximum output percentage; this feature is useful when output may need to be limited due to physical characteristics of the furnace.

The current PV value, along with the setpoint, is listed above the PID settings list.

Pressing the Start button will begin the auto tune process.

. The “Idle” line will change to display the process for the auto tune. The line will display a pointer

start

value.

Note: The process may take a few seconds to

Note: The Start button will be disabled while the tuning is running

process. If the confirming the action.

During the tuning, the temperature will oscillate around the setpoint 3 times before Tuning Assistant suggests tuning parameters. Depending on the heating and cooling abilities of the equipment, this can take a few minutes up to a few hours.

When the tuning is finished, the PID settings list will be populated with suggested values and the four buttons underneath will be enabled. The line above the PID settings list will read “Idle” again as well.

Damped set of values, press the

The under damped values will reach the setpoint faster, but there will be more overshoot involved. The over damped values will work to minimize the overshoot, but it will be slower than the under damped values.

Cancel button is pressed while a tuning is running, a message box will be displayed

Use CD button.

. The Return button in the bottom

. Pressing the Abort button will abort the

The user has the option to select only one of these sets of values: either the Under Damped set, the Critically Damped set, the Over Damped set, or the PI set. To select the set of values, press the corresponding button. For example, to select the Critically

Series 9205 Operations Manual Rev A 74

The critically damped values provide a balance between the underdamped and overdamped values with regard to time and overshoot.

P

The PI values are the proportional band and the reset value (the

Once a set of values has been accepted, the user can press the Return button to exit the screen. The accepted values can be viewed on the recent tuning parameters will be retained and adjusted PID sets will be offered.

PLC Data Mapping This option allows the user to custom map data from registers inside the PLC to the registers in the controller, and vice versa. The 9205 registers for mapping use a hexadecimal number to decode so 4100hex will get instrument 1 offset 0. 4101hex will get an instrument 1 offset 1. NOTE: Convert the Hexadecimal value to Decimal value before entering it into the 9205. 4400Hex is 17408 Decimal.

PID Loop Setup

menu option

and the I from

.

In future tuning sessions, the most

PID

).

Series 9205 Operations Manual Rev A 75

Analog Input Correction Curves This option allows the user to edit a curve on an input 1,2, or 3 at a specific temperature point. Select the appropriate curve and press points.

Select the point to be changed, and press Edit again. Input the correct Temperature and Error, and press to save.

Instrument Calculation The Instrument Calculation menu allows programming code-like lines to be executed at a variable time interval per step.

Note: It is important to contact Super

Edit to customize specific

OK

Systems at (513) 772-0060 before creating or modifying any Instrument Calculation customization.

General Description The Instrument Calculation allows for fifty (50) lines of program and fifty (50) program variables. Program variables allow for storage on intermediate results of calculations. A program variable is designated by a v followed by a number from 0 to the number of variables – 1. A Lower or Upper case “V” is valid, as well as leading zeroes. The following are all considered the same variable: V3, v3, v0003. The 9205’s Modbus registers can be used as input variables in the equations without restriction. To protect the instrument, Modbus registers are restricted as output registers. Modbus registers are designated by an upper or lower case “M” followed by a number.

Note – The standard Modbus routine is called to retrieve the Modbus variable, therefore a 0x8000 (-32768) will be returned for an invalid register

.

Note – Modbus registers are stored with integer values, so adjustments will need to be made for decimal

.

values

If the instrument can have external analog input boards, or the instrument is a Video Recorder or DAQ, these inputs can be accessed directly as A1 through A40. By using the “A” designation, the Modbus register number is not needed and the variable is scaled to the correct value (decimals included) based on the input type specified. In a Video Recorder, the slave instrument data slots can be defined as variables D1 through D32. D31 and D32 are extra slots and have no restrictions as output variables. D1 through D30 are shared with the first ten (10) slave instruments in groups of three (3) – PV, SP, PO – and caution should be used when assigning as outputs. A line in the program of the instrument calculation must start with a variable or a keyword. Variables must be followed by an equal sign (=) and then an expression. The expression can be a simple assignment (V1 = 3) or a variable operation variable as described below (V1 = M225 * 0.1).

MUST

Keywords The list of valid keywords is: IF, ELSE, ENDIF, QUE, RLY, and END. “IF” must be followed by an expression which is a variable, relationship operator, then variable. The list of valid relationship operators is: > (Greater Than), < (Less Than). = (Equals), >= (Greater Than or Equal To),

relationship operators are identical

The list of valid bitwise operators is: & (AND), | (OR), ^ (XOR), << (Left Shift), and >> (Right Shift). The result of the “IF” relationship test determines if the lines following the “IF” statement will be executed or not. The “ELSE” and “ENDIF” must be on a line by themselves. “ELSE” will toggle the program based on the result of the “IF” test. “ENDIF” will close out the “IF”.

Series 9205 Operations Manual Rev A 76

be entered in capital letters only.

<= (Less Than or Equal To), != (Not Equal To), and == (Equal To).

.

