West 6400 Operating Manual

-DIN

1 6

PROFILER/CONTROLLER

Product Manual

59129-2

HOW TO USE THIS MANUAL

This manual comprises two volumes:

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-DIN PROFILER/CONTROLLER

1 6

PRODUCT MANUAL

VOLUME I

OPERATING INSTRUCTIONS

In normal operation, the operator must not remove the Profiler/Controller from its housing or have unrestricted access to the rear terminals, as this would provide potential contact with hazardous live parts.

Installation and configuration must be undertaken only by technically-competent servicing personnel. This is covered in Volume II of this manual.

CONTENTS

1 BASE MODE 1-1

1.1 DISPLAY SEQUENCE - NO PROGRAM RUNNING 1-1

1.2 STARTING A PROGRAM 1-2

1.3 PUTTING A PROGRAM IN HOLD 1-2

1.4 RELEASING A PROGRAM FROM HOLD 1-2

1.5 ABORTING A PROGRAM 1-2

1.6 DISPLAY SEQUENCE - PROGRAM RUNNING 1-3

1.7 RaPID CONTROL FEATURE 1-4

1.8 PRE-TUNE FEATURE 1-4

1.9 ENGAGING BOTH PRE-TUNE AND RaPID FEATURES 1-5

1.10 INDICATION OF PRE-TUNE AND RaPID STATUS 1-5

1.11 VIEWING THE HARDWARE DEFINITION CODE 1-6

1.12 MANUAL CONTROL 1-7

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2 PROGRAM DEFINITION MODE -

CREATING/EDITING A PROGRAM 2-1

2.1 ENTRY 2-1

2.2 CREATING A PROGRAM 2-2

2.3 DEFAULT VALUES AND ADJUSTMENT RANGES 2-9

2.4 EXIT FROM PROGRAM DEFINE MODE 2-9

3 CONTROLLER SET-UP MODE 3-1

3.1 PARAMETER DETAILS 3-3

3.2 EXIT FROM CONTROLLER SET-UP MODE 3-9

4 MODBUS COMMUNICATIONS 4-1

4.1 INTRODUCTION 4-1

4.2 MODBUS FUNCTIONS SUPPORTED 4-1

4.3 MESSAGE FORMATS 4-1

4.4 PARAMETER NUMBERS 4-7

4.5 PROFILER STATUS BYTE 4-11

4.6 PROFILER COMMANDS 4-11

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1 BASE MODE

1.1 DIS P L A Y SEQUENCE - NO PROGRAM RUNNING

1.2 STARTING A PROGRAM

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To start a program running:

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1.3 PUTTING A PROGRAM IN HOLD

A program can be put in Hold (i.e. frozen) at any time whilst it is running. The program setpoint will stay at its value at the instant the program entered Hold until the program is released (see Subsection 1.4) or aborted (see Subsection 1.5). To

put a program in hold, momentarily press the RUN key. The RUN indicator will flash whilst the program is in hold.

1.4 RELEASING A PROGRAM FROM HOLD

To release a program currently in Hold, momentarily press the RUN key. The

RUN indicator will then go ON continuously.

1.5 ABORTING A PROGRAM

To abort the current-running (or held) program, hold down the RUN key for 5 seconds. The program will be aborted, the RUN indicator will go OFF and the

normal Controller functions will be resumed.

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NOTE: When a program is aborted, the instrument returns to the Controller Setpoint value. If a program is successfully completed, the Controller Setpoint is automaticaly set to the final setpoint value of the program. If it is desired to restore the initial Controller Setpoint value after the program is completed, this value should be used as the program Final Setpoint value.

1.6 DISPLA Y SEQ U EN CE - PROGRAM RUNNING

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1.7 RaPID CONTROL FEATURE

The RaPID control feature may be used when extra fast responses and minimum overshoot are required. The RaPID feature works best when PID terms are well-tuned; therefore, it is recommended that the Pre-Tune feature (see Subsection

1.8) is run before the RaPID feature is engaged.

To dis-engage RaPID control, use the same key actions. NOTE: The RaPID feature

cannot be engaged if Proportional Band 1 or Proportional Band 2 is set to 0.

1.8 PRE-TUNE FEATURE

This facility may be used to provide initial tuning of the Controller’s PID parameters. Pre-Tune may be engaged (and subsequently dis-engaged) as follows:

NOTE: The Pre-Tune facility will not engage if (a) a program is currently running, (b) the process variable is within 5% of input span of the setpoint, or (c) an erroneous key sequence is used. Pre-Tune is a single-shot process which automatically dis-engages itself when completed.

