NOVUS N1040 Temperature Controller Instruction Manual

NOVUS N1040 Temperature Controller

SAFETY ALERTS

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

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.

INSTALLATION / CONNECTIONS

The controller must be fastened on a panel, following the sequence of steps described below:

• Prepare a panel cut-out according to SPECIFICATIONS.
• Remove the mounting clamps from the controller.
• Insert the controller into the panel cut-out.
• Slide the mounting clamp from the rear to a firm grip at the panel.

ELECTRICAL CONNECTIONS
Figure 1 below shows the electrical terminals of the controller:

INSTALLATION RECOMMENDATIONS

• All electrical connections are made to the screw terminals at the rear of the controller.
• To minimize the pick-up of electrical noise, the low voltage DC connections and the sensor input wiring should be routed away from high-current power conductors.
• If this is impractical, use shielded cables. In general, keep cable lengths to a minimum. All electronic instruments must be powered by a clean mains supply, proper for instrumentation.
• It is strongly recommended to apply RC’S FILTERS (noise suppressor) to contactor coils, solenoids, etc. In any application it is essential to consider what can happen when any part of the system fails. The controller features by themselves cannot assure total protection.

FEATURES

INPUT TYPE SELECTION
Table 1 shows the sensor types accepted and their respective codes and ranges. Access the parameter in the INPUT cycle to select the appropriate sensor.

OUTPUTS
The controller offers two, three or four output channels, depending on the loaded optional features. The output channels are user configurable as Control Output, Alarm 1 Output, Alarm 2 Output, Alarm 1 OR Alarm 2 Output, and LBD (Loop Break Detect) Output.

• OUTPUT OUT1 Pulse type output of electrical voltage. 5 Vdc / 50 mA max. Available on terminals 4 and 5.
• OUTPUT OUT2 SPST-NO relay. Available on terminals 6 and 7.
• OUTPUT OUT3 SPST-NO relay. Available on terminals 13 and 14 (PRRR Model). Analog Output or Current Output. 0-20 / 4-20 mA, 500 R max. Available on terminals 13 and 14 (PRAR model).
• OUTPUT OUT4 SPDT relay. Available on terminals 10, 11, and 12.

CONTROL OUTPUT
It is the output that will command the process actuator (heating resistor, cooling compressor, etc.). The control output can be directed to a relay, an analog output, or even a Pulse type Electrical Voltage output, according to availability.

CONTROL MODE
The controller has two modes: Manual Mode or Automatic Mode. The parameter allows you to select one or the other control mode.
In Manual mode ( ), you determine the MV value applied to the Control Output.
In Automatic mode ( ), the controller is in control of the process, automatically setting the MV value to be applied to the output defined as the Control Output.
In Automatic mode there are two distinct control strategies: ON/OFF Control and PID Control.
The ON/OFF Control, obtained when you set the Proportional Band ( ) parameter to 0.0 , acts on the Control Output, based on the simple relation between SP and PV (measured temperature). The PID Control action is based on a mathematical control algorithm, which, considering the correlation between SP and PV, acts on the Control Output and on the values set for parameters . The determination of parameters , and is described in the PID PARAMETERS DEFINITION section.

ANALOG OUTPUT OR CURRENT OUTPUT
The controller has an analog output of electric current that can perform the following functions:

• Process control output
• Process PV retransmission output
• Process SP retransmission output

As a control output, it relates the MV range (0 to 100 %) to the current range: 4 to 20 mA or 0 to 20 mA. 0 % MV determines 4 mA (or 0 mA) on the Analog Output 100 % MV determines 20 mA on the Analog Output

As the PV / SP relay output of the process, the electrical current applied to the analog output will be proportional to the ratio between the value of the variable (PV or SP) and the retransmission range defined by parameters .  The analog output is electrically isolated from the other controller circuits. It has a measurement accuracy of 0.25 % of the Operating Range or 0.4 mA.

ALARM OUTPUT
The controller contains 2 alarms that can be directed (assigned) to any output channel. The alarm functions are described in Table 2.

Note: Alarm functions on Table 2 are also valid for Alarm 2 (SPA2).

Important note: Alarms configured with the and functions also trigger their associated output when a sensor fault is identified and signaled by the controller. A relay output, for example, configured to act as a High Alarm ( ), will operate when the SPAL value is exceeded and when the sensor connected to the controller input is broken.

INITIAL BLOCKING OF ALARM
The Initial Blocking option inhibits the alarm from being recognized if an alarm condition is present when the controller is first energized. The alarm will be enabled only after the occurrence of a non-alarm condition. The initial blocking is useful, for example, when one of the alarms is configured as a minimum value alarm, causing the activation of the alarm soon upon the process start-up, an occurrence that may be undesirable. The initial blocking is disabled for the sensor break alarm function (Open sensor).

