AMALGAMATED INSTRUMENT PM4-TCR Guide

PM4-TCR
Process Monitor/Controller
Operation and Instruction Manual
(inputs from RTDs, Thermocouple,
4-20mA or direct mV)

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power supply connections. . . . . . . . . . . . . . . . . . . . . . . . . 6
Input sensor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Relay connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input link settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Explanation of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Function Table for fully optioned instrument . . . . . . . . . . . . . . . . 19
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Input/Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setting up the relay PI controller . . . . . . . . . . . . . . . . . . . . . . . 27
Guarantee and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TC09 17F15 Page 2 of 34 PM4TCRMAN-1.7.0

1 Introduction
This manual contains information for the installation and operation of the PM4-TCR Monitor. The
PM4 is a general purpose monitor which may be configured to accept inputs from 100Ωor 1000ΩRTDs,
thermocouple types B, E, J, K, N, R, S or T, 4-20mA or direct mV input in ranges up to 200mV.
Theinstrumentmaybecalibratedtodisplaythetemperaturein°Cor°Forabsolute(degreesK)and
if required to display temperature units e.g. 22”C. A standard inbuilt relay provides an alarm/control
function, optional extra relays, retransmission (signal or dual channel) andexcitation voltage may also be
provided. Refer to the separate “PM4 Panel Meter Optional Output Addendum” booklet supplied when
optional outputs are fitted. Open circuit RTD or thermocouple inputs will cause an error message to appear
on the display "----" for RTD inputs or "OPEN" for thermocouple inputs. Any relay with a high setpoint
value set will be activated when either of these error messages is seen.
Unless otherwise specified at the time of order, your PM4 has been factory set to a standard
configuration. Like all other PM4 series instruments the configuration and calibration is easily changed by
the user. Initial changesmay require dismantling the instrument to alter PCBlinks, other changes aremade
by push button functions.
Fullelectrical isolation betweenpower supply, input voltage or currentandretransmission outputis
provided by the PM4, thereby eliminating grounding and common voltage problems. This isolation feature
makes the PM4 ideal for interfacing to computers, PLCs and other data acquisition devices
TheversatilePM4hasvariousfrontpaneloptions,thereforeinsomecasesthepushbuttonsmaybe
located on the front panel as well as the standard rear panel configuration.
The PM4seriesof Panel Mount Monitorsare designed for high reliability in industrial applications.
The high brightness LEDdisplay provides good visibility, even in areas with high ambient light levels. The
high contrast LCD displays provide good visibility and are ideal for batterypowered applications.
The^andvpushbuttonscanbe used totoggle tothecold junction temperature (preceded bythe
message coId) or the actualmVinput(preceded by themessage INPt) when using thermocoupleormV
input. The INPt display for 4-20mA input does not give a valid reading.
Inputs & outputs
Page 3 of 34 PM4TCRMAN-1.7.0
Alarm annunciator LEDs
(5 digit LED display only) Setup pushbuttons
(5, 6 & 8 digit LED
display models only)
Input:
100 Ohm RTD (Pt100)
1000Ohm RTD (Pt1000)
Thermocouple type B, E,
J, K,N, R, S or T.
4-20mA or
direct mV input (in ranges
up to200mV)
Output:
Optional outputs:
1 x setpoint relay
18V transmitter supply
(AC powered models only)
Up to six extra setpoint relays.
Analog output (single or dual channel)
Serial comms (RS232 or RS485)
BCD/binary retransmission
P F
A1
A2
A3
A4
Temperature C
o

