Eurotherm 3508 User manual

Engineering handbook
ENG
3508 3504
PROCESS
CONTROLLERS
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 1
3508 and 3504 Process Controllers
1. CHAPTER 1 INSTALLATION AND OPERATION.....................................10
1.1 WHAT INSTRUMENT DO I HAVE?............................................................................................. 10
1.1.1 Contents of Package ........................................................................................................................ 10
1.2 3504 AND 3508 ORDERING CODE............................................................................................... 11
1.2.1 Input and Output Modules............................................................................................................... 11
1.3 HOW TO INSTALL THE CONTROLLER.................................................................................... 12
1.3.1 Dimensions...................................................................................................................................... 12
1.3.2 To Install the Controller .................................................................................................................. 13
1.3.3 Unplugging the Controller............................................................................................................... 13
1.4 ELECTRICAL CONNECTIONS..................................................................................................... 14
1.4.1 Wire Sizes ....................................................................................................................................... 14
1.5 STANDARD CONNECTIONS......................................................................................................... 15
1.5.1 PV Input (Measuring Input) ............................................................................................................ 15
1.5.2 Digital I/O........................................................................................................................................ 16
1.5.3 Digital (Logic) Outputs ................................................................................................................... 16
1.5.4 Relay Output.................................................................................................................................... 16
1.5.5 Power Supply Connections.............................................................................................................. 17
1.6 PLUG IN I/O MODULE CONNECTIONS..................................................................................... 18
1.6.1 I/O Modules..................................................................................................................................... 18
1.6.2 Zirconia Probe Construction............................................................................................................ 22
1.6.3 Zirconia Probe Screening Connections............................................................................................22
1.7 DIGITAL COMMUNICATIONS CONNECTIONS...................................................................... 23
1.7.1 Modbus Slave (H or J Module) or EIBisynch................................................................................. 23
1.7.2 Devicenet Wiring............................................................................................................................. 24
1.7.3 Example Devicenet Wiring Diagram............................................................................................... 24
1.7.4 Profibus ........................................................................................................................................... 25
1.7.5 Example Profibus Wiring................................................................................................................ 25
1.7.6 Ethernet ........................................................................................................................................... 25
1.7.7 I/O Expander (or Additional Digital Input)..................................................................................... 26
1.7.8 Example Wiring Diagram................................................................................................................ 27
1.7.9 Snubbers.......................................................................................................................................... 27
1.8 GETTING STARTED....................................................................................................................... 28
1.9 QUICK START - NEW CONTROLLER (UNCONFIGURED) ................................................... 28
1.9.1 To Configure Parameters in Quick Start Mode ............................................................................... 28
1.9.2 Quick Start Parameters.................................................................................................................... 30
1.10 TO RE-ENTER QUICK START MODE.................................................................................... 33
1.10.1 Power up After a Quick Start Configuration ................................................................................... 33
1.10.2 Power up After A Full Configuration.............................................................................................. 33
1.11 NORMAL OPERATION.............................................................................................................. 34
1.11.1 Beacon Display and Description ..................................................................................................... 34
1.12 THE OPERATOR BUTTONS..................................................................................................... 35
1.12.1 Shortcut Key Presses....................................................................................................................... 35
1.13 TO SET THE REQUIRED TEMPERATURE (SETPOINT).................................................... 36
1.14 TO SELECT MANUAL OPERATION....................................................................................... 36
1.15 ALARM INDICATION................................................................................................................37
1.15.1 To Acknowledge an Alarm.............................................................................................................. 37
1.16 MESSAGE CENTRE.................................................................................................................... 38
1.16.1 Summary Pages ............................................................................................................................... 38
1.16.2 How to Edit Parameters................................................................................................................... 39
1.16.3 Programmer Summary Page............................................................................................................ 40
1.16.4 Alarm Summary Page...................................................................................................................... 42
1.16.5 Alarms Setting Page ........................................................................................................................ 42
1.16.6 Control Summary Page.................................................................................................................... 43
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Engineering Handbook 3500 series Controllers
2. Part No HA027988 Issue 3.0 Aug-04
2. CHAPTER 2 ACCESS TO FURTHER PARAMETERS............................. 44
2.1.1 Level 3............................................................................................................................................. 44
2.1.2 Configuration Level......................................................................................................................... 44
2.1.3 To Select Different Levels of Access .............................................................................................. 45
2.2 ACCESS PARAMETER LIST......................................................................................................... 46
3. CHAPTER 3 FUNCTION BLOCKS........................................................... 48
3.1 TO ACCESS A FUNCTION BLOCK.............................................................................................. 49
3.1.1 Sub-Lists or Instances...................................................................................................................... 49
3.1.2 To Access a Parameters in a Function Block................................................................................... 49
3.1.3 To Change the Value of a Parameter............................................................................................... 50
3.2 NAVIGATION DIAGRAM..............................................................................................................51
4. CHAPTER 4 FUNCTION BLOCK WIRING............................................... 52
4.1 SOFT WIRING.................................................................................................................................. 53
4.1.1 Wiring Example............................................................................................................................... 53
4.1.2 Wiring Through the Operator Interface...........................................................................................54
4.1.3 To Remove a Wire .......................................................................................................................... 55
4.1.4 Wiring a Parameter to Multiple Inputs............................................................................................ 56
4.1.5 Wiring Using iTools........................................................................................................................ 56
4.1.6 Wiring Floats with Status Information............................................................................................. 57
4.1.7 Edge Wires...................................................................................................................................... 59
4.1.8 Operation of Booleans and Rounding..............................................................................................60
5. CHAPTER 5 INSTRUMENT CONFIGURATION....................................... 61
