Instruction Manual No /02. Universal Temperature Controller Model ETC023

Transcription

1 Instruction Manual No. 99 8/2 Universal Temperature Controller Model ETC23

2 COPYRIGHT DISCLAIMER NOTICE Copyright 22 by Eclipse Combustion. All rights reserved worldwide. This publication is protected by federal regulation and shall not be copied, distributed, transmitted, transcribed or translated into any human or computer language, in any form or by any means, to any third parties, without the express written consent of Eclipse Combustion. In accordance with the manufacture s policy of continual product improvement, the product presented in this brochure is subject to change without notice or obligation. The material in this manual is believed adequate for the intended use of the product. If the product is used for purposes other than those specified herein, confirmation of validity and suitability must be obtained. Eclipse Combustion warrants that the product itself does not infringe upon any United States patents. Not further warranty is expressed or implied. LIABILITY AND WARRANTY We have made every effort to make this manual as accurate and complete as possible. Should you find errors or omissions, please bring them to our attention so that we may correct them. In this way we hope to improve our product documentation for the benefit of our customers. Please send your corrections and comments to our Marketing Communications Manager. It must be understood that Eclipse Combustion s liability for its product, whether due to breach of warranty, negligence, strict liability, or otherwise is limited to the furnishing of replacement parts and Eclipse Combustion will not be liable for any other injury, loss, damage or expenses, whether direct or consequential, including but not limited to loss of use, income, or damage to material arising in connection with the sale, installation, use of, inability to use, or the repair or replacement of Eclipse Combustion s products. 2 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

3 About this manual AUDIENCE SCOPE This manual has been written for the people who select and install the product and the technicians who work on it. They are expected to have previous experience with this kind of equipment. This manual contains essential information for the proper installation and operation of the Eclipse Universal Temperature Controller. Following the instructions in this manual should assure trouble free installation and operation. Read this manual carefully. Make sure that you understand its structure and contents. Obey all the safety instructions. Do not deviate from any instructions or applications limits in the manual without written consent from Eclipse Combustions. If you do not understand any part of the information in this manual, do not continue. Contact your Eclipse sales office or Eclipse Combustion, Rockford, Illinois. If you need help, you can contact your local Eclipse Combustion sales office. HOW TO GET HELP Power Equipment Company 2 Williamsburg Road Richmond, Virginia 2323 U.S.A. Phone: Fax: ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 3

4 Symbol Definitions The following table lists those symbols used in this document to denote certain conditions. Symbol Definition This CAUTION symbol on the equipment refers the user to the Product Manual for additional information. This symbol appears next to required information in the manual. WARNING PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 3 Vrms, 42.4 Vpeak, or 6 VDC may be accessible. Failure to comply with these instructions could result in death or serious injury. ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for handling electrostatic sensitive devices Protective Earth (PE) terminal. Provided for connection of the protective earth (green or green/yellow) supply system conductor. Functional earth terminal. Used for non-safety purposes such as noise immunity improvement. NOTE: This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements. Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements. Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements. 4 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

5 Table of contents INTRODUCTION...9. Overview CE Conformity (Europe)... 2 INSTALLATION Overview Preliminary Checks Control and Alarm Relay Contact Information Mounting Wiring Wiring the Controller CONFIGURATION Overview Configuration Procedure Steps to Configure a 4 ma to 2mA Output Controller Steps to Configure ON-OFF or HIGH-LOW Control Steps to Configure Three-Position-Step-Control...3 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 5

6 4 OPERATION Operator Interface and Key Functions Powering Up the Controller Monitoring Your Controller Startup Procedure for Operation Setpoints Timer Accutune II Fuzzy Overshoot Suppression Using Two Sets of Tuning Constants Alarms Three Position Step Control Algorithm Setting a Failsafe Output Value for Restart After a Power Loss Setting Failsafe Mode Entering a Security Code Lockout Feature Background Tests Restore Factory Calibration Setpoint Rate Setpoint Ramp APPENDIX A - ENVIRONMENTAL AND OPERATING CONDITIONS APPENDIX B PARAMETER CONFIGURATIONS Timer Set Up Group Tuning Set Up Group SP Ramp Set Up Group Accutune Set Up Group Algorithm Set Up Group Input Set Up Group Control Set Up Group Options Set Up Group Communications Set Up Group Alarms Set Up Group APPENDIX C - CONFIGURATION RECORD SHEET ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

7 Tables Table 2- Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 2-6 Table 3- Table 4- Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 4-6 Table 4-7 Table 4-8 Table 4-9 Table 4- Table 4- Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 6- Table 6-2 Table 6-3 Table 6-4 Table 6-5 Table 6-6 Table 6-7 Table 6-8 Table 6-9 Table 6- Preliminary Checks Control Relay Contact Information 4 Alarm Relay Contact Information 4 Mounting Procedure 6 Permissible Wiring Bundling8 Universal Output Functionality and Restrictions 8 Configuration Procedure 27 Annunciators 33 Lower Display Key Parameter Prompts 34 Error Messages 35 Procedure for Starting Up the Controller 36 Procedure for Switching Between Setpoints _37 Set Up Procedure _4 Procedure for Switching PID SETS from the Keyboard 4 Procedure for Displaying Alarm Setpoints 4 Procedure for Displaying 3Pstep Motor Position 42 Procedure for Setting a Failsafe Value 43 Procedure for Setting a Failsafe Mode 44 Procedure to Enter a Security Code 45 Background Tests 47 Restore Factory Calibration 48 Running A Setpoint Ramp5 TIMER Group (Numeric Code ) Function Prompts_53 TUNING Group (Numeric Code 2) Function Prompts 54 SPRAMP Group (Numeric Code 3) Function Prompts 56 ATUNE Group (Numeric Code 4) Function Prompts 57 ALGOR Group (Numeric Code 5) Function Prompts 58 INPUT Group (Numeric Code 6) Function Prompts 59 CONTRL Group (Numeric Code 8) Function Prompts 6 Options Group (Numeric Code 9) Function Prompts 63 Communications Group (Numeric Code ) 64 ALARMS Group (Numeric Code ) Function Prompts 65 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 7

8 Figures Figure - Figure 2- Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2- Figure 2- Figure 2-2 Figure 2-3 Figure 2-4 Figure 3- Figure 4- ETC23 Operator Interface9 Jumper Placements 3 Mounting Dimensions (not to scale) 5 Mounting Method6 Composite Wiring Diagram 2 Mains Power Supply 2 Input Connections 2 Electromechanical Relay Output 2 Current Output Connections 2 3-Position Step Control Connections for Internally Powered Motors 22 3-Position Step Control Connections for Externally Powered Motors 22 3-Position Step Connections for Eclipse Rotary Actuator 22 Alarm and Duplex Output Connections 23 External Interface Option Connections 23 Transmitter Power for 4-2 ma - 2 Wire Transmitter Using Auxiliary Output 24 Prompt Hierarchy 26 Operator Interface and Key Functions 32 8 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

9 Introduction. Overview The ETC23 is a microprocessor-based advanced multi-functional controller. It combines reliability and operating simplicity in a cost-effective /4-DIN size controller. The ETC23 monitors and controls temperatures and other variables in applications such as furnaces, ovens, environmental chambers, and other process machinery. Its features include: Universal AC Power Supply, Input/Output Isolation, Isolated Auxiliary Current Output / Digital Input, Timer, Accutune II Tuning with Fuzzy Logic Overshoot Suppression, Setpoint Ramp/Rate, Three Position Step Control, Duplex (Heat/Cool). ALM 2 OUT SP 8888 F C M A R L PV FUNCTION DISPLAY MAN-AUTO RESET SET UP AUTO TUNE RUN HOLD Figure - ETC23 Operator Interface ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 9

10 Introduction.2 CE Conformity (Europe) This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other CE Mark Directive(s) shall not be assumed. Product Classification: Class I: Permanently connected, panel-mounted Industrial Control Equipment with protective earthing (grounding). (EN6-). Enclosure Rating: Panel-mounted equipment, IP. This controller must be panel-mounted. Terminals must be enclosed within the panel. Front panel IP 65 (IEC 529). Installation Category (Overvoltage Category): Category II: Energy-consuming equipment supplied from the fixed installation, local level appliances, and Industrial Control Equipment. (EN6-) Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with occasional conductivity caused by condensation. (Ref. IEC 664-) EMC Classification: Group, Class A, ISM Equipment (EN55, emissions), Industrial Equipment (EN582-2, immunity) Method of EMC Assessment: Technical File (TF) Declaration of Conformity: Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Section 2.5, may invalidate this product s conformity with the Low Voltage and EMC Directives. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

