West Control Solutions Pro-EC44 User manual

Pro-EC44
2-Loop Graphical Profile
Controller & Recorder
Pro-EC44 User Guide 59540-2

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page i
This manual supplements the Concise Product manual supplied with each instrument at the
time of shipment. Information in this installation, wiring and operation manual is subject to
change without notice.
Copyright © September 2014, Danaher Corporation, all rights reserved. No part of this
publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or
translated into any language in any form by any means without the written permission of
Danaher/West Control Solutions.
Copies of this manual are available in electronic format on the West Control Solutions web
site (www.west-cs.com) Printed versions may be purchased from West Control Solutions or
its representatives.
WARNING: THE INTERNATIONAL HAZARD SYMBOL IS INSCRIBED
ADJACENT TO THE REAR CONNECTION TERMINALS. IT IS IMPORTANT
TO READ THIS MANUAL BEFORE INSTALLING OR COMMISSIONING THE
UNIT.
WARNING: THIS SYMBOL MEANS THE EQUIPMENT IS PROTECTED
THROUGHOUT BY DOUBLE INSULATION.
WARNING: PRODUCTS COVERED BY THIS MANUAL ARE SUITABLE FOR
INDOOR USE, INSTALLATION CATEGORY II, POLLUTION CATEGORY 2
ENVIRONMENTS.
Note: It is strongly recommended that applications incorporate a high or low limit
protective device, which will shut down the equipment at a pre-set process
condition in order to prevent possible damage to property or products.
This user guide covers all versions of the West Pro-EC44 controller.
©WCS –Product & specifications may be subject to change without notice - E&OE

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Page ii Pro-EC44 Product Manual - 59540-2 September 2014
Warranty and Returns Statement
These products are sold by West Control Solutions under the warranties set forth in the
following paragraphs. Such warranties are extended only with respect to a purchase of these
products, as new merchandise, directly from West Control Solutions or from a West Control
Solutions distributor, representative or reseller and are extended only to the first buyer
thereof who purchases them other than for the purpose of resale.
Warranty
These products are warranted to be free from functional defects in material and workmanship
for three years from the time the products leave West Control Solutions factory and to
conform at that time to the specifications set forth in the relevant West instruction manuals
sheet or sheets.
THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES, WHICH EXTEND BEYOND THE
WARRANTIES HEREIN AND ABOVE SET FORTH. NO WARRANTY IS MADE OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE
PRODUCTS.
Limitations
West Control Solutions shall not be liable for any incidental damages, consequential
damages, special damages, or any other damages, costs or expenses excepting only the
cost or expense of repair or replacement as described above. Products must be installed and
maintained in accordance with West Control Solutions instructions. There is no warranty
against damage to the product resulting from corrosion. Users are responsible for the
suitability of the products to their application.
For a valid warranty claim, the product must be returned carriage paid to the supplier within
the warranty period. The product must be properly packaged to avoid damage from
electrostatic discharge or other forms of harm during transit.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page iii
How to use this manual
This manual is structured to give easy access to the information required for all aspects of
the installation and use and of the controller. The main sections are shown here, with a full
table of contents at the end.
Warranty and Returns Statement .....................................................................................................ii
1Introduction.............................................................................................................................1
2Installation ..............................................................................................................................2
3Field Upgrade Options...........................................................................................................4
4Electrical Installation..............................................................................................................9
5Powering Up..........................................................................................................................29
6Messages & Error Indications..............................................................................................31
7Application Setup.................................................................................................................33
8Operation and Configuration Menus...................................................................................36
9Input Calibration & Multi-point Scaling...............................................................................70
10 Digital Inputs.........................................................................................................................75
11 Cascade Control...................................................................................................................78
12 Ratio Control.........................................................................................................................81
13 Redundant Input...................................................................................................................83
14 Valve Motor Drive / 3-Point Stepping Control.....................................................................84
15 Setpoint Sources..................................................................................................................86
16 Profiler...................................................................................................................................87
17 USB Interface........................................................................................................................96
18 Data Recorder.......................................................................................................................97
19 Controller Tuning..................................................................................................................99
20 Serial Communications......................................................................................................109
21 Glossary..............................................................................................................................204
22 PC Software ........................................................................................................................235
23 Specifications.....................................................................................................................245
24 Pro-EC44 Product Coding..................................................................................................255
25 Table of Contents ...............................................................................................................257

