United Process Versapro Owner's manual

Versapro
Temperature Controller
Installation and Operation
Handbook
Revision 1.11

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Copyright © 2013, United Process Controls Inc. All rights to copy, reproduce and transmit are reserved
Manual #: 022
Rev No: 1.11
Date: 30 October 2013
All trademarks used in this publication are duly marked and the sole property of their respective
owners. No attempt at trademark or copyright infringement is intended or implied.
COPYRIGHT
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system,
or translated into any language or computer language, in any form or by any means, electronic,
mechanical, magnetic, optical, chemical, manual, or otherwise, without prior written permission of
United Process Controls Inc.
DISCLAIMER:
The VersaPro is to be used by the industrial operator under his/her direction. United Process Controls
Inc. is not responsible or liable for any product, process, damage or injury incurred while using the
VersaPro. United Process Controls Inc. makes no representations or warranties with respect to the
contents hereof and specifically disclaim any implied warranties or merchantability or fitness for any
particular purpose.
For assistance please contact: United Process Controls Inc.
TEL: [phone] • FAX: [phone]
Toll-Free North America [phone]
[email protected]
www.group-upc.com

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TABLE OF CONTENTS
TABLEOFCONTENTS.....................................................................................................................................................................3
1.SafetyandEnvironmentInformation....................................................................................................................................7
1.1Serviceandrepair........................................................................................................................................................................7
2.InstallationSafetyRequirements..........................................................................................................................................7
2.1SafetySymbol..............................................................................................................................................................................7
2.2Personnel.....................................................................................................................................................................................7
2.3Enclosureofliveparts..................................................................................................................................................................8
2.4Livesensors..................................................................................................................................................................................8
2.5Wiring..........................................................................................................................................................................................8
2.6PowerIsolation............................................................................................................................................................................8
2.7Earthleakagecurrent..................................................................................................................................................................8
2.8OverCurrentprotection...............................................................................................................................................................8
2.9Voltagerating..............................................................................................................................................................................9
2.10Conductivepollution...............................................................................................................................................................9
2.11Over‐temperatureprotection.................................................................................................................................................9
2.12Groundingofthetemperaturesensorshield........................................................................................................................10
2.13InstallationrequirementsforEMC........................................................................................................................................10
2.14Routingofwires....................................................................................................................................................................10
3VersaProFeatures..............................................................................................................................................................10
4Installation.........................................................................................................................................................................11
4.1Mounting...................................................................................................................................................................................12
5ProcessControlOptions.....................................................................................................................................................13
6ControlModes...................................................................................................................................................................13
6.1TimeProportioning(TP).............................................................................................................................................................13
6.2TimeProportioningDual(TD)....................................................................................................................................................14
6.3TimeProportioningwithComplement(TC)...............................................................................................................................14
6.4PositionProportioning(PP).......................................................................................................................................................14
6.5ON/OFF(OF).............................................................................................................................................................................14
6.6ON/OFFDual(OD).....................................................................................................................................................................15
6.7ON/OFFwithComplement(OC)................................................................................................................................................15
6.8DirectCurrentOutput................................................................................................................................................................15
6.9DirectorReverseControlAction................................................................................................................................................16
7Alarms...............................................................................................................................................................................16

