Eurotherm 902 Series Handbook
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Eurotherm 902 Series Handbook

Eurotherm 902 Series Handbook

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902-904 Handbook
Guide to this Handbook
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Appendix
Every effort has been taken to ensure the accuracy of this handbook. However in order to
maintain our technological lead we are continuously improving our products which could, without
notice, result in amendments or omissions to this document. We cannot accept responsibility for
damage, injury loss or expenses resulting therefrom.
Contents
INSTALLATION
OPERATION
COMMISSION
CONFIGURE
CALIBRATION
COMMUNICATIONS
ERROR MESSAGES
Glossary of Terms
H A 0 2 3 7 5 2 I s s 9

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  • Page 1 Contents Guide to this Handbook Section 1 INSTALLATION Section 2 OPERATION Section 3 COMMISSION Section 4 CONFIGURE Section 5 CALIBRATION Section 6 COMMUNICATIONS Section 7 ERROR MESSAGES Appendix Glossary of Terms Every effort has been taken to ensure the accuracy of this handbook. However in order to maintain our technological lead we are continuously improving our products which could, without notice, result in amendments or omissions to this document.
  • Page 2 This is the guide for using this Handbook. Follow the directions below to obtain maximum benefit from this information provided. installation Follow the instructions in this section for successful mechanical mounting and correct electrical connections. Important notes on the application and operation of all temperature controllers are in this section.

  • Page 3: Table Of Contents

    Installation Section 1 - Installation Contents Page INSTALLATION ............. Dimensional Details .
  • Page 4 Installation INSTALLATION Before proceding with installing this instrument please ensure that you are acquainted with the caution notes in para. 3.0 of this section. If the instrument is to be panel mounted, a DIN-size 92mm by 92mm cut-out is required as illustrated. Should the instrument be required to be sealed to the panel surface, up to IP65,...

  • Page 5: Installation

    Installation Instrument Sealing A polythene bag within the instrument packing contains the 902 accessory kit (Part No. LA023792). In this accessory kit is a rubber seal. When this seal is correctly placed between the sleeve and the panel surface it will provide protection to the lP65 standard.

  • Page 6: Connections And Wiring

    Installation CONNECTIONS AND WIRING Electrical connections are made via individual screw terminal blocks on the rear of the instrument. All connections are low current and a 16/0.20 wire size is adequate. Max. 14 AWG (1.6mm)(0.064”) Wires, once connected to the instrument, can be run up/down the trough and secured by ties as shown in figure 4.

  • Page 7: Instrument Layout

    Installation Instrument Layout The 902/3/4 series of instruments can easily be configured to most customer requirements on site. The microprocessor, power supply and display boards are standard to all 902/3/4 series of instruments, see figure 5. Various plug-in hardware modules can then be fitted to provide the different functions. These modules can be allocated to one or two sites on the power supply board.

  • Page 8: Rear Terminal Connections

    Installation Rear Terminal Connections CHANNEL 4 , CHANNEL 3 ,ANALOGUE COMMS M I C R O O P T I O N S D I G I T A L C O M M S CHANNEL 1 D I G I T A L I N P U T S CHANNEL 2 PROCESS VARIABLE Screw I...

  • Page 9: Power Supply

    Installation 2.2.1 Power Supply The power supply can be 85V to 264V, or a low level ac/dc supply of 17-30Vac / 20 - 40Vdc. If a low level supply is used the positive may be connected to terminal 24. Power supply 20 - 40V dc 85 - 264V ac 17-30Vac...

  • Page 10: Inputs

    Installation 2.2.2 Inputs This instrument has one input which can be set in the configuration to accept a number of different sensor types. Having set the configuration, the sensor must be connected to the correct terminals as shown on the following pages. Thermocouple I n p u t When the instrument has been configured for internal cold junction...
  • Page 11 Installation DC Signals Input For inputs less than 100mV use terminals 2 and 4, polarity as shown. For inputs from 1 00mV to 1 OV use terminals 4 and 5, polarity as shown. For mA inputs a 5R resistor module will be supplied within the instrument packing.

  • Page 12: Heat / Process [+] Outputs

    Installation 2.2.3 Heat / Process [+] Outputs (Channel 1) Relay Relay Output The relays are shown in the de-energised state, i.e. with the instrument not powered. If the instrument has been configured as A3 . reverse acting then the relay will energise when power to the load is required for a conventional temperature controller.

  • Page 13: Cool / Process [-] Outputs

    Installation 2.2.4 Cool / Process[-] Output (Channel 2) Relay Output Relay The relays are shown in the de-energised state, i.e. with the instrument not powered. If the instrument has been configured as reverse acting then the relay will energise when power to the load is required for a conventional temperature controller.

  • Page 14: Valve Positioner Outputs

    lnstallatipn Valve Positioner Outputs (Channels 1 and 2) 2.2.5 Relay Connections. EitherRelav If relays are fitted in the controller, join terminals “A1’ to “B1 ” and also join these terminals to one side of the motor supply. Connect terminal “A3” to the raise connection of the motor and terminal “B3”...

  • Page 15: 2.2.6 Alarm Outputs

    Installation 2.2.6 Alarm Outputs A l a r m 1 R e l a y Alarm 1 Output (Channels 2 or 3) E i t h e r C H 2 In the instrument configuration alarm 1 can be set to be active from terminals “B”...

  • Page 16: Programme And Comms. Driven Relays

    Installation 2.2.7 Programme and Comms. Driven Relays (Channels 2, 3 or 4) Terminals “B”, " D " and “E” are those used for relay connections driven by segments of the programme or via the digital communications link. The instrument configuration sets the number of relays driven by the programme and / or the digital communications link which can be none, one, two or three.

  • Page 17: Digital Inputs

    Installation Digital Inputs 2.2.8 Three digital inputs a r e provided on this instrument. These inputs are not isolated from one another or from the input on “H” terminals. To activate any of these inputs connect between the particular input and the common “G4”, by either a resistance of less than 1 OO!A, or a voltage of less than 0.7 volts d.c.