Note – The “=” and “==”

Example: IF V1 >= 30 V3 = V2 * 1.5 ELSE V3 = 5 ENDIF In this example, if the value in V1 is greater than or equal to 30, then the value of V3 will be the value of V2 multiplied by 1.5. If the value in V1 is less than 30, the value of V3 will be 5.

EVERY

“IF” must have a closing “ENDIF”. However, the “ELSE” is optional. The “QUE” is used to send data to a slave instrument and must have three (3) variables separated by spaces. The first is the slave instrument number, the second is the register number, and the third is the data to send. Example: QUE 3 1129 V1 This example will send the value of V1 to register 1129 on instrument 3. The “RLY” is used to control a relay if the relay assignment is 999. The “RLY” must be followed by a variable which is the relay number ( Example: RLY 5 M554 < 2 This example would turn Relay 5 ON if the communication status for instrument 5 was bad. The “END” keyword will stop the lines from running, and start over from line 1. There are a few functions that are available as well. The list of valid functions is: FSIN (Sine), FCOS (Cosine), (Absolute Value), and A function must be in all caps and begin with an “F” and have a pair of parenthesis. An undefined function returns the value of the expression in the parenthesis.

FEXP (Exponent), FLOG (Logarithm), FLN (Natural Logarithm), FSQRT (Square Root), FABS

FPOW (Power). The Sine and Cosine functions need to have the parameter in radians.

considered an undefined function

The instrument calculation has limited parsing ability. This is kept to variables, operation, variable – i.e. V1 = 12.25 * V2. Another example is M128 = V1/100. A negative sign (-) in front of the number is considered part of the number – i.e. V1 = -2.55 + V2. A variable to the parser is one of the following: a program variable (Vxx), a Modbus register (Mxxx), a number, or a function. Example: V1 = (V2 * 1.35) + (V3 * V4) This example will multiple V2 by 1.35 and multiply V3 and V4 together, and add those two results and store that value in V1. The maximum length of a program line is thirty-one (31) characters. The following are the valid mathematical operators: + (Addition), - (Subtraction), * (Multiplication), / (Division), and % (Modulo Divide – integer only). The difference between Division and Modulo Division is that Modulo will always return an integer value. Example: 11 / 4 = 2.75 11 % 4 = 2 (The .75 will not be returned)

Calculation Time In MS (0 to Disable) This is the calculation time for the calculations. This will specify the delay between executing a line. Each line has the same delay between them, even if they are blank. A value of zero (0) will keep the calculations from being performed. The range is

1 – 8) and a relationship expression.

Note – A pair of parenthesis by themselves is

.

0 – 10000.

Series 9205 Operations Manual Rev A 77

Editor This option will display the screen where the calculations can be entered. To edit a line, click on the Edit button. This will bring up the keyboard, which will allow the user to change the text for the calculation. If

Edit is clicked on a blank line, a new calculation can be entered. To Insert a blank line in between lines, select the

BELOW

line and click on the

where the inserted line is going to go

Insert button. To delete a line, highlight the line and click on the Delete button. To erase a line, highlight the line and click on the Clear button.

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Chapter 3 – Configurator 2.0 Menus

The following section will detail the menus that are found with the Configurator 2.0 software for the 9205 controller.

Burnoff

Configurator - Burnoff menu option

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.

Burnoff: Clicking on this value allows users to manually initiate burnoff procedure. The user will have to confirm this action

Configurator – Confirm burnoff

The “Test Status” will show that a burnoff is in progress.

Impedance Test: Clicking on this value manually turns on/off the impedance test (this can test lasts 30 seconds. The user will have to confirm the action.

only

be initiated manually). This

Series 9205 Operations Manual Rev A 79

Configurator – Confirm impedance test

The “Test Status” will then become “Impedance Test”.

Cancel: Clicking on this value will manually turn off both the burnoff and the impedance test. The user will have to confirm this action.

Configurator – Confirm cancellation

Next Burnoff: (shown in minutes): This value is a displayed calculation based on the burnoff time set in the It displays the number of minutes until the next burnoff will be initiated.

Probe Burnoff Setup

menu option.

Test Status: This value displays the current testing status. The list of possible values are: Burnoff, Burnoff Recovery, Idle, Impedance Recovery, or Impedance

Timer: This value shows the remaining time, in seconds, for the Burnoff / Impedance Test / Recoveries.

mV: This value is a display of the current millivolt input value during a burnoff or impedance test.

TC: This value is a display of the current probe thermocouple input value during a burnoff or impedance test.

Start mV: This value is a display of the millivolt input value at the beginning of the Burnoff or impedance test.

Start TC: This value is a display of the probe thermocouple value at the beginning of the burnoff or impedance test.

Last Burnoff: This value shows the date and time of the last burnoff.

Last Impedance Test: This value shows the date and time of the last Impedance test.

Last Recovery: This value is a display of the time in seconds it took the millivolt input to return to 1% of the Start mV.

Series 9205 Operations Manual Rev A 80

Last Min mV: This value is a display of the minimum millivolts measured during the last burnoff or impedance test.

Last Impedance: This value is a display of the measured resistance, in Kohms, after the last impedance test.

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 9205 controller.

