D e u t s c h I t a l i a n o E s p a ñ o l CAL Controls F r a n ç a i s CAL 9500P Programmable Process Controller E n g l i s h Users Manual
E n g l i s h INDEX INSTRUMENT PANEL FEATURES FUNCTIONS MENU GETTING STARTED Initial Set-up AUTOTUNE Tune or tune at setpoint program PROPORTIONAL CYCLE-TIME Cycle-time recommendations SECOND AND THIRD SETPOINTS (SP2 and SP3) Error messages LINEAR INPUT Set-up procedure FUNCTION LIST Level 1 Level 2 Level 3 Output Options Table Re-transmission Level 4 Level A PROGRAMMER Function overview Getting started (Programmer) Program run mode Display functions Example program Function map Function list Memory alloca
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E n g l i s h GETTING STARTED After power-up the controller requires programming with the following information: Press and hold ✱ and use the ▲ or ▼ buttons to select from the choices Rly, SSd or AnLG depending on the model supplied. SP2 and SP3 outputs will be automatically allocated. (See output options table on page 8). Type of Sensor (See list of sensors p.22) Operating unit °C °F bAr PSi Ph rh SEt Allocation of Output Device to SP1/SP2 (Relay / SSd) or analogue. SP3 is always relay.
SECOND AND THIRD SETPOINTS (SP2 and SP3) Hereafter in the Manual the symbol (▲▼) signifies both buttons are held pressed for 3 seconds to ENTER or EXIT Program mode. TUNE OR TUNE AT SETPOINT PROGRAM PRIMARY ALARM MODES Configure SP2 output to operate as an alarm from SP2.A in Level 2 and set the alarm setting in SEt.2 Level 1. Enter program (▲▼) and from the display tunE : oFF press and hold ✱ and press ▲ to display tunE : on or tunE : At.SP Exit program mode (▲▼). Configure SP3 alarm mode SP3.
E n g l i s h SP2 / SP3 OUTPUT AND LED STATUS IN ALARM CONDITION LINEAR INPUT SP2 / SP3 ALARM ANNUNCIATOR Set-up Procedure If a Primary Alarm mode has been configured, when an alarm condition occurs the alarm annunciator -AL- will be displayed alternating with the process variable. The alarm together with the display, will be automatically reset as soon as the alarm condition has been cleared.
Note: A Functions Menu is shown on page 3. LEVEL 1 Function SELECT AUTOTUNE Options SEt.2 [0] to * °C/°F/units Adjust SP2 setpoint * Deviation Alarms DV.hi, DV.Lo, bAnd 25% sensor maximum. * Full scale alarms FS.hi, FS.Lo sensor range f/s ✢ bnd.2 0.1 - * °C/°F/units Adjust SP2 hysteresis or proportional band/gain (see CyC.2 setting) * 100% sensor f/s (Hi.Sc) [Factory settings] shown in brackets (see pages 4/5) tunE [oFF] on PArK At.
E n g l i s h LEVEL 2 CONTINUED INPUT SELECTION AND RANGING Re-transmission dI.SP [1] 0.1 Select display resolution: for display of process value, setpoint, OFSt, Set.2, hi.SC, LoSC. * These models above offer the option of using the analogue output for Re-transmission. Select bAnd or bnd.2 value in LEVL 1 to equal the full range setting in LEVL A and if using SP1 output, set int.t and dErt.t in LEVL 1 to off. ✢ hi.SC [sensor maximum] Set full scale ✢ Lo.
E n g l i s h LEVEL 3 CONTINUED Function Options [Factory settings] shown in brackets rEu.d Select output modes: Direct/Reverse Caution: Settings affect fail safe state. [1r.2d] 1d.2d 1r.2r 1d.2r SP1 Reverse Direct Reverse Direct SP2 Direct Direct Reverse Reverse Enter level 4 at Lock, release ▲ and ▼ together. Display reads LoCK nonE Program security using Lock [nonE] Select from three Lock options: Press and hold ✱, press ▲ to index. Select SP1/2 LED indicator modes [1n.2n] 1i.2n 1n.2i 1i.
E n g l i s h LEVEL A Function LEVL A Function Options [Factory settings] shown in brackets Linear Input Scaling Options brn.3 [uPSC] uPSC or dnSC Sensor burn-out / break protection Select upscale or downscale Please read in conjunction with Linear Input Set-up Procedure on page 6. ✢ An.hi -1999 to 9999 Adjusts required scale maximum [1000] ✢ An.Lo -1999 to 9999 Adjusts required scale minimum [0] hi.in Configure input maximum [50.0] 0.1 to 50.0 rEV.
INDEX Function overview 11 Getting started 12 Program run mode 12 Display functions 12 Example program 13 Function map 14 Function list 16 Memory allocation table 17 Memory full indicator 17 Programming example 18 Program edit example 18 E n g l i s h In addition to those settings that determine the segment profile, it is also necessary to set program start values, together with the preferred ramp rate time units for each individual program.
GETTING STARTED (PROGRAMMER) For users with previous experience of configuring programmers, the 12
E n g l i s h EXAMPLE PROGRAM TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE SPR SOAK STEP SPR LOOP SPR SOAK STEP SPR SPRR SINT T.SP SPRR PCYC SPRR SINT T.SP SPRR 105 45 85 55 1 105 45 85 55 Temp T.SP T.SP T.SP T.