  • Page 18: Remote Analogue Inputs

    Installation 2.2.9. Remote Analogue Inputs One remote analogue input can be configured within the instrument, this will appear at either terminals “B”, “C” or “E”. refer to the instrument label for the configuration of a specific controller. The remote analogue input can be a voltage or current. Potentiometer inputs can be accommodated but only when using terminals “Cl ", “C2”...
  • Page 19 Installation 2.2.10 Retransmission Analogue Output Only one retransmission output is available in the instrument and Either CH1 this will be routed to either terminals “A”, “B”, “C” or “D”. Refer to the terminal label oh the side of the instrument to confirm the configuration in this case.

  • Page 20: Digital Communications

    Installation 2.2.11. Digital Communications Digital Communications The instrument will support the digital communications specification type RS232 C or RS422. The instrument can be changed from one standard to the other by changing a link position on the rear of the microprocessor board, see Figure 1, paragraph 2.0, section 6, Communications.

  • Page 21: 3.0 Safety And Emc Information

    This controller conforms with the essential protection requirements of the EMC Directive 89/ 336/EEC, amended by 93/68/EEC, by the application of a technical construction file. SERVICE AND REPAIR This controller has no user serviceable parts. Contact your nearest Eurotherm agent for repair. Caution:...
  • Page 22 Installation TECHNICAL SPECIFICATION Equipment ratings 100 to 240Vac -15%, +10%, optionally 17-30Vac, 20-40Vdc. Supply voltage: Supply frequency: 50 / 60 +2Hz 10 Watts maximum. Power consumption: Earth leakage current: Less than 1mA. This may affect the design of an installation with multiple controllers protected by Residual Current Device, (Due to RFI Filtering) (RCD) or Ground Fault Detector, (GFD) type circuit breakers.
  • Page 23 Installation INSTALLATION AND OPERATING SAFETY REQUIREMENTS Safety Symbols Various symbols are used on the instrument, they have the following meaning: Caution, (refer to the I Functional earth accompanying documents) A functional earth is provided to ground RFI filters but is not required for safety purposes. Personnel Installation must only be carried out by qualified personnel.
  • Page 24 Installation Voltage rating The maximum continuous voltage applied between any of the following terminals must not exceed 264Vac: power supply to relay, logic or sensor connections; relay output to logic or sensor connections; any connection to ground. The controller should not be wired to a three phase supply with an unearthed star connection. Under fault conditions such a supply could rise above 264Vac with respect to ground and the product would not be safe.
  • Page 25 To ensure compliance with the European EMC directive certain installation precautions are necessary as follows: For general guidance refer to Eurotherm Controls EMC Installation Guide, HA025464. Input cables must be threaded through the ferrite ring supplied with the product. Loop the cables so there are four complete turns through the ring.
  • Page 26 Operation Section 2- Operation Contents Page GENERAL ............... Front Panel Keys............Access Levels & Security..........Operation............... Short Scroll List.............. Main Scroll List ............. Configuration (Read Only) ........... AUTO / MANUAL............SETPOINTS..............Working Setpoint............Remote Setpoint..

  • Page 27: General

    Operation 1 .o. GENERAL Display The front presentation of the instrument has been divided into two illustrations. The first shows the upper half of the display, containing the five large seven bar characters plus the five upper beacons. Illuminated when Remote Flashes when illuminated when Manual Alarm 2 is activ...

  • Page 28: Front Panel Keys

    Operation Key lock It is possible to configure a digital input to the function keylock. When the digital input is active all front panel keys are disabled. The same function can be enabled using the digital communications status word (SW). Digital Input inhibit It is possible to inhibit the action of digital input using the digital communications Optional Status word (OS).
  • Page 29 Operation The SELECT/TURBO or “I” key allows access into a scroll list for each option from the Main Scroll List. This key is also used in conjunction with the UP or I I h a DOWN key to accelerate the change of a parameter. The RUN/HOLD or “II”...

  • Page 30: Access Levels & Security

    Operation 1.2. Access Levels & Security When first powered up the instrument automatically enters the Short Scroll Menu. This gives the operator access to parameters that he is most likely to require, working setpoint, output power and the time remaining if the setpoint rate limit or a programme is enabled.
  • Page 31 Operation P.M.S. Disable Entering the correct security code into the parameter “SEC” in the Extended Main (Read Only) Scroll List, see paragraph 1.6, will override any configured P.M.S. The security will be reset if no key action is performed within 15 seconds. The code that will allow this security to be overridden is that stored under S2 in the instrument configuration.
  • Page 32 Operation Operation 1.3. It is quite possible that an individual user will not need to use all the key handling capability of the instrument. For this reason the instrument key handling has been divided up and presented under various paragraphs below, each describing a specific instrument application.
  • Page 33 Operation Indication that a parameter has not been inhibited from change is a flashing dot observed in the top of the lower display between the 2 least significant digits. If this dot is not flashing it may first be necessary to disable the security if this has been set in the configuration, see paragraph 1 .O of this section.
  • Page 34 Operation Forward Scroll 20.0 20.0 E n d Reverse Scroll P r e s s a n d 20.0 12 20.0 Turbo Action Large changes to a parameter, using the above procedure described in Reading and Setting Parameters, can take a long time. This time can be dramatically reduced by using the turbo action.

  • Page 35: Short Scroll List

    Operation 1.4. Short Scroll List On power up the instrument displays the version of installed software for approximately three seconds, before revealing the default parameter in the Short Scroll. The parameter now displayed is the Short Scroll screen viewed at power down.

