NOVUS N2000s Controller Universal Process Controller User Guide

N2000s Controller Universal Process Controller

N2000S Controller
UNIVERSAL PROCESS CONTROLLER USER GUIDE ­ V3.0x A

SAFETY SUMMARY
The symbols below are used on the equipment and throughout this document to draw the user’s attention to important operational and safety information.

PRESENTATION / OPERATION
The controller frontal panel is shown in Figure 1:

CAUTION OR WARNING:
Read complete instructions prior to installation and operation of the unit.

CAUTION OR WARNING: Electrical Shock Hazard

All safety related instructions that appear in the manual must be observed to ensure personal safety and to prevent damage to either the instrument or the system. If the instrument is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

INTRODUCTION
N2000S is a controller for servo positioners with two control relays: one to open and other to close the valve (or damper). Moreover, it has an analog output that can be programmed to control or retransmit input or setpoint signals. Its universal input accepts most industry manufactured sensors and signals. Configuration can be entirely achieved through the keyboard. No circuit changes are required. Selection of input and output type, alarms configuration, and other especial functions are accessed and programmed through the frontal panel. It is important that you read the manual thoroughly before using the controller. Be sure the manual corresponds to your instrument (the number of the software version can be seen when the controller is turned on).
· Sensors break protection in any condition.
· Universal input for multiple sensors without changing hardware.
· Potentiometer input for current position reading.
· Auto-tuning of PID parameters.
· Relay control outputs.
· Automatic/Manual “bumpless” transfer.
· 2 alarm outputs with the following functions: minimum, maximum, differential (deviation), open sensor and event.
· 2 alarm timers.
· 4-20 mA or 0-20 mA analog output for Process Variable (PV) or Setpoint (SP) retransmission.
· 4 function digital input.
· Ramp and soak with 7 concatenable 7-segment programs.
· RS-485 serial communication; RTU MODBUS protocol.
· Configuration protection.
· Dual voltage.

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Figure 1 ­ Identification of the frontal panel parts

PV / Programming Display: Shows the PV (Process Variable) value. When in operating or programming mode, shows the parameter mnemonic.

SP / Parameters Display: Shows the SP (Setpoint) and other programmable parameter values of the controller.

COM Indicator: Flashes when data is exchanged with the external environment.

TUNE Indicator: Lights when the controller runs the automatic tuning operation.

MAN Indicator: Indicates that the controller is in the manual control mode.

RUN Indicator: Indicates that the controller is active and with control and alarm outputs enabled.

OUT Indicator: When the analog output (0-20 mA or 4-20 mA) is configured for control mode, it remains constantly on.

A1, A2 Indicators: Indicates the respective alarm status.

A3 Indicators: Indicates the valve (I/O3) opening output status.

A4 Indicators: Indicates the valve/dumper (I/O4) closing output status.

PROG key: Key used to show the controller programmable parameters.

BACK Key: Keu used to return to the previous parameter shown in the parameter display.

Increase and parameter values.

Decrease keys: Key used to change the

Auto/Man key: Special function key used to switch the control mode between Automatic and Manual.

Programmable Function Key: Key used to perform the special functions described in the Key Functions.

When the controller is turned on, its firmware version is displayed for 3 seconds. After that, the controller starts operating normally. The PV and SV values are displayed in the upper and lower displays, respectively. Outputs are enabled at this moment as well.
The relay associated to the valve closing is activated during the time required for the complete valve to close (see parameter Ser.t) so that the controller starts operating with a known reference.

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To run smoothly, the controller requires some basic configuration: · Input type (Thermocouples, Pt100, 4-20 mA, etc.).
· Control setpoint value (SP). · Control output type (relays, 0-20 mA, pulse).
· PID parameters (or hysteretic for ON / OFF control). Other special functions, including ramp and soak, alarm timer, digital input, etc., can be used to achieve better performance. The setup parameters are grouped in cycles, in which each message is a parameter to be defined. The 7 parameter cycles are:

CYCLE 1 – Operation 2 – Tuning 3 – Programs 4 – Alarms 5 – Input configuration 6 – I/O 7 – Calibration

ACCESS Free
Reserved access

The operation cycle (1st cycle) is freely accessed. The other cycles require a keystroke combination to enable access, as shown below:

Press (BACK) and (PROG) simultaneously
When the required cycle is found, all the parameters within this cycle can be accessed by pressing the key (or pressing the key to go backwards). To return to the operation cycle, press many times up to all parameters of the current cycle have been shown.
All parameters set up are stored in a protected memory. Changed values are automatically saved when the user goes to the next parameter. The SP value is saved when parameters are changed or at every 25 seconds.

CONFIGURATION PROTECTION

It is possible to prevent undue changes, so that the parameter values cannot be changed after the final configuration. The parameters are still displayed but can no longer be changed. The protection happens with the combination of a key sequence and an internal key.

The sequence of keys to protect is

and , pressed

simultaneously for 3 seconds in the parameter cycle to protect. To

unprotect a cycle, just press and simultaneously for 3

seconds.

Displays will flash briefly to confirm locking or unlocking operation.