5.1 WHAT IS INSTRUMENT CONFIGURATION?........................................................................... 61
5.2 TO SELECT INSTRUMENT CONFIGURATION........................................................................ 61
5.3 TO ENABLE CONTROLLER OPTIONS...................................................................................... 61
5.3.1 Options Available in the Instrument Configuration List.................................................................. 62
5.4 DISPLAY FORMATTING............................................................................................................... 63
5.4.1 To Customise the Display................................................................................................................ 63
5.4.2 Bar Graph (3504 0nly) .................................................................................................................... 65
5.5 INSTRUMENT INFORMATION.................................................................................................... 65
5.6 INSTRUMENT DIAGNOSTICS...................................................................................................... 66
6. CHAPTER 6 PROCESS INPUT ................................................................ 68
6.1 TO SELECT PV INPUT................................................................................................................... 68
6.2 PROCESS INPUT PARAMETERS................................................................................................. 68
6.2.1 Input Types and Ranges .................................................................................................................. 70
6.2.2 CJC Type......................................................................................................................................... 71
6.2.3 Display Units................................................................................................................................... 72
6.2.4 Sensor Break Value......................................................................................................................... 72
6.2.5 Fallback........................................................................................................................................... 72
6.2.6 PV Offset......................................................................................................................................... 73
6.2.7 PV Input Scaling.............................................................................................................................. 74
7. CHAPTER 7 LOGIC INPUT/OUTPUT....................................................... 76
7.1 TO SELECT LOGIC IO LIST.........................................................................................................76
7.2 LOGIC IO PARAMETERS.............................................................................................................. 76
7.2.1 Example: To Configure a Time Proportioning Logic Output......................................................... 77
7.2.2 Example: To Calibrate a VP Output............................................................................................... 77
7.2.3 Logic Output Scaling....................................................................................................................... 78
7.2.4 Example: To Scale a Proportioning Logic Output.......................................................................... 78
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 3
8. CHAPTER 8 AA RELAY OUTPUT..........................................................80
8.1 TO SELECT AA RELAY LIST .....................................................................................................80
8.2 AA RELAY PARAMETERS..........................................................................................................80
8.2.1 Example: To Wire the AA Relay to an Alarm.............................................................................81
8.2.2 Relay Output Scaling.....................................................................................................................81
9. CHAPTER 9 MODULE CONFIGURATION .............................................82
9.1 TO FIT A NEW MODULE.............................................................................................................83
9.2 MODULE IDENTIFICATION ......................................................................................................84
9.3 MODULE TYPES............................................................................................................................84
9.3.1 Relay, Logic or Triac Outputs.......................................................................................................84
9.3.2 Single Isolated Logic Output.........................................................................................................86
9.3.3 DC Control Output or DC Retransmission....................................................................................87
9.3.4 Analogue Input..............................................................................................................................88
9.3.5 Input Types and Ranges ................................................................................................................90
9.3.6 Display Units.................................................................................................................................90
9.3.7 Triple Logic Input and Triple Contact Input .................................................................................91
9.3.8 Potentiometer Input.......................................................................................................................91
9.3.9 Transmitter Power Supply.............................................................................................................92
9.3.10 Transducer Power Supply..............................................................................................................93
9.4 MODULE SCALING......................................................................................................................94
9.4.1 Analogue Input Scaling and Offset................................................................................................94
9.4.2 Relay, Logic or Triac Output Scaling............................................................................................95
9.4.3 Analogue Output Scaling...............................................................................................................95
9.4.4 Potentiometer Input Scaling ..........................................................................................................96
10. CHAPTER 10 IO EXPANDER .................................................................98
10.1 TO CONFIGURE THE IO EXPANDER..................................................................................99
10.1.1 IO Expander Parameters................................................................................................................99
11. CHAPTER 11 ALARMS.........................................................................100
11.1 FURTHER ALARM DEFINITIONS ......................................................................................100
11.2 ANALOGUE ALARMS............................................................................................................101
11.2.1 Analogue Alarm Types................................................................................................................101
11.3 DIGITAL ALARMS..................................................................................................................102
11.3.1 Digital Alarm Types....................................................................................................................102
11.3.2 Alarm Relay Output.....................................................................................................................102
11.3.3 How Alarms are Indicated...........................................................................................................103
11.3.4 To Acknowledge an Alarm..........................................................................................................103
11.4 ALARM PARAMETERS.........................................................................................................104
11.4.1 Example: To Configure Alarm 1 ................................................................................................105
11.5 DIAGNOSTIC ALARMS.........................................................................................................106
11.6 TO SET UP ALARMS USING ITOOLS.................................................................................106
12. BCD INPUT..............................................................................................108
12.1 BCD PARAMETERS................................................................................................................108
12.1.1 Example: To wire a BCD Input..................................................................................................109
13. DIGITAL COMMUNICATIONS ................................................................110
13.1 SERIAL COMMUNICATIONS ..............................................................................................110
13.1.1 RS232..........................................................................................................................................110
13.1.2 RS485..........................................................................................................................................111
13.2 CONFIGURATION PORTS....................................................................................................112
13.2.1 IR Clip.........................................................................................................................................112
13.2.2 CFG Clip .....................................................................................................................................112
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Engineering Handbook 3500 series Controllers
4. Part No HA027988 Issue 3.0 Aug-04
13.3 BROADCAST MASTER COMMUNICATIONS.................................................................... 113
13.3.1 3500 Broadcast Master.................................................................................................................. 113