  • Page 36: Main Scroll List

    Operation 20.0 20.0 SP 180.0 OP 100.0 The time parameter is only included in the Short Scroll when either a program is running or a ramp is enabled. 20.0 Time H 5.2 1 .5. Main Scroll List To enter the Main Scroll list the scroll key must be depressed and held down. This action can be performed when viewing any parameter in the Short Scroll.
  • Page 37 Operation E n t r y f r o m t h e S h o r t = T i m e O u t S c r o l l . The meaning of the abbreviations used for these headings in the Main Scroll list are shown below :- OPEr Operator Menu...
  • Page 38 Operation Operator Scroll List This menu lists the parameters which control the operation of the instrument. These parameters can be viewed at all times but can only be changed if they are not inhibited, due to some other active controller function, or the instrument security barring access.
  • Page 39 Operation Operator Scroll List Parameters Display Units/ Setpoint Rate Limit Min (Hour)* On or Off Output Condition During Setpoint Rate Limit On or Off Output Condition at end of Setpoint Rate Limit Display Units Setpoint 1 Display Units Setpoint 2 Display units Local Setpoint Display Units...
  • Page 40 Operation Programmer Menu (Not Applicable to Model 902s) Access the parameters in this menu by pressing the select key. Main Scroll list 20.0 PrOG Parameters in this list can be viewed at any time, but can only be changed if a programme is not running, or is reset.
  • Page 41 Operation Proarammer Scroll List Parameters Loops remaining Number (read only)* Pnr** Selected programme number Number ** Display units/mins or hours** First ramp rate or + StEP, nOnE and End. Time to perform first ramp** Minutes or hours** + StEP, nOnE and End. Or1 ** State of relay(s) during Prl On or off...
  • Page 42 Operation Programmer Scroll List Parameters (Continued) Display units/min or hour** Sixth ramp rate or + StEP, nOnE and End. Time to perform sixth ramp* Minutes or hours + StEP, nOnE and End. State of the relay(s) during Pr6 On or off. Or6** Display units.
  • Page 43 Operation O r 8 P d 8 T i m e O u t O d 8 P L C E n d Supervisor Menu This scroll list contains parameters for setting the alarm setpoints, sensor break power and the address used for digital communications. As in other scroll lists all values may be read but alteration of parameters may be inhibited by the instrument security, see paragraph 6.3.
  • Page 44 Operation Main Scroll list installation Menu This menu lists the parameters which set the stability of the control loop. These values should be set at the installation stage, and thereafter should only require infrequent adjustment. Access to the parameters in this menu is by pressing the select key.
  • Page 45 Operation installation Scroll List Parameters % of span or display units. Proportional band Integral time Seconds or minutes. Manual reset % Output power. Seconds or minutes. D e r i v a t i v e t i m e Proportional band for SP 2 % of span or display units.

  • Page 46: Configuration (Read Only)

    Operation M a i n S c r o l l l i s t 2 0 . 0 InSt 1.6. Configuration ( Read Only ) The Configuration of the instrument is available, read only, as an extension to the Main Scroll List. A description of the parameters held in the Configuration (Read Only) Scroll menus are given in this section.
  • Page 47 Operation User Configuration Menu (Read Only) The user configuration contains that part most likely to require changing by the user. Access the parameters in this menu by pressing the select key. C o n f i g u r a t i o n ( R e a d T i m e O u t O n l y ) S c r o l l l i s t tyP Ramp...
  • Page 48 Operation C o n f i g u r a t i o n ( R e a d O n l y ) Time Out Scroll list Parameters in this menu can be observed but alteration of their values is not permitted.
  • Page 49 Operation C o n f i g u r a t i o n ( R e a d O n l y ) T i m e O u t Scroll list 20.0 r i h Parameters in this menu can be’observed but alteration of their values is not permitted.

  • Page 50: Auto/Manual

    Operation 2.0. AUTO/MANUAL The instrument can be switched into the manual mode at any time. Manual mode allows the output power, either heat/process+ or cool/process-, to be set directly by using the “UP” and “DOWN” keys. The instrument is switched into this mode by means of the “AUTO/MANUAL”...

  • Page 51: Remote Setpoint

    Operation Remote Setpoint 3.2. The instrument can control using a remote value derived from an external analogue signal fed into the controller. Selection of this remote setpoint is in the operation mode under the mnemonic "rE". This is a two-state parameter, and will therefore be enabled by pressing the “UP”...

  • Page 52: Operating A Programme

    Operation The instrument configuration may have been set to disable this feature in which case it will be necessary to amend the configuration. Indication of the enabling of this feature is the illumination of the RAMP beacon in the lower right hand corner of the display.
  • Page 53 Operation P r o g r a m m e Scroll list 20.0 20.0 P n r 2 Pnr 1 20.0 It may first be necessary to disable the security if this has been set in the configuration, see paragraph 1 ,O. of this section. If a digital input has been configured to activate this feature, its first closure will force the lower display to reveal the current selected programme, regardless of the screen being viewed.
  • Page 54 Operation A hold condition can be forced onto a running programme at any time by a further depression of the RUN/HOLD key or operation of a configured digital input. Some digital inputs require activating and others deactivating. Failure of this key action to activate a hold is indicative of the security within the configuration being set.

  • Page 55: Setpoint Tracking

    Operation 3.5. Setpoint Tracking Two types of tracking can be set in the instrument configuration, manual and remote. Selecting manual tracking will cause the setpoint to follow or track the measured value whilst the instrument is switched into the manual mode. This will eliminate any “BUMP”...
  • Page 56 Operation T i m e O u t 20.0 O p e r a t o r Scroll list Indication of the self tune feature enabled is the illumination of the “A-T” beacon in the top right hand corner of the display. If the setpoint screen in the short scroll is selected, it will be noted that the “SP”...

  • Page 57: Dual P.i.d

    Operation Once enabled the adaptive tune feature will remain active, even though the instrument may be powered down and up again, and can only be disabled by a manual intervention. The instrument will perform the adaptive tune routine every time the measured value moves more than the adaptive tune trigger level, mnemonic “Atr", away from setpoint.

  • Page 58: Alarms

    Operation ALARMS 5.0. There are two alarms, AL1 and AL2, installed within the instrument and each of these can be configured to one of the five following types; deviation high (DVH), deviation low (DVL), deviation band (DVB), full scale high (FSH), or full scale low (FSL).

  • Page 59: Output Power Limits

    Operation 6.0. OUTPUT POWER LIMITS Limits can be set on the maximum outputs from all channels driven by the controller output, heat/process+ on its own or with the cool/process- output. The’ parameters that control these limits are “HL” for the heat/ process+ channel and “CL”...

  • Page 60: 8.0. Digital Input Functions

    Operation 8.0. DIGITAL INPUT FUNCTIONS The operation of digital inputs can be described as level or edged triggered. The following descriptions are used to explain the digital input function table; Level Triggered HIGH 4.0 to 6.0V or open circuit 0 to 0.7V or closed circuit Edge Triggered RISE Rising edge FALL Falling edge...
  • Page 61 Operation Note 1:- PMS = Parameter Modification Security.(See paragraph 1 .O General) Note 2:- Not 4 PID1 P I D 2 Not 3 Not 4 PID1 PID2 Not 3 or 4 Not 3 PID1 PID2 Note 3:- RUN, HOLD and RESET functions apply to either programmer or (ramp) functions, depending on configuration.

