JUMO DICON 401 User manual

JUMO DICON 401/501
Universal Profile Controller
Universal Profile Generator
B 703580
Operating Manual
2013-10-01/00370044
Type 703585/1... Type 703580/0...
Type 703585/2...

Please read this operating manual before commissioning the instrument. Keep the manual in a
place which is accessible to all users at all times.
Your comments are appreciated and may help us in improving this manual.
All necessary settings are described in this operating manual. Manipulations not described in the
manual or expressly forbidden will jeopardize your warranty rights. Please contact the nearest sub-
sidiary or the head office, should you encounter problems.
When accessing the inner parts of the unit and returning modules, assemblies or components,
please observe the regulations accordings to EN 61340-5-1 and EN 61340-5-2 „Protection of
electrostatic sensitive devices“. Only use ESD packaging for transport.
Please note that we cannot accept any liability for damage caused by ESD.
ESD=Electro Static Discharge

E

Contents
1Introduction 7
1.1 Description .................................................................................................... 7
1.2 Block structure ............................................................................................. 7
1.3 Typographical conventions ......................................................................... 8
1.3.1 Warning signs ................................................................................................. 8
1.3.2 Note signs ...................................................................................................... 8
1.3.3 Presentation ................................................................................................... 8
2 Identifying the instrument version 9
2.1 Type designation .......................................................................................... 9
2.2 Accessories ................................................................................................ 10
3Installation 11
3.1 Location and climatic conditions .............................................................. 11
3.2 Dimensions ................................................................................................. 11
3.2.1 Type 703580/0... ........................................................................................... 11
3.2.2 Type 703585/1... .......................................................................................... 12
3.2.3 Type 703585/2... .......................................................................................... 12
3.3 Edge-to-edge mounting ............................................................................ 13
3.4 Fitting into position .................................................................................... 13
3.5 Cleaning the front panel ............................................................................ 13
3.6 Removing the controller chassis .............................................................. 14
4Electricalconnection 15
4.1 Installation notes ........................................................................................ 15
4.2 Connection diagrams ................................................................................. 16
4.2.1 Type 703580 ................................................................................................. 16
4.2.2 Type 703585 (portrait and landscape format) .............................................. 19
4.3 Isolation ....................................................................................................... 21

Contents
5 Operation 23
5.1 Displays and keys ....................................................................................... 23
5.2 Operating modes and states ..................................................................... 24
5.3 Principle of operation ................................................................................ 25
5.4 Entering values and selecting settings .................................................... 26
5.5 Operating modes ........................................................................................ 27
5.5.1 Basic status .................................................................................................. 27
5.5.2 Manual operating mode ............................................................................... 28
5.5.3 Automatic operating mode (program run) .................................................... 29
5.6 Shifting the setpoint ................................................................................... 30
5.7 Altering setpoints ....................................................................................... 30
5.8 Setpoint switching ..................................................................................... 31
5.9 Display switching ....................................................................................... 32
6Profileprogramstart 33
6.1 Instant start of program ............................................................................. 33
6.2 Delayed start of program ........................................................................... 33
7Profileprogrameditor 35
7.1 General ........................................................................................................ 35
7.2 Editing segments ........................................................................................ 37
7.3 Inserting segments .................................................................................... 38
7.4 Copying segments ..................................................................................... 38
7.5 Deleting segments ..................................................................................... 39
7.6 Programming repeat cycles ...................................................................... 39
7.7 Temporary alterations ................................................................................ 40