Within the controller, the PROT key completes the locking function. When PROT is OFF, the user can lock and unlock the cycles. When PROT is ON, changes are not allowed. If there are protections for the cycles, they cannot be removed; if they do not exist, they cannot be promoted.

CONTROL OPERATION
The controller is based on the SErt parameter (Servo excursion time). This is the time the serve requires to open completely when it is in the closed position. The output percentage calculated by the PID (0 to 100 %) is transformed into the serve activation time to reach a relative position.
A new output value of the PID is calculated at every 250 ms. The SErF parameter defines the time in seconds for the calculation and activation of a new output value. This parameter works as a filter. It makes the output slower and increases the time intervals.
The minimum resolution for a new position change is given by the parameter SErr. If the difference between the current output value and the new value calculated by the PID is lower than the programmed percentage of this parameter, no activation is performed.
If the calculated output is between 0 % or 100 % and it is maintained for some time, the opening relay (when in 0 %) or the closing relay (when in 100 %) will be periodically activated for a time fraction to assure that the real position is close to the estimated position, for mechanical problems or non- linearity of the process.

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Controller N2000S

CONFIGURATION / RESOURCES

INPUT TYPE SELECTION
The input type must be selected by the user in the Type parameter and using the keyboard (see input types in Table 1).

TYPE CODE

FEATURES

J

0 Range: -50 to 760 °C (-58 to 1400 °F)

K

1 Range: -90 to 1370 °C (-130 to 2498 °F)

T

2 Range: -100 to 400 °C (-148 to 752 °F)

N

3 Range: -90 to 1300 °C (-130 to 2372 °F)

R

4 Range: 0 to 1760 °C (32 to 3200 °F)

S

5 Range: 0 to 1760 °C (32 to 3200 °F)

Pt100

6 Range: -199.9 to 530.0 °C (-199.9 to 986.0 °F)

Pt100

7 Range: -200 to 530 °C (-328 to 986 °F)

4-20 mA 8 J Linearization. Programmable range: -110 to 760 °C

4-20 mA 9 K Linearization Programmable range: -150 to 1370 °C

4-20 mA 10 T Linearization. Programmable range: -160 to 400 °C

4-20 mA 11 N Linearization Programmable range: -90 to 1370 °C

4-20 mA 12 R Linearization Programmable range: 0 to 1760 °C

4-20 mA 13 S Linearization Programmable range: 0 to 1760 °C

4-20 mA 14 Pt100 Linearization. Prog. range: -200.0 to 530.0 °C

4-20 mA 15 Pt100 Linearization. Prog. range: -200 to 530 °C

0 ­ 5 0 mV 16 Linear. Programmable indication from ­1999 to 9999.

4-20 mA 17 Linear. Programmable indication from ­1999 to 9999.

0 ­ 5 Vdc 18 Linear. Programmable indication from ­1999 to 9999.

4-20 mA 19 Input square root extraction.

Table 1 ­ Input types
Note: All available input types are factory calibrated.

I/O CHANNELS CONFIGURATION
The controller input/output channels can undertake multiple functions: Control output, digital input, digital output, alarm output, PV, and SP retransmission. These channels are identified as I/O 1, I/O2, I/O 3, I/O 4, I/O 5, and I/O 6.
The function code of each I/O can be selected among the following options. Only valid function codes are displayed for each I/O.
I/O 1 and I/O2 ­ Used as ALARM outputs
2 SPDT relays are available in terminals 7 to 12. They can be assigned codes 0, 1 or 2. Where:
0 ­ Disables the alarm. 1 ­ Defines channel as alarm 1. 2 ­ Defines channel as alarm 2.

I/O 3 and I/O4 ­ Used as CONTROL outputs
2 SPST relays, available in terminals 3 to 6. They are assigned code 5. Where:
5 ­ Defines channel as control output.

I/O 5 ­ Analog output 0-20 mA or 4-20 mA analog channel output used to retransmit PV and SP values or perform functions of digital input and output. They can be assigned codes 0 to 16. Where:
0 ­ No function (disabled). 1 ­ Defines the channel as alarm 1. 2 ­ Defines the channel as alarm 2. 3 ­ Invalid selection. 4 ­ Invalid selection. 5 ­ Invalid selection. 6 ­ Defines the channel to behave as Digital Input and switch
between Automatic and Manual control mode: Closed = Manual control.

