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United Process Versapro Installation And Operation Handbook

Temperature controller
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Versapro
Temperature Controller
Installation and Operation
Handbook
Revision 1.11

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Summary of Contents for United Process Versapro

  • Page 1 Versapro Temperature Controller Installation and Operation Handbook Revision 1.11...
  • Page 2 United Process Controls Inc. DISCLAIMER: The VersaPro is to be used by the industrial operator under his/her direction. United Process Controls Inc. is not responsible or liable for any product, process, damage or injury incurred while using the VersaPro. United Process Controls Inc. makes no representations or warranties with respect to the contents hereof and specifically disclaim any implied warranties or merchantability or fitness for any particular purpose.

  • Page 3: Table Of Contents

      ON/OFF Dual (OD) ..................................  1 5     ON/OFF with Complement (OC) ..............................  1 5     Direct Current Output ................................  1 5     Direct or Reverse Control Action  ..............................  1 6     Alarms .................................... 16 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 4 Guaranteed Start Timer ................................  3 5     11.4 Guaranteed Soak Timer ................................  3 6     11.5 Timer Alarm Behavior ................................  3 6     11.6 Timer State Diagram  ................................  3 6     Timer SIO Operations ................................. 38 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 5 19.3 Start Monitor Mode ................................  6 0     19.4 ‘D’ Display Command  ................................  6 1     19.5 ‘L’ Write FLASH to RAM Defaults ............................  6 1     19.6 ‘K’ Write RAM to EEPROM ..............................  6 1 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 6 Environmental ratings ................................  6 5     20.2 Equipment ratings  .................................  6 5     20.3 General....................................  6 5     20.4 Electrical safety (pending approval) .............................  6 6     Versapro Memory Map .............................. 68 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 7: Safety And Environment Information

    (ground) terminal The functional earth connection is required for safety ground add to ground RFI filters. Personnel Installation must be carried out by qualified personnel. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 8: Enclosure Of Live Parts

    Fusing and interposing relays should be added to the control circuit if high current or large inductive loads are used. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 9: Voltage Rating

    Please note that the alarm relays within the controller will not give protection under all failure conditions. This instrument is not suited for over temperature protection and should not be used as a safety device. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 10: Grounding Of The Temperature Sensor Shield

    Where it is impractical to do this, use shielded cables with the shield grounded at one end. VersaPro Features The VersaPro is a single loop process controller / monitor has the following capabilities:  24 bit Sigma-Delta ADC for thermocouple with cold junction compensation.

  • Page 11: Installation

    Page 11 Installation The VersaPro instrument is designed for up to 1/8" panel mounting in a DIN standard opening of 3.62" square (adapter panels available by special order). Required rear clearance is 7.5” to allow for wiring. As with all solid state equipment, the controller should be located away from excessive heat, humidity, and vibration.

  • Page 12: Mounting

    To mount the instrument in a control panel, a hole must be cut 3.62" square in the necessary location on the panel. The following procedure should be followed to mount the VersaPro in the panel. Insert the unit into previously cut out 3.62" square hole in panel.

  • Page 13: Process Control Options

    VersaPro Temperature Controller Page 13 Process Control Options The Versapro is configured to perform as a single loop PID controller for a specific process. This instrument is setup as an oxygen controller. Table 1 Instrument Control Options Function Description Temperature Uses the temperature signals from a thermocouple to control to temperature setpoint.

  • Page 14: Time Proportioning Dual

    Hysteresis provides a delay between the control on point and the off point. Noise will not cause the control output to “chatter” with this gap applied. Hysteresis is ±20% of the deadband value. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 15: On/Off Dual

    ON when the first is control contact is OFF and vice versa. Direct Current Output The Versapro has two analog output channels that provide an isolated 4 to 20mA signal proportional to selectable process values. The analog outputs can be configured to control the process by driving actuators with a 4-20mA signal proportional to the calculated percent output of the PID loop.

  • Page 16: Direct Or Reverse Control Action

    KEYBOARD Fault alarm, contact assignable Reset instrument power. Do not push any keys while instrument is powered on. Return to Marathon if error does All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 17: Process Alarms

    Process Alarms The process alarms can be setup to activate either or both of the two alarm contacts provide on the VersaPro. Nine user selectable modes are available. The Full Scale HI, Full Scale LO, Fault, and Probe alarms are available in the monitor.