2 Mechanical Installation
If a choice of mounting sitesis available then choose a site asfar away as possible from sources of
electrical noise such as motors, generators, fluorescent lights, high voltage cables/bus bars etc. An IP65
access cover which may be installed on the panel and surrounds is available as an option to be used when
mounting the instrumentin damp/dusty positions.A wall mountcase is available, as an option, for situations
in which panelmountingis either not available or not appropriate. A portable carrycase isalso available, as
an option, for panel mount instruments.
Prepareapanelcutoutof45mmx92mm+1mm/-0mm(seediagrambelow).Inserttheinstrument
intothecutoutfromthefrontofthepanel.Then,fromtherearoftheinstrument,fitthetwo mountingbrackets
into the recess provided (see diagram below). Whilst holding the bracket in place, tighten the securing
screws being careful not to over-tighten, as this may damage the instrument.
Hint:usetheelasticbandprovidedtoholdthemountingbracketinplacewhilsttighteningsecuringscrews.
Page 4 of 34 PM4TCRMAN-1.7.0
92mm
45mm PANEL CUT OUT 92mm
45mm
PANEL
CUT
OUT
115mm
104mm
53mm
44mm
96mm
9mm
9.5mm
max
48mm 91mm
111mm
10mm
Mounting bracket
(2 off)
Horizontal mounting
Vertical mounting
(bar graph displays)

3 Electrical Installation
The PM4 PanelMeter is designed for continuous operation and nopower switch is fitted to the unit.
Itisrecommendedthatanexternalswitchandfusebeprovidedtoallowtheunittoberemovedforservicing.
The terminal blocks allow for wires of up to2.5mm
2
(terminals 1 to 6 and option outputs) or 1.5mm
2
(terminals 7 to 12) to be fitted. Connect the wiresto the appropriate terminals as indicated below. Refer to
other details provided in this manual to confirm proper selection of voltage, polarity and input type before
applying power to the instrument. When power is applied the instrument will cycle through a display
sequence, indicating the software version and other status information, this indicates that the instrument is
functioning. Acknowledgementof correct operation may be obtained byapplying an appropriate input to the
instrument and observing the resultant reading.
Page 5 of 34 PM4TCRMAN-1.7.0
SETUP
PUSHBUTTONS
1 2 3 4 5 6 7 89 101112
MAINS EARTH
AC ACTIVE
AC NEUTRAL COM
RELAY 1
N/O
(DC+)
(DC-)
4-20mA in
GND
3W/Transmitter supply +
In +
Gnd
Remote input
A B HC D E F J K
Instrument Rear Panel
1
3
2
5
6
7
8
9
10
11
12
MAINS EARTH
RELAY 1 COM
RELAY 1 N/O
REMOTE INPUT
GROUND
4-20mA in
3W / TRANSMITTER +
GROUND
IN +
240VAC NEUTRAL
240VAC ACTIVE
PM4-TCR-240-5E SERIALNo.
Instrument data label (example)

3 .1 Power supply connections
The power supply for the instrument is factory fitted and is of a fixed type. If you are unsure of the
supplyrequirementforyourinstrumentitcanbedeterminedbythemodelnumberontheinstrumentlabel:-
PM4-TCR-240-...... Requires 240VAC
PM4-TCR-110-...... Requires 110VAC
PM4-TCR-32-...... Requires 32VAC
PM4-TCR-24-...... Requires 24VAC
PM4-TCR-DC-...... Requires between 12 and 48VDC
PM4-TCR-DCH-...... Requires between 50 and 100VDC
3 .2 Input sensor wiring
3 .3 Relay connections
ThePM4is supplied withonealarmrelayas standard with connectionsonpins 5and6,extrarelays
are optionally available. The relay is a single pole, single throw type and is rated at 5A, 240VAC into a
resistive load. The relay contact is voltage free and may be programmed for normally open or normally
closed operation.
3 .4 Input link settings
See the "Input/Output Configuration" chapter for instructions on removing the input board.
Page 6 of 34 PM4TCRMAN-1.7.0
IN + IN + IN + 4-20
IN
4-20
IN 4-20
IN
12 12 12 9
9 9D
11 11 11 8
F
10 8
10 10
GND GND GND GND3W
V+ V+ V- GND
3W
RTD RTD
2 WIRE RTD
WIRE
LINK
WIRE
LINK
3WIRERTD THERMOCOUPLE OR
DIRECT mV INPUT 4-20mA INPUT
2 WIRE 4-20mA INPUT USINGSTANDARD
18V UNREGULATEDTRANSMITTER SUPPLY
NOTE: AN INTERNAL LINK SETTING IS
REQUIRED TO OBTAIN V+ AT TERMINAL 10
2WIRE 4-20mA INPUT
USING OPTIONAL INTERNAL
24VDC (+/-12V) TRANSMITTER SUPPLY
TRANSMITTER SUPPLY
4-20mA
TRANSMITTER 4-20mA TRANSMITTER
4-20mA
4-20mA
4-20mA
Note: Only one input type can be used at any one time - see function
INPt tYPE
3W
3W
3W
+18
+18
+18
RTD input selected
+18V unregulated
transmitter supply selected
(available on AC supply
models only)

