Eurotherm 2416 Owner's manual

Model 2416
PID Controller
Installation and
Operation handbook
ENG

Installation and Operation Handbook Contents
2416 Controller Issue 10 May 06 Applies to software version 4.0 1
MODEL 2416 PID CONTROLLER
INSTALLATION AND OPERATION HANDBOOK
Contents Page
1Chapter 1 INSTALLATION ........................................................................... 1-1
1.1 MECHANICAL INSTALLATION.......................................................................... 1-2
1.1.1 Controller labels ............................................................................................. 1-2
1.1.2 Outline dimensions......................................................................................... 1-2
1.1.3 Panel cut-out and recommended minimum spacing of controllers.................. 1-3
1.1.4 To install the controller ................................................................................... 1-3
1.1.5 Unplugging and plugging-in the controller....................................................... 1-3
1.2 Electrical installation ........................................................................................ 1-4
1.2.1 Rear Terminal Layout..................................................................................... 1-4
1.2.2 Fixed connections .......................................................................................... 1-5
1.2.3 Plug-in module connections ........................................................................... 1-6
1.2.4 Communications module................................................................................ 1-7
1.2.5 Wiring of 2-wire EIA-485 serial communications link ...................................... 1-8
1.3 Typical wiring diagram ..................................................................................... 1-9
1.3.1 Logic Drive Fan Out ..................................................................................... 1-10
1.4 otorised valve connections ............................................................................ 1-11
2Chapter 2 OPERATION ................................................................................ 2-1
2.1 FRONT PANEL LAYOUT ................................................................................... 2-2
2.2 basic operation ................................................................................................. 2-4
2.2.1 Alarms............................................................................................................ 2-4
2.3 Operating modes .............................................................................................. 2-5
2.3.1 Automatic mode ............................................................................................. 2-6
2.3.2 Manual mode ................................................................................................. 2-7
2.4 Parameters and how to access them .............................................................. 2-8
2.4.1 List header displays ....................................................................................... 2-8
2.4.2 Parameter names........................................................................................... 2-9
2.4.3 Parameter displays ........................................................................................ 2-9
2.4.4 To change the value of a parameter............................................................... 2-9
2.5 Navigation Diagram (Part A)........................................................................... 2-10
2.6 PArameter tables............................................................................................. 2-12
2.7 Alarms.............................................................................................................. 2-16
2.7.1 Alarm annunciation ...................................................................................... 2-16
2.7.2 Alarm acknowledgement and resetting......................................................... 2-16
2.7.3 Alarm modes................................................................................................ 2-16
2.7.4 Alarm types .................................................................................................. 2-16
2.7.5 Process alarms ............................................................................................ 2-16
2.8 Diagnostic alarms ........................................................................................... 2-17
3Chapter 3 ACCESS LEVELS........................................................................ 3-1
3.1 Edit level............................................................................................................ 3-4
4Chapter 4 TUNING........................................................................................ 4-1
4.1 WHAT IS TUNING? ............................................................................................ 4-1
4.2 AUTOMATIC TUNING ........................................................................................ 4-2
4.2.1 Typical automatic tuning cycle ....................................................................... 4-3
4.3 MANUAL TUNING .............................................................................................. 4-4
4.3.1 Setting the cutback values ............................................................................. 4-5
4.3.2 Integral action and manual reset .................................................................... 4-6
4.3.3 Automatic droop compensation (Adc) ............................................................ 4-6

