Novus N480 Installation manual

Novus Produtos Eletrônicos Ltda. / Tel: [phone] / www.novus.com.br 1/3
Controller N480
TEMPERATURE CONTROLLER – OPERATION MANUAL – V2.6x
N480
1. ASSEMBLY
The controller should be installed in a panel cut out as specified in
item 2.1. First remove the mounting clamp and insert the controller
into the panel cut out. Place the unit into the panel cut-out and slide
the mounting clamp from the rear to a firm grip at the panel.
The internal circuitry can be fully removed from the housing without
disconnecting any wiring. By using the thumb just press the tab in
the lower part of the front panel, grab firmly the front panel and pull
out the circuitry from the housing.
1.1. ELECTRICAL CONNECTIONS
Figure 1 shows the electrical terminals of the controller.
123456
78910 11 12
13
14
15 18
17
16
POWER
AC/DC
15-30V
85-264V
SENSOR INPUT AL2
OUT-B
OUT-A
PULSE
4-20mA
RELAY OUTPUT
PULSE OUTPUT
4-20mA OUTPUT POWER
ALARM 2
CONTROL
OUTPUT
OR ALARME 1
Figure 1 - Electrical connections
2. SPECIFICATIONS
2.1. GENERAL
• Dimensions: 48x48x106mm (1/16 DIN).
• Panel cut-out: 45,5x45,5mm
• Weight: 140g (1 relay), 160g (3 relays)
• Power: 85 to 264Vdc/ac, 50/60Hz, 3VA max. Optional: 15
to 30Vdc/ac
• Operation: 0 to 55°C, humidity 20 to 85%
2.2. CONTROL OUTPUT
• Relay output: SPST (U type) relay. Maximum current
3A/250Vac.
• Voltage pulse output: 5Vdc/20mA
Both outputs are available in the basic model and the desired
main control output is user selected via keyboard (refer to “
Cntr
CntrCntr
Cntr “ prompt). The remaining output can then be used as an
alarm output.
In case of sensor break or failure an error "Erro
ErroErro
Erro"message is
displayed and the control output is turned off.
2.3. ALARM OUTPUTS
• Alarm Output 1: SPST relay 3A/250Vac or 5Vdc/20mA
pulse
• Alarm Output 2: SPST relay 3A/250Vca (optional)
2.4. POWER
Mains power is connected to terminals 5 and 6. Check the upper
side of the housing for proper power indication.
2.5. TEMPERATURE SENSOR INPUT
• Pt100: 3-wire connection. Excitation current: 170µA
• Thermocouple input impedance: 10MΩ
• A/D converter resolution: 15000 steps
• Sampling rate: 10 measurements per second
• Accuracy: 0.2% of full scale for Pt100 and 0.25% of full
scale ±1°C for T/C
Thermocouples are connected to terminals 8 and 9 with positive in
terminal 8.
Pt100 sensors are connected to terminals 7, 8 and 9, as indicated in
figure 1. For full compensation of cable resistance only cables with
equal wire electrical resistance should be used.
Table 1 shows the sensor types accepted and their respective
codes. via keyboard.
TYPE CODE RANGE
J 0
00
0 -50 to 760°C (-58 to 1400°F)
K 1
11
1 -90 to 1370°C (-130 to 2498°F)
S 2
22
2 0 to 1760°C (32 to 3200°F)
Pt100 (Resolution 0,1°C) 3
33
3 -199.9 to 530.0°C (-199.9 to 986.0°F)
Pt100 (Resolution 1°C) 4
44
4 -200 to 530°C (-328 to 986°F)
T 5
55
5 -100 to 400 °C (-148 to 752°F)
E 6
66
6 -30 to 720°C (-22 to 1328°F)
N 7
77
7 -90 to 1300°C (-130 to 2372°F)
R 8
88
8 0 to 1760°C (32 to 3200°F)
Table 1 - Sensor types, codes and ranges
3. CONFIGURATION AND OPERATION
Prior to first operation the controller should be fully configured. The
user must set basic parameters as temperature type (“TYPE
TYPETYPE
TYPE”), the
desired control set point (“ SP
SPSP
SP “), the alarms set points (“SPA1
SPA1SPA1
SPA1” and
“SPA2
SPA2SPA2
SPA2”), etc.