13.3.2 Wiring Connections - Broadcast Communications........................................................................ 114
13.4 DIGITAL COMMUNICATIONS PARAMETERS................................................................. 115
13.4.1 Communications Identity............................................................................................................... 116
13.4.2 Communication Address................................................................................................................ 116
13.4.3 Baud Rate...................................................................................................................................... 116
13.4.4 Parity ............................................................................................................................................. 116
13.4.5 RX/TX Delay Time....................................................................................................................... 116
13.5 EXAMPLE 1:- TO SET UP INSTRUMENT ADDRESS........................................................ 116
13.6 EXAMPLE 2: TO SEND SP FROM THE MASTER TO PV IN A SLAVE......................... 117
13.7 MODBUS ADDRESSES............................................................................................................. 117
13.8 ETHERNET................................................................................................................................. 118
13.8.1 Instrument setup ............................................................................................................................ 118
13.8.2 MAC address display..................................................................................................................... 118
13.8.3 DHCP Settings............................................................................................................................... 118
13.8.4 Network Connection...................................................................................................................... 118
13.8.5 Dynamic IP Addressing................................................................................................................. 118
13.8.6 Fixed IP Addressing...................................................................................................................... 118
13.8.7 Additional notes............................................................................................................................. 118
13.8.8 iTools Setup................................................................................................................................... 119
13.8.9 Ethernet Parameters....................................................................................................................... 119
14. COUNTERS, TIMERS, TOTALISERS, REAL TIME CLOCK.................... 120
14.1 COUNTERS................................................................................................................................. 120
14.1.1 Counter Parameters ....................................................................................................................... 121
14.2 TIMERS....................................................................................................................................... 122
14.2.1 Timer Types .................................................................................................................................. 122
14.2.2 On Pulse Timer Mode ................................................................................................................... 122
14.2.3 Off Delay Timer Mode.................................................................................................................. 123
14.2.4 One Shot Timer Mode................................................................................................................... 124
14.2.5 Compressor or Minimum On Timer Mode.................................................................................... 125
14.2.6 Timer Parameters........................................................................................................................... 126
14.3 TOTALISERS.............................................................................................................................. 127
14.3.1 Totaliser Parameters...................................................................................................................... 127
14.4 REAL TIME CLOCK................................................................................................................. 129
14.4.1 Real Time Clock Parameters......................................................................................................... 129
15. APPLICATION SPECIFIC ......................................................................... 130
15.1 HUMIDITY CONTROL............................................................................................................. 130
15.1.1 Overview....................................................................................................................................... 130
15.1.2 Example Of Humidity Controller Connections.............................................................................. 130
15.1.3 Temperature Control Of An Environmental Chamber................................................................... 131
15.1.4 Humidity Control Of An Environmental Chamber........................................................................ 131
15.2 HUMIDITY PARAMETERS..................................................................................................... 132
15.3 ZIRCONIA (CARBON POTENTIAL) CONTROL................................................................. 133
15.3.1 Temperature Control ..................................................................................................................... 133
15.3.2 Carbon Potential Control............................................................................................................... 133
15.3.3 Sooting Alarm ............................................................................................................................... 133
15.3.4 Automatic Probe Cleaning............................................................................................................. 133
15.3.5 Endothermic Gas Correction ......................................................................................................... 133
15.3.6 Clean Probe................................................................................................................................... 133
15.3.7 Probe Status................................................................................................................................... 133
15.3.8 Sooting Alarm ............................................................................................................................... 133
15.4 ZIRCONIA PARAMETERS...................................................................................................... 134
15.5 EXAMPLE OF CARBON POTENTIAL CONTROL CONNECTIONS............................... 135
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 5
16. INPUT MONITOR ......................................................................................136
16.1.1 Maximum Detect........................................................................................................................... 136
16.1.2 Minimum Detect............................................................................................................................ 136
16.1.3 Time Above Threshold.................................................................................................................. 136
16.2 INPUT MONITOR PARAMETERS......................................................................................... 137
17. CHAPTER 17 LOGIC AND MATHS OPERATORS.................................138
17.1 LOGIC OPERATORS................................................................................................................ 138
17.1.1 Logic 8........................................................................................................................................... 138
17.1.2 Logic Operations........................................................................................................................... 139
17.1.3 Logic Operator Parameters............................................................................................................ 140
17.2 EIGHT INPUT LOGIC OPERATORS..................................................................................... 141
17.2.1 Eight Input Logic Operator Parameters......................................................................................... 141
17.3 MATHS OPERATORS............................................................................................................... 142
17.3.1 Math Operations............................................................................................................................ 143
17.3.2 Math Operator Parameters............................................................................................................. 144
17.3.3 Sample and Hold Operation .......................................................................................................... 145
17.4 EIGHT INPUT ANALOG MULTIPLEXERS.......................................................................... 146
17.4.1 Multiple Input Operator Parameters.............................................................................................. 146
17.4.2 Fallback......................................................................................................................................... 146
18. CHAPTER 18 INPUT CHARACTERISATION .........................................148
18.1 INPUT LINEARISATION ......................................................................................................... 148
18.1.1 Compensation for Sensor Non-Linearities..................................................................................... 149
18.1.2 Input Linearisation Parameters...................................................................................................... 150
18.2 POLYNOMIAL........................................................................................................................... 151
19. CHAPTER 19 LOAD................................................................................154