None of the values can be modified on this screen

Note:

For setup of the auxiliary instruments, go to the menu item Slave Instrument Setup

Auxiliary Analog Input

This menu option shows the process variables for the three analog inputs of the 9205 controller. It also shows the input types and any information from attached slave analog input modules.

modified on this screen

Note: None of the values can be

.

Series 9205 Operations Manual Rev A 81

WARNING!

Manual Event Control

Events are assignable outputs, used in recipes/programs. Typically, they are used to signal the recipe is complete, to turn process gases off and on, and tell the equipment to do a variety of tasks. The Manual Event Control submenu allows the user to force the events off or on.

The Manual Event Control menu option shows the user all of the events ( status. It also allows the user to manually control the status of any event by clicking on the value. A single click will display an input box that will allow the user to select either an value.

Before assigning or changing events, be certain that you are familiar with the function of the event whose status you are going to change. Changing the status of an event without knowledge of the result can lead to hazardous situations.

0 – 15) and their current

On value or an Off

Clicking on the OK button will set the value, while

clicking on the

Cancel button will cancel the action.

Clicking on the “Value” section of the “Turn off all events” field will force all of the events to Off status. The user will have to confirm this action. Clicking on the “Value” section of the “Turn ON all events” field will force all of the events to On status. The user will have to confirm this action.

Before assigning or changing events, be certain that you are familiar with the function of the event whose status you are going to change. Changing the status of an event without knowledge of the result can lead to hazardous situations.

Series 9205 Operations Manual Rev A 82

Probe Burnoff Setup

Configurator – Probe Burnoff Setup menu option

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.

This menu option allows the user to modify the settings that are associated with the probe burnoff (menu

Burnoff

option

Burnoff Time: This is the duration of the burnoff measured in seconds. SSi recommends a 90 second burnoff, and this will be the default value. However, it can be adjusted by the operator. Clicking on the value will allow the user to change the value.

).

Configurator – Enter new burnoff value

Series 9205 Operations Manual Rev A 83

Click on the OK button to set the new value, or click on the Cancel button to cancel.

Burnoff Recovery Wait Time: 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: This is the amount of time between the beginning of one burnoff and the beginning of the next scheduled burnoff, in minutes. Default time for the instrument is 720 minutes (12 hours). However, the amount of time between burnoffs should be determined by the application.

Burnoff Minimum Millivolts: The minimum measured millivolt tolerance of the probe required to start a burnoff. Clicking on the value will allow the user to change the value. SSi recommends the millivolt value gets down to 200 mV.

Burnoff Maximum Temperature: The maximum measured temperature allowed during a burnoff. If the temperature value is exceeded

burnoff will stop

value of 1800 degrees. Clicking on the value will allow the user to change the value.

Digital IN 4 Assignment: The value for the digital input 4 assignment. Clicking on the value will allow the user to change the value, which can be either

Burnoff Minimum Millivolts Alarm Setpoint: The minimum millivolt value that must be reached in order for the “Insufficient mV drop during BO” alarm not to be generated. If the millivolt value does not drop below the minimum, the alarm will be generated.

Burnoff Maximum Temperature Rise Limit: The maximum number of degrees that the temperature is allowed to increase before the “Excessive TC rise during BO” alarm is generated.

. This is done to help maintain the life and the accuracy of your probe. SSi recommends a

event or start BO.

the

Series 9205 Operations Manual Rev A 84

PID Loop Setup

PID is the tuning parameters entered for each Process Variable loop.

Prop Band (0 for On/Off) Proportional Band determines the response to the current error. The Proportional Band is the percent of the range of the process variable that will produce 100% output and is the inverse of the proportional gain. A low Proportional Band value results in a larger change in output for a given error. Conversely, a high Proportional Band value results in a smaller change in output for a given error. If the Proportional Band is too small, control may oscillate or be otherwise unstable. If the Proportional Band is too large the control action may be too sluggish in response to changes within the system. Note: If the Proportional Band is set to

0.0, only on/off control is performed. The range

Reset Reset determines the influence of past errors. The Reset, or integral action (expressed in repeats per minute), sums the error between the process variable and setpoint over time and adds this accumulated output to the proportional output. A “proportional only” controller generally operates with steady-state error because some error is required to produce control output. The goal of integral action is to drive the steady-state error to zero and eliminate this droop. The range is

0 – 327.67.

0 – 3276.0.

Rate Rate adjusts the response to future errors. The Rate, or derivative action (expressed in minutes), is used to predict system behavior and has a dampening effect. The more the controller tries to change the process variable the harder, the derivative will work to counter that effort. This dampening effect can be valuable in reducing overshoot but is most often useful when trying to improve control on systems with significant and predicable lag. The range

Mode This is the mode of the loop. The values are: Dual Reverse, Single Reverse, Dual Direct, or Single Direct. 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 equals a positive number and the output would bring the PV down toward setpoint that is direct. Reverse – If the PV - SP equals 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 temperature (PV) UP to a 1200 degree F temperature (SP), this would be Temperature Loop is

Integral Preset This field provides an offset for the starting point for PID control, also referred to as “Load Line” or “Manual Reset”. The range is

REVERSE

0 – 327.67. NOTE: The rate is not typically used for carbon control.