SAFE OUTPUT VALUE WITH SENSOR FAILURE
A function that places the control output in a safe condition for the process when is identified an error in the sensor input. With a fault identified in the sensor, the controller determines the percentage value defined in parameter   for the control output. The controller will remain in this condition until the sensor failure disappears. values are only 0 and 100 % when in ON/OFF control mode. For PID control mode, any value in the range from 0 to 100 % is accepted.

LBD FUNCTION – LOOP BREAK DETECTION
The parameter allows you to set a maximum time interval (in minutes) for the process temperature (PV) to react to the command from the control output. If the PV does not react properly within the time interval configured, the controller signals in its display the occurrence of the LBD event, which indicates problems in the control loop. The LBD event can also be sent to one of the output channels of the controller. To do this, simply configure the desired output channel with the LDB function which, in the event of this event, is triggered. This function is disabled with value 0 (zero). This function allows the user to detect problems in the installation, such as defective actuators, power supply failure, etc.

OFFSET
Feature that allows the user to make small adjustment in the temperature indication. Allows correcting measurement differences that appear, for example, when replacing the temperature sensor.

USB INTERFACE
The USB interface is used to CONFIGURE, MONITOR or UPDATE the controller FIRMWARE. The user should use QuickTune software, which offers features to create, view, save and open settings from the device or files on the computer. The tool for saving and opening configurations in files allows the user to transfer settings between devices and perform backup copies.For specific models, QuickTune allows to update the firmware (internal software) of the controller via the USB interface. For MONITORING purposes, the user can use any supervisory software (SCADA) or laboratory software that supports the MODBUSRTU communication over a serial communication port. When connected to a computer’s USB, the controller is recognized as a conventional serial port (COM x). The user must use QuickTune software or consult the DEVICE MANAGER on the Windows Control Panel to identify the COM port assigned to the controller. The user should consult the mapping of the MODBUS memory in the controller’s communication manual and the documentation of the supervision software to start the MONITORING process. Follow the procedure below to use the USB communication of the device:

1. Download QuickTune software from our website and install it on the computer. The USB drivers necessary for operating the communication will be installed with the software.
2. Connect the USB cable between the device and the computer. The controller does not have to be connected to a power supply. The USB will provide enough power to operate the communication (other device functions may not operate).
3. Run the QuickTune software, configure the communication and start the device recognition.

The USB interface IS NOT SEPARATE from the signal input (PV) or the controller’s digital inputs and outputs. It is intended for temporary use during CONFIGURATION and MONITORING periods. For the safety of people and equipment, it must only be used when the piece of equipment is completely disconnected from the input/outputsignals. Using the USB in any other type of connection is possible but requires a careful analysis by the person responsible for installing it. When MONITORING for prolonged periods of time and with connected inputs and outputs, we recommend using the RS485 interface.

OPERATION

The front panel can be seen in Figure 2:

• Display: Displays the measured variable, symbols of the configuration parameters and their respective values/conditions.
• COM Indicator: Flashes to indicate communication activity in the RS485 interface.
• TUNE Indicator: Stays ON while the controller is in tuning process.
• OUT Indicator: For relay or pulse control output; it reflects the actual state of the output.
• A1 and A2 Indicators: Signalize the occurrence of alarm situation.
• P Key: Used to walk through the menu parameters.
• Increment key and Decrement key: Allow altering the values of the parameters.
• Back key: Used to retrocede parameters.

STARTUP
When the controller is powered up, it displays its firmware version for 3 seconds, after which the controller starts normal operation. The value of PV and SP is then displayed, and the outputs are enabled. For the controller to operate properly in a process, its parameters need to be configured first, such that it can perform accordingly to the system requirements. The user must be aware of the importance of each parameter and for each one determines a valid condition. The parameters are grouped in cycles, according to their functionality and operation easiness. The 5 cycles of parameters are:1 – Operation / 2 – Tuning / 3 – Alarms / 4 – Input / 5 – Calibration The P key is used for accessing the parameters within a cycle. Keeping the P key pressed, at every 2 seconds the controller jumps to the next cycle of parameters, showing the first parameter of each cycle:

To enter a particular cycle, simply release the P key when the first parameter in that cycle is displayed. To walk through the parametersin a cycle, press the P key with short strokes. To go back to the previous parameter in a cycle, press . Each parameter is displayed with its prompt in the upper display and value/condition in the lower display. Depending on the level of parameter protection adopted, the parameter precedes the first parameter in the cycle where the protection becomes active. See section CONFIGURATION PROTECTION.

PARAMETER DESCRIPTION

OPERATION CYCLE

TUNING CYCLE

ALARMS CYCLE

INPUT CYCLE

CALIBRATION CYCLE
All types of input are calibrated in the factory. In case a recalibration is required; it shall be carried out by a specialized professional. In case this cycle is accidentally accessed, do not perform alteration in its parameters.