19.1 INPUT LINEARISATION PARAMETERS............................................................................. 154
20. CHAPTER 20 CONTROL LOOP SET UP...............................................156
20.1 WHAT IS A CONTROL LOOP? .............................................................................................. 156
20.2 LOOP PARAMETERS - MAIN ................................................................................................ 157
20.3 LOOP SET UP............................................................................................................................. 157
20.3.1 Types of Control Loop .................................................................................................................. 158
20.4 PID CONTROL........................................................................................................................... 159
20.4.1 Proportional Term......................................................................................................................... 159
20.4.2 Integral Term................................................................................................................................. 160
20.4.3 Derivative Term............................................................................................................................. 160
20.4.4 High and Low Cutback.................................................................................................................. 160
20.4.5 Integral action and manual reset.................................................................................................... 160
20.4.6 Relative Cool Gain........................................................................................................................ 160
20.4.7 Loop Break Time........................................................................................................................... 161
20.4.8 Cooling Algorithm......................................................................................................................... 161
20.4.9 Gain Scheduling ............................................................................................................................ 161
20.4.10 PID Parameters ......................................................................................................................... 162
20.5 TUNING....................................................................................................................................... 163
20.5.1 Automatic Tuning.......................................................................................................................... 163
20.5.2 One-shot Tuning............................................................................................................................ 163
20.5.3 Calculation of the cutback values.................................................................................................. 163
20.5.4 Manual Tuning .............................................................................................................................. 164
20.5.5 Setting the Cutback Values............................................................................................................ 164
20.5.6 Tune Parameters............................................................................................................................ 165
20.6 SETPOINT FUNCTION BLOCK ............................................................................................. 166
20.6.1 Setpoint Function Block................................................................................................................ 166
20.6.2 SP Tracking................................................................................................................................... 167
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Engineering Handbook 3500 series Controllers
6. Part No HA027988 Issue 3.0 Aug-04
20.6.3 Manual Tracking .........................................................................................................................167
20.6.4 Rate Limit....................................................................................................................................167
20.6.5 Setpoint Parameters.....................................................................................................................167
20.7 OUTPUT FUNCTION BLOCK...............................................................................................169
20.7.1 Power Feed Forward Enable........................................................................................................172
20.7.2 Output Limits...............................................................................................................................173
20.7.3 Effect of Control Action, Hysteresis and Deadband....................................................................174
21. CHAPTER 21 SETPOINT PROGRAMMER..........................................176
21.1 PROGRAMMER OPERATING STATES..............................................................................177
21.1.1 Reset............................................................................................................................................177
21.1.2 Run..............................................................................................................................................177
21.1.3 Hold.............................................................................................................................................177
21.1.4 Program Cycles ...........................................................................................................................177
21.1.5 Servo............................................................................................................................................177
21.1.6 Skip Segment...............................................................................................................................177
21.1.7 Advance Segment........................................................................................................................177
21.1.8 Fast x10 mode .............................................................................................................................177
21.1.9 Sensor break recovery .................................................................................................................177
21.1.10 Holdback (Guaranteed Soak)..................................................................................................178
21.1.11 Segment Types........................................................................................................................179
21.1.12 Power Fail Recovery...............................................................................................................180
21.1.13 Sync mode...............................................................................................................................181
21.2 CREATING OR EDITING A PROGRAM.............................................................................182
21.3 TO SELECT, RUN, HOLD OR RESET A PROGRAM........................................................185
21.4 PROGRAM EDITING USING ITOOLS................................................................................185
22. CHAPTER 22 SWITCH OVER ..............................................................186
22.1.1 Example: To Set the Switch Over Levels...................................................................................186
22.1.2 Switch Over Parameters ..............................................................................................................187
23. CHAPTER 23 TRANSDUCER SCALING..............................................188
23.1 AUTO-TARE CALIBRATION................................................................................................188
23.2 STRAIN GAUGE ......................................................................................................................189
23.3 LOAD CELL..............................................................................................................................189
23.4 COMPARISON CALIBRATION............................................................................................190
23.5 TRANSDUCER SCALING PARAMETERS..........................................................................191
23.5.1 Parameter Notes ..........................................................................................................................192
23.6 TRANSDUCER SUMMARY PAGE.......................................................................................193
23.6.1 Tare Calibration...........................................................................................................................193
23.6.2 Strain Gauge................................................................................................................................194
23.6.3 Load Cell.....................................................................................................................................195
23.6.4 Comparison Calibration...............................................................................................................196
24. CHAPTER 24 USER VALUES ..............................................................198
24.1 USER VALUE PARAMETERS...............................................................................................198
25. CHAPTER 25 CALIBRATION...............................................................200
25.1 INPUT CALIBRATION...........................................................................................................200
25.2 PRECAUTIONS........................................................................................................................200
25.2.1 To Calibrate mV Range...............................................................................................................201
25.2.2 To Save the New Calibration Data..............................................................................................202
25.2.3 To Return to Factory Calibration.................................................................................................202
25.2.4 Thermocouple Calibration...........................................................................................................203
