West Control Solutions Pro-EC44 User Manual

Download

Pro-EC44

2-Loop Graphical Profile

Controller & Recorder

Pro-EC44 User Guide 59540-1

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

WARNING: THE INTERNATIONAL HAZARD SYMBOL IS INSCRIBED ADJACENT TO THE REAR CONNECTION TERMINALS. IT IS IMPORTANT TO READ THIS MANUAL BEFORE INSTALLING OR COMMISSIONING THE UNIT.

WARNING: THIS SYMBOL MEANS THE EQUIPMENT IS PROTECTED THROUGHOUT BY DOUBLE INSULATION.

WARNING: PRODUCTS COVERED BY THIS MANUAL ARE SUITABLE FOR INDOOR USE, INSTALLATION CATEGORY II, POLLUTION CATEGORY 2 ENVIRONMENTS.

Note: It is strongly recommended that applications incorporate a high or low limit

protective device, which will shut down the equipment at a pre-set process condition in order to prevent possible damage to property or products.

This manual supplements the Concise Product manual supplied with each instrument at the time of shipment. Information in this installation, wiring and operation manual is subject to change without notice.

Copyright © October 2013, Danaher Corporation, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of Danaher/West Control Solutions.

Copies of this manual are available in electronic format on the West Control Solutions web site (www.west-cs.com) Printed versions may be purchased from West Control Solutions or its representatives.

This user guide covers all versions of the West Pro-EC44 controller.

©WCS – Product & specifications may be subject to change without notice - E&OE

Pro-EC44 Product Manual - 59540-1 October 2013 Page i

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Warranty and Returns Statement

These products are sold by West Control Solutions under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to a purchase of these products, as new merchandise, directly from West Control Solutions or from a West Control Solutions distributor, representative or reseller and are extended only to the first buyer thereof who purchases them other than for the purpose of resale.

Warranty

These products are warranted to be free from functional defects in material and workmanship for three years from the time the products leave West Control Solutions factory and to conform at that time to the specifications set forth in the relevant West instruction manuals sheet or sheets.

THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES, WHICH EXTEND BEYOND THE WARRANTIES HEREIN AND ABOVE SET FORTH. NO WARRANTY IS MADE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE PRODUCTS.

Limitations

West Control Solutions shall not be liable for any incidental damages, consequential damages, special damages, or any other damages, costs or expenses excepting only the cost or expense of repair or replacement as described above. Products must be installed and maintained in accordance with West Control Solutions instructions. There is no warranty against damage to the product resulting from corrosion. Users are responsible for the suitability of the products to their application. For a valid warranty claim, the product must be returned carriage paid to the supplier within the warranty period. The product must be properly packaged to avoid damage from electrostatic discharge or other forms of harm during transit.

Page ii Pro-EC44 Product Manual - 59540-1 October 2013

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

How to use this manual

This manual is structured to give easy access to the information required for all aspects of the installation and use and of the controller. The main sections are shown here, with a full table of contents at the end.

Warranty and Returns Statement ..................................................................................................... ii

1 Introduction............................................................................................................................. 1

2 Installation .............................................................................................................................. 2

3 Field Upgrade Options ........................................................................................................... 4

4 Electrical Installation .............................................................................................................. 9

5 Powering Up .......................................................................................................................... 29

6 Messages & Error Indications.............................................................................................. 31

7 Application Setup ................................................................................................................. 33

8 Operation and Configuration Menus ................................................................................... 36

9 Input Calibration & Multi-point Scaling ............................................................................... 70

10 Digital Inputs ......................................................................................................................... 75

11 Cascade Control ................................................................................................................... 78

12 Ratio Control ......................................................................................................................... 81

13 Redundant Input ................................................................................................................... 83

14 Valve Motor Drive / 3-Point Stepping Control ..................................................................... 84

15 Setpoint Sources .................................................................................................................. 86

16 Profiler ................................................................................................................................... 87

17 USB Interface ........................................................................................................................ 96

18 Data Recorder ................................................................ ....................................................... 97

19 Controller Tuning.................................................................................................................. 99

20 Serial Communications ...................................................................................................... 109

21 Glossary .............................................................................................................................. 204

22 PC Software ........................................................................................................................ 235

23 Specifications ..................................................................................................................... 245

24 Pro-EC44 Product Coding .................................................................................................. 255

25 Table of Contents ................................................................ ............................................... 257

Pro-EC44 Product Manual - 59540-1 October 2013 Page iii

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

1 Introduction

This product is a 1/4 DIN size (96 x 96mm front) microprocessor based graphical process controller, featuring a 160 x 80 pixel, monochrome LCD with dual colour (red/green) backlight. It operates from 100-240V at 50/60 Hz or 24V-48V AC/DC, depending on the model purchased. It can measure and control up to two process variables from a variety of sources such as temperature, pressure, flow and level. Primary and secondary control outputs are possible for each loop.

Optional features include a second process input, USB interface, remote setpoint inputs RS485 or Ethernet communications, profile control and data recording. Control options include cascade, ratio and 3-point stepping valve control. Automatic tuning or 5 stage gainscheduling are also available.

The USB Interface option allows uploading or downloading instrument configuration settings to/from a USB memory stick, for easy configuration of multiple instruments or transfer to/from the PC configuration software. If the data recorder or profiler options are fitted, recordings and profile information can be transferred via the memory stick.

The data recorder option allows the user to make recordings of the processes over time. Recordings can be transferred to a memory stick using the USB interface or downloaded via one of the communications options.

The Profiler option allows the user to predefine up 255 segments, shared amongst up to 64 Setpoint Profiles. These control the setpoint levels for the control loop(s) over time, increasing, decreasing or holding their values as required. When combined with the real-time clock (part of the Data Recorder option) the profiling capabilities are expanded to allow automatic program start at a defined time and day.

Inputs are user configurable for thermocouple and RTD probes, as well as linear process signal types such as mVDC, VDC or mADC. Two-point calibration or multipoint scaling can compensate for errors or non-linear signals. Output options include single or dual relays, single or dual SSR drivers, triacs or linear mA/V DC. These can be used for process control, alarms/events or retransmission of the process variable or setpoint to external devices. Transmitter power supply options can provide an unregulated 24V DC (22mA) auxiliary output voltage, or a 0 to 10VDC stabilised excitation for external signal transmitters.

Up to 7 alarms can be defined as process high or low, deviation (active above or below controller setpoint), band (active both above and below setpoint), rate of input change, control loop, PID power or signal break types. Alarm status can be indicated by lighting an LED, changing the display backlight colour or viewing the active alarm status screen. These alarms can be linked to any suitable output.

Configuration for basic applications is possible using the easy Setup Wizard run automatically at first power-up or manually later. Access to the full range of parameters is via a simple menu driven front panel interface, or the PC based configuration software.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 1

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Installation should be only performed by technically competent

personnel. It is the responsibility of the installing engineer to ensure that the configuration is safe. Local Regulations regarding electrical installation & safety must be observed (e.g. US National Electrical Code (NEC) or Canadian Electrical Code).

2 Installation

Unpacking

1. Remove the product from its packing. Retain the packing for future use, in case it is necessary to transport the instrument to a different site or to return it to the supplier for servicing.

2. The instrument is supplied with a panel gasket and push-fit mounting clamp. A multi-page concise manual is supplied with the instrument, in one or more languages. Examine the delivered items for damage or defects. If any are found, contact your supplier immediately.

Installation

Figure 1. Main dimensions

Panel-Mounting

The controller should be mounted in a properly earthed metal cabinet. The mounting panel must be rigid and may be up to 6.0mm (0.25 inches) thick. The cut-out size is:

92mm x 92mm (+0.5mm / -0.0mm).

Pro-EC44 Product Manual - 59540-1 October 2013 Page 2

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: The mounting clamp tongues may engage the ratchets either on the sides or the top/bottom faces of the Instrument housing. When installing several Instruments side-by-side in one cut-out, use the ratchets on the top/bottom faces.

CAUTION: Ensure the inside of the panel remains within the instrument

operating temperature and that there is adequate airflow to prevent overheating.

Gasket

Mounting Panel

Clamp

Ratchets

Instrument

Housing

1. Insert instrument into the panel cut-out.

2. Hold front bezel firmly (without pressing on the display area), and re-fit mounting clamp. Push the clamp forward, using a tool if necessary, until gasket compresses and instrument is held firmly in position.

CAUTION: Do not remove the panel gasket, as this may result in inadequate

clamping and sealing of the instrument to the panel.

Note: For an effective IP66 seal against dust and moisture, ensure gasket is well

compressed against the panel, with the 4 tongues located in the same ratchet slot.

Instruments may be mounted side-by-side in a multiple installation, but instrument to panel moisture and dust sealing will be compromised. Allow a 20mm gap above, below and behind the instrument for ventilation. The cut-out width (for n instruments) is:

(96n - 4) mm or (3.78n - 0.16) inches

If panel sealing must be maintained, mount each instrument into an individual cut-out with 10mm or more clearance between the edges of the holes.

Figure 2. Panel-Mounting the instrument

Once the instrument is installed in its mounting panel, it may be subsequently removed from its housing if necessary, as described in the Fitting and Removing Plug-in Modules section.

Cleaning

Clean the front panel by washing with warm soapy water and dry immediately. If the USB option is fitted, close the USB port cover before cleaning.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 3

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

PART

NUMBER

AVAILABLE OPTIONS & ACCESSORIES

BOARD

IDENTIFICATION

NUMBER

MODULE SLOT 1

PO1-R10

Single Relay Output for plug-in module slot 1

716/01

PO1-S20

Single SSR Driver Output for plug-in module slot 1

716/02

PO1-T80

Triac Output for plug-in module slot 1

716/03

PO1-C21

Linear mA / Voltage Output for plug-in module slot 1

639/01

MODULE SLOT 2 or 3

PO2-R10

Single Relay Output for plug-in module slot 2 or 3

717/01

PO2-W09

Dual Relay Output for plug-in module slot 2 or 3

644/01

PO2-S20

Single SSR Driver Output for plug-in module slot 2 or 3

717/02

PO2-S22

Dual SSR Driver Output for plug-in module slot 2 or 3

644/02

PO2-T80

Triac module Output for plug-in module slot 2 or 3

647/01

PO2-W08

24VDC Transmitter Power Supply for module slot 2 or 3

642/01

MODULE SLOT A

PA1-W03

Digital Input for plug-in module slot A

641/02

PA1-W04

Basic Auxiliary Input for plug-in module slot A

653/01

PA1-W06

RS485 Serial Communications for plug-in module slot A

680/01

PA1-ETH

Ethernet Communications for plug-in module slot A

707/01

ACCESSORIES

PS1-PRF

Profiler Enable Key-code

PS1-PRW

Blue Control PC Configuration Software & Lead

CAUTION: Plastic pegs prevent fitting of older non-reinforced single relay

modules (board identification numbers 637/01 and 638/01). Fitting the older relay modules reduces the isolation rating to Basic 240V isolation and is therefore not recommended. Remove this peg when fitting Dual Relay Modules.

Board Positions

Note: All dual relay modules have reinforced isolation.

3 Field Upgrade Options

Plug-Modules and Upgradeable Functions

Plug-Modules can be either pre-installed at the time of manufacture, or retrofitted in the field to expand the capabilities of the controller. Contact your supplier to purchase these items. Part numbers and circuit board identification numbers for the plug-in modules and accessories are shown in below:

Pro-EC44 Product Manual - 59540-1 October 2013 Page 4

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Board Mounting Struts (x4) Front Panel Removal Latch (x1) Plug-in Module A Plug-in Module 3

Power Supply Board 2nd Universal Input & Base

Option 2 Board 1st Universal Input & Base

Option 1 Board Plug-in Module 1

Plug-in Module 2 USB/Digital Input C Option

Board

CAUTION: Before removing the instrument from its housing, ensure that all

power has been removed from the rear terminals. Modules / boards should be replaced by a technically competent technician.

Figure 3. Rear view (uncased) & board positions

Preparing to Install or Remove Plug-in Modules

1. Grip the edges of the front panel (there is a finger grip on each edge) and pull it forwards

approximately 10mm, until the Front Panel Removal Latch prevents further movement. The purpose of the latch is to prevent removal of the instrument without the use of a tool.

2. The Front Panel Removal Latch must be pushed down to allow removal of the instrument.

Using a tool (e.g. screwdriver or pen tip), press down it down through the front central ventilation hole. This will release the instrument from the case.

3. The internal boards can now be accessed. Take note of the orientation of the instrument

and boards for subsequent replacement into the housing. The positions of the boards, their mountings and the Front Panel Removal Latch are shown above.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 5

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Main Board Connectors

POWER SUPPLY

BOARD

Transformer Colour

Code

100-240V (Yellow)

24-48V(Blue)

Display Board

Connections

1st UNIVERSAL

INPUT / BASE

OPTION 1 BOARD

Module Slot 3

Connector PL4B

Module Slot A

Connectors PL5, & PL6

Module Slot 1

Connectors PL7 & PL8

PC Configurator Socket SK1

Module Slot 2

Connector PL4A

CAUTION: Replacement of boards must be carried out by a technically

competent technician. If the Power Supply board does not match the labelling, users may apply incorrect voltage resulting in irreparable damage.

This product is designed to allow the user to reconfigure some hardware options in the field by changing the plug-in modules in slots 1, 2, 3, & A located on the power supply and 1st universal input boards. The main boards (display/CPU, power supply, inputs 1 & 2 and digital input/USB) are factory fitted, but may be removed while reconfiguring the plug-in modules. Take care when re-fitting these boards. Observe the power supply board transformer colour, and case labelling to check the supply voltage, otherwise irreparable damage may occur.

Figure 4. Main board connectors

Pro-EC44 Product Manual - 59540-1 October 2013 Page 6

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Check for correct orientation of the modules and that all pins

are located correctly.

CAUTION: Before replacing the instrument in its housing, ensure that all

power has been removed from the rear terminals.

CAUTION: Ensure that the instrument is correctly orientated. A mechanical

stop will operate if an attempt is made to insert the instrument in the wrong orientation, this stop MUST NOT be over-ridden.

Removing/Replacing Option Modules

1. To remove or replace Plug-in Modules 1, 2, 3 or A it is necessary to detach the power

supply and input boards from the front panel by lifting first the upper and then lower mounting struts.

2. Remove or fit the modules to the connectors on the power supply and input boards. The

location of the connectors is shown below. Plastic pegs prevent fitting of older nonreinforced single relay modules – Remove the peg to fit dual relay modules

3. Assemble the Power Supply and Input boards together. Tongues on each option module

locate into slots cut into the main boards, opposite each of the connectors. Hold the Power and Input boards together and relocate them back on their mounting struts.

4. Push the boards forward to ensure correct connection to the front Display/CPU board and

re-check the installation of the Option C and/or 2nd Input / Base Option 2 boards if present.

Replacing the Instrument in its Housing

With the required option modules correctly located into their respective positions the instrument can be replaced into its housing as follows:

1. Hold the Power Supply and Input boards together.

2. Align the boards with the guides in the housing.

3. Slowly and firmly, push the instrument into position in its case.

Auto Detection of Plug-in Modules

The instrument automatically detects which plug-in modules have been fitted into each slot. The menus and screens change to reflect the options compatible with the hardware. The modules fitted can be viewed in the product information menu, as detailed in the Product & Service Information Mode section of this manual.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 7

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Servicing of the Data Recorder/RTC circuit and replacement of

the lithium battery should only be carried out by a technically competent technician.

Data Recorder Board

If installed, the Data Recorder memory and Real Time Clock (RTC) components are located on a plug-in daughter board attached to the front Display/CPU board.

Profiler Enabling

If you purchased a controller with the Profiler option installed, these features will be enabled during manufacture. Controllers supplied without the Profiler option installed can be upgraded in the field by purchasing a licence code number from your supplier. A unique code must be purchased to enable profiling on each controller that requires it.

Entering the Profiler Enable Code

Hold down the L and D keys during the power-up “splash screen”. Using the D or U keys, enter the 16-character licence code in the displayed screen.

Press R to move on to the next character. Press L to move back to the previous character.

Press R after entering the final character.

To confirm if profiling is installed in your instrument, check the Controller Feature Information in Product & Service Information Mode.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 8

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Installation should be only performed by technically competent

CAUTION: The only wires that should run together are those of the same

category.

4 Electrical Installation

Avoiding EMC Problems

This controller has passed EMC compliance tests to EN61326. There should be no difficulty achieving this level of compliance in use, but it should be borne in mind that the wiring of the installation can significantly reduce the efficiency of instrumentation immunity due to the ease with which high frequency RF can enter via unprotected cables.

The following general recommendations can reduce the possibility of EMC problems.

1. If the instrument is being installed in existing equipment, wiring in the area should be checked to ensure that good wiring practices have been followed.

2. The controller should be mounted in a properly earthed metal cabinet. All round metal shielding is important, so the cabinet door may require a conductive sealing strip.

3. It is good practice to ensure that the AC neutral is at or near ground (earth) potential. A proper neutral will help ensure maximum performance from the instrument.

4. Consider using a separate isolation transformer to feed only the instrumentation. A transformer can protect instruments from noise found on the AC power supply.

Cable Isolation & Protection

Four voltage levels of input and output wiring may be used with the unit:

1. Analogue inputs or outputs (for example thermocouple, RTD, VDC, mVDC or mADC)

2. Relays & Triac outputs

3. Digital Inputs & SSR Driver outputs

4. AC power

If any wires need to run parallel with any from another category, maintain a minimum space of 150mm between them. If wires MUST cross each other, ensure they do so at 90 degrees to minimise interference.

Keep signal cables as short as possible. If an earthed thermocouple is used or if the sensor has a screened cable, it should be earthed at one point only, preferably at the sensor location or cabinet entry point, by means of a metal gland. Ideally all analogue and digital signals should be shielded like this, but for unscreened cables, large diameter ferrite sleeves at the cabinet entry point are an effective method of reducing RF interference. Looping cables through the ferrite sleeves a number of times improves the efficiency of the filtering. For mains input cables the fitting a suitable mains filter can provide good results.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 9

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Noise Suppression at Source

If possible, eliminate mechanical contact relays and replace with solid-state relays. Noise-generating devices such as Ignition transformers, arc welders, motor drives, relays and solenoids should be mounted in a separate enclosure. If this is not possible, separate them from the instrumentation, by the largest distance possible.

Many manufacturers of relays, contactors etc supply 'surge suppressors' to reduce noise at its source. For those devices that do not have surge suppressors supplied, ResistanceCapacitance (RC) networks and/or Metal Oxide Varistors (MOV) may be added.

Inductive coils:- MOVs are recommended for transient suppression in inductive coils. Connect as close as possible, in parallel to the coil. Additional protection may be provided by

adding an RC network across the MOV.

Figure 5. Transient suppression with inductive coils

Contacts:- Arcing may occur across contacts when they open and close. This results in electrical noise as well as damage to the contacts. Connecting a properly sized RC network can eliminate this arc.

For circuits up to 3 amps, a combination of a 47 ohm resistor and 0.1 microfarad capacitor (1000 volts) is recommended. For circuits from 3 to 5 amps, connect two of these in parallel.

Figure 6. Contact noise suppression

Pro-EC44 Product Manual - 59540-1 October 2013 Page 10

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: The placement of probes into pipe work some distance from the

heating vessel leads to transport delay, which results in poor control.

THERMOCOUPLE WIRE COLOUR CHART

Type

International

IEC584-3

USA ANSI

MC 96.1

British

BS1843

French

NFC 42-324

German

DIN 43710

Black

White

Black

Yellow

Black

Yellow

Black

Red

Blue

White

Red

Blue

Black

Blue

Brown

Blue

White

Blue

Yellow

Blue

Red

Brown

White

Red

Blue

Brown

Green

Yellow

Brown

Red

Yellow

Red

Green

White

Red

Blue

Purple

Green

Pink

Orange

Orange Orange

Orange

White

Red

Blue

Grey

Grey Grey

Grey

Red

Grey

White

Red

Grey

R & S

Orange

Black

Green

White

Green

Yellow

Green

Red

White

Red

Blue

Green

White

C (W5)

White

Red

Note: * = Wire is magnetic – a magnet can be used to assist with correctly

identifying the type and polarity of the conductors

+ Wire

Sheath

- Wire

Sensor Placement (Thermocouple or RTD)

If a temperature probe is to be subjected to corrosive or abrasive conditions, it must be protected by an appropriate thermowell.

Probes must be positioned to reflect the true process temperature:

1. In a liquid media - the most agitated area

2. In air - the best circulated area

For a two wire RTD, a wire link should be used in place of the third wire (see the wiring section for details). Two wire RTDs should only be used with lead lengths less than 3 metres. Use of three wire RTDs is strongly recommended to reduce errors do to lead resistance.

Thermocouple Wire Identification

The different thermocouple types are identified by their wires colour, and where possible, the outer insulation as well. There are several standards in use throughout the world, but most regions now use the International IEC584-3 standard.

The table below shows the wire and sheath colours used for most common thermocouple types. The format used in this table is:

Pro-EC44 Product Manual - 59540-1 October 2013 Page 11

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Installation should be only performed by technically competent

CAUTION: This equipment is designed for installation in an enclosure that

provides adequate protection against electric shock. The isolation switch should be located in close proximity to the unit, in easy reach of the operator and appropriately marked.