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 1
1 Introduction
This product is a 1/4DIN size (96 x 96mm front) microprocessor based graphical process
controller, featuring a 160 x 80 pixel, monochrome LCD with dual colour (red/green)
backlight. It operates from 100-240V at 50/60 Hz or 24V-48V AC/DC, depending on the
model purchased. It can measure and control up to two process variables from a variety of
sources such as temperature, pressure, flow and level. Primary and secondary control
outputs are possible for each loop.
Optional features include a second process input, USB interface, remote setpoint inputs
RS485 or Ethernet communications, profile control and data recording. Control options
include cascade, ratio and 3-point stepping valve control. Automatic tuning or 5 stage gain-
scheduling are also available.
The USB Interface option allows uploading or downloading instrument configuration settings
to/from a USB memory stick, for easy configuration of multiple instruments or transfer to/from
the PC configuration software. If the data recorder or profiler options are fitted, recordings
and profile information can be transferred via the memory stick.
The data recorder option allows the user to make recordings of the processes over time.
Recordings can be transferred to a memory stick using the USB interface or downloaded via
one of the communications options.
The Profiler option allows the user to predefine up 255 segments, shared amongst up to 64
Setpoint Profiles. These control the setpoint levels for the control loop(s) over time,
increasing, decreasing or holding their values as required. When combined with the real-time
clock (part of the Data Recorder option) the profiling capabilities are expanded to allow
automatic program start at a defined time and day.
Inputs are user configurable for thermocouple and RTD probes, as well as linear process
signal types such as mVDC, VDC or mADC. Two-point calibration or multipoint scaling can
compensate for errors or non-linear signals. Output options include single or dual relays,
single or dual SSR drivers, triacs or linear mA/V DC. These can be used for process control,
alarms/events or retransmission of the process variable or setpoint to external devices.
Transmitter power supply options can provide an unregulated 24V DC (22mA) auxiliary
output voltage, or a 0 to 10VDC stabilised excitation for external signal transmitters.
Up to 7 alarms can be defined as process high or low, deviation (active above or below
controller setpoint), band (active both above and below setpoint), rate of input change,
control loop, PID power or signal break types. Alarm status can be indicated by lighting an
LED, changing the display backlight colour or viewing the active alarm status screen. These
alarms can be linked to any suitable output.
Configuration for basic applications is possible using the easy Setup Wizard run
automatically at first power-up or manually later. Access to the full range of parameters is via
a simple menu driven front panel interface, or the PC based configuration software.

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Pro-EC44 Product Manual - 59540-2 September 2014 Page 2
2 Installation
Unpacking
1. Remove the product from its packing. Retain the packing for future use, in case it is
necessary to transport the instrument to a different site or to return it to the supplier for
servicing.
2. The instrument is supplied with a panel gasket and push-fit mounting clamp. A multi-page
concise manual is supplied with the instrument, in one or more languages. Examine the
delivered items for damage or defects. If any are found, contact your supplier
immediately.
Installation
CAUTION: Installation should be only performed by technically competent
personnel. It is the responsibility of the installing engineer to ensure that
the configuration is safe. Local Regulations regarding electrical installation
& safety must be observed (e.g. US National Electrical Code (NEC) or
Canadian Electrical Code).
Figure 1. Main dimensions
Panel-Mounting
The controller should be mounted in a properly earthed metal cabinet. The mounting panel
must be rigid and may be up to 6.0mm (0.25 inches) thick. The cut-out size is:
92mm x 92mm (+0.5mm / -0.0mm).