  • Page 18: Output Low

    Each alarm can also be configured for either reverse or direct latched conditions. In this mode the alarm contact will remain active until an acknowledgement is received through the event port or by pressing the ENTER key. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 19: Alarm Delay Times

    It may be necessary to adjust the oxygen exponent and/or the oxygen decimal point settings if these symbols occur. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 20: Serial Interface

    Page 20 Serial Interface The VersaPro has a single RS-485 half duplex (two wire) communications port. This port can be configured for either the Marathon protocol of Modbus RTU protocol. Baud rates and parities are selectable. The Modbus protocol only uses a parity of none. See the section on communications for details on both of these protocols.

  • Page 21: Front Panel Operation

    The lower display shows the instrument setpoint if the controller is in automatic or remote mode. The display will switch to control output level when the instrument is changed to manual. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 22: Enter Key

    When the controller is set to Automatic mode the “Auto” LED lights and the lower display indicates the process setpoint (default). When the controller is set to Remote mode the “Rem” LED lights and the VersaPro will accept a remote setpoint from a master on the host serial interface. The lower display indicates the process setpoint (default).
  • Page 23 ENTER key is pressed. A new menu can be select only when the menu heading is displayed. You can exit from the Setup mode by pressing the SETUP key at any time. The following tables outline the Setup menus available in the VersaPro Controller and Monitor when the operator presses the SETUP key.
  • Page 24 You can only select another menu heading when the display is at a menu heading. The following figures and tables outline the menu options and parameters under the Setup key. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 25 VersaPro Temperature Controller Page 25 Figure 5 Setup Menu Tree All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 26 Only in Linear mode -999 – 9999 Linear offset to scale Input A to Engineering Units when INPUT A is selected as the process All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 27 In POUT mode the offset is fixed to the LOPO value. When PROG is selected the LOPO for POUT offset is fixed at 0 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 28 – Deviation Low, defines a process band below the process setpoint. The alarm is active if the process moves outside this band. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 29 Range Description PROTOCOL PROP OR BUSS PROP is Marathon Monitors, Inc. protocol, BUSS is Modbus ADDRESS 1 TO 15 (MSI) 1 TO 255 (MOD) All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 30 OUTPUT 2 MIN Sets signal level for the minimum (CAL OUTPUT) mA output. OUTPUT 2 SPAN Sets signal level for the (CAL OUTPUT maximum mA output. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 31: Dual Key Functions

    Pressing the Setup key once at any point in the Setup menu will return the instrument to the normal process display. Dual Key Functions The VersaPro was four dual key functions as defined below: RIGHT arrow / Enter Start probe test sequence...

  • Page 32: Digital Input Event

    Page 32 Digital Input Event The VersaPro has a single digital input. This input is activated by making an isolated contact closure between terminals TB-B 11 and 12. This input is debounced for a momentary closure of at least 0.6 seconds.

  • Page 33: Strt (Controller Only)

    End (controller only) This selection will acknowledge the end condition of the timer, clear the end state, and reset the timer for another start. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 34: Timer Function

    Page 34 Timer Function The Versapro timer function is available on all process controller options. The timer can operate independently or it can be dependent on the process based on how either alarm contact is configured. The instrument has three possible functions; timer, guaranteed start timer, and guaranteed soak timer. These functions are set through the mode selection of alarm 1 or alarm 2 in the Setup menu.

  • Page 35: Time

    HOLD state. The following figure shows the behavior of the guaranteed start timer. Figure 6 Guaranteed Start All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 36: Guaranteed Soak Timer

    END state and stops flashing when the timer is acknowledged and returns to the IDLE state. 11.6 Timer State Diagram The following diagram shows the conditions that control the state of the timer function. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 37 Alarm Contact = OFF Rem Light = Flash Figure 8 Versapro Timer State Diagram The timer has four states. The IDLE state is the inactive condition. The RUN state is the active state when the timer is counting down. The HOLD state is when counting is paused due to either Digital Event = HOLD or a configured alarm is active.

  • Page 38: Timer Sio Operations

    Timer SIO Operations The Versapro allocates a second host address if the timer function is enabled and the host port protocol is set to PRoP (Marathon) using the Marathon slave protocol. If the host port protocol is set to buss (Modbus) or the Marathon block protocol is used, then the timer information is accessed directly.

  • Page 39: Controlling The Timer Remotely

    The input event configuration is in the lower byte of this word. Any configuration of the input event must be added to the timer function values when this word is written to the Versapro. In this example the event configuration is set to none (0).

  • Page 40: Tuning

    (Rate) The Versapro uses the Proportional Band as a representation of the Proportion section of PID, the Reset as a representation of the Integral section of PID, and the Rate as a representation of the Derivative section of PID.
  • Page 41 Make sure you record all operating parameters and keep them in a secure place for later reference. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 42 VersaPro Temperature Controller Page 42 Figure 9 PID Tuning Procedure All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 43: Scaling Analog Inputs

    53.2mV. The process display can be configured to display either 100 or 100.0. This process value can then be retransmitted to other control devices are a recorder. The control model of the Versapro will be able to control to a setpoint for the new process value.