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7.1ProcessAlarms...........................................................................................................................................................................17
OFF.................................................................................................................................................................................................17
FullScaleHI....................................................................................................................................................................................17
FullScaleLO....................................................................................................................................................................................17
DeviationBand...............................................................................................................................................................................17
DeviationHigh................................................................................................................................................................................17
DeviationLow.................................................................................................................................................................................17
OutputHigh....................................................................................................................................................................................17
OutputLow.....................................................................................................................................................................................18
Fault................................................................................................................................................................................................18
Time................................................................................................................................................................................................18
Start................................................................................................................................................................................................18
Soak................................................................................................................................................................................................18
7.2AlarmAction..............................................................................................................................................................................18
7.3AlarmDelayTimes.....................................................................................................................................................................19
7.4DiagnosticAlarms......................................................................................................................................................................19
8SerialInterface...................................................................................................................................................................20
9FrontPanelOperation........................................................................................................................................................21
9.1EnterKey....................................................................................................................................................................................22
9.2RemoteKey................................................................................................................................................................................22
9.3SetupKey...................................................................................................................................................................................22
9.4DualKeyFunctions....................................................................................................................................................................31
StartingProbeTests.......................................................................................................................................................................31
StartTimer......................................................................................................................................................................................31
EditTimer.......................................................................................................................................................................................31
MonitorMode................................................................................................................................................................................31
10DigitalInputEvent..............................................................................................................................................................32
OFF.................................................................................................................................................................................................32
PROB...............................................................................................................................................................................................32
AUTO(controlleronly)....................................................................................................................................................................32
rEn(controlleronly).......................................................................................................................................................................32
ACK.................................................................................................................................................................................................32
PrOC(controlleronly).....................................................................................................................................................................32
Strt(controlleronly).......................................................................................................................................................................33
HOLd(controlleronly)....................................................................................................................................................................33
End(controlleronly).......................................................................................................................................................................33
11TimerFunction...................................................................................................................................................................34
11.1SettingtheTimer..................................................................................................................................................................34
11.2Time......................................................................................................................................................................................35
11.3GuaranteedStartTimer........................................................................................................................................................35
11.4GuaranteedSoakTimer........................................................................................................................................................36
11.5TimerAlarmBehavior...........................................................................................................................................................36
11.6TimerStateDiagram.............................................................................................................................................................36
12TimerSIOOperations.........................................................................................................................................................38

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12.1ControllingtheTimerRemotely............................................................................................................................................39
13Tuning................................................................................................................................................................................40
13.1Whatistuning?.....................................................................................................................................................................40
14ScalingAnalogInputs.........................................................................................................................................................43
14.1LinearExample......................................................................................................................................................................43
14.2KeyboardFunctionduringInputSlope..................................................................................................................................43
15ScalingAnalogOutputs.......................................................................................................................................................44
16Calibration.........................................................................................................................................................................44
16.1CalibrationDisplaysandKeyboardOperation......................................................................................................................45
16.2PreparingforInputCalibration.............................................................................................................................................45
CalibrationoftheThermocoupleInput..........................................................................................................................................46
CalibrationoftheColdJunctionTemperature...............................................................................................................................46
CalibrationoftheAnalogOutputChannels...................................................................................................................................47
17Communications................................................................................................................................................................48
17.1Modbus.................................................................................................................................................................................48
RTUFraming...................................................................................................................................................................................48
AddressField..................................................................................................................................................................................48
FunctionField.................................................................................................................................................................................48
DataField.......................................................................................................................................................................................49
ErrorCheckField(CRC)...................................................................................................................................................................49
17.2MSIMessageProtocol..........................................................................................................................................................50
17.3InstrumentType‘U’CommandSet.......................................................................................................................................52
‘X’Command..................................................................................................................................................................................52
BlockCommands............................................................................................................................................................................54
MSIErrorCodes..............................................................................................................................................................................56
18TroubleshootingQuestions................................................................................................................................................57
18.1AnalogInputs........................................................................................................................................................................57
18.2ControlOutputs.....................................................................................................................................................................57
18.3DigitalCommunications........................................................................................................................................................58
18.4DisplayFunctions..................................................................................................................................................................58
18.5TimerFunction......................................................................................................................................................................58
19VersaproMonitorMode.....................................................................................................................................................59
19.1PrepareforConnection.........................................................................................................................................................59
19.2HowtoConnect.....................................................................................................................................................................59
19.3StartMonitorMode..............................................................................................................................................................60
19.4‘D’DisplayCommand............................................................................................................................................................61
19.5‘L’WriteFLASHtoRAMDefaults..........................................................................................................................................61
19.6‘K’WriteRAMtoEEPROM....................................................................................................................................................61