3.1. PARAMETERS FLOW CHART
The programming parameters are organized in 4 different sets or
levels:
• Operation level
• Alarms and tuning level
• Configuration level
• Calibration level
At power up the controller displays a prompt at the Operation Level
and remains in this level while under normal operation.
The other levels are only accessed when a change of parameters is
necessary (except for Set Point change). To reach these other
parameters the user must keep the INDEX Key ( ) pressed for
about three seconds. After this time the controller will show the first
parameter of the next level. By keeping the INDEX key pressed for
another 3 seconds the next level will be accessed.
Release the key when the desired level is reached. Press once
the to go to the next prompt in the same level.
When a parameter is shown the display will alternate its name and
value. The value can then be changed by pressing the or
key.

Controller N480
Novus Produtos Eletrônicos Ltda. Tel.:[phone]
After the last parameter in one level is reached the controller returns
to operation level and the display will indicate the measured
temperature.
The display will also go back to the measured temperature whenever
the display is inactive for 20 seconds or more.
When a parameter value is changed via keyboard the controller will
only accept the new value after the user presses the INDEX key to
go to next prompt or if the keyboard is left inactive for 20 seconds.
For disabling the keyboard, move the internal strap to the position
KEY DISABLE. All parameters will be protected, accept the SP
parameter.
KEY
DISABLE
KEY
DISABLE
Figure 2 – Strap in normal operating
position (enabled) Figura 3 – Strap position for inhibiting the keyboard
3.2. OPERATION LEVEL
TEMPERATURE
INDICATION
END
SP
Set Point
TEMPERATURE measured by the sensor.
At power up, the upper display shows the process
temperature value. It also shows the messages
described in chapter 5 of this manual.
The lower displays shows the set point value which
is the temperature value desired for the process.
rAte
rAtE
TEMPERATURE RATE OF RISE: The user defines
the rate of temperature rise from the starting
temperature to the value set in “ SP
SPSP
SP ”.
Rate is defined in °C / minute.
T Sp
time for soak
TIME FOR SOAK: Time in minutes which the
temperature will remain at the selected “ SP
SPSP
SP “.
Refer to item 4.
Rvn
run
RUN: At this prompt the user sets the control output
and alarms to active or to inactive.
0
00
0- inactive outputs; 1
11
1- active outputs;
3.3. TUNING AND ALARMS LEVEL
Atvn
Auto tune
AUTO-TUNE: Activates the auto-tuning of PID
parameters.
0
00
0- Auto-tune is off;
1
11
1- Auto-tune is on;
Pb
Proportional
band
PROPORTIONAL BAND: percentage of maximum
input span.
When set ot zero (0), control action is ON/OFF.
Ir
integral rate
INTEGRAL RATE: Integral time constant in
repetitions per minute (Reset). This constant is not
used when controller is set to ON/OFF action
(Pb=0).
Dt
derivative
time
DERIVATIVE TIME: Derivative time constant in
seconds. This constant is not used when controller
is set to ON/OFF action (Pb=0).
(t
Cycle time
CYCLE TIME: Pulse Width Modulation (PWM)
period in seconds. This term is not used when
controller is set to ON/OFF action (Pb=0).
KySt
HYSterisis
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).
A1SP
SP Alarm 1
SETPOINT for Alarm 1: Tripingpoint for alarm 1
A2SP
SP Alarm 2
SETPOINT for Alarm 2: Triping point for alarm 2
3.4. CONFIGURATION LEVEL
Type
tYPE
INPUT TYPE: Selects the input sensor type to be
connected to the controller. This is the first
parameter to be set.
0
00
0- Thermocouple type J;
1
11
1- Thermocouple type K;
2
22
2- Thermocouple type S;
3
33
3- Pt100 with 0,1° resolution;
4
44
4- Pt100 with 1° resolution;
5
55
5- Thermocouple type T;
6
66
6- Thermocouple type E;
7
77
7- Termopar tipo N;
8
88
8- Termopar tipo R;
Vnit
unit
TEMPERATURE UNIT: Selects display indication
for degrees Celsius or Farenheit.
