West Control Solutions

Temperature Controller

Page 2

West Control Solutions Pro-EC44 - Page 2

West Control Solutions Pro-EC44

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Table of Contents

Warranty and Returns Statement4
Table of Contents5
Introduction7
Installation8
Unpacking8
Panel-Mounting8
Cleaning9
Panel-Mounting the Instrument9
Field Upgrade Options10
Plug-Modules and Upgradeable Functions10
Board Positions10
Preparing to Install or Remove Plug-In Modules11
Rear View (Uncased) & Board Positions11
Main Board Connectors12
Removing/Replacing Option Modules13
Replacing the Instrument in Its Housing13
Auto Detection of Plug-In Modules13
Data Recorder Board14
Profiler Enabling14
Entering the Profiler Enable Code14
Electrical Installation15
Avoiding EMC Problems15
Cable Isolation & Protection15
Noise Suppression at Source16
Transient Suppression with Inductive Coils16
Contact Noise Suppression16
Sensor Placement (Thermocouple or RTD)17
Thermocouple Wire Identification17
Thermocouple Wire Colour Chart17
Pre-Wiring – Cautions, Warnings & Information18
Connections and Wiring19
Central Terminal Connections19
Outer Terminal Connections20
Power Connections21
Power Connections - Mains Powered Instruments21
Power Connections - 24/48V AC/DC Powered Instruments21
Mains Power Connections21
Universal Input 1 Connections22
Universal Input 1 Connections - Thermocouple (T/C)22
Universal Input 1 Connections – PT100 / NI120 (RTD) Input22
Input 1 - RTD Connections22
Universal Input 1 Connections - Linear Volt, MV or Ma Input23
Universal / Auxiliary Input 2 Connections23
Universal Input 2 Connections - Thermocouple (T/C)23
Universal Input 2 Connections – PT100 / NI120 (RTD) Input24
Universal / Auxiliary Input 2 Connections – Potentiometer24
Base Option 125
Base Option 1 Relay Output 425
Base Option 1 Linear Output 625
Base Option 2 Relay Output 525
Plug-In Module Slot 1 – Single Relay Output Module26
Plug-In Module Slot 1 – Single SSR Driver Output Module26
Plug-In Module Slot 1 - Triac Output Module27
Plug-In Module Slot 1 - Linear Voltage or Madc Output Module27
Plug-In Module Slot 2 Connections27
Plug-In Module Slot 2 – Single Relay Output Module27
Plug-In Module Slot 2 - Dual Relay Output Module28
Plug-In Module Slot 2 – Single SSR Driver Output Module28
Plug-In Module Slot 2 – Dual SSR Driver Output Module28
Plug-In Module Slot 2 - Triac Output Module29
Plug-In Module Slot 2 - Transmitter Power Supply Module29
Plug-In Slot 3 Connections29
Plug-In Module Slot 3 – Single Relay Output Module29
Plug-In Module Slot 3 - Dual Relay Output Module30
Plug-In Module Slot 3 – Single SSR Driver Output Module30
Plug-In Module Slot 3 – Dual SSR Driver Output Module30
Plug-In Module Slot 3 - Triac Output Module31
Plug-In Module Slot 3 - Transmitter Power Supply Module31
Plug-In Slot a Connections31
Plug-In Module Slot a – Basic Auxiliary Input Module31
Plug-In Module Slot a - Ethernet Communications Module32
Plug-In Module Slot a - RS485 Serial Communications Module32
Plug-In Module Slot a – Single Digital Input Module32
Option C Connections33
Option C Connections – Multiple Digital Input Module33
Special Wiring Considerations for Valve Motor Control34
Interlocking of Valve Motor Drive Relays34
Powering up Procedure35
Front Panel Overview35
Display35
LED Functions36
Keypad Functions & Navigation36
Keypad Button Functions36
Messages & Error Indications37
Plug-In Module Problems37
Sensor Break Detection37
Un-Calibrated Input Detection37
PV Over-Range or Under-Range Indication37
Auxiliary Input Over-Range or Under-Range Indication38
Cascade-Open38
Profile Not Valid38
USB Data Transfer Failure Message38
Getting Help38
Application Setup39
Pre-Commissioning Considerations39
How will the Instrument Physically Control the Process?39
What Are the Sources for the Setpoints?41
Is Input Re-Configuration Required?41
Which Other Features Are to be Used?41
Operation and Configuration Menus42
Operation Mode42
Navigating and Adjusting Values in Operator Mode42
Operation Mode Screen Sequence43
Calibration Check Due Warning43
Single Control Loop: Normal Operation43
Two Control Loops: Normal Operation43
Cascade Control: Normal Operation44
Ratio Control: Normal Operation44
Single Control Loop: Profiler Status44
Two Control Loops: Profiler Status45
Entry into the Main Menu48
Navigating the Main Menu48
Unlock Codes48
Main Menu Options48
Manual Entry to the Setup Wizard49