4 Explanation of Functions
The PM4 setup and calibration functions are configured through a push button sequence. Two
levels of access are provided for setting up and calibrating:-
FUNC mode (simple push button sequence) allows
accesstocommonlysetupfunctionssuchasalarmsetpoints.
CAL mode (power up sequence plus push button
sequence) allows access to all functions including calibration
parameters.
The three push buttons located at the rear of the
instrument (also at the front onsome display options) are used
to alter settings. Once CAL or FUNC mode has been entered
you can step through the functions, by pressing and releasing
the Fpush button, until the required function is reached.
Changes to functions are made by pressing the ^or vpush
button (in some cases both simultaneously) whenthe required
function is reached.
Page 7 of 34 PM4TCRMAN-1.7.0
Process Units
Front view of instrument
SETUP
PUSHBUTTONS
SETUP
PUSH BUTTONS
Rear view of instrument
1 2 3 4 5 6 7 8 9 10 11
SETUP
PUSHBUTTONS
F
F
^
^
v
v
Entering Mode
CAL
Entering Mode
FUNC
1. Remove power from
the instrument. Hold in the
button and reapply power.
The display will briefly indicate
as part of the
"wake up messages" when
the message is seen
you can release the
button. Move to step 2 below.
2.When the "wake up"
messages have finished
and the display has settled
down to its normal reading
press, then release the
button.
Move to step 3 below.
1.When the "wake up"
messages have finished
and the display has settled
down to its normal reading
press, then release the
button.
3.Within 2 seconds of
releasing the button
press, then release
the and buttons
together. The display will
now indicate followed
by the first function.
2.Within 2 seconds of
releasing the button
press, then release
the and buttons
together.The display will
now indicate followed
by the first function.
^
^
^ ^
FUNC
FUNC
F
F
F
FF
CAL
CAL
Note:If step 1 above has been completed then the
instrument will remain inthis modestate until
power is removed. i.e. there is no need to repeat step 1
when accessing function unless power hasbeen removed.
CAL
No special power up procedure
is required to enter mode.FUNC

Function Description
C.SEt Analog control setpoint - seen only when the analog retransmission option is fitted and
REC ctrI is set to on. Refer to the separate “PM4 DIN Rail Meter Optional Output
Addendum” booklet supplied when this option is fitted.
AxSP Alarm relay setpoint- displaysandsets the alarm relayPIcontrolsetpoint. This function is
only seen when the alarm operating mode is set to pulse width or frequency PI control
operation. Refer to the “Setting up the relay PI controller” chapter if this mode is used.
AxLo Alarm low setpoint - displays and sets the low setpoint value for the designated alarm
relay. The low alarm setpoint may be disabled by pressing the ^and vpushbuttons
simultaneously. Whenthe alarm is disabled the displaywill indicate OFF .Use ^or vto
adjust the setpoint value if required. The alarm will activate when the displayed value is
lower than the AxLo setpoint value. Each relay may be configured with both a low and
highsetpoint if required, if so the relay will be activated when the display reading moves
outside the band set between low and high setpoints.
The PM4 has an easy alarm access facility which allows access to the alarm setpoints
simply bypressing the Fbutton at the front or rearofthe instrument. Thefirstsetpoint will
thenappear and changesmaybemade to this setpoint via the ^orvbuttons.Pressthe
F button to accept any changes or to move on to the next setpoint.
The instrument must be set in the manner described below to enable the easy access
facility (if required):
1.TheR.INP functionmustbesetto SP.ACortheACCS functionmustbesettoEASY.
2.Atleastonealarmmusthaveasetpoint,nothingwillhappenifallthealarmsetpointsare
set to OFF.
3. The SP.AC function must be set to allow access to the relays required e.g. if set to
A1-2 thentheeasyaccesswillworkonlywithalarmrelays1and2evenifmorerelaysare
fitted.
4.The instrumentmustbein normalmeasuremode i.e. if the instrumentispowered up so
thatitisinCAL modethenthe easyaccess willnot function.Ifin doubt thenremovepower
from the instrument, wait for a few seconds then apply power again.
5. If the easy access facility is used then the only way to view or alter any other function
settings isto powerupviaCAL mode i.e.noentry toFUNC mode unless the instrument is
powered up in CAL mode.
AxHi Alarm high setpoint - displays and sets the high setpoint value for the designated alarm
relay. The high alarm setpoint may be disabled by pressing the ^and vpushbuttons
simultaneously. When the alarm is disabled the display will indicate OFF. Use ^or vto
adjust the setpoint value if required. The alarm will activate when the displayed value is
higher than the AxHi setpoint value. Each relay may be configured with both a low and
high setpoint if required, if so the relay will be activated when the display reading moves
outside the band set between low and high setpoints.
If the display shows the "----" or "OPEN" error message then any relay with a high
setpoint value will activate.
Page 8 of 34 PM4TCRMAN-1.7.0