Contents Installation and Operation Handbook
2 2416 Controller Issue 10 May 06 Applies to software version 4.0
4.3.4 Tune Error...................................................................................................... 4-6
4.4 motorised valve control.................................................................................... 4-7
4.5 Commissioning the Motorised Valve Controller............................................. 4-8
4.5.1 Adjusting the minimum on-time ‘mp.t’ ............................................................ 4-8
4.5.2 Inertia and backlash settings .......................................................................... 4-8
4.6 Gain scheduling ................................................................................................ 4-9
5Chapter 5 PROGRAMMER OPERATION..................................................... 5-1
6Chapter 6 CONFIGURATION .......................................................................... 1
6.1 Selecting configuration level .............................................................................. 2
6.1.1 Password entry ................................................................................................. 2
6.2 Selecting a configuration parameter .................................................................. 3
6.2.1 Parameter names.............................................................................................. 3
6.3 Changing the passwords..................................................................................... 3
6.4 Leaving configuration level................................................................................. 3
6.5 navigation diagram (PART A).............................................................................. 4
6.6 confIGURATION PARAMETER TABLEs .............................................................. 6
7Chapter 7 User Calibration.......................................................................... 7-1
7.1 WHAT IS the purpose of User calibration? ..................................................... 7-1
7.2 User Calibration Enable.................................................................................... 7-2
7.3 offset calibration ............................................................................................... 7-3
7.4 Two-point calibration........................................................................................ 7-5
7.5 Calibration points and Calibration offsets ...................................................... 7-8
8Chapter 8 LOAD CURRENT MONITORING AND DIAGNOSTICS ............. 8-1
8.1 Example Wiring Diagram (For mode 1 & 2 operation).................................... 8-2
8.2 Operation........................................................................................................... 8-3
8.2.1 To Read Load Current (mode 2 only) ............................................................. 8-3
8.2.2 To Display Load Current Continuously in the Lower Readout (mode 2 only) .. 8-3
8.2.3 Display Modes................................................................................................ 8-3
8.2.4 How Heater Alarms Are Displayed ................................................................. 8-4
8.3 To Set The Alarm Trip Levels ........................................................................... 8-5
8.4 Short Circuit SSR Alarm and Heater Fail Alarm.............................................. 8-5
8.5 relay outputs...................................................................................................... 8-5
8.6 TO CONFIGURE PDS LOAD CURRENT DIAGNOSTICS .................................. 8-6
8.7 To configure the Logic Module for PDS modes 1 or 2 ................................... 8-6
8.8 To Configure Low and High Current Trip Alarms ........................................... 8-8
8.9 To Attach Soft Alarms To A Relay Output ....................................................... 8-9
8.10 the scaling factor ............................................................................................ 8-10
8.10.1 To Adjust the Scaling Factor ................................................................... 8-10
Appendix A UNDERSTANDING THE ORDERING CODE ...................A-1
Appendix B SAFETY and EMC INFORMATION ..................................B-1
Appendix C TECHNICAL SPECIFICATION..........................................C-1
Appendix D RoHS STATEMENT ..........................................................D-1
“This product is covered by one or more of the following US Patents:
5,484,206; Additional patents pending.
PDSIO and INSTANT ACCURACY are trademarks of Eurotherm.”

Installation and Operation Handbook Installation
2416 Controller 1-1
1Chapter 1 INSTALLATION
The 2416 controller is a versatile, high stability temperature or process controller, with self
and adaptive tuning, in 1/16 DIN size (48 x 48mm). It has a modular hardware construction,
which accepts up to three plug-in output modules and one communications module, to satisfy
a wide range of control requirements. All 2416 controllers have a basic 8-segment
programmer built-in as standard.
The 2416 is available as either a:
•standard controller: Model 2416/CC
•setpoint programming controller: Models 2416/CP and 2416/P4
•motorised valve controller: Model 2416/VC
•setpoint programming motorised valve controller: Models 2416/VP and 2416/V4
This chapter consists of two parts:
•MECHANICAL INSTALLATION
•ELECTRICAL INSTALLATION.
Before proceeding, please read the chapter called, Safety and EMC Information.
Figure 1-1 2416 1/16 DIN controller
Panel retaining clips
Ratchets
Sleeve
Terminal covers
Label
Latching ears Panel sealing gasket
Display screen