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Open = Automatic control. 7 ­ Defines the channel to act as Digital Input that turns the
control on and off (RvN: YES / no). Closed = Outputs enabled. Open = Outputs disabled. 8 ­ Invalid selection. 9 ­ Defines the channel to control the programs operation. Closed = Enables the program execution. Open = Interrupts the program. Note: When the program is interrupted, the execution is suspended at the point where it is (the control is still active). The program resumes normal execution when the signal applied to the digital input allows (contact closed). 10 ­ Defines the channel to select the program 1 execution. This option is useful when you want to switch between the main Setpoint and a second Setpoint defined in the program of ramps and soaks. Closed = Selects program 1. Open = Assumes the main Setpoint. 11 ­ Configures the analog output to operate as an analog 0-20 mA control output. 12 ­ Configures the analog output to operate as an analog 4-20 mA control output. 13 ­ Analog 0-20 mA retransmission of PV. 14 ­ Analog 4-20 mA retransmission of PV. 15 ­ Analog 0-20 mA retransmission of SP. 16 ­ Analog 4-20 mA retransmission of SP.
I/O 6 ­ Digital Input 0 ­ Disables the alarm. 6 ­ Defines the channel to behave as Digital Input and switch between Automatic and Manual control mode: Closed = Manual control. Open = Automatic control. 7 ­ Defines the channel to act as Digital Input that turns the control on and off (RvN: YES / no). Closed = Outputs enabled. Open = Control outputs and alarms disabled. 8 ­ Invalid selection. 9 ­ Defines the channel to control the programs operation. Closed = Enables the program execution. Open = Interrupts the program. Note: When the program is interrupted, the execution is suspended at the point where it is (the control is still active). The program resumes normal execution when the signal applied to the digital input allows (contact closed). 10 ­ Defines the channel to select the program 1 execution. This option is useful when you want to switch between the main Setpoint and a second Setpoint defined in the program of ramps and soaks. Closed = Selects program 1. Open = Assumes the main Setpoint. Note: When a function is selected to operate through digital input, the controller does not respond to the equivalent function command given in the frontal keypad.
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Controller N2000S

POTENTIOMETER INPUT
The potentiometer of valve position can be seen in the controller. It must be 10 k and connections must be as Fig. 07 shows. The potentiometer reading does not power the valve position for control effects, it only informs the operator the valve current position. The control action happens regardless of the potentiometer.
To visualize the potentiometer reading, the Pot parameter must be enabled. When enabled (YES), the potentiometer position is displayed on the prompt screen that shows the Manipulated Variable (MV). When the potentiometer visualization is selected, the MV is not shown anymore, and the percentage value of valve opening is shown instead. The MV screen is the second prompt of the main cycle.

ALARM CONFIGURATION The controller has 2 independent alarms. They can be programmed to operate with nine different functions, represented in Table 3.
· Open Sensor It is activated whenever the input sensor is broken or disconnected.
· Event Alarm It activates alarm(s) in specific segments of the program. See item Alarm Cycle in this manual.
· Resistance Fail It detects a heater broken condition by monitoring the load current when the control output is activated. This alarm function requires an optional device (option 3).
· Minimum Value It triggers when the measured value is below the value set by the alarm Setpoint.

TYPE SCREEN Disabled off

Sensor Break
(input Error)
Event Alarm (ramp and
Soak)
Detection resistance
failure
Low Alarm

ierr rs
rfail lo

ACTION No active alarm. This output can be used as a digital output to be set by the serial communication. Alarm will be ON if PV sensor breaks, input signal is out of range or Pt100 is shorted.
Can be activated at a specific segment of ramp and soak program.
Detects a heater broken condition.
PV

High Alarm ki

SPAn PV

Differential difl Low

SPAn PV

SV – SPAn

SV

positive SPAn

PV

SV

SV – SPAn

negative SPAn

Differential difk High

PV

SV

SV + SPAn

positive SPAn

PV

SV + SPAn

SV

negative SPAn

Differential dif

PV

SV – SPAn

SV

SV + SPAn

positive SPAn

PV

SV + SPAn

SV

SV – SPAn

negative SPAn

Table 3 ­ Alarm functions

SPAn refers to SPA and SPA2 alarm Setpoints.
· Maximum Value
It triggers when the measured value is above the value set by the alarm Setpoint.
· Differential (or Band) In this function, the parameters SPA1 and SPA2 represent the PV deviation as compared to the main SP.
In a positive deviation, the differential alarm will be triggered when the measured value is out of the range defined in:
(SP ­ Deviation) and (SP + Deviation)
In a negative deviation, the differential alarm will be triggered when the measured value is within the range defined above.

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· Minimum Differential It is activated when the measured value is below the value defined in.
(SP ­ Deviation) · Maximum Differential It is activated when the measured value is above the value defined in:
(SP + Deviation)

ALARM TIMER
Alarms can be programmed to have timer functions. The user can delay alarm activation, set one pulse per activation, or make the alarm signals operate in sequential pulses. Alarm timer is available only for alarms 1 and 2 when A1t1, A1t2, A2t1 and A2t2 parameters are programmed.
Figures shown in Table 4 represent these functions, t 1 and t 2 may vary from 0 to 6500 seconds and their combinations define the timer mode. For normal operation, with no alarm timer activation, t 1 and t 2 must be assigned 0 (zero).
The LEDs associated to the alarms will flash whenever an alarm condition is acknowledged, regardless the actual state of the output relay, which may be temporarily off because of temporization.