Contents
8Operatinglevel 41
9 Parameter level 43
10 Configuration level 1 45
10.1 Controller .................................................................................................... 47
10.2 Limit comparators ...................................................................................... 49
10.3 Inputs ........................................................................................................... 52
10.4 Outputs ........................................................................................................ 57
10.5 Profile controller ......................................................................................... 59
10.6 Maths and logic module ............................................................................ 62
10.7 Display ......................................................................................................... 67
10.8 Logic functions ........................................................................................... 70
10.9 Interface ..................................................................................................... 73
11 Optimisation 75
11.1 Self-optimisation ........................................................................................ 75
11.2 Checking the optimisation ........................................................................ 76
11.3 Fuzzy parameters ....................................................................................... 77
12 Retrofitting of cards 79
13 Interfaces 83
13.1 RS422/485 interfaces ................................................................................. 83
13.2 PROFIBUS-DP ........................................................................................... 84
14 Accessories 85
14.1 External relay module/logic module ER8/EL8 ......................................... 85
14.2 Setup program with commissioning software ........................................ 86

Contents
15 Appendix 87
15.1 Technical data ............................................................................................. 87
15.2 Alarm messages and display priorities .................................................... 90
15.3 Character set for matrix display ............................................................... 93
15.4 Instrument features (configuration level 2) .............................................. 94
15.5 Notes for instruments with Germanischer Lloyd (GL) approval ........... 95
15.5.1Technical data .............................................................................................. 95
15.5.2 Alarm messages ......................................................................................... 95
15.5.3Inhibits ......................................................................................................... 95
15.5.4Manual mode ............................................................................................... 95
15.5.5Additional notes ........................................................................................... 95
16 Index 97

7
1 Introduction
1.1 Description
This series of universal, freely configurable profile controllers/profile genera-
tors is available in the formats 96mm x 96mm and 96mm x 48mm (portrait
and landscape format). The instruments feature two 4-digit 7-segment dis-
plays, five or eight LEDs for indicating the switching status and the operating
modes, an 8-digit matrix display, as well as six keys for operation and configu-
ration.
The user has flexibility in assigning the instrument slots, in accordance with
the block structure.
10 profile programs with up to 100 segments can be programmed; a total of
100 segments can be implemented.
Additional functions include self-optimisation, parameter set switching, a real-
time clock, up to eight limit comparators and a maximum of eight operating
contacts. Linearisation for the usual transducers are stored in the memory,
and a customized linearisation table can be programmed. The instruments can
be adapted to the most diverse tasks with the aid of a maths module. The in-
struments can be integrated into a data network via a serial interface, or they
can be expanded through an external relay module. A setup program with a
program editor is available for easy configuration from a PC.
The electrical connection is at the rear by screw terminals.
1.2 Block structure
Type 703580 only
Analogue inputs:
- Resistance thermometer
- Thermocouples
- Standard signals
- Potentiometer
Outputs:
- Relay
- Solid-state relay
- Logic output 5V
- Logic output 22V
- Analogue output
- Supply for
2-wire transmitter

1 Introduction
8
1.3 Typographical conventions
1.3.1 Warning signs The signs for Danger and Warning are used
in this manual under the following conditions:
VDanger This sign is used when there may be danger
to personnel if the instructions are disregard-
ed or not followed accurately.
Warning This sign is used when there may be damage
to equipment or data if the instructions are
disregarded or not followed accurately.
EWarning This sign is used when special care must be
taken when handling components that are
sensitive to electrostatic discharges.
1.3.2 Note signs
Note This symbol is used when your attention is
drawn to a specific remark.
Reference This sign refers to additional information in
other manuals, chapters or sections.
HAction This sign refers to an action to be performed.
The individual steps are marked by this
asterisk, e. g.:
hPress Ikey
1.3.3 Presentation
E+ IKey combination The depiction of keys together with a plus
sign means that first the Ekey has to be
pressed and held down, and then a further
key is pressed.
CONFIG 1 Dot-matrix display Texts and messages are visualised in the dot-
matrix display.