25.2.5 RTD Calibration..........................................................................................................................204
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 7
25.3 CALIBRATION PARAMETERS............................................................................................205
26. CHAPTER 26 CONFIGURATION USING ITOOLS...............................208
26.1 FEATURES................................................................................................................................208
26.2 ON-LINE/OFF-LINE EDITING..............................................................................................208
26.3 CONNECTING A PC TO THE CONTROLLER ..................................................................209
26.4 PARAMETER SET UP.............................................................................................................210
26.5 DEVICE PANEL.......................................................................................................................211
26.6 USER PAGES EDITOR............................................................................................................212
26.6.1 To Create a User Page.................................................................................................................212
26.6.2 Style Examples............................................................................................................................213
26.7 RECIPE EDITOR .....................................................................................................................215
26.7.1 Recipe Menu Commands.............................................................................................................216
26.8 TO SET UP ALARMS USING ITOOLS.................................................................................217
26.8.1 Example: To Customise Analogue Alarm Messages..................................................................217
26.8.2 Alarm Summary Page in iTools...................................................................................................218
26.8.3 To Customise Digital Alarm Messages .......................................................................................219
26.9 PROGRAM EDITOR...............................................................................................................220
26.9.1 Analog View................................................................................................................................220
26.9.2 Event Outputs..............................................................................................................................221
26.9.3 The Spreadsheet ..........................................................................................................................221
26.9.4 Menu Entries and Tool Buttons...................................................................................................221
26.9.5 The Context Menu.......................................................................................................................221
26.9.6 Naming Programs........................................................................................................................222
26.9.7 Entering a Program......................................................................................................................222
26.9.8 Making Changes to a Program.....................................................................................................222
26.9.9 Saving Programs..........................................................................................................................222
26.9.10 Moving Programs Around.......................................................................................................222
26.9.11 Printing a Program..................................................................................................................222
26.10 GRAPHICAL WIRING EDITOR...........................................................................................223
26.10.2 Using Function Blocks............................................................................................................224
26.10.3 Tooltips...................................................................................................................................225
26.10.4 Series 3000 Instruments..........................................................................................................225
26.10.5 Using Wires.............................................................................................................................226
26.10.6 Using Comments.....................................................................................................................227
26.10.7 Using Monitors .......................................................................................................................228
26.10.8 Downloading To Series 3000 Instruments ..............................................................................228
26.10.9 Selections................................................................................................................................228
26.10.10 Colours....................................................................................................................................229
26.11 DIAGRAM CONTEXT MENU ...............................................................................................229
26.11.1 Other Examples of Graphical Wiring......................................................................................230
26.12 CLONING..................................................................................................................................232
26.12.1 Save to File .............................................................................................................................232
26.12.2 To Clone a New Controller.....................................................................................................232
26.12.3 To Clone Directly from One Controller to Another................................................................232
27. APPENDIX A PARAMETER INDEX......................................................234
28. APPENDIX B SAFETY AND EMC INFORMATION...............................250
29. APPENDIX C TECHNICAL SPECIFICATION....... 254
29.1.1 Control Options................................................................................ 254
29.1.2 Display.............................................................................................. 254
29.1.3 Standard Digital I/O ......................................................................... 254
29.1.4 All Analogue and PV Inputs............................................................. 255
29.1.5 PV Input ........................................................................................... 255
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Engineering Handbook 3500 series Controllers
8. Part No HA027988 Issue 3.0 Aug-04
29.1.6 Analogue Input Module................................................................................................................. 256
29.1.7 Digital Input Modules.................................................................................................................... 257
29.1.8 Digital Output Modules................................................................................................................. 257
29.1.9 Analogue Output Modules............................................................................................................. 257
29.1.10 Transmitter PSU........................................................................................................................ 257
29.1.11 Transducer PSU........................................................................................................................ 257
29.1.12 Potentiometer Input................................................................................................................... 257
29.1.13 Digital communications ............................................................................................................ 257
29.1.14 Master communications ............................................................................................................ 257
29.1.15 Alarms....................................................................................................................................... 257
29.1.16 Control Functions...................................................................................................................... 258
29.1.17 Setpoint Programmer ................................................................................................................ 258
29.1.18 I/O Expander............................................................................................................................. 258
29.1.19 Advanced Functions.................................................................................................................. 259
29.1.20 General Specification................................................................................................................ 259
30. DECLARATION OF CONFORMITY..........................................................260
Issue Status of This Manual
Issue 3.0 of this manual applies to software version 1.2.
Notes about this handbook:-
1. Chapter 1 Installation and Operation, Part Number HA027987, is essentially the same as the User
Handbook, supplied with the product.
2. Further chapters describe configuration of the controller and operation in level 3. The order of
chapters is the same order as the subject headers presented in the controller.
3. Related handbooks, all of which can be downloaded from www.eurotherm.co.uk, may be useful for
further information
a. EMC booklet Part No. HA025464
b. 2000 Series Communications Part No. HA026230
c. DeviceNet Communications Part No. HA027506
d. Profibus Communications Part No. HA026290
e. IO Expander Part No. HA026893
4. Whenever the symbol ☺
☺☺
☺appears in this handbook it indicates a helpful hint
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 9
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Engineering Handbook 3500 series Controllers
10. Part No HA027988 Issue 3.0 Aug-04
3508 and 3504 Process Controllers
1. CHAPTER 1 INSTALLATION AND OPERATION
1.1 What Instrument Do I Have?
Thank you for choosing this Controller.
