West Control Solutions ProVU 4 User Manual
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
ProVU4 Graphical Controller
with optional Profiling & Recording
User Guide
Part Number: 59407-1
Price: £12.00
$20.00
€18.00
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
This manual supplements the Concise Product manual(s) supplied with each instrument at
the time of shipment. Information in this installation, wiring and operation manual is subject to
change without notice.
Copyright © March 2008, 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
West Instruments.
Copies of this manual are available in electronic format on the West Instruments web site
(www.westinstruments.com) Printed versions are available from West or its agents at the
price published on the front cover.
Note:
It is strongly recommended that applications incorporate a high or low limit protective
device, which will shut down the equipment at a preset process condition in order to
prevent possible damage to property or products.
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.
Products covered by this manual are suitable for Indoor use, Installation Category II,
Pollution category 2 environments.
This user guide covers all versions of the West ProVU4 controller.
59407, Issue 1 – March 2008 Page iii
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Warranty and Returns Statement
These products are sold by West Instruments 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 Instruments or from a West Instruments 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
at the time the products leave West Instruments factory and to conform at that time to the
specifications set forth in the relevant West instruction manuals sheet or sheets, for such
products for a period of three years.
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 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 Instruments 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 iv 59407, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
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 Graphical Controller. The main sections are shown here,
followed by a full table of contents.
Section 1: Introduction - A brief description of the product and it’s features.
Section 2: Installation - Unpacking, installing and panel mounting instructions.
Section 3: Field Upgrade Options - Installation of the plug-in option modules.
Section 4: Wiring Instructions - Guidance on good wiring practice, noise avoidance,
wiring diagrams and input/output connections.
Section 5: Powering Up - Powering up procedure and descriptions of displays & switches.
Section 6: Messages & Error Indications - Display Messages and fault indications.
Section 7: Configuration & Use - Describes operating and configuration modes available.
These include Operation Mode; the Main and Configuration menus; the Easy Setup Wizard;
Supervisor Mode; Automatic tuning; Product and Service Information. Also available on
some models are menus to setup and use the USB, Data Recorder and Profiler features.
Section 8: The USB Interface Option – Describes uploading or download of instrument
settings, profiles or recorder log to a USB memory stick.
Section 9: The Data Recorder Option – Describes the Data recorder feature. This allows
process data to be stored in to memory for later download and analysis.
Section 10: The Profiler Option – Describe the Profiler feature. A profile controls the value
of the setpoint over time; increasing, decreasing or holding its value as required.
Section 11: Manually Tuning Controllers - Advice on manually adjusting the controller to
the Process characteristics.
Sections 12: Serial Communications - Details the physical layer and message formats
used for the RS485 and Ethernet communications options.
Sections 13: Modbus Parameters - Details the parameter addresses and data formats used
for the Modbus RTU and TCP communications protocols.
Section 14: Calibration - Step-by-step instructions to calibrate the instrument. This section
is intended for use by suitably qualified personnel.
Appendix 1: Glossary - Explanations of the terms used and product features.
Appendix 2: PC Software – Using the software suite.
Appendix 3: Specifications - Technical specifications for all products in the range.
Appendix 4: Product Coding - Product model/ordering codes.