Function Description
AxHY Alarmhysteresis[deadband])-displaysandsetsthealarmhysteresislimitandiscommon
for both high and low setpoint values. The hysteresis value may be used to prevent too
frequent operation of the setpoint relay when the measured value stays close to the
setpoint. Without ahysteresis setting (AxHY setto zero) the alarm will activate when the
display value goes above the alarm setpoint (for high alarm) and will reset when the
display value falls below the setpoint, this can result in repeated on/off switching of the
relay at around the setpoint value. The hysteresis setting operates as follows:
In the high alarm mode, oncethe alarm is activated the input must fall below the setpoint
value minus the hysteresis value to reset the alarm.
e.g. if A1Hi is set to 50.0 and A1Hy is set to 3.0 then the setpoint output relay will
activate once the display value goes above 50.0 and will reset when the display value
goes below 47.0 (50.0 minus 3.0).
In the low alarm mode, oncethe alarm is activated theinputmust rise above the setpoint
value plus the hysteresis value to reset the alarm.
e.g. if A1Lo is set to 20.0 and A1Hy is set to 10.0 then the alarm output relay will
activate when the display value falls below 20.0 and will reset when the display value
goes above 30.0 (20.0 plus 10.0).
The hysteresis units are expressed in displayed engineering units.
Axtt Alarm trip time - displays and sets the alarm trip time and is common for both alarm high
andlow setpoint values. Thetrip timeis the delay timebefore the alarm relay will activate,
or trip, when an alarm condition is present. The alarm condition must be present
continuously for the trip time period before the alarm will trip. This function is useful for
preventing an alarm trip dueto short non critical deviations from setpoint. The trip time is
selectable over 0.0 to 999.9 seconds.
Axrt Alarm resettime -displaysand sets the alarm relayreset time.With the alarmcondition is
removed the alarm relay will stay in its alarm condition for the time selected as the reset
time. The reset time is selectable over 0.0 to 999.9 seconds.
Axn.o or
Axn.c Alarm x normally open or normally closed - displays and sets the setpoint alarm relay action to normally open (de-energised) or normally closed (energised), when no alarm
conditionispresent.A normallyclosedalarmisoftenusedtoprovideapowerfailurealarm
indication.
AxLtch Alarm x latching operation. If set to OFF the alarm relays will not latch i.e. they will
automatically reset when the display moves out of alarm condition. If set to on the relay
will latch and will not reset until either the remote input or Pbutton is used to clear the
latchconditionorifpowerisremoved.TheR.INP orP.but functionmustbesettoA.cIr
to clear the latch setting, see the R.INP function A.cIr function for a more detailed
description of the operation of this function.
Ifthe5digitdisplaywithalarmannunciatorLED'sis used thealarmannunciatorsoperates
in the following manner:
Light off - display not in alarm condition.
Lightflashingwith"on"timelongerthan"off"time-displayin alarmcondition,relaylatched
and latch not cleared.
Light flashing with "off" time longer than "on" time - display not in alarm condition, relay
latched and latch not cleared.
Light solidly on - display in alarm condition and latch cleared i.e. relay will now reset
automatically when the display value moves out of the alarm condition.
Page 9 of 34 PM4TCRMAN-1.7.0