11 2 Installation 2. Overview Introduction Installation of the ETC23 consists of mounting and wiring the controller according to the instructions given in this section. 2.2 Preliminary Checks Introduction Before you install the controller, remove the chassis and make any preliminary checks necessary as listed in Table 2-. Figure 2- shows the locations for jumper placements. Check Number Preliminary Check Table 2- Preliminary Checks Description Input I Jumper Placement Check the internal jumper for INPUT to make sure it is set for the correct input type. The jumper is located at position S on the printed wiring board. Figure 2- shows the location of the jumper and position selections. The jumper is factory shipped set to position for thermocouples. 2 Control Relay Check the internal jumper (W) for CONTROL. The relay is shipped as N.O. (Normally Open). Figure 2- shows the location of the jumper and position selections. See Table 2-2 for Control Relay contact information. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

12 Installation Check Number Preliminary Check Description 3 Control Relay 2 and Alarm Relay Action. The controller has been shipped with ALARM relays configured for N.C. (Normally Closed). If you want to change to N.O. refer to Figure 2-, Jumper positions W2 and W22: W2 is the ALARM RELAY jumper. W22 is for CONTROL RELAY #2 for Duplex Output or 3 position step control and an ALARM RELAY 2 for all others. 3 position Step and Time Duplex must have Output 2-jumper (W22) set to N.O. (Normally Open). W22 is factory set for N.O. See Table 2-2 for Control Relay contact information, and Table 2-3 for Alarm Relay contact information. See Alarm Relay Attention Note, Section ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

13 Installation Jumper Placements Note: Jumpers enlarged for clarity S2 2 NO W2 Alarm Relay # W2 NC W22 NO NO NC NO NC NC (default) NO NC S W NO Main Board Output #2/ Alarm Relay #2 W22 NO NC NC NO NC NC NO (default) Input # S Position : thermocouple (default) NO Output # W Position 2: mv, Volt, RTD Position 3: not used NC NC Position 4: ma NO NO (Default) No jumper: volts - volts NC Figure 2- Jumper Placements ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 3

14 Installation 2.3 Control and Alarm Relay Contact Information Control Relays ATTENTION Control relays operate in the standard control mode (that is, energized when output state is on). Off On Unit Power Table 2-2 Control Relay Contact Information N.O. N.C. N.O. N.C. Control Relay Wiring Open Control Relay Contact Closed Open Closed Closed Open Off Off On Off On # or #2 Output Indicator Status Alarm Relays ATTENTION Alarm relays are designed to operate in a Failsafe mode (that is, de-energized during alarm state). This results in alarm actuation when power is OFF or when initially applied, until the unit completes self-diagnostics. If power is lost to the unit, the alarms will function. Off On Unit Power Alarm Relay Wiring Table 2-3 Alarm Relay Contact Information Variable NOT in Alarm State Relay Contact Indicators N.O. Open Off Open N.C. Closed Variable in Alarm State Relay Contact Closed N.O. Closed Off Open N.C. Open Closed Off On Indicators 4 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

15 Installation 2.4 Mounting Physical Considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied. Adequate access space must be available at the back of the panel for installation and servicing activities. The controller s mounting enclosure must be grounded according to CSA standard C22.2 No..4 or Factory Mutual Class No. 382 paragraph The front panel is moisture rated NEMA 3/IP65 (IEC) when properly installed with panel gasket. Overall Dimensions = Panel Cutout Max Panel Thickness Max (2) with optional.3 rear cover Dimensions: Millimeters Inches 275 Figure 2-2 Mounting Dimensions (not to scale) ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 5

16 Installation Mounting Method Before mounting the controller, refer to the nameplate on the outside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration. Panel 2752 Figure 2-3 Mounting Method Step Table 2-4 Mounting Procedure Action Mark and cut out the controller hole in the panel according to the dimension information in Figure Remove the screw cover and loosen the screw on the front of the controller. Pull the chassis out of the case. 3 Orient the case properly and slide it through the panel hole from the front. 4 Remove the mounting kit from the shipping container and install the kit as follows: Install the screws into the threaded holes of the clips. Insert the prongs of the clips into the two holes in the top and bottom of the case. Tighten both screws to secure the case against the panel. Carefully slide the chassis assembly into the case, press to close, and tighten the screw. Replace the screw cover. 6 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

17 Installation 2.5 Wiring Electrical Considerations The controller is considered rack and panel mounted equipment per EN6-, Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part : General Requirements. Conformity with 72/23/EEC, the Low Voltage Directive requires the user to provide adequate protection against a shock hazard. The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals. Mains Power Supply This equipment is suitable for connection to 9 Vac to 264 Vac, 5/6 Hz, power supply mains. It is the user s responsibility to provide a switch and non-time delay (North America), quick-acting, high breaking capacity, Type F (Europe), /2A, 25V fuse(s), or circuit-breaker, as part of the installation. The switch or circuit breaker shall be located in close proximity to the controller, within easy reach of the OPERATOR. The switch or circuit breaker shall be marked as the disconnecting device for the controller. Controller Grounding PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to a local ground, using a No. 2 (4 mm 2 ) copper conductor, is recommended. Control/Alarm Circuit Wiring The insulation of wires connected to the Control/Alarm terminals shall be rated for the highest voltage involved. Extra Low Voltage (ELV) wiring (input, current output, and low voltage Control/Alarm circuits) shall be separated from HAZARDOUS LIVE (>3 Vac, 42.4 Vpeak, or 6 Vdc) wiring per Permissible Wiring Bundling, Table 2-5. Electrical Noise Precautions Electrical noise is composed of unabated electrical signals, which produce undesirable effects in measurements and control circuits. Digital equipment is especially sensitive to the effects of electrical noise. Your controller has built-in circuits to reduce the effect of electrical noise from various sources. If there is a need to further reduce these effects: Separate External Wiring Separate connecting wires into bundles (See Permissible Wiring Bundling - Table 2-5) and route the individual bundles through separate conduit metal trays. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 7

18 Installation Use Suppression Devices - For additional noise protection, you may want to add suppression devices at the external source. Appropriate suppression devices are commercially available. Permissible Wiring Bundling Table 2-5 Permissible Wiring Bundling Bundle No. Wire Functions Line power wiring Earth ground wiring Control relay output wiring Line voltage alarm wiring 2 Analog signal wire, such as: Input signal wire (thermocouple, 4 ma to 2 ma, etc.) 4-2 ma output signal wiring Digital input signals 3 Low voltage alarm relay output wiring Low voltage wiring to solid state type control circuits Universal Output Functionality and Restrictions Output Type (OUTALG) Table 2-6 Universal Output Functionality and Restrictions Output Position Relay # (4-5) Relay #2 (9 - ) Relay #3 ( - 2) Current Output (3-4) Time Simplex (RLY) Output Alarm 2 Alarm Optional Use Time Simplex 2 (RLY2) N/A Output Alarm Optional Use Current Simplex (CUR) Remove Alarm 2 Alarm Output Time Duplex (RLYD) Output Output 2 Alarm Optional Use 3 Position Step (TPSC) Output Output 2 Alarm Optional Use * Current Dup. (CURD) Remove Alarm 2 Alarm Output *2 Current/Time (CURT) Remove Output Alarm Output Timer/Current (TCUR) Remove Output Alarm Output N/A = The output form or the individual output is Not Available or is not used for this output form. Optional Use = Auxiliary Output is not needed to provide the desired output function and can be used for another purpose. Auxiliary Output could also be used as a substitute for current Output. Remove = Relay # must be removed to prevent rapid cycling (chattering) of the contacts. * On TPSC: setting AUXOUT to OUT or IN2 will not function and will remain at the % value. *2 Do not use the Current Duplex setting, select CURT or TCUR. 8 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

19 Installation 2.6 Wiring the Controller Using the information contained in the model number, select the appropriate wiring diagrams from the composite wiring diagram below. Refer to the individual diagrams listed to wire the controller according to your requirements. Figure 2-4 Composite Wiring Diagram 2 Figure 2-5 Mains Power Supply 2 Figure 2-6 Input Connections 2 Figure 2-7 Electromechanical Relay Output 2 Figure 2-8 Current Output Connections 2 Figure Position Step Control Connections for Internally Powered Motors 22 Figure 2-3-Position Step Control Connections for Externally 22 Powered Motors Figure 2-3-Position Step Connections for Eclipse Rotary 22 Actuator Figure 2-2 Alarm and Duplex Output Connections 23 Figure 2-3 External Interface Option Connections 23 Figure 2-4 Transmitter Power for 4-2 ma - 2 Wire Transmitter 24 Using Auxiliary Output ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 9

