West 4400 Operating Manual

PROG

1

-DIN

4

SETPOINT PROGRAMMER

Site Manual

59216-1

PREFACE

This manual is intended for use in support of installation, commissioning and
configuration of the

1

-DIN Setpoint Programmer. For information on the day-to-day

4

operation, refer to the associated Operator's manual (see below).

Associated Documents

Title Part No.

1

-DIN Setpoint Programmer Operator's Manual 59215

4

The procedures described in this manual must be undertaken only by
technically-competent and authorised servicing personnel.

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Contents

1 INTRODUCTION 1-1

2 INSTALLATION 2-1

2.1 UNPACKING PROCEDURE ....................... 2-1

2.2 PANEL-MOUNTING THE SETPOINT PROGRAMMER ............ 2-1

2.3 CONNECTIONS AND WIRING ..................... 2-4

2.3.1 Mains (Line) In put ......................... 2-5

2.3.2 24V (Nomi nal) AC/DC Sup ply ................... 2-5

2.3.3 Ther mo cou ple In put ........................ 2-7

2.3.4 RTD In puts ............................. 2-7

2.3.5 Lin ear In puts............................2-7

2.3.6 Digi tal In puts............................2-7

2.3.7 Re lay Out puts ...........................2-8

2.3.8 SSR Drive Out puts..........................2-9

2.3.9 DC Out puts............................. 2-9

2.3.10 Event Out puts ...........................2-9

2.3.11 RS485 Se rial Com mu ni ca tions Link.................2-9

3 INTERNAL LINKS AND SWITCHES 3-1

3.1 REMOVING THE SETPOINT PROGRAMMER FROM ITS HOUSING ..... 3-1

3.2 REMOVING/REPLACING THE OUTPUT 2/OUTPUT 3 OPTION PCBs..... 3-3

3.3 REMOVING/REPLACING THE RS485 COMMUNICATIONS OPTION PCB . 3-3

3.4 INSTALLING/REMOVING THE DIGITAL INPUT OPTION PCB ........ 3-4

3.5 INSTALLING/REMOVING THE EVENT OUTPUT OPTION PCB ........ 3-5

3.6 REPLACING THE SETPOINT PROGRAMMER IN ITS HOUSING ....... 3-5

3.7 SELECTION OF INPUT TYPE ....................... 3-6

3.8 SELECTION OF PRIMARY OUTPUT (OUTPUT 1) TYPE............ 3-7

3.9 OUTPUT 2 TYPE/OUTPUT 3 TYPE ..................... 3-8

4 CONFIGURATION MODE 4-1

4.1 ENTRY INTO CONFIGURATION MODE .................. 4-1

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4.2 HARDWARE DEFINITION CODE..................... 4-1