ALARM FUNCTION

t1

Normal

0

t2

ACTION

0

Alarm Output

Delayed

Alarm Event

0

1 to 6500 s

Alarm Output

T2

Pulse

1 to 6500 s

0

Alarm Event

Alarm

Output

T1

Alarm Event

Oscillator

1 to 6500 s

1 to 6500 s

Alarm Output

T1

T2

T1

Alarm Event

Table 4 ­ Temporization functions for Alarms 1 and 2

ALARM INITIAL BLOCKING
The Initial Blocking option prevents the alarm from being recognized if an alarm condition is present when the controller is turned on for the first time. The alarm could be activated only after the occurrence of a non-alarm condition followed by a new occurrence of an alarm condition.
The initial blocking is useful, for example, when one of the alarms is programmed as minimum value alarm, which can trigger the alarm at the system startup. This is not always required.
The initial blocking is disabled for the Open Sensor function.

PV AND SP ANALOG RETRANSMISSION
The controller has an analog output (I/O 5) that can make a 0-20 mA or 4-20 mA retransmission proportional to the PV or SP values assigned. The analog retransmission is scalable, this means it has maximum and minimum limits that define the output range, which can be defined in parameters SPLL and SPkL.
To obtain voltage retransmission the user must install a shunt resistor (550 max.) in the analog output terminal. The resistor value depends on the voltage range required.

KEY FUNCTIONS key (special function key) in the frontal panel of the controller can perform the same function as the Digital Input I/O 6 (except function 6). The key function is defined by the user in the fFvn parameter: 0 ­ Disables the alarm. 7 ­ Defines the channel to act as Digital Input that turns the control on and off (RvN: YES / no).
Closed = Outputs enabled. Open = Control output and alarms disabled. 8 ­ Invalid selection.
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Controller N2000S
9 ­ Defines the channel to control the programs operation. Closed = Enables the program execution. Open = Interrupts the program. Note: When the program is interrupted, the execution is suspended at the point where it is (the control is still active). The program resumes normal execution when the signal applied to the digital input allows (contact closed).
10 ­ Defines the channel to select the program 1 execution. This option is useful when you want to switch between the main Setpoint and a second Setpoint defined in the program of ramps and soaks. Closed = Selects program 1. Open = Assumes the main Setpoint. Note: When a function is selected to operate through digital input, the controller does not respond to the equivalent function command given in the frontal keypad.
KEY No function.
INSTALLATION / CONNECTIONS
The controller must be panel-mounted following the steps presented below: · Make the panel slot. · Remove fixing brackets. · Insert the controller into the panel slot. · Replace the clamps in the controller pressing it to reach a firm
grip at the panel. It is not necessary to disconnect the rear panel terminals to remove the internal circuit. Figure 2 shows how signals are distributed in the controller rear panel:
Figure 2 ­ Back panel terminals
INSTALLATION RECOMMENDATIONS · Conductors of input signals must be distant from activation or
high-tension/current conductors, preferably passing through grounded conduits. · A specific electrical power supply network should be provided for instruments use only. · In controlling and monitoring applications, possible consequences of any system failure must be considered in advance. The internal relay alarm does not provide total protection. · RC filters (for noise reduction) in inductor charges (contactors, solenoids, etc.) are recommended.
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POWER SUPPLY CONNECTIONS

Observe the requested supply
voltage

Figure 3 ­ Power supply connections

INPUT CONNECTIONS
It is important that they are very well connected; the sensor wires must be well fixed in the terminals of the rear panel.
· Thermocouple (T/C) and 50 mV:
Figure 3 shows how connections are made. If extension of the thermocouple is required, proper compensation cables should be provided.

Figure 3 ­ Thermocouple and Figure 4 – Pt100 wiring with

0-50 mV

three conductors

· RTD (Pt100):
Figure 4 shows the Pt100 wiring for 3 conductors. Terminals 22, 23, and 24 must have the same wire resistance for proper cable length compensation (use conductors with the same gauge and length). In case the sensor has 4 wires, one should be left loose near the controller. For 2-wire Pt100, short circuit terminals 22 and 23.

Figure 5 ­ Connection of 4-20 Figure 6 ­ Connection of 5

mA

Vdc

· 4-20 mA Figure 5 shows the 4-20 mA current signals wiring. · 0-5 Vdc Figure 6 shows the 0-5 Vdc voltage signals wiring. · Alarm and output connection When I/O channels are set up as output channels, they must have their capacity respected, according do specifications.

Figure 7 – Potentiometer connection

Note: It is recommended to disable/suspend the control (rvn = NO)
whenever it is necessary to change the device settings.

CONFIGURATION PARAMETERS

OPERATION CYCLE

PV Indication
(Red)
SV Indication
(Green)

PV AND SP INDICATION: The upper status display shows the current value of PV. The lower parameter display shows SP value of automatic control mode.
The upper display shows – – – – whenever PV exceeds the maximum range or there is no signal at the input.

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Controller N2000S

PV Indication
(Red)
MV Indication
(Green)

MANIPULATED VARIABLE VALUE (MV) (control output):
The upper display shows PV value, and the lower display shows the percentage of MV applied to the control output. When in manual control, the MV value can be changed. When in auto mode, the MV value is only for visualization.

To distinguish the MV display from the SP display, the MV flashes intermittently.