20 Installation Transmitter Power for 4-2 ma 2-wire transmitters Using Aux Output See Figure 2-4 Input Connections See Figure 2-6 Control Output Terminals See Note Mains Power Supply Terminals See Figure L2 / N L Alarm and Duplex O See Figure 2-2 External Interface Options Terminals See Figure 2-3 NOTE : Electromechanical Relay Output See Figure 2-7 Current Output Connections See Figure 2-8 Three Position Step Control Output See Figures 2-9, 2-, 2- Figure 2-4 Composite Wiring Diagram Mains power supply 2 Neutral Hot Ground L2 / N L PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed, shall be in accordance with National and Local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to a local ground, using a No. 2 (4 mm 2 ) copper conductor, is recommended. Before powering the controller, see Preliminary Checks in this section of the user manual for switch and jumper settings. 2 Provide a switch and non-time delay (North America), quick-acting, high breaking capacity, type F (Europe), /2 A, 25 V fuse(s), or circuit-breaker as part of the installation. Figure 2-5 Mains Power Supply 2 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

21 Installation Thermocouple RTD mv, Volts (except -V), or Milliamperes Use Thermocouple extension wire only R Platinum RTD R mv, Volt, or Milliampere Source R Figure 2-6 Input Connections Load Supply Power Control Relay Load 5 amp Fast Blo OUT 5 4 OUT2/ALM e Control relays are configured N.O. as shipped. Alarm relays are configured N.C. as shipped. N.O. or N.C. configurations are selectable by jumpers on the main printed wiring boards. See Preliminary Checks for details. Each SPST relay is rated at 5 A, for 2 Vac and 3 Vdc, and 2.5 A for 24 Vac. User-provided fuses should be sized accordingly. See Figure 2-2 Alarm and Duplex Output Connections. See Table 2-2 and Table 2-3 for Control Relay Contact Information. Figure 2-7 Electromechanical Relay Output 2 Controller Load to 75 Ohms 24862e + - Current output 4 to 2 ma CAUTION Installing a current output instrument into a case wired for relay outputs will damage the instrument. Connect shield to ground at one end only. See Figure 2-2 Alarm and Duplex Output Connections. See Table 2-2 and Table 2-3 for Control Relay Contact Information Figure 2-8 Current Output Connections ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 2

22 Installation Close Open Control Relay # 5 4 ETC 23 Control Relay #2 9 Figure Position Step Control Connections for Internally Powered Motors Close Open ETC 23 Control Relay #2 Motor Power Supply 2 amp Fast Blo Control Relay # Figure 2-3-Position Step Control Connections for Externally Powered Motors Control Relay # 5 4 ETC 23 Control Relay #2 9 ACT4 P - 5 P - 4 P - Figure 2-3-Position Step Connections for Eclipse Rotary Actuator 22 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

23 Installation Control or Alarm Relay #2 Load Alarm Relay # Load 2 5 amp Fast Blo Load Supply Power Load 5 amp fast Blo Supply Power Control relays and 2 are configured N.O. as shipped. Alarm relay is configured N.C. as shipped. The N.O. or N.C. configurations are selectable by jumpers on main printed wiring boards. See Preliminary Checks in this section of the User Manual for details. Each SPST relay is rated at 5 A, 2 Vac and 3 Vdc, 2.5 A, 24 Vac. Alarm #2 not available for Time Proportional Duplex or Three Position Step Control. Figure 2-2 Alarm and Duplex Output Connections Auxiliary Current Output Digital Inputs _ Auxiliary Load - 5Ω _ Contact Input Switch Connect shield to ground at one end only. Connect shield to ground at one end only. AuxOut and digital input are mutually exclusive. Figure 2-3 External Interface Option Connections ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 23

24 Installation 2 Wire Transmitter _ INPUT AUXOUT Configure: AUXOUT = OUT Auxiliary Output Calibration ZEROVAL = 495 SPANVAL = 495 Figure 2-4 Transmitter Power for 4-2 ma - 2 Wire Transmitter Using Auxiliary Output 24 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

25 3 Configuration 3. Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent control data best suited for your application. To assist you in the configuration process, there are prompts that appear in the upper and lower displays. These prompts let you know what group of configuration data (Set Up prompts) you are working with and also, the specific parameters (Function prompts) associated with each group. Figure 3- shows you an overview of the prompt hierarchy as they appear in the controller. As you will see, the configuration data is divided into main Set Up groups. The status group has no adjustments but shows the continuous background tests that are being performed. Also when enabled prompts for calibration will show within the Set Up Groups. 3.2 Configuration Procedure Introduction Each of the Set Up groups and their functions are pre-configured at the factory with default settings. The factory settings are shown in Table 6- through Table 6- in Section 6 Appendix B and in Section 7 Appendix C. If you want to change any of these selections or values, follow the procedure in Table 3-Configuration Procedure. This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt. Record your selections on the Configuration Record Sheet found in Section 7 Appendix C. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 25

26 Configuration Figure 3- Prompt Hierarchy Set Up Group Function Prompts TIMER TIMER PERIOD START L DISP RESET INCRMT TUNING PB or GAIN RATE T I MIN or I RPM MANRST PB 2 or GAIN 2 RATE2T I2 MIN or I2 RPM CYC T or CT X3 CYC2T2 or CT2 X3 SECUR LOCK AUTOMA A TUNE RN HLD SP SL SPRAMP SPRAMP TI MIN FINLSP PVSTRT SPRATE EUHRUP EUHRDN ATUNE FUZZY TUNE AT ERR ALGOR CTRALG OUTALG RLY TYP INPUT DECMAL UNITS INTYP XMITR IN HI IN LO RATIO BIAS FILTR BRNOUT EMISS FREQ LNGUAG CONTRL PIDSET SW VAL LSP S SP TRK PWR UP PWROUT SP Hi SP Lo ACTION OUT Hi OUT Lo D BAND HYST FAILSF FSMODE PBorGN MINRPM OPTION AUXOUT PCT PCT DIG IN DI COM COM COMSTA (DIS) ALARMS ASVA AS2VA A2SVA A2S2VA ASTY AS2TY A2STY A2S2TY ASHL ASEV AS2HL AS2EV A2SHL A2SEV A2S2HL A2S2EV ALHYST ALARM BLOCK STATUS VERSON FAILSF TESTS 26 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

27 Configuration Procedure ATTENTION The prompting scrolls at a rate of 2/3 seconds when the SET UP or FUNCTION key is held in. Also, [ ] [ ] keys will move group prompts forward or backward at a rate twice as fast. Table 3- Configuration Procedure Step Operation Press Result Enter Set Up Mode 2 Select any Set Up Group 3 Select a Function Parameter 4 Change the Value or Selection 5 Enter the Value or Selection 6 Exit Configuration SET UP SET UP FUNCTION [ ] [ ] FUNCTION DISPLAY Upper Display = SET Lower Display = TIMER (This is the first Set Up Group title) Sequentially displays the other Set Up group titles. You can also use the [ ] [ ] keys to scan the Set Up groups in both directions. Stop at the Set Up group title that describes the group of parameters you want to configure. Then proceed to the next step. Upper Display = the current value or selection for the first function prompt of the selected Set Up group. Lower Display = the first Function prompt within that Set Up group. Sequentially displays the other function prompts of the Set Up group you have selected. Stop at the function prompt that you want to change, then proceed to the next step. Increments or decrements the value or selection that appears for the selected function prompt. If you change the value or selection of a parameter while in Set Up mode then decide not to enter it, press [MAN- AUTO/RESET] once the original value or selection is recalled. Enters value or selection made into memory after another key is pressed. Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made. If you do not press any keys for 3 seconds, the controller times out and reverts to the mode and display used prior to entry into Set Up mode. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 27

28 Configuration 3.3 Steps to Configure a 4 ma to 2mA Output Controller Step Operation Press Result Enter Set Up Mode and Select ALGOR Set Up Group 2 Select CTRALG Function Parameter 3 Set to Proportional Control Mode 4 Select OUTALG Function Parameter 5 Set to Relay Output Type 6 Select Relay Type 7 Set to Mechanical Relay type 8 Select OPTION Set Up Group 9 Set to Auxiliary Output Set Auxiliary Output to follow the Output Value SET UP FUNCTION [ ] [ ] FUNCTION [ ] [ ] FUNCTION [ ] [ ] SET UP FUNCTION [ ] [ ] Upper Display = SET ; press sequentially until Lower Display = ALGOR Note: you can also use the [ ] [ ] keys to scan the Set Up groups in both directions. Upper Display = the current value Lower Display = CTRALG Upper Display = PIDA (PIDB & PDMR are valid also) Lower Display = CTRALG Upper Display = the current value Lower Display = OUTALG Upper Display = RLY Lower Display = OUTALG Note: current output is configured in the OPTIONS group below. Upper Display = the current value Lower Display = RLYTYP Upper Display = MECH Lower Display = RLYTYP Press sequentially until Lower Display = OPTION Upper Display = DIS Lower Display = AUXOUT Note: if the Lower Display shows DIG IN instead of AUXOUT, press the Up/Down keys until the Upper Display shows NONE. Upper Display = OUT Lower Display = AUXOUT Verify percent FUNCTION Upper Display =. Lower Display = PCT 28 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

