Carbpro (V. 3.5)
Carbpro (V. 3.5)
5
Users Manual
COPYRIGHT© 2002
MARATHON SENSORS INC
Marathon Sensors Inc.
Part # F200004
COPYRIGHT © 2002
MARATHON SENSORS INC.
3100 East Kemper Road, Cincinnati, Ohio 45241
1-800-547-1055 (513) 772-1000 FAX: (513) 326-7090
No part of this document may be stored or reproduced by any means whatsoever without prior written permission of Marathon
Sensors Inc.
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.
DISCLAIMER:
The CARBPRO is a Process Controller/Programmer to be used by the industrial operator under his/her direction. Marathon
Sensors makes no warranties express or implied beyond the written warranty presented at initial purchase. Marathon Sensors Inc.
is not responsible or liable for any product, process, damage or injury incurred while using the CARBPRO. Marathon Sensors,
Inc. makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties
or merchantabillity or fitness for any particular purpose.
The Marathon Sensors Inc. CARBPRO Controller/Programmer represents the latest technology
in microprocessor-based process control instrumentation. Through flexible PID (Proportional,
Integral, Digital) control along with programmable features, even the most complex, system can
be handled. For a thorough explanation of PID please refer to Zeigler and Nichols; “Optimum
Settings for Automatic Controllers”, Transactions of ASME, Nov. 1942. Or St. Clair, David W.;
Controller Tuning and Control Loop Performance, a Primer; Straight-Line Control Company,
Newark ,Delaware 1989.
The CARBPRO's control actions are based upon input from a Thermocouple, RTD,
Voltage or Current source. The CARBPRO allows Manual, Automatic, or Programmed
control of a single loop. Its built-in RS-422 computer interface allows it to be completely
supervised by a computer, either on-site or in some remote location within the plant. The
Programmer can be used, and is strongly recommended, to allow complete control of
temperature or other process cycles.
The following features have been included to allow use of the instrument in a wide variety of
applications:
Fully site-configurable for single point control from one of three (3) fully isolated analog input
sources, each separately configurable for thermocouple, RTD, voltage, or current.
Powerful process/logic programmer that can store up to two-hundred (200) programs, each
consisting of nineteen (19) steps, subroutine calls, test and branch capability, and full access to
all instrument parameters.
Two (2) control output triacs for use in single or dual control mode.
Two (2) fully isolated analog outputs, each separately configurable for voltage or current output.
Two (2) configurable alarm triacs, assignable as process Alarms, deviation alarms, program
alarms, or fault alarms.
Four (4) programmer events, assignable in any combination as either inputs or outputs
(expandable to 16 I/O with external event boards).
Three (3) communication ports for talking with host computers, controllers, and discrete digital
and / or analog event expansion racks.
This manual provides all of the information required to install, operate and maintain the MSI
CARBPRO.
The manual is divided into parts: Installation, Setup and Configuration, Operation, Programming,
and Maintenance and Troubleshooting. Installation and Setup and Configuration will be used
initially to get the instrument into use. Operation and Programming will be used daily.
The equation used as the basis for the Controller's calculation of %C is:
%C=((5.102)EXP((E-786)/(.0431 T)))/
((0.2/PcoM)(945.7(af)/PcoA)+
EXP((E-786)/(.0431 T)))
Where:
E = oxygen probe output millivoltage
T = temperature of atmosphere (degrees Kelvin)
PcoA = assumed partial pressure of carbon monoxide in atmosphere (=%CO/100 at 1 atm.
pressure)
PcoM = Measured partial pressure of carbon monoxide in atmosphere (=%CO/100 at 1 atm.
pressure)
af = alloy factor for a given steel (close to 1 for most carburizing steels); can be calculated from
the equation: af (for low alloy steels only)=1+ %Si(.15+.033%Si) + .0365(%Mn) -
%Cr(.13-.0055%Cr) + %Ni(.03+.00365%Ni) - %Mo(.025+.01%Mo) - %Al(.03+.002%Al) -
%Cu(.016+.0014%Cu) - %V(.22-.01%V)
Note:
PcoM is automatically set to 0.2 if the auxiliary input is not being used for CO measurement.