59407, Issue 1 – March 2008 Page 5
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Contents
Page Number:
Warranty and Returns Statement.................................................................................................... iv
1 Introduction ..........................................................................................................................14
2 Installation ............................................................................................................................15
Unpacking ...........................................................................................................................................15
Installation...........................................................................................................................................15
Panel-Mounting ...................................................................................................................................15
Cleaning..............................................................................................................................................16
3 Field Upgrade Options......................................................................................................... 17
Options Modules and Functions...........................................................................................................17
Preparing to Install or Remove Options Modules..................................................................................18
Removing/Replacing Option Modules ..................................................................................................19
Replacing the Instrument in its Housing ...............................................................................................20
Auto Detection of Option Modules........................................................................................................20
Replacement of Power Supply or Input Boards ....................................................................................20
Data Recorder Board...........................................................................................................................21
Profiler Enabling ..................................................................................................................................21
4 Electrical Installation ........................................................................................................... 22
Installation Considerations...................................................................................................................22
AC Power Wiring - Neutral (for 100 to 240V AC versions) ....................................................................22
Wire Isolation.......................................................................................................................................22
Use of Shielded Cable .........................................................................................................................23
Noise Suppression at Source...............................................................................................................23
Sensor Placement (Thermocouple or RTD)..........................................................................................24
Thermocouple Wire Identification Chart ...............................................................................................24
Connections and Wiring.......................................................................................................................25
Power Connections ........................................................................................................................26
Universal Input Connections ...........................................................................................................27
Option Slot 1 Connections ..............................................................................................................29
Option Slot 2 Connections ..............................................................................................................30
Option Slot 3 Connections ..............................................................................................................32
Option Slot A Connections..............................................................................................................35
Option Slot B Connections..............................................................................................................36
5 Powering Up .........................................................................................................................37
Powering Up Procedure.......................................................................................................................37
Front Panel Overview ..........................................................................................................................37
Display ................................................................................................................................................37
LED Functions.....................................................................................................................................38
Keypad................................................................................................................................................38
6 Messages and Error Indications .........................................................................................39
Page 6 Table Of Content 59407-6, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Start-up Errors.....................................................................................................................................39
Input Problems ....................................................................................................................................39
USB Data Transfer Problems...............................................................................................................40
Getting Help ........................................................................................................................................40
7 Configuration and Use .........................................................................................................41
Operation Mode...................................................................................................................................41
Base, Trend & Profile Operating Screens....................................................................................... 41
Adjusting the Local Setpoint(s) ...................................................................................................... 43
Adjusting the Setpoint Ramp Rate ................................................................................................. 44
Selecting Automatic or Manual Mode............................................................................................. 44
Control Enable or Disable.............................................................................................................. 44
Main Menu...........................................................................................................................................45
Entry into the Main Menu............................................................................................................... 45
Unlock Codes................................................................................................................................ 45
Setup Wizard.......................................................................................................................................46
Manual entry to the Setup Wizard.................................................................................................. 46
Supervisor Mode .................................................................................................................................47
Entry into Supervisor Mode............................................................................................................ 47
Configuration Menu .............................................................................................................................48
Entry into the Configuration Menu.................................................................................................. 48
Input Configuration Sub-Menu .............................................................................................................49
Control Configuration Sub-Menu..........................................................................................................50
Output Configuration Sub-Menu...........................................................................................................52
Alarm Configuration Sub-Menu............................................................................................................53
Communications Configuration Sub-Menu ...........................................................................................53
Recorder Configuration Sub-Menu.......................................................................................................54
Clock Configuration Sub-Menu ............................................................................................................55
Display Configuration Sub-Menu..........................................................................................................55
Lock Code View...................................................................................................................................56
Lost Lock Codes............................................................................................................................ 56
Resetting To Defaults ..........................................................................................................................57
Automatic Tuning Menu .......................................................................................................................57
Profiler Setup Menu.............................................................................................................................58
Profiler Control Menu...........................................................................................................................60
USB Menu...........................................................................................................................................61
Recorder Menu....................................................................................................................................62
Product Information Mode....................................................................................................................62
Service Information Mode ....................................................................................................................63
8 The USB Interface.................................................................................................................64
Using the USB Port..............................................................................................................................64
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ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
USB Memory Stick Folders & Files .................................................................................................64
9 The Data Recorder Option................................................................................................... 65
Introduction .........................................................................................................................................65
Changes To Operation Mode...............................................................................................................65
10 The Profiler Option...............................................................................................................66
Profile Components .............................................................................................................................66
Profile Starting & Standard Segments..................................................................................................67
Loops Segments..................................................................................................................................68
Profile Running / Holding vs. Hold Segments .......................................................................................68
The Auto-Hold Feature ........................................................................................................................69
Profile Cycles & Repeat Sequences.....................................................................................................70
Power/Signal Lost Recovery Actions....................................................................................................70
Profile End Actions ..............................................................................................................................71
Profile Abort Actions ............................................................................................................................72
11 Manually Tuning Controllers ...............................................................................................73
Single Control Tuning (PID with Primary Output only) ..........................................................................73
Dual Control Tuning (PID with Primary and Secondary Outputs) ..........................................................74
PI Tuning (Valve, Damper& Speed Controller) .....................................................................................74
Fine Tuning. ........................................................................................................................................76
12 Serial Communications........................................................................................................77
Supported Protocols ............................................................................................................................77
RS485 Configuration ...........................................................................................................................77