  • Page 62: 9.0 Keyhandling Overview

    Operation 9.0 KEYHANDLING OVERVIEW English Keyhandling Overview The following pages give the full list of screens and parameters. The combination appearing in any particular instrument is dependant upon the configuration. Power Up Supervisor List I n s t a l l a t i o n L i s t (See page (See page O p p o s i t e )
  • Page 63 Operation Scroll List Scroll Header Screen F r o m Oneration To change this value Operator List Programme List Supervisor List Installation List SPr SP Ramp Rate Pnr1 Prog Number AL1 Alarm 1 SP Pb Prop Band Prl Prog Ramp 1 Or Ramp Output AL2 Alarm 2 SP Integral Time...

  • Page 64: 9.2. French Keyhandling Overview

    Operation 9.2. French Keyhandling Overview The following pages give the full list of screens and parameters. The combination appearing in any particular instrument is dependant upon the configuration. Power Up -- - m m- Operateur List R e g u l a r g e L i s t (See page (See page O p p o s i t e )
  • Page 65 Operation Scroll List Scroll Header Screen F r o m Operation To change this value Operateur List Programme List Supervision List Regularge List Pnrl Prog Number AL7 Alarm 1 SP P b Prop Band Sr Ramp Output Pr1 Prog Ramp 1 AL2 Alarm 2 SP Integral Time Fin End Output...
  • Page 66 Operation Extended Main Scroll Lists User Config List instrument Config. Range List List (English) (English) (English) Config Operateur Config Reguleur Echelle List (French) (French) (French) Digital IP’s C1 Input Type dSL Dsp Low Lim Power F,dback C2 Channels 1,2 dSh Dsp High Lim C3 Ch 3,4 &...
  • Page 67 Commission Section 3 - Commission Page Contents 1 . 0 GENERAL .........._.._.._.._.._..1 2 .
  • Page 68 Commission Section 3 - Commission (Cont) Page Contents OPTICAL PYROMETER I N P U T S ........8 . 0 emissivity ............... Setting SENSOR BREAK POWER ..........Setting Sensor Break Power ..........DIGITAL COMMUNICATIONS ........... 1 0 . 0 Setting the address ............10.1 11 .o MOTOR VALVE POSITIONER CONTROL .......

  • Page 69: General

    Commission GENERAL The instrument is despatched from the factory with “default values” in all of the settable parameters. These values can be overwritten by the method described in section 2 Operating. When the instrument is first installed on a process the parameters mentioned in this section may be adjusted as described below.

  • Page 70: Setting The Heat/Cool Deadband

    Commission Setting Heat/Cool Dead Band On instruments fitted with a cool channel a parameter “db” sets the distance between the heat and cool proportional bands. This parameter has a maximum range of + 5% of the proportional band. Proportional Band Range of Dead Band “db”...

  • Page 71: Tuning The Loop

    Commission Tuning the Loop Having set the above parameters the controller should be coupled to the finalised process and configured as proportional only. This can be achieved by selecting the parameters “ti”, integral time and “td” derivative time and setting them to the off position.

  • Page 72: Setting The Relative Cool Gain

    Commission The value of the proportional band (Pb) where oscillations commenced, and the time of oscillation (T) should be used in the following table to determine the critically damped values for a proportional, proportional+integraI or a proportional+integral+derivative control loop. F i n a l Setting of controller parameters Control for critical damping.

  • Page 73: Automatic Tuning

    Commission Setting High and Low Cutback The parameters for cutback high “cbh” and cutback low “cbL” should both be initially set to one proportional band width, converted into display units. This can be calculated by taking the value in percentage that has been installed into the parameter “Pb”...
  • Page 74 Commission Self Tuning This routine is a single-shot process which will disable itself on completion. Once enabled the instrument exercises its output channels in a prescribed way, observing the effect this has on the measured value. Display Units Loop Setpoir PseudoSetpoir Instruments with Output 2...

  • Page 75: Adaptive Tuning

    Commission * cbL only set if,at self tune enable, the measured value was more than 5% of span below the setpoint and the parameter was not set to “off”. * cbh only set if, at self tune enable, the measured value was more than 5% of span above the setpoint and the parameter was not set to “off”.

  • Page 76: Setting An End Event Output

    Commission Setting a Setpoint Rate Limit Function The parameter “SPr” in the Operator Scroll List sets the setpoint rate limit. The value is set in display units per minute or per hour depending on the setting of the configuration. The value of the parameter “Uni Ramp” in the User Configuration indicates whether this ramp rate is in display units per minute or per hour, “LO”...

  • Page 77: Entering A Programme

    Commission ENTERING A PROGRAMME All models except the 9025 are fitted with the programmer feature. This may however have been disabled in the configuration in which case it will be necessary to enter this mode to re-enable this feature. Model 902P contains one programme whilst 903P and 904P contain a maximum of four and fifteen programmes respectively.

  • Page 78: Setting Ramp Event Output

    Commission Some applications require instantaneous changes to the setpoint, in certain parts of the programme, instead of a ramp. This can be achieved instead of setting a ramp under parameters “Prl-8” by keeping the down key depressed after the smallest value is displayed in which case “StEP” is displayed. This will cause the programmer set point to instantaneously jump from the level in the previous segment to the level in the next segment.

  • Page 79: Setting Dwell Event Output

    Commission Setting the Level F l a s h i n g d o t i n d i c a t e s t h i s P r o g r a m m e r p a r a m e t e r can Scroll list b e c h a n g e d .

  • Page 80: Ramp-Ramp Or Dwell-Dwell Programmes

    Commission P r o g r a m m e r Scroll list - 3 - 4 Ramp-Ramp or Dwell-Dwell Programmes The programme sequence of this controller is Ramp - Dwell - Ramp-Dwell etc. Programmes that do not conform to this convention can be entered i.e. Ramp Ramp - Dwell etc.

  • Page 81: Ending A Progamme

    Commission setting the intermediate segment to either “None“ for a Ramp or “0.0” for a Dwell, which will remove that segment from the programme. When setting “Pr 1- 8”, if the “down” key is kept depressed after the lowest numerical value is displayed, the value “None”...