It should be noted that if the Carbon Monoxide content of the furnace is not known, the term in
the equation involving af and Pco can be thought of as a single, overall constant for a given set of
furnace and load conditions. It is for this reason that this term was chosen as the location for the
"Process Factor" adjustment in the Carbon Controller. Mathematically, the Process Factor
adjustment is entered on the front panel for a given case relates to the term in the above equation
as follows:
Unless configured otherwise (see "Setup and Configuration"), the Controller will use a constant
value for CO (PcoM=.2). If the auxiliary input of CO is to be taken into account and assuming
the switch setup is correct, the Controller will use that value as PcoM,and the %C calculation
will vary as the input of CO to the instruments varies. The nominal input range for interact CO
compensation is 0-2 Vdc corresponding to 0-30% CO.
As a practical matter, the exactly-correct Process Factor for a given set of circumstances is best
determined from experimentation with shim stock and/or carbon test bars; the above equations
may then be used as a basis for correcting the factor from a mathematical standpoint. It is usually
easier, however, to correct the Process Factor in real-time by simply changing its value and
observing the results in the %C display in relation to a known %C in the furnace. When using
this method, care must be taken to gather enough solid data before making adjustments; not
allowing for statistical variations between loads can be a potential cause of serious error in
setting up a Process Factor.
If a significantly different Process Factor then seems logical must be used to get a correct %C
display, a number of things must be investigated. The necessity of using a relatively high Process
Factor (for example, a value of 250 in methane-based endo) can possibly be taken to mean
(among other things) that soot is present in the furnace, or that the oxygen probe in incorrectly
located (a conditions for which the Process Factor can never be reliably adjusted). A low value
for Process Factor might indicate a problem with reference air supply to the probe or impending
failure of the probe altogether.
Dewpoint
As a convenience for use mainly in the control of endothermic generators, the MSI Carbon
Controller may be used to calculate and control Dewpoint, in F, from the probe input and
temperature.
The reaction of interest is:
This equation is scaled so that if a Process Factor of 149 is selected for the carbon calculation
(indicating 20 %CO), then this same process factor will imply a 40% hydrogen content for the
dewpoint calculation. Thus for normal 20/40 endo, the instrument may use the same Process
Factor for %C and Dewpoint without a Process Factor adjustment.
The auxiliary input cannot be used in the calculation of dewpoint. The normal method of setting
the Process Factor in Dewpoint mode is to adjust it as required until the displayed Dewpoint is
equal to the Dewpoint measured by a more direct method (i.e. Alnor). For endo generators where
the probe is operating at 200-400 F below the catalyst bed temperature, the Process Factor may
have to be set to 250-450 to get agreement with Alnor dewpointer.
The range of Dewpoint as displayed on the instrument is -99 to +212 F. Even when the
instrument is run in C, the Dewpoint reading will still be in F.
The setpoint in Dewpoint mode may range from
-99 to +250oF. The process deviation band ALARM, if used, is +10 F around setpoint.
Time proportioning adjusts the duty cycle of the control device to maintain control. This is
usually done with solenoid valves controlling the flow of a critical material to the process. The
control loop percent output is the ON time percentage of the value. The cycle time parameter
determines the total cycle time, ON time plus OFF time. For example if the control loop percent
output is 34% and the cycle time is 10 seconds, then the ON time would be 3.4 seconds and the
OFF time would be 6.6 seconds. The selection of the proper cycle time is a trade off between
excess wear and tear on the solenoid valve with short cycle times and rough (pulsing) flow of the
control material with long cycle times. Only one control output triac is used in this mode.
This mode is identical to the time proportioning mode except that two control output triacs are
used. The second control output is the complement of the first, that is when the first output is
ON the second is OFF and vice versa. This mode is used with single action motorized valves
that open quickly when a voltage is applied to one terminal and close quickly when voltage is
applied to the other terminal.
This mode is used when there is two process materials to control that have complementary
effects; like gas and air in a heat treating furnace. If the carbon potential is too low then more gas
is required. If the carbon potential is too high then once the gas flow has been shut off air is
required. The time proportioning dual mode uses two control output triacs; one for gas and one
for air. There is never a time when both outputs are on simultaneously. The control loop
computes a percent output from -100 to +100%. When positive, the proportioning action applies
to the forward (gas) output. When negative the proportioning action applies to the reverse (air)
output.
This mode is used for motorized valves that have a slidewire feedback. This mode requires a
slidewire board for input C of the CARBPRO. The motor slidewire is then wired to this input.