, and since this would take a

Single Reverse.

–100 to 100.

SINGLE

output from the controller, the Mode for the

Series 9205 Operations Manual Rev A 85

Cycle Time This field is typically set to the valve travel time multiplied by 1.5. The range is 0 – 300.

Setpoint Change Limit This is a smart time feature that allows 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.

must

The Output percentage selected under this category of the furnace at heat. The options are: OFF, 80%, 70%, 60%, 50%, 40%, 30%, or 20%. Example: If the furnace runs at 40% output at heat for the maximum load, the setpoint change limit should be set to 60%.

Low Limit This is the low limit for the loop. The range is –100 to 100.

High Limit This is the high limit for the loop. The range is –100 to 100.

0 Setpoint Stops Control If the Setpoint is zero, then all outputs are turned off. The option is either Yes or No.

IN1 high limit shuts down ctrl If input 1’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

be above the normal operating output percentage

IN2 high limit shuts down ctrl If input 2’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

IN3 high limit shuts down ctrl If input 3’s high limit is reached, then all outputs are turned off. The value can either be Yes or No.

PID Auto Switch This is the PID auto switch field. The value can either be Yes or No.

PID auto switch is a feature within the instrument that allows multiple PID Loops to be used for various temperature ranges. This feature can be extremely helpful when a single PID Loop is not accurate across a wide temperature range. The most common indication that PID auto switching may improve furnace ability is failure to pass Temperature Uniformity Surveys (TUS). In many examples, a certain PID Loop may prevent under- or over-shoot at normal operating temperatures; but produce unacceptable overshoot at lower temperature.

This feature allows the user to utilize (up to) three distinct loops to obtain more accurate heating curves. In most applications, it is helpful to use the built-in Tuning Assistant feature to determine appropriate PID values. These values can be recorded and manually entered as described below. The chart below demonstrates this feature.

Series 9205 Operations Manual Rev A 86

Parameter

Value

PID Loop Setup -> Loop 1 -> PID Auto Switch

Yes

PID Loop Setup -> Loop 1 -> Switch Point PID 1-2

800

PID Loop Setup -> Loop 1 -> Switch Point PID 2-3

1500

Alternate PID Setup -> LP1 set 1 -> Prop Band

1.0

Alternate PID Setup -> LP1 set 1 -> Reset

2.0

Alternate PID Setup -> LP1 set 1 -> Rate

3.0

Alternate PID Setup -> LP1 set 2 -> Prop Band

1.3

Alternate PID Setup -> LP1 set 2 -> Reset

2.3

Alternate PID Setup -> LP1 set 2 -> Rate

3.3

Alternate PID Setup -> LP1 set 3 -> Prop Band

1.6

Alternate PID Setup -> LP1 set 3 -> Reset

2.6

Alternate PID Setup -> LP1 set 3 -> Rate

3.6

In the example above, proper use of the Tuning Assistant allows the user to find the following optimal PID settings for the following temperature ranges:

• 0-800F -> PID Group 1 (P = 1.0, I = 2.0, D = 3.0)

• 801-1500F -> PID Group 2 (P = 1.3, I = 2.3, D = 2.3)

• 1501F+ -> PID Group 3 (P = 1.6, I = 2.6, D = 3.6)

The following settings must be made via the touch screen:

Switch Point PID 1 -> 2 This is the PID Switch Point field. This is used in conjunction with the PID Auto Switching feature. See the

PID Auto Switch

Switch Point PID 2 -> 3 This is the PID Switch Point field. This is used in conjunction with the PID Auto Switching feature. See the

PID Auto Switch

section for more information. The range is –300 to 4000.

Setpoint Lower Limit This is the lower limit of the setpoint. The range is –100 to 100.

Series 9205 Operations Manual Rev A 87

Output (in %)

Second Passed

100.0

1

99.0

2

99.0

3

98.0

4

97.0

5

Output (in %)

Seconds Passed

-20.0

1

-20.0

2

-21.0

3

-21.0

4

-22.0

5

Setpoint Upper Limit This is the upper limit for the setpoint. The range is –100 to 100.

PV Source The options for PV Source are either Internal or External. If External is selected, the loop’s PV must be written by an external source. Selecting Internal will continue normal operation where the source is determined by the PID loop and the PV type.

Minimum Forward On Time (sec) This setting specifies the minimum number of seconds for which output must be positive (heating) before the control is turned off. The maximum value for this setting is 100.

Minimum Forward Off Time (sec) This setting specifies the minimum number of seconds for which the control must be off after heat is applied. The maximum value for this setting is 100.

Minimum Reverse On Time (sec) This setting specifies the minimum number of seconds for which output must be negative (cooling) before the control is turned off. The maximum value for this setting is 100.

Minimum Reverse Off Time (sec) This setting specifies the minimum number of seconds for which the control must be off after cooling is applied. The maximum value for this setting is 100.

Positive Output Accumulator The Positive Output Accumulator is the sum of the positive outputs (given in percentages up to one decimal place) measured each second. Therefore, if the following outputs are recorded over five seconds:

Then the value for the Positive Output Accumulator after five seconds will be (100.0 + 99.0 + 99.0 + 98.0 +

97.0) or 493.0.