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Pro-EC44 Product Manual - 59540-2 September 2014 Page 3
Instruments may be mounted side-by-side in a multiple installation, but instrument to panel
moisture and dust sealing will be compromised. Allow a 20mm gap above, below and behind
the instrument for ventilation. The cut-out width (for ninstruments) is:
(96n- 4) mm or (3.78n- 0.16) inches
If panel sealing must be maintained, mount each instrument into an individual cut-out with
10mm or more clearance between the edges of the holes.
Note: The mounting clamp tongues may engage the ratchets either on the sides
or the top/bottom faces of the Instrument housing. When installing several
Instruments side-by-side in one cut-out, use the ratchets on the top/bottom faces.
CAUTION: Ensure the inside of the panel remains within the instrument
operating temperature and that there is adequate airflow to prevent
overheating.
Gasket
Mounting Panel
Clamp
Ratchets
Instrument
Housing
1. Insert instrument into the
panel cut-out.
2. Hold front bezel firmly
(without pressing on the
display area), and re-fit
mounting clamp. Push the
clamp forward, using a tool if
necessary, until gasket
compresses and instrument
is held firmly in position.
Figure 2. Panel-Mounting the instrument
CAUTION: Do not remove the panel gasket, as this may result in inadequate
clamping and sealing of the instrument to the panel.
Once the instrument is installed in its mounting panel, it may be subsequently removed from
its housing if necessary, as described in the Fitting and Removing Plug-in Modules section.
Cleaning
Clean the front panel by washing with warm soapy water and dry immediately. If the USB
option is fitted, close the USB port cover before cleaning.
Note: For an effective IP66 seal against dust and moisture, ensure gasket is well
compressed against the panel, with the 4 tongues located in the same ratchet
slot.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 4
3 Field Upgrade Options
Plug-Modules and Upgradeable Functions
Plug-Modules can be either pre-installed at the time of manufacture, or retrofitted in the field
to expand the capabilities of the controller. Contact your supplier to purchase these items.
Part numbers and circuit board identification numbers for the plug-in modules and
accessories are shown in below:
PART
NUMBER AVAILABLE OPTIONS & ACCESSORIES BOARD
IDENTIFICATION
NUMBER
MODULE SLOT 1
PO1-R10 Single Relay Output for plug-in module slot 1 716/01
PO1-S20 Single SSR Driver Output for plug-in module slot 1 716/02
PO1-T80 Triac Output for plug-in module slot 1 716/03
PO1-C21 Linear mA / Voltage Output for plug-in module slot 1 639/01
MODULE SLOT 2 or 3
PO2-R10 Single Relay Output for plug-in module slot 2 or 3 717/01
PO2-W09 Dual Relay Output for plug-in module slot 2 or 3 644/01
PO2-S20 Single SSR Driver Output for plug-in module slot 2 or 3 717/02
PO2-S22 Dual SSR Driver Output for plug-in module slot 2 or 3 644/02
PO2-T80 Triac module Output for plug-in module slot 2 or 3 647/01
PO2-W08 24VDC Transmitter Power Supply for module slot 2 or 3 642/01
MODULE SLOT A
PA1-W03 Digital Input for plug-in module slot A 641/02