WARNING: This symbol means the equipment is protected throughout by double insulation. All external circuits connected must provide double insulation. Failure to comply with the installation instructions may impact the protection provided by the unit.

Pre-wiring – Cautions, Warnings & Information

WARNING:

TO AVOID ELECTRICAL SHOCK, AC POWER WIRING MUST NOT BE CONNECTED TO THE SOURCE DISTRIBUTION PANEL UNTIL ALL WIRING PROCEDURES ARE COMPLETED. CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 12

Connections and Wiring

Note: The wiring diagram below shows all possible combinations to the main

connections (numbered 1 to 24) in the centre of the case rear. The actual connections required depends upon the features and modules fitted.

Central Terminal Connections

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Figure 7. Central Terminals 1 to 24

WARNING:

CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 13

Outer Terminal Connections

Note: The wiring diagram below shows the Central Terminals (numbered 25 to

42) at the sides of the case rear. Connections for the 2nd Input, Base Option 2 and Digital Input C are shown. The actual connections required depends upon the features and modules fitted.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Figure 8. Outer Terminals 25 to 42

Pro-EC44 Product Manual - 59540-1 October 2013 Page 14

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: This equipment is designed for installation in an enclosure that

provides adequate protection against electric shock. An isolation switch should be located in close proximity to the unit, in easy reach of the operator and appropriately marked.

Power Connections

WARNING:

CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

Power Connections - Mains Powered Instruments

Mains powered instruments operate from a 100 to 240V (±10%) 50/60Hz supply. Power consumption is 20VA. Connect the line and neutral as illustrated via a UL listed fuse type: 250V AC 1Amp anti-surge and a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker located within easy reach of the operator and appropriately marked. If relays switch mains voltage this should be separate from the instruments mains supply.

Figure 9. Mains Power Connections

Power Connections - 24/48V AC/DC Powered Instruments

24/48V AD/DC powered instruments will operate from a 20 to 48V AC or 22 to 55V DC supply. AC power consumption is 15VA max, DC power consumption is 12 watts max. Connection should be via a UL listed fuse type: 65v dc 350mAamp anti-surge and a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker located within easy reach of the operator and appropriately marked.

Figure 10. 24/48V AC/DC Power Connections

Pro-EC44 Product Manual - 59540-1 October 2013 Page 15

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Universal Input 1 Connections

Universal Input 1 is present on all models. This input is normally used for the measured variable signal from a process to be controlled. It can be connected to thermocouples; resistance temperature detectors; analogue mA; mV or V DC signals. The input settings are in the Input 1 Configuration sub-menu. Connections for the various types are shown below. Ensure that the signal is correctly connected, paying particular attention to the polarity.

Universal Input 1 Connections - Thermocouple (T/C)

Supported thermocouple types & ranges are listed in the input specifications section on page

245. Only use the correct thermocouple wire or compensating cable from the sensor to the instrument terminals avoiding joints in the cable if possible. Where joints are made, special thermocouple connectors must be used. Failure to use the correct wire type and connectors will lead to inaccurate readings. Ensure correct polarity of the wires by cross-referencing the colours with the thermocouple reference table above.

Figure 11. Input 1 - Thermocouple Connections

Universal Input 1 Connections – PT100 / NI120 (RTD) input

The inputs supports two types of RTD. PT100 (platinum sensor, 100Ω at 0°C). For three wire RTDs, connect the resistive leg and the common legs of the RTD as illustrated. For a two wire RTD a wire link should be fitted across terminals 2 & 3 (in place of the third wire). Two wire RTDs should only be used when the leads are less than 3 metres long. Avoid cable joints.

Figure 12. Input 1 - RTD Connections

Four wire RTDs can be used, provided that the fourth wire is left unconnected. This wire should be cut short or tied back so that it cannot contact any of the terminals on the rear of the instrument.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 16

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Universal Input 1 Connections - Linear Volt, mV or mA input

The input supports the following linear/analogue signals: 0 to 50mV; 10 to 50mV; 0 to 5V; 1 to 5V; 0 to 10V; 2 to 10V; 0 to 20mV; 4 to 20mA from any suitable source. Voltage & millivolt signals are connected to terminals 2 & 3, milliamp signals are connected to 1 & 3. Carefully observe the position & polarity of the connections.

Figure 13. Input 1 - DC Volt, mV & mA Connections

Universal / Auxiliary Input 2 Connections

An Auxiliary Input 2 option is fitted to some models. This can connect to a potentiometer; analogue mA; mV or V DC signal for a remote setpoint input signal, or for flow/valve position feedback information. Alternatively, a second Universal Input 2 option may be fitted. In addition to the remote setpoint input signal or feedback information possible with the auxiliary input, the 2nd Universal Input can be used as a second process control loop for two control loops, or used in conjunction with input one in more complex single control loops. Universal Input 2 can be connected to thermocouples; resistance temperature detectors; potentiometers; analogue mA; mV or V DC signals.

The settings are in the Input 2 Configuration sub-menu. Connections for the various types are shown below. Ensure that the signal is correctly connected, paying particular attention to the polarity.

Universal Input 2 Connections - Thermocouple (T/C)

The optional 2nd universal input, supports various thermocouple types. Supported types & ranges are listed in the input specifications section on page 245. Only use the correct thermocouple wire or compensating cable from the sensor to the instrument terminals avoiding joints in the cable if possible. Where joints are made, special thermocouple connectors must be used. Failure to use the correct wire type and connectors will lead to inaccurate readings. Ensure correct polarity of the wires by cross-referencing the colours with a thermocouple reference table.

Figure 14. Input 2 - Thermocouple Connections

Pro-EC44 Product Manual - 59540-1 October 2013 Page 17

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Universal Input 2 Connections – PT100 / NI120 (RTD) input

The optional 2nd universal input, supports two types of RTD. PT100 (platinum sensor, 100Ω at 0°C). For three wire RTDs, connect the resistive leg and the common legs of the RTD as illustrated. For a two wire RTD a wire link should be fitted across terminals 35 & 36 (in place of the third wire). Two wire RTDs should only be used when the leads are less than 3 metres long. If possible, avoid cable joints.

Figure 15. Input 2 - RTD Connections

Four wire RTDs can be used, provided that the fourth wire is left unconnected. This wire should be cut short or tied back so that it cannot contact any of the terminals on the rear of the instrument.

Universal / Auxiliary Input 2 Connections - Linear Volt, mV or mA input

The optional auxiliary or 2nd universal input supports the following linear/analogue signals: 0 to 50mV; 10 to 50mV; 0 to 5V; 1 to 5V; 0 to 10V; 2 to 10V; 0 to 20mV; 4 to 20mA from any suitable source. Voltage & millivolt signals are connected to terminals 2 & 3, milliamp signals are connected to 1 & 3. Carefully observe the polarity of the connections.

Figure 16. Input 2 - DC Volt, mV & mA Connections

Universal / Auxiliary Input 2 Connections – Potentiometer

The optional auxiliary or 2nd universal input, the terminals detailed below can be used to connect a feedback potentiometer. Minimum potentiometer resistance is ≥100Ω.

Figure 17. Input 2 - Potentiometer Connections

Pro-EC44 Product Manual - 59540-1 October 2013 Page 18

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Base Option 1

Base Option 1 provides one or two factory fitted outputs. A relay designated as Output 4 is fitted on all models, and an optional linear mA/V DC designated as Output 6. Base options cannot be added after manufacture. The functions of outputs 4 & 6 are set in the Output Configuration sub-menu. Connect as illustrated below.

Base Option 1 Relay Output 4

Present on all instruments, Output 4 is a SPST relay, rated at 2 amps at 240 VAC resistive. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly switched and fused.

Figure 18. Relay Output 4 Connections

Base Option 1 Linear Output 6

Part of base option 1, Output 6 is an optional linear mV/V DC analogue output. The type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to 20mA.

Figure 19. Linear Output 6 Connections

Base Option 2

Base Option 2 provides one or two factory fitted outputs. An optional relay designated as Output 5, and an optional linear mA/V DC designated as Output 7. Base options cannot be added after manufacture. The functions of outputs 5 & 7 are set in the Output Configuration sub-menu. Connect as illustrated below.

Base Option 2 Relay Output 5

Part of base option 2, Output 5 is a SPST relay, rated at 2 amps at 240 VAC resistive. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly switched and fused.

Figure 20. Relay Output 5 Connections

Pro-EC44 Product Manual - 59540-1 October 2013 Page 19

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Base Option 2 Linear Output 7

Part of base option 2, Output 7 is an optional linear mV/V DC analogue output. The type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to 20mA.

Figure 21. Linear Output 7 Connections

Plug-in Module Slot 1 Connections

A selection of plug-in modules are available for Module Slot 1. They can be fitted during manufacture, or purchased and fitted later by the user. Modules in slot 1 are designated Output 1. They are not interchangeable with those in slot 2 or 3. Their function is set in the Output Configuration sub-menu. Connect as illustrated below.

Plug-in Module Slot 1 – Single Relay Output Module

If fitted with a single relay output module, connect as shown. The relay contacts are SPDT and rated at 2 amps resistive, 240 VAC. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly switched and fused.

Figure 22. Plug-in Module Slot 1 – Single Relay Module

Plug-in Module Slot 1 – Single SSR Driver Output Module

If fitted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 23. Plug-in Module Slot 1 – Single SSR Driver Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 20

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Plug-in Module Slot 1 - Triac Output Module

If fitted with a triac output module, connect as shown. This output is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. Isolated from all other inputs and outputs. A snubber should be fitted across inductive loads to ensure reliable switch off of the Triac.

Figure 24. Plug-in Module Slot 1 - Triac Module

Plug-in Module Slot 1 - Linear Voltage or mADC Output module

If fitted with a DC linear output module, connect as shown. Output type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to 20mA. Isolated from all other inputs and outputs.

Figure 25. Plug-in Module Slot 1 - Linear Voltage & mADC Module

Plug-in module slot 2 Connections

A selection of plug-in modules are available for Module Slot 2. They are interchangeable with slot 3, but not slot 1.They can be fitted during manufacture, or purchased and fitted later by the user. Modules in slot 2 are designated Output 2, and for dual modules Output 2A and 2B. Their functions are set in the Output Configuration sub-menu. Connect as illustrated below.

Plug-in Module Slot 2 – Single Relay Output Module

Figure 26. Plug-in Module Slot 2 – Single Relay Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 21

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Plug-in Module Slot 2 - Dual Relay Output Module

If fitted with a dual relay output module, connect as shown. This module has two independent SPST relays for outputs 2A and 2B, with a shared common terminal. The contacts are rated at 2 amp resistive 240 VAC. If used to switch mains voltages, the supply should be separate from the instruments mains supply and the contacts should be correctly switched and fused.

Figure 27. Plug-in Module Slot 2 - Dual Relay Module

Plug-in Module Slot 2 – Single SSR Driver Output Module

If fitted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 28. Plug-in Module Slot 2 – Single SSR Driver Module

Plug-in Module Slot 2 – Dual SSR Driver Output Module

If fitted with a dual SSR Driver output module, the two solid-state relay driver outputs are designated as Output 2A and 2B. The outputs are 10V DC pulse signals, (load ≥500 ohms). They are isolated from all inputs/output except other SSR driver outputs. Connect as shown making note of the shared positive common terminal.

Figure 29. Plug-in Module Slot 2 – Dual SSR Driver Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 22

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Plug-in Module Slot 2 - Triac Output Module

If fitted with a Triac output module, connect as shown. This output is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. Isolated from all other inputs and outputs. A snubber should be fitted across inductive loads to ensure reliable switch off of the Triac.

Figure 30. Plug-in Module Slot 2 - Triac Module

Plug-in Module Slot 2 - Transmitter Power Supply Module

If fitted with a transmitter power supply module (TxPSU), connect as shown. The output is a 24V nominal (unregulated, 19 to 28V DC), supply at 22mA max. Only one TxPSU is supported, do not fit in slot 2 if one is already fitted in slot 3.

Figure 31. Plug-in Module Slot 2 - Transmitter Power Supply Module

Plug-in Slot 3 Connections

A selection of plug-in modules are available for Module Slot 3. They are interchangeable with slot 2, but not slot 1.They can be fitted during manufacture, or purchased and fitted later by the user. Modules in slot 3 are designated Output 3, and for dual modules Output 3A and 3B. Their functions are set in the Output Configuration sub-menu. Connect as illustrated below.

Plug-in Module Slot 3 – Single Relay Output Module

Figure 32. Plug-in Module Slot 3 – Single Relay Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 23

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Plug-in Module Slot 3 - Dual Relay Output Module

If fitted with a dual relay output module, connect as shown. This module has two independent SPST relays for outputs 3A and 3B, with a shared common terminal. The contacts are rated at 2 amp resistive 240 VAC. If used to switch mains voltages, the supply should be separate from the instruments mains supply and the contacts should be correctly switched and fused.

Figure 33. Plug-in Module Slot 3 - Dual Relay Module

Plug-in Module Slot 3 – Single SSR Driver Output Module

If fitted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 34. Plug-in Module Slot 3 – Single SSR Driver Module

Plug-in Module Slot 3 – Dual SSR Driver Output Module

If fitted with a dual SSR Driver output module, the two solid-state relay driver outputs are

designated as Output 3A and 3B. The outputs are 10V DC pulse signals, (load ≥500 ohms).

They are isolated from all inputs/output except other SSR driver outputs. Connect as shown making note of the shared positive common terminal.

Figure 35. Plug-in Module Slot 3 – Dual SSR Driver Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 24

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Plug-in Module Slot 3 - Triac Output Module

Figure 36. Plug-in Module Slot 3 - Triac Module

Plug-in Module Slot 3 - Transmitter Power Supply Module

Figure 37. Plug-in Module Slot 3 - Transmitter Power Supply Module

Plug-in Slot A Connections

A selection of plug-in modules are available for Module Slot A. They can be fitted during manufacture, or purchased and fitted later by the user. Depending on their functions, they are setup Input or Communications configuration sub-menus. Connect as illustrated below.

Plug-in Module Slot A – Basic Auxiliary Input Module

If fitted with a basic auxiliary mA/V DC analogue input module, connect as shown. Isolated from all inputs/outputs. Consider using the 2nd auxiliary input (if available) instead, as this has additional features and leaves plug-in module slot A free for other modules.

Figure 38. Plug-in Module Slot A – Basic Auxiliary Input Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 25

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: External computing devices connected to the communications

port should comply with the standard, UL 60950.

Plug-in Module Slot A - Ethernet Communications Module

If fitted with the Ethernet communication module, the communications protocol available is Modbus TCP. Isolated from all inputs/outputs. If necessary, cut out the removable panel to access the RJ45 connector through the top of the case. No rear connections are required.

Plug-in Module Slot A - RS485 Serial Communications Module

If fitted with the RS485 serial communication module, the protocol used is Modbus RTU. Isolated from all inputs/outputs. Carefully observe the polarity of the A (Rx/Tx +ve) and B (Rx/Tx -ve) connections.

Figure 39. Plug-in Module Slot A – RS485 Serial Communications Module

Plug-in Module Slot A – Single Digital Input Module

If a digital input module is fitted, it provides a fully isolated input that is held high via a pull-up resistor. The input can be connected to either to voltage free contacts (e.g. from a switch), or a TTL compatible signal. Logic High = Open contacts (>5000Ω) or 2 to 24VDC signal. Logic Low = Closed contacts (<50Ω) or -0.6 to +0.8VDC signal.. Connect as shown.

Figure 40. Plug-in Module Slot A – Digital Input A Module

Pro-EC44 Product Manual - 59540-1 October 2013 Page 26

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Option C Connections

Option C offers a factory fitted multiple digital input option. The board also accommodates the USB port if that is option is fitted. The USB port does not have connections on the rear terminal, it is accessed via the front panel.

Option C Connections – Multiple Digital Input Module

If the Multiple Digital Input option is fitted, the connections are as illustrated. The 8 optoisolated inputs each have a positive input terminal and share a common negative terminal. The inputs are held high with internal pull-up resistors, so may be connected to either voltage free contacts (e.g. from a switch), or TTL compatible signals: Logic High = Open contacts (>5000Ω) or 2 to 24VDC signal. Logic Low = Closed contacts (<50Ω) or -0.6 to +0.8VDC signal.

Figure 41. Option C - Multiple Digital Inputs C1 to C8

Pro-EC44 Product Manual - 59540-1 October 2013 Page 27

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: The windings of a valve motor effectively form an

autotransformer. This has a voltage doubling effect when power is applied to either the Open or Close terminal, causing twice the supplied voltage at the other terminal. For this reason, switching devices directly connected to the valve motor must only be used up to half of their rated voltage. The maximum motor voltage when using the internal relays/triacs is therefore 120V unless interposing relays are used. Interposing relays or other devices used to control the valve must themselves be rated for twice the motor supply voltage.

Open Valve Winding

Close Valve Winding

Valve Common

“OPEN” RELAY

N/O

N/C

N/C C N/O

“CLOSE” RELAY

N/C C N/O

120VAC SUPPLY

2 x 120V = 240V

120V

Special Wiring Considerations for Valve Motor Control

Valve Motor Drive (VMD) controllers require two identical outputs to be assigned to position the valve. One to open and one to close the valve. These outputs can be two single relays, two triacs, two SSR drivers or one dual relay, but it is recommended to use two single relays (SPDT change-over contacts), and to interlock the relay wiring as shown. This prevents both motor windings from being driven at the same time, even under fault conditions.

Switching actuators directly connected to the valve motor must only be used up to half of their rated voltage (see CAUTION below). The internal relay and triac outputs are rated at 240VAC, so the maximum motor voltage when using them in this way is therefore 120V unless interposing relays are used. Interposing relays or other devices used to control the valve must themselves be rated for twice the motor supply voltage.

Figure 42. Interlocking of Valve Motor Drive Relays

Pro-EC44 Product Manual - 59540-1 October 2013 Page 28

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Ensure safe wiring practices have been followed. When powering

up for the first time, disconnect the output connections. The instrument must be powered from a supply according to the wiring label on the side of the unit. The supply will be either 100 to 240V AC, or 24/48V AC/DC powered. Check carefully the supply voltage and connections before applying power

5 Powering Up

Powering Up Procedure

At power up, a self-test procedure is automatically started, during which a splash screen is displayed and the LED indicators are lit. At the first power up from new, a Setup Wizard runs to assist configuration of basic applications (refer to the Setup Wizard section on page 43). At all other times, the instrument returns to the normal operation mode once the self-test procedure is complete.

Front Panel Overview

The illustration below shows an instrument fitted with the optional USB socket located to the right of the four keypad buttons. Clean the front panel by washing with warm soapy water and dry immediately. If the USB option is fitted, close the port cover before cleaning.

Figure 43. A Typical Front Panel

Display

The instrument has a 160 x 80 pixel monochrome graphical display with dual colour (red/green) backlight. The main display typically shows the process variables, setpoints, power / deviation bar graphs or graphical trends during normal operation. There are recorder and profile status screen. The top line of the display has labels for the 4 LED indicators. If desired, the backlight colour can be changed to indicate the presence of an active alarm or latched output. Refer to the Display Configuration section - page 59

Pro-EC44 Product Manual - 59540-1 October 2013 Page 29

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Keypad Button Functions

Button

Function

Moves backwards to the previous parameter or screen in the current mode. Holding this key down for more than 1 second skips immediately to the previous screen accepting ALL values as shown.

CAUTION: If editing a parameter, ensure that the current

(highlighted) parameter value is correct before pressing the key as this action will update and store the value displayed.

In menus and configuration choice screens, this key moves to the next item on the list. Editable values can be decreased by pressing this key. Holding the key down speeds up the change. In Trend views this key moves the Cursor Line back through the stored data points

In menus and configuration choice screens, this key moves to the previous item on the list. Editable values can be increased by pressing this key. Holding the key down speeds up the change. In Trend views this key moves the Cursor Line forward through the stored data points

Moves forwards to the next parameter or screen in the current mode. Holding this key down for more than 1 second skips immediately to the next screen accepting ALL values as shown.

CAUTION: If editing a parameter, ensure that the current

(highlighted) parameter value is correct before pressing the key as this action will update and store the value displayed.

Pressing the U key while holding down the R key causes the instrument to move up one menu level. From Operation Mode and in most menus, this will result in entry to the Main Menu. From sub-menus, it is necessary to carry out this sequence more than once to reach the main menu.

CAUTION: If editing a parameter, ensure that the current

(highlighted) parameter value is correct before pressing the key as this action will update and store the value displayed.

LED Functions

There are four red LEDs that by default indicate the status of the primary & secondary outputs, automatic tuning and alarm status. The top line of the graphical display has four labels for LED indicators. The function of these LEDs and their display labels can be changed using the PC configuration software. The information in this manual assumes standard functions for these LEDs.

Keypad Functions & Navigation

Each instrument has four keypad switches, which are used to navigate through the user menus and adjust the parameter values. In configuration screens, a context sensitive scrolling help text is displayed that guides the user about the function of the keys.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 30

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Do not continue using the product until the the error is resolved.