29 Configuration Step Operation Press Result 2 Verify percent 3 Exit Configuration Note: use the Up/Down keys to adjust if necessary FUNCTION Upper Display =. DISPLAY Lower Display = PCT Note: use the Up/Down keys to adjust if necessary Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made. 3.4 Steps to Configure ON-OFF or HIGH-LOW Control Step Operation Press Result Enter Set Up Mode and Select ALGOR Set Up Group 2 Select CTRALG Function Parameter 3 Set to On-Off Control Mode 4 Select OUTALG Function Parameter 5 Set to Relay Output Type 6 Select Relay Type 7 Set to Mechanical Relay type 8 Exit Configuration SET UP FUNCTION [ ] [ ] FUNCTION [ ] [ ] FUNCTION [ ] [ ] DISPLAY Upper Display = SET ; press sequentially until Lower Display = ALGOR Note: you can also use the [ ] [ ] keys to scan the Set Up groups in both directions. Upper Display = the current value Lower Display = CTRALG Upper Display = ONOF Lower Display = CTRALG Upper Display = the current value Lower Display = OUTALG Upper Display = RLY Lower Display = OUTALG Upper Display = the current value Lower Display = RLYTYP Upper Display = MECH Lower Display = RLYTYP Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 29

30 Configuration 3.5 Steps to Configure Three-Position-Step-Control Step Operation Press Result Enter Set Up Mode and Select ALGOR Set Up Group 2 Select CTRALG Function Parameter 3 Set to 3- Position-Step Control Mode 4 Verify OUTALG Function Parameter 5 Select TUNING Set Up Group 6 Select LOCK Function Parameter 7 Enable Calibration Menu 8 Select CAL TPSC Set Up Group 9 Select Motor Time Function Parameter Set Actuator Motor Travel Time Select TUNING Set Up Group 2 Select LOCK Function Parameter SET UP FUNCTION [ ] [ ] FUNCTION SET UP FUNCTION [ ] [ ] SET UP FUNCTION [ ] [ ] SET UP FUNCTION Upper Display = SET ; press sequentially until Lower Display = ALGOR Note: you can also use the [ ] [ ] keys to scan the Set Up groups in both directions. Upper Display = the current value Lower Display = CTRALG Upper Display = TPSC Lower Display = CTRALG Upper Display = TPSC Lower Display = OUTALG Upper Display = SET ; press sequentially until Lower Display = TUNING Upper Display = the current value Lower Display = LOCK Upper Display = NONE Lower Display = LOCK Upper Display = CAL ; press sequentially until Lower Display = TPSC Upper Display = the current value Lower Display = MTR TI Upper Display = set value in seconds Lower Display = MTR TI Upper Display = SET ; press sequentially until Lower Display = TUNING Upper Display = NONE (the current value) Lower Display = LOCK 3 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

31 Configuration Step Operation Press Result 3 Disable Calibration Menu 4 Exit Configuration [ ] [ ] DISPLAY Upper Display = CAL Lower Display = LOCK Note: any other selection besides NONE will prevent access to instrument calibration settings. Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 3

32 4 Operation 4. Operator Interface and Key Functions Upper Display - Four digits Normal operation - Process Variable Configuration mode - displays parameter value or selection TUNE- Accutune in progress ALM - Alarm conditions exist OUT - Control Relay or 2 on ALM 2 OUT 8888 F C M A R L PV F - Fahrenheit being used C - Centigrade being used M or A - Manual/Auto display R - Local SP2 setpoint active L - Local setpoint active Keys FUNCTION 2 SP 8888 DISPLAY MAN-AUTO RESET SET UP Lower Display - Six alphanumeric characters Normal operation displays the Setpoint, other parameters are selected by the DISPLAY key Configuration mode - displays functions and parameters AUTO TUNE RUN HOLD FUNCTION DISPLAY MAN-AUTO RESET SET UP Selects functions within each configuration group. Selects 2nd Setpoint. Returns Controller to normal display from Set Up mode. Toggles various operating parameters for display. Selects Manual or Auto mode. Resets the latching Limit Controller relay. In Set Up mode, used to restore original value or selection. Scrolls through the configuration Setup groups. AUTO TUNE RUN HOLD Figure 4- Operator Interface and Key Functions Initiates tuning (Accutune). Increases setpoint or output value. Increases the configuration values or changes functions in Configuration mode groups. Decreases setpoint or output value. Decreases the configuration values or changes functions in Configuration mode groups. Enables Run/Hold of the SP Ramp plus Timer start. Key Error Message When a key is pressed and the prompt KEYERR appears in the lower display, it will be for one of the following reasons: parameter is not available, not in Set Up mode, press SET UP key first, key malfunction. 32 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

33 Operation 4.2 Powering Up the Controller Apply Power When power is applied, the controller will run three diagnostic tests. After these tests are completed, TEST DONE is displayed. Test Failures If one or more of these tests fail, the controller will go to the Failsafe Manual Mode, and FAILSF will flash in the lower display and a message indicating which test failed will appear in the lower display. Then, DONE will appear in the lower display. 4.3 Monitoring Your Controller Annunciators The following annunciator functions have been provided to help monitor the controller: Annunciator ALM 2 OUT 2 A or M F or C L or R Table 4- Annunciators Indication A visual indication of each alarm Blinking indicates alarm latched and needs to be acknowledged before extinguishing when the alarm condition ends A visual indication of the control relays A visual indication of the mode of the controller A Automatic Mode M Manual Mode A visual indication of the temperature units F Degrees Fahrenheit C Degrees Celsius A visual indication of setpoint being used L Local Setpoint is active R LSP 2 is active The upper display is used to show other annunciator functions TUNE Accutuning in progress ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 33

34 Operation Viewing the operating parameters Press the DISPLAY key to scroll through the operating parameters listed in Table 4-2. The lower display will show only those parameters and their values that apply to your specific settings. Lower Display OT SP Table 4-2 Lower Display Key Parameter Prompts Description OUTPUT Output value is percent; for Three Position Step control, this is an estimated motor position. LOCAL SETPOINT # Also current setpoint when using SP Ramp. 2L LOCAL SETPOINT #2 DE DEVIATION Maximum negative display is PIDSX TUNING PARAMETER SELECTED SET where X is either or 2. RPXXXM AX Sn BI TIME REMAINING Time that remains on timer in Hours:Minutes ELAPSED TIME Time that has elapsed on timer in Hours:Minutes. SETPOINT RAMP TIME Time remaining in the setpoint ramp in minutes. AUXILIARY OUTPUT Same as OT for standard 4-2mA output SP RATE SETPOINT Current setpoint for setpoint rate applications BIAS Displays the manual reset value for algorithm PD+MR. 34 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

35 Operation Diagnostic Error Messages The ETC23 performs background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed. In the case of more than one simultaneous malfunction, the messages will be displayed sequentially on the lower display. Prompt Table 4-3 Error Messages Description EE FAIL INFL CFGERR INRNG PV LIM FAILSF LOCK Unable to write to nonvolatile memory. Two consecutive failures of input integration. Configuration Errors Low limit greater than high limit for PV, SP, Reset, or Output. Input Out-of-Range PV Out-of-Range PV = (PV source x PV source ratio) + PV source bias Failsafe Check inputs or configuration. The Lockout feature has been enabled to prevent unauthorized changes of certain functions or parameters. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 35

36 Operation 4.4 Start Up Procedure for Operation Table 4-4 Procedure for Starting Up the Controller Step Operation Press Result Select Manual Mode 2 Adjust the Output 3 Tune the Controller 4 Enter the Local Setpoint 5 Select Automatic Mode MAN/AUTO RESET [ ] [ ] SET UP DISPLAY [ ] [ ] MAN/AUTO RESET Until M indicator is ON. The controller is in manual mode. To adjust the output value and ensure that the final control element is functioning correctly. Upper Display = PV Value Lower Display = OT and the output value in % Make sure the controller has been configured properly and all the values and selections have been recorded on the Configuration Record Sheet. Refer to Tuning Set Up group to ensure that the selections for PB or GAIN, RATE T, and I MIN, or I RPM have been entered. Use Accutune to tune the controller; see the procedure in this section. Upper Display = Pv Value Lower Display = SP and the Local Setpoint Value to adjust the local setpoint to the value at which you want the process variable maintained. The local setpoint cannot be changed if the Setpoint Ramp function is running. Until A indicator is ON. The controller is in Automatic mode. The controller will automatically adjust the output to maintain the process variable at setpoint. 36 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