4.3 CONFIGURATION MODE PARAMETERS ................. 4-4

4.4 ALARM INHIBIT FACILITY ........................4-7

4.5 EXIT FROM CONFIGURATION MODE .................. 4-7

5 SERIAL COMMUNICATIONS - ASCII PROTOCOL 5-1

5.1 RS485 CONNECTIONS.........................5-1

5.2 COMMUNICATIONS ENABLE/DISABLE .................. 5-1

5.3 SELECTION OF COMMUNICATIONS ADDRESS ............. 5-1

5.4 ASCII COMMUNICATIONS PROTOCOL ................. 5-1

5.4.1 Type 1 Mes sage ..........................5-3

5.4.2 Type 2 Mes sage ..........................5-3

5.4.3 Type 3 Mes sage ..........................5-4

5.4.4 Type 4 Mes sage ..........................5-4

5.5 PROGRAMMER PARAMETERS (Start of Message character = R)....5-5

5.6 PROGRAMMER COMMANDS ..................... 5-8

5.7 PROGRAMMER STATUS 1........................ 5-8

5.8 CURRENT SEGMENT EVENT STATUS ................... 5-9

5.9 POWER FAIL RECOVERY ........................ 5-9

5.10 PROGRAM/SEGMENT DEFINITIONS ................... 5-9

5.11 PROGRAM SCAN TABLE........................ 5-10

5.12 SEGMENT MODE........................... 5-10

5.13 PROGRAMMER STATUS 2 .......................5-11

5.14 USER TAG NAMES........................... 5-11

5.15 CONTROLLER PARAMETERS (Start of Message character = L) .... 5-12

5.16 CONTROLLER SCAN TABLE ...................... 5-16

5.17 ERROR RESPONSE .......................... 5-16

5.18 MASTER COMMUNICATIONS MODE.................. 5-16

6 MODBUS RTU SERIAL COMMUNICATIONS 6-1

6.1 COMMUNICATIONS WRITE ENABLE/DISABLE .............. 6-1

6.2 PHYSICAL REQUIREMENTS ....................... 6-1

6.2.1 Char ac ter Trans mis sion ...................... 6-1

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6.2.2 Line Turn- round........................... 6-1

6.3 MODBUS RTU PROTOCOL .......................6-1

6.3.1 Mes sage For mats .........................6-2

6.3.2 Er ror and Ex cep tion Re sponses .................. 6-6

6.3.3 Ad dress Range........................... 6-6

6.3.4 Bit Pa rame ters........................... 6-7

6.3.5 Word Pa rame ters..........................6-7

6.4 PROGRAMMER COMMANDS.....................6-11

6.5 PROGRAMMER STATUS 1.......................6-11

6.6 SEGMENT MODE........................... 6-12

6.7 PROGRAMMER STATUS 2.......................6-12

6.8 CURRENT SEGMENT EVENT STATUS .................. 6-12

6.9 POWER FAIL RECOVERY ....................... 6-12

A PRODUCT SPECIFICATION A-1

59216-FM (v)

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SECTION 1

INTRODUCTION

The Setpoint Programmer is equipped with a universal (thermocouple, RTD or
linear) input and up to three outputs (relay, SSR or linear). It can be
panel-mounted in an appropriate-sized cut-out using the “no-tools” fixing strap
supplied. Several instruments can be installed in a side-by-side multiple
installation in one single cut-out.

The Setpoint Programmer is front-panel configurable, enabling the user to tailor
the instrument to suit the application.

The Setpoint Programmer is equipped with a 96 - 264V 50/60Hz power supply as
standard; a 24V AC/DC option is available.

The Setpoint Programmer is constructed such that, once the instrument is correctly
configured and installed, most changes to its use or application can be
accommodated without removing it from its panel installation.

The options available on the Setpoint Programmer include:

• Re mote con trol and se lec tion of pro gram via a Digi tal In put Op tion PCB

• Sec ond con trol (COOL) out put

• Valve mo tor drive (VMD) out put

• Up to four Event re lay out puts via an Event Out put Op tion PCB

• Re corder out put (set point or pro cess vari able)

• RS485 se rial com mu ni ca tions (AS CII or MOD BUS pro to col)

• Real Time Clock

For a full list of options, refer to Appendix A .

1-1 59216-1

SECTION 2

INSTALLATION

2.1 UNPACKING PROCEDURE

1. Remove the Setpoint Programmer from its packing. The Setpoint
Programmer is supplied with a panel gasket and push-fit fixing strap. Retain
the packing for future use, should it be necessary to transport the Setpoint
Programmer to a different site or to return it to the supplier for repair/testing.

2. Examine the delivered items for damage or deficiencies. If any is found,
notify the carrier immediately.

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2.2 PANEL-MOUNTING

92.0 mm +0.8 -0.0

THE SETPOINT
PROGRAMMER

The panel on which the Setpoint
Programmer is to be mounted must
be rigid and may be up to 6.0mm
(0.25 inches) thick. The cut-out
required for a single etpoint
Programmer is as shown in Figure
2-1.