Ethernet Configuration.........................................................................................................................77
Supported Modbus Functions ..............................................................................................................79
Function Descriptions ..........................................................................................................................79
Exception Responses.....................................................................................................................81
13 Modbus Parameters............................................................................................................. 82
Example Register Address Calculations .........................................................................................82
Universal Process Input Parameters ....................................................................................................83
Option Slot A Parameters ....................................................................................................................85
Option Slot B Parameters ....................................................................................................................86
Option Slot 1 Parameters.....................................................................................................................87
Option Slot 2 Parameters.....................................................................................................................89
Option Slot 3 Parameters.....................................................................................................................92
Option Slot 4 Parameters.....................................................................................................................95
Setpoint Parameters..........................................................................................................................100
Control Parameters............................................................................................................................101
Alarm parameters ..............................................................................................................................103
Recorder & Clock Parameters............................................................................................................105
Display Parameters ...........................................................................................................................108
Profiler Control & Status Parameters .................................................................................................111
Page 8 Table Of Content 59407-6, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Profile Setup Over Modbus ................................................................................................................113
Instrument Data.................................................................................................................................128
14 Calibration...........................................................................................................................129
Calibration Reminder .........................................................................................................................129
Equipment Required For Checking or Calibrating the Universal Input.................................................129
Calibration Check ..............................................................................................................................129
Recalibration Procedure ....................................................................................................................130
15 Appendix 1 – Glossary of Terms Used..............................................................................131
Active Setpoint...................................................................................................................................131
Actual Setpoint ..................................................................................................................................131
Alarm Configuration...........................................................................................................................131
Alarm Operation ................................................................................................................................133
Alarm Inhibit ......................................................................................................................................134
Alarm Types ......................................................................................................................................134
Alternative Setpoint............................................................................................................................134
Auto Pre-Tune ...................................................................................................................................134
Automatic Reset ................................................................................................................................134
Auxiliary Input....................................................................................................................................135
Auxiliary Input Lower Limit .................................................................................................................135
Auxiliary Input Offset..........................................................................................................................135
Auxiliary Input Type ...........................................................................................................................135
Auxiliary Input Upper Limit .................................................................................................................135
Band Alarm Value..............................................................................................................................135
Bar Graphs........................................................................................................................................136
Bias (Manual Reset) ..........................................................................................................................136
Bumpless Transfer.............................................................................................................................136
Cascade Control................................................................................................................................136
Clock Configuration ...........................................................................................................................137
Communications Write Enable...........................................................................................................137
Configuration Menu ...........................................................................................................................137
Contactor...........................................................................................................................................137
Control Configuration.........................................................................................................................137
Control Deviation ...............................................................................................................................138
Control Action....................................................................................................................................138
Control Enable/Disable ......................................................................................................................138
Control Type......................................................................................................................................138
Controller...........................................................................................................................................138
Controller Mode.................................................................................................................................138
Correcting Variable............................................................................................................................138
CPU ..................................................................................................................................................139
59407, Issue 1 – March 2008 Introduction Page 9
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Current Proportioning Control ............................................................................................................139
Custom Display Mode........................................................................................................................139
Cycle Time ........................................................................................................................................139
Data Recorder ...................................................................................................................................139
Deadband..........................................................................................................................................139
Derivative Action................................................................................................................................139
Deviation Alarm Value .......................................................................................................................140
Digital Input .......................................................................................................................................140
Direct Acting Control..........................................................................................................................140
Display Configuration.........................................................................................................................140
Display Languages ............................................................................................................................140
Display Resolution.............................................................................................................................141
Engineering Units ..............................................................................................................................141
Ethernet.............................................................................................................................................141
Indicator ............................................................................................................................................141
Input Configuration ............................................................................................................................141
Input Filter Time Constant..................................................................................................................141
Input Range.......................................................................................................................................141
Input Span.........................................................................................................................................142
Integral Time Constant.......................................................................................................................142
Latching Relay...................................................................................................................................142
LED...................................................................................................................................................142
Linear Input .......................................................................................................................................142
Linear Output.....................................................................................................................................142
Limit Controller ..................................................................................................................................142
Local Setpoints..................................................................................................................................143
Lock Codes .......................................................................................................................................143
Logical Combination of Alarms...........................................................................................................143
Loop Alarm........................................................................................................................................144
LSD...................................................................................................................................................144
mADC ...............................................................................................................................................144
Main Menu ........................................................................................................................................144
Manual Loop Alarm Time...................................................................................................................144
Manual Mode.....................................................................................................................................145
Master & Slave Controllers ................................................................................................................145
Minimum Duration Of Change............................................................................................................145
Modbus RTU .....................................................................................................................................146
Modbus TCP .....................................................................................................................................146
Modulating Valve ...............................................................................................................................146
Multi-Point Scaling.............................................................................................................................147