This mode uses two control output triacs; one to drive the motor forward (open) and the other to
drive it reverse (closed). This mode is effectively a control loop within a control loop. The main
control loop computes a desired output percentage. The secondary loop then drives the motor
(forward or reverse) until the slidewire indicates that the valve is open the proper percentage. To
prevent the motor from "hunting" a deadband can be set using the DIP switches. This value can
be set from .2 % to 10%. In most applications the motor with slidewire does not provide any
better control than position proportioning (see below).
This mode is used with motorized valves that do not have slidewire feedback. This mode is
sometimes referred to as the "bump" mode because it "bumps" the valve slightly more open or
closed. This mode uses two control output triacs; one to drive the motor forward (open) and the
ON/OFF (OF)
ON/OFF control is exactly what it implies, the control action is either ON or OFF. With true
ON/OFF control the control output triac is ON whenever the process is below the setpoint value
and OFF when the process is at or above the process value. In many real world applications this
simple control method will cause "contact chatter" because of noisy signals which will switch the
ON and OFF states rapidly. Also since the control action does not turn OFF until the setpoint is
reached, the process will overshoot due to lags in the control action. Marathon controllers
incorporate two features that prevent this problems from occurring; Hysteresis and deadband.
Hysteresis provides a gap between the process turn on point and the turn off point. With this gap
noise will not cause the control output to "chatter". Deadband allows the process to deviate away
from the setpoint by the width of the deadband before any control action occurs. The deadband
on the CARBPRO is adjusted with the proportion band setup (the reset and rate must be set to 0
for ON/OFF control). For temperature control a proportional band of 10 would represent a
deadband of 10 degrees. A proportional band of 5 would represent 5 degrees of deadband, etc.
This is accomplished by allowing the PID control loop to calculate in a normal fashion. The
percent output is then used to determine when the output should be turned on or off. The output
is turned on when the percent output reaches 10%. Hysteresis is added by not turning off the
output until the percent output drops to 2%. With the temperature control example where the
proportion band is set at 10, the output would turn on when the process dropped to 10 degrees
below the setpoint and turn off when the temperature reached 2 degrees below the setpoint. With
a proportional band of 1 these points would be 1 degree and 0.2 degrees respectively.
This mode is exactly like ON/OFF control with the addition of a second control output triac. The
second triac would be ON when the first is OFF and vice versa.
This mode is similar to time proportioning dual in that two control output triac are used such as
in a heat/cool application. The forward (heat) output would act as described in the ON/OFF
description above. The reverse (cool) output would respond when the process is above the
setpoint. To facilitate this process the PID control loop computes a percent output from -100 to
+100%. The plus values mean the process is below setpoint and the minus values mean the
process is above setpoint. The forward contact would turn on when the percent output reaches
10% or above. It would not turn off until the percent output dropped to 2% or below. In a
similar fashion, the reverse contact would turn on when the percent output dropped to -10% or
lower (more negative). It would turn off when the percent output rose to -2% or higher (more
positive). For the temperature example with a proportional band of 10, the heat contact would
Installation
Installation Location
The CARBPRO instrument is designed for 1/8 inch panel mounting in a DIN standard opening
of 5.43 inches square (adapter panels available by special order). Required rear clearance is 10.5
inches to allow for wiring. As with all solid state equipment, the controller should be away from
excessive heat, humidity, and vibration (refer to specifications). Since the unit uses red LED
display devices, avoid placing it in direct sunlight to reduce interference with the display's
visibility. The instrument requires 100/120/200/240 VAC (jumper selectable on power
interconnect board inside the rear panel) 50/60 Hz. It should not be on the same circuit with
other noise-producing equipment such as induction machines, large electrical motors, etc. All
instrument wiring must be run separate from all control wiring.
Panel Mounting/Removal
Because the instrument uses a ventilated enclosure, it is not dust-tight and should therefore
always be mounted in a sealed control panel. To mount the CARBPRO in a control panel, a hole
must be cut 5.43 inches square in the necessary location on the panel. The following procedure
should be followed to mount the CARBPRO in the panel.
1. Insert the unit into previously cut out 5.43 inches square hole in the panel.
2. While supporting the unit, insert one slotted clamping bracket, with head of the bolt
facing to the rear of the unit, into the 0.62 inch by 0.82 inch cutout on the side of the unit.
Warning
To prevent warping of the unit's case, do not over tighten the clamp bolts.
To remove the unit, loosen the side clamping brackets and reverse steps 1 through 3 above.
Note
On subsequent removals and installations the rear panel can be removed (4
screws) and the wiring does not have to be disturbed.