37 Operation 4.5 Setpoints Introduction You can configure the following setpoints for the ETC23 controller. A Single Local Setpoint (SP) 2 Local Setpoints (L, R) Switching between setpoints You can switch between two Local setpoints when configured. Table 4-5 Procedure for Switching Between Setpoints Step Operation Press Result Select the Setpoint FUNCTION To switch between the 2 Local Setpoints (L and R) ATTENTION KEY ERROR will appear in the lower display, if: the 2 nd local setpoint is not configured as a setpoint source you attempt to change the setpoint while a setpoint ramp is enabled, or if you attempt to change the setpoint with the setpoint select function key disabled. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 37

38 Operation 4.6 Timer Introduction The Timer provides a configurable Time-out period of from to 99 hours:59 minutes or to 99 minutes:99 seconds. Timer Start is selectable as either the RUN/HOLD key or Alarm 2. The Timer display can be either Time Remaining or Elapsed Time. Configuration check Make sure: TIMER is enabled A TIMEOUT period has been selected (in hours and minutes or minutes and seconds) A TIMER FUNCTION START has been selected (KEY or AL2) A TIMER display has been selected (Time remaining or Elapsed time) A timer increment selected Timer reset selected Refer to Section 6. for details. Viewing Times The times are viewed on the lower display as follows: TIME REMAINING will show as a decreasing Hrs:Min value (HH:MM) or Min:Sec value (MM:SS) plus a counterclockwise rotating clock face. ELAPSED TIME will show as an increasing Hrs:Min value(hh:mm) or Min:Sec value (MM:SS) plus a clockwise rotating clock face. Operation When the Timer is enabled (RUN/HOLD key or ALARM 2), it has exclusive control of Alarm relay. At TIME-OUT : Alarm is active The clock character has stopped moving The Time display shows either : or the time-out period depending on the configuration selection The Timer is ready to be reset. At RESET : Alarm relay is inactive The time display shows the time-out period The time-out period can be changed at this time using the or keys. The Timer is ready to be activated. 38 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

39 Operation 4.7 Accutune II Operation TUNE (Accutune II) algorithm provides foolproof, trouble-free on-demand tuning in the ETC23 controller. No knowledge of the process is required at start-up. The operator simply initiates the tuning while in the automatic mode. The ETC23 controller immediately starts controlling to the setpoint while it identifies the process, calculates the tuning constants and enters them into the Tuning group, and begins PID control with the correct tuning parameters. This works with any process, including integrating type processes, and allows retuning at a fixed setpoint. The tuning sequence will cycle the controller s output two full cycles between % and % (or low and high output limits) while allowing only a very small Process Variable change above and below the SP during each cycle. TUNE flashes in the upper display until tuning is completed. After TUNE has been enabled: Start Tuning by pushing the AUTOTUNE key while in Automatic control mode. To abort Accutune and return to the last previous operation (SP or output level), press MAN-AUTO/RESET key to abort the Accutune process. Completing Accutune When Accutune is complete, the calculated tuning parameters are stored in their proper memory location in the controller, and the controller will control at the local setpoint using the newly calculated tuning constants. 4.8 Fuzzy Overshoot Suppression Introduction Fuzzy Overshoot Suppression minimizes Process Variable overshoot following a setpoint change or a process disturbance. This is especially useful in processes which experience load changes or where even a small overshoot beyond the setpoint may result in damage or lost product. Configuration To configure this item, refer to Section 3 Configuration and Section 6.4 Set Up Group ATUNE Function Prompt FUZZY Select ENAB (enable) or DIS (disable) Use or. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 39

40 Operation 4.9 Using Two Sets of Tuning Constants Introduction You can use two sets of tuning constants for single output types and choose the way they are to be switched (Does not apply for Duplex control). See Table 4-6. Table 4-6 Set Up Procedure Step Operation Press Action Select Tuning Set Up Group 2 Select the tuning constants SET UP FUNCTION until you see TUNING in the Lower Display to successively display the available constants in the Lower Display. The value is displayed in the Upper Display 3 [ ] [ ] To change the value of any of the above listed prompts in the lower display. Switch between two sets via keyboard (without automatic switch-over) Table 4-7 Procedure for Switching PID SETS from the Keyboard Step Operation Press Result Select Control Set-up Group DISPLAY Until you see: Upper Display = (the PV value) Lower Display = PIDS X(X= or 2) 2 [ ] [ ] To change PID SET to PID SET2 or Vice Versa. You can use Accutune on each set. 4 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

41 Operation 4. Alarms Introduction An alarm consists of a relay contact and an operator interface indication. The alarm relay is de-energized if setpoint or setpoint 2 is exceeded. The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis (ALHYST). The relay contacts can be wired for normally open (NO) energized or normally closed (NC) de-energized using internal jumper placement. See Table 2-3 Alarm Relay Contact Information. There are four alarm setpoints, two for each alarm. The alarm type and state (High or Low) is selected during configuration. There are several alarm types that can be selected for each alarm setpoint. Alarm Setpoints Display Table 4-8 Procedure for Displaying Alarm Setpoints Step Operation Press Action Access the Alarm Set Up group 2 Access the Alarm Setpoint Values 3 Return to normal operation SET UP FUNCTION [ ] [ ] DISPLAY until you see ALARMS in the Lower Display. to successively display the alarm setpoints and their values. to change any alarm setpoint value you select in the upper display. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 4

42 Operation 4. Three Position Step Control Algorithm Introduction The Three Position Step Control algorithm allows the control of a valve (or other actuator) with an electric motor driven by two controller output relays; one to move the motor upscale, the other to move it downscale, without a feedback slidewire linked to the motor shaft. Estimated Motor Position The Three-Position Step control algorithm provides an output display ( OT ) which is an estimated motor position since the motor is not using any feedback. although this output indication is only accurate to a few percent, it is corrected each time the controller drives the motor to one of its stops (% or %). it avoids all the control problems associated with the feedback slidewire (wear, dirt, and noise). when operating in this algorithm, the estimated OT display is shown to the nearest percent (that is, no decimal). Motor Position Display Table 4-9 Procedure for Displaying 3Pstep Motor Position Step Operation Press Result Access the Displays DISPLAY Until you see: Upper Display = PV Lower Display = OT (The estimated motor position in %) 42 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

43 Operation 4.2 Setting a Failsafe Output Value for Restart After a Power Loss Introduction If the power to the controller fails and power is reapplied, the controller goes through the power up tests, then goes to a user configured FAILSAFE OUTPUT VALUE. Set a Failsafe Value Table 4- Procedure for Setting a Failsafe Value Step Operation Press Result Select Control Set-up Group 2 Select Failsafe Function Prompt SET UP FUNCTION Until you see: Upper Display = SET Lower Display = CONTRL You will see: Upper Display = (range) within the range of the Output to for all output types except 3 Position Step 3 Position Step = motor goes to closed position = motor goes to open position Lower Display = FAILSF 3 Select a value [ ] [ ] To select a Failsafe output value in the upper display 4 Return to Normal Display DISPLAY At power up, the output will go to the value set. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 43

44 Operation 4.3 Setting Failsafe Mode Introduction You can set the Failsafe Mode to be Latching or Non-Latching. Set Failsafe Mode Table 4- Procedure for Setting a Failsafe Mode Step Operation Press Result Select Control Set-up Group 2 Select Failsafe Function Prompt SET UP FUNCTION Until you see: Upper Display = SET Lower Display = CONTRL You will see: Upper Display = LACH (Controller goes to manual and output goes to Failsafe value) NO L (controller mode does not change and output goes to Failsafe value) Lower Display = FSMODE 3 Select a value [ ] [ ] To select a Failsafe mode in the upper display. 4 Return to Normal Display DISPLAY At power up, the output will go to the value set. 44 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