Several controllers may be installed
in a single cut-out, side-by-side. For
n Setpoint Programmers mounted
side-by-side, the width of the cut-out would be:

(96n - 4) millimetres or (7.56n - 0.16) inches.

The Setpoint Programmer is 100mm deep (measured from the rear face of the
front panel). The front panel is 96mm high and 96mm wide. When
panel-mounted, the front panel projects 10mm from the mounting panel. The
main dimensions of the Setpoint Programmer are shown in Figure 2-2.

Figure 2-1 Cut-out Dimensions

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Figure 2-2 Principal Dimensions

To panel-mount the Setpoint Programmer:

1. Insert the rear of the Setpoint Programmer housing through the cut-out
(from the front of the mounting panel) and hold the Setpoint Programmer
lightly in position against the panel. Ensure that the panel gasket is not
distorted and that the Setpoint Programmer is positioned squarely against
the mounting panel. Apply pressure to the front panel bezel only.

CAU TION: Do not remove the panel gasket, as this may result in
inadequate clamping of the instrument in the panel.

2. Slide the fixing strap in place (see Figure 2-3) and push it forward until it is
firmly in contact with the rear face of the mounting panel (the tongues on
the strap should have engaged in matching rachet positions on the
Setpoint Programmer housing and the fixing strap springs should be pushing
firmly against the mounting panel rear face).

Once the Set point Pro gram mer is in stalled in its mount ing panel, it may be
sub se quently re moved from its hous ing, if nec es sary, as de scribed in Sub sec tion

3.1.

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Figure 2-3 Panel-mounting the Setpoint Programmer

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2.3 CONNECTIONS AND WIRING

Figure 2-4 Rear Terminals

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2.3.1 Mains (Line) In put

The Setpoint Programmer will operate on 96 - 264V AC 50/60Hz mains (line) supply.
The power consumption is approximately 4 VA.

CAUTION: This equipment is designed for installation in an enclosure
which provides adequate protection against electric shock. Local
regulations regarding electrical installation should be rigidly
observed. Consideration should be given to prevention of access to
the power terminations by unauthorised personnel. Power should be
connected via a two-pole isolating switch (preferably situated near
the equipment) and a 1A fuse, as shown in Figure 2-5.

Figure 2-5 Mains (Line) Sup ply Con nec tions

If the Setpoint Programmer has relay outputs in which the contacts are to
carry mains (line) voltage, it is recommended that the relay contact mains
(line) supply should be switched and fused in a similar manner but should
be separate from the Setpoint Programmer mains (line) supply.

2.3.2 24V (Nomi nal) AC/DC Sup ply

The supply connections for the 24V AC/DC option of the Setpoint Programmer are
as shown in Figure 2-6. Power should be connected via a two-pole isolating switch
and a 315mA slow-blow (anti-surge Type T) fuse.

Figure 2-6 24V AC/DC Sup ply Con nec tions

With the 24V AC/DC supply option fitted, these terminals will accept the following
supply voltage ranges:

24V (nominal) AC 50/60Hz - 20 - 50V

24V (nominal) DC - 22 - 65V

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Table 2 -1 Ther mo cou ple Ca ble Col our Codes

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2.3.3 Ther mo cou ple In put

The correct type of thermocouple extension leadwire or compensating cable
must be used for the entire distance between the Setpoint Programmer and the
thermocouple, ensuring that the correct polarity is observed throughout. Joints in
the cable should be avoided, if possible. The Setpoint Programmer’s CJC facility
must be enabled (normal conditions) for this input (see Subsection 4.3).

NOTE: Do not run ther mo cou ple ca bles ad ja cent to power- carrying
con duc tors. If the wir ing is run in a con duit, use a sepa rate con duit
for the ther mo cou ple wir ing. If the ther mo cou ple is grounded, this
must be done at one point only. If the ther mo cou ple ex ten sion lead
is shielded, the shield must be grounded at one point only.