The 3508 controller is supplied in the standard 1/8 DIN size (48 x 96mm front panel). The 3504 controller is
supplied in the standard ¼ DIN size (96 x 96mm front panel). They are intended for permanent installation,
for indoor use only, in an electrical panel which encloses the rear housing, terminals and wiring on the back.
1.1.1 Contents of Package
When unpacking your controller please check that the following items have been included.
1.1.1.1 3508 or 3504 Controller Mounted in its Sleeve
The 3504 contains up to six plug-in
hardware modules; the 3508 has up to
three. Additionally digital
communications modules can be fitted
in two positions.
The modules provide an interface to a
wide range of plant devices and those
fitted are identified by an ordering code
printed on a label fixed to the side of
the instrument. Check this against the
description of the code given in section
1.2 to ensure that you have the correct
modules for your application. This code
also defines the basic functionality of the instrument which may be:-
• Controller only
• Programmer and controller
• Control type – Standard PID, valve
positioner
• Digital communications type
• Options
1.1.1.2 Panel Retaining Clips
Two clips are required to secure the instrument sleeve in the panel. These are supplied fitted to the sleeve.
1.1.1.3 Accessories Pack
For each input a load resistor value 2.49Ωis supplied for mA measurement. This will need to be fitted
across the respective input terminals
A User Guide Part No HA027987. This guide is repeated here as Chapter 1 and explains:-
• How to install the controller
• Physical wiring to the plant devices
• First switch on - ‘out of the box’.
• Principle of operation using the front panel buttons
• Introduction to configuration through iTools PC software
p
icture of mounting
clips
3508 Controller 3504 Controller
Label
showing:-
Instrument
Order Code
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 11
1.2 3504 and 3508 Ordering Code
Model
Number
Function Supply
Voltage
No of
Loops
Application Programs Recipes Toolkit
Wires
Colour
1.2.1 Input and Output Modules
IO Slot 1 IO Slot 2 IO Slot 3 IO Slot 4 IO Slot 5 IO Slot 6 Comms H Comms J
Config Tools Product Language Manuals Language Warranty Cal Cert Custom Label
Example 3504/VH/1/XX/10/4/60/G/TT/XX/XX/XX/XX/XX/Y2/XX/IT/ENG/ENG/WL003/XXXX
3504 CONTROLLER, 100-240Vac, 10 programs, 4 recipes, 60 wires, dual triac output, 2-wire J485 comms, iTools, English manual
Model Number
3504 3504 Standard
3508 3508 Standard
Supply Voltage
VH 100-240Vac
VL 20-29Vac/dc
Function
Null Controller
F Profibus
controller
Application
XX Standard
VP Valve Position
ZC Zirconia
Programs
01 1 prog 5 segments
10 10 prog 50 segments
25 25 prog 100 segments
50 50 prog 200 segments
Recipes
1 1 recipe
4 4 recipes
8 8 recipes
Toolkit Wires
XX 30 wires
60 60 wires
120 120 wires
250 250 wires
Colour
G Eurotherm
green
S Silver
Loops
1 Single
3504 only
Manuals Language
ENG English
FRA French
GER German
SPA Spanish
XXX None
Extended Warranty
WL005 Extended 5 year
J Comms Slot
XX Not Fitted
A2 232 Modbus
Y2 2-wire 485 Modbus
F2 4-wire 485 Modbus
EX IO Expander
Instrument Language
ENG English
FRA French
GER German
SPA Spanish
Cal Certificate
XXXXX None
CAL1 Cert of
conformity
CAL2 Factory cal cert
CAL3 Custom Cal Cert
Custom Labels
F1234 Special No
XXXXX None
IO Slots 1-3 (3508); 1-6 (3504)
XX None fitted
R4 Change over relay
R2 2 pin relay
RR Dual relay
T2 Triac
TT Dual triac
D4 DC control
AM Analogue input (not slot 2 or
5)
D6 DC retransmission
TL Triple logic input
TK Triple contact input
TP Triple logic output
VU Potentiometer input
MS 24Vdc transmitter PSU
G3 Transducer PSU 5 or 10Vdc
LO Isolated single logic output
H Comms Slot
XX Not Fitted
A2 232 Modbus
Y2 2-wire 485 Modbus
F2 4-wire 485 Modbus
AE 232 EI-Bisynch
YE 2-wire 485 EI-Bisynch
FE 4-wire 485 EI-Bisynch
ET Ethernet 10base
PB Profibus
DN Devicenet
Config Tools
XX None
IT Standard
iTools
Non-standard Option
EU1234 Special No
EC1234 Custom curve
EE1234 Custom config
ES1234 Cust software
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Engineering Handbook 3500 series Controllers
12. Part No HA027988 Issue 3.0 Aug-04
1.3 How to Install the Controller
This instrument is intended for permanent installation, for indoor use only, and to be enclosed in an
electrical panel.
Select a location where minimum vibrations are present and the ambient temperature is within 0 and 50oC
(32 and 122oF).
The instrument can be mounted on a panel up to 15mm thick.
To assure IP65 and NEMA 4 front protection, use a panel with smooth surface texture.