mVDC ...............................................................................................................................................147
Page 10 Table Of Content 59407-6, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
On-Off Control ...................................................................................................................................147
On-Off Differential (On-Off Hysteresis)...............................................................................................147
Operation Mode.................................................................................................................................147
Output Configuration..........................................................................................................................148
Overlap/Deadband.............................................................................................................................148
PD Control.........................................................................................................................................149
PI Control ..........................................................................................................................................149
PID Control........................................................................................................................................149
PLC...................................................................................................................................................149
Pre-Tune ...........................................................................................................................................149
Power Output Limits ..........................................................................................................................150
Primary Proportional Band.................................................................................................................151
Process High Alarm n Value ..............................................................................................................151
Process Input ....................................................................................................................................151
Process Low Alarm n Value ...............................................................................................................151
Process Variable (PV)........................................................................................................................151
Process Variable Offset .....................................................................................................................152
Profile Control Menu ..........................................................................................................................152
Profile Events ....................................................................................................................................152
Profile Header....................................................................................................................................152
Profile Segments ...............................................................................................................................152
Profile Setup Menu ............................................................................................................................152
Profiler...............................................................................................................................................153
Profiler Mode .....................................................................................................................................153
Proportional Control...........................................................................................................................153
Rate ..................................................................................................................................................153
Rate Of Change Alarm.......................................................................................................................153
Recorder Configuration......................................................................................................................153
Recorder Option ................................................................................................................................154
Recorder Menu..................................................................................................................................154
Relay.................................................................................................................................................154
Remote Setpoint (RSP) .....................................................................................................................154
Retransmit Output..............................................................................................................................154
Retransmit Output n Scale Maximum.................................................................................................154
Retransmit Output n Scale Minimum..................................................................................................155
Reset To Defaults..............................................................................................................................155
Reverse Acting Control ......................................................................................................................155
RS485 ...............................................................................................................................................155
RTD...................................................................................................................................................156
Scale Range Upper Limit ...................................................................................................................156
Scale Range Lower Limit ...................................................................................................................156
59407, Issue 1 – March 2008 Introduction Page 11
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Secondary Proportional Band ............................................................................................................156
Self-Tune...........................................................................................................................................157
Sensor Break Pre-Set Power .............................................................................................................157
Serial Communications Configuration ................................................................................................158
Serial Communications Option...........................................................................................................158
Setpoint.............................................................................................................................................158
Setpoint Upper Limit ..........................................................................................................................158
Setpoint Lower Limit ..........................................................................................................................158
Setpoint Ramping Editing ..................................................................................................................158
Setpoint Ramp Rate ..........................................................................................................................159
Setpoint Selection..............................................................................................................................159
Setup Wizard.....................................................................................................................................159
Solid State Relay (SSR).....................................................................................................................159
Solenoid Valve ..................................................................................................................................160
Supervisor Mode ...............................................................................................................................160
Thermocouple ...................................................................................................................................160
Three Point Stepping Control.............................................................................................................160
Time Proportioning Control ................................................................................................................161
Trend Display ....................................................................................................................................161
Tuning...............................................................................................................................................161
Tuning Menu .....................................................................................................................................161
Triac..................................................................................................................................................162
USB Menu.........................................................................................................................................162
Valve Motor Drive Control (VMD).......................................................................................................162
VDC ..................................................................................................................................................162
VMD..................................................................................................................................................162
16 PC SOFTWARE................................................................................................................... 163
Using The Software ...........................................................................................................................163
Instrument Configuration....................................................................................................................164
Profile Creation And Editing...............................................................................................................165
Changing the Start-up Splash Screen ................................................................................................167
Changing the Alternate Display Language .........................................................................................167
Instrument Simulation........................................................................................................................167
Configuring The Connection ..............................................................................................................167
Network Configuration For Modbus TCP Options...............................................................................169
17 Appendix 2 - Specifications............................................................................................... 171
Universal Process Input .....................................................................................................................171
General Input Specifications .........................................................................................................171
Thermocouple Input......................................................................................................................171
Resistance Temperature Detector (RTD) Input .............................................................................172
DC Linear Input ............................................................................................................................173
Page 12 Table Of Content 59407-6, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Auxiliary Inputs ..................................................................................................................................173
Digital Inputs......................................................................................................................................174
Output Specifications.........................................................................................................................175
Communications................................................................................................................................177
Display ..............................................................................................................................................178
Control Loop......................................................................................................................................178
Data Recorder ...................................................................................................................................178
Profiler...............................................................................................................................................179
Alarms...............................................................................................................................................179
Conditions For Use ............................................................................................................................180
Standards..........................................................................................................................................180
Dimensions........................................................................................................................................180
18 Appendix 3 - Product Coding.............................................................................................181
59407, Issue 1 – March 2008 Introduction Page 13
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
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 a dual colour (red/green)
backlight. It can control process variables from a variety of sources such as temperature,
pressure, flow and level.
