Novus N1030 User manual

NOVUS AUTOMATION 1/4
N103
0 Controller
TEMPERATURE CONTROLLER
– INSTRUCTIONS MANUAL – V1.0x A
SAFETY ALERTS
The symbols below are used on the equipment and throughout this
document to draw the user’s attention to important operational and
safety information.
CAUTION:
Read the manual thoroughly
before installing and operating
the equipment.
CAUTION OR DANGER:
Electrical shock hazard
All safety related instructions that appear in the manual must be
observed to ensure personal safety and to prevent damage to either
the instrument or the system. If the instrument is used in a manner not
specified by the manufacturer, the protection provided by the
equipment may be impaired.
INSTALLATION / CONECTIONS
The controller must be fastened on a panel, following the sequence
of steps described below:
•Prepare a panel cut-out of 46 x 46 mm;
•Remove the mounting clamps from the controller;
•Insert the controller into the panel cut-out;
•Slide the mounting clamp from the rear to a firm grip at the panel.
ELECTRICAL CONNECTIONS
Fig. 01 below shows the electrical terminals of the controller:
Fig. 01 - Connections of the back panel
RECOMMENDATIONS FOR THE INSTALLATION
•All electrical connections are made to the screw terminals at the
rear of the controller.
•To minimize the pick-up of electrical noise, the low voltage DC
connections and the sensor input wiring should be routed away
from high-current power conductors. If this is impractical, use
shielded cables. In general, keep cable lengths to a minimum.
•All electronic instruments must be powered by a clean mains
supply, proper for instrumentation.
•It is strongly recommended to apply RC'S FILTERS (noise
suppressor) to contactor coils, solenoids, etc. In any application it
is essential to consider what can happen when any part of the
system fails. The controller features by themselves can not assure
total protection.
FEATURES
INPUT TYPE SELECTION
Table 01 shows the sensor types accepted and their respective
codes and ranges. Access the parameter
TYPE
in the INPUT level to
select the appropriate sensor.
TYPE
CODE
RANGE OF MEASUREMENT
Termopar
J
Tc j
Range: -110 to950 ºC (-166 to 1742 ºF)
TermoparK
Tc k
Range: -150 to1370 ºC (-238 to 2498 ºF)
TermoparT
Tc t
Range: -160 to400 ºC (-256 to 752 ºF)
Pt100
Pt
Range: -200 to850 ºC (-328 to 1562 ºF)
Table 01 – Input types
The input type should be the first parameter to be configured on the
controller. Any modifications on the input type will automatically
change other related parameters. The user must verify the
configuration every time that an input type modification occurs.
OUTPUTS
The controller has two outputs. The user can configure these outputs
to operate as Control Output (
(trl
)or Alarm Output (
al
).
OUT1 - Output Voltage pulse, 5 Vdc / 25 mA
OUT2 - Output Relay SPST-NO
CONTROL OUTPUT (
(TRL
)
The control strategy can be ON/OFF (when
PB
= 0.0) or PID. The
PID parameters can be automatically determined enabling the auto-
tuning function (
ATvN
).
ALARM OUTPUT (
al
)
The controller contains 2 alarms that can be directed (assigned) to any
output channel. The alarm functions are described in Table 02.
off
Output is not used as alarm.
lo
Alarm of Absolute Minimum
Value. Triggers when the
value of measured PV is
below the value defined for
alarm Setpoint (SPAL).
SPAL
PV
ki
Alarm of Absolute Maximum
Value. Triggers when the
value of measured PV is
above the value defined for
alarm Setpoint.
SPAL
PV
dif
Alarm of Differential. In this function the parameters,
SPAL represent the deviation of PV in relation to the
SP of CONTROL.
SP
PV
SP + SPAL
SP – SPAL
SP
PV
SP – SPAL
SP + SPAL
Positive SPAL Negative SPAL

N1030 Controller
NOVUS AUTOMATION 2/4
difl
Alarm of Minimum Differential Value. It triggers when
the value of PV is below the defined point by
SP-SPAL.
SP
PV
SP – SPAL
SP
PV
SP – SPAL
Positive SPAL Negative SPAL
difk
Alarm of Maximum Differential. Triggers when the
value of PV is above the defined point by SP+SPAL.
SP
PV
SP + SPAL
SP
PV
SP + SPAL
Positive SPAL Negative SPAL
ierr
Alarms of the Sensor Break (Sensor Break Alarm). It
is activated when the Input presents problems such
as interrupted sensor, bad connection, etc.