9
2 Identifying the instrument version
2.1 Type designation
* Type 703580 only
Delivery package
-Profilecontroller/generator
- 2 mounting brackets
-seal
- Operating Manual B 703580
(1) (2) (3) (4) (5) (6) (7)
703580/ 0 – – – – / ,
Format 96 mm x 96 mm
703585/ – 0 0 – 0 0 0 – – / ,
Format 48 mm x 96 mm and 96 mm x 48 mm
(1) Basic type extension
Format:
96mm x 96mm 0
48mm x 96mm portrait 1
96mm x 48mm landscape 2
Version:
Standard with factory default
settings 8
Customized programming 9
Language for instrument texts:
German 1
English 2
French 3
(2) Analogue input 1 2 3 4
not assigned 0 0 0 0
Universal input
(all transducers except
voltage -10/2/0 — 10V) 1111
voltage -10/2/ 0 — 10V 2 2 2 2
(3) Output 1 2 3 4 5 6
not assigned 0 0 0 0 0 0
Relay (changeover
contact) 1 1 1 1 1 1
Solid-state relay
230V 1A 2 2 2 2 2 2
Logic 0/5V 3 3 3 3 3 3
Logic 0/22V 4 4 4 4 4 4
Analogue output 5 5 5 5 5 5
Supply
for 2-wire transmitter 6 6 6 6 6 6
Two logic inputs 7 7 7 - - -
(4) Supply
110 — 240V AC +10/-15%
48 — 63Hz
20 — 30V AC/DC 48 — 63Hz
2
2
3
5
(5) Interface
not assigned 0 0
RS422/485 5 4
PROFIBUS-DP
(no GL approval)
64
(6) Maths and logic module
not available 0 0
available 0 3
(7) Approvals
DIN EN 14597*056
Germanischer Lloyd (GL)*062
DIN EN 14597 and GL*063
DIN EN 14597 and UL*064
GL and UL*065
DIN EN 14597, GL and UL*066

2 Identifying the instrument version
10
2.2 Accessories
External relay module ER8 (3A/230V)
Supply 110 — 240V AC
Part no. 00405292
(no GL approval)
External relay module ER8 (3A/230V)
Supply 20 — 53V DC/AC
Part no. 00405297
(no GL approval)
External logic module EL8 (0/12V)
Supply 110 — 240V AC
Part no. 00439131
(no GL approval)
External logic module EL8 (0/12V)
Supply 20 — 53V DC/AC
Part no. 00471459
(no GL approval)
PC interface for setup program
with USB/TTL converter, 2 adapters (socket, pins)
Part no. 00456352
Setup program and program editor for
Windows®NT4.0/2000/XP/Vista/7 (32/64 bit)
Part no. setup program: 00379085
Part no. program editor: 00379547
Hardware requirements:
- 512 Mbyte RAM
- 50 Mbyte available on hard disk
- CD-ROM drive
- 1 free serial interface or USB interface

11
3 Installation
3.1 Location and climatic conditions
The conditions at the instrument location must conform to the require-
ments listed under Technical data. The ambient temperature at the loca-
tion should be between –5 and 55 °C, at a relative humidity of not more
than 95%.
3.2 Dimensions
3.2.1 Type 703580/0...
Setup plug
panel cut-out to
IEC 61554

3 Installation
12
3.2.2 Type 703585/1...
3.2.3 Type 703585/2...
Setup plug
panel cut-out to
IEC 61554
Setup
plug
panel cut-out to
IEC 61554

13
3 Installation
3.3 Edge-to-edge mounting
3.4 Fitting into position
hFit the seal provided onto the
instrument body.
hInsert the controller from the front
into the panel cut-out.
hInsert the mounting brackets from
the rear of the panel into the guides
at the sides of the housing.
The flat sides of the brackets must
be against the housing.
hPlace the brackets against the rear
of the panel and tighten them evenly
with a screwdriver.
3.5 Cleaning the front panel
The front panel can be cleaned with the usual rinsing and cleaning agents. It
has a limited resistance to organic solvents (e. g. methylated spirits, white spir-
it, P1, xylol, etc.). Do not use high-pressure cleaning equipment.
Minimum spacing of the panel cut-outs
Type horizontal vertical
without setup plug:
703580/0...
703585/1... (portrait format)
703585/2... (landscape format)
11mm
11mm
30mm
30mm
30mm
11mm
with setup plug:
703580/0...
703585/1... (portrait format)
703585/2... (landscape format)
11mm
11mm
65mm
65mm
65mm
11mm