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1.9 ENGAGING BOTH PRE-TUNE AND RaPID FEATURES

The Pre-Tune and RaPID features can be engaged in one key action sequence:

Pre-Tune will operate first. When it is completed it will dis-engage itself and the RaPID feature will then operate automatically.

1.10 INDICATION OF PRE-TUNE AND RaPID STATUS

The responses to the RaPID feature being engaged are:

Pre-Tune Status when

RaPID engaged

Not operational. RaPID activated.

Operational. Pre-Tune completes routine,

then RaPID activated.

The responses to the RaPID feature being dis-engaged are:

Pre-Tune Status when

RaPID dis-engaged

Not operational. RaPID de-activated.

Operational. Pre-Tune completes routine,

then RaPID de-activated return to normal control.

The responses to Pre-Tune being engaged are:

Response Indication

AT indicator goes ON.

AT indicator flashes at

double rate then comes ON.

Response Indication

AT indicator goes OFF.

AT indicator flashes at

double rate then goes OFF.

RaPID status when Pre-Tune engaged

Not operational. Pre-Tune activated and

routine completed

Operational. RaPID interrupted, Pre-Tune

activated. Pre-Tune completes routine, then RaPID control resumed.

Response Indication

AT indicator flashes at

normal rate the goes OFF.

AT indicator flashes at

double rate then goes ON.

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The responses to Pre-Tune being dis-engaged (manually or automatically) are:

RaPID Status when

Pre-Tune dis-engaged

Not operational. Pre-Tune dis-engaged,

Response Indication

AT indicator goes OFF.

normal control resumed.

Operational. Pre-Tune dis-engaged,

AT indicator goes ON.

RaPID control resumed.

1.11 VIEWING THE HARDWARE DEFINITION CODE

NOTE: An automatic return is made to the normal Base Mode display after 30 seconds.

The Hardware Definition Code has the following significance:

Value 0 1 2 3 4 5 7 8

Input RTD/

Linear

Thermocouple

Linear DC mA

Linear DC V

DC mV

Output 1

Output 2/3

Not fitted

Relay SSR

Drive

Relay SSR

Drive

DC 0 - 10VDC0 - 20mADC0 - 5VDC4 - 20mA

* Output 2 only

Solid State

Solid State*

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1.12 MANUAL CONTROL

In Base Mode, with no program running or held, Manual Control may be selected as follows:

The lower display shows the output power in the form Pxxx (xxx is in the range 000% to 100% of maximum output power). This may be adjusted using the Up and Down keys.

To return to automatic control:

2 PROGRAM DEFINITION MODE -

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CREATING/EDITING A PROGRAM

2.1 ENTRY

To enter Program Definition Mode:

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NOTE: If the Program Define Mode lock code has been set to 0, pressing the Scroll key in Step 2 will give direct access to Program Define Mode; no entry of lock code is required.

Upon entry into Program Define Mode, the first Segment Definition parameter for Segment 1 of Program 1 will be displayed.

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2.2 CREATING A PROGRAM

A program is created in two steps:

1. Define the segments of your program; the parameters used depend on what Program Mode has been configured - Rate Mode (see Subsection

2.2.2) or Time Mode (see Subsection 2.2.3). The segment definitions determine whether the selected segment is a Ramp Segment, a Dwell (soak) Segment or an End Segment.

2. Set the required Program Options (see Subsection 2.2.4). These determine:

(i) The number of cycles performed by the program, (Ii) The timebase to be used (hours/minutes or minutes/seconds) (Iii) The width of the Guaranteed Soak Band (if enabled), (Iv) The state of the event indicator for each segment in the program, (v) The lock code to be used for subsequent entries into Program Define Mode.

2.2.1 Basic Guidelines

1. The Profiler/Controller may contain up to four programs.

2. Each program may comprise up to 16 segments.

3. Each segment may be:

(a) a Ramp Segment (setpoint changing at a defined rate or between the initial value and a pre-determined final value over a defined time), (b) a Dwell Segment (setpoint constant for a defined time,) or (c) an End Segment (marking the end of the program).