The colour codes used on thermocouple extension leads are shown in Table 2-1.

2.3.4 RTD In puts

The compensating lead should be connected to Terminal 3. For two-wire RTD
inputs, Terminals 2 and 3 should be linked. The extension leads should be of
copper and the resistance of the wires connecting the resistance element should
not exceed 5 ohms per lead (the leads should be of equal resistance).

2.3.5 Lin ear In puts

For linear mA input ranges, connection is made to Terminals 1 and 4 in the
polarity shown in Figure 2-4. For linear mV and V ranges, connection is made to
Terminals 2 and 3 in the polarity shown in Figure 2-4. For details of the linear input
ranges available, refer to Appendix A.

2.3.6 Digi tal In puts

These inputs will accept TTL, Open Collector or voltage-free (switch) connections.
A Digital Input Option PCB must be fitted and the External Option parameter (in
Configuration Mode - see Subsection 4.2 of this manual) must be set to inP or
both for these terminals to be operable. The degree of external selection/control is
defined by the External Selection parameter in Program Define Mode (see
Operator’s Manual, Section 8). It is assumed that all external selection/run control
functions are enabled for the purposes of this description.

Terminals 31 (R2) to 33 (R0) provide a binary-coded input which is used to select
the program:

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Digital Inputs = TTL Level Digital Inputs = Contavts (switches)

Digital Inputs Program Selected Digital Inputs Program Selected

R0 R1 R2 R0 R1 R2

0 0 0 Program 1 Closed Open Open Program 1
1 0 0 Program 2 Open Closed Open Program 2
0 1 0 Program 3 Closed Closed Open Program 3
1 1 0 Program 4 Open Open Closed Program 4
0 0 1 Program 5 Closed Open Closed Program 5
1 0 1 Program 6 Open Closed Closed Program 6
0 1 1 Program 7 Closed Closed Closed Program 7
1 1 1 Program 8 Open Open Open Program 8

For the Program Control inputs, the following convention has been adopted: for
TTL inputs OFF = logic 0, ON = logic 1; for contact (switch) inputs, OFF = open,
ON = closed.

Terminal 30 is the Program Abort control. It is edge-sensitive; an OFF-ON transition
at any time will cause an immediate Program Abort.

Terminal 29 provides the remote Run Program/Hold Program control and has an
identical effect to that of the Run/Hold key on the front panel. An OFF-ON
transition will cause the currently-selected program to be run (or to be resumed if
it is currently held); An ON-OFF transition will cause the currently-running program
to be held. Powering-up the Setpoint Programmer with this terminal ON will not

cause a program to run.

Terminal 28 provides the “x60" program timebase selection. This terminal is
level-sensitive: ON (contacts closed) = minutes/seconds, OFF (contacts open) =
hours/minutes). When the Setpoint Controller is powered-up, the initially-selected

timebase will be according to the level on this terminal at power-up.

NOTE: All re mote se lec tion/con trol func tions ex cept the Abort
func tion have prece dence over the cor re spond ing front panel
con trols. The “x60" func tion will also take prece dence over any
”Pre- set x60" pa rame ter set ting (see Op era tor Man ual, Sec tion 8).

2.3.7 Re lay Out puts

Out puts 1, 2 and 3: con tacts rated at 2A re sis tive at 120/240V AC.

End of Pro gram/Event out puts: con tacts rated at 5A re sis tive at 120/240V AC.

NOTE: With VMD con trol, ei ther Out put 1 or Out put 2 is switched on
(to open or close the valve) How ever, un der fault con di tions, both
Out put 1 and Out put 2 re lays could be switched on si mul ta ne ously.
For safety pur poses, an in ter lock can be in cluded which con nects
the sup ply to the mo tor via the “nor mally closed” con tacts on the
Out put 1 and Out put 2 re lays (see Fig ure 2-7).