Navigating in the Setup Wizard49
Setup Wizard Screens49
Entry into Supervisor Mode50
Navigating in Supervisor Mode50
Supervisor Mode Screens50
Configuration Menu51
Entry into the Configuration Menu51
Navigating the Configuration Menu51
Input Configuration Sub-Menu Screens52
Control Configuration Sub-Menu Screens56
Outputs Configuration Sub-Menu Screens62
Alarm Configuration Sub-Menu Screens62
Communications Configuration Sub-Menu Screens63
Data Recorder Configuration Sub-Menu Screens:64
Clock Configuration Sub-Menu Screens65
Display Configuration Sub-Menu Screens65
The USB Menu66
The USB Menu Is Entered from the Main Menu66
Navigating in the USB Menu66
Lock Code Configuration Sub-Menu Screen66
Reset to Defaults Sub-Menu Screen66
Entry into the USB Menu66
Usb Menu Screens67
Entry into the Recorder Control Menu68
Recorder Menu Screens68
Entry into the Profiler Setup Menu69
Profiler Setup Menu Screens69
Profiler Control Menu Screens72
Entry into Service & Product Information Mode73
Entry into the Automatic Tuning Menu74
Automatic Tuning Menu Screens74
Lost Lock Codes75
Forcing Lock Code Configuration75
Input Calibration & Multi-Point Scaling76
User Calibration76
Single Point Calibration76
Calibration Reminder76
Two Point Calibration77
Multi-Point Scaling78
Base Calibration Adjustment78
Required Equipment78
Performing a Calibration Check79
Recalibration Procedure79
Input Calibration Phases79
Digital Inputs81
Digital Signal Type81
Inverting Digital Inputs81
Soft Digital Inputs82
Digital Input Functions82
Single Functions82
Profile Selection Via Digital Inputs83
Using Binary to Select Profile Numbers83
Using BCD to Select Profile Numbers83
Cascade Control84
Example Cascade Application84
Cascade Example84
Normal Cascade Operation85
Manual Mode85
Cascade Tuning85
Cascade-Open85
To Manually Tune a Cascade86
Ratio Control87
Stoichiometric Combustion87
Ratio Control Example87
Redundant Input89
Valve Motor Drive / 3-Point Stepping Control90
Position Feedback91
Valve Limiting91
Setpoint Sources92
Loop 1 Setpoint Sources92
Loop 2 Setpoint Sources92
Loop 2 Profile Setpoint92
Profilerprofile Components93
Profile Header & Segment Information93
Profile Starting & Standard Segments94
Profile Starting and Standard Segment Types94
Two Loop Profiles95
Both Loops on same Time-Base95
Loop-Back Segments96
Profile Running / Holding Vs. Hold Segments96
Run/Hold & Hold Segments96
The Auto-Hold Feature97
Auto Hold Examples97
Auto-Hold on a Dwell Segment97
Auto Hold on Ramps98
Auto-Hold on a Ramp Segment98
Profile Cycles & Repeat Sequences98
Profile Cycles & Repeats98
Power/Signal Lost Recovery Actions99
Possible Recovery Methods99
Profile End Actions100
Possible Profile End Actions100
Profile Abort Actions101
Possible Profile Abort Actions101
USB Interface102
Using the USB Port102
USB Memory Stick Folders & Files102
Data Recorder103
Recordable Values103
Recorder Control and Status103
Uploading Data104
Additional Features & Benefits from the Recorder104
Controller Tuning105
PID Sets & Gain Scheduling105
Automatic Tuning106
Pre-Tune106
Pre-Tune Operation106
Auto Pre-Tune107
Self-Tune107
Self-Tune Operation107
Manually Tuning108
Tuning Control Loops - PID with Primary Output Only108
Manually Tuning - PID with Primary Output108
Tuning Control Loops - PID with Primary & Secondary Outputs109
Method 1 – for Simple Processes109
Method 2 – for Asymmetrical Processes109
Valve, Damper & Speed Controller Tuning110
Manually Tuning – PI Control111
Fine Tuning112
Cycle Times112
Proportional Cycle Times112
Proportional Bands112
Integral Time Constant113
Derivative Time Constant113
Derivative Time113
Integral Time113
Anti Wind-Up114
Manual Reset114
Serial Communications115
Supported Protocols115
RS485 Configuration115
RS485 Device Addressing115
Link Layer116
Modbus Link Layer116
Supported Modbus Functions117
Function Descriptions117
Function 03 / 04 - Read Holding/Input Registers117
Function 06 - Write Single Register117
Function 08 - Loopback Diagnostic Test118
Function 16 - Write Multiple Registers (0X10 Hex)118
Function 23 Hex - Read / Write Multiple Registers (0X17 Hex)118
Exception Responses118
Modbus Parameters119
Data Formats119
Parameter Register Address Listings119
Calibration Reminder Parameters120
Universal Process Input 1 Parameters120
Plug-In Module Slot 1 Parameters143
Linear Output 6 Parameters153
Linear Output 7 Parameters154
Loop 1 Setpoint Parameters155