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19.7‘J’DisplayEEPROMValues....................................................................................................................................................62
19.8‘S’StatusDisplay...................................................................................................................................................................62
19.9‘W’WriteRAMwithEEPROMorDataValues......................................................................................................................62
19.10‘X’ExitCommand..................................................................................................................................................................62
19.11ViewingStatusandMemory.................................................................................................................................................62
19.12LoadingDefaultValues.........................................................................................................................................................63
19.13Whatifanerroroccurs.........................................................................................................................................................64
20TechnicalSpecification.......................................................................................................................................................65
20.1Environmentalratings..........................................................................................................................................................65
20.2Equipmentratings.................................................................................................................................................................65
20.3General..................................................................................................................................................................................65
20.4Electricalsafety(pendingapproval).....................................................................................................................................66
21VersaproMemoryMap......................................................................................................................................................68

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1. Safety and Environment Information
Please read this section carefully before installing the controller
This instrument is intended for industrial applications used in conjunction with Marathon Monitors zirconia
oxygen sensors and standard thermocouple types. It is assumed that any installation meets either CE
standards for industrial safety or NEC standard wiring practices. Failure to observe these standards or the
installation instructions in this manual may degrade the safety or electrical noise protection provided by this
instrument. It is the installer’s responsibility to ensure the safety and electrical noise compatibility of any
installation.
1.1 Service and repair
This controller has user replaceable fuses but no other user serviceable parts. Contact your Marathon
Monitors Service (800-547-1055) for repair.
Caution: Charged capacitors
Before removing an instrument from its case, disconnect the supply and wait at least two minutes to allow
capacitors to discharge. Failure to observe this precaution will expose capacitors that may be charged with
hazardous voltages. In any case, avoid touching the exposed electronics of an instrument when withdrawing it
from the case.
Electrostatic Discharge (ESD) Precautions
When the controller is removed from its case, some of the exposed electronic components are vulnerable to
damage by electrostatic discharge. Anyone who is not probably ground using an ESD wrist strap or in contact
with a ground while handling the controller may damage exposed electronic components.
2. Installation Safety Requirements
2.1 Safety Symbol
Various symbols are used on the instrument, they have the following meaning:
Caution, (refer to the
accompanying documents)
Functional earth
(ground) terminal
!
The functional earth connection is required for safety ground add to ground RFI filters.
2.2 Personnel
Installation must be carried out by qualified personnel.

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2.3 Enclosure of live parts
To prevent hands or metal tools touching parts that may be electrically live, the controller should be installed in
an enclosure. The contacts on the rear of the instrument case or finger save but it is still possible for loose
wiring, or metal objects to come in contact with live terminal connections. It is recommended that power be
removed from the instrument connections before they are disconnected. However, instrument’s power
connector can be removed with power applied. Care should be taken that the connector does not come in
contact with any grounded object.
2.4 Live sensors
The dc inputs, dc logic, and dc outputs are all electrically isolated from chassis ground. If the temperature
sensor is connected directly to an electrical heating element then the inputs will also be live. The controller is
designed to operate under these conditions. However you must ensure that this will not damage other
equipment connected to these inputs and that service personnel do not touch connections to these terminals
while they are live. With a live sensor, all cables, connectors and switches for connecting the sensor and non-
isolated inputs and outputs must be mains rated.
2.5 Wiring
It is important to connect the controller in accordance with the wiring data given in this handbook. Take
particular care not to connect AC supplies to the low voltage sensor input or other low level inputs and outputs.
Only use copper conductors for connections (except thermocouple inputs) and ensure that the wiring for
installations comply with all local wiring regulations. For example, in the UK, use the latest version of the
wiring regulations, BS7671. In the USA use NEC Class 1 wiring methods.
2.6 Power Isolation
The installation must include a power isolating switch or circuit breaker. This device should be in close
proximity to the control actuator, and within easy reach of the operator. There is no means of disconnecting
power from the instrument other than removing the connectors from the rear of the instrument. It is
recommended that additional power disconnects are provided in the installation to remove power from these
connectors as well.
2.7 Earth leakage current
Due to RFI Filtering there is an earth leakage current of less than 0.5mA. This may affect the design of an
installation of multiple controllers protected by Residual Current Device, (RCD) or Ground Fault Detector,
(GFD) type circuit breakers.
2.8 Over Current protection
The instrument has an internal 3.15 Amp fuse (P/N MFU-3.15PCTT) for instrument power and 1 Amp fuses
(P/N MFU-1.0PCTT) for the control contacts and alarms. It is recommended that additional protection against
excess currents be used for loads exceeding this rating. Fusing and interposing relays should be added to the
control circuit if high current or large inductive loads are used.