PA1-W04 Basic Auxiliary Input for plug-in module slot A 653/01
PA1-W06 RS485 Serial Communications for plug-in module slot A 680/01
PA1-ETH Ethernet Communications for plug-in module slot A 707/01
ACCESSORIES
PS1-PRF Profiler Enable Key-code
PS1-PRW Blue Control PC Configuration Software & Lead
CAUTION: Plastic pegs prevent fitting of older non-reinforced single relay
modules (board identification numbers 637/01 and 638/01). Fitting the older
relay modules reduces the isolation rating to Basic 240V isolation and is
therefore not recommended.
Remove this peg when fitting Dual Relay Modules.
Board Positions
Note: All dual relay modules have reinforced isolation.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 5
Board Mounting Struts (x4)
Front Panel Removal Latch (x1)
Plug-in Module A
Plug-in Module 3
Power Supply Board
2nd Universal Input & Base
Option 2 Board
1st Universal Input & Base
Option 1 Board
Plug-in Module 1
Plug-in Module 2
USB/Digital Input C Option
Board
Figure 3. Rear view (uncased) & board positions
Preparing to Install or Remove Plug-in Modules
CAUTION: Before removing the instrument from its housing, ensure that all
power has been removed from the rear terminals. Modules / boards should
be replaced by a technically competent technician.
1. Grip the edges of the front panel (there is a finger grip on each edge) and pull it forwards
approximately 10mm, until the Front Panel Removal Latch prevents further movement.
The purpose of the latch is to prevent removal of the instrument without the use of a tool.
2. The Front Panel Removal Latch must be pushed down to allow removal of the instrument.
Using a tool (e.g. screwdriver or pen tip), press down it down through the front central
ventilation hole. This will release the instrument from the case.
3. The internal boards can now be accessed. Take note of the orientation of the instrument
and boards for subsequent replacement into the housing. The positions of the boards,
their mountings and the Front Panel Removal Latch are shown above.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 6
Main Board Connectors
POWER SUPPLY
BOARD
Transformer Colour
Code
100-240V (Yellow)
24-48V(Blue)
Display Board
Connections
1st UNIVERSAL
INPUT / BASE
OPTION 1 BOARD
Module Slot 3
Connector PL4B
Module Slot A
Connectors PL5, & PL6
Module Slot 1
Connectors PL7 & PL8
PC Configurator
Socket SK1
Module Slot 2
Connector PL4A
Figure 4. Main board connectors
This product is designed to allow the user to reconfigure some hardware options in the field
by changing the plug-in modules in slots 1, 2, 3, & A located on the power supply and 1st
universal input boards. The main boards (display/CPU, power supply, inputs 1 & 2 and digital
input/USB) are factory fitted, but may be removed while reconfiguring the plug-in modules.
Take care when re-fitting these boards. Observe the power supply board transformer colour,
and case labelling to check the supply voltage, otherwise irreparable damage may occur.
CAUTION: Replacement of boards must be carried out by a technically
competent technician. If the Power Supply board does not match the
labelling, users may apply incorrect voltage resulting in irreparable
damage.