0
00
0- degrees Celsius ( °C );
1
11
1- degrees Farenheit ( °F );
A(t
ACtion
CONTROL ACTION:
0
00
0- reverse action. Generally used for heating.
1
11
1- direct action. Generally used for cooling.
(ntr
Control
CONTROL OUTPUT:
0
00
0- Sets control output to terminals OUT A.
1
11
1- Sets control output to terminals OUT B.
As control output is defined to terminals OUT A,
alarm output is automatically set to OUT B.
If control output is defined to OUT B alarm 1 will
then be automatically set to OUT A.
spll
SP Low Limit
SET POINT LOW LIMIT: sets the lower range for
SV
spKl
SP High Limit
SET POINT HIGH LIMIT: Sets the upper range for SV.
A1fv
Alarm 1 Function
FUNCTION OF ALARM 1: Refer to table 2 for
function description and respective codes to set at
this prompt.
A2fv
Alarm 2 Function
FUNCTION OF ALARM 2: Refer to table 2 for
function description and respective codes to set at
this prompt.
Aiky
A2ky
AlarmHYsteresis
ALARM 1 AND ALARM 2 HYSTERESIS: Defines
the differential range between the PV value at
which the alarm is turned on and the value at which
it is turned off (in engineering units).
3.5. CALIBRATION LEVEL
A T E N T I O N
These parameters are used to calibrate the temperature
measurement and should only be dealt with by experienced and well
equipped personnel.
Inl(
Input Low
Calibration
SENSOR OFFSET CALIBRATION. Sets the
temperature sensor low calibration (offset). The
display shows only the corrected temperature and
not the offset added. A signal simulator should be
used to inject a low value signal to properly adjust
the offset.
InK(
Input High
Calibration
INPUT HIGH CALIBRATION. Sets the sensor input
circuit gain or high calibration.
A signal simulator should be used to inject a high
value signal to properly adjust the offset.
(j L
Cold Junction Low
Calibration
COLD JUNCTION OFFSET CALIBRATION: Sets
the cold junction offset calibration. A good
thermometer or a temperature simulator should be
used to properly adjust this parameter.

Controller N480
Novus Produtos Eletrônicos Ltda. Tel.:[phone]
4. RAMP TO SOAK FUNCTION CHARACTERISTICS
This function makes the process temperature rise gradually from the
starting point (present PV) to the temperature value set in “ SP
SPSP
SP “
(Ramp). The user defines the rate of rise in degrees per minute at
the “rAtE
rAtErAtE
rAtE” prompt.
When SP is reached the temperature is leveled at this point for 1 to
9999 minutes as programmed at the “ t SP
t SPt SP
t SP ” prompt. Setting 0
(zero) at “ t SP
t SPt SP
t SP ” defines an infinite length soak profile.
To disable the ramp function Set 0.0 at the “rAtE
rAtErAtE
rAtE” prompt. To
disable the soak function set 1at the “ t SP
t SPt SP
t SP ” prompt (thus making
a 1 minute soak) and the control output will go off in 1 minute. To
restart control set 1 at the “ rvn
rvnrvn
rvn ” prompt.
After a power failure the controller will resume ramp to soak
execution at the equivalent previous ramp point. If the proces
temperature is the same as the SP (no temperature drop) the
controller will repeat the soak segment.SoakTemperature
PV
Ramp
Time
SP
Figure 2 - Ramp to Soak Function
5. PROBLEMS WITH THE CONTROLLER
Connection and configuration errors state for most of the problems in
using the controller. A final revision of parameters will save time and
further losses.
Error messages are displayed to help the user to identify possible
problems. : Process temperature is below the selected sensor
range. : Process temperature is above the selected sensor
range : Controller or sensor error. Example:
• Broken thermocouple or Pt100.
• Pt100 badly connected, short-circuited or high cable
resistance.