CAUTION: Correct the signal/wiring problem to continue normal operation.

CAUTION: Perform a full base calibration of the input before continuing

normal operation (see page 72). If the problem persists, return the instrument for servicing.

6 Messages & Error Indications

Plug-in Module Problems

If an invalid or unknown module is detected in one of the plug-in module slots during the power-up self-test, the message “Fault Found, Press R, for details” is shown. This is followed by “Replace faulty module in Module Slot n, Press R,” (where n is the faulty slot

location). The Service Contact information is displayed next showing details of who to contact if a fault persists

Replace the module in slot “n”. If this does not solve the problem, return the instrument for investigation.

Sensor Break Detection

Whenever a problem is detected with a process variable or auxiliary input connection, the displayed value for that input is replaced with the word “OPEN”; except in Ratio control where an open input 1 or 2 is shown as “x1-Open” or “x2-Open”. See Redundant Input (page 83) to protect critical processes from sensor faults.

This may be the result of a failed sensor, a broken connection or an input circuit fault. In this condition, the control outputs go to the pre-set power value (see Control Configuration

– page 50).

Un-Calibrated Input Detection

The instrument is fully calibrated during manufacture. If a fault occurs and calibration data is lost, the process input displays are replaced with the word “ERROR” and error is shown instead of “Calibrated” for effected inputs in Service & Product Information mode. In this condition, the control outputs go to the pre-set power value (see Control Configuration – page 50).

PV Over-range or Under-range Indication

If a measured process input value is more than 5% above than the Scaled Input Upper Limit, its value is replace by the word “HIGH” to indicate that it is out of range.

If a measured process input value is more than 5% below than the Scaled Input Lower Limit, its value is replaced by the word “LOW” to indicate that it is out of range.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 31

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Auxiliary Input Over-range or Under-range Indication

If the auxiliary Remote Setpoint input is more than 5% above than the Auxiliary Input Upper Limit, its value is replaced by the word “HIGH” to indicate that it is out of range.

If the auxiliary Remote Setpoint input is more than 5% below than the Auxiliary Input Lower

Limit, its value is replace by the word “LOW” to indicate that it is out of range.

Cascade-Open

“Cascade Open” is shown on the main screen if the internal link has be severed between cascaded master and slave control loops. This mode should only be used for diagnostics and slave tuning. Close the cascade for proper operation. Refer to the Cascade Control section (page 78) for more information.

Profile Not Valid

If the user attempts to run a profile that would take the setpoint beyond the current setpoint limits, the profile will not run and the message “Profile Not Valid” is displayed at the bottom of the profile status screen.

USB Data Transfer Failure message

If the instrument cannot successfully write to the USB memory stick, the message “Data Transfer Failure” will be displayed. Check that there is adequate disk space on the memory

stick, then retry. If the instrument cannot successfully read data from the USB memory stick, the message

“Data Transfer Failure” will also appear. Check that this operation would not cause the

maximum number of profiles and/or segments to be exceeded then retry.

Getting Help

First Level Support

If the errors persist or other problems are encountered, refer your supplier for first level support. This includes help with configuration, tuning, servicing and replacement modules.

Second Level Support

If your supplier is unable to assist or cannot be contacted, check the Service & Product Information screen on the main menu for details of who to contact.

Third Level Support

If further assistance is required, contact the nearest company from those listed on the back page of this manual.

Servicing

If you need to return your instrument for servicing, contact your supplier or check the Service & Product Information screen on the main menu for instructions for its return.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 32

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Process Type*

Loop 1 / Master

Loop 2 / Slave

(only if 2nd input fitted)

Control Configuration: Control Select

Control Configuration: Control Type

Control Configuration: Control Select

Control Configuration: Control Type

One Loop*

Input 2 Configuration | Input 2 Usage = Not Used

Standard PID Control Select = Control Standard Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Valve Motor Drive Control Select = VMD (TPSC) Control

7 Application Setup

Before beginning configuration, consider how the controller will be used in your application. For instance, how many control loops are needed, is cascade or ratio control required, will the unit control a valve motor, do you need setpoint profiling etc. Consideration should also be given to the output types, alarms and tuning method.

This section is intended to help with this process, guiding you through the major configuration settings. Additional information can be found in the relevant sections of this manual, including the glossary, configuration menus, and dedicated sections for major features. These are listed in the table of contents.

Pre-commissioning Considerations

An easy Setup Wizard is available for basic applications (see page 43) where the most commonly required parameters are present for adjustment in turn. The wizard has a sub-set of the full configuration menu options. For more complex applications where the wizard is not sufficient, consideration must be given to the following fundamental questions:

If fitted, how will the 2nd input be used?

 One loop only (if the 2nd input not fitted or not used in this application)  Two independent control loops (see page 50).  Valve feedback for loop 1 (see page 85Error! Bookmark not defined.).  A “redundant” backup for the 1st input (see page 83).  Cascaded with the first control loop (see page 78).  A reference input for ratio control (see page 81).

How will the instrument physically control the process?

 Primary only or primary & secondary control outputs (see page 210).  Direct valve motor drive outputs (see page 84).

The table below shows the main input and control configuration settings for these application types (see page 45 for the configuration menus).

Pro-EC44 Product Manual - 59540-1 October 2013 Page 33

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Process Type*

Loop 1 / Master

Loop 2 / Slave

(only if 2nd input fitted)

Control Configuration: Control Select

Control Configuration: Control Type

Control Configuration: Control Select

Control Configuration: Control Type

Two Loops*

Input 2 Configuration | Input 2 Usage = Standard

Standard PID Control Select = Control Standard Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Valve Motor Drive Control Select = VMD (TPSC) Control

+Feedback*

Input 2 Configuration | Input 2 Usage = Feedback

Valve Motor Drive Control Select = VMD (TPSC) Control

Redundant*

Input 2 Configuration | Input 2 Usage = Redundant Input

Standard PID Control Select = Control Standard Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Valve Motor Drive Control Select = VMD (TPSC) Control

Cascade*

Input 2 Configuration | Input 2 Usage = Standard

AND Loop 1 / Master Configuration | Control Mode = Cascade

Standard PID Control Select = Control Standard Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Valve Motor Drive Control Select = VMD (TPSC) Control

Ratio*

Input 2 Configuration | Input 2 Usage = Standard

AND Loop 1 / Master Configuration | Control Mode = Ratio

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Which outputs will be used for control, and are alarms or event outputs needed?

 Output configuration (see page 56).  Alarms & Profile Events (see page Alarm Types207 & 225).

Pro-EC44 Product Manual - 59540-1 October 2013 Page 34

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Configuration & commissioning must be completed before

proceeding to Operation Mode. It is the responsibility of the installing engineer to ensure that the configuration is safe.

What are the sources for the setpoints?

 Local setpoint(s) only, or a remote setpoint input (see page 216 & 227).  Profile Control (see page 87).

Is Input re-configuration required?

 Analogue input calibration & scaling (see page 70).  Digital input functions (see page 75).

Which other features are to be used?

 Data Recorder (see page 97).  Serial Communications (see page 109).  USB Interface (see page 96).

Once you have an understanding of your application and how the controller will be used, continue on to the configuration and use section below.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 35

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Set all Configuration parameters as required before starting

normal operations. It is the responsibility of the installing engineer to ensure that the configuration is safe for the intended application.

8 Operation and Configuration Menus

This section contains information on all of the controller’s modes and the configuration menus.

Operation Mode

This is the mode used during normal operation of the instrument. It can be accessed from the Main Menu, and is the usual mode entered at power-up. The available displays are dependent upon the features/options fitted and the way in which it has been configured.

The Base screen is the usual screen displayed during operation. It provides “at a glance” information about the process. The Profile Status screen shows similar information when using profiles.

Subsequent screens allow the display and selection/adjustment* of the setpoints. From display configuration, a selection of other parameter screens can be made available for operator selection/adjustment*. These include: profile control; cascade open/close; auto/manual control; setpoint ramp rate; setpoint source; control enable; clear latched outputs; data recording & status trend views. Optional operator mode screens are marked ◘ in the screen lists. Some screens will persist until the user navigates away, others will ‘time-out’ back to the base screen. * If required, all Operation Mode parameters can be made read only (see Display Configuration on page 59Error! Bookmark not defined.). Otherwise parameters such as setpoints can be adjusted within their configured limits.

WARNING:

DURING NORMAL USE, THE USER MUST NOT REMOVE THE CONTROLLER FROM ITS HOUSING OR HAVE UNRESTRICTED ACCESS TO THE REAR TERMINALS, AS THIS WOULD PROVIDE POTENTIAL CONTACT WITH HAZARDOUS LIVE PARTS.

Navigating and Adjusting Values in Operator Mode

Press R to move forward or L to move backwards through the available screens. When a displayed value can be adjusted, use D or U to change its value.

The next/previous screen follows the last parameter. If no further changes are needed, hold down R or L for >1sec to skip straight to the next/previous screen accepting

ALL values shown. In Trend Views, pressing D or U moves the cursor line back and forward through the

last 240 data points.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 36

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

OPERATION MODE SCREEN SEQUENCE

All possible screens are listed below. The sequence shown depends on the configuration and status. E.g. settings for “Loop 2” only apply if 2nd input is fitted and configured for 2-loop control.

◘ Some screens are only shown if set to do so in Display Configuration.

After 2 minutes without key activity, the most screens revert to the Base Operating Screen. Screens marked  do not revert automatically. They remain displayed until the user navigates away.

Calibration Check Due Warning

If a Calibration Reminder is set and the due date has passed this will be shown at every power up, and repeated once per day. Press R to acknowledge and continue using the instrument temporarily

without recalibration. Change the due date or disable the reminder to cancel the warning. This feature is only possible if the recorder is fitted. It is enabled in Input Configuration.

 Single Control Loop: Normal Operation

LED Indicators

LED Function Labels

Process Variable Value

Effective Actual Setpoint

Value

Engineering Units

Control Deviation Graph

(scaled ±5% of input span)

Power Graph (0-100% primary, ±100% primary & secondary)

1-LOOP OPERATION

Default LED indicator functions are PRI, SEC, TUNE & ALARM - the functions and their labels can be altered only with the PC configuration software.

In valve motor drive mode, the power bar-graph is replaced by valve Open / Stop / Close unless the 2nd input is used for position feedback, where it shows 0 to 100% valve position. In manual mode the effective setpoint is replaced by the %Manual Power and the label “MAN”. In manual mode with valve motor drive the setpoint is replaced by valve Open / Stop / Close. If control is disabled the effective setpoint value is replaced by “OFF”.

 Two Control Loops: Normal Operation

LED Indicators

LED Function Labels

Process Variable* & Actual

Setpoint Values*

Indicators for Alarm and Remote Setpoint active*

Loop Description*

Control Deviation (±5% of span) & Power Graphs*

Engineering Units*

* = in loop 1 & 2 screen area

2-LOOP OPERATION

Default LED indicator functions are PRI 1, PRI 2, TUNE & ALARM - the functions and their labels can be altered only with the PC configuration software.

In valve motor drive mode, the power bar-graph is replaced by valve Open / Stop / Close. In manual mode the effective setpoints are replaced by the %Manual Power and the label “MAN”. In manual mode with valve motor drive the setpoint is replaced by valve Open / Stop / Close. If control is disabled the effective setpoint value of that loop is replaced by “OFF”.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 37

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 Cascade Control: Normal Operation

LED Indicators

LED Function Labels

Cascade Status

Master Process Value

Slave Process Value

Master Setpoint (Slave SP if

Cascade Open) Control Deviation (±5% of span) & Power Graphs

CASCADE CONTROL

Default LED indicator functions are PRI, SEC, TUNE & ALARM - the functions and their labels can be altered only with the PC configuration software.

Cascade Status shows “Cascade” when cascade is operating normally and “Cascade Open” when the master / slave link has been disconnected. Master & Slave Process Values. In valve motor drive mode, the power bar-graph is replaced by valve Open / Stop / Close. In manual mode the slave setpoint is replaced by the %Manual Power and the label “MAN”. In manual mode with valve motor drive the slave setpoint is replaced by valve Open / Stop / Close. If control is disabled the effective master setpoint value is replaced by “OFF”.

 Ratio Control: Normal Operation

LED Indicators

LED Function Labels

Relative Process Value

Ratio & Setpoint Labels

Relative Setpoint

Control Deviation (±5% of span) & Power Graphs

RATIO CONTROL

Default LED indicator functions are PRI, SEC, TUNE & ALARM - the functions and their labels can be altered only with the PC configuration software.

In manual mode the ratio setpoint value is replaced by the %Manual Power and the label “MAN”. If control is disabled the effective setpoint value is replaced by “OFF”.

Operator Profile Control

Allows the operator to control the defined profiles. If a profile is running, the choices are: Do Nothing; Abort Profile (end immediately); Jump to Next Segment; Hold Profile or Release Hold. If no profile is running, the choices are: Do Nothing; Run Profile; End Profile Control (returns to standard controller operation) or Select Profile.

◘ only shown if set to do so in Display Configuration.

 Single Control Loop: Profiler Status

LED Indicators

LED Function Labels

Process Value & Setpoint

Engineering Units

Profile Name & Progress

Segment No, Type &

Progress (or Delayed Start

Time)

Profile Status Indicator: ► Run, ▌▌ Held, ■ Stopped

1-LOOP PROFILE STATUS

Default LED indicator functions are as shown in the initial base screen. In manual mode the effective setpoint is replaced by the %Manual Power and the label “MAN”. In manual mode with valve motor drive the setpoint is replaced by valve Open / Stop / Close. If control is disabled the effective setpoint value is replaced by “OFF”.

Note: If power is lost when a profile is running and recovery is set to continue, the bar-graph re-starts from the beginning but the overall time remains correct.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 38

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 Two Control Loops: Profiler Status

LED Indicators

LED Function Labels

Engineering Units*

Profile Status Indicators*:

► Run, ▌▌ Held, ■

Stopped

Process Variable Values & Setpoints*

Loop Descriptions*

Profile Name & Progress Segment No. Type & Progress (or Delayed Start Time)

* = in loop 1 & 2 screen area

2-LOOP PROFILE STATUS

Default LED indicator functions are as shown in the initial base screen. In manual mode the effective setpoints are replaced by the %Manual Power and the label “MAN”. In manual mode with valve motor drive the setpoints are replaced by valve Open / Stop / Close.

Note: If power is lost when a profile is running and recovery is set to continue, the bar-graph re-starts from the beginning but the overall time remains correct.

Event Status

Lists all configured profile events with their current status (Active or Inactive) – Shown only when the instrument is in profiler mode.

Cascade Mode

Allows the user to open the cascade, breaking the master-slave link for commissioning & tuning.

CAUTION: Return to Cascade-CLOSE when finished!

◘ only shown if set to do so in Display Configuration.

Auto/Manual Control Selection – Loop 1 (or Cascade Slave)

Switches loop 1 (or the cascade slave loop) between automatic and manual control modes. Switching between these modes uses “Bumpless Transfer”.

◘ only shown if set to do so in Display Configuration.

When using standard PID control, Manual mode replaces the Setpoint display with a -100 to 100% power output level value, labelled “Man”.

The D or U keys are used to adjust the manual power value.

When using VMD control, Manual mode replaces the Setpoint display with the valve movement status (Opening, Closing or Stopped), labelled “Man”.

The D key opens the valve and the U key closes the valve. If Manual control is selected when in Cascade mode, the slave loops % power

value shown. This is the power output fed directly to the control actuator (e.g. power to the heater elements).

CAUTION: Manual mode overrides the automatic control loop. It also

ignores any output power limits, valve open/close limits and the control enable/disable setting. The operator is responsible for maintaining the process within safe limits.

Note: In Manual mode a running profile will hold until automatic

control is reselected.

Setpoint Value Display & Adjustment – Loop 1

View and adjust the main and alternate setpoints for loop 1 (or the master loop in cascade mode). The setpoints can be set to any value within the setpoint limits set in Control Configuration. View and adjust local (internal) setpoints for the loop. The currently selected setpoint is marked as “active”. If the alternate setpoint is remote it cannot be adjusted from the keypad.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 39

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Setpoint Ramp Rate – Loop 1

The setpoint ramp rate adjustment for loop 1. Adjustable between 0.1 and

9999.0 display units per hour. When set to “OFF”, setpoint changes will step immediately to the new value - ◘ only shown if set to do so in Display.

Note: If the setpoint ramp feature is used, it disables pre-tune completely, and if self-tune is used, it will only calculate new terms after the ramp has completed and the setpoint is constant.

Select Active Setpoint – Loop 1

Select if the main or alternate setpoint is to be the “active” setpoint for loop 1 (or the master loop in cascade mode). ◘ only shown if set to do so in Display.

Control Enable – Loop 1

Enables or disables loop 1 control outputs. When disabled, the primary and secondary control outputs of loop 1 are set to zero 0% (unless manual mode has been selected) and the setpoint value is replaced by “OFF”.

◘ only shown if set to do so in Display.

CAUTION: The instrument cannot control the process when disabled.

Auto/Manual Control Selection – Loop 2

Switches loop 2 between automatic and manual control modes. Switching between these modes uses “Bumpless Transfer”.

◘ only shown if set to do so in Display Configuration.

When using standard PID control, Manual mode replaces the Setpoint display with a -100 to 100% power output level value, labelled “Man”.

The D or U keys are used to adjust the manual power value.

When using VMD control, Manual mode replaces the Setpoint display with the valve movement status (Opening, Closing or Stopped), labelled “Man”.

The D key opens the valve and the U key closes the valve.

CAUTION: Manual mode overrides the automatic control loop. It also

ignores any output power limits, valve open/close limits and the control enable/disable setting. The operator is responsible for maintaining the process within safe limits.

Note: In manual mode a running profile will hold if it is controlling

the setpoint of loop 2, until automatic control is reselected.

Setpoint Value Display & Adjustment – Loop 2

View and adjust the main and alternate setpoints for loop 2. The setpoints can be set to any value within the setpoint limits set in Control Configuration. View and adjust local (internal) setpoints for the loop. The currently selected setpoint is marked as “active”. If the alternate setpoint is remote it cannot be adjusted from the keypad.

Setpoint Ramp Rate – Loop 2

The setpoint ramp rate adjustment for loop 2. Adjustable between 0.1 and

9999.0 display units per hour. When set to “OFF”, setpoint changes will step immediately to the new value - ◘ only shown if set to do so in Display.

Note: If the setpoint ramp feature is used, it disables pre-tune completely, and if self-tune is used, it will only calculate new terms after the ramp has completed and the setpoint is constant.

Select Active Setpoint – Loop 2

Select if the main or alternate setpoint is to be the “active” setpoint for loop 2

(or the master loop in cascade mode). ◘ only shown if set to do so in Display.

Control Enable – Loop 2

Enables or disables loop 2 control outputs. When disabled, the primary and secondary control outputs of loop 2 are set to zero 0% (unless manual mode has been selected) and the setpoint value is replaced by “OFF”.

◘ only shown if set to do so in Display Configuration.

CAUTION: The instrument cannot control the process when disabled.

Alarm Status

Lists the status of the alarms. Shown if any of the 7 alarms is active.

The titles “Alarm n” can be replaced with the PC configuration software to a user defined 8 character name for each alarm.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 40

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Clear Latched Outputs

Hold down D or U for 3 seconds to clear the selected latched output – An output will only reset if the condition that caused it to latch on is no-longer present. ◘ only shown if set to do so in Display Configuration.

Recorder Memory Full Warning

Indicates that the Data Recorder memory is full and that recording has either stopped or is overwriting older data if in FIFO recording mode.

Manual Recording Trigger

Set the manual recording trigger on or off.

◘ only shown if set to do so in Display Configuration.

Note: Setting the manual trigger to off may not stop the recording. Data recording will still take place if another recording trigger is active.

Recorder Status Information

Shows the recording status (“Stopped” or “Recording”); icons for any active recording triggers; the recording mode (FIFO or Record Until Memory Is Used); the approximate recording time remaining* and a memory usage bargraph. In FIFO mode, the time remaining is replaced with “FIFO” when full. *If the status of alarms is recorded, extra samples are taken when the alarms

change state reducing the available recording time. Take this into account when determining if there is sufficient memory available.

Icons for Active Recorder Triggers

Manual

Record ON

Digital Input

Record ON

Profile

Record ON

Alarm

Record ON

 Trend Views: One per Control Loop

Active Alarm(s)

Trend Upper Scale Value

Cursor Line

Process Variable Trend

PV Value At Cursor Line

Setpoint Trend (dotted)

Trend Lower Scale Value

Loop No, & Time Markers

(10 samples per marker)

Sample Interval (or time at cursor line) TREND VIEW

Trend views can be shown of each loop. They are auto-scaling graphs with alarm indication and other process information. The trend can be set to show the process variable only; the process variable & setpoint (dotted line), or the minimum and maximum value of the process variable measured since the last sample. Any active alarm(s) are indicated above the graph. Graph types and data sample intervals 1 sec to 30 mins) are set in Display Configuration. Trend scale values adjust automatically to visible data (between 2 to 100% of the input span).

120 data points are visible. Pressing D or U moves the cursor line back through the graph to examine up to 240 data points. The process variable value of that data point is shown to the right of the cursor line and the sample rate value is replaced by the time represented by the cursor position.