The operating voltage is either 100-240V at 50/60 Hz or 24V-48V AC/DC depending on the
model purchased. Optional features include a USB interface, RS485 or Ethernet
communications, profile controlling and data recording. Non-volatile memory protects against
data or configuration loss during power outages. If the unit is left un-powered, a lithium
battery powers the data recorder’s real-time clock for a minimum of one year.
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 of Profiler options are fitted, recordings
and profile information can also be transferred via the memory stick.
The Data Recorder option allows the user to make recordings over time. Recordings can be
transferred to a memory stick using the USB Port or downloaded using 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 level over time, increasing, decreasing or
holding its value as required. When combined with the real-time clock 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. Multipoint scaling can compensate for nonlinear signals. Output options include relays, SSR drivers, triacs or linear mV/voltage
modules. These can be used for process control, alarms or retransmission of the process
variable or setpoint to external devices. A Transmitter Power Supply option module can
provide an unregulated 24V DC (22mA) auxiliary output voltage for external signal
transmitters.
Alarm indication is standard on all instruments; up to five alarms can be defined. Alarms may
be set 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 or signal break
types. Alarm status can be indicated by lighting an LED’s, changing the display backlight
colour or viewing the alarm status screen. These alarms can be linked to any suitable output.
The controller can be programmed for on-off, time proportioning, or current proportioning
control implementations, depending on the output modules fitted, and feature manual or
automatic tuning of the PID parameters. A secondary control output is available when
additional output modules are fitted. Optional analogue Remote Setpoint inputs can be
included. Configuration of the major settings is made easy by a Setup Wizard that runs
automatically at first ever power-up or whenever option modules have been changed. Access
to the full range of parameters is via a simple menu driven front panel interface, or the PC
based configuration software.
Page 14 Table Of Content 59407-6, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
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
repair/testing.
2. The instrument is supplied with a panel gasket and push fit fixing strap. A single sheet
concise manual is also supplied in one or more languages. Examine the delivered items
for damage or defects. If any are found, contact your supplier immediately.
Installation
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).
Figure 1. Main dimensions
Panel-Mounting
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).
59407, Issue 1 – March 2008 Installation Page 15
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Instrument
and instrument is clamped in
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
6mm or more clearance between the edges of the holes.
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-byside 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
Slide mounting clamp over
the instrument housing
Mounting Panel
towards rear face of
Clamp
Ratchets
Housing
mounting panel until the
tongues engage in ratchets
position.
Hold instrument firmly in
position (apply pressure to
bezel only)
Figure 2. Panel-Mounting the instrument
CAUTION:
Do not remove the panel gasket, as this may result in inadequate clamping and
sealing of the instrument to the panel.
Once the instrument is installed in its mounting panel, it may be subsequently removed from
it’s housing, if necessary, as described in the Fitting and Removing Option 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.