3 Installation
14
3.6 Removing the controller chassis
The controller chassis can be removed from the housing for servicing.
hPress together the ribbed surfaces
top and bottom (or left and right with
the landscape format) and pull out
the controller chassis.
H
When inserting the controller chassis, care must be taken that the lugs
(underneath the ribbed surfaces) snap into position.

15
4 Electrical connection
4.1 Installation notes
❑The choice of cable, the installation and the electrical connection of the in-
strument must meet the requirements of VDE 0100 “Regulations on the in-
stallation of power circuits with nominal voltages below 1000 V” or the ap-
propriate local regulations.
❑The electrical connection must only be carried out by qualfied personnel.
❑The instrument shall be operated by mains protected with a branch circuitry
overcurrent protection device not more than 20 Amps.
For servicing/repairing a Disconnecting Device shall be provided to discon-
nect all conductors.
❑A current-limiting resistor interrupts the supply circuit in the event of a short
circuit. The load circuit must be fused for the maximum relay current to pre-
vent welding of the output relay contacts in the event of a short circuit.
❑Electromagnetic compatibility conforms to the standards and regulations
specified under Technical Data.
❑Input, output and supply lines should be run separately, not parallel to one
another.
❑All input and output cables without connection to the mains supply must be
arranged as twisted and screened cables. Earth the screen at one end at
the instrument terminal TE.
❑Earth the instrument at terminal TE to the earth conductor. This line must
have at least the same cross-section as the supply lines. Earth lines should
be run in a star layout to a common earth point which is connected to the
earth conductor of the supply. Do not loop the earth connections, i. e. do
not run them from one instrument to another.
❑Do not connect any additional loads to the supply terminals of the instru-
ment.
❑The instrument is not suitable for installation in hazardous areas.
❑Apart from faulty installation, there is a possibility of interference or damage
of controlled processes due to incorrect settings on the controller (setpoint,
data of parameter and configuration levels, internal adjustments). Safety
devices independent of the controller, such as overpressure valves or
temperature limiters/monitors, should always be provided and should be
capable of adjustment only by specialist personnel. Please refer to the
appropriate safety regulations in this connection. Since adaptation (self-
optimisation) cannot be expected to handle all possible control loops, there
is a theoretical possibility of unstable parameter settings. The resulting
process value should therefore be monitored for its stability.
❑The maximum permitted voltage difference between the inputs of the con-
troller and TE is 30 V AC or 50 V DC.

4 Electrical connection
16
4.2 Connection diagrams
4.2.1 Type 703580
+ – + –
+– +
–
+ +
– –
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
11109874321
S
EA
SEA
1
Thermocouples
Logic inputs 1+2 Analogue input 2 Analogue input 1
Resistance
thermometer
(3-wire)
Resistance
thermometer
(2-wire)
Voltage
0/2—10V
Current
0/4—20mA
Potentiometer
BE1
BE2
V
The electrical connection must only be
made by suitably qualified personnel
H
The instrument version can be identified
by the type code.
H
PROFIBUS-DP:
vInterface Description B 703560.2.3
H
When a thermocouple with internal temperature compensation is wired up to the analo-
gue inputs 1, 3 or 4, no Pt500, Pt1000 or KTY must be connected to analogue input 2.
vSection 12 “Retrofitting of cards”
Additional analogue input signals
Signal Connection like
0—1V 0—10V
-1to +1V 0 — 10V
-10 to +10V 0 — 10V
0—100mV thermocouple
-100 to +100mV thermocouple