To reset the Positive Output Accumulator, simply click Edit while the Positive Output Accumulator is highlighted and confirm the reset. This will cause the Positive Output Accumulator to be reset to zero and start accumulating values again from that point.

Negative Output Accumulator The Negative Output Accumulator is the sum of the negative outputs (given in percentages up to one decimal place) measured each second. The sum of the negative values is expressed as a positive value. This means that, if an output of -50% is recorded after one second, a value of 50 will be added to the Negative Output Accumulator. Similarly, if the following outputs are recorded over five seconds:

Series 9205 Operations Manual Rev A 88

Then the value for the Negative Output Accumulator after five seconds will be (20.0 + 20.0 + 21.0 + 21.0 +

or 104.

22.0)

To reset the Negative Output Accumulator, simply click Edit while the Negative Output Accumulator is highlighted and confirm the reset. This will cause the Negative Output Accumulator to be reset to zero and start accumulating values again from that point.

Overshoot Control Logic (No/Yes)

f th

Overshoot control logic is activated when a large setpoint change occurs. I

e logic is active and a large setpoint occurs, it sets a working setpoint at an appropriate distance from the desired setpoint to prevent the PV from overshooting the desired final setpoint. When the PV reaches or crosses this working setpoint, then the logic exponentially ramps the working setpoint to the desired final setpoint.

Ramp Detect Logic (No/Yes) The Ramp Detect logic works in conjunction with the instrument recipe programmer. If the control loop is the temperature loop for the recipe programmer, and the OPCODE is a ramp, then the control loop does some special checks. If the Overshoot Control Logic is active, then the final setpoint of the ramp is used to determine the working setpoint band. However, the ramp setpoint is used until the band is reached. Also, once the band is reached, if the ramp is faster than the overshoot logic exponential ramp, then the program is temporarily put on hold as needed to sync the two ramps.

Ramp Level 1 Control (No/Yes) and Ramp Level 2 Control (No/Yes) Ramp Level 1 and 2 Control are only active if the Ramp Detect logic is active.

Ramp Level 1 Control provides mild overshoot protection during a recipe ramp.

mp Level 2 Control is only active if the Ramp Level 1 control is active.

Ra

Ramp Level 2 Control provides enhanced overshoot protection during a recipe ramp.

Output rate change limit, %/sec This option causes the 9205 controller to limit the rate at which the output changes in the furnace. For example, if the output rate change limit is 5% per second, the controller will increase the output at a rate no greater than 5% each second until the output reaches the level needed to reach setpoint. This limit can be useful in cases where (for example) a heating element should not (for operational and safety reasons) heat up to a high output immediately. If the output needs to reach 100% to achieve setpoint, the Output Rate Change Limit will apply the output incrementally, rather than allowing the output to climb to 100% as soon as the heat is turned on.

PID Switch Variable This is the parameter that triggers the PID switch. The options are Process variable and Setpoint. Note that PID Auto Switch must be set to Yes in order to use PID Switching.

Series 9205 Operations Manual Rev A 89

Event Run Program Setup

Event run program setup is used to start a program that is stored in the 9205 controller (zero for buffered) or by a defined event input.

*Program must be configured under the menu option

*Used to define an event input to initiate a program start and to define which program to start (zero starts the last program run) from the contact closure. The range of programs to run is

Event Control

0 to 300.

*WARNING* If a JUMP (to another program) is used in a previous program, the program that will run would be the last program jumped to not the first program run.

If you stop a program in a GOSUB the program that will be run will be the GOSUB.

Load T/C Configuration

Configuration of any analog input device must be completed under this menu item.

Load TC Enable This value will manually toggle between on, on + alarms, and off. On – T/C Enabled On + Alarms – T/C Enabled, Programmer alarm114 provided if out of band (Default wait limits) Off – T/C not enabled

Control TC This value allows the user to set the TC to be part of the group of Load TCs that can hold the program if it is out of band. The values are

active or not active (shown as blank).

Series 9205 Operations Manual Rev A 90

TC 1 – 27 and Input 1 - 3 This value allows the user to manually turn the T/C from active to not active, shown as blank, to be part of the group of TCs that can hold the program if it’s out of band. Analog Input 1 – Analog Input 3 correspond to TC 28-30. The values are

active or not active (shown as blank).

Port Setup

Note about ADAM module support: Communications with ADAM analog input modules manufactured by Advantech are not supported as of 9205 firmware revision 2.34. To determine the firmware version of your 9205 instrument, perform a controller data backup using the System Management -> Backup/Restore menu in Configurator. Select Files list for the 9205 as shown in the screen shot. The firmware revision level will be shown.

Backup -> Online Device. Once the backup is performed, check the Backup

Series 9205 Operations Manual Rev A 91

Host 232 Baud This will set the baud rate for RS-232 communications. The list of options is: 1200 14400 57600 2400 19200 76800 4800 28800 115200 9600 38400

Host 232 Mode This will set the mode rate for RS-232 communications. This list of options is: Modbus Cal term Modbus/DF1 Master

Host 485 (3,4) Baud This will set the baud rate for RS-485 communications. The list of options is: 1200 14400 57600 2400 19200 76800 4800 28800 115200 9600 38400

Host 485 (3,4) Mode This is the mode for RS-485 communications. It is fixed on Modbus.