Installation Installation and Operation Handboo
k
1-2 2416 Controller
WARNING
You must ensure that the controller is correctly configured for your application.
Incorrect configuration could result in damage to the process being controlled, and/or
personal injury. It is your responsibility as the installer to ensure that the configuration
is correct. The controller may either have been configured when ordered, or may need
configuring now. See Chapter 6, Configuration.
1.1 MECHANICAL INSTALLATION
1.1.1 Controller labels
The labels on the sides of the controller identify the ordering code, the serial number, and the
wiring connections.
Appendix A, Understanding the Ordering Code explains the hardware and software
configuration of your particular controller.
1.1.2 Outline dimensions
AUTO RUN
HOLD
2416
MAN
OP1
OP2
SP2
REM
Figure 1-2 Outline dimensions
The electronic assembly of the controller plugs into a rigid plastic sleeve, which in turn fits
into the standard DIN size panel cut-out shown in Figure 1-3.
48mm 150mm
1.89in 5.91in
48mm
1.89in
IP65, NEMA 4X sealing gasket
OP1
OP2
SP2
REM
2416
200.0
200.0

Installation and Operation Handbook Installation
2416 Controller 1-3
1.1.3 Panel cut-out and recommended minimum spacing of controllers
Figure 1-3 Panel cut-outs and minimum spacing
1.1.4 To install the controller
1. Prepare the control panel cut-out to the size shown in Figure 1-3.
2. Insert the controller through the panel cut-out.
3. Spring the upper and lower panel retaining clips into place. Secure the controller in
position by holding it level and pushing both retaining clips forward.
4. Peel off the plastic film protecting the front of the indicator.
Note: If the panel retaining clips subsequently need removing, in order to extract the
controller from the control panel, they can be unhooked from the side with either your fingers
or a screwdriver.
1.1.5 Unplugging and plugging-in the controller
If required, the controller can be unplugged from its sleeve by easing the latching ears
outwards and pulling it forward out of the sleeve. When plugging the controller back into its
sleeve, ensure that the latching ears click into place in order to secure the IP65 sealing.
38mm (1.5in)10mm (0.4in)
Panel cut-out
45 x 45mm
1.77 x 1.77in
-0
+0.6
-0
+0.02

Installation Installation and Operation Handboo
k
1-4 2416 Controller
1.2 ELECTRICAL INSTALLATION
This section consists of five topics:
•Rear terminal layout
•Fixed connections
•Plug-in module connections
•Typical wiring diagram
•Motorised valve connections
All electrical connections are made to the screw terminals at the rear of the controller. These
screw terminals accept wire sizes from 0.5 to 2.5mm2(14 to 22 awg) and should be tightened
to a torque of 0.4 Nm (3.5 lb in). If you wish to use crimp connectors, we recommend AMP
part number 16500. These accept wire sizes from 0.5 to 1.5 mm2(16 to 22 AWG).
1.2.1 Rear Terminal Layout
Terminals are arranged in three columns at the rear of the controller. Each column is
protected by a clear plastic hinged cover to prevent hands or metal making accidental contact
with live wires. Viewed from the rear and with the controller upright, the right-hand column
carries the connections for the power supply and sensor input. The other two columns carry
the connections to the plug-in modules. The connections depend upon the type of module
installed, if any. To discover which plug-in modules are installed in your controller, please
refer to the ordering code and wiring data on the labels on the sides of the controller.
The rear terminal layout is shown below.
Note: The plug-in sleeve supplied with high voltage controllers are keyed to prevent a low
voltage unit being inserted into them.
Figure 1-4 Rear terminal layout
*The ground connection is provided as a return for internal EMC filters. It is not required for
safety purposes, but must be connected in order to satisfy EMC requirements.
+
PV
−
RTD/
Pt100
N
L
2B
1B
1A
3B
2A
3A
Line
Neutral
Ground*
+
−
T/C
VI
HD
M
O
D
U
L
E
3
V+
HE
V−
HF
H
A
HB
HC
C
O
M
M
S
M
O
D
U
L
E
2
M
O
D
U
L
E
1
85 to 264Vac
20 −29Vac/dc
Ground*
24
24
Low voltage supply