Pr n
Program number

PROGRAM EXECUTION: Selects the ramp and soak program to be executed.
0 ­ Does not run any program.
1, 2, 3, 4, 5, 6 ­ Respective program.
When the control is enabled, the program selected runs immediately.
In the program cycle of ramp and soak there is a parameter with the same name. In that context, the parameter is associated with the number of the program that will run.

rvn

ENABLES CONTROL AND ALARMS OUTPUT: YES ­ Control and alarm enabled. NO ­ Control and alarms disabled.

TUNING CYCLE

atvn
Auto-tune

Auto-tune of PID parameters. See item PID Parameters Auto-Tuning.
YES ­ Run auto-tune.
NO ­ Does not run auto-tune.

Pb
Proportional band

PROPORTIONAL BAND: P term value of the PID control, percentage of maximum input type span. Adjustable between 0 and 500 %.
If adjusted to zero, control is ON/OFF.

xyst

CONTROL HYSTERESIS: Hysteresis value for ON/OFF control. This parameter is shown only for ON/OFF control

HYSteresis (Pb=0).

Ir`

INTEGRAL RATE: Value of I term of PID control in repetitions per minute (Reset). Adjustable between 0 and

integral rate 24.00. Presented if proportional band 0.

dt

DERIVATIVE TIME: Value of D term of the PID control in seconds. Adjustable between 0 and 250 s. Presented if

derivative time proportional band 0.

sert Time of servo excursion, from totally open to totally closed.
Servo time Programmable from 15 to 600 s.

serr Control resolution. Determines the dead band of servo
Servo activation. Very low values (<1 %) make the servo resolution “nervous”

serF
Servo filter

PID output filter, before use by the servo control. It is the time the PID mean is made, in seconds. The output is only activated after this time.
Recommended value: > 2 s.

act
Action

CONTROL ACTION: Only in the automatic control mode Reverse action (rE) ­ Usually used for heating. Direct action (rE) ­ Usually used for cooling.

Sp.a1 Sp.a2
SetPoint of Alarm

ALARM SP: Value that defines the trigger point of alarms programmed with the Lo or Hi functions. In alarms programmed with the function Differential this parameter defines the deviation.
It is not used in other alarm functions.

PROGRAM CYCLE

tbas
time base

TIME BASE: Selects the time base for the ramp and soak. Valid for all profile programs.
0 ­ Time base in seconds.
1 ­ Time base in minutes.

Pr n PROGRAM EDITING: Selects the ramp and soak program to
Program be edited in the next screens of this cycle. number

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Ptol
Program tolerance

PROGRAM TOLERANCE: Maximum deviation between PV and SP. Whenever this deviation is exceeded the time counter is halted until deviation lowers to acceptable values. Set zero to disable this function.

Psp0
Psp7
Program SetPoint

PROGRAM SPs, 0 TO 7: Set of 8 SP values that define the ramp and soak program profile.

Pt1 PROGRAM SEGMENTS TIME, 1 to 7: It defines the duration Pt7 time (in seconds or minutes) of each segment of the
program. Program time

Pe1 Pe7
Program event
Lp
Link to Program

EVENT ALARMS, 1 to 7: Parameters that define which alarms must be triggered while a program segment is running, according to codes from 0 to 3 presented in Table 6. Alarm function depends on rS setting.
LINK TO PROGRAM: Number of the next program to be connected. Programs can be linked to generate profiles of up to 49 segments.
0 ­ Do not connect to any other program. 1 ­ Connect to program 1. 2 ­ Connect to program 2. 3 ­ Connect to program 3. 4 ­ Connect to program 4. 5 ­ Connect to program 5. 6 ­ Connect to program 6. 7 ­ Connect to program 7.

ALARM CYCLE

Fva1 Fva2
Function of Alarm

ALARM FUNCTION: Defines the alarm functions according to options shown in Table 3.
oFF, iErr, rS, rFAil, Lo, xi, DiFL, DiFx, DiF

bla1 bla2
blocking for Alarms

ALARM INITIAL BLOCKING: Alarm initial blocking function for alarms 1 to 4
YES ­ Enables initial blocking.
NO ­ Disables initial blocking.

xya1 ALARMS HYSTEREIS: Defines the differential range xya2 between the PV value at which the alarm is turned on and
the value at which it is turned off. Hysteresis of
Alarms One hysteresis value is set for each alarm.

A1t1
Alarm 1 time 1

ALARM 1 TIME 1: Defines the period, in seconds, in which the alarm output will be on when alarm 1 is activated. Set zero to disable this function.

A1t2
Alarm 1 time 2

ALARM 1 TIME 2: Defines the period in which alarm 1 will be off after being activated. Set zero to disable this function.

A2t1
Alarm 2 time 1

ALARM 2 TIME 1: Defines the period, in seconds, in which the alarm output will be on when alarm 2 is activated. Set zero to disable this function.

A2t2
Alarm 2 time 2

ALARM 2 TIME 2: Defines the period in which alarm 2 will be off after being activated. Set zero to disable this function.
Table 4 shows the advanced functions one can obtain with timer.