  • Page 82: Linking Prorammes

    Commission 7.10 Linking Programmes For multi-programmers, consecutive programmes may be linked, producing programmes of 32, 48, 64 etc. segments. Setting the Loop Count in any programme to “COnt” will automatically link that programme to the next highest numbered programme. The value of the loop count in the last of a number of linked programmes set the number of repeats of the whole linked programme.

  • Page 83: Optical Pyrometer Inputs

    Commission OPTICAL PYROMETER INPUTS If the instrument has been configured for use with an optical pyrometer the value of character C and D of parameter “Cl ” in the instrument configuration “ICOnF” will be 18, 19, 21, 22, 23, 24, 26, 27, 28, 29 or 30. Configuration of the instrument for this type of input will cause the parameter “ES”...

  • Page 84: 9.0 Sensor Break Power

    Commission 9.0 SENSOR BREAK POWER Sensor break power is the default power to be requested when a process variable sensor break condition is detected. This could be a sensor going open circuit, over range or under range. During a sensor break condition, the main display will be replaced with a flashing indication;...

  • Page 85: Digital Communications

    Commission 10.0 DIGITAL COMMUNICATIONS If the digital communications port is to be used on this instrument, with either the RS 232 or RS 422 standard then a value must be entered under the address parameter “Add” in the Supervisor Scroll List. This address must agree with the value written into the supervisory software for that particular control loop.

  • Page 86: Motor Valve Positioner Control

    Commission MOTOR VALVE POSITION CONTROL 11.0 Valve Position control uses the standard PID algorithm, modified by dedicated VP output drivers. Power feedback is not available. The VP may operate with either symetric or asymetric valve travel times. Provision is also made for a valve position indication and limiting, using feedback from a potentiometer fitted to the valve.

  • Page 87: Minimum On Time

    Commission F r o m I n s t r u m e n t S c r c ” Minimum On Time The parameter, “ot”, is set to allow for inertia in the motorised valve. The value defines the minimum “raise” or “lower” output pulse duration from the controller, which should be slightly greater than the minimum response time of the valve mechanism.

  • Page 88: Valve Update Time

    Commission Valve Update Time 11.3 The parameter, “Ut”, is set to minimise the amount of valve activity. The value defines the interval at which the required output is recalculated. Setting larger values reduces valve activity, but gives less stable control. Values between 0.1 second to travel time may be entered.
  • Page 89 Configure Section 4 -Configure Contents Page GENERAL ..............1 1 .o HARDWARE VARIANTS .

  • Page 90: General

    Configure GENERAL The 902/3/4 instruments can easily be configured to most users’ requirements on site. Changing the configuration will involve altering the software and may also involve hardware changes. The instrument is always fitted with a power supply PCB, a microprocessor PCB and a display PCB. To facilitate a large number of options a further two mutually exclusive options PCB’s may be installed.
  • Page 91 Configure Channel Number Module Function Heat output Cool output Alarm 1 Alarm 2 Programmer relay Comms controlled relay Remote input Retrans output VP lower VP raise There are also limitations on the type of modules allowed to perform certain functions. A list of these permissible functions is given below :- Module Function Module Type Relay...

  • Page 92: User Configuration

    Configure 3) Retransmission/control output modules and analogue communications options boards are each fitted with two links, each designated “V” and “I”. Placing both links into the “V” position gives a voltage output whilst both links placed into the “I” position gives a current output. USER CONFIGURATION 3 .
  • Page 93 Configure The various parameters in the user configuration are then scrolled by depressing the SCROLL key. individual parameters in the scroll list can be viewed and changed using either the UP or DOWN key, as shown below. COnF COnF 0211 Para.

  • Page 94: Key Handling In The Configuration Mode

    Configure Key Handling in the Configuration Mode The key handling in the read /write configuration mode is very similar to the operating mode except when adjusting the code numbers of "diG", “Cl”, “C2”, “C3”, "C4", “C5”, "C6”, “C7”, “C8”, “C9” and “Cl 0”. After selecting the desired mnemonic using the procedure outlined in Figure 4, the first depression of either the “UP”...

  • Page 95: Dig

    diG inputs diG = (ABCD) (See Operation 8.0 for function explanation.) Unused Code Digital Input 1 None Manual Remote Setpoint 2 PID 2 Adaptive tune Run/Hold Programme number monitor/step ( Digital input 1 = down key ( Digital input 2 = up key )[C and D are ignored] ( Digital input 3 = select/turbo key) Code...

  • Page 96: Holdback

    Configure 3.3.2 Holdback The holdback mnemonic “Hb” has a number of values which are given in the table below together with an explanation of their meaning. MNEMONIC DESCRIPTION nOnE No holdback Deviation band holdback HIGH High deviation holdback Low deviation holdback 3.3.3 Programme and Ramp Parameters An explanation of the other mnemonics used in the user configuration list is...

  • Page 97: Instrument Configuration

    Configure 4.0. INSTRUMENT CONFIGURATION This mode of operation contains the software that determines the basic operation of the instrument. It is very unlikely that the user will need to enter this level but if this becomes necessary the procedure outlined in paragraph 4.1 of this section should be followed.