◘ only shown if set to do so in Display Configuration.

Note: Trend data is not retained at power down or if the sample interval is changed.

- Custom Display Screens

You can copy up to 50 configuration menu parameters into normal operation mode using the PC software. These extended operator mode screens appear at the end of the normal sequence. If the parameter is normally displayed on screen with another parameter, both parameters will appear.

Note: In this mode screens are not pass-code protected, they can be freely adjust. It is possible to make operation mode “read only”, including any custom screens from Display Configuration.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 41

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

MAIN MENU OPTIONS

Operation Mode

The normal operation screens, displaying the process and setpoint values; selection/adjustment of the setpoints; auto/manual control; alarm/event status; trend views; data recorder and profile information.

Setup Wizard



An easy, step-by-step parameter setup for simple applications.

Supervisor Mode



If configured from the PC software, a sub-set of up to 50 Configuration screens can be accessed.

Configuration Menu



Accesses the sub-menus for Inputs; Control Loops; Outputs; Alarms; Communications; Recorder; Clock; Display and Lock Codes. There is an option to Reset to Defaults wiping all user settings from the instrument.

Automatic Tuning



Selection of Pre-tune, Self-tune and Auto Pre-tune for the control loops.

USB Menu



Uploading/downloading instrument configuration, profile information and data recordings.

Recorder Control



Manually starting, stopping and deleting recordings.

Profile Setup



Setting global parameters for all profiles; plus profile creation, editing and deletion.

Profile Control



Selection of profiles. Running, holding or aborting the selected profile.

Service & Product Information

Contact information for service/support, followed by instrument information, including features and plug-in modules installed, serial number, firmware version etc.

Main Menu

This menu is used to access the various features and configuration settings. The available menus are dependent upon the features and options fitted and how it has been configured.

Entry into the Main Menu

Holding down Rand pressing U from Operation Mode and most other screens will cause the unit to enter the Main Menu. Each time this key press sequence is made, the instrument moves to the next menu level above. Sub-menu levels will require this sequence to be pressed more than once in order to reach the Main Menu.

Navigating the Main Menu

Once in the Main Menu, press D or U to select the required option Press R to enter the chosen menu.

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Unlock Codes

To prevent unauthorised entry, most menus require a pass-code (1 to 9999) to gain entry. These menus are indicated by the symbol. The codes can be viewed and changed from the Lock Code Configuration sub-menu of Configuration Mode. The factory default unlock code is 10 for all modes but for security, these should be changed to new values. If the Configuration Mode lock code is lost, refer to Lost Lock Codes on page 69.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 42

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Resetting defaults all parameters, not just those covered by the

quick setup wizard. For more complex applications the user may have to reconfigure other Configuration Menu settings before using the instrument.

 SETUP WIZARD SCREENS

Setup Wizard Unlocking

Enter correct code number to access Setup Wizard. Factory Default value is 10.

- key screens from Configuration Menu (those marked w)

Press R to select each major configuration parameter in turn. Follow onscreen prompts to alter the values.

Setup Wizard Completed

Confirms completion of the Setup Wizard. Exits to Operation Mode.

Note: With the exception of the first ever power-up, entry into this mode is security-protected by the Setup Wizard Lock Code. Refer to the Lock Code Configuration sub-menu.

Setup Wizard

An easy Setup Wizard runs automatically at first ever power-up. Follow the Wizard to setup parameters required for basic applications. The parameters covered by the Setup Wizard are marked with a w in the following sections covering the configuration mode sub-menus. Once completed, the Setup Wizard exits to Operation Mode.

The Wizard can be run again at any time from the Main Menu. An option to reset all parameters to default (recommended) is offered when manually running the wizard.

Experts or users with more complex applications can select the parameters they wish to setup directly from the Configuration Menus bypassing the Wizard.

Manual entry to the Setup Wizard

To select the Setup Wizard from the Main Menu.

Hold down Rand press U to enter the Main Menu. Press D or U to select Setup Wizard.

Press R to enter the Setup Wizard.

Navigating in the Setup Wizard

Press R to move forward, or L to move backwards through the screens. Press D or U to change the value as required.

Holding down R or L for more than 1 second skips immediately to the next/previous screen accepting ALL values as shown.

Hold down R and press U to return to the Main Menu

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 43

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Adjustments to these parameters should only be performed by

personnel competent and authorised to do so.

 SUPERVISOR MODE SCREENS

Supervisor Mode Unlocking

If Supervisor Mode is configured, enter correct code number to continue. Factory Default value is 10.

- Supervisor Mode Screens …

Press R to select each selected parameter in turn. Follow on-screen prompts to alter the values.

Note: Entry into this mode is security-protected by the Supervisor Mode Lock Code. Refer to the Lock Code Configuration sub-menu.

Supervisor Mode

This mode is only available if it has been configured from the PC software. Its purpose is to allow selected operators access to a lock-code protected sub-set of the configuration parameters, without providing them with the higher level configuration menu unlock code.

The PC software can copy up to 50 parameters from configuration menus for inclusion in the supervisor mode screen sequence. If the parameter is normally displayed on screen with another parameter, both parameters will appear. It is not possible to configure supervisor mode screens without using the software.

Entry into Supervisor Mode

Supervisor Mode is entered from the Main Menu

Hold down Rand press U to enter the Main Menu. Press D or U to select Supervisor Mode

Press R to enter the Supervisor Mode.

Navigating in Supervisor Mode

Press R to move forward, or L to move backwards through the screens. Press D or U to change the value as required.

The next/previous screen follows the last parameter. If no further changes are required, hold down R or L >1sec to skip straight to next/previous screen accepting

ALL values shown. Hold down Rand press U to return to the Main Menu

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 44

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Adjustments to these parameters should only be performed by

personnel competent and authorised to do so.

Note: Entry into this mode is security-protected by the Configuration Menu

Lock Code. Refer to the Unlock Code section for more details.

Configuration Menu

This menu can be used as an alternative to the more limited Setup Wizard when the instrument is configured for the first time in more complex applications, or when further changes are required to the instruments settings. The configuration menu contains a number of sub-menus that allow access to all of the available parameters. The correct settings must be made before attempting to use the instrument in an application. Screens marked w are also shown in the Setup Wizard.

Entry into the Configuration Menu

Configuration is entered from the Main Menu

Hold down Rand press U to enter the Main Menu. Press D or U to select Configuration Menu

Press R to enter the Configuration Menu.

Navigating the Configuration Menu

Configuration contains sub-menus to set-up the Inputs; Control; Outputs; Alarms; Communications; Recorder; Clock; Display and Lock Codes. There is also an option to reset the instrument to its factory default settings. The Input and Control sub-menus contain further sub-menus with configuration and calibration settings for each process input; control loops 1 & 2 and the digital inputs. Only parameters that are applicable to the hardware and options fitted will be displayed.

From the Configuration Menu, press D or U to select the required sub-menu. Press R to enter the sub-menu. If required, press D or U to select the next level sub-menu, then press R to enter. Hold down Rand press U to return to next higher menu level.

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 45

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 CONFIGURATION MENU SCREENS:

Configuration Mode Unlocking

Enter correct code number to access Configuration Mode. Factory Default value is 10.

Configuration Options

Select the required Configuration Sub-Menu Option from: Inputs; Control; Outputs; Alarm; Communications; Recorder; Clock; Display; Lock Code or Reset To Defaults.

INPUT CONFIGURATION SUB-MENU SCREENS

Input 1 Setup - Sub-menu to setup Input 1. Press D + R to return to Input Menu

Input Type

Select from various Thermocouple, RTD and Linear mA, mV or VDC inputs. - see specifications section on page 245, for available input types.

Note: Recheck the units and decimal point settings if you change the input type.

Engineering Units

Select display units from: °C; °F; °K; bar; %; %RH; pH; psi or none. Temperature sensor inputs are limited to °C; °F

Decimal Point Position

Sets the maximum display resolution to 0; 1; 2 or 3 decimal places. Numbers >99.999 never display more than 2 dec places, >999.99 never display more than 1 dec place and >99999 always display without a decimal place. Temperature inputs are limited to 0 or 1 decimal place.

Scaled Input Lower Limit

For temperature inputs, upper & lower limits set the usable span. The minimum span = 100 units, maximum span = range limits for the sensor type selected - see specs on page 245. For DC linear inputs, the limits define the values shown (-9999 to 9999.9) when input is at minimum and maximum values. Min span = 100 units.

Scaled Input Upper Limit

Multi-Point Scaling Enable

Enables or disables multi-point scaling. This allows up to 15 point input linearization for DC signals - not possible with temperature sensor inputs

Scaling Point n

If multi-point scaling is enabled, up to 15 breakpoints* can scale input vs. displayed values between the scaled input limits. Each breakpoint has a % value for the input signal, and the value to display when the input is at that value. *A Scaling Point set to 100% input ends the scaling sequence.

Display Value n

CJC Enable/Disable

Enables/disables internal thermocouple Cold Junction Compensation. If disabled, external compensation will be required for thermocouples. The default value is Enabled.

Input Filter Time

Removes unwanted signal noise. Adjustable from 0.1 to 100.0 seconds or OFF (default = 2s). Use the smallest value that gives acceptable results.

Caution: Large values slow the response to changes in the process.

Input 1 Calibration - Sub-menu to calibrate Input 1. Press D + R to return to Input Menu

Calibration Type

Select the calibration type from base; single or 2-point calibration. Select single to apply a calibration offset across the entire measured range. Use 2-point to enter calibration offsets at both low and high points of the usable range – refer to the User Calibration details on page 70.

Caution: The default is Base Calibration. For single or 2-point

calibration, the user must enter values to adjust the displayed value to match a known standard or accurate external reading.

Calibration Offset

The single point calibration offset. Limited by the input span, +Ve values add to, –Ve values subtract from, the measured input across entire range.

Calibration Low Value

The displayed value for the 1st (low) adjustment of 2-point calibration. Choose a value close to the lowest level used in the application.

Calibration Low Offset

The adjustment value for the 1st (low) point when using 2-point calibration. +Ve values add to, –Ve values subtract from measured input at this point.

Calibration High Value

The displayed value for the 2nd (high) adjustment of 2 point calibration. Choose a value close to the highest level used in the application.

Calibration High Offset

The adjustment value for the 2nd (high) point when using 2-point calibration. +Ve values add to, –Ve values subtract from measured input at this point.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 46

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Input 2 Setup - Sub-menu to setup Input 2. Press D + R to return to Input Menu

Input 2 Usage

Input 2 can be used as a standard process input for a second control loop (including its use as part of a cascade), a redundant input or a feedback signal input from a valve or flow meter. Redundant or Feedback disables the input as an independent control loop.

Input Type

If input 2 is selected as a standard process input, select from various Thermocouple, RTD and Linear mA, mV or VDC inputs. - see specifications

section on page 245, for available input types.

If input 2 is selected as feedback possible types are limited to Linear mA, mV, VDC or Potentiometer. Redundant inputs automatically assume the same input type as input 1.

Note: Recheck the units and decimal point settings if you change the input type.

Engineering Units

Select display units from: °C; °F; °K; bar; %; %RH; pH; psi or none. Temperature sensor inputs are limited to °C; °F

Decimal Point Position

Scaled Input Lower Limit

Scaled Input Upper Limit

Multi-Point Scaling Enable

Enables or disables multi-point scaling. This allows up to 15 point input linearization for DC signals - not possible with temperature sensor inputs

Scaling Point n

Display Value n

CJC Enable/Disable

Enables/disables internal thermocouple Cold Junction Compensation. If disabled, external compensation will be required for thermocouples. The default value is Enabled.

Input Filter Time

Removes unwanted signal noise. Adjustable from 0.1 to 100.0 seconds or OFF (default = 2s). Use the smallest value that gives acceptable results.

Caution: Large values slow the response to changes in the process.

Set Valve Lower Position

If input 2 is selected as feedback indication, this stores the feedback value equal to the minimum valve travel. The procedure below moves the valve to the fully closed position to find the feedback value:

Press D and U simultaneously to begin feedback limit adjustment. Press D until the valve is closed to its limit of its travel. Press D and U simultaneously to store the feedback level.

Set Valve Upper Position

If input 2 is selected as feedback indication, this stores the feedback value equal to the maximum valve travel. The procedure below moves the valve to the fully open position to find the feedback value:

Press D and U simultaneously to begin feedback limit adjustment. Press U until the valve is opened to its limit of its travel. Press D and U simultaneously to store the feedback level.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 47

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Input 2 Calibration - Sub-menu to calibrate Input 2. Press D + R to return to Input Menu

Calibration Type

If input 2 is selected as a standard process input, the user can select the calibration type from base; single or 2-point calibration. Select single to apply a calibration offset across the entire measured range. Use 2-point to enter calibration offsets at both low and high points of the usable range – refer to the User Calibration details on page 70.

Caution: The default is Base Calibration. For single or 2-point

calibration, the user must enter values to adjust the displayed value to match a known standard or accurate external reading.

Calibration Offset

The single point calibration offset. Limited by the input span, +Ve values add to, –Ve values subtract from measured input across the range.

Calibration Low Value

The displayed value for the 1st (low) adjustment of 2-point calibration. Choose a value close to the lowest level used in the application.

Calibration Low Offset

The adjustment value for the 1st (low) point when using 2-point calibration. +Ve values add to, –Ve values subtract from measured input at this point.

Calibration High Value

The displayed value for the 2nd (high) adjustment of 2 point calibration. Choose a value close to the highest level used in the application.

Calibration High Offset

The adjustment value for the 2nd (high) point when using 2-point calibration. +Ve values add to, –Ve values subtract from measured input at this point.

Calibration Reminder - Calibration reminder Sub-menu. Press D + R to return to Input Menu

Calibration Reminder Enable/Disable

Enables/disables the Calibration Reminder shown at start-up (and daily thereafter), if the due date has passed - Recorder version only

Calibration Reminder Date

Sets the due date for Calibration Reminder - Recorder version only

Auxiliary Input A Setup - Sub-menu to setup auxiliary A input. Press D + R to return to Input Menu

Auxiliary Input A Type

The analogue input type/range to be applied to auxiliary input A. Select the type from 0-20 or 4-20mA; 0-5, 1-5, 0-10 or 2-10VDC.

Aux A Input Lower Limit

These scale values relate to when auxiliary input A is at the range minimum & maximum values. They are adjustable between ±0.001 & ±10000. When auxiliary input A provides a remote setpoint, the scaled input becomes the effective setpoint (although always constrained within setpoint limits).

Caution: Take care to scale correctly especially if being used as the

remote setpoint source for both loops.

Aux A Input Upper Limit

Auxiliary Input A Offset

An offset applied to the scaled auxiliary input A value. Adjustable, from +/-

0.001 to 20000 units or OFF, with. +Ve values add, –Ve values subtracted. Useful in multi-zone setpoint slave applications. Default = OFF.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 48

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Digital Input Setup - Sub-menu to setup the Digital Inputs. Press D + R to return to Input Menu

Digital Input Status

A diagnostic status ( = OFF,  = ON, Ø = not available) for digital inputs A; C1 to C8 and “Soft “digital inputs S1 to S4. If used for profile selection, it also shows bit pattern type (binary or BCD) and selected profile number.

Tick Digital Inputs To Invert

Select digitals input with  to invert their operation (making them appear OFF when their actual state is ON). Inputs shown as Ø are not available.

Profile Selection Type

Select the bit pattern to be used for profile selection. Binary or BCD (Binary Coded Decimal). Select None if profile selection not is required.

Choose Profile Selection

For profiler versions, the Multi-Digital Input option can be used to select the profile to run with a standard binary bit pattern or binary coded decimal from BCD switches. C1 is the least significant bit (LSB) of the bit pattern. Profiles are numbered from 0 to 63. Use the table to choose inputs C1 to Cn for the number of profiles to select:

C1 to C2

C1 to C3

C1 to C4

C1 to C5

C1 to C6

C1 to C7

Binary

0 to 1

0 to 3

0 to 7

0 to 15

0 to 31

0 to 63

BCD

0 to 1

0 to 3

0 to 7

0 to 9

0 to 19

0 to 39

0 to 63

Any inputs chosen for profile selection are not available for other uses. – refer to the Digital Inputs on page 75.

Configure Digital Inputs

Select any available digital input or soft digital input to be configured for use. The current status of each is shown as Assigned or Unused.

Soft Digital Input n Digital Input Logic

Set up a “Soft” digital input n that is the result of the Boolean AND selections of physical inputs, globally OR’d with the OR selections.

Press U or D to select  / deselect  the options. Inputs shown as Ø are not available – refer to the Digital Inputs on page 75.

Soft Digital Input n Alarm-Event

Further set up of “Soft” digital input n that adds the Boolean OR of Alarms & Events to the physical digital inputs already selected.

Press U or D to select  / deselect  the options. Inputs shown as Ø are not available – refer to the Digital Inputs on page 75.

Digital Input n Function

Select the function to be operated from digital input n. – The possible functions are: Loop 1 or 2 Setpoint Select; Loop 1 or 2 Auto/Manual Select; Loop 1 or 2 Control Select; Loop 1 or 2 Pre-Tune Select; Loop 1 or 2 Self-Tune Select Clear All Latched Outputs; Output n Clear Latch; Output n Forcing On or Off; Profile Run/Hold; Profile Hold Segment Release; Profile Abort; Data

Recorder Trigger or Key n Mimic (replicating pressing L D U or R).

Pro-EC44 Product Manual - 59540-1 October 2013 Page 49

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CONTROL CONFIGURATION SUB-MENU SCREENS

Control Loop 1 - Sub-menu to setup Control Loop 1. Press D + R to return to Input Menu

These settings apply to the master loop if the controller has been setup for cascade control.

Control Mode

Select the fundamental application type, from: Standard; Cascade or Ratio.

Refer to the Application Setup section on page 33.

Note: Choosing Cascade or Ratio disables the use of the 2nd input as a fully independent control loop.

Cascade Mode

Opens or closes the cascade link. Cascade-Open breaks the master-slave connection. This allows slave loop to be tuned & adjusted independently.

Caution: Return to Cascade when finished!

Control Select

Select from Control Standard or Control VMD (TPSC). Use Control VMD to directly drive the windings of a motorised valve. This uses a 3-point stepping algorithm giving “open” and “close” outputs. Use Standard for all other applications (including solenoid valves or modulating valves with positioning circuitry requiring mA or VDC signals).

Control Enable/Disable

Used to temporarily disable the control outputs. Select control Enabled (normal) or Disabled – when disabled, control output(s) for this loop are turned off (unless manual mode has been selected), and the setpoint value is replaced by “OFF”.

Caution: The instrument is not able to control the process when

control is disabled and the Output Power Limits are ignored.

Auto/Manual Control Selection

Switches the control loop between Automatic and Manual Control. The operator monitors and alters power to correctly control the process (0 to 100% or -100 to +100% for dual control).

Caution: Manual mode overrides the automatic control loop. It also

ignores any output power limits, valve open/close limits and the control enable/disable setting. The operator is responsible for maintaining the process within safe limits.

Control Type

Select Single Control for primary control only (e.g. heating only or cooling only) or Dual for primary and secondary control outputs (e.g. heating and cooling) - Dual is not possible with Ratio or VMD Control.

Primary Control Action

Set the primary control output for Reverse or Direct Action. Reverse action applies additional primary power as the process falls further below setpoint (e.g. heating applications). Direct action applies additional primary power as the process rises higher above setpoint (e.g. cooling applications). In dual control, secondary output action is opposite to primary action.

Control Status

A “read-only” diagnostic status display of the current loop 1 process variable and effective setpoint values to assist with manual tuning.

Power Output Levels

A “read-only” diagnostic status display of the current loop 1 primary and secondary % output power levels to assist with manual tuning – Not shown with VMD Control. Does not apply if control is disabled or in manual mode.

Gain Schedule PID Set in use

A “read-only” diagnostic status display showing the PID set in use. The set used may vary based on the current setpoint or process variable value. – Only shown if Gain Scheduling is in use.

PID Set Selection

Choose to use one of five PID Sets; or choose Gain Schedule on SP or PV. – This selects a fixed PID set to be “Active”; or automatically switch sets based changes in SP or PV values.

Set n – Primary Pb

The primary proportional band for PID Set n (n = up to 5). Set as On-Off control, or a proportional band from 1 to 9999 display units – Only the set(s) in use are shown.

Set n – Secondary Pb

The secondary proportional band for PID Set n (n = up to 5) if dual control is used. Set as On-Off control, or a proportional band from 1 to 9999 display units – Only the set(s) in use are shown.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 50

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Set n – Integral

The integral time value (Automatic Reset) for PID Set n (n = up to 5). Adjustable from 1s to 99min 59s or OFF – Only the set(s) in use shown.

Set n – Derivative

The derivative time value (Rate) for PID Set n (n = up to 5). Adjustable from 1s to 99 min 59s or OFF – Only the set(s) in use are shown.

Set n – Overlap

The overlap (+ve) or deadband (-ve) between primary & secondary proportional bands for PID Set n (n = up to 5). In display units - limited to 20% of the combined primary & secondary prop band width.