  • Page 44: Scaling Analog Outputs

    DACV1 or DACV2 registers. Calibration There are two analog inputs, a cold junction compensation sensor, and two analog outputs on the VersaPro. The input level is determined by which terminals are used for the input signal. There are two pairs of input terminals: TB-B 1, 2 for the thermocouple (T/C) input and TB-B 3, 4 for the probe millivolt input.

  • Page 45: Calibration Displays And Keyboard Operation

    The first part of the calibration is in linear mode first. The thermocouple setting has no effect on the millivolt readings in the first part of the input calibration but will effect the reading during the cold junction adjustment. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 46: Calibration Of The Thermocouple Input

    Change the copper wire with the correct thermocouple extension wire 2. Set the calibrator to a typical temperature level. 3. Use the Versapro Enter key to advance to the CJ Adjustment display. 4. Using the arrow keys, adjust the displayed value to equal the calibrator input.

  • Page 47: Calibration Of The Analog Output Channels

    20mA is 3150. The maximum cal factor is 4095. 8. Press the SETUP key to save the calibration values and exit the calibration routine. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 48: Communications

    Each device is assigned an address to distinguish it from all other connected devices. The VersaPro recognizes three Modbus RTU (Remote Terminal Unit) commands. These are: read single I registers (command 4), read a single H register (command 3), and preset a single H register (command 6) In the RTU protocol sends data in 8-bit binary characters.

  • Page 49: Data Field

    PLC on the MODBUS industrial communications system. Command codes were established to manipulate PLC registers and coils. As far as the VersaPro is concerned, they are all just memory locations, but the response to each command is consistent with Modbus specifications.

  • Page 50: Msi Message Protocol

    ‘U’ block protocol. The following command set applies to the ‘A’ command and is used for the Versapro and other 10PRO type instruments such as temperature controller slaves. The command set is sent by a master to a 10PRO slave instrument.
  • Page 51 Here is an example that shows how the HOST changes the instrument’s remote setpoint. The instrument’s address is 15. The HOST has sent a command to update the remote setpoint with 1450. The instrument responds by echoing the command. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 52: Instrument Type 'U' Command Set

    11 blocks or more. The Versapro, 10Pro-E, and Version 3.5 Carbpro have only table 0. The table value is assumed to be 0 and the parameter is addressed directly with the possible range of 0 to 71. These number correspond with the decimal numbers in the Versapro Memory Map table.
  • Page 53 Transmit from Host or Master Prefix Table Data Delim Delim NULL 0x31 0x55 0x58 0x30 0x30 0x24 0x30 0x30 0x30 0x30 0x00 0x1E 0x04 0x30 0x36 All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 54: Block Commands

    Block Commands Block transfer commands are used to read and write data in a group of 24 words. The Versapro has only three blocks in table zero. The block transfer command has to identify the table as well as the block.
  • Page 55 (bb) Block number (HEX) (tt) Table number (HEX) (*) Block Read command character (I) Instruement Prefix: U = Versapro instrument prefix. (A) Address of instrument. Figure 11 Block Read Response Format The following is an example is for a block request from the Host and a reply from the instrument. The Host sends the command: 1U*0000<00>N<04><06>...

  • Page 56: Msi Error Codes

    MSI Error Codes The Marathon protocol for the Versapro has three error codes that can be generated by the instrument: E1 = Incorrect LRC detected on received message, E2 = Invalid command detected, and E3 = Invalid table or parameter address.

  • Page 57: Troubleshooting Questions

    PID control calculation into oscillation. It would be necessary to set the LOPO to 20% and the HIPO to 100% to achieve stable control. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 58: Digital Communications

    How come I have communications problems with an instrument address following a Versapro address setting. If the timer function has been enabled and the Versapro host protocol is set to ‘Prop’ for the Marathon protocol, the instrument will take the next host address setting to respond with the timer parameters. The problem can be corrected by turning of the timer function in the Control menu or setting to next instrument address to Versapro host address + 2.

  • Page 59: Versapro Monitor Mode

    EEPROM values. These parameters will include the thermocouple type, alarm functions, and probe care settings. For the controller version of the Versapro this will also include control and PID settings as well. Note the instrument calibration settings for the two analog output channels by going into the SETUP mode, selecting CAL OUT –...