  • Page 98: Instrument Configuration Parameters

    Configure 4.2. instrument Configuration Parameters Mnemonics “Cl to C10”, which are all code numbers, are initially displayed in this level. Each code consists of four numerals which are referred to in the following descriptions as A, B, C and D. Character A being the extreme left hand numeral in the display and character D being the extreme right hand one.
  • Page 99 Configure Cl INPUT (Cl ABCD)[Continued] Input Type Code Description El Code Range “C CD = 00 NiCr/NiAl -270 1372 (Default IP) = 01 Fe/CuNi -210 1200 = 02 Fe/CuNi -270 = 03 NiCr/NiAl -270 1372 = 04 Cu/CuNi -270 = 05 Pt/PtRh13% 1767 = 06 Pt/PtRh10% 1767...
  • Page 100 Configure C2 CHANNEL 1 and 2 (C2 = ABCD) 4.2.2. Channel Relationship Code Channel 1 and 2 separate Channel 2 = Channel 1 [C2(D) is ignored] Code Channel Sense for PID Control Channel 1 normal, Channel 2 normal Channel 1 normal, Channel 2 inverted Channel 1 inverted, Channel 2 normal Channel 1 inverted, Channel 2 inverted Code...
  • Page 101 Configure C3 CHANNEL 3 AND 4 AND ALARM DEFINITION (C3 = ABCD) 4.2.3. Code Alarm Relay Status (see note 1) Alarm 1 and 2 de-energised in alarm Alarm 1 de-energised, alarm 2 energised in alarm Alarm 1 energised, alarm 2 de-energised in alarm Alarm 1 and 2 energised in alarm Alarm 1 Function (Channel 2 or 3) Code...
  • Page 102 Configure C4 CONTROL OPTIONS (C4 ABCD) 4.2.4. Programmer function Code No programmer function Ramp function Single Programme programmer Multiprogramme programmer(4 or 15) PID polarity Code Reverse acting Direct acting Derivative action Code Error driven PV driven Dual PID parameters Code Single set of commissioning parameters Dual set of commissioning parameters C5 UNITS (C5 = ABCD)
  • Page 103 Configure 4.2.6 C6 DISPLAY (C6 = ABCD) Power-fail recovery strategy Code Returns to dwell setpoint at previous ramp rate Returns to dwell setpoint immediately Code Parameter modification security (PMS) No modification of any parameter Modification of “OPEr” parameters only (set points) Modification of “OPEr”...
  • Page 104 Configure C7 DIGITAL COMMUNICATIONS (C7 = ABCD) 4.2.7. Comms. resolution (J-Bus and Modbus only) Code Integer only Full resolution Parity (J-Bus and Modbus only) Code No parity Even parity Baud rate Code 9600 Baud 4800 Baud 3600 Baud 2400 Baud 1200 Baud 600 Baud 300 Baud (Not available for J-Bus or Modbus)
  • Page 105 Configure C8 ANALOGUE COMMUNICATIONS (C8 = ABCD) 4.2.8. Hardware type Code No analogue comms. are required, or remote-input and/or retransmission module(s) fitted or VP Pot input Analogue communications PCB fitted Digital communications remote input Analogue retransmission Code None Setpoint Process variable Error Output power Inverted set point...
  • Page 106 Configure 4.2.9. C9 SELECTION OF RUN, HOLD, RESET AND TUNER (C9 = ABCD) Code Selection of run/hold Run/hold available rear only (only valid for ramp and programmer) Run/hold available front and rear (only valid for ramp and programmer) Code Selection of reset Reset available rear only (only valid for ramp and programmer) Reset available front and rear...

  • Page 107: (Selection Of Remote And Auto/Man. Options)

    Configure 4.2.10 C 10 SELECTION OF REMOTE AND AUTO/MAN OPTIONS (C10 ABCD) Setpoint tracking in remote Code Setpoint 1 hold Setpoint 1 tracks remote setpoint Setpoint 1 tracks local setpoint Selection of remote input Code Not available Remote available front and rear Remote available rear only Setpoint tracking in manual Code...

  • Page 108: Idn" Hardware Identification

    Configure 4.2.11. “idn” HARDWARE IDENTlFlCATlON If the scroll button is depressed when the mnemonic “C10” is on the display the instrument will show the mnemonic “idn”. To display the value of “idn” the up and down keys must be depressed together. The display will change to a four character code, in the form “ABCD”...

  • Page 109: Exit From Instrument Config

    Configure 4.3. Exit from Instrument Configuration The method of exiting the instrument configuration level is to scroll to the menu “LEAVE” and press the select key. COnF COnF COnF C l 0 ICOnF rAnGE Short Scroll M o d e COnF COnF 20.0...

  • Page 110: Range Configuration Parameters

    Configure Range Configuration Parameters The mnemonics used in this level of the configuration are shown below and the method of entering the value of each mnemonic is shown below. F l a s h i n g D o t I n d i c a t e s COnF COnF...

  • Page 111: Exit From Range Configuration

    Configure Exit From Range Configuration 5.3. The method of exiting the range configuration level is given in tabular form below:- COnF 20.0 COnF LEAVE SP 1 8 0 . 0 1) Press the “SELECT/TURBO” key. 2) This will cause “rAnGE” to appear on the display. 3) Pressing the “Scroll”...

  • Page 112: Security Codes

    Configure 6 . 0 SECURITY CODES Two security codes are used within the instrument which are as follows:- S1 A code which allows access beyond User Configuration to Instrument Configuration, Range and Calibration levels. S2 A code which overrides the parameter modification security (PMS) These codes are set to zero when the instrument is despatched from the factory.
  • Page 113 Calibration Section 5 - Calibration P a g e C o n t e n t s GENERAL ..............1 2 .

  • Page 114: General

    Calibration GENERAL The 902, 3 or 4 controller can be calibrated whilst installed in its sleeve if the relevant wiring can be re-routed to the calibration device. Alternatively the instrument can be removed from its sleeve and calibrated on a bench, in which case an additional 902 sleeve, (Part Number SUB 902 SPARE SLEEVE), is required.

  • Page 115: Partial Calibration

    Calibration PARTIAL CALIBRATION The table below shows which mnemonics have to be selected to calibrate a particular range and input. The configured range of the Selected instrument being calibrated Mnemonic Pyrometer or voltage inputs where input span is < 10mV Pyrometer or voltage inputs where input span is >...

  • Page 116: Access To Instrument Calibration

    Calibration ACCESS TO INSTRUMENT CALIBRATION To alter the calibration of the instrument the configuration (Read/Write) mode has to be entered using the key operations shown below Access into the calibration level of the controller is barred until the correct security code is entered. Software Version Number This code is set to “O”, (no security), when the instrument is despatched from the...

  • Page 117: Calibration Technique

    Calibration After entering the correct code access to the calibration level is attained using the following key handling procedure. (See Para. 5.1) (See Para. 5.2) i10 (See Para. 5.3) (See Para. 5.4) cJc (See Para. 5.5) rtL )(See Para. 5.6) hLL (See Para.
  • Page 118 Calibration 10mV Calibration Procedure. C O N T R O L L E R UNCOMPENSATED MILLIVOLT SOURCE ( E U R O T H E R M Note:- During this calibration routine the resistor supplied with mA input instruments must not be connected across the input C O N D U C T O R S...