2 -8 59216-2

Figure 2-7 Valve Mo tor Drive Out puts with In ter lock

2.3.8 SSR Drive Out puts

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These outputs produce a time-proportioned non-isolated DC signal (0 - 4.3V
nominal, output impedance 250 ohms).

2.3.9 DC Out puts

See Appendix A.

2.3.10Event Out puts

These outputs are only available if the Event Output PCB is fitted and if the External
Option parameter in Configuration Mode (see Subsection 4.2 of this manual) is set
to either out or both. They are single pole single throw Normally Open relay
contacts. For the current segment of the currently-running/held program, these
outputs are in the states defined by the Event parameter (see Operator’s Manual,
Section 8) for that segment. 0 = open, 1 = closed.

2.3.11RS485 Se rial Com mu ni ca tions Link

The “A” terminal (Terminal 17) on the Setpoint Programmer should be connected
to the “A” terminal on the master device; the “B” terminal (Terminal 16) on the
Setpoint Programmer should be connected to the “B” terminal on the master
device. Where several Setpoint Programmers are connected to one master port,
the master port transceiver in the active state should be capable of driving a load
of 12kΩ per Setpoint Programmer; the master port transceiver in the passive state
must have pull-up/pull-down resistors of sufficiently low impedance to ensure that
it remains in the quiescent state whilst supplying up to +/-100
Programmer transceivers in the high impedance state.

µA each to the Setpoint

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SEC TION 3

INTERNAL LINKS AND SWITCHES

3.1 REMOVING THE SETPOINT PROGRAMMER FROM ITS HOUSING

CAUTION: Before removing the Setpoint Programmer from its housing,
ensure that all power has been removed from the rear terminals.

To withdraw the Setpoint Programmer from its housing, simply grip the side edges
of the front panel (there is a finger grip on each edge) and pull the panel
forwards. This will release the Setpoint Programmer from its rear connectors in the
housing and will give access to the PCBs. Take note of the orientation of the
Setpoint Programmer for subsequent replacement into the housing.The positions of
the PCBs are shown in Figure 3 -1 .

Figure 3-1 PCB Positions

3 -1 59216-3

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Figure 3-2 Removing the Output 2/Output 3 Option PCBs

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3.2 REMOVING/REPLACING THE OUTPUT 2/OUTPUT 3 OPTION PCBs

With the Setpoint Programmer removed from its housing:

1. Gently push the rear ends of the CPU PCB and Power Supply PCB apart
slightly, until the two tongues on each of the Output 2/Output 3 Option PCBs
become dis-engaged - see Figure 3-2B; The Output 2 Option PCB tongues
engage in holes in the Power Supply PCB and the Output 3 Option PCB
tongues engage in holes on the CPU PCB.

2. Carefully pull the required Option PCB (Output 2 or Output 3) from its
connector (Output 2 Option PCB is connected to the CPU PCB and Output 3
Option PCB is connected to the Power Supply PCB) - see Figure 3-2C. Note
the orientation of the PCB in preparation for its replacement.

Adjustments may now be made to the link jumpers on the CPU PCB, the Output
2/Output 3 Option PCBs (if DC output) and (if fitted) the DC Output 1 PCB. The
replacement procedure is a simple reversal of the removal procedure.

3.3 REMOVING/REPLACING THE RS485 COMMUNICATIONS OPTION PCB

The RS485 Communications Option PCB is mounted on the inner surface of the
Power Supply PCB and can be removed when the Setpoint Programmer is
removed from its housing (see Subsection 3.1) Figure 3 -3 illustrates the
removal/replacement procedure. It is not necessary to remove the Output

2/Output 3 Option PCBs to perform this procedure.

Figure 3-3 Re mov ing/Replacing the RS485 Communications Op tion PCB

3-3 59216-3

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3.4 INSTALLING/REMOVING THE DIGITAL INPUT OPTION PCB

The location of the Digital Input Option PCB is shown in Figure 3-4. It is connected
to the CPU PCB via a flexi-strip connector, as shown.