Table 02 – Alarm functions
INITIAL BLOCKING OF ALARM
The initial blocking option inhibits the alarm from being recognized
if an alarm condition is present when the controller is first energized
(or after a transition from run YES NO). The alarm will be enabled
only after the occurrence of a non alarm condition followed by a new
occurrence for the alarm.
The initial blocking is useful, for instance, when one of the alarms is
configured as a minimum value alarm, causing the activation of the
alarm soon upon the process start-up, an occurrence that may be
undesirable.
The initial blocking is disabled for the sensor break alarm function
ierr
.
OFFSET
Allows fine adjustments to the PV reading for compensation of
sensor error.
OPERATION
The controller’s front panel, with its parts, can be seen in the Fig. 02:
Fig. 02 - Identificationof thepartsreferring to the front panel
Display of PV / Programming (top display, red color): Displays the
current value of PV (Process Variable). When in configuration mode,
it shows the parameters names.
Display of SP / Parameters (bottom display, green color): Displays
the value of SP (Setpoint). When in configuration mode, it shows the
parameters values.
TUNE Indicator: Stays ON while the controller is in tuning process.
OUT Indicator: For relay or pulse control output; it reflects the actual
state of the output.
A1 and A2 Indicators: signalize the occurrence of alarm situation.
P Key: used to walk through the menu parameters.
Increment key and
- Decrement key: allow altering the
values of the parameters.
Back key: used to retrocede parameters.
OPERATION
When the controller is powered up, it displays its firmware version for
3 seconds, after which the controller starts normal operation. The
value of PV and SP is then displayed and the outputs are enabled.
In order for the controller to operate properly in a process, its
parameters need to be configured first, such that it can perform
accordingly to the system requirements. The user must be aware of
the importance of each parameter and for each one determine a valid
condition.
The parameters are grouped in levels according to their functionality
and operation easiness. The 3 levels of parameters are
1 –Tuning / 2 – Input / 3 – Calibration
The “P”key is used for accessing the parameters within a level.
Keeping the “P” key pressed, at every 2 seconds the controller jumps
to the next level of parameters, showing the first parameter of each
level:
PV >>
atvn
>>
type
>>
PASS
>> PV …
To enter a particular level, simply release the “P” key when the first
parameter in that level is displayed. To walk through the parameters
in a level, press the “P” key with short strokes. To go back to the
previous parameter in a level, press
:
Each parameter is displayed with its prompt in the upper display and
value/condition in the lower display. Depending on the level of
parameter protection adopted, the parameter
PASS
precedes the
first parameter in the level where the protection becomes active. See
section Configuration Protection.
DESCRIPTION OF THE PARAMETERS
OPERATION LEVEL
PV + SP PV Indication screen. On the higher display (red) the
value of the measured variable (PV) temperature is
shown. On the lower display (green), the control
setpoint (SP) is shown.
TUNING LEVEL
Atvn
AUTO-TUNE: enables the auto-tuning function for the
PID parameters (
pb
,
ir
,
dt
). Defines the control
strategy to be taken:
off
- Turned off. (no PID tuning)
Fast
- Automatic tuning.
Full - More accurate automatic tuning.
PB
Proportional Band - Value of the term Pof the control
mode PID, in percentage of the maximum span of the
input type. Adjust of between 0 and 500.0 %.
When set to zero (0), control action is ON/OFF.
ir
Integral Rate - Value of the term Iof the PID algorithm,
in repetitions per minute (Reset). Adjustable between 0
and 99.00. Displayed only if proportional band ≠0.
dt
Derivative Time - Value of the term Dof the control
mode PID, in seconds. Adjustable between 0 and 300.0
seconds. Displayed only if proportional band ≠0.
(t
Level time: Pulse Width Modulation (PWM) period in
seconds. Adjustable between 0.5 and 100.0 seconds.
Displayed only if proportional band ≠0.
kyst
Control hysteresis
: Is the hysteresis for ON/OFF
control (set in temperature units). This parameter is
only used when the controller is in ON/OFF mode
(Pb=0).

N1030 Controller
NOVUS AUTOMATION 3/4
A(t
Action Control:
re
Control with Reverse Action. Appropriate for
heating. Turns control output on when PV is
below SP.
dir
Control with Direct Action
. Appropriate for
cooling. Turns control output on when PV is
above SP.
0vt1
Assign functions to the Output channels OUT1, OUT2
Off
- Not used.
(trL
- Control output.
AL
- Alarm output.
0vt2
INPUT LEVEL
Type
Input Type: Selects the input signal type to be
connected to the process variable input. Refer to
Table 01 for the available options.
Dp.po
Selects the decimal point position to be viewed in both
PV and SP.
vnit
Selects display indication for degrees Celsius or
Fahrenheit:
(
- Indication in Celsius.
f
- Indication in Fahrenheit.