Set n – On/Off Diff

The on-off control hysteresis (deadband) for PID Set n (n = up to 5). Adjustable from 1 to 300 display units, centred about the setpoint – Only the set(s) in use are shown.

Set n - Breakpoint

The SP or PV value where the PID Set n (n = up to 5) if gain scheduling is used. Set 1 is used from Scaled Input Lower Limit to the Set 2 Breakpoint, then Set 2 used to the Set 3 Breakpoint etc. If a breakpoint is set to OFF subsequent PID sets are not used. The final PID set runs to the Scaled Input Upper Limit.

Manual Reset (Bias)

The Manual Reset value to bias the control working point within the proportional band(s). Adjustable from 0 to 100% for single control or 100 to +100% for dual control. Typically set to 80% of typical power needed for setpoint, but lower values can help inhibit start-up overshoot.

Anti Wind-Up Limit

Adjusts the value at which the “reset wind-up inhibit” is applied. Above this power level further integral action is suspended. Adjustable from 10 to 100% of PID power. Lower values inhibit overshoot.

Caution: If set too low control deviation can occur (the process

settles, but is offset above or below the setpoint). It this is observed, increase the value until the deviation error is removed.

Ratio SFAC

The nominal ratio scaling factor used for Stoichiometric Ratio Control in burner fuel/air control applications. Adjustable from 0.010 to 99.999.

– refer to the Ratio Control section on page 81Error! Bookmark not defined.

Ratio NO

A constant between 0.0 & 9999.0, added to the x1 (input 1) value in Stoichiometric Ratio Control mode to allow for atomizing air when calculating the process value. The total air flow is therefore x1 + NO.

Primary Cycle Time

The primary power cycle time. Adjustable from 0.5 to 512 seconds. Applied for time proportioned primary relay, SSR driver or triac control outputs – Not used for VMD Control modes.

Secondary Cycle Time

The secondary power cycle time when dual control is used. Adjustable from 0.5 to 512 seconds. Applied for time proportioned primary relay, SSR driver or triac control outputs – Not used for VMD Control modes.

Primary Power Lower Limit

The minimum primary output power limit. The control algorithm will not allow the power output fall below this level. Adjustable from 0 to 90% but is always at least 10% below the primary power upper limit.

Caution: The instrument will not be able to control the process

correctly if the lower limit is above the level required to maintain setpoint.

Primary Power Upper Limit

The maximum primary output power limit. The control algorithm will not allow the power output rise above this level. Adjustable from 10 to 100% but is always at least 10% above the primary power lower limit.

Caution: The instrument will not be able to control the process

correctly if the upper limit is below the level required to maintain setpoint.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 51

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Secondary Power Lower Limit

The minimum secondary output power limit. The control algorithm will not allow the power output fall below this level. Adjustable from 0 to 90% but is always at least 10% below the secondary power upper limit.

Caution: The instrument will not be able to control the process

correctly if the lower limit is above the level required to maintain setpoint.

Secondary Power Upper Limit

The maximum secondary output power limit. The control algorithm will not allow the power output rise above this level. Adjustable from 10 to 100% but is always at least 10% above the secondary power lower limit.

Caution: The instrument will not be able to control the process

correctly if the upper limit is below the level required to maintain setpoint.

Sensor Break Pre-set Power Output

Set the power level to be applied if the process input signal or an active remote setpoint input is lost. Adjustable from 0 to 100% for single control or

-100 to +100% for dual control. The default value is OFF (0% power). Does not apply if control is disabled or in manual mode.

Caution: Ensure the value set will maintain safe process conditions.

Motor Travel Time

The motor travel time (valve movement time from fully open to fully closed in mm:ss). Adjustable from 5s to 5 mins - In VMD Control Mode only.

Minimum Motor On Time

The minimum drive effort (in seconds) to begin moving the motorised valve in VMD Control Mode. Adjustable from 0.02 to





of the Motor Travel Time.

Valve Open Limit

The maximum position the controller will attempt to drive the valve to in VMD Control Mode. Adjustable from the valve close limit+1% to 100.0% (fully open) - Only possible if the 2nd input is used for valve feedback.

Valve Close Limit

The minimum position the controller will attempt to drive the valve to in VMD Control Mode. Adjustable from 0.0% (fully closed) to the valve open limit-1% - Only possible if the 2nd input is used for valve feedback.

Valve Sensor Break Action

The direction to drive the valve if the process input signal or an active remote setpoint input is lost. The default action is to drive the valve closed.

– Applies to VMD Control Mode only. Does not apply if control is disabled or in manual mode.

Caution: Set to safe values for the process!

Setpoint Lower Limit

The minimum allowable setpoint value. Adjustable within the scaled input limits, but cannot be above the setpoint upper limit. Applies to local, remote and profile setpoints.

Caution: Set to safe values for the process. Operators can adjust

local setpoints to any value between the limits set.

Setpoint Upper Limit

The maximum allowable setpoint value. Adjustable within the scaled input limits, but cannot be below the setpoint lower limit. Applies to local, remote and profile setpoints.

Caution: Set to safe values for the process. Operators can adjust

local setpoints to any value between the limits set.

Setpoint Ramp Rate

Setpoint Ramp Rate value, adjustable from 1 to 9999 display units per hour, or OFF. The ramp is applied at power-up (from current PV to SP) and whenever the setpoint value or source is changed. If set to OFF, the setpoint steps immediately to the new setpoint value.

Main Setpoint Source

Select the source of the main setpoint. This can only be a “Local” setpoint set from the keypad, or Not used.

Alternate Setpoint Source

Select the source of the alternate setpoint. This can be a “Local” setpoint, not used, or an analogue remote setpoint (RSP) signal applied to input 2 or auxiliary input A – depending on available hardware.

Main Setpoint Value

Sets the current value of the main setpoint between the setpoint upper and lower limits.

Alternate Setpoint Value

Sets the current value of the alternate setpoint between the setpoint upper and lower limits – is read-only if alternate setpoint source is RSP.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 52

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Select Active Setpoint

Select if the main or alternate setpoint is to be the current “active” setpoint for this loop.

Main Setpoint Offset

An offset that can be added to the main setpoint (+ve values) or subtracted from it (-ve values) when the instrument is a comms slave in a multi-zone application. This changes the effective setpoint used for control.

Caution: It should be set to zero if an offset is not required.

Alternate Setpoint Offset

An offset that can be added to the alternate setpoint (+ve values) or subtracted from it (-ve values) when the instrument is a comms slave in a multi-zone application. This changes the effective setpoint used for control.

Caution: It should be set to zero if an offset is not required.

Control Loop 2 - Sub-menu to setup Control Loop 1. Press D + R to return to Input Menu

These settings apply to the slave loop if the controller has been setup for cascade control.

Control Select

Control Enable/Disable

Caution: The instrument is not able to control the process when

control is disabled and the Output Power Limits are ignored.

Auto/Manual Control Selection

Switches the control loop between Automatic and Manual Control.

Caution: Manual mode overrides the automatic control loop. It also

ignores any output power limits, valve open/close limits and the control enable/disable setting. The operator is responsible for maintaining the process within safe limits.

Control Type

Primary Control Action

Control Status

A “read-only” diagnostic status display of the current loop 2 process variable and effective setpoint values to assist with manual tuning.

Power Output Levels

A “read-only” diagnostic status display of the current loop 2 primary and secondary % output power levels to assist with manual tuning – Not shown with VMD Control. Does not apply if control is disabled or in manual mode.

Gain Schedule PID Set in use

A “read-only” diagnostic status display showing the PID set in use. The set use may vary based on the current setpoint or process variable value. – Only shown if Gain Scheduling is in use.

PID Set Selection

Choose to use one of five PID Sets; or choose Gain Schedule on SP or PV. – This selects a fixed PID set to be “Active”; or automatically switch sets based changes in SP or PV values.

Set n – Primary Pb

The primary proportional band for PID Set n (n = up to 5). Set as On-Off control, or a proportional band from 1 to 9999 display units – Only the set(s) in use are shown.

Set n – Secondary Pb

The secondary proportional band for PID Set n (n = up to 5) if dual control is used. Set as On-Off control, or a proportional band from 1 to 9999 display units – Only the set(s) in use are shown.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 53

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Set n – Integral

The integral time value (Automatic Reset) for PID Set n (n = up to 5). Adjustable from 1s to 99min 59s or OFF – Only the set(s) in use shown.

Set n – Derivative

The derivative time value (Rate) for PID Set n (n = up to 5). Adjustable from 1s to 99 min 59s or OFF – Only the set(s) in use are shown.

Set n – Overlap

The overlap (+ve) or deadband (-ve) between primary & secondary proportional bands for PID Set n (n = up to 5). In display units - limited to 20% of the combined primary & secondary prop band width.

Set n – On/Off Diff

The on-off control hysteresis (deadband) for PID Set n (n = up to 5). Adjustable from 1 to 300 display units, centred about the setpoint – Only the set(s) in use are shown.

Set n - Breakpoint

Manual Reset (Bias)

Anti Wind-Up Limit

Caution: If set too low control deviation can occur (the process

settles, but is offset above or below the setpoint). It this is observed, increase the value until the deviation error is removed.

Primary Cycle Time

The primary power cycle time. Adjustable from 0.5 to 512 seconds. Applied for time proportioned primary relay, SSR driver or triac control outputs – Not used for VMD Control modes.

Secondary Cycle Time

Primary Power Lower Limit

Caution: The instrument will not be able to control the process

correctly if the lower limit is above the level required to maintain setpoint.

Primary Power Upper Limit

Caution: The instrument will not be able to control the process

correctly if the upper limit is below the level required to maintain setpoint.

Secondary Power Lower Limit

Caution: The instrument will not be able to control the process

correctly if the lower limit is above the level required to maintain setpoint.

Secondary Power Upper Limit

Caution: The instrument will not be able to control the process

correctly if the upper limit is below the level required to maintain setpoint.

Sensor Break Pre-set

Set the power level to be applied if the process input signal or an active

Pro-EC44 Product Manual - 59540-1 October 2013 Page 54

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Power Output

remote setpoint input is lost. Adjustable from 0 to 100% for single control or

-100 to +100% for dual control. The default value is OFF (0% power). Does not apply if control is disabled or in manual mode.

Caution: Ensure the value set will maintain safe process conditions.

Motor Travel Time

The motor travel time (valve movement time from fully open to fully closed in mm:ss). Adjustable from 5s to 5 mins - In VMD Control Mode only.

Minimum Motor On Time

The minimum drive effort (in seconds) to begin moving the motorised valve in VMD Control Mode. Adjustable from 0.02 to





of the Motor Travel Time.

Slave SP Scale Min

The effective cascade slave setpoint value equating to 0% power demand from the master controller - Limited by the slave input scaling.

Caution: Set to safe values for the process!

Slave SP Scale Max

The effective cascade slave setpoint value equating to 100% power demand from the master controller - Limited by the slave input scaling.

Caution: Set to safe values for the process!

Valve Sensor Break Action

The direction to drive the valve if the process input signal or an active remote setpoint input is lost. The default action is to drive the valve closed.

– Applies to VMD Control Mode only. Does not apply if control is disabled or in manual mode.

Caution: Set to safe values for the process!

Setpoint Lower Limit

The minimum allowable setpoint value. Adjustable within the scaled input limits, but cannot be above the setpoint upper limit. Applies to local, remote and profile setpoints.

Caution: Set to safe values for the process. Operators can adjust

local setpoints to any value between the limits set.

Setpoint Upper Limit

The maximum allowable setpoint value. Adjustable within the scaled input limits, but cannot be below the setpoint lower limit. Applies to local, remote and profile setpoints.

Caution: Set to safe values for the process. Operators can adjust

local setpoints to any value between the limits set.

Setpoint Ramp Rate

Main Setpoint Source

Select the source of the main setpoint. This can only be a “Local” setpoint set from the keypad, or Not used.

Alternate Setpoint Source

Select the source of the alternate setpoint. This can be a “Local” setpoint, not used, or an analogue remote setpoint signal applied to input 2 or auxiliary input A – depending on available hardware.

Main Setpoint Value

Sets the current value of the main setpoint between the setpoint upper and lower limits.

Alternate Setpoint Value

Sets the current value of the alternate setpoint between the setpoint upper and lower limits.

Select Active Setpoint

Select if the main or alternate setpoint is to be the “active” setpoint for this

loop.

Main Setpoint Offset

Caution: It should be set to zero if an offset is not required.

Alternate Setpoint Offset

Caution: It should be set to zero if an offset is not required.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 55

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

OUTPUTS CONFIGURATION SUB-MENU SCREENS

Output n Configuration - Up to 9 outputs listed. Any already used show as “Assigned” but can be

changed. If “Digital” is shown, the output is driven directly via a digital input (see input configuration). Relevant screen sequences repeat for outputs fitted. Press D + R to return to Configuration Menu

Linear Output n Type

Set the desired type for any linear outputs fitted. From: 0-5, 0-10, 1-5, 2-10V & 0-20, 4-20mA or 0-10VDC adjustable transmitter PSU.

Adjustable 0-10V Transmitter PSU n

Sets the voltage required if linear output n type is 0-10VDC adjustable transmitter PSU.

Output n Usage

Sets the use for the output. From: Loop 1 or 2 Primary / Secondary Power; Logical OR or AND of Alarms & Profile Events (direct or reverse acting); Retransmission (of loop 1 or 2 effective setpoint, Input 1 or 2 process values). Choices offered are appropriate for the output type fitted (e.g. only linear outputs can retransmit).

OPn OR Selection

When an output usage is set for logical OR of alarms & profile events, this selects the alarms or events to be OR’d. Press U or D to select ☑ or deselect ☐ Alarms 1 to 7; Events 1 to 5; PR (Profile running); PE (Profile

Ended). Direct outputs turn on, & reverse outputs turn off according to the selected logical OR combination.

OPn AND Selection

When an output usage is set for logical AND of alarms & profile events, this selects the alarms or events to be AND’d. Press U or D to select ☑ or deselect ☐ Alarms 1 to 7; Events 1 to 5; PR (Profile running); PE (Profile

Ended). Direct outputs turn on, & reverse outputs turn off according to the selected logical AND combination.

Output n Latch Enable

If enabled, an output will remain latched ON even if the condition that caused it to be on is no-longer present, and remains latched even if the instrument is powered off-on. The output latch must be reset to turn it off.

Note: An output cannot reset if the condition that caused it to turn on is still present.

Output n Lower Retransmit Limit

The displayed value at which the retransmission output reaches its minimum level (e.g the display value when a 4 to 20mA retransmission output is at 4mA). Adjustable from -9999 to 9999.9. The output is at its minimum below this value. Above this value, it rises linearly in line with the displayed value to reach its maximum at the Upper Retransmit Limit display value.

Output n Upper Retransmit Limit

The displayed value at which a retransmission output will be at its maximum level (e.g. the display value when a 4 to 20mA retransmission output is at 20mA). Adjustable from -9999 to 9999.9. The output is at its maximum above this display value. Below this value, it falls linearly in line with the displayed value to reach its minimum at the Lower Retransmit Limit display value.

ALARM CONFIGURATION SUB-MENU SCREENS

Alarm n Configuration - 7 alarms listed with any already used shown as “Assigned”. Relevant

screen sequences repeat for each alarm (n = 1 to 7). Press D + R to return to Configuration Menu

Alarm n Type

Sets the function of alarm n from: Unused; Process High; Process Low; PV-SP Deviation; Band; Control Loop; Rate Of Signal Change per minute; Input Signal Break; % of Recorder Memory Used, Control Power High, Control Power Low.

Alarm n Source

The signal source of Alarm n from: Input 1, Input 2 & Auxiliary Input A; Control Loop 1; Control Loop 2; Loop 1 Primary or Secondary Power; Loop 2 Primary or Secondary Power – auxiliary input A is only possible if fitted and the alarm type can only be input signal break.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 56

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Alarm n Value

The Alarm n activation point – The value is limited by the scaled input limits for Process High; Process Low; PV-SP Deviation (+ve above, -ve below setpoint), Band (above or below setpoint) type alarms. Rate of Signal Change is a rate of 0.0 to 99999 (rate in units per minute). Memory used, Control Power High, Control Power Low are 0.0 to 100.0% – not required for Control Loop or Input Signal Break alarm types.

Alarm n Hysteresis

The deadband on the “safe” side of alarm n, through which signal must pass before alarm deactivates - not for Rate of Change, Control Loop, Input Break or Percentage of Memory used alarms.

Alarm n Minimum Duration

The minimum time that alarm n must be passed its threshold before activating (deactivation is not affected by this parameter). Adjustable from

0.0 to 9999.0 secs. – not used for signal break, memory or loop alarms.

Caution: If the duration is less than the time set, the alarm will not

become active.

Alarm n Inhibit

If the inhibit is enabled, it prevents the initial alarm activation if the alarm condition is true at power up. Activation only occurs once the alarm condition has passed and then reoccurred.

Control n Loop Alarm Type

Sets the loop alarm time source, from: Manual Loop Alarm Time (as set in the loop alarm n time screen) or Automatic (twice the integral time constant setting). If configured, a Loop Alarm activates if no response is seen in loop n after this time following the saturation of its power output. – Only seen if an alarm is set for control loop type.

Control n Loop Alarm Time

The time (max 99:59 mm:ss) for loop n to begin responding after PID power output reaches saturation, if a manual loop alarm type is configured.

COMMUNICATIONS CONFIGURATION SUB-MENU SCREENS

No Communications Warning

If Communications Configuration menu is entered without a communications module fitted.

Modbus Parity

The setting for Modbus comms parity bit checking, from: Odd; Even or None. Set the same parity for all devices on the network – Only seen if RS485 or Ethernet communications option is fitted.

Modbus Data Rate

The setting for the Modbus comms data speed. From: 4800; 9600; 19200; 38400; 57600 or 115200 bps. Set the same speed for all devices on the network – Only seen if RS485 or Ethernet communications option is fitted.

Master Mode, or Slave Address

Slave address (1 to 255), or multi-zone Setpoint Master Mode – Only seen if RS485 or Ethernet communications option is fitted, but Master mode is not available over Ethernet.

Target Register In Slave

Target memory register for the setpoint value in attached slave controllers. All slaves must have the same setpoint register address as set here Appears only if unit is in Master mode.

Master Mode Format

The data format required by the attached setpoint slaves. From: Integer; integer with 1 decimal place or float - Appears only if unit is in Master mode.

Serial Communications Write Enable

Enables/disables writing via RS485 or Ethernet communications. When disabled, parameters can be read, but attempts to change their values over comms are blocked.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 57

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

DATA RECORDER CONFIGURATION SUB-MENU SCREENS:

No Recorder Warning

If the Recorder Configuration menu is entered on an instrument without this option fitted.

Recording In Progress Warning

A warning if recording when attempting to enter recorder configuration. Access to the configuration is denied unless the recording is paused.

Pause (Override Trigger)

Select No to continue recording or Yes to enter recorder configuration.

Note: Recording is paused until recorder configuration is completed. It restarts automatically on exit from this menu.

Recorder Status Information

Current information about the data recorder feature, including if a recording is in progress (Recording or Stopped); the recording mode (FIFO or Record Until Memory Is Used); a % memory use bar-graph and the estimated available time remaining based on the data selected and memory left.

If the alarm status is recorded and is likely to change often, take this into account when determining if there is sufficient memory available.

Icons are displayed for active recording triggers. If any trigger is active, the selected data will be recorded.

Manual Record

Digital Input

Profile Record

Alarm Record

- see the Data Recorder in section on page 97

Recorder Mode

Choose Record Until Memory Used (stops recording when full) or Continuous FIFO (First In - First Out).

Caution: A FIFO recording will overwrite previous recordings in

memory, starting with the oldest data first. Download the previous data before selecting this option.

Recording Sample Interval

Recording of the selected data will happen once every sample interval. From every: 1; 2; 5; 10; 15; 30 Seconds, or 1; 2; 5; 10; 15; 30 Minutes.

- The recording interval does not affect Trend View sample rates.

Note: Shorter intervals reduce the possible recording duration.

Recorder Auto Trigger

Automatic recording triggers. From: None; On Alarm; During Profile and Alarm or Profile. Data is recorded if any trigger is active (including a digital input or manual recording start).

Trigger On Alarms

Any combination of alarms 1 to 7 can be set to trigger a recording (TRG) or not (OFF). If any alarm set to TRG becomes active, the alarm recording trigger will also activate.

Loop 1 Values To Record

Any combination of loop 1 values can be recorded from: Process Variable; Maximum or Minimum PV (since the previous sample was taken); Setpoint; Primary Power, Secondary Power. Set to Record (REC) or not (OFF).

Note: Recording more parameters reduces the possible recording duration.

Loop 2 Values To Record

Any combination of loop 2 values can be recorded from: Process Variable; Maximum or Minimum PV (since the previous sample was taken); Setpoint; Primary Power, Secondary Power. Set to Record (REC) or not (OFF).

Note: Recording more parameters reduces the possible recording duration.

Other Values To Record

If required, select to record the value of auxiliary input A.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 58

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Activities To Record

Multiple process events can be recorded from: Alarm n Status (n = 1 to 7) or Unit turned Off/On.

Note: If an alarm changes state between samples, this will also be recorded using extra memory. The remaining recording time is reduced accordingly.