5.1. ELECTRONIC SERIAL NUMBER VISUALIZATION
To read the 8-digit serial number go to the Operation Level and
press the key for 3 seconds. The display will show the first 4
digits. Keep the key pressed for 3 seconds and the display will
show the last 4 digits.
FIRST 4 DIGITS
SERIAL NUMBER
LAST 4 DIGITS
When powering the unit the display will show the software version
for a few seconds.
6. ALARM FUNCTIONS
Low and high alarms are used to signal minimum and maximum
temperature values as programmed in the “SPA1
SPA1SPA1
SPA1” ande “SPA2
SPA2SPA2
SPA2”
prompts.
Differential alarms are used to indicate deviations from the desired
setpoint (SP) temperature. These deviations are programmed at the
“SPA1
SPA1SPA1
SPA1” and “SPA2
SPA2SPA2
SPA2” prompts.
Error alarm shows sensor defects or not properly connected.
Alarm hysteresis is fixed and factory set as described below:
• Pt100: 1.1ºC
• Thermocouples: type J: 1.3ºC; types K and S: 2.3ºC
6.1. ALARM INITIAL BLOCKING
The initial blocking option inhibits the alarm from being recognized if
an alarm condition is present when the controller is first energized.
The alarm will actuate only after the occurrence of a non alarm
condition followed by a new occurrence for the alarm.
Table 2 shows each alarm function operation with their respective
code. Alarm 1 is used as an example.
TYPE CODE ACTION
LOW 0
00
0
SPA1
Alarm ON TEMPERATURE
HIGH 1
11
1
SPA1
Alarm ON TEMPERATURE
LOW
differential 2
22
2
SPA1
Negative SP + SPA1SP
Alarm ON TEMPERATURE
SPA1
Positive SP + SPA1 SP
Alarm
ON TEMPERATURE
HIGH
differential 3
33
3
SPA1
Negative SP + SPA1 SP
Alarm ON TEMPERATURE
SPA1
Positive SP + SPA1SP
Alarm
ON TEMPERATURE
differential
or
deviation
4
44
4
SPA1
Negative SP + SPA1SP - SPA1 SP
Alarm ON TEMPERATURE
SPA1
Positive SP + SPA1SP - SPA1 SP
Alarm
ON
Alarm
ON TEMPERATURE
Input
sensor
error or
heater
break
detection
5
55
5
Alarm is ON whenever:
• Temperature is below/above selected range;
• Termocouple or Pt100 is broken;
• Pt100 is shorted;
• Pt100 is badly connected or wire impedance is
too high;
• The heater resistence is broken
End of
Program 6
66
6
Activated when the programmed soak time is run
out. Refer to item 4 of this manual.
7
77
7 Low limit alarm disabled at power-up
8
88
8 High limit alarm disabled at power-up
9
99
9 Differential low limit alarm disabled at power-up
10
1010
10 Differential high limit alarm disabled at power-up
Alarm
Functions
With alarm
inhibition a
t
power-up
11
1111
11 Differential alarm disabled at power-up
Table 2 - Alarm functions and their identification codes
7. PID AUTO TUNE
During auto tune the temperature is controlled in ON/OFF mode at
the programmed Set Point (SV). Depending on the process
characteristics large oscillations above and below SV may occur and
auto tuning may take several minutes to be concluded.
The recommended procedure is as follows:
• Program a new SP close to the desired final temperature
other than the present measured temperature.
• Enable the auto tune at the “Atvn
AtvnAtvn
Atvn” prompt by selecting 1.
• Set 1at the “rvn
rvnrvn
rvn” prompt.
During auto tune large oscillations will be induced around the
setpoint. Make sure the process can accept these oscillations.
If auto tuning results are not satisfactory refer to table 3 for manual
fine tuning procedure.
PARAMETER RESPONSE SOLUTION
Proportional Slow Response Decrease
Band Large Oscillation Increase
Integral Slow Response Increase
Rate Large Oscillation Decrease
Derivative Slow Response or
Instability Decrease
Time Large Oscillation Increase
Table 3 - Suggestions for manual tuning of PID parameters