Eurotherm 2604 Owner's manual

Installation and operation
handbook
2604
CONTROLLER
ENG

2604 Controller Contents
User Guide Part No HA026491 Issue 3.0 Apr-02 a-1
MODEL 2604 CONTROLLER
USER GUIDE
Contents Page
Chapter 1 INTRODUCTION 1-1
Chapter 2 INSTALLATION 2-1
Chapter 3 OPERATION 3-1
Chapter 4 PROGRAMMER OPERATION 4-1
Chapter 5 ALARM OPERATION 5-1
Appendix A ORDER CODE A-1
Appendix B SAFETY AND EMC INFORMATION B-1
Appendix C TECHNICAL SPECIFICATION C-1

Contents 2604 Controller
a-2 User Guide Part No HA026491 Issue 3.0 Apr-02
Issue Status of this Manual
Section Issue
Contents 3.0
Chapter 1 3.0
Chapter 2 3.0
Chapter 3 3.0
Chapter 4 3.0
Chapter5 3.0
Appendix A 3.0
Appendix B 3.0
Appendix C 3.0
Notes
1. Section are up-dated independently and so may be at different issues
2. The Contents section and the manual as a whole always take the issue number of the
most recently up-dated section
3. This issue applies to software version 5.1

2604 Controller Introduction
User Guide Part No HA026491 Issue 3.0 Apr-02 1-1
1. Chapter 1 INTRODUCTION ......................................2
1.1. WHAT IS 2604.........................................................................................2
1.2. BEFORE YOU BEGIN...........................................................................3
1.2.1. Unpacking.............................................................................................3
1.2.2. Contents of Packaging...........................................................................3
1.2.3. Does the Controller Match the Process? ...............................................3
1.3. OPERATOR INTERFACE - OVERVIEW ..........................................5
1.3.1. LED Status Indicators ...........................................................................6
1.3.2. Operator Buttons...................................................................................7
1.4. INSTALLATION - OVERVIEW...........................................................8
1.5. I/O MODULES........................................................................................9

Introduction 2604 Controller
1-2 User Guide Part No HA026491 Issue 3.0 Apr-02
1. Chapter 1 INTRODUCTION
Thank you for selecting the 2604 High Performance Programmer/Controller.
This controller can be supplied or can be fully configured to be process specific.
It is important to note, therefore, that the actual displays shown in this guide
may not be identical to those shown on your controller.
This guide, therefore, is intended to describe the principle of operation and
installation of the controller, and is intended as a ‘Getting Started Guide’.
A detailed Engineering Handbook is also available, part no. HA026761, for those wishing to
configure and commission the controller.
1.1. WHAT IS 2604
The 2604 is a modular, fully configurable, high
accuracy, high stability temperature and process
controller which is available in a single, dual or
three loop format.
It is supplied in accordance with an ordering code
which can be found printed on a label on the side of
the instrument case. A description of the order
code is given in Appendix A of this guide and
should be checked with that shown on the label.
It has a dual 7-segment display of process value and
setpoint with a LCD panel for display of
information and user defined messages.. The user
interface is menu driven via the display and seven
front panel keys.
Figure 1-1: General View of 2704 Controller
Features include:
•Advanced ramp/dwell programmer with storage of up to 50 programs.
•Application specific controllers such as Carbon Potential, Humidity and Melt Pressure
•A wide variety of inputs which can be configured, including thermocouples, Pt100
resistance thermometers and high level process inputs.
•Each loop can be defined to be PID, On/Off or motorised valve position and can control
using a variety of strategies including single, cascade, override and ratio control.
•PID control outputs can be relay, logic, triac or dc with motorised valve position outputs
being relay triac or logic.
•Auto tuning and PID gain scheduling are available to simplify commissioning and
optimise the process
L