Warning
All connections, rear panel installations and removals; plus triac board installations and
removals must be done with power removed from TBA and TBB. All PC boards should
only be removed or installed with power off via the switch mounted on the triac board.
Otherwise, serious personal and/or equipment damage can occur.
The wiring used to connect the signal wires to the instrument should be run in a conduit, separate
from any AC lines in the area. This provides noise immunity and physical protection.
Thermocouples should be wired with the appropriate alloy extension wire with no termination
other than at the instrument. As with all cold-junction compensating instruments, extreme care
should be used when an existing thermocouple is to be used for both the Controller and another
instrument at the same time.
Control Devices
The CARBPRO provides simple ON/OFF as well as Proportional control through its two contact
closure Control Outputs (TBA-7, TBB-7, TBA-8, and TBB-8) and two Analog Outputs (TBD-13
through TBD-16). Refer to the Section on Control Modes for more details on the outputs. This
allows control through simple ON/OFF devices or through Proportional control methods.
The CARBPRO provides many ways to use the above control methods. Setup has details for
setting the Control Modes to determine the method to be used. Some typical applications for the
Proportioning method are:
1. GAS/AIR application system: Set Control Modes for Time-Proportioning. This provides
that CONTROL OUTPUT #1 (TBA-7, TBB-7) and CONTROL OUTPUT #2 (TBA-8, TBB-8)
are in opposite conditions at either extreme of the control range and are both OFF at the midpoint
of the control range.
2. ANALOG OUTPUT control: Set Control Modes for Time-Proportioning. This provides
a 0 to 5 VDC or 4 to 20 mA output which is selectable on the ANALOG OUTPUT BOARD
(TBD-13 through TBD-16, see Section 2.14 and Section 8.0 for more details). The output
control is based on 0 to 99% of the output device's control range. For example, 50% control
would equal 2.5 VDC out where 5 VDC equals maximum heat output of the drive. This can be
used with servo drives that require a voltage or current command signal for controlling heat
output or servo positioning.
3. POSITIONING MOTOR with SLIDEWIRE FEEDBACK: Set Control Modes for Single
Position-Proportioning with slidewire feedback. CONTROL OUTPUT #1 will drive the motor
in the open direction, CONTROL OUTPUT #2 in the close direction.
Remember, the above methods are just examples of the typical applications of the CARBPRO.
Please call your MSI representative or application engineer for questions concerning your
particular system.
Chart Recorders
If a chart recorder is to be used, it must have input specifications within the following ranges:
0 to 5 VDC
4 to 20 mA
Computer Interface
If you wish to take advantage of the CARBPRO's RS-422 digital communications capabilities,
refer to "Communications" for more details.
Alarms
Programmer
The Programmer can run an entire process, depending on how thoroughly the capabilities are set
up and used. Refer to "Operation" and "Programming" for further information.
Connections to the unit are made via four terminal blocks, on the rear panel, labeled TBA, TBB,
TBC, and TBD. (Position 1 is at the top the position 10 (TBA and TBB) or 18 (TBC and TBD)
is at the bottom of the terminal strip.) AC power, event, control, and alarm connections are made
on TBA and TBB. All communications are on TBC and all analog I/O signals are on TBD.
Refer to the Figure below for a complete layout of the CARBPRO rear panel connections.
AC Power
Communications
Three communications busses are at TBC and use RS-422 full or half duplex protocol for all
ports. (Refer to "Communications" in Maintenance and Troubleshooting.) Typically, the HOST
port will connect to a host computer, the AUXILIARY BUSS to other instruments, and the
OPTOMUX PORT to OPTOMUX
I/O devices.
Analog Inputs
The CARBPRO allows for three analog inputs with their individual functions determined by
"daughter board" located on the analog input board inside the unit. The standard connection, at
TBD, will have the first input as a thermocouple, the second for the oxygen probe, and the third
optionally used to input voltage or milliamp signals.
Analog Outputs
Two, separate, isolated analog outputs are provided on TBD and can be selected as 4-20 mV (for
maximum accuracy, see Specifications for further details) or 0-10 V output through DIP switch
settings on the analog output board. Additionally, outputs can be calibrated by placing a jumper
on the two terminals supplied.