Series 9205 Operations Manual Rev A 92

Host 485 Address This will set the address for RS-485 communications. The range is 1 – 247.

Slave 1 (5,6) Baud This will set the baud rate for Slave 1 communications. The list of options is: 1200 14400 57600 2400 19200 76800 4800 28800 115200 9600 38400

Slave 1 (5,6) Mode This will set the mode for Slave 1 communications. The list of options is: Modbus Master Yokogawa Modbus Host

Slave 1 (5,6) Bits This will set the data bits, parity, and stop bits (in that order). The list of options is: 8, none, 1 8, odd, 1 8, even, 1 8, none, 2

Slave 2 Baud This will set the baud rate for Slave 2 communications. The list of options is: 1200 14400 57600 2400 19200 76800 4800 28800 115200 9600 38400

Slave 2 Mode This will set the mode for Slave 2 communications. This list of options is: MMI Modbus N/A SSi Analog Input Board Yokogawa

Slave 1 (5,6) Bits This will set the data bits, parity, and stop bits (in that order). The list of options is: 8, none, 1 8, odd, 1 8, even, 1 8, none, 2

PLC Type This value defines the type of PLC being used. The options are: Micrologix Modbus, MCMmodule Modbus, DF1 PLC5, DF1 Slik, Passive.

Host 232-2 Baud This will set the baud rate for RS-232 communications. The list of options is: 1200 14400 57600 2400 19200 76800 4800 28800 115200

Series 9205 Operations Manual Rev A 93

9600 38400

Host 232-2 Mode This will set the mode for RS-232 communications. The list of options is: Modbus Cal term Televac

Slave Instrument Setup

** 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.

This screen will allow the user to configure up to eighteen (18) slave instruments through the 9205 controller (7 are reserved).

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.

List of Instruments The following is the list of instruments available as slave instruments:

SSi AC20 [A]Yokogawa 750 [A]Honeywell UDC3300 [A]Dualpro LP1 Modbus [A]Dualpro LP2 Modbus [A]Dualpro LP1 MMI [A]Dualpro LP2 MMI [A]Eurotherm 2404 [A]Eurotherm 2500 [A]CarbPro v3.5 [A]CarbPro v3.0 CarbPC [A]9200 LP1 IR Base MGA

Honeywell UDC3200 SSi 7EK [T]Yokogawa 750 [T]Honeywell UDC3300 [T]Dualpro LP1 Modbus [T]Dualpro LP2 Modbus [T]Dualpro LP1 MMI [T]Dualpro LP2 MMI [T]Eurotherm 2404 [T]Eurotherm 2500 Unipro v3.5 Unipro v3.0 [T]Carbpro v3.5 Slave [T]Carbpro v3.0 Slave 10Pro

Dualpro IN C [T]9200 LP1 [T]9200 LP2 [T]9200 LP3 9100 LP2 Eurotherm 2704 LP1 Eurotherm 2704 LP2 Eurotherm 2704 LP3 VC Base 1 VC Base 2 VC Base 3 VC Base 4 AIPC SSi 7SL AEC Flow Board

Series 9205 Operations Manual Rev A 94

UMC800 LP1 SSi Quad AO1 SSi Quad AO2 SSi Quad AO3 SSi Quad AO4 Yokogawa UT350 Yokogawa 750 Lp 2 Yokogawa UP350 Honeywell DCP551 Ascon 08 SSi X5 SSi M4L SSi X5/Timer SSi SPUD SSi AIB3 SSi H2 Cell Flow Meter Short SSi O2 Remote

Some instruments may not be shown in the list of instruments. User Instruments 1 through 16 are used to set up a non-listed instrument as a slave instrument using the Generic Instrument Setups

Address This value allows the user to select the address that corresponds with the controller selected, with a range

0 to 249.

of

SSi Dual Motor Board SSi Smart AIB 3 O2 Block Waukee Valvetronic+ SSi eSPP EL-Flow SSi AC E Yokogawa 750E Mod Mux Dualpro E Modbus Dualpro E MMI Carbpro E v3.5 Carbpro E v3.0 Eurotherm 2500 SSi 8-8 SSi 9200 E Micrologix PLC MCM Module

PLC DF1 SLC DF1 User 1 User 2 User 3 User 4 User 5 User 6 User 7 User 8 User 9 User 10 User 11 User 12 User 13 User 14 User 15 User 16

menu.

Port The options for this field are: Slave 1, Slave 2, RS-232, IP Address 1, IP Address 2, IP Address 3, IP Address 4, Passive, or Slave 3/RS-232. Slave 1 – terminals 5(-), 6(+) Slave 2 – terminals 22(+), 23(-) RS-232

Zone Assignments

A zone assignment on the 9205 controller allows the recipe programs to change setpoints on all slave instruments of a multi-zone furnace (up to 10 zones).

WARNING: This screen should not be changed without consulting SSi at 800-666-

4330.