2604 Controller Introduction
User Guide Part No HA026491 Issue 3.0 Apr-02 1-3
1.2. BEFORE YOU BEGIN
1.2.1. Unpacking
The packaging is designed to withstand reasonable transit shocks. It is suggested that each
item is unpacked carefully and the contents inspected for damage.
If there is evidence of shipping damage, please notify your supplier within 72 hours. The
packaging should be retained for inspection.
All packaging contains anti-static materials to prevent the build up of static which can damage
electronic assemblies.
1.2.2. Contents of Packaging
Each box contains the following parts:-
1. The 2604 controller fitted into its corresponding sleeve. Labels on the sleeve identify the
controller code, its serial number, and the customer reference number. These details
should be checked against your requirements before installing the unit into the panel.
2. Two panel retaining clips
3. Burden resistors for use with mA inputs
4. This User Guide
Please refer to Figure 1-2 showing a general view of the controller.
1.2.3. Does the Controller Match the Process?
Every controller is supplied with a specific hardware configuration to match the process which
it is designed to control. For example, there are five ‘slots’ which can contain different plug
in modules. These are defined by a hardware code as shown in Appendix A. Before installing
the 2604 controller check the label on the side of the instrument against the instrument coding
given in Appendix A for correct type.
Where possible the controller is supplied with its software configured to match the process.
This is defined by a quick start order code given in Appendix A. This should also be checked
on the instrument label to ensure that the controller is suitable for the process to be controlled.

Introduction 2604 Controller
1-4 User Guide Part No HA026491 Issue 3.0 Apr-02
Figure 1-2: General View of 2604 Controller

ó
ø
í
ö
ú
÷
ì
í
ó
ö
KEY
Display screen
óLatching ears
ìPanel sealing gasket
öPanel retaining clips
úLabel
÷Sleeve
øTerminal covers
íRatchets

2604 Controller Introduction
User Guide Part No HA026491 Issue 3.0 Apr-02 1-5
1.3. OPERATOR INTERFACE - OVERVIEW
The front panel of the 2604 consists of two 5 digit numeric displays, one alpha numeric LCD
panel for display of messages and other information, eight LED staus indicators and seven
operator push-buttons. See Figure 1-3 below.
•The display is used to show the process conditions.
•The seven operator buttons allow adjustments to be made to the controller.
Figure 1-3: Operator Interface
Upper Display
(usually indicates
Process Variable
)
Middle Display
(usually indicates
Setpoint
)
Lower Alpha/Numeric
LCD Display (usually
indicates messages)
Alarm Beacon
Standby Mode
LED status
indicators (see
fi
g
ure 1–4
)
Operator buttons

Introduction 2604 Controller
1-6 User Guide Part No HA026491 Issue 3.0 Apr-02
1.3.1. LED Status Indicators
Indicator Function
AUTO The selected loop is in automatic (closed loop) control
MAN The selected loop is in manual (open loop) control
LP1
LP2 Indicates which control loop is selected
LP3
AUX Indicates that the selected loop has a second control function.
For example, if a loop is configured as cascade, ratio or override then
a second press of the loop button will cause the AUX indicator to
illuminate together with the loop indicator.
RUN Indicates a program is activated
HOLD Indicates a program is held at its current levels
ALARM BEACON This is a red LED which will flash when any new alarm occurs. It will
be accompanied by a message displayed on the lower readout. The
beacon will be permanently lit when an alarm is acknowledged but is
still present. See Chapter 7 ‘Alarm Operation’ for further details.
STANDBY
BEACON This is a green LED which will be lit when the controller is in Standby mode. When the controller is in standby mode all interfaces to the
plant are switched to a rest condition. For example, all control outputs
= 0.
When this beacon is lit the controller is no longer controlling the
process.
This beacon will be lit when:-
•The controller is in configuration mode
•Standby mode has been selected through the user interface or via
an external digital input
•During the first few seconds after start up
Table 1-1: Status Messages
LP1
LP2
LP1
AUX
AUTO
MAN
RUN
HOLD