CONFIGURATION PROTECTION

The controller provides means for protecting the parameters configurations, not allowing modifications to the parameter values,avoiding tampering or improper manipulation. The parameter Protection ( ), in the Calibration Cycle, determines the protection strategy, limiting the access to levels, as shown in the table below:

Table 3 – Levels of Protection for the Configuration

ACCESS PASSWORD
The protected cycles, when accessed, request the user to provide the Access Password for granting permission to change the configuration of the parameters on these cycles. The prompt precedes the parameters on the protected cycles. If no password is entered, the parameters of the protected cycles can only be visualized. The Access Password is defined by the user in the parameter Password Change , present in the Calibration Cycle. The factory default for the password code is 1111.

PROTECTION ACCESS PASSWORD
The protection system built into the controller blocks for 10 minutes the access to protected parameters after 5 consecutive frustrated attempts of guessing the correct password.

MASTER PASSWORD
The Master Password is intended for allowing the user to define a new password in the event of it being forgotten. The Master Password does not grant access to all parameters, only to the Password Change parameter . After defining the new password, the protected parameters may be accessed (and modified) using this new password. The master password is made up by the last three digits of the serial number of the controller added to the number 9000. As an example, for the equipment with serial number 07154321, the master password is 9 3 2 1. Controller serial number is displayed by pressing for 5 seconds.

DEFINITION OF PID PARAMETERS

During the process of determining automatically the PID parameters, the system is controlled in ON/OFF in the programmed Setpoint. The auto-tuning process may take several minutes to be completed, depending on the system. The steps for executing the PID autotuning are:

• Select the process Setpoint.
• Enable auto-tuning at the parameter , selecting or
  .
  The option performs the tuning in the minimum possible time, while the option gives priority to accuracy over the speed. The sign TUNE remains lit during the whole tuning phase. The user must wait for the tuning to be completed before using the controller. During auto tuning period the controller will impose oscillations to the process. PV will oscillate around the programmed set point and controller output will switch on and off many times. If the tuning does not result in a satisfactory control, refer to Table 4 for guidelines on how to correct the behavior of the process.

Band Proportional

| Slow answer| Decrease
Great oscillation| Increase

Rate Integration

| Slow answer| Increase
Great oscillation| Decrease

Derivative Time

| Slow answer or instability| Decrease
Great oscillation| Increase

Table 4 – Guidance for manual adjustment of the PID parameters

MAINTENANCE

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

Other error messages may indicate hardware problems requiring maintenance service.

INPUT CALIBRATION
All inputs are factory calibrated and recalibration should only be done by qualified personnel. If you are not familiar with these procedures do not attempt to calibrate this instrument. The calibration steps are:

Note: When checking the controller calibration with a Pt100 simulator, pay attention to the simulator minimum excitation current requirement, which may not be compatible with the 0.170 mA excitation current provided by the controller.

ANALOG OUTPUT CALIBRATION

SERIAL COMMUNICATION

The controller can be supplied with an asynchronous RS485 digital communication interface for master-slave connection to a hostcomputer (master). The controller works as a slave only and all commands are started by the computer which sends a request to the slave address. The addressed unit sends back the requested reply. Broadcast commands (addressed to all indicator units in a multidrop network) are accepted but no reply is sent back in this case.

FEATURES

• Signals compatible with RS485 standard. MODBUS (RTU) Protocol. Two wire connection between 1 master and up to 31 (addressing up to 247 possible) instruments in bus topology.
• Communication signals are electrically isolated from the INPUT and POWER terminals. Not isolated from the retransmission circuit and the auxiliary voltage source when available.
• Maximum connection distance: 1000 meters.
• Time of disconnection: Maximum 2 ms after last byte.
• Programmable baud rate: 1200 to 115200 bps.
• Data Bits: 8.
• Parity: Even, Odd, or None.
• Stop bits: 1
• Time at the beginning of response transmission: maximum 100 ms after receiving the command. The RS485 signals are:

PARAMETER CONFIGURATION
Two parameters must be configured for using the serial type:

COMMUNICATION PROTOCOL
The MOSBUS RTU slave is implemented. All configurable parameters can be accessed for reading or writing through the communication port. Broadcast commands are supported as well (address 0).

The available Modbus commands are:

• 03 – Read Holding Register
• 06 – Preset Single Register
• 05 – Force Single Coil

HOLDING REGISTERS TABLE
Follows a description of the usual communication registers. For full documentation download the Registers Table for Serial Communication in the product section of NOVUS website (www.novusautomation.com). All registers are 16-bit signed integers.