Please read the safety information, Appendix B, before proceeding and refer to the EMC Booklet part
number HA025464 for further information.
1.3.1 Dimensions
Panel
retaining clips
150mm (5.91in)
Latching ears
48mm
(1.89in)
96mm
(3.78in)
Panel
retaining clips
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 13
1.3.2 To Install the Controller
1.3.2.1 Panel Cut-out
1. Prepare the panel cut-out to the size
shown in the diagram
2. Insert the controller through the cut-
out.
3. Spring the panel retaining clips into
place. Secure the controller in position
by holding it level and pushing both
retaining clips forward.
4. Peel off the protective cover from the
display
1.3.2.2 Recommended Minimum Spacing
5. The recommended minimum spacing
between controllers shown here should
not be reduced to allow sufficient
natural air flow
1.3.3 Unplugging the Controller
The controller can be unplugged from its sleeve by easing the latching ears outwards and pulling it forward
out of the sleeve. When plugging it back into its sleeve, ensure that the latching ears click back into place to
maintain the IP65 sealing.
10mm (0.4 in)
38mm
(1.5 in)
(Not to scale)
45 mm - 0.0 + 0.6
1.77 in -0.00, +0.02
92 mm - 0.0 + 0.8
3.62 in -0.00, +0.03
3504 3508
92 mm -
0.0 + 0.8
3.62 in -
0.00, +0.03
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Engineering Handbook 3500 series Controllers
14. Part No HA027988 Issue 3.0 Aug-04
1.4 Electrical Connections
3508
3504
* Polarising Key
Polarising keys are intended to prevent modules which are not supported in this controller from being fitted
into the controller. An example might be an unisolated module (coloured red) from a 2400 controller
series. When pointing towards the top, as shown, the key prevents a controller, fitted with an unsupported
module, from being plugged into a sleeve which has been previously wired for isolated modules. If an
unisolated module is to be fitted, it is the users responsibility to ensure that it is safe to install the controller
in the particular application. When this has been verified the polarising key may be adjusted with a
screwdriver to point in the down direction.
1.4.1 Wire Sizes
The screw terminals accept wire sizes from 0.5 to 1.5 mm (16 to 22AWG). Hinged covers prevent hands or
metal making accidental contact with live wires. The rear terminal screws should be tightened to 0.4Nm
(3.5lb in).
Live
Neutral
Ground
Logic I/O A
Logic I/O B
Logic I/O Com
MODULE 1MODULE 2MODULE 3
Power
Supply
Digital
Inputs/outputs
Fixed Relay
(form C)
PV input
COMMS MODULE 1COMMS MODULE 1
Polarising Keys* One per module
T/C RTD mV mA
Live
Neutral
Ground
Logic I/O A
Logic I/O B
Logic I/O Com
COMMS MODULE HCOMMS MODULE J
MODULE 1MODULE 2
MODULE 3
MODULE 4MODULE 5MODULE 6
Power
Supply
Digital
Inputs/outputs
Fixed Relay
(form C)
PV input
Polarising Keys * One per module
T/C RTD mV mA
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 15
1.5 Standard Connections
These are connections which are common to all instruments in the range.
1.5.1 PV Input (Measuring Input)
Notes:
1. Do not run input wires together with power cables
2. When shielded cable is used, it should be grounded at one point only
3. Any external components (such as zener barriers, etc) connected between sensor and input terminals
may cause errors in measurement due to excessive and/or un-balanced line resistance or possible
leakage currents
4. Not isolated from the logic outputs and digital inputs
1.5.1.1 Thermocouple or Pyrometer Input
Use the correct type of thermocouple compensating cable, preferably shielded, to
extend wiring
1.5.1.2 RTD Input
The resistance of the three wires must be the same
The line resistance may cause errors if it is greater than 22Ω
Note: the RTD wiring is not the same as 2400 series instruments. It is the same as
26/2700 series
1.5.1.3 Linear Input V, mV and High Impedance V
mV range +40mV or +80mV
High level range 0 – 10V
High Impedance mid level range 0 – 2V
A line resistance for voltage inputs may cause measurement errors
1.5.1.4 Linear Input mA
Connect the supplied load resistor equal to 2.49Ωfor mA input
The resistor supplied is 1% accuracy 50ppm
A resistor 0.1% accuracy 15ppm resistor can be supplied as an orderable option
VI
V+
V- T/C
0 – 20mA
4- 20mA
VI
V+
V-
RTD
For 2-wire
this is a
local link
VI
V+
V-
+80mV
0 – 2V
0 – 10V
VI
V+
V-
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Engineering Handbook 3500 series Controllers
16. Part No HA027988 Issue 3.0 Aug-04
1.5.2 Digital I/O
These terminals may be configured as logic inputs, contact inputs or logic outputs in any combination. It is
possible to have one input and one output on either channel.
!The Digital IO is not isolated from the PV input
1.5.2.1 Logic Inputs
Voltage level logic inputs, 12V, 5-40mA
Active > 10.8V
Inactive < 7.3V
1.5.2.2 Contact Closure Inputs
Contact open > 1200Ω
Contact closed < 480Ω
1.5.3 Digital (Logic) Outputs
The logic outputs are capable of driving SSR or thyristors up to 9mA, 18V
It is possible to parallel the two outputs to supply 18mA, 18V.
Note : The Digital IO terminals are not isolated from the PV.