2604 Controller Introduction
User Guide Part No HA026491 Issue 3.0 Apr-02 1-7
1.3.2. Operator Buttons
Auto/Manual
button
The Auto/Manual button only operates from
the loop view. 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.
Loop select
button
Repeat pressing to select:-
Loop1
4
Loop2
4
Loop 3
4
Back to Loop1
If any one loop is cascade, ratio or override the
AUX indicator will illuminate as well as the
loop indicator
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.
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 parameter value.
Up button Press to increase a parameter value.
Figure 1-4: Operator Buttons
AUTO
MAN
RUN
HOLD
LP1
LP2
LP1
AUX
LP1
LP2
LP1
AUX
AUTO
MAN
RUN
HOLD

Introduction 2604 Controller
1-8 User Guide Part No HA026491 Issue 3.0 Apr-02
1.4. INSTALLATION - OVERVIEW
The 2604 controller must be mounted and wired in accordance with the instructions given in
Chapter 2.
The controller is intended to be mounted through a cut out in the front panel of an electrical
control cabinet. It is retained in position using the panel mounting clips supplied.
All wires are connected to terminals at the rear of the instrument. Each block of six terminals
is protected by a hinged cover which clicks into closed position.
Figure 1-5: Rear Terminals
Hinged
cover in
open
position
N
L
BB
BA
BC
2D
2B
2A
2C
1D
1B
1A
1C
M
O
D
U
L
E
1
M
O
D
U
L
E
3
HF
HD
HE
JF
JD
JE
D8
E2
E1
AC
AA
AB
HB
HA
HC
JB
JA
JC
D5
D4
D3
D1
DC
D2
D7
D6
V-
VI
VH
V+
M
O
D
U
L
E
4
M
O
D
U
L
E
5
M
O
D
U
L
E
6
Power
Supply
Digital
Input
Relay
Analogue
input
0-10V
6D
6C
6B
6A
5D
5C
5B
5A
4D
4C
4B
4A
PV
input
I/O
Expander
or Digital
input
Digital
I/O
3B
3A
3C
3D
C
O
M
M
S
M
O
D
U
L
E
H
C
O
M
M
S
M
O
D
U
L
E
JAnalogue
input
screen
The functionality of the two outer rows of terminals is
common to all instrument variants, as follows:-
PV input VH, VI, V+, V-
Analogue input BA, BB
I/O expander E1, E2
Fixed changeover relay AA, AB, AC
Digital I/O channels D1 to D8 and DC
Power supply L, N, Earth
* Terminals 2A, 2B, 2C, 2D must not be wired to.
*
*
*
*

2604 Controller Introduction
User Guide Part No HA026491 Issue 3.0 Apr-02 1-9
1.5. I/O MODULES
The 2604 controller has the facility to fit optional plug in modules. The connections for these
modules are made to the inner three connector blocks as shown in Figure 1-6
The modules are:
•Communications modules See also section 2.4
•I/O modules See also section 2.4
These modules are fitted simply by sliding them into the relevant position as shown below.
Figure 1-6: View of the Plug-in Modules

Introduction 2604 Controller
1-10 User Guide Part No HA026491 Issue 3.0 Apr-02

2604 Controller Installation
User Guide Part No HA026491 Issue 3.0 Apr-02 2-1
2. CHAPTER 2 INSTALLATION....................................2
2.1. MECHANICAL INSTALLATION........................................................2
2.1.1. Positioning ............................................................................................2
2.1.2. Outline dimensions Model 2604 ...........................................................2
2.1.3. Mounting the Controller........................................................................3
2.1.4. Unplugging and Plugging in the Controller...........................................3
2.2. WIRING...................................................................................................4
2.2.1. Electrical Connections...........................................................................4
2.2.2. Rear Terminal Layout ...........................................................................4
2.3. STANDARD CONNECTIONS ..............................................................6
2.3.1. Power Supply Wiring............................................................................6
2.3.2. Relay Output .........................................................................................7
2.3.3. Sensor Input Connections......................................................................8
2.3.4. Analogue Input Connections.................................................................9
2.3.5. I/O Expander (or Additional Digital Input).........................................10
2.3.6. Digital I/O...........................................................................................11
2.4. OPTIONAL PLUG IN MODULE CONNECTIONS.........................12
2.4.1. Digital Communications Connections.................................................12
2.4.2. Devicenet Wiring................................................................................14
2.4.3. Master/Slave Communications............................................................16
2.4.4. I/O Modules ........................................................................................18
2.5. TO CONNECT ZIRCONIA (DUAL SIGNAL) PROBE....................24
2.5.1. Zirconia Probe Screening....................................................................25