Page 16 Installation 59407, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
3 -Field Upgrade Options
Options Modules and Functions
The available plug-in modules, options and accessories are shown in below:
Table 1. Options & Accessories
PART
NUMBER
OPTION SLOT 1
PO1-R10
PO1-S20
PO1-T80
PO1-C21
OPTION SLOT 2 or 3
PO2-R10
PO2-W09
PO2-S20
PO2-S22
PO2-T80
PO2-C21
PO2-W08
OPTION SLOT A
PA1-W03
PA1-W04
PA1-W06
PA1-ETH
OPTION SLOT B
PB1-W0R
OPTION SLOT 4
PO4-R10
ACCESSORIES
PS1-PRF
PS1-PRW
DESCRIPTION
Single Relay Output for option slot 1
Single SSR Driver Output for option slot 1
Triac Output for option slot 1
Linear mA / Voltage Output module for option slot 1
Single Relay Output for option slot 2 or 3
Dual Relay Output for option slot 2 or 3
Single SSR Driver Output for option slot 2 or 3
Dual SSR Driver Output for option slot 2 or 3
Triac module Output for slot 2 or 3
Linear mA / Voltage Output for option slot 2 or 3
24VDC Transmitter Power Supply for option slot 2 or 3
Digital Input for option slot A
Basic Auxiliary Input for option slot A
RS485 Serial Communications for option slot A
Ethernet Communications for option slot A
Full Auxiliary Input (inc digital input B) for option slot B
4-Relay Output for option slot 4
Profiler Enable Key-code
PC Configuration Software & Lead
BOARD
IDENTIFICATION
NUMBER
716/01
716/02
716/03
639/01
717/01
644/01
717/02
644/02
647/01
640/01
642/01
641/02
653/01
680/01
707/01
641/01
703/01
Note:
Modules can be either pre-installed at the time of manufacture, or retrofitted in the field.
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.
Note:
All dual relay modules have reinforced isolation.
59407, Issue 1 – March 2008 Field Upgrade Options Page 17
Board Positions
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Board Mounting Struts
Option 4 Module
Option A Module
Option 3 Module
Universal Input Board
Power Supply Board
Option B Module
Option 1 Module
(hidden below B)
Option 2 Module
Option C Module
Figure 3. Rear view (uncased) & board positions
Preparing to Install or Remove Options Modules
CAUTION:
Before removing the instrument from it’s housing, ensure that all power has been
removed from the rear terminals. Modules / boards should only be replaced by a
trained technician.
1. Remove the instrument from its housing by gripping the edges of the front panel (there is a
finger grip on each edge) and pull the instrument forwards. This will release the instrument
from the rear connectors in the housing and will give access to the boards.
2. Take note of the orientation of the instrument for subsequent replacement into the
housing. The positions of the boards in the instrument are shown above.
Page 18 Field Upgrade Options 59407, Issue 1 – March 2008
Main Board Connectors
POWER SUPPLY
Transformer Colour
48V(Blue)
Display Board
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
BOARD
Code
100-240V (Yellow)
24-
Connections
UNIVERSAL INPUT
BOARD
Option 3 Slot
Connector PL4B
Option Slot A
Connectors PL5, & PL6
Option 1 Slot
Connectors PL7 & PL8
PC Configurator
Socket SK1
Option 2 Slot
Connector PL4A
Option Slot B
Connectors PL2A, PL2B &
PL2C
Figure 4. Main board connectors
Removing/Replacing Option Modules
1. To remove or replace modules in Option Slots 1, 2, 3, A or B, 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 a 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. Remove or replace the Slot C and 4 modules as required.
5. Push the boards forward to ensure correct connection to the front Display/CPU board.
CAUTION:
Check for correct orientation of the modules and that all pins are located correctly.
59407, Issue 1 – March 2008 Field Upgrade Options Page 19
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Replacing the Instrument in its Housing
CAUTION:
Before replacing the instrument in it’s housing, ensure that all power has been
removed from the rear terminals.
With the required option modules correctly located into their respective positions the
instrument can be replaced into it’s 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 in position.
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.
Auto Detection of Option Modules
The instrument automatically detects which option modules have been fitted into each slot.
The menus and screens change to reflect the options compatible with the hardware fitted.
The modules fitted can be viewed in the products information menu, as detailed in the
Product Information Mode section of this manual.
Replacement of Power Supply or Input Boards
It is recommend that users change these boards only if unavoidable.
1. Remove the instrument from it’s housing as detailed above.
2. Remove all option modules.
3. Replace the Power Supply or Input board as required. Carefully observe the transformer
colour and the case labelling to check the supply voltage when replacing the power
supply board.
4. Reassemble the unit in it’s case.
5. If the input board has to be replaced, a full recalibration must be carried out before the
instrument is used. Refer to the calibration section of this manual for instructions.