1.5.4 Relay Output
Relay rating, min: 1V, 1mAdc. Max: 264Vac 2A resistive
Relay shown in de-energised state
Isolated output 240Vac CATII
1.5.4.1 General Note About Inductive Loads
High voltage transients may occur when switching inductive loads such as some contactors or solenoid
valves.
For this type of load it is recommended that a ‘snubber’ is connected across the normally open contact of
the relay switching the load. The snubber typically consists of a 15nF capacitor connected in series with a
100Ωresistor and will also prolong the life of the relay contacts.
!When the relay contact is open and it is connected to a load, the snubber passes a current
(typically 0.6mA at 110Vac and 1.2mA at 240Vac. It is the responsibility of the installer to ensure that this
current does not hold on the power to an electrical load. If the load is of this type the snubber should not
be connected.
Output 1
Output 2
Common
LA
LB
LC
Input 1
Input 2
Common
LA
LB
LC
Input 1
Input 2
Common
LA
LB
LC
AA
AB
AC
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 17
1.5.5 Power Supply Connections
1. Before connecting the instrument to the power line, make sure that the line
voltage corresponds to the description on the identification label
2. For supply connections use 16AWG or larger wires rated for at least 75oC
3. Use copper conductors only
4. For 24V the polarity is not important
5. It is the Users responsibility to provide an external fuse or circuit breaker.
For 24 V ac/dc fuse type T rated 4A 250V
For 100/240Vac fuse type T rated 1A 250V
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 supply more than one instrument
100 to 240Vac
50/60Hz
N
L
24V ac or dc
24
24
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Engineering Handbook 3500 series Controllers
18. Part No HA027988 Issue 3.0 Aug-04
1.6 Plug in I/O Module Connections
Plug in I/O modules can be fitted in three positions in the 3508 and six positions in 3504. The positions are
marked Module 1, Module 2, Module 3, Module 4, Module 5, Module 6. With the exception of the
Analogue Input module, any other module listed in this section, can be fitted in any of these positions. To
find out which modules are fitted check the ordering code printed on a label on the side of the instrument.
If modules have been added, removed or changed it is recommended that this is recorded on the
instrument code label.
The function of the connections varies depending on the type of module fitted in each position and this is
shown below. All modules are isolated.
1.6.1 I/O Modules
I/O Module Typical
usage
H/W
Code
Connections and examples of use
Note: The order code and terminal number is pre-fixed by the module number.
Module 1 is connected to terminals 1A, 1B, 1C, 1D; module 2 to 2A, 2B, 2C, 2D, etc.
Relay (2 pin)
and
Dual Relay
2A, 264Vac
max
1mA 1V min
Heating,
cooling,
alarm,
program
event,
valve raise,
valve lower
R2 and
RR
Isolated output 240Vac CATII
Change Over
Relay
(2A, 264Vac
max)
1mA 1V min
Heating,
cooling,
alarm,
program
event, valve
raise, valve
lower
R4
Isolated output 240Vac CATII
Triple Logic
Output
(18Vdc at
8mA max.)
Heating,
cooling,
program
events
TP
Isolated output 240Vac CATII
Isolated
Single Logic
Output
Heating,
cooling,
program
events
LO
Isolated output 240Vac CATII
A
B
D
C +
_
_
_
+
+
+
Output A
Output B
Output C
Common
SSR or
thyristor
unit
+
-
A
B
D
C
Voltage
supply
Contactor
Relay
Panel lamp
etc
A
B
D
C
Voltage
supply
Contactor
Relay
Panel lamp
etc
First relay
Second relay (dual
relay only)
Contactor
Relay
Panel lamp
etc
A
B
D
C
+
_
_
_
+
Output A
Common
SSR or
thyristor
unit
+
-
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3500 Series Controllers Engineering Handbook
Part No HA027988 Issue 3.0 Aug-04 19
Triac
and Dual
Triac
(0.7A, 30 to
264Vac
combined
rating)
Heating,
cooling,
valve raise,
valve lower
T2
and TT
Note 1: Dual relay modules may be used in place of dual triac.
Isolated output 240Vac CATII
Note 2:-
The combined current rating for the two triacs must not
exceed 0.7A.
I/O Module Typical
usage
H/W
Code
Connections and examples of use
DC Control
(10Vdc,
20mA max)
Heating,
cooling
e.g. to a
4-20mA
process
actuator
D4
Isolated output 240Vac CATII
DC Re-
transmission
(10Vdc,
20mA max)
Logging of
PV, SP,
output
power, etc.,
(0 to 10Vdc,
or
0 to 20mA)
D6
Isolated output 240Vac CATII
Triple Logic
Input
Events
e.g. Program
Run, Reset,
Hold
TL
Isolated output 240Vac CATII
Triple
Contact
Input
Events
e.g. Program
Run, Reset,
Hold
TK
Isolated output 240Vac CATII
A
B
Actuator
0-20mA
or
0-10Vdc -
+
A
B
To other
controllers
0-20mA
or
0-10Vdc
-
+
A
B
D
C
Voltage
supply
Motorised
valve
Raise
Lower Second triac
First triac
A
B
D
C
Common
Input 1
Input 3
Input 2
Logic inputs
<5V OFF
>10.8V ON
Limits:
-3V, +30V
A
B
D
C
Common
Input 1
Input 3
Input 2
External
Switches or
Rela
y
s
Contact
inputs
<100!ON
>28K!OFF
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