Function Description
Ax.SP,
Ax.t1,
Ax.t2 etc.
Relay operation independent setpoint or trailing setpoint - each alarm may be
programmed to operate withan independent setpoint setting or may be linked (or trailing)
tooperateatafixeddifferencetoanotherrelaysetpoint.Theoperationisasfollows:Alarm
1(AI)isalwaysindependent.Alarm2(A2)maybeindependentormaybelinkedtoAlarm
1. Alarm 3 (A3) may be independentor may belinked toAlarm1 or Alarm2. Alarm 4 (A4)
may be independent or may be linked to Alarm 1, Alarm 2 or Alarm 3. The operation of
eachalarmisselectablewithintheFunctionSetupModebyselecting,forexample,(Alarm
4)A4.SP = Alarm4 normalsetpointor A4.t1 = Alarm4 trailing Alarm1orA4.t2 =Alarm
4 trailing Alarm 2 or A4.t3 = Alarm 4 trailing Alarm 3. For trailing set points the setpoint
value isenteredasthe difference from thesetpointbeingtrailed.Ifthetrailing setpointis to
operate ahead of the prime setpoint then the value is entered as a positive number and if
operating behind the prime setpoint then the value is entered as a negative number. For
example, with Alarm 2 set to trail alarm 1, if A1Hi isset to 1000 and A2Hi is set to 50
thenAlarm1 willactivateat1000and alarm 2willactivate at1050(i.e.1000+ 50).IfAlarm
2 had been set at -50 then alarm 2 would activate at 950 (i.e. 1000 - 50). See the trailing
alarm table which follows.
AxOPEr Alarm relay operating mode - this function allows selection of standard alarm on/off
setpointoperation(Ax.AL)usingthealarmfunctionsdescribedinthischapterorPIcontrol
operation (AxtP or Axfr). Refer to the "Setting up the relay PI controller" appendix for
details of the PI control operations and functions.
brgt Display brightness - displays and sets the digital display brightness. The display
brightness is selectable from 1 to 15, where 1 = lowest intensity and 15 = highest
intensity. This function is useful for improving the display readability in dark areas or to
reduce power consumption.
dULL Remote display brightness - displays and sets the level for remote input brightness
switching, see R.INP function. When the remote input is set to dULL the remote input
canbe usedto switch between the displaybrightnesslevel set by the brGt function and
the displaybrightnesssetby thedULL function.Thedisplaybrightnessisselectablefrom
0to 15, where 0= lowest intensity and 15 = highest intensity. This function is useful in
reducing glare when the display needs to be viewed in both light and dark ambient light
levels.
rEC_ Analog output low value - seen only when analog output option fitted. Refer to the
separate “PM4 Panel Meter Optional Output Addendum” booklet supplied when this
option is fitted. Displays and sets the analog retransmission (4-20mA, 0-1V or 0-10V, link
selectable)outputlowvalue(4mAor0V)indisplayedengineeringunits.e.g.ifitisrequired
to retransmit 4mA when the display indicates 0then select 0inthis function via the ^or
vbutton.
rEC~ Analog output high value - seen only when analog output option fitted. Refer to the
separate “PM4 Panel Meter Optional Output Addendum” booklet supplied when this
option is fitted. Displays and sets the analog retransmission (4-20mA, 0-1V or 0-10V, link
selectable) output high value(20mA, 1V or 10V) in displayed engineering units. e.g.if itis
required to retransmit 20mA when the display indicates 500 then select 500 in this
function via the ^or vbutton.
rEC_ Ch 2 Analog output 2 low value - seen only when dual analog output option fitted. See REC_
above for a description.
rEC~ Ch 2 Analog output 2 high value- seen only when dual analog output optionfitted. See REC~
above for a description.
The functions which follow are accessible via CAL mode only.
Page 10 of 34 PM4TCRMAN-1.7.0
Trailing Alarm Table
Showing Possible Alarm Assignments
A2 A3 A4
A1 A2.t1 A3.t1 a4.t1
A2 A3.t2 A4.t2
A3 a4.t3