4. A program may contain only one End Segment (the last segment in the program).

5. If the program comprises 16 segments, Segment 16 is automatically an End Segment.

2.2.2 Defining Segm ents - Rate Mode

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2.2.3 Defining Segments - Time Mode

2.2.4 Prog ram O ptions

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2.2.5 Guaran teed Soak Band

The Guaranteed Soak Band is applicable to Dwell segments only and operates as follows (depending on whether Guaranteed Soak has been enabled or Manual Guaranteed Soak has been configured):

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2.2.6 Segment Event Status

For every segment in a program there is an event indicator. This may be set ON or OFF for that segment. The status for the segments in the currently-selected program appears in the following form in the upper display:

The first display shows the current event status for Segments 1 - 8 and the second display shows the current event status for Segments 9 - 16. Each event marker may be set ON (Up key) or OFF (Down key) in order of segment number. Only the event indicators for the segments in the program are displayed. If the program has less than 16 segments (including the End Segment), the non-applicable display positions are blank; if the program has eight segments or less, the second display is not included.. The lower display shows the current segment number. Thus, the key sequence to define the event markers for Segments 1 - 8 could be:

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Pressing the Scroll key would then display the event markers for Segments 9 - 16 (as applicable), which could be defined in a similar manner.

2.3 DEFAULT VALUES AND ADJUSTMENT RANGES

Parameter Range Minimum Range Maximum Default

Ramp Rate 0 = Dwell segment

9999, then INF 100

-1 = End segment

Final (End of

Range Minimum Range Maximum Range Minimum

Ramp) Setpoint

Segment Time 00:00 99:59 01:00

Number of Cycles 1 9999 then INF 1

Guaranteed Soak

1 Span plus OFF OFF

Band

2.4 EXIT FROM PROGRAM DEFINE MODE

A return is then made to the normal Base Mode display.

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3 CONTROLLER SET-UP MODE

In this mode, the parameters which define the operation of the controller are defined. Controller Set-Up Mode can be entered (whether or not there is a program currently running) as follows:

NOTES:

1. If the Controller Set-Up Mode lock code has been set to 0, pressing the Scroll key in Step 2 will give direct access to Controller Set-Up Mode; no entry of lock code is required.

2. If the upper display initially shows all decimal points illuminated (see right), one or more configuration parameters have been altered and, as a consequence, all ControllerSet Up Mode parameters have been automatically set to their default values/settings. To clear this display, simply alter the value/setting of any Controller Set Up Mode parameter.

Upon entry into Controller Set-Up Mode, the first in a sequence of controller parameters will be displayed. The operator may then step through the parameter sequence using the Scroll key, adjusting the setting/value of each displayed parameter using the Up/Down keys. The parameter sequence is as follows:

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NOTES

1. Not operative if Proportional Band = 0.

2. Switching differential for ON/OFF control output.

3. Optional; only one legend will appear for each alarm.

4. Only applicable if a DC linear input is fitted.

5. Only applicable if Output 2 is fitted as a secondary control (COOL) output.

6. Applicable only if the Communications Option is fitted.

7. When a program is running, respective to program setpoint.

3.1 PARAMETER DETAILS

Parameter Function Adjustment Range

Input Filter Time Constant

P rocess Variable Offset

Output Power 1 Current Output 1 power level 0 to 100% Read only

Output Power 2 Current Output 2 power level 0 to 100% Read only

Proportional Band 1 (PB1)

Proportional Band 2 (PB2)

Reset (Integral Time Constant)

Filter removes extraneous impulses from the process variable input

Modifies actual process variable (PV) value: Offset PV + actual PV

= PV value used

Portion of input span in which Output 1 power level is proportional to the (offset) process variable value (see Figure 3-1).

Portion of input span in which Output 2 power level is proportional to the (offset) process variable value (see Figure 3-1).

Integral time constant 1sec. to 99min. 59

OFF, 0.5 to 100.0 seconds in 0.5 second increments

±input span of

Controller

0.0 to 999.9% of input span

secs. and OFF

Default

value

2.0 seconds

10.0%

5 mins. 00 secs.

Rate (Derivative Time Constant)

Overlap/ Deadband

Manual Reset (Bias)

Derivative time constant 00 secs. to 99 mins. 59

secs.

Portion of proportional band (PB1 + PB2) in which both outputs are active (overlap) or neither output is active (deadband) - see Figure 3-1).

Bias applied to output power, expressed as a percentage of output power.