Installation 2604 Controller
2-2 User Guide Part No HA026491 Issue 3.0 Apr-02
2. Chapter 2 INSTALLATION
2.1. MECHANICAL INSTALLATION
2.1.1. Positioning
The controller can be mounted vertically or on a sloping panel of maximum thickness 15mm
(0.6in). Adequate access space must be available at the rear of the instrument panel for wiring
and servicing purposes. The outline dimensions are shown in figure 2-1.
Take care not to cover ventilation holes in the top, bottom and sides of the instrument.
Before proceeding please read Appendix B ‘Safety and EMC Information’.
2.1.2. Outline dimensions Model 2604
Figure 2-1: Outline Dimensions
Front
Panel
Height
96mm
(3.78in)
Overall depth behind
panel 150mm
(5.91in)
Front panel
width 96mm
(3.78in)
Panel thickness up
to 12mm, 0.5in.

2604 Controller Installation
User Guide Part No HA026491 Issue 3.0 Apr-02 2-3
2.1.3. Mounting the Controller
1. Prepare the panel cut-out to the size shown in Figure 2-2. Ensure that there is sufficient
spacing between instruments as shown by the minimum dimensions given in Figure 2-2.
Ensure also that the controller is not mounted close to any device which is likely to
produce a significant amount of heat which may affect the performance of the controller.
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.
Note:- If the 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.
Figure 2-2: Panel Cut-out and Minimum Spacing Requirements
2.1.4. Unplugging and Plugging in the Controller
If required, the controller can be unplugged from its sleeve by easing the latching ears
outwards and pulling the controller forward out of the sleeve. When plugging the controller
back into its sleeve, ensure that the latching ears click into place.
It is recommended that the power to the controller is switched off when un-plugging or
plugging the controller into its sleeve. This is to prevent premature wear on the controller
connectors when current is flowing through them.
Panel cut-out
92 x 92 mm
3.62 x 3.62 in
-0
+0.8
-0
+0.03
Recommended
minimum
spacing of
controllers 38mm
(1.5in)
10mm
(0.4in)
(Not to
scale
)

Installation 2604 Controller
2-4 User Guide Part No HA026491 Issue 3.0 Apr-02
2.2. WIRING
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 2604
Engineering Manual Part Number HA026761 for details.
Before proceeding further, please read Appendix B, Safety and EMC information.
2.2.1. Electrical Connections
All electrical connections are made to the screw terminals at the rear of the controller. They
accept wire sizes from 0.5 to 1.5 mm2(16 to 22 AWG) and should be tightened to a torque of
0.4Nm (3.5lbin). If you wish to use crimp connectors, the correct size is AMP part number
349262-1. The terminals are protected by a clear plastic hinged cover to prevent hands, or
metal, making accidental contact with live wires.
2.2.2. Rear Terminal Layout
The rear terminal layout is shown in Figure 2-3, which identifies terminal designations and
their functions. Refer to the individual diagrams to wire the controller to your requirements.
The two outer terminal strips have fixed hardware for all versions of the instrument, as
follows:-
•A Process Variable input which can be configured for:-
•Thermocouple, RTD, Pyrometer, Voltage (e.g. 0-10Vdc) or Milliamp (e.g. 4-
20mA) plus vacuum – log10
•Seven Digital I/O, configurable as input or output
•Inputs are logic (-1 to 35Vdc) or contact closure, and can be configured for:-
Manual, Remote, Run, Hold, Reset, etc,
•Outputs are open collector requiring an external power supply, and can be
configured as event, status time proportioning or valve position outputs.
•One digital input
•An I/O expander which allows additional digital I/O via an external unit, or an extra
digital input
•A changeover relay which can be configured as an alarm or event output. It cannot be
configured as a time proportioning output
•An analogue input for volts (e.g. 0-10Vdc) or Milliamp (e.g. 4-20mA) signals to a second
PID loop, setpoint, etc,. (This input can be characterised to match a particular curve from
a transmitter. It cannot accept thermocouple inputs directly)
•Power supply to the unit. The supply may be 85 - 264Vac 50 or 60 Hz,
!

