Eurotherm 902 Series User manual

Contents
Guide to this Handbook
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Appendix
INSTALLATION
OPERATION
COMMISSION
CONFIGURE
CALIBRATION
COMMUNICATIONS
ERROR MESSAGES
Glossary of Terms
0 Copyright Eurotherm Limited 1991
Every effort has been taken to ensure the accuracy of this handbook. However in order to
maintain our technological lead we are continuously improving our products which could, without
notice, result in amendments or omissions to this document. We cannot accept responsibility for
damage, injury loss or expenses resulting therefrom.
902-904 Handbook HA023752 Iss 9

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2
3
4
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This is the guide for using this Handbook.
Follow the directions below to obtain maximum benefit from this information provided.
installation
Follow the instructions in this section for successful mechanical mounting and correct
electrical connections.
Important notes on the application and operation of all temperature controllers are in
this section. Please read carefully before proceding.
Operation
This section contains the instructions which are normally needed in day to day operation
of your 902, 3 or 4 instrument. It is recommended that the procedures in this section
are understood before continuing to further sections,
Commission
This section contains instructions for correct matching of your instrument to the load
being controlled. Described are the procedures needed to be followed when first
installing the instrument and subsequently when carrying out any changes to the
control loop.
Configure
Your 902, 3 or 4 instrument has been pre-configured to your requirements according to
the order code. e.g. Range, Alarm types, etc. If there is a need to modify the basic
operation of your instrument, use this section and then return to section 3
(Commission), or section 2 (Operation).
Calibration
Your controller has been factory calibrated to a very high standard. However you may
wish to perform a regular calibration. This section provides all the information neces-
sary or alternatively contact our service organisation at your local area office (Ad-
dresses at the back of this book for information on our field calibration service).
Communications
This section contains all the information required for successfully operating your
controller via its communications port. This allows the instrument to be connected as
part of a computer controlled network or singly to a host computer.
Error Messages
This provides information relating to the current state of the control hardware, software
and information about the measured values. This information can be used to localise a
controller fault to a particular section of the instrument, thus enabling the user to rectify
the problem and return the unit to correct operation quickly.

Installation
Section 1 - Installation
Contents Page
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Dimensional Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Instrument Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Rear Terminal Cover r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.0
1.1
1.2
1.3
2.0
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8,
2.2.9
2.2.10
2.2.11
CONNECTIONS AND WIRING
..................................... 3
Instrument Layout .......................................................... 4
Rear Terminal Connections ......................................
. ....
5
Power Supply ................................................................. 6
Inputs ............................................................................. 7
Heat
/ Process [+] Outputs ............................................. 9
Cool
/ Process [-] Outputs ............................................ 10
Valve Positioner Outputs .............................................
1 1
Alarm Outputs .............................................................. 12
Programme and Comms. Driven Relays ..................... 13
Digital Inputs ................................................................ 14
Remote Analogue inputs ............................................
. 15
Retransmission Outputs ............................................... 16
Digital Communications ............................................... 17
3.0 SAFETY and EMC INFORMATION ............................. 18

Installation
1.0
INSTALLATION
Before proceding with installing this instrument please ensure that you are
acquainted with the caution notes in para. 3.0 of this section.
If the instrument is to be panel mounted, a DIN-size 92mm by 92mm cut-out is
required as illustrated.
Should the instrument be
required to be sealed to the
panel surface, up to IP65,
follow the instructions
detailed in ‘Instrument
Sealing’ paragraph 1.2.
Insert the instrument
through the cutout via the
front of the panel. Install
the mounting clamps, one
on the top and the other
below the instrument.
These clamps are located
from the rear to ensure that
the four feet are firmly
seated in the slots in the
case, as shown in figure
1.
1.1 Dimensional Details
r
!
Figure 1
_____-
~.
Tighten the screws firmly with a screwdriver from the rear of the mounting panel;
a torque limiter in each clamp prevents over-tightening.
Panel cut-out
i
92 x 92 +0.8
-0 mm

Installation
1.2 Instrument Sealing
A polythene bag within the instrument packing contains the 902 accessory kit
(Part No. LA023792). In this accessory kit is a rubber seal. When this seal is
correctly placed between the sleeve and the panel surface it will provide
protection to the lP65 standard.
If protection of the instrument is not required this seal need not be fitted and only
the installation instructions need be followed.
Fitting the seal should be
carried out as soon as the
instrument is removed from
the packing. Place the seal
over the front of the
instrument so that it sits as
shown in figure 2, against the
back of the bezel. The
instrument can now be
mounted into the panel cut-
out and assembly continued
as described in the
installation instructions.
When fully compressed this
seal increases the projection
of the bezel in front of the
panel by
1.5mm.
Note: It is important that the
panel cut out dimensions are
adhered to for IP65 to be
effective. There must be no
sharp or burred edges.,
1.3
Rear Terminal Cover
To remove the rear terminal
protection cover four catches
have to be released, two at
the top and two at the bottom.
Insert the tool supplied, in the
accessory kit, to release each
pair of catches.
Refit the cover so that the
four catches engage in their
respective slots.
Figure 2
-
Figure 3
2