INPUT CONFIGURATION CYCLE

Type

INPUT TYPE: Selection of the type of signal connected to the PV input. See Table 1.

tYPE This must be the first parameter to be set up.

Dppo DECIMAL POINT POSITION: Only for inputs 16, 17, 18 and
decimal Point 19. Determines the position of the decimal point in all Position parameters related to PV and SP.

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Controller N2000S

vnI t TEMPERATURE: Selects the temperature unit: Celsius (°C)
unit or Fahrenheit (°F). Invalid for inputs 16, 17, 18 and 19.

Offs

OFFSET for PV: Offset value to be added to the PV to compensate sensor error. Default value: zero. Adjustable

oFFSet between -400 and +400.

Spll
SetPoint Low Limit

SETPOINT LOW LIMIT: For linear inputs, selects the minimum value of indication and adjustment for parameters related to PV and SP.
For thermocouples and Pt100, selects the minimum value for SP adjustment.
Also defines the lower limit value for retransmission of PV and SP.

Spxl
SetPoint High Limit

SETPOINT HIGHER LIMIT For linear inputs, selects the maximum value of indication and adjustment for parameters related to PV and SP. For thermocouples and Pt100, selects the maximum value for SP adjustment. Also defines the higher limit value for retransmission of PV and SP.

Selects value that will be displayed in the MV screen (the
Pot second screen of the main cycle).

Potentiometer

YES ­ Shows the potentiometer value. NO ­ Shows the PID output.

COMMUNICATION BAUD RATE Available with RS485.
Bavd 0=1200 bps; 1=2400 bps; 2=4800 bps; 3=9600 bps; 4=19200
bps

Addr

COMMUNICATION ADDRESS: With RS485, number that identifies the controller in the communication between 1 and

Address 247.

I/O CYCLE (INPUTS AND OUTPUTS)

I o 1
(input/output 1/2) ­ Alarm outputs 1 and 2.
I o 2

I o 3
(input/output 3 / 4) ­ Control outputs.
I o 4

(input/output 5) I/O 5 FUNCTION: Selects the I/O function

I

o

5

to be used at I/O 5. Options 0 to 16 are available. Usually employed in analog control or retransmission. Refer to the

I/O Channels Configuration item for details.

(input/output 6) I/O 6 FUNCTION: Selects the I/O function to be used at I/O 6. Refer to the I/O Channels
I o 6 Configuration item for details.

Options 0, 7, 8, 9 and 10 are possible for this input.

f.fvnc

Key function: Allows definition of the

key

function. Available functions:

0 ­ Key not used.

7 ­ Controls output and alarm outputs (RUN function).

8 ­ Invalid selection.

9 ­ Hold program execution.

10 ­ Selects program 1.

These functions are described in item Key function.

CALIBRATION CYCLE
All input and output types are factory calibrated. Recalibration is not recommended. If necessary, recalibration must be performed by specialized personnel. If this cycle is accessed by mistake, do not press or keys, go all through the prompts up to the operation cycle is reached again.

Inl(
input Low Calibration
Inx(
input High Calibration

INPUT OFFSET CALIBRATION: Makes possible to calibrate the PV offset. To change one digit, press or
as many times as necessary.
INPUT SPAN CALIBRATION (gain): Makes possible to calibrate the PV offset.

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Ovll
output Low Calibration
Ovx(
output High Calibration
(j l
Potl
Potx

OUTPUT OFFSET CALIBRATION: Value to calibrate the offset of the current control output.
OUTPUT HIGH CALIBRATION: Value for current output high calibration.
COLD JOINT OFFSET CALIBRATION: Parameter to adjust the cold joint temperature offset.
POTENTIOMETER LOW CALIBRATION. To change one digit, press and as many times as necessary.
CALIBRATION OF THE POTENTIOMETER’S FULL SCALE.

RAMP AND SOAK PROGRAM

Feature that allows to elaborate a behavior profile for the process. Each program is composed of a set of up to 7 segments, named RAMP AND SOAK PROGRAM, defined by SP values and time intervals.

When the program is defined and runs, the controller starts to automatically generate the SP according to the program.

At the end of the program execution, the controller turns the control output off (rvn = no).

Up to 7 different programs of ramp and soak can be created. The figure below shows an example of the program:

SP SP3 SP4 SP5 SP6

SP1

SP2

SP0

SP7

T1 T2 T3 T4 T5 T6 T7

time

Figure 8 ­ Example of the ramp and soak program.

To execute a profile with fewer segments, set 0 (zero) for the time intervals that follow the last segment to be executed.

SP

SP1 SP2

SP3

SP0 T1

T2 T3 T4=0 time

Figure 9 ­ Example of a program with a few segments

The PtoL Tolerance Function defines the maximum deviation between PV and SP during the program execution. If this deviation is exceeded, the program will be interrupted until the deviation falls within the tolerance range (regardless of time). Programming 0 (zero) at this prompt disables the tolerance; the profile execution will not be halted even if PV does not follow SP (only considers time).