0ffs
Sensor Offset: Offset value to be added to the PV
reading to compensate sensor error. Default value:zero.
Spll
SP Low/High Limit. Defines SP upper and lower limits.
It defines the maximum and minimum PV indication
range.
This parameter does not limit the Alarm SP
configuration.
Spxl
Fval
Functions of Alarms. Defines the functions for the
alarms among the options of the Table 02.
Sp.al
Alarm SP: Value that defines the point of activation of
the alarm outputs.
For the alarms programmed with the functions of the
type Differential, these
parameters represent the
deviations.
For the
ierr
alarm function, this parameter has no
meaning.
blal
Blocking Alarm. This function blocks the alarms.
YES
- enables initial blocking
NO
- inhibits initial blocking
xyal
Histeresis of Alarm. Defines the difference between
the value of PV at which the alarm is triggered and the
value at which it is turned off.
CALIBRATION LEVEL
All types of input are calibrated in the factory. In case a
recalibration is required; it shall be carried out by a specialized
professional. In case this level is accidentally accessed, do not
perform alteration in its parameters.
pass
Password. This parameter is presented before the
protected levels. See item Protection of Configuration.
(al
Calibration. Enables the possibility for calibration of
the indicator. When the calibration is not enabled, the
related parameters are hidden.
inL(
Input Low Calibration. Enter the value corresponding
to the low scale signal applied to the analog input.
ink(
Input High Calibration. Enter the value corresponding
to the full scale signal applied to the analog input.
rstr
Restore. Restores the factory calibration for all inputs
and outputs, disregarding modifications carried out by
the user.
Pas.(
Password Change.
Allows defining a new access
password, always different from zero.
Prot
Protection. Sets up the Level of Protection.
See Table 04.
CONFIGURATION PROTECTION
The controller provides means for protecting the parameters
configurations, not allowing modifications to the parameters values,
avoiding tampering or improper manipulation. The parameter
Protection (
PROt
), in the Calibration level, determines the
protection strategy, limiting the access to particular levels, as shown
by the Table 04.
PROTECTION
LEVEL
PROTECTION LEVELS
1
Only the Calibration level is protected.
2
Calibration and Input levels.
3
Calibration, Input and Tuning levels.
4
All levels are protected, including SP.
Table 04 – Levels of Protection for the Configuration
ACESS PASSWORD
The protected levels, when accessed, request the user to provide the
Access Password for granting permission to change the
configuration of the parameters on these levels.
The prompt
PASS
precedes the parameters on the protected levels.
If no password is entered, the parameters of the protected levels can
only be visualized.
The Access Password is defined by the user in the parameter
Password Change (
PAS.(
), present in the Calibration Level. The
factory default for the password code is 1111.
PROTECTION ACCESS PASSWORD
The protection system built into the controller blocks for 10 minutes
the access to protected parameters after 5 consecutive frustrated
attempts of guessing the correct password.
MASTER PASSWORD
The Master Password is intended for allowing the user to define a
new password in the event of it being forgotten. The Master
Password doesn’t grant access to all parameters, only to the
Password Change parameter (
PAS(
). After defining the new
password, the protected parameters may be accessed (and
modified) using this new password.
The master password is made up by the last three digits of the serial
number of the controller added to the number 9000. As an example,
for the equipment with serial number 07154321, the master
password is 9 3 2 1.
Controller serial number is displayed by pressing
for 3 seconds.
DETERMINATION OF PID PARAMETERS
During the process of determining automatically the PID parameters,
the system is controlled in ON/OFF in the programmed Setpoint. The
auto-tuning process may take several minutes to be completed,
depending on the system. The steps for executing the PID auto-
tuning are:
•Select the process Setpoint.
•Enable auto-tuning at the parameter “
Atvn
”, selecting
FAST
or
FULL
.
The option
FAST
performs the tuning in the minimum possible time,
while the option
FULL
gives priority to accuracy over the speed.

N1030 Controller
NOVUS AUTOMATION 4/4
The sign TUNE remains lit during the whole tuning phase. The user
must wait for the tuning to be completed before using the controller.
During auto tuning period the controller will impose oscillations to the
process. PV will oscillate around the programmed set point and
controller output will switch on and off many times.
If the tuning does not result in a satisfactory control, refer to Table 05
for guidelines on how to correct the behavior of the process.
PARAMETER
VERIFIED PROBLEM
SOLUTION
Band Proportional Slow answer Decrease
Great oscillation
Increase
Rate Integration Slow answer Increase
Great oscillation
Decrease
Derivative Time Slow answer or instability Decrease
Great oscillation Increase
Table 05 - Guidance for manual adjustment of the PID parameters
For further details on PID tuning, visit our web site:
www.novusautomation.com.