Profiler Events To Record

The Profiler Event n Status can be recorded (n = 1 to 5).

Note: If a profile event changes state between samples, this will also be recorded using extra memory. The remaining recording time is reduced accordingly.

CLOCK CONFIGURATION SUB-MENU SCREENS

Date Format

The format used for all displayed dates: dd/mm/yyyy (Day / Month / Year) or mm/dd/yyyy (Month / Day / Year). – Recorder versions only.

Set Date

Set the internal clock Date – Entered in the format defined by Date Format screen. – Recorder versions only.

Set Time

Set the internal clock Time. - In hh:mm:ss (Hours : Minutes : Seconds) format. – Recorder versions only.

Note: Clock settings cannot be changed when the data recorder is active.

DISPLAY CONFIGURATION SUB-MENU SCREENS

Language

Select English or the alternate local language. The alternate language is selected at time of order, but can be changed later using the PC software.

Enable Custom Display Mode

Enables/disables the Custom Operation Mode, if configured. The screens seen in this mode are configured using the PC configuration software.

Read Only Operation Mode?

Allows Operation Mode to be Read/Write or Read-Only where screens can be seen but the values cannot be changed.

Display Colour

From: Red only; Green only; Red to Green on Alarm or Green to Red on Alarm; Red to Green if Output Latched or Green to Red if Output Latched.

Invert Display

Standard or Inverted display image.

Display Contrast

Screen contrast (10 and 100) to improve clarity. 100 = maximum contrast.

Loop 1 Trend Sample Interval

The Interval between the displayed values on the loop 1 trend graph. From: Every 1; 2; 5; 10; 15; 30 Seconds, or 1; 2; 5; 10; 15; 30 Minutes.

- Independent from the loop 2 trend graph and data recorder sample rates.

Loop 1 Trend View Mode

The data to display on the loop 1 trend graph. From: Process Value only, PV (solid) & SP (dotted) at sample time, or the Max & Min PV between samples (candle-stick graph). Alarm active indication is always shown at the top of graph.

Loop 2 Trend Sample Interval

The Interval between the displayed values on the loop 2 trend graph. From: Every 1; 2; 5; 10; 15; 30 Seconds, or 1; 2; 5; 10; 15; 30 Minutes.

- Independent from the loop 1 trend graph and data recorder sample rates.

Loop 2 Trend View Mode

Operator Visibility

Extra parameters can be made visible/adjustable in Operation Mode from: Profile Control; Recorder Start/Stop; Recorder Status; Loop 1 & 2 Setpoint Select; Loop 1 & 2 Auto/Manual Select; Loop 1 & 2 Control Select; Loop 1 & 2 Trend View; Loop 1 & 2 Setpoint Ramp Rate.

See ◘ in Operator Mode lists.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 59

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

LOCK CODE CONFIGURATION SUB-MENU SCREEN

Lock Code Configuration

Set Lock Codes (passwords) for the following configuration and control menus: Setup Wizard; Configuration Mode; Tuning Menu; Supervisor Mode; USB Menu; Recorder Menu, Profiler Setup and Profiler Menu. Independently adjustable from 1-9999 or OFF.

Note: The factory default value is 10 for all lock codes. For security, users are recommended to change these codes.

RESET TO DEFAULTS SUB-MENU SCREEN

Reset To Defaults

The user can set all parameters back to their factory default values before preparing the instrument for installation in a new application.

Caution: The user must reconfigure all of the required settings before

using the instrument.

CAUTION: Do not remove the memory stick from the USB port whilst a

Data Transfer to or from the USB stick is in progress. Data loss or corruption may result.

Note: Entry into this mode is security-protected by the USB Menu Lock Code.

Refer to the Lock Code Configuration sub-menu.

The USB Menu

A notification is shown if a USB memory stick is inserted or removed from the USB port. The USB Menu will automatically be offered after insertion. The USB menu can also be accessed from the Main Menu.

Entry into the USB Menu

The USB Menu is entered from the Main Menu

Hold down Rand press U to enter the Main Menu. Press D or U to select the USB Menu

Press R to enter the USB Menu.

Navigating in the USB Menu

Press R to move forward, or L to move backwards through the screens. Press D or U to change the value as required.

The next/previous screen follows the last parameter. If no further changes are required, hold down R or L >1sec to skip straight to next/previous screen accepting

ALL values shown.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 60

Hold down R and press U to return to the Main Menu

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 USB MENU SCREENS

USB Mode Unlocking

Enter correct code number to access the USB Menu. Factory Default value is 10.

Read/Write To USB Device

Select the required action from: Read Configuration File; Write Configuration File; Write Recorder Log File. Read Profile Files; Write Profile Files.

Note: “Writing” is downloading from the Instrument to the USB stick. “Reading” is uploading from the USB stick to the

Instrument.

Write

Select Profile To Write

If writing a profile to the USB memory stick, choose a profile to write from the list provided.

Enter A File Name

Enter an 8-character file name if writing configurations or profiles. A file extension is automatically added to the end of file name (bct for configurations or pfl for profiles).

Caution: Existing files with the same name will be over-written.

Enter A Folder Name

Recorder logs can contain multiple files. The user enters an 8-character folder name for these logs. See the Data Recorder section on page 97.

Note: To prevent existing recordings being over-written, an error message is shown if the folder name entered already exists.

Writing Profile, Configuration or Log

An animated screen is shown the files are being written.

Caution: Do not disconnect USB device until completed! Data loss or

corruption may result.

Transfer Successful

Confirmation that the data transfer to the USB stick completed correctly. Press R to continue

Transfer Failure

For write failures, check for adequate disk space on the USB stick.

Read

Select File

Select the Configuration or Profile file to transfer from the USB stick.

Caution: Configuration reads overwrite all of the instruments existing

settings with new values.

Reading Profile or Configuration File

An animated screen is shown while files are being read.

Caution: Do not remove the memory stick whist this operation is in

progress. Data corruption may result.

Transfer Successful

Confirmation that the data transfer from the USB stick completed correctly. Press R to continue.

Transfer Failure

For read failures, check the maximum number of profiles and/or segments is not being exceeded.

Note: During Data Transfer, normal operation carries on in the background, but operator access to other screens is not possible. The transfer of a full memory can take up to 20 minutes. Only begin a transfer when you are certain that access (e.g. setpoint changes) will not be required.

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 61

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 RECORDER MENU SCREENS

Recorder Mode Unlocking

Enter correct code number to access the Data Recorder Menu. Factory Default value is 10.

Recording In Progress Warning

Shown if a recording is in progress when the recorder control menu is entered.

Start/Stop Data Recording

Turn on or off the manual recording trigger.

Note: Recording continues if another record trigger is active (e.g. on alarm/profile or via a digital input). Access is restricted to this screen only until recording stops (remove all active triggers).

Note: Entry into this mode is security-protected by the recorder control menu lock code. Refer to the Lock Code Configuration sub-menu.

Recorder Control Menu

This menu allows the user to manually start a recording or to delete previous recordings. Refer to the Recorder Configuration sub-menu in Configuration Mode for information about how to setup the data to be recorded and the recording interval and the Data Recorder Option section on page 97 for general information about the recorder feature.

Entry into the Recorder Control Menu

The Recorder Control Menu is entered from the Main Menu

Hold down R and press U to enter the Main Menu. Press D or U to select the Recorder Control Menu

Press R to enter the Recorder Control Menu.

Navigating the Recorder Control Menu

Press R to move forward, or L to move backwards through parameters & screens. Holding down R or L for more than 1 second skips immediately to the next/previous

screen accepting ALL values as shown. Press D or U to select or change the value as required.

The next/previous screen follows the last parameter. If no further changes are required, hold down R or L >1sec to skip straight to next/previous screen accepting

ALL values shown. Hold down Rand press U to return to the Main Menu

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 62

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Recorder Status Information

If the alarm status is recorded and is likely to change often, take this into account when determining if there is sufficient memory available.

Icons are displayed for active recording triggers. If any are active, the selected data will be recorded.

Manual Record

Digital Input

Profile Record

Alarm Record

- see the Data Recorder in section on page 97

Clear Recordings

Clears the recorder memory. Download any recorded data before use.

Caution: This permanently deletes All recorded data.

 PROFILER SETUP MENU SCREENS

Profiler Setup Menu Unlocking

Enter correct code number to access Profiler Setup Menu. Factory Default value is 10.

Profile Setup Options

Select the required profile setup sub-menu option from: General Configuration; Create a Profile; Edit a Profile Header; Edit a Profile Segment; Insert a Segment; Delete a Segment; Delete a Profile or Delete ALL Profiles.

Note: Entry into this mode is security-protected by the profiler setup menu lock code. Refer to the Lock Code Configuration sub-menu.

Profiler Setup Menu

Screens marked  will not time-out automatically. They must be completed for a valid profile to be created. Refer to the Profiler section on page 87 for more details about the profiler.

Entry into the Profiler Setup Menu

The Profiler Setup Menu is entered from the Main Menu

Hold down R and press U to enter the Main Menu. Press D or U to select the Profiler Setup Menu

Press R to enter the Profiler Setup Menu.

Navigating the Profiler Setup Menu

Press R to move forward, or L to move backwards through the screens. Press D or U to select or change the value as required. Holding down R or L for more than 1 second skips immediately to the next/previous

screen accepting ALL values as shown. Hold down R and press U to return to the Main Menu

Pro-EC44 Product Manual - 59540-1 October 2013 Page 63

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

General Profile Configuration

Sub-menu with global settings affecting all profiles. Press D + R to return to Profile Setup Menu

General

Enable Edit While Running

Enables or disables the ability to edit profiles whist a profile is running.

Caution: Edits made to the current or next segment of the running

profile will take effect until after the profile is restarted.

Timer Start Function

Enable or disable automatic starting of profiles. When enabled, delayed starts are possible, or if the selected profile has a day & time trigger it waits until the time set before starting.

Note: If the Timer Start Function is disabled, profiles can only be manually started, and with immediate effect even if they have a delay or day & time trigger defined.

Create A Profile



Sub-menu to create a new profile. A header is created first, followed by the segments – see below.

Caution: It is not possible to exit from this sub-menu until profile

creation is fully complete. Do not turn off the power during profile creation or editing. When the profile creation/editing is complete the instrument returns automatically to the profile setup main menu.

Note: A warning is displayed if the maximum number of 64

profiles or 255 segments is exceeded.

Profile Header Details

Profile Header: Settings that apply to the chosen profile as a whole.

Enter Profile Name



Give each profile a unique descriptive name of up to 16 characters. The name is shown in the profile status screen and in profile selection lists.

Set the Number of Loops



Select if a profile controls the setpoint of first loop only or both control loops.

This screen is “read only” when editing a profile. The number cannot be

changed once the profile has been created.

Note: the segment type and time settings are common to both loops. Some segment types are not available with 2-loop profiling.

Profile Starting Point



The setpoint value used at the beginning of the first segment. From: Current Setpoint or Current Process Variable. The setpoint starts from the measured PV(s) or effective setpoint(s) of the process as it begins running.

Profile Start Trigger



From: None (profile start is not delayed); After Delay or Day and Time.

- Day and Time possible on the recorder version only.

Note: If the Timer Start Function has been disabled, profiles can only be manually started, and with immediate effect even if they have a delay or day & time trigger defined.

Profile Start Time



If Day and Time is the Profile Start Trigger, this is the time (hh:mm:ss) when the profile will begin if it is selected to run.

Profile Start Day(s)



If Day and Time is the Profile Start Trigger, this is the Day(s) when the profile should run. From: Mon; Tue; Wed; Thu; Fri; Sat; Sun; Mon-Fri; MonSat; Sat-Sun or All.

Profile Start Delay Time



If After Delay is the Profile Start Trigger, this is the delay time of up to 99:59 (hh:mm) before a profile begins after a start request has been given.

Profile Recovery Method



The power-on action if profile was running at power-down (e.g. after a power cut), or following correction of a signal break. From: Control outputs off; Restart profile from the beginning; Maintain last profile setpoint; Use controller setpoint; Continue profile from where it was when power failed.

Profile Recovery Time



The Recovery Method is ignored (the profile continues from where power failed), if power off for less than this time. Max 99:59 (hh:mm). - Recorder version only.

Profile Abort Action



The action taken after profile has been forced to stop early. From: Control outputs off; Maintain last profile setpoint or Use controller setpoint.

Profile Cycles



The number of times the program should run each time it is started. From 1 to 9999 or Infinite.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 64

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Profile Segment Details

Profile Segments: Settings that apply to individual profile segments

Segment Number



Shows the number of the profile segment being created. The maximum number of profiles across all profiles is 255.

Segment Type



Set the segment type from: Ramp Time (time to reach target SP); Ramp Rate (rate of change towards target SP – Single loop profiles only); Step (jump to target SP), Dwell (keep current SP); Hold (hold profile until released); Loop (back to previous segment); Join (to another profile); End or Repeat Sequence Then End (repeat a sequence of joined profiles).



Note: Segment Ramp Rate is not available if the profile controls two loops. A Join, End or Repeat Sequence Then End isthe last segment in the profile. Repeat Sequence Then End is always the last profile in a sequence.

Loop 1 Target Setpoint.



The setpoint value to be reached control loop 1 by the end of this segment, if the type is Ramp Time, Ramp Rate or Step.

Loop 2 Target Setpoint.



If the profile is controlling 2 loops, this is the setpoint value to be reached control loop 2 by the end of the segment, if the type is Ramp Time or Step.

Segment Ramp Time



The time (hh:mm:ss) to reach the segment target setpoint if the segment type is Ramp Time.

Segment Ramp Rate



The rate of change towards the Segment Target Setpoint if segment type is Ramp Rate. The rate can be from 0.001 to 9999.9 display units per hour.

Segment Dwell Time



The time (hh:mm:ss) to maintain the current setpoint if the segment type is Dwell.

Number of Loops



If the segment type is Loop, enter the number of times to repeat the loop back, before continuing forward to the next segment.

Back to Segment Number



If the segment type is Loop, enter the segment to loop back to.

Note: Two Loop-backs cannot be set to cross each other.

Loop 1 AutoHold Type



The auto-hold type for this segment to ensure loop 1 tracks the setpoint. From: None (no auto-hold); Above Setpoint (hold if too high only); Below Setpoint (hold if too low only) or Band (hold if too high or low).

Loop 1 AutoHold Band Value



The distance loop 1 can be from setpoint. Beyond this the profile is held for the selected Auto-Hold Type.

Note: For Two-Loop Profiles, either loop can cause the profile to hold. The profile continues only when both loops are within their Auto-Hold Bands.

Loop 2 AutoHold Type



The auto-hold type for this segment to ensure loop 2 tracks the setpoint. From: None (no auto-hold); Above Setpoint (hold if too high only); Below Setpoint (hold if too low only) or Band (hold if too high or low).

Loop 2 AutoHold Band Value



The distance loop 2 can be from setpoint. Beyond this the profile is held for the selected Auto-Hold Type.

Note: For Two-Loop Profiles, either loop can cause the profile to hold. The profile continues only when both loops are within their Auto-Hold Bands.

Segment Hold Release Type



A hold segment can either be released by an Operator/Digital input or be set to wait until a specified Time of Day - Recorder version only.

Hold Release Time



The time of day (hh:mm:ss) when a Hold Segment will release if the Release Type is Time Of Day. The profile is held by the hold segment and only released at the next occurrence of the time of day set.

Times To Repeat Sequence



The number of times the entire sequence of profiles should run. – if the last segment is Repeat Sequence Then End.

Segment End Type



The action taken after the profile ends normally. From: Control Outputs Off; Maintain Last Profile Setpoint or Use Controller Setpoint.

Select Profile To Join



Choose a profile to join to from the list provided – if the final segment type is Join. The selected profile will start immediately the current profile ends.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 65

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Event n



Select the events to be active during this segment. n = 1 to 5. Note: For end segments, the events selected to be active stay on until the instrument exits from profiler mode or a new profile runs.

Note: For end segments, the events selected to be active stay on until the instrument exits from profiler mode or a new profile runs.

Edit A Profile Header



Choose the profile to be edited from the list of names provided, then alter any values as required – The profile header details are as shown in “Create A Profile” above.

Edit A Profile Segment



Choose the profile, then the segment to be edited from the lists provided. Alter any values as required – The profile segment details are as shown in “Create A Profile” above.

Note: The last segment type can only be set to Join, End or Repeat Sequence Then End. Use Insert or Delete to change the end position.

Insert A Segment



Choose the profile, then the new segment’s position from the lists provided – Enter the new segment values as required – The profile segment details

are as shown in “Create A Profile” above.

Note: The new segment type cannot be set to Join, End or Repeat Sequence Then End. Use Delete to change the end position.

Delete A Segment



Choose the profile, then the segment to be deleted from the lists provided. End, Join or Repeat segments cannot be deleted.

Delete A Profile



Choose the profile to be deleted from the list of names is provided. The user is prompted confirm the deletion.

Delete All Profiles



If selected, the user is prompted to confirm that the profiles should be deleted.

Caution: This deletes all profiles from memory!

 PROFILER CONTROL MENU SCREENS

Profiler Control Menu Unlocking

Enter correct code number to access Profiler Control Menu. Factory Default value is 10.

Profile Control

If a profile is running, from: Do Nothing; Abort Profile (end immediately); or Jump to Next Profile Segment; Hold Profile or Release Hold. If profile not running, from: Do Nothing; Run Profile; End Profile Control (return to normal controller operation) or Select Profile.

Select Profile

Selects a profile. If Run Profile was chosen in the previous screen, the profile starts (after a delay if one is enabled). Otherwise the profile is selected, but waits for a run instruction (e.g. via digital input or timer).

Note: Selection is “read only” if profile selection is via a digital input.

Otherwise choose from the list of profile names provided.

Profiler Control Menu

Pro-EC44 Product Manual - 59540-1 October 2013 Page 66

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

SERVICE & PRODUCT INFORMATION SCREENS:

Plug-in Module Information

Lists the type plug-in modules types in Slots 1, 2, 3 or A – see page 4 for a full list of field upgradeable plug-in options.

Base Options

Lists factory fitted base options, from: 2nd Universal/Aux input; Output 4 & 5 Relay; Output 6 & 7 Linear mA/V DC.

Optional Features

Lists which other optional features are fitted/enabled, from: Profiler; USB Port; Data Recorder and 8 Digital Inputs.

Firmware Information

The type and version of firmware installed in the instrument.

Product Revision Level

Software and Hardware update status.

Serial Number

The instrument serial number.

Date of Manufacture

The instrument Date of Manufacture (date format is dd/mm/yyyy).

Input 1 Calibration Status

The base calibration status for each signal type on input 1.

Caution: Re-calibrate input 1 for mVDC, VDC, mADC, RTD or

Thermocouple CJC if they do not say “Calibrated” – see page 72

Input 2 Calibration Status

The base calibration status for each signal type on optional input 2.

Caution: Re-calibrate input 2 for mVDC, VDC, mADC, RTD or

Thermocouple CJC if they do not say “Calibrated” – see page 72

Calibration Check Due Date

The date re-calibration is due. – only shown if the Calibration Reminder is enabled in the Input Configuration menu.

For Service Contact

Contact information for service, sales or technical support.

Service & Product Information Mode

This is read only information about the instrument, its modules and enabled features. It has contact information to tell the user where they can obtain service, sales or technical support for the product. Normally this is the manufacturer or suppliers’ details. Using the PC software, the user can enter their own contact information. There are 7 lines of text - each up to 25 characters in length.

Entry into Service & Product Information Mode

The Service & Product Information Mode is entered from the Main Menu

Hold down R and press U to enter the Main Menu. Press D or U to select the Service & Product Information Mode Press R to enter the Service & Product Information Mode.

Navigating Product Information Mode

Press R to move forward or L to move backwards through the displayed information.

Hold down R and press U to return to the Main Menu Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 67

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

 AUTOMATIC TUNING MENU SCREENS

Automatic Tuning Mode Unlocking

Enter correct code number to access the Automatic Tuning Menu. Factory Default value is 10.

Control loop 1 or 2

Select which control loop you want to tune –if unit has 2 control loops.

Cascade Mode

To pre-tune a cascade slave, select open-cascade.

Note: When slave tuning is completed, repeat choosing open-cascade to tune the master.

Pre-Tune Method

From: Pre-Tune Standard or Pre-Tune at Value. Standard Pre-Tune tests the process response half-way from the activation point to the setpoint. Pre-Tune at Valve allows the user to specify where the test occurs.

Pre-Tune Value

Sets the value at which the process is tested for Pre-Tune at Valve.

Caution: Consider possible over-shoot!

Pre-Tune Save Location

Store the pre-tune result to one of 5 PID sets. The new PID terms can be stored to any set, without changing the “active set” from control configuration.

Run Pre-Tune on Set n Now?

Turns pre-tune on/off for the chosen PID Set. If configured, the TUNE LED indicator flashes whilst pre-tune is operating - *see below.

Note: Pre-tune is disabled in on-off control mode; if the PV is less than 5% of span from setpoint; during Profiles; if the setpoint is ramping or if the selected control loop has been disabled.

Pre-Tune Status

Shows the current pre-tune status: Running or Stopped. If an attempt to run pre-tune failed, the reason is shown.