Installation and Operation Handbook Installation
2416 Controller 1-5
1.2.2 Fixed connections
The power supply and sensor inputs are always wired to the same fixed positions whatever
plug-in modules are installed.
1.2.2.1 Power supply connections
These are as shown in Figure 1-4.
1.2.2.2 Sensor input connections
The diagrams below show the connections for the various types of input.
The input will have been configured in accordance with the ordering code.
Fig 1-5 Sensor input connections
VI
V+
V-
VI
V+
V-
VI
V+
V-
VI
V+
V-
Thermocouple Resistance
thermometer mA input Volts or mV inputs
+
-
PV
2.49Ω
current
sense
resistor

Installation Installation and Operation Handboo
k
1-6 2416 Controller
1.2.3 Plug-in module connections
In Figure 1-4, Modules 1, 2 and 3, and Comms are plug-in modules.
1.2.3.1 Modules 1, 2 and 3
Module positions 1, 2 and 3 each have two terminals. They will accept four types of module:
Relay, Logic (non-isolated), Triac, and DC (non-isolated) output.
Collectively, these can be configured to operate in six different ways:
Heating control
Cooling control
Alarm output
Program event output
PDS mode 1*, which provides logic heating using a Eurotherm TE10S solid state relay
with feedback of a load failure alarm.
PDSIO mode 2*, which provides logic heating using a Eurotherm TE10S solid state relay,
with feedback of the load current reading and two alarms: solid state relay failure and
heater circuit failure.
*PDS stands for ‘Pulse Density Signalling Input/Output’. This is a proprietary technique
developed by Eurotherm for bi-directional transmission of analogue and digital data over a
simple 2-wire connection.
Snubbers
The relay and triac modules have an internal 15nF/100Ω‘snubber’ connected across their
output, which is used to prolong contact life and to suppress interference when switching
inductive loads, such as mechanical contactors and solenoid valves.
WARNING
When the relay contact is open or the triac is off, the snubber circuit passes 0.6mA at
110Vac and 1.2mA at 240Vac. You must ensure that this current, passing through the
snubber, will not hold on low power electrical loads. It is your responsibility as the
installer to ensure that this does not happen. If the snubber circuit is not required, it can
be removed from the relay module (but not the triac) by breaking the PCB track that
runs crosswise adjacent to the edge connectors of the module. Insert the blade of a
screwdriver into one of the two slots that bound it, and twist.
The table below shows the module connections and which functions each module can
perform. The heating output is normally connected to module 1, the cooling output to
module 2 and the alarm output to module 3, although the actual function of each module will
depend upon how your controller has been configured.
Note: Module 1 is connected to terminals 1A and 1B
Module 2 is connected to terminals 2A and 2B
Module 3 is connected to terminals 3A and 3B.

Installation and Operation Handbook Installation
2416 Controller 1-7
Module type Terminal identity Possible functions
A B
Relay: 2-pin
(2A, 264 Vac max.)
Heating, Cooling, or Alarm output
Program event output
Valve raise or lower
Logic: non-isolated
(18Vdc at 20mA)
+ −Heating, Cooling, or Alarm output
PDSIO mode 1,
PDSIO mode 2,
Program event
Triac
(1A, 30 to 264Vac)
Heating, Cooling,
Program event
Valve raise or lower
DC control: non-isolated
(10Vdc, 20mA max.)
+−Heating, Cooling.
Retransmission of PV, setpoint or
control output
Table 1-1 Module 1, 2 and 3 connections
To check which modules are installed in your particular controller, and which functions they
are configured to perform, refer to the ordering code and the wiring information on the
controller side labels.
1.2.4 Communications module
The Communications module position will accept any of the modules listed in Table 1-2
below.
The serial communications can be configured for either Modbus, or EI bisynch protocol.
Communications module Terminal identity (COMMS)
Module type HA HB HC HD HE HF
2-wire EIA-485 serial
communications
−−−Common A (+) B (−)
EIA-232 serial
communications
−−−Common Rx Tx
4-wire EIA-485 serial
communications
−A′
(Rx+)
B′
(Rx−) Common A
(Tx+)
B
(Tx−)
PDSIO Setpoint
retransmission
−−−−Signal Common
PDSIO remote setpoint input -- -- -- -- Signal Common
Table 1-2 Communications connections
Line Load