Loop 2 Setpoint Parameters156
Aux a Input Parameters157
Loop 1 Control Parameters157
Alarm Parameters169
Profile Setup Via Modbus193
Instruction Sequence to Edit an Existing Profile Header194
Instruction Sequence to Read a Profile195
Creating or Editing a Profile Header195
Creating, Editing or Inserting Segments197
Segment Data198
Deleting All or Single Profiles199
Delete a Segment200
Get Segments Remaining201
Edit Response Message from Instrument201
Command Response Data201
Read a Profile Header Request & Response Sequence202
Glossary210
Active Setpoint210
Actual Setpoint210
Alarm Activation Inhibit210
Alarm Operation212
Alarm Types213
Alternate Setpoint213
Auxiliary Input213
Auxiliary Input Lower Limit213
Auxiliary Input Offset214
Auxiliary Input Type214
Auxiliary Input Upper Limit214
Bar Graphs214
Calibration215
Communications Write Enable215
Control Configuration216
Control Deviation216
Control Action216
Control Power Alarm216
Controller217
Controller Mode217
Correcting Variable217
Cycle Time217
Derivative Action218
Deviation Alarm218
Direct Acting Control218
Display Configuration219
Display Languages219
Display Resolution219
Engineering Units219
Indicator220
Input Configuration220
Input Filter Time Constant220
Input Range220
Invert Digital Input221
Latching Output221
Linear Input221
Linear Output221
Local Setpoints222
Lock Codes222
Logical Output Combinations222
Examples of Logical Outputs222
Loop Alarm223
Lsd223
Madc223
Main Menu223
Manual Loop Alarm Time224
Master & Slave Controllers224
Modbus RTU225
Minimum Motor on Time225
Modulating Valve226
Motor Travel Time226
MVDC226
On-Off Control226
On-Off Differential227
On-Off Hysteresis227
Output Configuration227
PC Software228
PD Control229
PI Control229
PID Control229
PID Gain Sets229
Power Output Limits230
Primary Proportional Band230
Process High Alarm230
Process Inputs230
Process Variable (PV)231
Profile Control Menu231
Profile Events231
Profile Header231
Profiler232
Profiler Mode232
Rate of Change Alarm232
Recorder Configuration233
Recorder Menu233
Remote Setpoint (RSP)233
Retransmit Output233
Retransmit Output Scale Minimum234
Reset to Defaults234
Reverse Acting Control234
Rs485234
Scaled Input Upper Limit235
Scaled Input Lower Limit235
Secondary Proportional Band235
Sensor Break Pre-Set Power236
Serial Communications Configuration236
Serial Communications Option236
Set Valve Opened Position236
Setpoint Upper Limit237
Setpoint Lower Limit237
Setpoint Ramp Rate237
Solid State Relay (SSR)238
Solenoid Valve238
Thermocouple238
Time Proportioning Control239
Trend Displays239
Tuning239
Tuning Menu239
Triac240
USB Menu240
Valve Motor Drive Control (VMD)240
Valve Position or Flow Indication240
Using the PC Software241
Main Parameter Screen241
Instrument Simulation242
Button Bar & View Menu242
Configuring the Connection242
West Pro-EC44 Instrument Simulation242
Connection from PC to Bottom Configuration Socket243
Connection from PC to Rear RS485 Communications Option243
Connection from Pc/Network to Ethernet Port244
Changing the IP Address244
Instrument Configuration245
Main Parameter Adjustment245
Extending Functionality Via Software246
LED Functions & Labels246
Alarm Status Screen Labels246
Configuring the Supervisor Mode246
Changing the Start-Up Splash Screen247
Changing the Alternate Display Language247
Supervisor/Enhanced Operation Mode Configuration247
Profile Creation and Editing248
Profile Editor – Header248
Data Recorder Trend Upload & Analysis249
Analysing Data249
Project Documentation250
Specifications251
Reference Test Conditions251
Universal Process Inputs251
Thermocouple Input251
Thermocouple Performance252
Resistance Temperature Detector (RTD) Input252
RTD Types & Ranges252
DC Linear Input252
DC Linear Performance253
Input Functions253
Auxiliary Input a Types & Ranges253
Auxiliary Input Performance253
Digital Input Performance254
Output Specifications255
Output Module Types255
Single Relay Output 1-3 Performance255
Dual Relay Output 2-3 Performance255
Dual SSR Driver Output 2-3 Performance256
Triac Output 1-3 Performance256
Single DC Linear Output Types & Ranges256
DC Linear Output 1, 6-7 Performance256
24V Transmitter Power Supply 2-3 Performance257
Communications257
Supported Communication Methods257
Operating Conditions260
24 Pro-EC44 Product Coding261
Table of Contents263
Pro-EC44 Product Manual - 59540-2 September 2014265

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