45 Operation 4.4 Entering a Security Code The level of keyboard lockout may be changed in the Set Up mode. However, knowledge of a security code number ( to 495) may be required to change from one level of lockout to another. When a controller leaves the factory, it has a security code of, which permits changing from one lockout level to another without entering any other code number. If you require the use of a security code, select a number from to 495 and enter it when the lockout level is configured as NONE. Thereafter, that selected number must be used to change the lockout level from something other than NONE. CAUTION Write the number on the Configuration Record Sheet in Section 7 - Appendix C so you will have a permanent record. Table 4-2 Procedure to Enter a Security Code Step Operation Press Result Enter Set Up Mode 2 Select any Set Up Group 3 Security Code Entry SET UP Upper Display = SET UP Lower Display = TUNING FUNCTION Upper Display = [ ] [ ] Lower Display = SECUR To enter a four digit number in the upper display ( to 495) This will be your security code. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 45

46 Operation 4.5 Lockout Feature Introduction The lockout feature in the ETC23 is used to inhibit changes (via keyboard) of certain functions or parameters by unauthorized personnel. Lockout levels There are different levels of Lockout depending on the level of security required. These levels are: NONE No Lockout. CAL Calibration prompts are locked out. CONF Timer, Tuning, SP Ramp, and Accutune are Read/Write. All other Setup groups are Read only. Calibration Group is not available. VIEW Timer, Tuning, and SP Ramp are Read/Write. No other parameters are available. ALL Timer, Tuning, and SP Ramp are Read only. No other parameters are viewable. Security Code (See previous section) Individual key lockout There are four keys that can be disabled to prevent unauthorized changes to the parameters associated with these keys. First set the Lock prompt to NONE. These keys are: AUTOTUNE Key - you can disable the Autotune key at configuration Set up, group prompt Tuning, function prompt A TUNE RUN/HOLD Key - you can disable the Run/Hold key for Set Point Programming at configuration Set Up group prompt Tuning, function prompt RN HLD AUTO/MAN Key - you can disable the Auto/Manual key at configuration Set Up, group prompt Tuning, function prompt AUTOMA FUNCTION Key - you can disable the Set Point Select function key at configuration Set Up group prompt Tuning, function prompt SP SEL See section 6.2- Tuning Parameters Set Up Group prompts to enable or disable these keys. 46 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

47 Operation 4.6 Background Tests Introduction The ETC23 performs ongoing background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed (blinking) in the lower display. In the case of simultaneous malfunctions, the messages will appear in sequence in the lower display. Table 4-3 lists these background tests, the reason for their failure, and how to correct the problem. Table 4-3 Background Tests Lower Display E FAIL FAILSF INRNG Reason for Failure Unable to write to non-volatile memory. Anytime you change a parameter and it is not accepted, you will see E FAIL. This error message shows whenever the controller goes into a failsafe mode of operation. This will happen if: RAM test failed Configuration test failed Calibration test failed Burnout configured for none and the input failed. Input out of range. The process input is outside the range limits. How to Correct the Problem. Check the accuracy of the parameter and reenter. 2. Try to change something in configuration. 3. Run through Read STATUS tests to re-write to EEPROM.. Run through STATUS check to determine the reason for the failure. 2. Press the SET UP key until STATUS appears in the lower display. 3. Press the FUNCTION key to see whether the tests pass or fail, then run through the STATUS codes a second time to see if the error cleared.. Make sure the range and actuation are configured properly. 2. Check the input source (wiring, EMI). 3. Restore the factory calibration (see Section 4.7) or field calibrate. IN_FL Two consecutive failures of input integration. i.e., cannot make analog to digital conversion. This will happen if: Upscale or Downscale burnout is selected Input not configured correctly. Make sure the actuation is configured correctly. See Section Make sure the input is correct. 3. Check for gross over-ranging. Check S jumper position. See Figure 2- Jumper Placements 4. Restore factory calibration. See Section 4.7 CNFERR PV low limit is > PV high limit SP low limit is > SP high limit Output low limit > Output high limit. Check the configuration for each item and reconfigure if necessary. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 47

48 Operation Lower Display PV LIM Reason for Failure PV out of range. PV = INP x RATIO+ INP BIAS How to Correct the Problem. Make sure the input signal is correct. Recheck the calibration. 2. Make sure the Ratio and Bias settings are correct. Use Bias of. 4.7 Restore Factory Calibration Introduction The factory calibration constants for all the input actuation types that can be used with the controller are stored in its nonvolatile memory. Thus, you can quickly restore the Factory Calibration for a given input actuation type by simply changing the actuation type to another type and then changing it back to the original type. Refer to Table 4-4 for procedure. ATTENTION A restored factory calibration overwrites any previous field calibration done for the input and may change the High and Low Range Limits. Be sure to protect any field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration. See Section 4.5 for specific instructions to set the lockout. Table 4-4 Restore Factory Calibration Step Operation Press Result Set LOCKOUT to NONE SET UP FUNCTION [ ] [ ] until you see: Upper Display = SET UP Lower Display = TUNING Until you see: Upper Display = one of the following: NONE all parameters are read/write CAL all parameters are read/write except Calibration CONF configuration parameters are Read Only; no writes permitted VIEW Tuning and Setpoint Ramp parameters are read/write. No other parameters can be viewed. ALL Tuning and Setpoint Ramp parameters are available for read only. No other parameters can be viewed. Lower Display = LOCK Until NONE is in the upper display 48 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

49 Operation Step Operation Press Result 2 Enter INPUT Setup Group 3 Scroll through Functions 4 Return to Normal Operation SET UP FUNCTION [ ] [ ] FUNCTION [ ] [ ] DISPLAY until you see: Upper Display = SET UP Lower Display = INPUT until you see: Upper Display = the current selection Lower Display = INxTYP to change the current selection to another selection until the lower display rolls through the rest of the functions and returns to: Upper Display = the new selection Lower Display = INxTYP until you change the input selection in the upper display back to the proper selection. You will see: Upper Display = Original Input Selection that matches your type of sensor. Lower Display = INxTYP to return to Normal operating mode. 4.8 Setpoint Rate Introduction When you have configured a SETPOINT RATE, it will apply immediately to local setpoint change. Configuration check Make sure: SPRATE is enabled SPRAMP is disabled A Rate Up (EUHRUP) or Rate Down (EUHRDN) value has been configured in Engineering units per hour. ATTENTION: A value of will imply an immediate change in setpoint, that is, NO RATE applies. See Subsection 6.3 Configuration group SPRAMP for details.) ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 49

50 Operation Operation When a change to local setpoint is made, this controller will ramp from the original setpoint to the target setpoint at the rate specified. The current setpoint value can be viewed at Sn on the lower display. Power outages If power is lost before the target setpoint is reached, upon power recovery, the controller powers up with Sn = Current PV value and it automatically Restarts from Sn = current PV value up to the original target setpoint. 4.9 Setpoint Ramp Introduction When you have configured a SETPOINT RAMP, the ramp will occur between the current local setpoint and a final local setpoint over a time interval of from to 255 minutes. You can RUN or HOLD the ramp at any time. Configuration Check Operation Make sure SPRAMP is enabled SP RATE is disabled A Ramp Time (TIMIN) in minutes has been configured A final setpoint value (FINLSP) has been configured. See section 6.3 Configuration group SPRAMP for details. Running a Setpoint Ramp includes starting, holding, viewing the ramp, ending the ramp and disabling it. See Table 4-5. Table 4-5 Running A Setpoint Ramp Step Operation Press Result Select Automatic Mode 2 Set Start Setpoint MAN/AUTO DISPLAY A indicator is on. Upper Display = Hold and PV value Lower Display = SP and Present value Until start SP value is in lower display Upper Display = Hold and PV value Lower Display = SP and start SP value 5 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

51 Operation Step Operation Press Result 3 Start the Ramp RUN/HOLD You will see Upper Display = Run and a changing PV value Lower Display = SP and a changing SP value increasing or decreasing toward a final SP value 4 Hold/Run the Ramp RUN/HOLD This holds the ramp at the current setpoint value. Press again to continue. 5 View the remaining ramp time DISPLAY Until you see Upper Display = RUN or HOLD and the PV value Lower Display = RP xx HH.MM (time remaining) 6 End the Ramp When the final setpoint is reached, RUN changes to HOLD in the upper display and the controller operates at the new final setpoint. 7 Disable SPRAMP See Section 6.3 Configuration group SPRAMP for details. Power Outage PV Start If power is lost during a ramp, upon power-up the controller will be in HOLD and the setpoint value will be the setpoint value prior to the beginning of the setpoint ramp. The ramp is placed in hold at the beginning. Configure the mode at Set up Group CONTROL, function prompt PWRUP. See Table 6-7 CONTRL Group (Numeric Code 8) Function Prompts in Section 6.7 Control Set Up Group. This function determines whether LSP or PV is used as the setpoint when the controller is initially changed from HOLD to RUN. The selections are: DISABL = When initially changed from HOLD to RUN the present LSP value is captured as the default setpoint. If the program is terminated or the power cycled before the program has completed, the LSP is used as the control setpoint. The beginning uses this value as the initial ramp setpoint. ENABL = When initially changed from HOLD to RUN the present PV value is captured and used as the beginning setpoint value for the ramp. If the program is terminated before completion, the setpoint value will revert back to the PV value captured at the initial HOLD to RUN transition. If the power is cycled before program completion, upon power-up the setpoint is set to the PV value at power-up and when the ramp is restarted that setpoint value is used initially. ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 5