LINK OF PROGRAMS
It is possible to create a more complex program, with up to 49 segments, joining the 7 programs. This way, at the end of a program execution the controller immediately starts to run another one.
When a program is created, it must be defined in the LP screen whether there will be or not another program.
To make the controller run a given program or many programs continuously, it is only necessary to link a program to itself or the last program to the first.

SP

Prog 1

Prog 2

SP3 SP4 SP1 SP2

SP5 / SP0

SP3

SP1 SP2

SP0 T1 T2 T3 T4 T5 T1

SP4

T2 T3 T4

time

Figure 10 ­ Example program 1 and 2 linked (interconnected

Controller N2000S

EVENT ALARM
This function makes possible to program the activation of alarms in specific segments of a program.
For such, alarms must have their function set as rS and be programmed in PE1 to PE7 according to Table 6. The number programmed in the event prompt defines the alarms to be activated.

CODE ALARM 1 ALARM 2

0

1

×

2

×

3

×

×

Table 6 ­ Event values for ramps and soaks

To configure a ramp and soak program:
· Tolerance values, SPs, time, and event should be programmed.
· If an alarm will be used with the event function, set up its function to Event Alarm.
· Set control mode to automatic.
· Enable program execution at the rS screen.
· Start the control at the rvn screen. Before executing the program, the controller waits for PV to reach the initial Setpoint (SP0). Should any power failure occur, the controller resumes at the beginning of the segment it was running.

PID PARAMETERS AUTO-TUNING
During auto tune the process is controlled in ON / OFF mode at the programmed SP. Depending on the process features, large oscillations above and below SP may occur. Auto-tuning may take several minutes to be concluded in some processes. The recommended procedure is as it follows:
· Disable the control output at the rvn screen.
· Select automatic mode operation at the Avto screen.
· Select a value different form zero for the proportional band.
· Disable the Soft Start function.
· Disable the ramp and soak function and program SP to a value different from the current PV value and close to the value at which the process will operate after tuning.
· Enable auto-tuning at the Atvn screen.
· Enable the control at the rvn screen.

The TUNE flag will remain on during the auto-tuning process.
For the control output with relays or current pulse, automatic tune calculates the highest possible value for the PWM period. This value can be reduced in cases of low instability. For a relay of solid state, reduction to 1 second is recommended.
If the automatic tune does not result a satisfactory control, Table 7 guides how to correct the process behavior.

PARAMETER Proportional band
Integral rate
Derivative time

PROBLEM Slow response Large oscillation Slow response Large oscillation Slow response or instability Large oscillation

SOLUTION Decrease Increase Increase Decrease Decrease Increase

Table 7 ­ Suggestions for manual tuning of PID parameters

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CALIBRATION

INPUT CALIBRATION
All input and output types are factory calibrated. Recalibration is not recommended for operators with no experience. In case recalibration of any scale is necessary, proceed as it follows:
a) Set up the input type to be calibrated.
b) Set the lower and upper limits of extreme values for the input type.
c) Apply a signal to the input that corresponds to a known value and a little bit over the lower limit of the indication.
d) Access the inLC parameter. By using the and keys, select the expected value that will appear in the parameters display.
e) Apply a signal to the input that corresponds to a known value and a little bit under the lower limit of the indication.
f) Access the inLC parameter. By using the and keys, select the expected value that will appear in the parameters display.
g) Repeat c to f up to no new adjustment is necessary.
Note: When the controller is calibrated, check if the required excitation current of Pt100 is compliant to the Pt100 excitation current used in this instrument: 0.17 mA.

ANALOG OUTPUT CALIBRATION

1. Configure I/O 5 for 11 (0-20 mA) or 12 (4-20 mA) values.

2. Connect a mA meter in the analog control output.

3. Disable Auto-Tune and Soft Start functions.

4. Program the lower limit of MV in the ovLL screen with 0.0 % and the upper limit of MV in the ovxL screen with 100.0%.

5. Set no for the manual mode avto screen.

6. Enable the control (YES) at the rvn screen.

7. Program MV in 0.0 % in the operation cycle.

8. Select the ovLC screen. Use the and keys to obtain the 0 mA (or 4 mA for type 12) reading in the mA meter.

9. Program MV in 100.0 % in the operation cycle.

10. Select the ovxC screen. Use the and 20 mA.

keys to obtain the

11. Repeat 7 to 10 up to no new adjustment is necessary.

POTENTIOMETER CALIBRATION a) Set up the input type to be calibrated. b) Set the lower and upper limits of indication for the extremes of the
input type. c) Adjust the potentiometer with the minimum value. d) Access the PotL parameter. By using the and keys,
select 0.0 in the parameters display. e) Adjust the potentiometer with the maximum value. f) Access the Potk parameter. By using the and keys,
select 100.0 in the parameters display.
g) Repeat c to f up to no new adjustment is necessary.

SERIAL COMMUNICATION
An optional master-slave RS485 serial communication interface is available. It is used for communication with a supervisor machine (master). The controller is always the slave.
Communication starts only with the master, which sends a command to the slave address with which it wants to communicate. The slave takes the command and sends the correspondent response to the master.
The controller accepts also broadcast commands.