17
4 Electrical connection
+ –
+–
+–
ϑ
ϑ
ϑ
ϑ
12111054321
S
EA
RxD
(+)
RxD
()–
TxD
(+)
RxD/
TxD
(+)
TxD
()–
RxD/
TxD
()–
GND
GND
RS422
RS485/ER8
2
Thermocouples
Interface
Analogue input 3
(option)
Resistance
thermometer
(3-wire)
Resistance
thermometer
(2-wire)
Voltage
0/2—10V
Current
0/4—20mA
Potentiometer
BAGND
PROFIBUS DP
+5 V
20 mA
+–
+–
+–
ϑ
ϑ
ϑ
ϑ
121110876321
S
EA
3
Thermocouples
* Supply for
2-wire transmitter (22V)
Output 6
(Slot 6)
Output 5
(Slot 5)
Analogue input 4
(option)
Resistance
thermometer
(3-wire)
Resistance
thermometer
(2-wire)
Voltage
0/2—10V
Current
0/4—20mA
Potentiometer
+
+
–
–
ii
+
+
–
–
uu
+
+
–
–
230V/3A 230V/3A
5V(22V)/30mA* 5V(22V)/30mA*
230V/1A 230V/1A
-10/0/2—10V -10/0/2—10V
-20/0/4—20mA -20/0/4—20mA
The output must be config-
ured accordingly.
vSection 10.4 “Outputs”
vSection 12 “Retrofitting of cards”
Additional analogue input signals
Signal Connection like
0—1V 0—10V
-1 to +1V 0 — 10V
-10 to +10V 0 — 10V
0—100mV thermocouple
-100 to +100mV thermocouple
H
Earth the screen for the
interface cable at one
end only to TE.
A
B
Contact protection circuit for the relay outputs:
56Ω/15nF between common-make/common-break
Type 703580

4 Electrical connection
18
TENL1321
5
+–
i
+–
u
+–
230V/3A
Logic inputs 3+4
(Slot 1) Mains supply
Output 1
(Slot 1)
5V(22V)/30mA*
230V/1A
* Supply for
2-wire transmitter (22V)
-10/0/2—10V
-20/0/4—20mA
20—30V
AC/DC
!
!
AC
110—240V
+
–
BE3
BE4
The output must be config-
ured accordingly
vSection 10.4 “Outputs”
Type 703580
Contact protection circuit for the relay outputs:
56Ω/15nF between common-make/common-break

19
4 Electrical connection
4.2.2 Type 703585 (portrait and landscape format)
V
The electrical connection must only be
made by suitably qualified personnel.
H
The instrument version can be identified
by the type code.
* Supply for 2-wire
transmitter
The output must be config-
ured accordingly.
vSection 10.4 “Outputs”
H
Earth the screen for the
interface cable at one
end only to TE.
BA
Contact protection circuit for the relay outputs:
56Ω/15nF between common-make/common-break
H
PROFIBUS-DP:
vInterface Description B 703560.2.3

4 Electrical connection
20
+ – + –
+– +
–
+ +
– –
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
ϑ
11109874321
S
EA
SEA
6
Thermocouples
Logic inputs 1+2 Analogue input 2 Analogue input 1
Resistance
thermometer
(3-wire)
Resistance
thermometer
(2-wire)
Voltage
0/2 10V
Current
0/4 20mA
Potentiometer
BE1
BE2
H
When a thermocouple with internal temperature compensation is wired up to analogue
input 1, no Pt500, Pt1000 or KTY must be connected to analogue input 2.
vSection 12 “Retrofitting of cards”
Additional analogue input signals
Signal Connection like
0—1V 0—10V
-1to +1V 0 — 10V
-10 to +10V 0 — 10V
0—100mV thermocouple
-100 to +100mV thermocouple
* Supply for
2-wire transmitter
The output must be configured
accordingly.
vSection 10.4 “Outputs”
Contact protection circuit for the relay outputs:
56Ω/15nF between common-make/common-break
Type 703585