2604 Controller Installation
User Guide Part No HA026491 Issue 3.0 Apr-02 2-5
The three central terminal strips are for optional plug in modules, as follows:-
•Terminals marked 2A to 2D are reserved for a Memory Module only. No connections
should be made to these terminals
•Terminals marked HA to HF are connections for optional RS232, RS485, or RS422
communications modules
•Terminals marked JA to JF are connections for an optional slave communications module
or second communications port used to communicate with other instruments
The modules fitted into the above two communications slots can be inter-changed
For a full list of available modules refer to the Ordering code - Appendix A and the Technical
Specification - Appendix C.
!
Figure 2-3: Rear Terminal Connections
N
L
BB
BA
BC
2D
2B
2A
2C
1D
1B
1A
1C
M
O
D
U
L
E
1
M
O
D
U
L
E
3
HF
HD
HE
JF
JD
JE
D8
E2
E1
AC
AA
AB
HB
HA
HC
JB
JA
JC
D5
D4
D3
D1
DC
D2
D7
D6
V-
V1
VH
V+
M
O
D
U
L
E
4
M
O
D
U
L
E
5
M
O
D
U
L
E
6
Power
Supply
Digital
Input
Relay
Analogue
input Hi
Level eg
0-10V
6D
6C
6B
6A
5D
5C
5B
5A
4D
4C
4B
4A
PV
input
I/O
Expander
or Digital
input
Digital
I/O
3B
3A
3C
3D
C
O
M
M
S
M
O
D
U
L
E
H
C
O
M
M
S
M
O
D
U
L
E
JAnalogue
input
screen
Warning:- Take care that mains supplies are connected only to the power
supply terminals (85 to 254Vac only), the fixed relay terminals or to relay or
triac modules. Under no circumstances should mains supplies be connected to
an
y
other terminals.

Installation 2604 Controller
2-6 User Guide Part No HA026491 Issue 3.0 Apr-02
2.3. STANDARD CONNECTIONS
2.3.1. Power Supply Wiring
Controllers supplied with the VH Supply Voltage option are suitable for connection to a
power supply of between 85 and 264Vac 50 or 60 Hz.
Controllers supplied with the VL Supply Voltage option are suitable for connection to a power
supply of between 20 and 29Vac 50 or 60 Hz or 20 to 29Vdc. Polarity not important.
Notes:
1. Make sure the voltage corresponds to the description on the identification label
2. It is the user’s responsibility to provide an external fuse or circuit breaker. Suitable fuses
are :-85 to 264 volt supply T type (EN60127 time-lag type) rated at 1A
20 to 29 volt supply T type (EN60127 time-lag type) rated at 4A
3. Use copper conductors only
4. To avoid electric shock, connect the power line at the end of the wiring procedure
5. Do not run power cables with signal wires such as input, output or digital
communications
6. The safety requirements for Permanently Connected Equipment say:
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
a single switch or circuit breaker can drive more than one instrument
Figure 2-4: Supply Voltage Connections
Line 85 to
264Vac
85 to 264Vac Voltage Supply – Code VH
Neutral
Earth
L
N
20 to 29ac/dc Voltage Supply – Code VL
20 to
29Vac/dc
Earth
24
24

2604 Controller Installation
User Guide Part No HA026491 Issue 3.0 Apr-02 2-7
2.3.2. Relay Output
A single changeover relay is provided as standard. It can be configured as a control output or
an alarm or event output.
Notes:
1. To avoid electric shock, connect the power line at the end of the wiring procedure
2. Use copper conductors only
3. Do not run power wires with input or digital communications wiring
Figure 2-5: Wiring Connections For Fixed Relay Output
Fixed relay connections
AC
AA
AB
Normally
Open
Normally
Closed
Common
Relay Rating
Max
264Vac, 2A
Min
1V, 1mA