E n g l i s h PROGRAMMER FUNCTION MAP START HERE Press and hold ▼▲ for 3 seconds ENTER PROGRAM Paste only appears after a program is copied TUNE OFF Copies the selected program To add new program, press ▲ once ▼ PROG ADD ▲ RUN OFF EDIT PSTE EDIT COPY Program editing functions. Insert EDIT INS Program editing functions.
▲ EDIT INS Delete a segment EDIT DEL Event output To add new segments press ▲ once SEG ADD Insert new segment in the menu ✱ 3 secs ✱ 3 secs New segment now inserted into 2. Old segment 2 becomes 3 SEG 2 SURE ✱ ▲ NO SURE YES Call up another program Add new segments at top of existing list Segment 3 now appears in menu Program re-cycles Step Soak ✱ ▲ SEG 1 Ramp ▲ Set the segment to be adjusted Default: 1 Segment 3 deleted 3 secs E.OP 2E3D E.OP 2D3D TYPE CALL Returns to SEG SUB.
E n g l i s h Function FUNCTION LIST (LEVEL P) PROGRAMMER LEVEL P Press ▲ or ▼ to change TyPE Press ▲ or ▼ to change Press ✱ ▲ or ✱ ▼ to change ProG Program number [1] Add new programs (1 to 31) run Run Program [oFF] Program not running on Run program hoLd Pause program Edit dEL Delete program †❖ Edit inS Insert new program † Edit CoPy Copy another program † Edit PStE Paste copied program † [rSEt] Reset to program start Cont Continue from interruption hoLd Hold at interrupt
E.oP Press ▲ or ▼ to change Press ✱ ▲ or ✱ ▼ to change Event output [nonE] Segment type Memory required Ramp 4 Bytes Loops (4+) 2 Bytes 2d SP2A de-energised to mark event Call 1 Byte 2E SP2A energised to mark event Event Output 1 Byte 3d SP3A de-energised to mark event Program Header 1 Byte 3E SP3A energised to mark event 2d.3d SP2A and SP3A de-energised to mark event SP2A energised SP3A de-energised to mark event 2E.3E SP2A and SP3A energised to mark event 2d.
E n g l i s h PROGRAMMING EXAMPLES SURE YES ✱ 3 secs PROG 2 Program 1 now pasted as Program 2 KE Y Arrows drawn thus signify several key operations Program Edit Function KEY ✱ ▼ OR ✱ ▲ TOGETHER TO VIEW OR CHANGE SETTINGS Make copy of Program 1 and paste as new Program 2 18 ADD (next) PROG EDIT PSTE ✱ 3 secs SURE NO Programmer functions shown as white characters on black background have Default settings RUN OFF KEY ▼ OR ▲ TO VIEW FUNCTIONS EDIT COPY PROG 1 PROG 3 ✱ 3 secs PROG 1 RUN OFF
E n g l i s h MECHANICAL INSTALLATION ELECTRICAL INSTALLATION (See important Safety Information page 20) The Controller is designed to be sleeve mounted in a 1/16 DIN panel cutout with only the front panel rated to NEMA4/IP66, provided that: ● the panel is smooth and the panel cutout is accurate; OUTPUT DEVICES WARNING: Three types of output device may be factory fitted to the controllers, and users must choose how to allocate these to outputs SP1 and SP2. (SP3 is always RLY).
E n g l i s h EN61010 - /CSA 22.2 No 1010.1 92 TYPICAL APPLICATION Compliance shall not be impaired when fitted to the final installation. Designed to offer a minimum of Basic Insulation only. The body responsible for the installation is to ensure that supplementary insulation suitable for Installation Category II or III is achieved when fully installed.
OUTPUT: HARDWARE OPTIONS & TERMINATIONS Standard Input Code Spare Input (+) (–) 1 2 (+) 3 4 5 6 Supply L N 7 Model Output Codes 17 18 1 2 4 20 21 22 23 24 95111P 21 22 23 24 95001P SSd (+) (–) Spare Supply L N 5 7 (+) 3 19 8 Thermocouple Input (+) (–) E n g l i s h INPUT OPTIONS 6 17 18 19 20 8 SSd SSd (+) (–) (+) (–) 95–––PA Wire link RTD/PT100 2 wire 17 18 Input (+) (–) 1 2 Spare Supply L N 5 7 (+) 3 4 6 19 20 21 22 23 24 95221P 19 20 21 22 23 24 9
E n g l i s h Resistance thermometer RTD-2/Pt100 2 wire Standards: INPUT SENSOR SELECTION Temperature sensors Thermocouples tC tC tC tC tC tC tC tC tC b E J K L n r s t Resistance thermometer rtd 2/3 wire Notes: 1 2 Description Sensor range Pt-30%Rh/Pt-6%Rh Chromel/Con Iron/Constantan Chromel/Alumel Fe/Konst NiCrosil/NiSil Pt-13%Rh/Pt Pt-10%Rh/Pt Copper/Con 0 to 1800 °C 0 to 600 °C 0 to 800 °C -50 to 1200 °C 0 to 800 °C -50 to 1200 °C 0 to 1600 °C 0 to 1600 °C -200 / 250 °C 2.0 * 0.5 0.5 0.25* 0.
INSTALLATION Designed for use: UL873 - only in products where the acceptability is determined by Underwriters Laboratories Inc. EN61010-1 / CSA 22.2 No 1010.1 - 92 To offer a minimum of Basic Insulation only. Suitable for installation within Catagory II and III and Pollution Degree 2. SEE ELECTRICAL INSTALLATION Page 19 It is the responsibility of the installation engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations.
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