Installation Installation and Operation Handboo
k
1-8 2416 Controller
1.2.5 Wiring of 2-wire EIA-485 serial communications link
Com
Note:
All resistors are 220 ohm 1/4W carbon composition.
Local grounds are at equipotential. Where equipotential is not available wire into
separate zones using a galvanic isolator.
Use a repeater (KD845) for more than 32 units.
A
B
PC
Eurotherm Universal
Communications Interface
KD485
RXTX
Com
Com TXRX
Up to 32 S2000 controllers or
Interface Units may
be included on the network
232
Com B A
Com
A
B
Com
A
B
Com
A
B
Local Earth
Local
Ground
Zone 1
Local
Ground
Zone 2
Area 1 Com
A
B
E
F
D
Local
Earth
HE
HF
HD
Series 2000
Controller
HE
HF
HD
Series 2000
Controller
For reasons of safety
do not connect to
local earth here.
Local
Earth
Local
Earth
Local
Earth
Local
Earth
Local
Earth
HE
HF
HD
Series 2000
Controller
Galvanic
Isolation
Barrier
Local
Ground
Zone 1
Local
Ground
Zone 1
Local
Ground
Zone 1
Figure 1-6 EIA-485 wiring
2-wire EIA-485 is a connection which allows up to 32
controllers to be multi-dropped from a single communications
link over a distance of up to 1.2Km. To ensure reliable
operation of the communications link, (without data
corruption due to noise or line reflections) the connections
between the controller should be made using a twisted pair of
wires inside a screened cable with the connections
terminated with resistors in the manner shown in this
diagram. This diagram also shows the use of a Eurotherm
KD485 converter to connect the EIA-485 link into a standard
EIA-232 computer port.

Installation and Operation Handbook Installation
2416 Controller 1-9
1.3 TYPICAL WIRING DIAGRAM
Fig 1-7 Typical wiring diagram, Model 2416 Controller
Safety requirements for permanently connected equipment state:
•A switch or circuit breaker shall be included in the building installation
•It shall be in close proximity to the equipment and within easy reach of the operator
•It shall be marked as the disconnecting device for the equipment.
Note: a single switch or circuit breaker can drive more than one instrument.
For logic drive capability see following chart:-
Comms
Neutral
Heating
power fuse
(load
dependent)
Line
Thermocouple
Cooling Power
Fuse 1A(T)
Controller
Fuse 2A(T)
Solid State
Relay
e.g. TE10
+
-
Snubber
Heater
JA
JF
B
HA
HB
HC
HD
HE
HF
1A
1B
2A
2B
3A
3B
L
N
V1
V+
V-
Cooling
solenoid
valve
Circuit
breaker

Installation Installation and Operation Handboo
k
1-10 2416 Controller
1.3.1 Logic Drive Fan Out
The logic outputs from the 2400 series controllers are capable of driving more than one solid
state relay (SSR) in series or parallel. The following table shows the number of SSRs which
can be driven depending on type of SSR. S = Series; P = Parallel.
Drive
mA
SVDA RVDA TE10S 425S
Logic
DC
Logic
DC
Logic
DC
Logic
10V
Logic
24V
Logic
20mA
Logic 18V@2
0
4S6P 4S3P 3S2P 3S3P 1S2P 6S1P
Triple
logic
12V@9 3S3P 2S1P 2S1P 2S1P 1 4S1P
450 TC1027
CE
TE200S TC2000
CE
RS3D
A
Standard TTL Multi-
drive
Logic V Logic
DC
Logic
DC
Logic
DC
Logic 2S3P 1S2P 6S1P 3S3P 3S3P 3S1P 4S2P
Triple
logic
1 1 4S1P 2S1P 2S1P 0 0

Installation and Operation Handbook Installation
2416 Controller 1-11
1.4 MOTORISED VALVE CONNECTIONS
Motorised valves are wired to relay, or triac, outputs installed in module positions 1 and 2.
The convention is to configure Output 1 as the RAISE output and Output 2 as the LOWER
output. The controller does not require a position feedback potentiometer.
Fig 1-8 Motorised valve connections
RTD/
Pt100
Line
Neutral
Ground
+
−
+
PV
−
Motor supply
LOWER
RAISE
Motorised
valve
T/C
Comms
JA
JF
BA
HA
HB
HC
HD
HE
HF
1A
1B
2A
2B
3A
3B
L
N
V1
V+
V-