Automatic Tuning Menu

The automatic tune menu is used to engage pre-tune and/or self-tune to assist setting up proportional bands and the integral and derivative time values used by the control loops.

Pre-tune can be used to set PID parameters approximately. Self-tune may then be used to optimise the tuning if required. See the Tuning section on page 99 for more information. Pre-tune can be set to run automatically after every power-up by enabling Auto Pre-Tune.

Entry into the Automatic Tuning Menu

The Automatic Tuning Menu is entered from the Main Menu

Hold down R and press U to enter the Main Menu. Press D or U to select the Automatic Tuning Menu. Press R to enter the Automatic Tuning Menu.

Navigating the Automatic Tuning Menu

Press R to move forward or L to move backwards through the selections. Press D or U to change values or engage and disengage the tuning as required. Hold down R and press U to return to the Main Menu

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 68

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Engage Self-Tune

Turns self-tune on/off for the active PID Set. If configured, the TUNE LED indicator is continuously on whilst self-tune is operating - *see below.

Note: Self-Tune disabled if control is On-Off or disabled. If engaged during setpoint ramping, profile ramps or pre-tuning it is suspended until the ramp or pre-tune is completed.

Self-Tune Status

Shows current self-tune status: Running or Stopped. If an attempt to run self-tune failed, the reason is shown.

Auto Pre-Tune At Power Up

Enables/disables automatic pre-tune. When enabled, this attempts to tune the active PID set at every power-up (see Run Pre-Tune Now above).

Note: Auto Pre-tune applies standard pre-tune engagement rules at power-up. It is disabled in on-off control mode; if the PV is less than 5% of span from setpoint; during Profiles; if the setpoint is ramping or if the selected control loop has been disabled.

Note: Pre-tune will flash the LED instead of turning it on, but flashing will be obscured if the LED had been configured to be used in conjunction with other functions and one of these is on.

* TUNE indication is the default function of LED 3 but the user may have altered the LED functions or the labels using the PC Configuration Software. If LED 3 is used as a TUNE indicator, it flashes while pre-tune is operating, and is continuously on whilst self-tune is operating. If both pre-tune and self-tune are engaged the TUNE indicator will flash until pretune is finished, and is then continuously on.

Lost Lock Codes

All menu lock codes can be viewed or changed from configuration mode – see page 60. In the event that the configuration mode lock code is forgotten, the instrument can be forced into Lock Code Configuration from power-up, where the codes can be checked or set to new values.

Forcing Lock Code Configuration

Power down the instrument. Re-apply the power and hold down R and U for more than 5 seconds as the start-

up splash screen appears. The Lock Code Configuration menu is displayed. Press R to move forward or L to move backwards through the screen elements. Make note of the codes or press D or U to change their values if required. Hold down R and press U to return to the Main Menu

Scrolling “Help Text” is shown at the bottom of the screens to aid navigation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 69

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: Incorrect use of Calibration & Scaling can make the displayed

value very different from the actual process variable. There is no front panel indication of when these parameters are in use.

Note: These methods do not alter the internal instrument calibration. Simply

choose Base Calibration to restore normal measured values. Re-calibration of the internal base values is possible, but should only be attempted by qualified personnel as it overwrites the factory calibration – see Base Calibration Adjustment below if you think this may be required.

This example shows a positive offset value. For example: If the process displays 27.8 when it should read 30, The error is -2.2 so an applied offset of +2.2 would change the displayed value to 30.

The same offset is applied to all values, so at 100.0 the new displayed value would be 102.2.

Single Point ‘Offset

Calibration’ value

New Displayed Value

Original Displayed Value

9 Input Calibration & Multi-point Scaling

User Calibration

The process inputs can be adjusted to remove sensor errors or to match the characteristics of the attached process. For each loop, independent use of base (unadjusted), single point offset or two point calibration strategies are possible, as is the use of multi-point scaling for the displayed values of linear inputs. These parameters are in the Input 1 & 2 calibration submenus of Input Configuration Sub-Menu Screens - page 46.

Calibration Reminder

If the Data Recorder feature is fitted, a calibration reminder can be set for a future date. From this date a daily reminder is shown (and shown at every start-up), until a new date has been set. This is useful in applications that require a regular check of the measured accuracy – see Input Configuration Sub-Menu Screens on page 46.

Single Point Calibration

This is a ‘zero offset’ applied to the process variable across the entire span. Positive values are added to the reading, negative values are subtracted. It can be used if the error is constant across the range, or the user is only interested in a single critical value. To use, select Single Point Calibration from the input calibration menu, and simply enter a value equal, but opposite to the observed error to correct the reading.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 70

Figure 44. Single Point Calibration

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

This example shows a positive Low Offset and a negative High Offset. For example: If the process displays a low end error of +0.5 at zero, an offset of -0.5 would change the value to 0.0

A high end value of 98.3 with a +1.7 offset would read 100.0.

There is a linear relationship between these two calibration points.

CAUTION: Choose values as near as possible to the bottom and top of

your usable span to achieve maximum calibration accuracy. The effect of any error can grow at values beyond the chosen calibration points.

Original Displayed Value

New Displayed Value

Calibration High Offset

Calibration Low Offset

Calibration High

Process Value

Calibration Low

Process Value

Two Point Calibration

This method is used where an error is not constant across the range.

Separate offsets are applied at two points in the range to eliminate both “zero” and “span”

errors. To use:

1. Measure and record the error at a low point in the process.

2. Measure and record the error at a high point in the process.

3. Go to the first two point input calibration screen. a. Enter the desired low point value as the Calibration Low PV value. b. Enter an equal, but opposite value to the observed error as the Calibration Low

Offset to correct the error at the low point.

4. Go to the second two point input calibration screen. a. Enter the desired high point as the Calibration High PV value. b. Enter an equal, but opposite value to the observed error as the Calibration High

Offset to correct the error at the high point.

Figure 45. Two Point Calibration

Pro-EC44 Product Manual - 59540-1 October 2013 Page 71

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Set the scale limits, and then enter the 1st scaling point (this is a % of the scaled input span, and the desired display value to be shown at that input value. Next set the 2nd point and display value, followed by the 3rd etc. Continue unit all breakpoints are used or you have reached 100% of the input span. A breakpoint set at 100% ends the sequence

CAUTION: Any calibration adjustment must only be performed by

personnel who are technically competent and authorised to do so. The equipment used must be in a known good state of calibration.

New Linearized

Displayed Values

Non-linear signal

Scale Lower Limit

Scaling Points 2, 3 & 4

To Scale Upper Limit

Scaling Point 1

Multi-point Scaling

If an input is connected to a linear input signal (mA, mV or VDC), multi-point scaling can be enabled. This allows the linearization of a non-linear signal. – see Input Configuration Sub- Menu Screens on page 46.

The Scale Input Upper & Lower Limits define the values shown when the input is at its minimum and maximum values. Up to 15 breakpoints can scale the input vs. displayed value between these limits. It is advisable to concentrate the break points in the area of the range with the most non-linearity, or an area of particular importance to the application.

Figure 46. Multi-point Scaling

Base Calibration Adjustment

Calibration of each input type is carried out during manufacture. This can be verified in the Service and Product Info screens.

Re-calibration of the internal base values is possible, but should only be attempted by qualified personnel as it overwrites the factory calibration. For most applications, base re-calibration is not required during the lifetime of the instrument.

WARNING:

BASE CALIBRATION SHOULD ONLY BE PERFORMED IF ERRORS HAVE BEEN ENCOUNTERED. REFER TO CALIBRATION CHECK BELOW.

Required Equipment

To verify the accuracy of the instrument or to carry out recalibration, a suitable calibration signal source is required for each input type as listed below. Accuracy must be better than ±0.05% of reading:

1. DC linear inputs: 0 to 50mV, 0 to 10VDC and 0 to 20mADC.

2. Thermocouple inputs - complete with 0ºC reference facility, appropriate thermocouple functions and compensating lead wire.

3. RTD inputs: decade resistance box with connections for three-wire input.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 72

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: The 50mV calibration phase MUST always be calibrated before calibration of the thermocouple input.

INPUT CALIBRATION PHASES

Type

Signal

(<0.05% error)

Cable Type

Input 1 Terminals

Input 2 Terminals

+ - +

DC milli-volt

50 mV

Copper Wire

2 3 6

DC voltage

10 V

Copper Wire

2 3 6

DC milliamps

20 mA

Copper Wire

3 1 7

RTD

200 ohm

Copper 3-Wires

2 & 3

6 & 7

Thermocouple

0ºC K type source

K Thermocouple Wire

2 3 6

Performing a Calibration Check

1. Setup input 1 for the input signal type to be checked.

2. Power up the instrument and correctly connect the signal source. Leave powered up for at least five minutes for RTD and DC linear inputs, and at least 30 minutes for thermocouple inputs.

3. After the appropriate delay for stabilisation, check the calibration at a number of cardinal points by applying the appropriate input signal. The observed readings should be within the tolerances stated in the specifications (see page 245).

4. Test the other signal types as above if required.

5. Repeat the process for input 2 if fitted.

Recalibration Procedure

For each process input, recalibration is carried out in five phases as shown in the table below; each phase corresponds to a basic input type.

1. For optimum accuracy, leave the instrument power-up for >30 minutes to warm up before beginning the calibration, and then toggle the power off/on to restart the instrument.

2. During the power-up “splash screen”, press D and R together until the Input 1 Calibration Status screen is displayed.

3. Correctly connect the 1st phase signal (50mV), then press R to select the first phase

4. Press D + U to initiate the calibration.

5. During calibration the message “50mV DC Input Calibrating” will display for a few seconds. This should be followed by the “Calibration Successful” confirmation.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 73

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: The Calibration Mode automatically exits if there is no button activity for two minutes.

6. If the input is misconnected or an incorrect signal is applied, the calibration will be aborted

and the values will not be altered. The display will show “Failed: Signal Too Small!” or “Failed: Signal Too Large!”. Correct the problem and repeat that phase before continuing.

7. Press R to select the next calibration phase.

8. Repeat this process for each input type until all the phases are calibrated. For each phase, ensure that the correct input is applied, using the appropriate connections.

9. If the instrument has 2 process inputs, when the first input sequence completes, the Input 2 Calibration Status screen is displayed. Repeat the procedure from 3 above for this input.

10. Once calibration is complete, recorder versions will ask for a Calibration Reminder Date. If required, this can be changed to the date of your next calibration check. Ensure that Calibration Reminders are enabled in Input Configuration to receive a reminder.

11. Press R + U to exit to the main menu.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 74

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: The response time is ≥0.25 seconds. Signals applied for less

than this time may not register and the function might not change state.

A diagnostic screen assists commissioning and fault finding by showing the current signal state for all digital inputs.

Slot A, C1 to C8 & Soft digital input status ( = Active, Ø = Unavailable)

Profile select bit format (BCD or Binary) Profile selected (example shown: C1-C3 = 011 = 6)

Digital inputs can be inverted to reverse their action making an “on” input behave as off.

Step thorough each input using the R key. Press U to invert  the highlighted input and D to un-invert . Hold R down to skip to next

screen accepting the values shown.

Highlighted Input

10 Digital Inputs

Digital inputs are driven to one of two states (active or inactive) by an applied voltage signal or a contact opening/closing.

A total of 9 physical digital inputs are possible on this instrument. A multiple digital input can be installed at time of purchase, and a single plug-in module can be fitted in option slot A.

Digital Signal Type

The digital inputs can be connected to volt-free contacts, or to a voltage signal (compatible with TTL). They can often be used in parallel with equivalent menu selections, where either can change function status.

Some inputs are level sensitive, while others are edge sensitive requiring a High to Low or Low to High transition to change functions status. Pre-Tune is always off at power-up (except if auto pre-tune is enabled), but other edge sensitive functions retain their power off status at power on. See the tables below for details.

Open contacts (>5000Ώ) or 2 to 24VDC signal = Logic High (logic low if inverted). Closed contacts (<50 Ώ) or -0.6 to +0.8VDC signal = Logic Low (logic high if inverted).

Inverting Digital Inputs

Pro-EC44 Product Manual - 59540-1 October 2013 Page 75

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

The four soft digital inputs can be configured by combining physical inputs, alarms & events using Boolean logic. Input AND selections are then globally OR’d with the input OR selections, the alarms & the events. By using the invert inputs function, NAND & NOR equivalents can be created.

Some or all of inputs C1 to C7 can be used for profile selection. If used in this way they cannot be used for any other functions. Soft inputs and any physical digital inputs not allocated for profile selection can be used to change the instrument status. Each input can only perform a single function. The possible functions are listed below.

Function

Logic High*

Logic Low*

Sensitivity / Functions’ Power On State

Loop 1 Control Select

Enabled

Disabled

┌ ┐

/ Retained

Loop 2 Control Select

Enabled

Disabled

┌ ┐

/ Retained

Loop 1 Auto/Manual Select

Automatic

Manual

┌ ┐

/ Retained

Loop 2 Auto/Manual Select

Automatic

Manual

┌ ┐

/ Retained

Loop 1 Setpoint Select

Main SP

Alternate SP

┌ ┐

/ Retained

Loop 2 Setpoint Select

Main SP

Alternate SP

┌ ┐

/ Retained

Loop 1 Pre-Tune Select

Stop

Run

┌ ┐

/ OFF

Loop 2 Pre-Tune Select

Stop

Run

┌ ┐

/ OFF

Loop 1 Self-Tune Select

Stop

Run

┌ ┐

/ Retained

Soft Digital Inputs

In addition to the physical digital inputs, four “soft” digital inputs are available. They are used to select functions in the same way as the physical inputs.

Digital Input Functions

Single Functions

Digital inputs can often work in parallel with equivalent menus, where either can change function status.

In the table below, █ = Level Sensitive: Where a High or low signal sets the function status.

┌ ┐

= Edge Sensitive: High-Low or Low-High transition changes the function status. Pre-Tune is always off at power on (except if auto pre-tune is in use), and profile recovery is as configured, but others functions retain their power off status when the power returns.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 76

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Loop 2 Self-Tune Select

Stop

Run

┌ ┐

/ Retained

Profile Run/Hold

Hold

Run

┌ ┐

/ As configured

Profile Hold Segment Release

No Action

Release

┌ ┐

/ Retained

Profile Abort

No Action

Abort

█ / As Digital Input

Data Recorder Trigger

Not Active

Active

█ / As Digital Input

Output n Forcing

Off/Open

On/Closed

█ / As Digital Input

Clear All Latched Outputs

No Action

Reset

█ / As Digital Input

Output n Clear Latch

No Action

Reset

█ / As Digital Input

Key n Mimic (for L D U R)

No Action

Key Pressed

█ / As Digital Input

C1 to C2

C1 to C3

C1 to C4

C1 to C5

C1 to C6

C1 to C7

Binary

0 to 1

0 to 3

0 to 7

0 to 15

0 to 31

0 to 63

BCD

0 to 1

0 to 3

0 to 7

0 to 9

0 to 19

0 to 39

0 to 63

Using Binary To Select Profile Numbers

Selection of profiles is via a simple binary bit pattern. C1 is the least significant bit (LSB).

C6 to C1

C5 to C1

C4 to C1

C3 to C1

C2 to C1

000000 to 111111

00000 to 11111

0000 to 1111

000 to 111

00 to 11

0 to 1

(0 to 63)

(0 to 31)

(0 to 15)

(0 to 7)

(0 to 3)

(0 to 1)

Using BCD To Select Profile Numbers

A single BCD switch can be used to select profiles 0 to 9 using C1 to C4, with a bit pattern identical to standard binary. For larger numbers, a double BCD switch arrangement is needed. A separate binary pattern is applied to C5 to C7 for the “tens” digit (10 = 001, 20 = 010, 30 = 011 etc). Any number combination higher than 63 is invalid.

Multiples of ten (0x to 6x)

Multiples of one (x0 to x9)

C7 to C1

C6 to C1

C5 to C1

C4 to C1

C3 to C1

C2 to C1

000 to 110

00 to 11

0 to 1

0000 to 1001

000 to 111

00 to 11

0 to 1

(0x to 6x)

(0x to 3x)

(0x to 1x)

(x0 to x9)

(x0 to x7)

(x0 to x3)

(x0 to x1)

Profile Selection via digital inputs

For instruments with the profiler option, the multi-digital input option can be used to select the profile to run using either a standard binary bit pattern, or binary coded decimal from BCD switches. Profile selection inputs are all level sensitive ( █ ), with a high/open signal equating to a binary 1 (assuming non-inverted), and a low/closed signal equating to a binary 0 (assuming non-inverted). Profiles are numbered 0 to 63. Select inputs C1 to Cn for the required number of profiles, from the table:

Pro-EC44 Product Manual - 59540-1 October 2013 Page 77

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: Cascade control is only available on models fitted with the 2nd control loop. The master loop uses input 1; and the slave loop uses input 2.

PRODUCT

0-300°C

Slave SP

0-100% Output

SLAVE SENSOR

MASTER SENSOR

250°C Master Setpoint

HEATER

OIL JACKET

MASTER

IP1

SLAVE

IP2

11 Cascade Control

Applications with long time lags (e.g. with two or more capacities such as heated jackets) can be difficult to control with a single control loop. The solution is to split the process into two or more cascaded loops consisting of a Master and Slave(s) acting on a common actuator.

Ideally, the slave loop’s natural response time should be at least 5 times faster than the

master. The master controller measures the process temperature and compares it to the desired

product setpoint. Its correcting variable (0 to 100% PID output) becomes the slave’s effective setpoint (scaled to suit the process). This setpoint is compared to the slave’s process input, and the controlling actuator is adjusted accordingly.

Example Cascade Application

In this example the controlling actuator is a heater, indirectly heating the product via an oil jacket. The maximum input to the slave represents 300ºC, thus restricting the jacket temperature. At start-up the master compares the product temperature (ambient) to its setpoint (250ºC) and gives 100%. This sets the maximum slave setpoint (300ºC), which is compared to the oil temperature (ambient) and the slave requests maximum heater output.

Figure 47. Cascade example

As the oil temperature rises towards the slave setpoint, its output falls. Gradually, the product temperature will also begin rising, at a rate dependant on the transfer rate/lag between the oil jacket and the product. Eventually this causes the master’s PID output to decrease, reducing

Pro-EC44 Product Manual - 59540-1 October 2013 Page 78

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: The master process value is not under control when the

cascade is open, but will be affected by the slave process. The operator is responsible for maintaining safe conditions.

CAUTION: Manual mode disables the cascade loop. It also ignores any

output power limits, valve open/close limits and the control enable/disable setting. The operator is responsible for maintaining the process within safe limits.

Note: The cascade remains open until you pre-tune the master or manually

select Cascade-Closed.

the slave setpoint. The oil temperature is reduced towards the new slave setpoint. This continues until the system becomes balanced. The result is quicker, smoother control with the ability to cope with changes in the load. Overshoot is minimised and the jacket temperature is kept within acceptable tolerances.

Normal Cascade Operation

During operation, the master and slave are coupled together and. "Cascade" is displayed. The master process value and setpoint are most relevant to the user. The master setpoint is directly adjustable. The process value of the slave controller is displayed for information only.

Cascade-Open

The cascade can be disconnected (via digital inputs or menu selection), switching from normal operation to direct control of the slave. "Cascade-Open" is displayed. Opening the cascade is “Bumpless”. The current cascade value is used as the initial slave setpoint (displayed as “SlaveSP”). The process is then controlled and adjusted solely by the slave controller using this setpoint. Switching back to Cascade is also bumpless.

Manual Mode

The controller can be put into manual mode (via digital inputs or menu selection), switching

from normal operation to direct control of the slave loop’s correcting variable. Manual power

is adjusted from 0% or -100 to 100%. "MAN" is displayed.

Cascade Tuning

The user can tune the slave and master loops manually, or use the pre-tune feature (see Controller Tuning on page 99). In either case the slave control loop must first be optimised on its own, followed by the master loop in combination with the previously tuned slave.

To automatically pre-tune a cascade:

1. Go to the Automatic Tuning menu

2. Select “Cascade-Open” from the pre-tune menu to tune the PID set(s) on the slave.

3. After the slave has successfully tuned, pre-tune the master/slave combination by selecting “Cascade-Closed” from the pre-tune menu.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 79

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

To manually tune a cascade:

1. Select Cascade-Open from the Cascade Control menu, breaking the link between the master and slave loops.

2. Set the slave controller setpoint manually to the appropriate value for your application.

3. Tune the slave for relatively fast control (‘proportional only’ is often sufficient).

4. Select Cascade-Closed from the Cascade Control menu to link the master and slave loops, then tune the master/slave combination.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 80

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: Ratio control is available on models with the 2nd Auxiliary Input, or two loop models. The feature and information displayed is optimised for control of burner fuel/air, but can be used in other flow ratio applications.

Atomization Air

Burner

Air

Fuel

Air Valve

12 Ratio Control

A ratio control loop is used where the quantity of one of the material is to be controlled in proportion to the measured quantity of a second material. The controller mixes the materials at the desired ratio by adjusting the flow of input 1. The flow of input 2 may be controlled separately, but is not controlled by the ratio control loop itself. The process value used by the controller is therefore determined by the ratio of the two inputs rather than a single measured variable.