− 20% to +20% of

(Proportional Band 1 + Proportional Band 2)

0% to 100% (Output 1 only);

−100% to +100%

(Output 1 & Output 2)

1 min. 15 secs.

25%

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Parameter Function Adjustment Range

ON/OFF Differential

Setpoint Lock Enables/disables setpoint (SP)

Recorder Output Scale Maximum

Recorder Output Scale Minimum

Output 1 Power Limit

Output 1 Cycle Time

Output 2 Cycle Time

Switching differential for one output or both outputs set to ON/OFF control (PB1, PB2 or both = 0) - see Figure 3-1.

adjustment in Base Mode.

Process variable or setpoint value (as applicable) for which the recorder output is a maximum

Process variable or setpoint value (as applicable) for which the recorder output is a minimum

Limits Output 1 power level (to protect the process)

Limits the frequency of operation of output relay to maximise relay life

0.1% to 10.0% of input span

OFF - SP adjustable ON - SP not adjustable

−1999 to 9999

(decimal point position as for input range)

−1999 to 9999

(decimal point position as for input range)

0% to 100% of full power

0.5, 1, 2, 4, 8, 16, 32, 64, 128, 256 or 512 secs.

Default

value

0.5%

OFF

Input Range Maximum

Input Range Minimum

100%

32 secs.

Process High Alarm 1

Process Low Alarm 1

Band Alarm 1 If Alarm 1 is a Band Alarm, the band of

Deviation Alarm 1

Alarm 1 Hysteresis

If Alarm 1 is a Process High Alarm, the value of the process variable at or above which Alarm 1 will be active (see Figure 3-2)

If Alarm 1 is a Process Low Alarm, the value of the process variable at or below which Alarm 1 will be active (see Figure 3-2)

process variable values, centred on the (program) setpoint, outside which the process variable will cause this alarm to be active (see Figure 3-2)

If Alarm 1 is a Deviation Alarm, gives a value above (positive value) or below (negative value) the (program) setpoint. If the process variable deviates from the setpoint by a marging greater than this value, the alarm becomes active (see Figure 3-2)

Defines a hysteresis band on the “safe” side of the Alarm 1 value

Input Range Minimum to Input Range Maximum

0 to input span from (program) setpoint

± input span from

(program) setpoint

1 to 250 units 1 unit

Input Range Maximum

Input Range Minimum

5 units

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Parameter Function Adjustment Range

Process High Alarm 2

Process Low Alarm 2

Band Alarm 2 If Alarm 2 is a Band Alarm, the band

Deviation Alarm 2

If Alarm 2 is a Process High Alarm, the value of the process variable at or above which Alarm 2 will be active (see Figure 3-2)

If Alarm 2 is a Process Low Alarm, the value of the process variable at or below which Alarm 2 will be active (see Figure 3-2)

of process variable values, centred on the (program) setpoint, outside which the process variable will cause this alarm to be active (see Figure 3-2)

If Alarm 2 is a Deviation Alarm, gives a value above (positive value) or below (negative value) the (program) setpoint. If the process variable deviates from the setpoint by a marging greater than this value, the alarm becomes active (see Figure 3-2)

Input Range Minimum to Input Range Maximum

0 to input span from (program) setpoint

±input span from

(program) setpoint

Default

value

Input Range Maximum

Input Range Minimum

5 units

Alarm 2 Hysteresis Defines a hysteresis band on the

“safe” side of the Alarm 2 value

Scale Range Decimal Point Position

Scale Range Maximum

Scale Range Minimum

Manual Control Enable/Disable

Setpoint Strategy Determines whether or not the

Communications Enable/Disable

Controller Set-Up Mode Lock Code

For linear inputs only, defines the decimal point position

For linear inputs only, defines the scaled input value when the process variable input is at its maximum value

For linear inputs only, defines the scaled input value when the process variable input is at its minimum value

setpoint is adjustable in the normal Base Mode display

Enables/disables changing of parameter values via the communications link

Defines the four-digit code required to enter the Controller Set-Up Mode

1 to 250 units 1 unit

0 (xxxx), 1 (xxx.x), 2 (xx.xx) or 3 (x.xxx)

−1999 to 9999

0 (Disabled) or 1 (Enabled)

0 = not adjustable, 1 = adjustable

0 (disabled) or 1 (Enabled)

0 to 9999 10

1 (xxx.x)

1000

0000

0 (Disabled)

1 (Enabled)

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