  • Page 119: 0Mv Calibration Procedure

    Calibration 20mV Calibration Procedure 1) Press the scroll key until “i02” is displayed. 2) Set the output of the calibrator to 20.000mV. 3) Repeat the procedure 4 to 9 of paragraph 5.1 above for mnemonic ‘i02”. 4) If no further calibrations are required leave configuration as described in paragraph 6.0 of this section.

  • Page 120: C.j.c. Calibration Procedure

    Cali bration C.J.C. Calibration Procedure 7) The leads between the calibrator and the instrument should now be changed for compensating cable, see Figure 2. C O N T R O L L E R COMPENSATED MILLIVOLT SOURCE Figure2 instrument connections for C J C calibration procedure.

  • Page 121: Resistance Thermometer Calibration Procedure

    Calibration 10) If the reading drifts by more than a few tenths of a degree in 30 seconds the calibration of ‘cJc’ has been unsucessful. Check the calibrator, instrument and compensating cable wiring. 11) Press the “up” and “down” keys simultaneously together to repeat the calibration of “cJc”.

  • Page 122: Volt Calibration Procedure

    Calibration 8) Press the “up” and “down” keys simultaneously. 9) The “rth” will disappear and the top dot of the LSD will flash for approximately 15 seconds. 10) The display will now read 250.0 11) If the reading drifts by more than a few tenths of an !A in thirty seconds, the RT calibration is unsucessful.
  • Page 123 Calibration 6) The display will now indicate a voltage reading of 10.000. A drift of more than a few mV’s in this reading in 30 seconds indicates that the calibration procedure was unsuccessful. 7) If unsuccessful check the calibrator, instrument and interconnections. 8) Press the “up”...
  • Page 124 Calibration 6) The “up” or “down” keys can now be used to adjust this percentage value to the desired minimum output i.e. for a 0-5.0 volt output, set 0.0%; for a 4- 20mA output, set 20.0%. 7) The above procedure is sufficient for the outputs indicated as control in the table above.

  • Page 125: Remote Input Calibration Procedure

    2) Connect the calibrator to the pair of terminals used for the remote input on the specific instrument to be calibrated, as in Figure 6. C O N T R O L L E R VOLTAGE SOURCE (EUROTHERM 239) Alternative connections depending upon which...
  • Page 126 The amplitude of this voltage is the relevant currents, in amps, multiplied by 50. 4) Connect a voltage source such as the Eurotherm 239 to the instrument as Figure 6 using the terminals numbers selected from the table above.

  • Page 127: Valve Positioner Potentiometer

    C a l i b r a t i o n Valve Positioner Potentiometer Calibration Procedure 5.10 (Only applicable to controllers where the Valve Positioner output has been configured to be used with a potentiometer) The motorised valve plus potentiometer, that is to be used, must be wired to the controller, as shown in Figure 7, before commencing this calibration procedure.

  • Page 128: Exit From Calibration

    Calibration This calibration procedure rescales the potentiometer, under the mnemonic “op” making the maximum and minimum selected positions now equal to 100% and 0% respectively. These settings limit the travel of the motor in the “Auto” mode. Potentiometer limits “PL” and “Ph” in the Installation Mode Scoll list can further restrict the movement of the motor if they are set to other than 0% and 100% respectively.
  • Page 129 Communications Section 6 - Communications Con tents Page 1 .o GENERAL ..............TRANSMISSION STANDARDS .

  • Page 130: General

    *Note:- Although the 902/3/4 controller meets all the drive specifications of the RS 485 standard the Eurotherm system does not support the half duplex clauses within the standard. Converting the instrument from one standard to the other is achieved by...

  • Page 131: Protocol

    Even or None. Comms. 125mS/125mS 1 0mS/125mS Latency (Read/Write) Two Eurotherm publications are available which contain more details on communication standards than can be covered in this text. 900 Series Digital Communications Handbook(HA 023776) 4.0. ASCII COMMUNICATIONS 4.1. Data Format Four types of data format are supported in the digital communications used in the 902/3/4 controller.
  • Page 132 Communications Numerical Fixed Format:- In this format 5 character positions must be filled, and for negative values, the decimal point is replaced by a minus sign. Therefore + 5.3 can be entered as : (5.300) ( 05.30) and -5.3 can be entered as : ( 5-300) ( 05-30) This system has the advantage of having the same resolution for positive and...

  • Page 133: Polling Sequence, Instrument To Supervisor

    Communications Polling Sequence, instrument to Supervisor. 4.2. PROTOCOL ESTABLISH PHASEB TERMINATION MESSAGE TRANSFER PROCEDURE CONNECTION : SENDER SUPERVISOR : INSTRUMENT SUPERVISOR : SUPERVISOR SUPERVISOR MASTER SLAVE MASTER STATUS INSTRUMENT SLAVE MASTER SLAVE REPLY SELECT NEXT , PARAMETER FROMLIST 4.3. Selection Sequence, Supervisor to Instrument PROTOCOL ESTABLISH PHASE A...

  • Page 134: Ascii Fast Poll

    Communications 4.4. ASCII Fast Poll The order of the list of mnemonics given in paragraph 4.7 is important. An “ACK” transmitted back to the 902/3/4 after a request for data will initiate a fast poll and cause the instrument to automatically transmit the next mnemonic in the list together with its data.

  • Page 135: Ascii Parameter Mnemonics List

    Communications ASCII Parameter Mnemonic List 4.7. The order of this table is that which would be obtained if a fast poll was performed commencing from Instrument Identifier (II). This is a complete list of all the communication mnemonics. The actual list on any specific controller will be a configuration dependant subset of this list.
  • Page 136 Communications PARAMETER AVAILABILITY MNEMONIC (Lr) Loops remaining for current Programmer configured and programme is programme running or in hold. (R/O except in hold) ( P r 1 ) Ramp rate 1 or Time to Target 1 Programmer configured (Pl1) Ramp level 1 Programmer configured (Pd1) Programmer configured...
  • Page 137 Communications MNEMONIC PARAMETER AVAILABILITY Cycle time for channel 1 Channel 1 configured as CH (Hc) time proportioning. XP (Pb) Proportional band PID heat configured Integral time PID heat configured (ti) (rES) Manual Reset On/Off, P or PD controller Derivative time (td) PID heat configured HB (cbh)
  • Page 138 Communications Note 4 :- The true limit of PV are 1H + 10% of (1H - 1L) to 1 L - 10% of (1 H -lL). Note 5 :- In Auto Mode output power is read only. In Manual Mode output power is read /write.