Installation Installation and Operation Handboo
k
1-12 2416 Controller

Installation and Operation Handbook Operation
2416 Controller 2-1
2Chapter 2 OPERATION
This chapter has nine topics:
•FRONT PANEL LAYOUT
•BASIC OPERATION
•OPERATING MODES
•AUTOMATIC MODE
•MANUAL MODE
•PARAMETERS AND HOW TO ACCESS THEM
•NAVIGATION DIAGRAM
•PARAMETER TABLES
•ALARM MESSAGES

Operation Installation and Operation Handbook
2-2 2416 Controller
2.1 FRONT PANEL LAYOUT
AUTO RUN
HOLD
2416
MAN
OP1
OP2
SP2
REM
Figure 2-1 Front panel layout
Remote setpoint active
(flashes for comms)
Output 2 on
Output 1 on
Setpoint 2 active
A
uto/Man button
A
uto mode active
Upper readout
Lower readout
Manual mode active
Program running
Run/Hold button
(Press & hold to reset)
Program in Hold
Page
Button
Scroll
Button
Down
Button
Up
Button
2416
REM
OP1
SP2
OP2

Installation and Operation Handbook Operation
2416 Controller 2-3
Button or
indicator
Name Explanation
OP1
Output
1
If a DC
output is
installed
When lit, it indicates that the output installed in
module position 1 is on. This is normally the heating
output on a temperature controller.
OP2
Output
2
OP1 &
OP2 will
not light
When lit, it indicates that the output installed in
module position 2 is on. This is normally the cooling
output on a temperature controller.
SP2 Setpoint 2 When lit, this indicates that setpoint 2, (or a setpoint
3-16) has been selected.
REM Remote setpoint When lit, this indicates that a remote setpoint input
has been selected.
‘REM’ will also flash when communications is active.
AUTO
MAN
Auto/Manual
button
When pressed, this toggles between automatic and
manual mode:
• If the controller is in automatic mode the AUTO
light will be lit.
• If the controller is in manual mode, the MAN light
will be lit.
The Auto/Manual button can be disabled in
configuration level.
RUN
HOLD
Run/Hold button
• Press once to start a program (RUN light on.)
• Press again to hold a program (HOLD light on)
• Press again to cancel hold and continue running
(HOLD light off and RUN light ON)
• Press and hold in for two seconds to reset a
program (RUN and HOLD lights off)
The RUN light will flash at the end of a program.
The HOLD light will flash during holdback or when a
PDS retransmission output is open circuit.
Page button Press to select a new list of parameters.
Scroll button Press to select a new parameter in a list.
Down button Press to decrease a value in the lower readout.
Up button Press to increase a value in lower readout.
Figure 2-2 Controller buttons and indicators

Operation Installation and Operation Handbook
2-4 2416 Controller
2.2 BASIC OPERATION
Switch on the power to the controller. It runs through a self-test sequence for about three
seconds and then shows the temperature, or process value, in the upper readout and the
setpoint in the lower readout. This is called the Home display. It is the one that you will use
most often.
Figure 2-3 Home display
On this display you can adjust the setpoint by pressing the or buttons. Two
seconds after releasing either button, the display blinks to show that the controller has
accepted the new value.
Note: You can get back to the Home display at any time by pressing and together.
Alternatively you will always be returned to the Home display if no button is pressed for 45
seconds, or whenever the power is turned on. If, however, a flashing alarm message is present
the controller reverts to the Home display after 10 seconds.
2.2.1 Alarms
If the controller detects an alarm condition, it flashes an alarm message in the Home display.
For a list of all the alarm messages, their meaning and what to do about them, see Alarms at
the end of this chapter.
Measured temperature,
or process value
Setpoint
26.0
20.0