CAUTION:
Replacement of boards must be carried out by a trained technician.
If the Power Supply board does not match the labelling, users may apply incorrect
voltage resulting in irreparable damage.
Page 20 Field Upgrade Options 59407, Issue 1 – March 2008
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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.
CAUTION:
Servicing of the Data Recorder/RTC circuit and replacement of the lithium battery
should only be carried out by a trained technician.
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 A Profiler Enable Code
Hold down the and keys during the power-up “splash screen”.
Using the or keys, enter the 16-character licence code in the displayed screen.
Press to move on to the next character. Press to move back to the previous
character.
Press after entering the final character.
To confirm if profiling is installed in your instrument, refer to the Controller Feature
Information in Product Information mode.
59407, Issue 1 – March 2008 Field Upgrade Options Page 21
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
4 Electrical Installation
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).
Installation Considerations
Ignition transformers, arc welders, motor drives, mechanical contact relays and solenoids are
examples of devices that generate electrical noise in typical industrial environments. The
following guidelines MUST be followed to minimise their effects.
1. If the instrument is being installed in existing equipment, the wiring in the area should be
checked to ensure that good wiring practices have been followed.
2. Noise-generating devices such as those listed should be mounted in a separate
enclosure. If this is not possible, separate them from the instrument, by the largest
distance possible.
3. If possible, eliminate mechanical contact relays and replace with solid-state relays. If a
mechanical relay being powered by an output of this instrument cannot be replaced, a
solid-state relay can be used to isolate the instrument.
4. A separate isolation transformer to feed only the instrumentation should be considered.
The transformer can isolate the instrument from noise found on the AC power input.
AC Power Wiring - Neutral (for 100 to 240V AC versions)
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.
Wire Isolation
Four voltage levels of input and output wiring may be used with the unit:
1. Analogue input or output (for example thermocouple, RTD, VDC, mVDC or mADC)
2. Relays & Triac outputs
3. SSR Driver outputs
4. AC power
CAUTION:
The only wires that should run together are those of the same category.
If any wires need to run parallel with any other lines, maintain a minimum space of 150mm
between them.
If wires MUST cross each other, ensure they do so at 90 degrees to minimise interference.
Page 22 Wiring Instructions 59407, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Use of Shielded Cable
All analogue signals must use shielded cable. This will help eliminate electrical noise
induction on the wires. Connection lead length must be kept as short as possible keeping the
wires protected by the shielding. The shield should be grounded at one end only. The
preferred grounding location is at the sensor, transmitter or transducer.
Noise Suppression at Source
Usually when good wiring practices are followed, no further noise protection is necessary.
Sometimes in severe electrical environments, the amount of noise is so great that it has to be
suppressed at source. Many manufacturers of relays, contactors etc supply 'surge
suppressors' which mount on the noise source. For those devices that do not have surge
suppressors supplied, Resistance-Capacitance (RC) networks and/or Metal Oxide Varistors
(MOV) may be added.
Inductive coils:- MOVs are recommended for transient suppression in inductive coils,
connected in parallel and as close as possible 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
59407, Issue 1 – March 2008 Wiring Instructions Page 23
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
Sensor Placement (Thermocouple or RTD)
If the temperature probe is to be subjected to corrosive or abrasive conditions, it must be
protected by an appropriate thermowell. The probe must be positioned to reflect true process
temperature:
1. In a liquid media - the most agitated area
2. In air - the best circulated area
CAUTION:
The placement of probes into pipe work some distance from the heating vessel
leads to transport delay, which results in poor control.
For a two wire RTD a wire link should be used in place of the third wire. Two wire RTDs must
only be used with lead lengths less than 3 metres. Use of three wire RTDs is strongly
recommended.
Thermocouple Wire Identification Chart
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.