*Only used when running recipes

*Slave Instrument Setup must be configured prior to Zone Assignment setup

* Temperature zones link instruments to Temperature Setpoints

The zone assignment feature allows the Series 9205 program to change setpoints on all instruments of a multi-zone furnace. The Series 9205 has up to five temperature zone assignments available ( Assignment 1 – Zone Assignment 5) on two programmers. The Series 9205 programmer looks for

Zone

Series 9205 Operations Manual Rev A 95

Step

Opcode

Temperature

Option 1

ZONE_OFF

25

Zone 1

2

ZONE_OFF

50

Zone 3

3

SETPT

1750

appropriate zone assignments whenever a set point is to be sent to the temperature controller. The temperature set point is sent to every instrument number in the temperature zone assignment.

ZONE_OFF

If the zone instrument would have the offset added. For example, a 3-zone pit furnace, where the bottom zone usually has a higher set point. The middle zone and the top zone usually have a lower set point. The bottom zone temperature controller is assigned to zone 1, the middle temperature controllers to zone 2, and the top zone controller to zone 3.

If the first three steps of a program are as shown below, then the bottom zone set point is 1775, the middle zone is 1750, and the top zone is 1800.

The first step sets the offset for zone 1 to 25 degrees; therefore, the bottom zone controller would be sent a set point of 1775 when step 3 is executed. Likewise step 2 sets the offset for zone 3 to 50 degrees. The top zone then receives a set point of 1800. The middle zone controller would receive the 1750. The temperature controller displayed on the Status Display is instrument #2. If instrument #2 were the top zone controller then the Status Display would show the 1800-degree set point.

When using the multi-zone offset feature, the temperature controller assigned as instruments 1 and 2 should be in zones that will not be offset.

Atm Instrument This will allow the user to set the atmosphere instrument for the zone assignment. The options are

Loop 1 Instrument 5 Instrument 12 Instrument 19 Loop 2 Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Atm Zone Number This option will allow the user to set the zone number for the assignment. The range is 0 – 5.

Atm Zone Offset This option will allow the user to enter an offset for the assignment. The range is -4000 – 4000.

Temp Instrument This will allow the user to set the temperature instrument for the zone assignment. The options are:

Loop 1 Instrument 5 Instrument 12 Instrument 19 Loop 2 Instrument 6 Instrument 13 Instrument 20 Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

(Zone Offset) opcode had been used in the program, the set point sent to the specified

Series 9205 Operations Manual Rev A 96

Temp Zone Number This option will allow the user to set the zone number for the assignment. The range is 0 – 5.

Temp Zone Offset

This option will allow the user to enter an offset for the assignment. The range is -4000 – 4000.

Furnace Setup

The Furnace Setup menu option is an administrative access only option. Do not make any adjustments on the screen without first contacting Super Systems, Inc. at (513) 772-0060.

Note for controllers with Cascade control: When in cascade mode, the 9xxx treats loop 2 as the furnace loop and loop 3 as the load loop. It feeds the output of the load loop into the set point of the furnace loop

PVT Type There are nine PVT choices for the 9205:

%Carbon Cascade Dew Point % Carbon + Redundant TC Millivolts Dew Point + Redundant TC Multi-loop Millivolts + Redundant TC % Carbon + Dual Temp

%Carbon: Process variable will calculate for carbon potential along with a temperature loop. Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals 29, 30 probe TC). These two inputs together constitute loop 1. Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

Cascade: Three loops of temperature control work together in a cascade setting.

Dew Point: Control will be for dew point along with a temperature loop. Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals 29, 30 probe TC). These two inputs together constitute loop 1. Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

%Carbon + Redundant TC: This functions the same way as the %Carbon option with an additional thermocouple for Loop 3. The two thermocouples are used to control carbon, and the operator can choose the setting that will be used.

Millivolts: Control is based on what the millivolt reading is and also reads temperature.

Dew Point + Redundant TC: This functions the same way as the Dew Point option with an additional thermocouple for Loop 3. The two thermocouples are used to control dew point, and the operator can choose the setting that will be used.

Multiloop: Three loops of control can be assigned as selected.

.

Series 9205 Operations Manual Rev A 97

Millivolts + Redundant TC: Control is based off of the millivolt reading and also reads temperature. Loop 3 is another thermocouple.

%Carbon + Dual Temp: This functions similarly to %Carbon. Input 2 is the control TC. IT is not used to calculate carbon potential with input one and to control furnace temperature. Input 3 in the third loop and is another TC.

IMPORTANT:

If the 9205 is controlling % Carbon or Dew Point, control will be disabled if either or both of

the following are true:

• Millivolts registered by probe are below 500 mV or above 1300 mV.

• Temperature registered by probe is below 900°F or above 2100°F.