52 5 Appendix A - Environmental and Operating Conditions Operating Limits Accuracy CE Conformity Special Conditions (Europe) Ambient Temperature: 32 F to 3 F ( C to 55 C) Relative Humidity: 5% to 9% RH up to 4 F (4 C) Vibration: Frequency: Hz to 2 Hz Acceleration:.6g Mechanical Shock: Acceleration: 5 g Duration: 3 ms Power: 9 Vac to 264 Vac, 5/6 Hz (CSA models rated to 25 Vac maximum) Power Consumption: 2 VA maximum ±.25% of span typical ± digit for display 5-bit resolution typical Shielded twisted-pair cables are required for all analog I/O, process variable, RTD, thermocouple, dc Millivolts, low level signal, 4-2 ma, digital I/O, and computer interface circuits. 52 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

53 6 Appendix B Parameter Configurations 6. Timer Set Up Group Introduction The Timer Set Up group allows you to configure a time-out period and to select the timer start by either the keyboard (RUN/HOLD key) or Alarm 2. The optional digital input can also be configured to start the timer. The timer display is selectable as either time remaining (TREM) or elapsed time (ET). Alarm is activated at the end of the time-out period. When the timer is enabled, it has exclusive control of the alarm relay any previous alarm configuration is ignored. At time-out, the timer is ready to be activated again by whatever action has been configured. Function Prompts English Table 6- TIMER Group (Numeric Code ) Function Prompts Prompt Numeric Code Description TIMER Enable or Disable Timer Selection or Range of Setting Numeric Code DIS ENAB English PERIOD 2 Time-out Period : to 99:59 Select length of time in Hours and Minutes, or Minutes and Seconds. START 3 Timer Function Start L DISP 4 Timer Display RESET 5 Timer Reset Control INCRMT 6 Timer Count Increment KEY (Run/Hold key) AL2 (Alarm 2) TREM (time remaining) ET (elapsed time) KEY (Run/Hold key) AL (Alarm or Key) MIN (Counts HR/MIN) SEC (Counts MIN/SEC) Factory Setting DIS : KEY TREM KEY MIN ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 53

54 Parameter Configurations 6.2 Tuning Set Up Group Introduction Tuning consists of establishing the appropriate values for the tuning constants you are using so that your controller responds correctly to changes in process variable and setpoint. You can start with predetermined values but you will have to watch the system to see how to modify them. The Accutune feature automatically selects Gain, Rate, and Reset on demand. ATTENTION Because this group contains functions that have to do with security and lockout, we recommend that you configure this group last, after all other configuration data has been loaded. Function Prompts English PB or GAIN Table 6-2 TUNING Group (Numeric Code 2) Function Prompts Prompt Numeric Code Description 2 Proportional Band or Gain Selection or Range of Setting Numeric Code English PB =.% to % Gain =. to RATE T 22 Rate in Minutes. to. minutes.8 or less = OFF I MIN or I RPM 23 Reset in minutes/repeat Reset in repeats/minute.2 to 5..2 to 5. MANRST 24 Manual Reset -% to % Output PB 2 or GAIN 2 25 Proportional Band 2 or Gain 2 RATE2T 26 Rate 2 in Minutes I2 MIN or I2 RPM 27 Reset in minutes/repeat Reset in repeats/minute PB =.% to % Gain =. to. to. minutes.8 or less = OFF.2 to 5..2 to 5. Factory Setting ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

55 Parameter Configurations English CYC T or CTX3 CYC2T2 or CT2 X3 Prompt Numeric Code Description 28 Cycle Time (Heat) Cycle times are in either second or /3 second increments depending upon the configuration of RLY TYP in the Algorithm Set Up group. 29 Cycle Time (Cool) Cycle times are in either second or /3 second increments depending upon the configuration of RLY TYP in the Algorithm Set Up group. Selection or Range of Setting Numeric Code English to 2 to 2 SECUR 2 Security Code to 495 LOCK 2 Lockout AUTOMA 22 Auto/Manual Key Lockout A TUNE 23 Autotune Key Lockout RN HLD 24 Run/Hold Key Lockout SP SEL 25 Setpoint Select Function Lockout NONE CAL CONF VIEW ALL DIS ENAB DIS ENAB DIS ENAB DIS ENAB Factory Setting CAL ENAB ENAB ENAB ENAB ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 55

56 Parameter Configurations 6.3 SP Ramp Set Up Group Introduction A single setpoint ramp [SPRAMP] can be configured to occur between the current local setpoint and a final local setpoint over a time interval of from to 255 minutes. SPRATE lets you configure a specific rate of change for any local setpoint change. You can also configure a 2-segment program from a Ramp/Soak profile. You can start and stop the ramp/program using the RUN/HOLD key. PV Hot Start is standard and means that at power up, the setpoint is set to the current PV value and the Ramp or Rate or Program then starts from this value. Function Prompts Table 6-3 SPRAMP Group (Numeric Code 3) Function Prompts English Prompt Numeric Code Description SP RAMP 3 Single Setpoint Ramp Rate and Program must be disabled TI MIN 3 Single Setpoint Ramp Time FINLSP 32 Setpoint Ramp Final Setpoint PVSTRT 36 Program starts at PV value SPRATE 34 Setpoint Rate Ramp and Program must be disabled Selection or Range of Setting Numeric Code DIS ENAB English to 255 Minutes 3 Enter a value within the setpoint limits DIS ENAB DIS ENAB EUHRUP 35 Rate Up to 9999 in Engineering units per hour EUHRDN 36 Rate Down to 9999 in Engineering units per hour Factory Setting DIS ENAB DIS 56 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

57 Parameter Configurations 6.4 Accutune Set Up Group Introduction Accutune II automatically calculates GAIN, RATE, and RESET TIME (PID) tuning constants for your control loop. When initiated on demand, the Accutune algorithm measures a process step response and automatically generates the PID tuning constants needed for no overshoot on your process. Fuzzy Overshoot Suppression, when enabled, will suppress or eliminate any overshoot that may occur as a result of the existing tuning parameters, as the PV approaches the setpoint. Function Prompts English Table 6-4 ATUNE Group (Numeric Code 4) Function Prompts Prompt Numeric Code Description FUZZY 4 Fuzzy Overshoot Suppression TUNE 42 Demand Tuning AT ERR 43 Accutune Error Codes (Read Only) Selection or Range of Setting Numeric Code DIS ENAB DIS TUNE NONE IDFL ABRT RUN English Factory Setting DIS TUNE ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 57

58 Parameter Configurations 6.5 Algorithm Set Up Group Introduction This data deals with various algorithms in the controller: Control algorithm, Output algorithm, Current Duplex Range, and Relay Cycle Time Increment. Function Prompts English Table 6-5 ALGOR Group (Numeric Code 5) Function Prompts Prompt Numeric Code Description CTRALG 5 Control Algorithm OUTALG 52 Output Algorithm RLYTYP 54 Relay Cycle Time Increment Selection or Range of Setting Numeric Code English ONOF PIDA PIDB PDMR TPSC (3 position step) RLY (Time simplex Relay ) RLY2 (Time simplex Relay 2) CUR (Current simplex) TPSC (3 Position step) RLYD (Time duplex) CURD (Current duplex) CURT (Current/time duplex) TCUR (Time/current duplex) MECH (one sec. increments) S S (/3 sec increments) Factory Setting PIDA RLY MECH 58 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

59 Parameter Configurations 6.6 Input Set Up Group Function Prompts English Prompt Table 6-6 Numeric Code INPUT Group (Numeric Code 6) Function Prompts Description DECMAL 6 Decimal Point Selection UNITS 62 Temperature Units INTYP 63 Input Actuation Type XMITR 64 Transmitter Characterization Selection or Range of Setting Numeric Code (none) F C NONE English Numeric English Numeric English B E H E L J H J L K H K L NNMH NNML N9H N9L NIC R S T H T L W H W L H L 2 5 RADH RADI m 5m m Numeric English Numeric English B E H E L J H J L K H K L NNMH NNML N9H N9L NIC R S T H T L W H W L H L 2 5 RADH RADI LIN SrT Factory Setting 8888 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 59 F K H LIN