Figure 3-4 Location of Digital Input Option PCB and

Event Output Option PCB

To install the Digital Input Option PCB:

1. Hold the PCB ap proxi mately in po si tion and care fully in sert the free end
of the flexi- strip ca ble into the socket near the bot tom edge of the CPU PCB
(en sur ing that none of the pins on the end of the flexi- strip be come bent
and that the flexi- strip is not twisted).

2. Fully in sert the Digi tal In put Op tion PCB into its con nec tor at the rear of
the front panel (when the PCB is fully in serted, it will be come en gaged in
the slots above and be low its con nec tor).

To remove the Digital Input Option PCB:

1. Dis- engage the PCB from its slots (above and be low the con nec tor at the
rear of the front panel) and with draw the PCB clear of the con nec tor.

2. Dis con nect the flexi- strip from the con nec tor near the bot tom edge of
the CPU PCB.

3. Re move the Digi tal In put Op tion PCB com pletely from the in stru ment.

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3.5 INSTALLING/REMOVING THE EVENT OUTPUT OPTION PCB

The location of the Event Output Option PCB is shown in Figure 3 -4 . It is connected
to the CPU PCB via a flexi-strip connector, as shown.

To install the Event Output Option PCB:

1. Hold the PCB ap proxi mately in po si tion and care fully in sert the free end
of the flexi- strip ca ble into the socket near the top edge of the CPU PCB
(en sur ing that none of the pins on the end of the flexi- strip be come bent
and that the flexi- strip is not twisted).

2. Fully in sert the Event Out put Op tion PCB into its con nec tor at the rear of
the front panel (when the PCB is fully in serted, it will be come en gaged in
the slots above and be low its con nec tor).

To remove the Event Output Option PCB:

1. Dis- engage the PCB from its slots (above and be low the con nec tor at the
rear of the front panel) and with draw the PCB clear of the con nec tor.

2. Dis con nect the flexi- strip from the con nec tor near the top edge of the
CPU PCB.

3. Re move the Event Out put Op tion PCB com pletely from the in stru ment.

3.6 REPLACING THE SETPOINT PROGRAMMER IN ITS HOUSING

To replace the Setpoint Programmer, simply align the CPU PCB and Power Supply
PCB with their guides and connectors in the housing and slowly but firmly push the
Setpoint Programmer into position.

CAU TION: En sure that the in stru ment is cor rectly ori en tated. A stop will
op er ate if an at tempt is made to in sert the in stru ment in the wrong
ori en ta tion (e.g. upside- down). This stop must not be over- ridden.

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3.7 SELECTION OF INPUT TYPE

The se lec tion of in put type is ac com plished on link jump ers LJ1/LJ2/LJ3 on the CPU
PCB (see Fig ure 3-5 and Ta ble 3 -1 ).

Figure 3-5 CPU PCB (Relay/SSR Drive Output 1)

Table 3 -1 Input Type Selection

Input Type Link Jumper Fitted

RTD or DC (mV) None (parked)

Thermocouple LJ3

DC (mA) LJ2

DC (v) LJ1

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3.8 SELECTION OF PRIMARY OUTPUT (OUTPUT 1) TYPE

The re quired type of Out put 1 is se lected by Link Jump ers LJ4/LJ5/LJ6/LJ7/LJ8/LJ9
on the PSU PCB (see Fig ure 3-6 and Ta ble 3 -2 ).

Figure 3-6 PSU PCB Link Jumpers

Table 3 -2 Output 1 Type Selection

Output Type Link Jumpers

Fitted

Relay LJ5 & LJ6

SSR Drive LJ4 & LJ7

DC (0 - 10V) LJ8

DC (0 - 20mA) LJ9

DC (0 - 5V) LJ8

DC (4 - 20mA) LLJ9

3 -7 59216-3