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2.9 Voltage rating
The maximum continuous voltage applied between any of the following terminals must not exceed 250VAC:
line or neutral to any other connection;
relay output to logic, dc or sensor connections;
any connection to ground.
The controller should not be wired to a three phase supply with an unearthed star connection. Under fault
conditions in this supply could rise above 264VAC with respect to ground and the product would not be safe.
Voltage transients across the power supply connections, and between the power supply and ground, must not
exceed 2.5kV. Where occasional voltage transients over 2.5kV are expected or measured, the power
installation to both the instrument supply and load circuits should include a transient limiting device.
These units will typically include gas discharge tubes, metal oxide varistors, and constant voltage transformers
help suppress voltage transients on the supply line due to lightning strikes or inductive load switching. Devices
are available in a range of energy ratings and should be selected to suit conditions at the installation.
2.10 Conductive pollution
Electrically conductive pollution must be excluded from the cabinet in which the controller is mounted. For
example, carbon dust is a form of electrically conductive pollution. To secure a suitable atmosphere in
conditions of conductive pollution, fit an air filter to the air intake of the cabinet. Where condensation is likely,
for example at low temperatures, include a thermostatically controlled heater in the cabinet.
2.11 Over-temperature protection
When designing any control system it is essential to consider what will happen if any part of the system should
fail. In temperature control applications the primary danger is that the heating will remain constantly on. Apart
from scrapping the product, this could damage any process machinery being controlled or even cause a fire.
Reasons why the heating might remain constantly on include:
the temperature sensor becoming detached from the process;
thermocouple wiring becoming a short circuit;
the controller failing with its heating output constantly on;
an external valve or contactor sticking in the heating condition;
the controller setpoint set too high.
Where damage or injury is possible, we recommend fitting a separate over-temperature protection unit. Factory
Mutual requires that any over temperature device use an independent temperature sensor, which will isolate
the heating circuit.
Please note that the alarm relays within the controller will not give protection under all failure conditions. This
instrument is not suited for over temperature protection and should not be used as a safety device.

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2.12 Grounding of the temperature sensor shield
In some installations it is common practice to replace the temperature sensor while the controller is still
powered up. Under these conditions, as additional protection against electric shock, we recommend that the
shield of the temperature sensor be grounded at one end of the wire. Do not rely on grounding through the
framework of the machine.
2.13 Installation requirements for EMC
To ensure compliance with European EMC directives certain installation precautions are necessary as follows:
When using relay outputs it may be necessary to fit a filter suitable for suppressing the emissions. The filter
requirements will depend on the type of load. For typical applications such as Schaffner FN321 or FN612
line filters or equivalents.
If the unit is used in table top equipment which is plugged into a standard power socket, it is likely that
compliance to the commercial and light industrial emissions standard is required. In this case, to meet the
conducted emissions requirement, a suitable mains filter should be installed. Recommended filters would
be Schaffner types FN321 and FN612 or equivalents.
2.14 Routing of wires
To minimize the pick-up of electrical noise, the wiring for low voltage dc and particularly the sensor input
should be routed away from high-current power cables. Where it is impractical to do this, use shielded cables
with the shield grounded at one end.
3 VersaPro Features
The VersaPro is a single loop process controller / monitor has the following capabilities:
24 bit Sigma-Delta ADC for thermocouple with cold junction compensation.
Two (2) 4-20 milliamp outputs for control or chart recorder.
Sixteen character LCD with two four-digit LED segment displays.
Two (2) Form A control contacts. (controller)
Two (2) Form A alarm contacts.
PID control modes. (controller)
Serial Communication with Marathon Monitors or Modbus Protocol.
EEPROM stores setup and calibration values.