60 Parameter Configurations English Prompt Numeric Code Description IN HI 65 Input High Range Value IN LO 66 Input Low Range Value Selection or Range of Setting Numeric Code English 999 to 9999 floating in engineering units 999 to 9999 floating in engineering units Factory Setting RATIO 67 Ratio on Input -2. to 2.. BIAS 68 Bias on Input -999 to FILTR 69 Filter for Input to 2 seconds = No Filter BRNOUT 6 Burnout Protection (Sensor Break) 2 3 NONE UP (Upscale) DOWN (Downscale) NOFS (No Failsafe) EMISS 6 Emissivity. to. (RADH & RADI only) FREQ 62 Power Line Frequency LNGUAG 64 Language Selection ENGL FREN GERM SPAN ITAL NUMB (Numeric) 24. UP. 6 ENGL 6 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

61 Parameter Configurations 6.7 Control Set Up Group Introduction The functions listed in this group deal with how the controller will control the process including: Number of Tuning Parameter Sets, Setpoint Source, Tracking, Power-up Recall, Setpoint Limits, Output Direction and Limits, Deadband, and Hysteresis. Function Prompts English Prompt Table 6-7 CONTRL Group (Numeric Code 8) Function Prompts Numeric Code Description PIDSET 8 Number of Tuning Parameter Sets SW VAL 82 Automatic Switchover Value Selection or Range of Setting Numeric Code LSP S 83 Local Setpoint Source SP TRK 85 Setpoint Tracking PWR UP 86 Power Up Controller Mode Recall PWROUT 87 TPSC (Three Position Step Control) Output Start-up Mode English ONE 2KBD (Keyboard) 2 PR (PV switch) 2 SP (SP switch) Value in engineering units within PV or SP range limits ONE TWO NONE PROC (LSP tracks PV manual) RSP (N/A-do not use) MAN (Manual/LSP/Failsafe) ALSP (Auto/last LSP) ARSP (N/A-Auto/last RSP) AMSP (Last mode/last SP) AMLS (Last mode/last LSP) LAST (Last output) FSAF (Failsafe output) Factory Setting ONE. ONE NONE AMLS LAST SP Hi 88 Setpoint High Limit to % of the PV range 24 SP Lo 89 Setpoint Low Limit to % of the PV range. ACTION 8 Control Output Direction DIR REV REV ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 6

62 Parameter Configurations English Prompt Numeric Code Description OUT Hi 8 High Output Limit OUT Lo 82 Low Output Limit Selection or Range of Setting Numeric Code English -5 to 5 % of Output (Current). to. % of Output (Relay) -5 to 5 % of Output (Current). to. % of Output (Relay) D BAND 83 Deadband -5 to 25. % (Time Duplex) HYST 84 Hysteresis (Output Relay Only) FAILSF Failsafe Output Value FSMODE 87 Failsafe Mode PBorGN 88 Proportional Band Units MINRPM 89 Reset Units.5 to 5. % (3 position step) Factory Setting to. % of PV.5 to % For 3 Position Step (Closed position) (Open position) No L (Mode does not clear once unit goes to FS Output) LACH (Unit goes to manual and FS output) GAIN PB MIN RPM. NO L PB RPM 62 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

63 Parameter Configurations 6.8 Options Set Up Group Function Prompts English Prompt Table 6-8 Numeric Code Options Group (Numeric Code 9) Function Prompts Description Numeric Code AUXOUT 9 Auxiliary Output PCT 92 Auxiliary Output Low Scaling Factor PCT 93 Auxiliary Output High Scaling Factor DIG IN 94 Digital Input DI COM 95 Digital Input Combinations Selection or Range of Setting English DIS Disabled IN Input IN2 Input 2 PROC Process Variable DEV Deviation OUT Output SP Setpoint LSP Local Setpoint Factory Setting OUT Value in Engineering Units. Value in Engineering Units. None MAN To Manual LSP To Local SP SP2 To Local SP 2 DIR Direct Control HOLD Hold SPP/SP Ramp PID2 PID Set 2 RUN Start a stopped SPP/SP Ramp Begn SPP Reset NO I Inhibit Integral MNFS Manual, Failsafe Output LOCK Keyboard Disable TIMR Start Timer TUNE Start Tune INIT Init SP to PV RSP Remote SP MNLT Latching Manual TRAK Output tracks Input 2 DIS Disabled + PD2 PID Set 2 + DIR Direct + SP2 Set Point 2 + SP Set Point + RUN Start SPP NONE ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 63 DIS

64 Parameter Configurations 6.9 Communications Set Up Group Function Prompts English Prompt Numeric Code Table 6-9 Communications Group (Numeric Code ) Description COMSTA Communications State Numeric Code 2 Selection or Range of Setting English DIS Disabled R422 (N/A do not use) MODB (N/A do not use) Factory Setting DIS 64 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

65 Parameter Configurations 6. Alarms Set Up Group Function Prompts English Prompt AxSxVA AS AS2 A2S A2S2 AxSxTY AS AS2 A2S A2S2 AxSxHL AS AS2 A2S A2S2 Table 6- ALARMS Group (Numeric Code ) Function Prompts Numeric Code Description Alarm Setpointx Value X = or 2 Alarmx Setpointx Type X = or 2 Alarmx Setpoint State X = or 2 Numeric Code Selection or Range of Setting English within the range of the selected parameter or of the PV Span for Deviation configurations NONE No Alarm IN Input IN 2 Input 2 (do not use) PROC Process Variable DE Deviation OUT Output SHED Shed Com (do not use) E-ON Event ON (do not use) E-OF Event OFF (do not use) MAN Alarm on Manual RSP Remote (do not use) FSAF Failsafe P_RT PV Rate of Change DI Alarm on Digital Input DE II DEV Alarm SP2 based BRAK Loop break alarm LOW Low Alarm HIGH High Alarm ALHYST 3 Alarm Hysteresis. to. % of span or full output as appropriate ALARM 4 Latching Alarm Output BLOCK 5 Alarm Blocking 2 3 NO L LACH DIS Disable Blocking BK Block Alarm only BK2 Block Alarm 2 only BK2 Blocks both Alarms Factory Setting 9 NONE HIGH. NO L DIS ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 65

66 7 Appendix C - Configuration Record Sheet Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured. Group Prompt Function Prompt Value or Selection Factory Setting Group Prompt Function Prompt Value or Selection Factory Setting TIMER TIMER PERIOD START L DISP RESET INCRMT DIS : KEY TREM KEY MIN ATUNE FUZZY TUNE AT ERR DIS TUNE --- TUNING PB or GAIN RATE T I MIN or I RPM MANRST PB2 or GAIN 2 RATE2T I2 MIN or I2 RPM CYCT or CTX3 CYC2T2orCT2X3 SECUR LOCK AUTOMA A TUNE RN HLD SP SEL CAL ENAB ENAB ENAB ENAB ALGOR CTRALG OUTALG RLYTYP PIDA RLY MECH SPRAMP SPRAMP TI MIN FINLSP PVSTRT SPRATE EUHRUP EUHRDN DIS 3 ENAB DIS INPUT DECIMAL UNITS INTYP XMITR IN HI IN LO RATIO BIAS FILTR BRNOUT EMIS FREQ LNGUAG 8888 F K H LIN UP. 6 ENGL 66 ETC23 Universal Temperature Controller Instruction Manual 99, 8/2

67 Configuration Record Sheet Group Prompt Function Prompt Value or Selection Factory Setting Group Prompt Function Prompt Value or Selection Factory Setting CONTRL PIDSET SW VAL LSP S SP TRK PWR UP PWROUT SP Hi SP Lo ACTION OUT Hi OUT Lo D BAND HYST FAILSF FSMODE PBorGN MINRPM ONE. ONE NONE AMLS LAST 24. REV NO L PB RPM COM ComSTA Disabl e OPTIONS AUXOUT PCT PCT DIG IN DIG COM OUT.. NONE DIS ALARMS ASVA AS2VA A2SVA A2S2VA ASTY ASTY A2STY A2S2TY ASHL AS2HL A2SHL A2S2HL ALHYST ALARM BLOCK NONE NONE NONE NONE HIGH HIGH HIGH HIGH. NO L DIS ETC23 Universal Temperature Controller Instruction Manual 99, 8/2 67

68 Offered By: Power Equipment Company 2 Williamsburg Road Richmond, Virginia 2323 Phone (84) Fax (84)