Temperature Mode

This allows the operator to choose either degree Fahrenheit or Celsius for the temperature. The options

°C or °F. Pressing OK will set the choice.

are

Loop 1 Instrument

Internal Loop 1 (typical) Instrument 5 Instrument 12 Instrument 19 Internal Loop 2 Instrument 6 Instrument 13 Instrument 20 Internal Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Loop 2 Instrument

Internal Loop 1 Instrument 5 Instrument 12 Instrument 19 Internal Loop 2 (typical) Instrument 6 Instrument 13 Instrument 20 Internal Loop 3 Instrument 7 Instrument 14 Instrument 21 Instrument 1 Instrument 8 Instrument 15 Instrument 22 Instrument 2 Instrument 9 Instrument 16 Instrument 23 Instrument 3 Instrument 10 Instrument 17 Instrument 24 Instrument 4 Instrument 11 Instrument 18 Instrument 25

Event Instrument

Allows for a slave instrument (or internal) to be the defined event control device. The types of instruments

Internal, Instrument 1 – Instrument 25. Internal is typical.

are:

Quench Instrument

Allows for slave instrument (or internal) to be the defined quench control device. The types of instruments

Internal Loop 1 – Internal Loop 3, Instrument 1 – Instrument 25.

are:

End of Quench Event Tells the programmer which event to signal end of quench (related to which relay it is assigned). The default event for this is Event 7, but it can be changed in the furnace setup menu. This event turns on for one (1) minute when the quench timer is complete. The list of possible values is:

0 – 14.

Series 9205 Operations Manual Rev A 98

Quench Speed Event Tells the programmer which event will signal the quench speed. The list of possible values is: 0 – 14.

Quench Run Event Tells the programmer which event will signal quench run. The list of possible values is: 0 – 14.

Date and Time This value is the current date and time on the 9205 controller only (not the local computer or the touch screen, if applicable). The time on the controller is displayed in the 24-hour format, so 8 = 8 AM, and 14 = 2

Note: The date and time of the touch screen can be changed (if necessary) by selecting the date and

PM.

time in the lower right corner on the touch screen, once the screen software has been shut down and the Windows™ desktop is visible. Then, at the CE screen the date and time can be changed by double taping the time in the bottom right corner and setting it, then select “apply”. For this to take effect the screen needs to be rebooted; on the older TPC 642 displays the registry needs to be saved under TPC Configuration icon, the Misc Tab and then reboot the touch screen. The date and time that is recorded on the flash card

(and therefore the datalog data) is the date and time of the Advantech display, not the controller

.

Cascade Inhibit

Note: This field is only applicable if the controller is in Cascade mode

off. When inhibit = enabled, the 9205 functions as a multi-loop controller with three control loops. The options are:

PV Difference Cutback

enabled or disabled.

Note: This field is only applicable if the controller is in Cascade Mode

Range EOPV and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop. This will turn the PV difference cutback feature on or off. The options are:

Cascade Lower Range EOPV

Note: This field is only applicable if the controller is in Cascade Mode

of PV difference. This is used with the PV Difference Cutback and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop. Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop. The range is

Cascade Upper Range EOPV

-300 to 10000.

Note: This field is only applicable if the controller is in Cascade Mode

of PV difference. This is used with the Cascade Lower Range EOPV and PV Difference Cutback to limit the absolute % output of the furnace loop. Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop. The range is

Example: With the Lower EOPV set to 10 and the Upper EOPV set to 110, if the load PV is 1700 and the furnace PV is 1710, the full 100% output is available. If the load PV is 1600 and the furnace PV is 1710, the furnace output will not go above 0%. If the load PV is 1655 and the furnace PV is 1710, the maximum output for the furnace loop will be limited to 55%: (1710 – 1655)/(110-10) * (1.0).

-300 to 10000.

. This will turn cascade control on or

. This is used with the Cascade Lower

enabled or disabled.

. This is the cascade lower range end

. This is the cascade upper range end

Default Hold Time This value is the default holding time for the furnace. The range is 0 to 10000.

Deviation Alarm delay This value is the delay for the alarm if a deviation alarm is detected. The range is 0 to 10000.

Series 9205 Operations Manual Rev A 99

Super Systems 9205 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Installation Safety Requirements

Chapter 1 - Overview

Mounting

Dimensional Drawings

Wiring

Electrical Installation

Pin Out

Ancillary Items

Setup

Additional Features

Ethernet Connections

Flash Card & Flash Card Reader

Operator Interface Screen Saver

Default Status Screen

Menu

Chart

Chart Sub Menu

Recipe

Loops

Ack (Alarm Acknowledge)

Data Logging using Flash Card

Chapter 2 - CONFIGURATION

Menu (Configuration)

About

Logs

Recipe Edit

Load T/C Configuration

Communications Setup

Zone Assignments

Furnace Setup

Alarm Setup

Relay Assignments

Analog Output Setup

Redundant TC Setup

Event Hold/Reset

Curve Entry

Alternate PID Setup

Overview

Equipment needed

Notes

T/C Extension Correction Curves

Tuning Assistant

Analog Input Correction Curves This option allows the user to edit a curve on an input 1,2, or 3 at a specific temperature point. Select the appropriate curve and press points.

Chapter 3 – Configurator 2.0 Menus

Burnoff

Slave Instruments

Auxiliary Analog Input

Manual Event Control

Probe Burnoff Setup

PID Loop Setup

Event Run Program Setup

Load T/C Configuration

Port Setup

Slave Instrument Setup

Zone Assignments

Furnace Setup