Installation
2.0 CONNECTIONS AND WIRING
Electrical connections are made
via individual screw terminal
blocks on the rear of the
instrument. All connections are
low current and a 16/0.20 wire
size is adequate. Max. 14 AWG
(1.6mm)(0.064”)
Wires, once connected to the
instrument, can be run up/down
the trough and secured by ties
as shown in figure 4.
The instrument supply should
be fused externally, in
accordance with local wiring
regulations.
Do not over tighten screws as
this will cause damage. Max.
screw torque is 0.4Nm.
Instrument Labels
Labels on the instrument and
case indicate the specific
configuration and terminal
number connections for the
instrument.
This label is found on the
sleeve of the instrument and
indicates the rear terminal
connections for the
instrument ordered.
Figure 4
Product Code : 902S/IS/HRE/CTR/SRE/VH/XM///LE
IT/HAP/CLL/SA/XA///0/600/C/01
Serial Number: G34534-001-008-03-91
A
This label is found on the rear of
the instrument and indicates the
ordering code, serial no. etc.
Code : 902S/IS/HRE/CTR/SRE/VH/XM///LE
IT/HAP/CLL/SA/XA////0/600/C/01
Serial Number : G34534-001-006-03-91
Software Ver. : 1 .OO Service Tel. :
[phone]
3

Installation
2.1 Instrument Layout
The 902/3/4 series of instruments can easily be configured to most customer
requirements on site. The microprocessor, power supply and display boards are
standard to all 902/3/4 series of instruments, see figure 5. Various plug-in
hardware modules can then be fitted to provide the different functions. These
modules can be allocated to one or two sites on the power supply board. If an
options or analogue communications board is fitted in the instrument, a further
two sites are available for installing these modules, as shown in Figure 6.
I
I
Power Supply Board ____)
Options Board
Microprocessor Board
Figure 5. Printed Circuit Board Positions
Channel 1
Channel 3
Channel 2
Channel
4
Figure 6. Plug-in Module Slot Positions
4

Installation
2.2 Rear Terminal Connections
CHANNEL 1
CHANNEL 2
Screw I
Termin:
I
CHANNEL 4
, CHANNEL 3
I I
,ANALOGUE COMMS
OPTIONS MICRO
PSU
I I I
- DIGITAL COMMS
-
DIGITAL INPUTS
-
PROCESS VARIABLE
Ident. Label Wire Connection
5

Installation
2.2.1 Power Supply
The power supply can be 85V to 264V, or a low level ac/dc supply of 17-30Vac /
20 - 40Vdc. If a low level supply is used the positive may be connected to
terminal 24.
Power supply
85V to 264V ac,
17V to 30V ac,
20V to 40V dc
85 - 264V ac 17-30Vac
20 - 40V dc
III
Suppression Earth
j-m
Terminal R is the radio frequency interference reference for the instrument.
When
despatched from the factory, terminal R and &are connected together.
In most cases it is acceptable to connect these terminals to supply earth.
Terminals R and 4 are connected together by a
link on the power supply pcb.
Link 1
aR0 -
In a particularly noisy environment it may be
advantageous to separate the RFI from the
mains earth and connect to a cleaner earth
reference if available. If this is the case cut link
LK 1.
1
I
I-
)
L
15
6

Installation
2.2.2 Inputs
This instrument has one input which can be set in the configuration to accept a
number of different sensor types. Having set the configuration, the sensor must
be connected to the correct terminals as shown on the following pages.
Thermocouple
Input
When the instrument has been configured for internal cold junction
*
compensation (CJC), compensation cable of the correct type for the
’
thermocouple used, or the thermocouple itself, must be wired to
’
these terminals. Copper wire must NOT be used.
Ii
If an external cold junction (oven/ice reference) is to be used, then copper wires
must be used between the rear terminals of the instrument and the cold junction
reference.
Resistance Thermometer Note: When three conductors between
input
the bulb and the rear terminals have
2 Wire 3 Wire 4 Wire
identical resistances, the lead resistance
error be minimised. When a four wire
RTD is used the fourth wire is insulated
from all other connections. If a two wire
system is used the lead resistance will
Pyrometer
Input (Low Level)
Input (High Level)
The pyrometer model number determines the rear terminal
connections to be used. Paragraph 4.2.1 of section 4, the
configuration, gives a table listing the various pyrometer model
numbers. If the last column of this table carries the abbreviation
“HL
l/P” then the “Input (High Level)” terminals should be used.
For all other models of pyrometer, use the “Input (Low Level)”
terminals. For pyrometer codes 48 and 51, (Q004, Q005), a
5OOQ resistor must be connected across the rear terminals “H2”
and “H4”, together with the pyrometer wiring. In this case a
suitable resistor, Part No. SUB902 SPARE 500R, colour coded
yellow, will be found in the instrument packing. Pyrometer code 54, (R026/ORK),
requires cold junction compensation within the instrument. The instrument
software will automatically enable this feature, but the value of
“C1 (A)“, see
paragraph 4.2.1 of section 4, the configuration, must be set to
“O”, to ensure the
correct amount of compensation is applied.
7