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Removing/Replacing Option Modules
1. To remove or replace Plug-in Modules 1, 2, 3 or A it is necessary to detach the power
supply and input boards from the front panel by lifting first the upper and then lower
mounting struts.
2. Remove or fit the modules to the connectors on the power supply and input boards. The
location of the connectors is shown below. Plastic pegs prevent fitting of older non-
reinforced single relay modules –Remove the peg to fit dual relay modules
3. Assemble the Power Supply and Input boards together. Tongues on each option module
locate into slots cut into the main boards, opposite each of the connectors. Hold the Power
and Input boards together and relocate them back on their mounting struts.
4. Push the boards forward to ensure correct connection to the front Display/CPU board and
re-check the installation of the Option C and/or 2nd Input / Base Option 2 boards if present.
CAUTION: Check for correct orientation of the modules and that all pins
are located correctly.
Replacing the Instrument in its Housing
CAUTION: Before replacing the instrument in its housing, ensure that all
power has been removed from the rear terminals.
With the required option modules correctly located into their respective positions the
instrument can be replaced into its housing as follows:
1. Hold the Power Supply and Input boards together.
2. Align the boards with the guides in the housing.
3. Slowly and firmly, push the instrument into position in its case.
CAUTION: Ensure that the instrument is correctly orientated. A mechanical
stop will operate if an attempt is made to insert the instrument in the wrong
orientation, this stop MUST NOT be over-ridden.
Auto Detection of Plug-in Modules
The instrument automatically detects which plug-in modules have been fitted into each slot.
The menus and screens change to reflect the options compatible with the hardware. The
modules fitted can be viewed in the product information menu, as detailed in the Product &
Service Information Mode section of this manual.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 8
Data Recorder Board
If installed, the Data Recorder memory and Real Time Clock (RTC) components are located
on a plug-in daughter board attached to the front Display/CPU board.
CAUTION: Servicing of the Data Recorder/RTC circuit and replacement of
the lithium battery should only be carried out by a technically competent
technician.
Profiler Enabling
If you purchased a controller with the Profiler option installed, these features will be enabled
during manufacture.
Controllers supplied without the Profiler option installed can be upgraded in the field by
purchasing a licence code number from your supplier. A unique code must be purchased to
enable profiling on each controller that requires it.
Entering the Profiler Enable Code
Hold down the Land Dkeys during the power-up “splash screen”.
Using the Dor Ukeys, enter the 16-character licence code in the displayed screen.
Press Rto move on to the next character. Press Lto move back to the previous
character.
Press Rafter entering the final character.
To confirm if profiling is installed in your instrument, check the Controller Feature Information
in Product & Service Information Mode.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 9
4 Electrical Installation
CAUTION: Installation should be only performed by technically competent
personnel. It is the responsibility of the installing engineer to ensure that
the configuration is safe. Local Regulations regarding electrical installation
& safety must be observed (e.g. US National Electrical Code (NEC) or
Canadian Electrical Code).
Avoiding EMC Problems
This controller has passed EMC compliance tests to EN61326. There should be no difficulty
achieving this level of compliance in use, but it should be borne in mind that the wiring of the
installation can significantly reduce the efficiency of instrumentation immunity due to the ease
with which high frequency RF can enter via unprotected cables.
The following general recommendations can reduce the possibility of EMC problems.
1. If the instrument is being installed in existing equipment, wiring in the area should be
checked to ensure that good wiring practices have been followed.
2. The controller should be mounted in a properly earthed metal cabinet. All round metal
shielding is important, so the cabinet door may require a conductive sealing strip.
3. It is good practice to ensure that the AC neutral is at or near ground (earth) potential.
A proper neutral will help ensure maximum performance from the instrument.
4. Consider using a separate isolation transformer to feed only the instrumentation. A
transformer can protect instruments from noise found on the AC power supply.
Cable Isolation & Protection
Four voltage levels of input and output wiring may be used with the unit:
1. Analogue inputs or outputs (for example thermocouple, RTD, VDC, mVDC or mADC)
2. Relays & Triac outputs
3. Digital Inputs & SSR Driver outputs
4. AC power
CAUTION: The only wires that should run together are those of the same
category.
If any wires need to run parallel with any from another category, maintain a minimum space
of 150mm between them. If wires MUST cross each other, ensure they do so at 90 degrees
to minimise interference.
Keep signal cables as short as possible. If an earthed thermocouple is used or if the sensor
has a screened cable, it should be earthed at one point only, preferably at the sensor
location or cabinet entry point, by means of a metal gland. Ideally all analogue and digital
signals should be shielded like this, but for unscreened cables, large diameter ferrite sleeves
at the cabinet entry point are an effective method of reducing RF interference. Looping
cables through the ferrite sleeves a number of times improves the efficiency of the filtering.
For mains input cables the fitting a suitable mains filter can provide good results.