The table below shows the wire and sheath colours used for most
common thermocouple types. The format used in this table is:
+ Wire
- Wire
Sheath
Table 2. Thermocouple Extension Wire Colours
Type International
IEC584-3
Black White Yellow Yellow Red
J
White
-
Brown Blue White Yellow Red
+
T
+*
White
-
Green Yellow Brown Yellow Red
K
N
+
White
-*
Pink Orange Orange
+
White
-
Grey Grey Red
+
B
White
-
Black
Brown
Green
Pink
Grey
USA ANSI
MC 96.1
Black
Red
Blue
Red
Yellow
Red
Orange
Red
Grey
Red
British
BS1843
Blue
Blue
Blue
Blue
Black
Blue
Red
Orange
French
NFC 42-324
Black
Black
Blue
Blue
Yellow
Purple
German
DIN 43710
Blue
Blue
Brown
Brown
Green
Green
Grey
Grey
R & S
C (W5)
+
White
-
+
-
Orange
Red
White
Red
Green
White
Blue
Green
Green
Green
White
White
Orange Black White Yellow Red
Note:
* = Wire is magnetic
Page 24 Wiring Instructions 59407, Issue 1 – March 2008
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Connections and Wiring
This symbol means the equipment is protected throughout by double insulation.
CAUTION:
All external circuits connected must provide double insulation. Failure to comply
with the installation instructions may impact the protection provided by the unit.
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.
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 depend
upon the features available on the model and the modules and options fitted.
Figure 7. Main Rear terminals
Note:
59407, Issue 1 – March 2008 Wiring Instructions Page 25
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
13
14LN
The wiring diagram below shows the additional connections (numbered 25 to 42) at the
sides of the case rear. These are required for Options Slots 4 and C if fitted.
Figure 8. Additional Option terminals
Note:
Use single strand (1.2mm / AWG18 max size) copper wire throughout, except for the
thermocouple input, where the correct thermocouple or compensating cable and
connectors must be used.
Power Connections
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 voltage (live and neutral) as illustrated via a two-pole
IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker and a UL listed fuse
type: 250V AC 1Amp anti-surge. If the instrument has relay outputs with contacts carrying
mains voltage, it is recommended that the relay contacts supply should be switched and
fused in a similar manner, but should be separate from the instruments mains supply.
Figure 9. Mains Power Connections
WARNING:
CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT
VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.
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.
Page 26 Wiring Instructions 59407, Issue 1 – March 2008
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1314_
+32 + _
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 two-pole IEC60947-1 & IEC60947-3 compliant isolation switch /
circuit breaker and a UL listed fuse type: 65v dc 1Aamp anti-surge.
Figure 10. 24/48V AC/DC Power Connections
WARNING:
CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT
VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.
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.
Universal Input Connections
Universal Input Connections - Thermocouple (T/C)
Use only the correct thermocouple wire or compensating cable from the probe to the
instrument terminals avoiding joints in the cable if possible. Failure to use the correct wire
type will lead to inaccurate readings. Ensure correct polarity of the wires by crossreferencing the colours with a thermocouple reference table.
Figure 11. Thermocouple Input Connections
59407, Issue 1 – March 2008 Wiring Instructions Page 27
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
RTD
32143
21+ __
+
Universal Input Connections – PT100 / NI120 (RTD) input
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 used in place of the third wire (shown by
dotted line). Two wire RTDs should only be used when the leads are less than 3 metres long.
Avoid cable joints.
Figure 12. RTD Input 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 Input Connections - Linear Volt, mV or mA input
Linear DC voltage, millivolt or milliamp input connections are made as illustrated. Carefully
observe the polarity of the connections.
mV/V
mA
Figure 13. DC Volt, mV & mA Input Connections
Page 28 Wiring Instructions 59407, Issue 1 – March 2008
ProVU4 Controller, Profiler & Recorder/Controller - Product Manual
19
20
N/C
COM
21
N/O
19
20
_21+2021
Option Slot 1 Connections
Option Slot 1 – Single Relay Output Module
If option slot 1 is fitted with a single relay output module, make connections as illustrated.
The relay contacts are SPDT and rated at 2 amps resistive, 240 VAC.
Figure 14. Option Slot 1 – Single Relay Module
Option Slot 1 – Single SSR Driver Output Module
If option slot 1 is fitted with a single SSR driver output module, make connections as
illustrated. The solid-state relay driver is a 0-10V DC signal, load impedance must be no less
than 500 ohms. SSR driver outputs are not isolated from the signal input or other SSR driver
outputs.
Figure 15. Option Slot 1 – Single SSR Driver Module
Option Slot 1 - Triac Output Module
If option slot 1 is fitted with a Triac output module, make connections as shown. This output
is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. A snubber should be fitted across inductive
loads to ensure reliable switch off the Triac.
Figure 16. Option Slot 1 - Triac Module
59407, Issue 1 – March 2008 Wiring Instructions Page 29
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