MAINTENANCE
PROBLEMS WITH THE CONTROLLER
Connection errors and inadequate programming are the most
common errors found during the controller operation. A final revision
may avoid loss of time and damages.
The controller displays some messages to help the user identify
problems.
MESSAGE DESCRIPTION OF THE PROBLEM
----
Open input. No sensor or signal.
Err1
Err6
Connection and/or configuration problems.
Check the wiring and the configuration.
Other error messages may indicate hardware problems requiring
maintenance service.
PROCESS VARIABLE INPUT CALIBRATION
All inputs are factory calibrated and recalibration should only be done
by qualified personnel. If you are not familiar with these procedures
do not attempt to calibrate this instrument.
a) Set the type parameter according to the input
type
.
b) Configure the lower and upper limits of indication for the
maximum span of the selected input type.
c) Access the calibration level.
d) Enter the password.
e) Enable the calibration setting YES in the parameter
(Alib
.
f) With the aid of an electrical signals simulator, apply a signal level
close the lower limit of the measuring range of the input, on the
corresponding terminals.
g) Access the parameter “
inLC
”. With the keys and adjust the
display reading such as to match the applied signal. Then press the
key.
h) Inject a signal that corresponds to a value a little lower than the
upper limit of indication.
i) Access the parameter “
ink(
”. With the keys “ ” and “ ”,
adjust the display reading such as to match the applied signal.
Then press the key “
P
” until return to the Display PV screen.
j) Validate the calibration performed.
Note: When checking the controller calibration with a Pt100
simulator, pay attention to the simulator minimum excitation current
requirement, which may not be compatible with the 0.170 mA
excitation current provided by the controller.
IDENTIFICATION
N1030-PR Version with power supply 100~240 Vac
48~240 Vdc
N1030-PR-24V Version with power supply 12~24 Vdc / 24 Vac
SPECIFICATIONS
DIMENSIONS:............................................................48 x 48 x 35 mm
Approximate Weight:...............................................................60g
POWER SUPPLY: .........................100 to 240 Vac (±10 %), 50/60 Hz
...................................................................48 to 240 Vdc (±10 %)
Optional 24 V:................... 12 to 24 Vdc / 24 Vac (-10 % / +20 %)
Maximum consumption: ........................................................ 5 VA
ENVIRONMENTAL CONDITIONS:
Operation Temperature:............................................... 0 to 50 °C
Relative Humidity:...................................................80 % @ 30 °C
...............For temperatures above 30 °C, reduce 3 % for each °C
...... Internal use; Category of installation II, Degree of pollution 2;
altitude < 2000 meters
INPUT...... Thermocouples J; K; Tand Pt100 (according of Table 01)
Internal Resolution:......................................32767 levels (15 bits)
Resolution of Display:.........12000 levels (from -1999 up to 9999)
Rate of input reading:...........................................up 5 per second
Precision: Thermocouples J, K, T: 0.25 % of the span ±1 °C (*)
................................................................Pt100: 0.2 % of the span
Input Impedance:..................Pt100 and thermocouples: > 10 MΩ
Measurement of Pt100:.........................3-wire type, (α=0.00385)
With compensation for cable length, excitation current of 0.170
mA.
(*) The use of thermocouples requires a minimum time interval of 15
minutes for stabilization.
OUTPUTS: OUT1:................................Voltage pulse, 5 Vdc / 25 mA
OUT2:..................Relay SPST; 1,5 A / 240 Vac / 30 Vdc
FRONT PANEL:..........................IP65, Polycarbonate (PC) UL94 V-2
ENCLOSURE:..............................................IP30, ABS+PC UL94 V-0
ELECTROMAGNETIC COMPATIBILITY:...............EN 61326-1:1997
and EN 61326-1/A1:1998
EMISSION:............................................................CISPR11/EN55011
IMMUNITY:......................EN61000-4-2, EN61000-4-3, EN61000-4-4,
EN61000-4-5, EN61000-4-6, EN61000-4-8 and EN61000-4-11
SAFETY:..........................EN61010-1:1993 and EN61010-1/A2:1995
SPECIFIC CONNECTIONS FOR TYPE FORK TERMINALS;
PROGRAMABLE LEVEL OF PWM: from 0.5 up 100 seconds;
STARTS UP OPERATION: after 3 seconds connected to the power
CERTIFICATION:
WARRANTY
Warranty conditions are available on our web site
www.novusautomation.com/warranty.
P