Stoichiometric Combustion

Below is an example of stoichiometric combustion ratio control. For optimum combustion the fuel-air ratio is set so that there are no flammable residues in the waste gas.

Figure 48. Ratio Control Example

It is normal in this application to display the process value and setpoint as relative values rather than the physical ratio or absolute values. A scaling factor is set such that the displayed value will be 1.00 at the correct stoichiometric ratio for the application.

Inputs 1 and 2 are configured and scaled to match the attached flow meters. In this example a 4 to 20mA signal at x1 represents 0 to 1000m3/h of airflow controlled by a valve. The second 4 to 20mA signal at x2 represents 0 to 100m3/h of fuel oil. The fuel flow is not affected by this control loop. Atomizing air is fed in with the fuel oil at a constant rate ‘NO’. This must be considered when calculating the correct fuel/air mix. Total airflow is x1 + NO. The stoichiometric factor, SFac is entered to match the desired ratio. E.g for 10 parts total airflow to one part fuel, SFac would be 10.

The setpoint (entered as a relative value such as 1.00) is multiplied by SFac when calculating the control deviation. E.g. with a setpoint of 1.00 and SFac of 10 the controller

Pro-EC44 Product Manual - 59540-1 October 2013 Page 81

Pro-EC44 2-Loop Graphical Profile Controller & Recorder











  











  

attempts to make the physical ratio 10. With a setpoint of 1.03 it would attempt to make the ratio 10.3 for 3% excess air.

The instantaneous (controlled) process value is calculated from the physical ratio, divided by SFac. Like the setpoint, this is displayed as relative value.

E.g. if SFac is 10, with 59.5m3/h airflow measured at x1, 0.5m3/h atomising air applied at NO and 6m3/h fuel is measured at x2, the instantaneous process value would be:

If fuel flow remained at 6m3/h and the setpoint was adjusted to 1.05 (5% excess air), the controller would increase the x1 air flow to 62.5m3/h.

Typical Ration display with Setpoint at 1.05

Pro-EC44 Product Manual - 59540-1 October 2013 Page 82

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: The user may not even be aware of a sensor fault, so it is strongly recommended that signal break alarms are configured for both inputs to provide a notification if problems occur.

Note: If both signals are lost at the same time, the PV value display is replaced with “OPEN” and the normal sensor break actions occur.

13 Redundant Input

If the 2nd universal input is fitted, the second input can be configured as a redundant input for the main process input. This increases process security by protecting against the possible loss of valuable product resulting from sensor failure.

A second sensor is connected to input 2 so that if the main sensor fails, the instrument automatically switches to this backup or “redundant” sensor. In this condition, if input 1 has a signal break alarm configured it will activate, but any other process input or control status alarms seamlessly switch to the 2nd input. The 2nd input continues to be used until the signal to input 1 is restored.

The redundant sensor must be of the same type, and be correctly located in the application ready to take over if needed. If the redundant input option is selected, the 2nd input cannot be used for other functions.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 83

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: Some modulating valves have positioning circuitry to adjust the valve position. These require a DC linear mA or voltage output and use the standard control algorithm (Set Control Mode to Standard).

CAUTION: The windings of a valve motor effectively form an

autotransformer. This causes a voltage doubling effect when power is applied to either the Open or Close terminal, causing twice the supplied voltage at the other terminal.

“Open” Relay

“Close” Relay

120V Supply

Open Valve Winding Close Valve

Valve Common

14 Valve Motor Drive / 3-Point Stepping Control

When directly controlling the motor of a modulating valve or damper, set the Control Mode to VMD in configuration mode to enable the 3-point stepping Valve Motor Drive control algorithm. The term “3-point stepping” is used because there are 3 output states, open valve, close valve or stopped (no action). Switched outputs move the valve further open, or further closed when a control deviation error is detected. If the error is reduced to zero, no further output is required until the load conditions change.

VMD mode doesn’t allow on-off control (the minimum proportional band equates to 0.5% of the scaled input span) and usually requires PI control, where the derivative parameter is set to OFF.

Special Wiring Considerations for Valve Motor Control

Valve motor drive mode must have two identical outputs assigned to position the valve. One to open and one to close the valve. These outputs can be two single relays, two triacs, two SSR drivers or one dual relay, but it is recommended to use two single relays (SPDT change-over contacts), and to interlock the wiring as shown. This prevents both motor windings from being driven at the same time, even under fault conditions.

Switching actuators directly connected to the valve motor must only be used up to half of their rated voltage. The internal relay and triac outputs in this instrument are rated at 240VAC Therefore, the maximum motor voltage when using them is therefore 120V unless interposing relays are used. Interposing relays or other devices used to control the valve must themselves be rated for twice the motor supply voltage.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 84

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

CAUTION: These limits must be used with care. They are effectively control

power limits. Do not set values that prevent proper control of the process!

Position Feedback

In VMD mode this instrument uses a boundless (open-loop) 3-point stepping algorithm. It does not require any kind of position feedback in order to correctly control the process and can therefore avoids problems associated with faulty feedback signals.

However, where valve feedback is available it can still be displayed in a bar-graph as a percentage open (0 to 100%). Position feedback is usually provided by means of a potentiometer mechanically linked to the valve. The output of a related flow meter can also be used to indicate the relative valve position. Flow meters typically have linear 0-20/4-20mA or 0-5/0-10V signals. To display the position/flow signal the 2nd input is must be configured for this purpose.

The input is adjusted and scaled to show 0 to 100% representing valve fully closed to fully open, or a flow rate equating to fully closed to fully open. The valve position scaling parameters are set in the Input Configuration sub menus – see page 46.

Valve Limiting

When valve position/flow indication is in use, the signal can be used by the controller to limit the valve movement. Upper and/or lower limits can be set beyond which it will not attempt to drive the valve. The valve open and close limits are set in the Control Configuration sub menu – see page 50.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 85

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

15 Setpoint Sources

The setpoint is the target value at which the instrument attempts to maintain the process variable. Each loop can have a Main “local” setpoint set from the keypad and an Alternate setpoint.

Loop 1 Setpoint Sources

Loop 1 can have a Main “local” setpoint set from the keypad and an Alternate setpoint. The alternate setpoint source can be either another local Setpoint or a remote setpoint (RSP), set by a mA or V DC signal applied to the 2nd input or to auxiliary input A. The control loop can only use one setpoint source at a time for each loop. This is called the “Active Setpoint”. If the profiler option is fitted this provides the setpoint when the profiler is in use, replacing both main an alternate setpoints.

Main/alternate setpoint selection can be made via a digital input; from the Control Configuration menu or if enabled in the Display Configuration sub-menu, an operator screen can be used to select the setpoint. The chosen setpoint selection method can be used to permanently select one of the setpoints, or allow switching between them.

Refer to the Control Configuration Sub-Menu Screens on page 50 for setpoint settings.

Loop 1 Profile Setpoint

When in profile control mode, the selected profile always provides the active setpoint source for loop 1 (see page 87). Once profile control mode is exited, the selected main or alternate setpoint for loop 1 becomes active again.

Loop 2 Setpoint Sources

Loop 2 can have a Main “local” setpoint set from the keypad and an Alternate setpoint. The alternate setpoint source can be either another local Setpoint” or a remote setpoint

(RSP), set by a mA or V DC signal applied to auxiliary input A. The control loop can only use one setpoint source at a time for each loop. This is called the “Active Setpoint”. If the profiler option is fitted this provides the setpoint, replacing both main an alternate setpoints, when 2loop profiling is in use.

Refer to the Control Configuration Sub-Menu Screens on page 50 for setpoint settings.

Loop 2 Profile Setpoint

If the selected profile was configured to control the setpoint of both loops, it will provide the active setpoint source (see page 87). Once profile control mode is exited, the selected main or alternate setpoint for loop 2 becomes active again.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 86

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: Even if profile editing is enabled, changes to the current and next segment or a running profile will not take effect until the profile is next run. Changes to other segments will take effect immediately.

Note: Profile Header information is only stored to memory as the Segment creation sequence begins. No profile is created if you exit before this point. Segment information is stored as each segment is created, but the profile remains invalid until an end or join segment is defined.

16 Profiler

This section covers the Profiler (or setpoint programmer) option. To confirm if profiling is enabled on your controller, refer to the Service & Product Info menu (see page 67).

Introduction

The Profiler feature allows the user to store up to 255 profile segments, shared between a maximum of 64 Profiles. Each profile controls the value of the setpoint over time; increasing, decreasing or holding their values as required. The profile can control both setpoints if the 2nd control loop is fitted.

Profiler options and screens are added to the Main Menu and Operation Mode – See pages 63, 66 & 36.

Profiler Enabling

Controllers supplied without the Profiler option installed can be upgraded by purchasing a licence code number. Refer to the Field Upgrade information on page 4.

To obtain the correct code you must tell your supplier the instrument serial number – this can be found in the Service & Product Info menu (see page 67).

To enter the licence code, hold down the L + D keys during the power-up splash screen. Enter the 16-character licence code in the displayed screen and press R.

Profile Components

General profile configuration settings apply to all profiles. They enable or disable “profile editing while running”, and automatic starting of the selected profile if it has been configured with a delay or day & time start trigger.

If delay or day & time start triggers are disabled, profiles can only be manually started, and this is with immediate effect even if they have a delay or day & time trigger defined. If delay or day & time start triggers are enabled, delayed starts are possible, and if the selected profile has a day & time trigger it will wait until the time set and before starting.

Profile Header & Segment Information

Each profile has its own header information plus 1 or more segments. The header information is unique for each profile, it contains the profile’s name; if it controls just one or both loops; how it should start & stop; the abort & power-loss recovery actions; and how many times it should be repeated.

Segments can be ramps, dwells, steps or special segments such as holds, ends, joins or loop-backs.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 87

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: Profiles outside current setpoint limits will not run, A “profile not valid” error shows if you attempt to run a profile under these circumstances.

PROFILE 1

PROFILE 9

Seg. 1 Target SP

Ramp (Time/Rate)

Starting Setpoint

Start

Trigger

Step

End

Timer or Delay Dwell

Join (Profile 1 to Profile 9)

Note: When using the instrument as a two loop profiler Ramp-Rate type

segments are not available. Calculate the time from the starting value to the target setpoint and use Ramp-Time instead.

If the instrument also has the data recorder option, its real time clock (RTC) expands the profiling capabilities by adding Day & Time profile start options, releasing of hold segments at a specific time of day and changing the power fail recovery option to one based on the length of time the power has been off. These features are explained below and in the Profiler Setup and Profile Control menus (See pages 63 & 66).

Profile Starting & Standard Segments

The example profile below explains the standard segment types required to make a simple profile or profile sequence. A Start Trigger is the instruction to begin the selected profile. This can be from the profile control menu, a digital input signal, via a serial communications command or if enabled in the display configuration, the profile can be controlled from an operator screen.

Following a Start Trigger, profiles can start immediately, after a delay, or using the Day & Time start timer (Day & Time start available on with the Recorder option only). Following the start trigger, the remaining delay time or the start day & time are shown in the profile status bar-graph until the profile begins running.

Figure 49. Profile Starting and Standard Segment Types

Ramps and Step Segments have target setpoint that they will reach as they finish. If a segment is a Ramp-Time type, the slope needed to reach the target setpoint in the defined time will change depending on the starting setpoint value. For a Ramp-Rate segment, the slope is defined by the segments Ramp Rate, so the time to reach the target setpoint will change instead. This is of particular significance for the first segment, since the starting value of the process may not be known in advance.

A Dwell (often called a “soak”) holds the previous setpoint value for the specified dwell time. Step segments jump straight to the new target setpoint value. An End segment ends the profile or profile sequence. If the last segment is a Join, the “join target” profile will begin running.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 88

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: If the join target has been deleted the profile sequence will abort and the last profiles abort action will apply.

Note: When using the instrument as a two loop profiler Ramp-Rate type segments are not available. Calculate the time from the starting value to the target setpoint and use Ramp-Time instead.

2-LOOP PROFILE

Independent

Setpoints

Loop 1

Loop 2

Seg. Nos

Both loops on same time-base

Note: Auto-Hold settings are independent for each loop. Either loop can cause

the profile to auto-hold, holding both loops at the current setpoint value. The profile continues only when both loops are back within their hold bands.

Two Loop Profiles

If the instrument is configured to control two control loops, the setpoint of both loops can be maintained when profiling. Both setpoints are synchronised to a common segment timebase, but have independent target setpoints for each of the segments.

The example below shows how two loop profiling works in practice. Auto-Hold settings and target setpoints are independent for each loop, but the segment types and time settings are the same.

Seg. 󰪦 & 󰪧 shows a ramp and a dwell with the shared time base The ramp direction can be different (Seg. 󰪨), and although one loop cannot ramp while the other dwells, a "dwell" is achieved by a ramp with its final setpoint value at the same value as the previous segment (Seg. 󰪩). Similarly, if only one loop is to Step to a new value, make the other “step” to its existing setpoint value. If you later change the previous setpoint, you may have to change both segments. The Loop-back feature takes both loops back to the same defined earlier segment.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 89

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Loop-back target segment

End

Loop Segment

Hold Start

Run

Continue Triggers

End

Hold Stop

Hold Segments

Note: A running segment will hold if the operator or a digital input instructs it to. It

can also hold due to “auto-hold”, if one of the profile control loops is disabled, if a cascade is set to “open” or if manual control is selected.

Example: Runs segments 1 to 5, then repeats segments 3 to 5 again 500 times, before continuing on to segments 7

Loop-back Segments

A Loop-back segment goes back to a specified segment in the current profile. This action is repeated for the required number of times (1 to 9999) before the profile continues onwards. More than one Loop Segment can be used in a profile, but they cannot cross.

Figure 50. Loop-back Segments

Profile Running / Holding vs. Hold Segments

Figure 51. Run/Hold & Hold Segments

A Hold condition during a segment maintains the current profile setpoint value(s). Once the hold condition is stopped the Ramp or Dwell continues. The user can request that the profile holds, or it can be instigated automatically.

A Hold Segment is a pre-planned hold programmed into the profile. It maintains the value of the previous segment and the profile does not continue until a Continue Trigger occurs. This can be via a key-press, serial communications, a digital input signal or after waiting until a pre-set time of day (time of day is available with the recorder option only).

Pro-EC44 Product Manual - 59540-1 October 2013 Page 90

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Note: The segment time is increased by the time that the process is out of bounds, extending the total profile run time.

Note: For two-loop profiles, either loop can cause the profile to hold. The entire profile (i.e. both loops) will be held if either process is outside of its auto-hold band. It continues only when both loops are back within their auto-hold bands.

Held if Auto-Hold set to Above Setpoint or Band

Dwell Segment

Setpoint

Hold Band

Process Variable

Held if Auto-Hold set to Below Setpoint or Band

The Auto-Hold Feature

There are independent auto-hold settings for each segment of each loop controlled by the profile. When utilised, auto-hold ensures that the profile and the actual processes remain synchronised. If the process does not closely match the setpoints (within the defined Hold Bands), the profile will be held until it returns within bounds. When Auto-Hold becomes active, the profile status is shown as “Held”.

Auto-hold can be configured to hold the profile if the process goes beyond the hold band Above The Setpoint only, Below The Setpoint only or it can be set to Band (either side of the setpoint).

Auto Hold Examples

Auto Hold on Dwells

Figure 52. Auto-Hold on a Dwell Segment

During a Dwell, the dwell time is increased by the time that the process is outside of the hold band in the selected direction(s). This ensures the process was at the desired level for the required amount of time.

Pro-EC44 Product Manual - 59540-1 October 2013 Page 91

Auto Hold on Ramps

Held if Auto-Hold set to Above Setpoint or Band

Process Variable

Ramp Setpoint

(without Auto-

Hold)

Hold Band

Ramp Setpoint (with Auto-Hold)

Held if Auto-Hold set to Below Setpoint or Band

PROFILE 4

PROFILE 31

PROFILE 7

Join (Profile 4 to Profile 31)

Join (Profile 31 to Profile 7)

Example:

Runs profile 4 once, profile 31 three times & profile 7 once. This sequence is repeated ten times.

Profile 31

Cycles = 3

Repeat Sequence = 10

Repeat Then End

(times to repeat = 10)

Profile 4

Cycles = 1

Profile 7

Cycles = 1

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Figure 53. Auto-Hold On A Ramp Segment

During a Ramp segment, the ramp is held at the current setpoint value while the process is outside of the hold band in the selected direction(s). The time taken to complete the ramp is increased by the time taken by the Auto-Hold.

Profile Cycles & Repeat Sequences

A profile can be configured to run itself from 1 to 9999 times or continuously using the Profile Cycles setting. A profile ending with Repeat Then End will run the entire sequence of profiles again from 1 to 9999 times before ending.

Figure 54. Profile Cycles & Repeats

Pro-EC44 Product Manual - 59540-1 October 2013 Page 92

Pro-EC44 2-Loop Graphical Profile Controller & Recorder

Possible Recovery Methods:

See

note

below

End the profile and maintain the setpoint value(s) from the time the power failed.

End the profile and use Controller Setpoint value(s).

End the profile with the Control outputs off - setpoint value replaced by “OFF”.

Restart the profile again from the beginning.

Continue profile from the point it had reached when the power failed

Note: Recorder versions always use option E (Continue profile) if the “off time” is less than the Profile Recovery Time setting. If the “off time” is longer, the defined Profile Recovery Method is used.

Note: With option E, after the power returns profile bar graph resets and shows the remaining/elapsed time for the profile only since re-starting.

Controller SP

Run (Start-on SP)

Power off or input lost

Power / input returns

= Control Off

Planned Profile

Off Time

Power/Signal Lost Recovery Actions

If the power is cut or the input signal is lost while a profile is running, the instrument will use the defined Profile Recovery Method once the signal / power returns. The profile recovery method is set in the profile header.

The possible profile recovery options are explained below.

Figure 55. End, Abort and Recovery Actions

Pro-EC44 Product Manual - 59540-1 October 2013 Page 93

West Control Solutions Pro-EC44 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Warranty and Returns Statement

1 Introduction

2 Installation

Unpacking

Installation

Panel-Mounting

Cleaning

3 Field Upgrade Options

Plug-Modules and Upgradeable Functions

Preparing to Install or Remove Plug-in Modules

Removing/Replacing Option Modules

Replacing the Instrument in its Housing

Auto Detection of Plug-in Modules

Data Recorder Board

Profiler Enabling

Entering the Profiler Enable Code

4 Electrical Installation

Avoiding EMC Problems

Cable Isolation & Protection

Noise Suppression at Source

Sensor Placement (Thermocouple or RTD)

Thermocouple Wire Identification

Pre-wiring – Cautions, Warnings & Information

Connections and Wiring

Central Terminal Connections

Outer Terminal Connections

Power Connections

Power Connections - Mains Powered Instruments

Power Connections - 24/48V AC/DC Powered Instruments

Universal Input 1 Connections

Universal Input 1 Connections - Thermocouple (T/C)

Universal Input 1 Connections – PT100 / NI120 (RTD) input

Universal Input 1 Connections - Linear Volt, mV or mA input

Universal / Auxiliary Input 2 Connections

Universal Input 2 Connections - Thermocouple (T/C)

Universal Input 2 Connections – PT100 / NI120 (RTD) input

Universal / Auxiliary Input 2 Connections - Linear Volt, mV or mA input

Universal / Auxiliary Input 2 Connections – Potentiometer

Base Option 1

Base Option 1 Relay Output 4

Base Option 1 Linear Output 6

Base Option 2

Base Option 2 Relay Output 5

Base Option 2 Linear Output 7

Plug-in Module Slot 1 Connections

Plug-in Module Slot 1 – Single Relay Output Module

Plug-in Module Slot 1 – Single SSR Driver Output Module

Plug-in Module Slot 1 - Triac Output Module

Plug-in Module Slot 1 - Linear Voltage or mADC Output module

Plug-in module slot 2 Connections

Plug-in Module Slot 2 – Single Relay Output Module

Plug-in Module Slot 2 - Dual Relay Output Module

Plug-in Module Slot 2 – Single SSR Driver Output Module

Plug-in Module Slot 2 – Dual SSR Driver Output Module

Plug-in Module Slot 2 - Triac Output Module

Plug-in Module Slot 2 - Transmitter Power Supply Module

Plug-in Slot 3 Connections

Plug-in Module Slot 3 – Single Relay Output Module

Plug-in Module Slot 3 - Dual Relay Output Module

Plug-in Module Slot 3 – Single SSR Driver Output Module

Plug-in Module Slot 3 – Dual SSR Driver Output Module

Plug-in Module Slot 3 - Triac Output Module

Plug-in Module Slot 3 - Transmitter Power Supply Module

Plug-in Slot A Connections

Plug-in Module Slot A – Basic Auxiliary Input Module

Plug-in Module Slot A - Ethernet Communications Module

Plug-in Module Slot A - RS485 Serial Communications Module

Plug-in Module Slot A – Single Digital Input Module

Option C Connections

Option C Connections – Multiple Digital Input Module

Special Wiring Considerations for Valve Motor Control

5 Powering Up

Powering Up Procedure

Front Panel Overview

Display

LED Functions