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 10
Noise Suppression at Source
If possible, eliminate mechanical contact relays and replace with solid-state relays.
Noise-generating devices such as Ignition transformers, arc welders, motor drives, relays
and solenoids should be mounted in a separate enclosure. If this is not possible, separate
them from the instrumentation, by the largest distance possible.
Many manufacturers of relays, contactors etc supply 'surge suppressors' to reduce noise at
its source. For those devices that do not have surge suppressors supplied, Resistance-
Capacitance (RC) networks and/or Metal Oxide Varistors (MOV) may be added.
Inductive coils:- MOVs are recommended for transient suppression in inductive coils.
Connect as close as possible, in parallel to the coil. Additional protection may be provided by
adding an RC network across the MOV.
Figure 5. Transient suppression with inductive coils
Contacts:- Arcing may occur across contacts when they open and close. This results in
electrical noise as well as damage to the contacts. Connecting a properly sized RC network
can eliminate this arc.
For circuits up to 3 amps, a combination of a 47 ohm resistor and 0.1 microfarad capacitor
(1000 volts) is recommended. For circuits from 3 to 5 amps, connect two of these in parallel.
Figure 6. Contact noise suppression

Pro-EC44 2-Loop Graphical Profile Controller & Recorder
Pro-EC44 Product Manual - 59540-2 September 2014 Page 11
Sensor Placement (Thermocouple or RTD)
If a temperature probe is to be subjected to corrosive or abrasive conditions, it must be
protected by an appropriate thermowell.
Probes must be positioned to reflect the true process temperature:
1. In a liquid media - the most agitated area
2. In air - the best circulated area
CAUTION: The placement of probes into pipe work some distance from the
heating vessel leads to transport delay, which results in poor control.
For a two wire RTD, a wire link should be used in place of the third wire (see the wiring
section for details). Two wire RTDs should only be used with lead lengths less than 3 metres.
Use of three wire RTDs is strongly recommended to reduce errors do to lead resistance.
Thermocouple Wire Identification
The different thermocouple types are identified by their wires colour, and where possible, the
outer insulation as well. There are several standards in use throughout the world, but most
regions now use the International IEC584-3 standard.
The table below shows the wire and sheath colours used for most
common thermocouple types. The format used in this table is:
THERMOCOUPLE WIRE COLOUR CHART
Type International
IEC584-3 USA ANSI MC 96.1 British BS1843 French NFC 42-324 German DIN 43710
J +*Black Black White Black Yellow Black Yellow Black Red Blue
- White Red Blue Black Blue
T + Brown Brown Blue Blue White Blue Yellow Blue Red Brown
- White Red Blue Blue Brown
K + Green Green Yellow Yellow Brown Red Yellow Yellow Red Green
-*White Red Blue Purple Green
N + Pink Pink Orange Orange Orange Orange
- White Red Blue
B + Grey Grey Grey Grey Red Grey
- White Red Grey
R & S + Orange Orange Black Green White Green Yellow Green Red White
- White Red Blue Green White
C (W5) + White White
- Red
Note: * = Wire is magnetic –a magnet can be used to assist with correctly
identifying the type and polarity of the conductors
+Wire Sheath
-Wire

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Pre-wiring –Cautions, Warnings & Information
CAUTION: Installation should be only performed by technically competent
personnel. It is the responsibility of the installing engineer to ensure that
the configuration is safe. Local Regulations regarding electrical installation
& safety must be observed (e.g. US National Electrical Code (NEC) or
Canadian Electrical Code).
CAUTION: This equipment is designed for installation in an enclosure that
provides adequate protection against electric shock. The isolation switch
should be located in close proximity to the unit, in easy reach of the
operator and appropriately marked.
WARNING: This symbol means the equipment is protected throughout by
double insulation. All external circuits connected must provide double
insulation. Failure to comply with the installation instructions may impact
the protection provided by the unit.
WARNING:
TO AVOID ELECTRICAL SHOCK, AC POWER WIRING MUST NOT BE CONNECTED TO THE
SOURCE DISTRIBUTION PANEL UNTIL ALL WIRING PROCEDURES ARE COMPLETED.
CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT
VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

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Connections and Wiring
Central Terminal Connections
Note: The wiring diagram below shows all possible combinations to the main
connections (numbered 1 to 24) in the centre of the case rear. The actual
connections required depends upon the features and modules fitted.
.
Figure 7. Central Terminals 1 to 24
WARNING:
CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.

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Outer Terminal Connections
Note: The wiring diagram below shows the Central Terminals (numbered 25 to
42) at the sides of the case rear. Connections for the 2nd Input, Base Option 2
and Digital Input C are shown. The actual connections required depends upon
the features and modules fitted.
Figure 8. Outer Terminals 25 to 42