IDENTIFICATION

A: Outputs features:

• PR: OUT1 = Pulse / OUT2 = Relay
• PRRR: OUT1 = Pulse / OUT2 = OUT3 = OUT4 = Relay
• PRAR: OUT1 = Pulse / OUT2 = Relay / OUT3 = 0-20 / 4-20 mA OUT4 = Relay

B: Serial communication:

• Blank: (basic version, without serial communication)
• 485: (version with RS485 serial, Modbus protocol)

C: Power supply:

• Blank:

  • ………………………………………………….. Standard model
  • …………………………. 100~240 Vdc / 24 Vac; 50~60 Hz 24 V:
    …………………………………………………………  Model

• 24 V   …………………………….. 12~24 Vdc / 24 Vac; 50~60 Hz

SPECIFICATIONS

DIMENSIONS: …………………………………… 48 x 48 x 80 mm (1/16 DIN)

• Panel cut-out: …………………………. 45.5 x 45.5 mm (+0.5 -0.0 mm)
• Approximate weight: ……………………………………………………… 75 g

POWER SUPPLY:

• Standard model: ………………….100 to 240 Vac (±10 %), 50/60 Hz
• …………………………………………………………. 48 to 240 Vdc (±10 %)
• 24 V model:………………….. 12 to 24 Vdc / 24 Vac (-10 % / +20 %)
• Maximum consumption: ………………………………………………… 6 VA

ENVIRONMENTAL CONDITIONS:

• Operation temperature: ………………………………………… 0 to 50 °C
• Relative humidity: …………………………………………… 80 % @ 30 °C
  For temperatures above 30 °C, reduce 3 % for each °C. Internal use; Category of installation II, Pollution degree 2; Altitude < 2000 meters

INPUT ……. Thermocouples J, K, T, and Pt100 (according to Table 1)

• Internal resolution: ………………………………… 32767 levels (15 bits)
• Display resolution: ………….. 12000 levels (from -1999 up to 9999)
• Rate of input reading: ……………………………… up 10 per second (*)
• Accuracy: Thermocouples J, K, T: 0.25 % of the span ±1 °C (**)
• ………………………………………………………. Pt100: 0.2 % of the span
• Input impedance: ……………… Pt100 and thermocouples: > 10 MΩ
• Pt100 measurement: ……………………….. 3-wire type, (α=0.00385)

With compensation for cable length, excitation current of 0.170 mA. All input types are factory calibrated. Thermocouples according to NBR 12771/99 standard; Pt100 NBR 13773/97.

• Value adopted when the Digital Filter parameter is set to 0 (zero) value. For Digital Filter values other than 0, the Input Reading Rate value is 5 samples per second.
• The use of thermocouples requires a minimum time interval of 15 minutes for stabilization.

OUTPUTS:

• OUT1: ………………………………….. Voltage pulse, 5 V / 50 mA max.

• OUT2: …………………………… SPST relay; 1.5 A / 240 Vac / 30 Vdc

• OUT3 (PRRR):……………….. SPST relay; 1.5 A / 240 Vac / 30 Vdc

• OUT3 (PRAR): ……………………………………….. 0-20 mA or 4-20 mA
  ………………………………….. 500 Ohms max.; 12000 levels; Isolated
  …………………………………………………… Accuracy: 0.25 % F.S. (***)

• OUT4: ……………………………… SPDT relay; 3 A / 240 Vac / 30 Vdc

• FRONT PANEL: ……………………. IP65, Polycarbonate (PC) UL94 V-2

• HOUSING: ……………………………………………. IP20, ABS+PC UL94 V-0

• ELECTROMAGNETIC COMPATIBILITY: …………… EN 61326-1:1997 and EN 61326-1/A1:1998

• EMISSION: …………………………………………………… CISPR11/EN55011

• IMMUNITY: …………………. EN61000-4-2, EN61000-4-3, EN61000-4-4, EN61000-4-5, EN61000-4-6, EN61000-4-8, and EN61000-4-11

• SAFETY: …………………….. EN61010-1:1993 and EN61010-1/A2:1995

SPECIFIC CONNECTIONS FOR TYPE FORK TERMINALS.

• PROGRAMMABLE CYCLE OF PWM : From 0.5 up 100 seconds.
• STARTS UP OPERATION: After 3 seconds connected to the power supply.
• CERTIFICATIONS: CE, UKCA, and UL.(***) F.S.= Full scale. Maximum range of the sensor used.

WARRANTY

Warranty conditions are available on our website www.novusautomation.com/warranty.

References

• NOVUS Automation Inc. - Controllers, Thermostats, Data Loggers, Solid State Relays, Sensors, Transmitters, SCADA, Data Acquisition and Temperature Controllers
• NOVUS Automation Inc. - Controllers, Thermostats, Data Loggers, Solid State Relays, Sensors, Transmitters, SCADA, Data Acquisition and Temperature Controllers
• Warranty - Company - NOVUS Automation Inc.

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