  • Page 60: Start Monitor Mode

    "MONITOR MODE”, (about 5 seconds). The instrument will send a prompt to the HyperTerminal screen that should look like figure 1. If the Versapro is already in Monitor Mode it may only have the Power light on with no other display. Cycle power on the instrument while connected to see the “Marathon Monitors, Inc.”...

  • Page 61: D' Display Command

    Exits Monitor mode Resets processor idle counter The Versapro is placed into Monitor mode when the <Enter> and <Rem> keys on the instrument are pressed simultaneously and held for about 5 seconds. The LCD display will display the prompt ‘MONITOR MODE’ and the LED display will be blank.

  • Page 62: J' Display Eeprom Values

    The ‘D’ command is followed by the start of the memory locations to be displayed. In this case the EEPROM memory block is being displayed starting at hexadecimal address 0800. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 63: Loading Default Values

    Enter. The ‘X’ command causes the instrument to exit monitor mode, resets the processor, and returns to operation mode. This sequence is shown in the following figure. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 64: What If An Error Occurs

    RAM or EPROM procedures then the instrument memory maybe damaged. The instrument should be returned to Marathon Monitors, Inc. for testing and possible repair. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 65: Technical Specification

    Probe verification and impedance for oxygen probes. Communications port: RS-485 Half Duplex Only Protocol: 10Pro, MMI block transfer, or Modbus RTU Baud rates: 1200, 2400, 4800, 9600, 19.2K All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 66: Electrical Safety (Pending Approval)

    Conductive pollution must be excluded from the cabinet in which the instrument is mounted. Environmental Conditions Operating Temperature -20 °C to 65 °C (-4 to 176 F) All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 67 -40 °C to 85 °C (-40 to 185 F) Operating and Storage Humidity 85% max relative humidity, noncondensing, from –20 to 65°C Note: Specifications may change without notification. All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.

  • Page 68: Versapro Memory Map

    Range = -999 to 9999. Default = 0000 ALARM2 Alarm value is based on process value display READ ONLY decimal point and exponent. Both are required to All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 69 1000 = PROBE IMPEDANCE / VERIFY 1001 = SPARE 1010 = SPARE 1011 = SPARE 1100 = START 1101 = SOAK 1110 = TIMER 1111 = FAULT All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 70 0111 = Millivolt INPUT A 1000 = GC Carbon BIT 4 = NORMAL (0) FREEZE CONTROL OUTPUT (1) BITS 5 – 7 = MODE 000 = TIME PROPORTIONING All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 71 0000 = LINEAR (DEFAULT) All other bit combinations are spare BITS 12 – 15 are spare CTRLOUT Control Output, unsigned integer READ ONLY Actual control output where: All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 72 0110 = Redox value 0111 = Output Power 1000 = Control Output 1 1001 = Control Output 2 1010 = Linear Input B 1011 = Programmable* All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 73 Analog Output of 4 mA. The source value is based on the selection in ASRC upper byte AOUTRN2 ANALOG OUTPUT 2 RANGE READ ONLY Maximum source value that correlates to maximum All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 74 00 = Even Parity, 7 bits, 1 Stop bit 01 = No Parity, 8 bits, 1 Stop bit 10 = Odd Parity, 7 bits, 1 Stop bit All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 75 2109 = 2.109 ohms. PRTM LAST PROBE RECOVERY TIME FROM READ ONLY IMPEDANCE TEST (SECONDS) RANGE = 0 to 255 Available for Redox, Carbon, and Dewpoint. Not All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 76 RANGE = 0 to 999 DEFAULT = 30 Burnoff function available for Redox, Carbon, and Dewpoint. BOREC BURN OFF RECOVERY TIME SETTING READ ONLY (SECONDS) All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 77 TC SPAN CALIBRATION NUMBER READ/WRITE MV_ZERO MV ZERO CALIBRATION NUMBER READ/WRITE MV_SPAN MV SPAN CALIBRATION NUMBER READ/WRITE DAC_OFFSET_1 DAC 1 OFFSET CALIBRATION READ ONLY All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 78 DEFAULT = 20 (% CO FOR CARBON) DEFAULT = 40 (% H2 FOR DEWPOINT) For TruCarb this value is the shim stock offset in % carbon, i.e. 0145 = 1.45% All rights to copy, reproduce and transmit are reserved Copyright © 2013, United Process Controls Inc.
  • Page 79 VersaPro Temperature Controller Page 79 Reach us at www.group-upc.com United Process Controls brings together leading brands to the heat treating industry including Waukee Engineering, Furnace Control, Marathon Monitors and Process-Electronic. We provide prime control solutions through our worldwide sales and services network with easy-to- access local support.

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