  • Page 139: Ascii Status Word Format

    Communications ASCII Status Word Format 4.8. Status words are used to transmit controller bi-state information over the communication lines. The data format for status words is identical to all other forms, except for the first character, which is always a ">" sign, indicating that the following four characters are hexadecimal.
  • Page 140 Communications Optional Status Word (OS) Format (>ABCD) Digit Bit Function Attribute Clear / Set Prog/Rmp St’us(LSB) See Note 2 Prog/Rmp St’us See Note 2 ProglRmp St’us See Note 2 Prog/Rmp St’us(MSB) See Note 2 Log of hold events No hold/hold Skip current segm’t Remain/skip Ramp/dwell...
  • Page 141 Communications Extension Status Word (XS) Format (>ABCD) Digit Bit Function Attribute Clear / Set R / W Off/St active Self tune Adaptive tune Off/At active Disable Broadcast Disable/Enable SP+PID/PID PID control R / W independent PID 1 / PID 2 Active PID set Dig Input 3 Off/on...
  • Page 142 Communications Output Channel 3 (01) Format (>ABCD) Status of program controlled digital output 3 during each segment Attribute Clear / Set Digit Bit Segment ramp 1 to output 3 Active/non active Active/non active dwell 1 to output 3 ramp 2 to output 3 Active/non active Active/non active dwell 2 to output 3...
  • Page 143 Communications Digital Output Status Word 3 (03) Format (>ABCD) Status of output 4 during each segment Digit Bit Segment Attributes Clear/Set ramp 1 to output 4 Active/non active Active/non active dwell 1 to output 4 ramp 2 to output 4 Active/non active Active/non active dwell 2to output 4...
  • Page 144 Communications Digital Output Status Word 5 (05) Format (>ABCD) Status of output 2 during each segment Clear/Set Segment Attributes Digit Bit Active/non active ramp 1 to output 2 dwell 1 to output 2 Active/non active ramp 2 to output 2 Active/non active Active/non active dwell 2 to output 2...

  • Page 145: J Bus And Modbus

    Communications 5 . 0 . J BUS AND MODBUS Parameter Words and Status Bits Address Maps. Parameter Maps Absolute Attribute Parameter Decimal Mnemonic Address J-Bus Modbus Measured Value Setpoint 1 Output Power (R/W in manual) Status Word Setpoint 1 Prop. Band Set to Zero Integral Time Derivative Time...
  • Page 146 Communications Absolute Attribute Parameter Decimal Mnemonic Address J-Bus Modbus Error Optional Status Word Extended Status Word Motor Low limit R/W. Motor High Limit Travel Time Down Minimum On Time Valve Update Time Set to 8000/H Proportional Band (2) Integral Time (2) Manual Reset (2) Derivative Time (2) Relative Cool Gain (2)
  • Page 147 Communications Attribute Absolute Parameter Decimal Mnemonic Address J-Bus Modbus Dwell 6 Ramp 7 Level 7 Dwell 7 Ramp 8 Level a Dwell 8 Output Status 5 Output Status 6 Set to 8000/H Software Version Number Instrument Type = 9020 Display Max. Display Min.
  • Page 148 Communications Bit Map Attribute Origin/Description Absolute Decimal Address J-BUS MODBUS Sensor Break Manual R/W* Remote Setpoint 2 Alarm (1) Active Alarm (2) Active Self tune R / W * Adaptive tune Sensor Break Keylock Parameter changed via keys Alarm 2 Alarm 1 Alarm 1 or 2 R/W*...
  • Page 149 Communications Absolute Attribute Origin/Description Decimal Address J-BUS MODBUS Skip Current Segment Dwell (0 = Ramp) Segment No. (LSB) Segment No. Segment No. Segment No. (MSB) Dig. Output 2(Ch.4) Dig. Output 1 (Ch.3) Dig. Input 2 Dig. Input 1 Programme status is set by the value of the nibble created by addresses 41, 42, 43 and 44 as above where 41 = bit 0,42 = bit 1, 43 = bit 2 and 44 = bit 3.
  • Page 150 Error Messages Section 7 -Error Messages Contents Page GENERAL ..............CONFIGURATION MODE ERROR MESSAGES .
  • Page 151 Error Messages 1 .o General The 902/3/4 controller has incorporated in its software programmes to detect faults in the operating procedures of the instrument. If one of these faults are detected, an error message will appear in either the upper or lower displays. These error messages can then be used to determine the corrective action necessary to return the instrument to full operational status.
  • Page 152 Error Messages COnF COnF 0162 COnF COnF 0122 Figure 2 If the instrument mains supply is interrupted whilst an illegal value is set, then after performing the entry to configuration procedure(see paragraph 4.1 of section 4), “C Er” will be appear on the upper display. This indicates that the illegally set mnemonic, C 1 to C10 or dlG must be corrected.
  • Page 153 Error Messages Error Message Fault Description Necessary Corrective Action 1 Er Watchdog Register Change Microprocessor P.C.B. 3 Er Stack Depth Change Microprocessor P.C.B.. 4 Er Watchdog Timeout Change Microprocessor P.C.B. C Er Invalid Config. Value Enter Config., ammend incorrect value, exit config. H Er Invalid Hardware ldent Check connections on all plug...
  • Page 154 Appendix Glossary of Terms Adaptive tune is a background algorithm which continuously monitors Adaptive Tune the error signal (P.V. - S.P.) and analyses the loop response during process disturbances. If the algorithm recognises an oscillitory or under damped response it then recalculates the P.I.
  • Page 155 Appendix Auto/Manual Alternative control conditions that can be selected within the controller. The instrument can be set into an automatic mode or set into manual operation. In ‘auto’ a closed loop condition, the power to the process is automatically computed and set by the sensor output relative to the setpoint.
  • Page 156 Appendix integral Action Integral action is used to achieve zero steady state control error. The product of error and proportional gain is integrated into an accumulator which is added to output signal. A problem with integral action is that when large error signals exist for a significant period of time, such as following a large scale setpoint step, the integral accumulator assumes a very large value.
  • Page 157 Appendix An action which returns a completed or running programme to the R e s e t start condition i.e. controlling on SP1, SP2 or remote SP. Control action such that the output decreses as the process value Reverse Action increases.

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