Controller N2000S

FEATURES
Signals compliant to the RS-485 standard. Two-wire connection between the master and up to 31 instruments in bus topology (it may address up to 247 instruments). Maximum cable length: 1,000 meters. Time to disconnect from the controller. Maximum 2 ms after the last byte.
Communication signals are electrically isolated from the rest of the device, speed options are 1200, 2400, 4800, 9600 or 19200 bps.
Number of data bits: 8, without parity.
Number of stop bits: 1.
Time of response transmission start: Maximum 100 ms after receiving the command.
Protocol used: MODBUS (RTU), available in most market-available supervisory software.
RS-485 signals are:

D1 D D + B Bidirectional data line.

Terminal 25

D0 D – A Inverted bidirectional data line.

Terminal 26

C

Optional connection which improves Terminal 27

the communication performance.

COMMUNICATION PARAMETERS CONFIGURATION
Two parameters must be configured for serial use:
bavd: Communication speed. All equipment’s with the same speed.
Addr: Controller communication address. Each controller must have an exclusive address.

PROBLEMS WITH THE CONTROLLER
Connection errors and inadequate programming are the most common errors found during the controller operation. A final review may avoid loss of time and damages.
The controller displays some messages to help the user identify problems.

MESSAGE —-
Err1

PROBLEM Open input. Without sensor or signal. Connection problems in the Pt100 cable.

Table 8 ­ Problems

Other error messages displayed by the controller can account for errors in the input connections or type of selected input noncompliant with the sensor or signal applied to the input. If errors persist even after a review, contact the manufacturer. Also inform the device serial number. To find out the serial number, press for more than 3 seconds.
The controller also has a visual alarm (the display flashes) when the PV value is out of the range set by spxl and spll.

SPECIFICATIONS
DIMENSIONS:………………………………….. 48 x 96 x 92 mm (1/16 DIN). …………………………………………………….Approximate weight: 250 g
PANEL CUT-OUT: ………………………………45 x 93 mm (+0.5 -0.0 mm)
POWER: ……………………………100 to 240 Vac / dc (±10 %), 50/60 Hz. Optional 24 V:………………. 12 to 24 Vdc / 24 Vac (-10 % / +20 %) Max. Consumption:………………………………………………………. 3 VA
ENVIRONMENTAL CONDITIONS: ………………………………..5 to 50 °C Relative humidity (maximum): …………………………. 80 % up to 30 °C ………………… For temperatures above 30 °C, decrease 3 % per °C …………… Internal use, Installation category II. Pollution degree 2.
………………………………………………………………… Altitude < 2000 m

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INPUT: T/C, Pt100, voltage and current, configurable according to Table 1
Internal resolution: …………………………………………….. 19500 levels Display resolution: ………………. 12000 levels (from -1999 to 9999) Input sample rate:………………………………………………5 per second Accuracy: ……..Thermocouples J, K and T: 0.25 % of span ±1 ºC …………………………. Thermocouple N, R, S: 0.25 % of span ±3 ºC …………………………………………………………….Pt100: 0.2 % of span ………………………………4-20 mA, 0-50 mV, 0-5 Vdc: 0.2 % of span Input impedance: … 0-50 mV, Pt100 and thermocouples: >10 M ……………………………………………………………………… 0-5 V: >1 M ………………………………………… 4-20 mA: 15 (+2 Vdc @ 20 mA) Pt100 measurement: 3-wire circuit, cable resistance compensation (=0.00385), Excitation current: 0.170 mA All input types are factory calibrated. Thermocouples according to NBR 12771/99, RTD’s NBR 13773/97. DIGITAL INPUT (I/O6): ………………Dry contact or NPN open collector
ANALOG OUTPUT (I/O5):…………..0-20 mA or 4-20 mA, 550 max. 1500 levels, isolated, control output or PV or SP retransmission
CONTROL OUTPUT: 2 Relays SPDT (I/O1 and I/O2): 3 A / 240 Vac 2 Relays SPST-NO (I/O3 and I/O4): 1.5 A / 250 Vac Voltage pulse for SSR (I/O 5): 10 V max. / 20 mA
AUXILIARY VOLTAGE SUPPLY: ………………. 24 Vdc, ±10 %; 25 mA
EMC:…………………………. EN 61326-1:1997 and EN 61326-1/A1:1998
SAFETY: …………………….. EN61010-1:1993 and EN61010-1/A2:1995
PROPER CONNECTIONS FOR 6.3 MM PIN TYPE THERMINALS. FRONT PANEL: ……………………………. IP65, polycarbonate UL94 V-2
HOUSING:…………………………………………… IP20, ABS+PC UL94 V-0
CERTIFICATIONS: CE, UL and UKCA PROGRAMMABLE PWM CYCLE FROM 0.5 TO 100 SECONDS. AFTER POWER UP, IT STARTS OPERATION AFTER 3 SECONDS.
WARRANTY
Warranty conditions are available on our website www.novusautomation.com/warranty.

Controller N2000S

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