The user may use the CARBPRO in a multi-instrument system by giving the instrument a unique
HOST address, specified by using the DIP switches on the Interface Board inside the CARBPRO
To get to the DIP switches, loosen the black knurled knob on the front panel by turning in a
counterclockwise direction. Carefully remove the front panel but DO NOT remove the ribbon
cable connecting the front panel to the Interface Board. Safely support the front panel near the
instrument. Adjust the DIP switches per Section 2.16 for the desired operating mode. When
switch adjustment is complete, replace the front panel to prevent contamination.
Bank 0
Switch # Description
1 Probe test Enable
2 Unassigned
3 Slide wire Deadband (see the following table)
4 Slide wire Deadband (see the following table)
5 Slide wire Deadband (see the following table)
6 Unassigned
7 Unassigned
8 Service (Must be OFF)
The thermocouple jumper selects either a full upscale or a full down scale reaction to take place
when a thermocouple fails or becomes open. The jumper can be found on the thermocouple
board, and has two possible settings (see Figure). For full scale upwards, place the jumper from
the + to the C, and for full scale downwards, place the jumper from the - to the C.
Front Panel
The front panel of the CARBPRO consists of three main parts, two display windows and a keyboard. Refer to
the figure shown below for a layout of the front panel. The display windows each contain four 14-segment
digits that are used to display helpful messages and numerical parameter values.
PROCESS Display
This 4 digit 14-segment display provides the value of the current process value, along with messages for ease of
operator use when setting up parameters. The PROCESS window displays the step number and OPCODE
when in the Program Editor.
SET Display
This 4 digit 14-segment display provides the value of the process setpoint value during Auto and Program
operation. In Manual mode the Time-Proportioning % Output value is displayed. During operator input
procedures this display shows the data being entered. The SET window displays the corresponding data for the
OPCODES displayed in the PROCESS window when in the Program Editor.
LEDs
Several small LEDs indicate operations and functions of the CARBPRO. Ten are on the face
and three are in the keys.
Aux indicates the PROCESS display is showing the auxiliary input value.
Manual indicates that no control action is being executed by the CARBPRO. If flashing, a
program is in HOLD.
Alarm indicates when the process value has closed the relay based upon trip point and
type of alarm.
Setpt indicates that the Setpt Enter mode has been selected.
Cntrl Parm indicates that the Control Parameter Enter mode has been selected.
Alarm Set indicates that the Alarm Setup mode has been selected or one or both alarm values
are non-zero.
Keyboard
The CARBPRO keyboard consists of ten keys for operating and programming the instrument.
There are no "hidden" keys on the CARBPRO keyboard.
Various operations with the CARBPRO involve dual-key operations using the [Shift] key in the
same way a shift key on a typewriter is used. When activating a dual-key assignment do not try
to press both keys simultaneously; rather, follow the sequence below:
KEY DESCRIPTION
This key selects the operating mode of the CARBPRO. The mode selected
Prog is indicated by the illuminated LED.
Auto
Man
This key selects the Setpoint Enter mode where the Setpoint, Setpoint
Offset and Reference Number can be accessed and altered. When used in
the dual-key operation, Display + Setpt, it allows the operator to pull
Setpt programs into the edit space or decrease the remaining time of a program
step if a program is currently running.
This key selects the Control Parameter Enter mode where the Proportional
Pr. Fact Band, Reset, Rate, Cycle Time and Percent Output values (if in solenoid
Ctl.Parm mode) can be accessed and altered. When used in the dual-key operation,
Display + PrFact Control Parm, it selects the keyboard Lock Level change
mode.
This key selects the Alarm Setup mode where the Alarm 1 and Alarm 2
conditions can be accessed and altered or Alarm 2 can be used to determine
Alarm setpoint for auxiliary control loop. When used in the dual-key operation
Set Shift/Alarm Set it selects the Thermocouple Type, Custom Features, and
Events Partition. After Shift/Alarm Set the Thermocouple Type is initially
displayed, if Enter is pressed the Custom Feature option is available while
the second press of Enter allows the Events Partition to be observed and
altered if necessary.
This key selects which parameter (Aux, %C, O2MV, Temp) is displayed in
the Process display. It is also used as a shift key in two key operations.
Display
The Right and Left arrow keys are used to select the digit to be modified
in a data entry mode. In Manual mode these keys will cause the control
output to go to the full reverse or full forward control direction while the
value is displayed in the SET window. In Automatic mode pressing "left
arrow" causes the % on-time valve position to be displayed in the SET
window. (positive-Output 1, negative-Output 2). In the Programmer
Status Display it causes the display to move to a new page.**
Usually used to decrease the value of a digit in the data entry mode or
scroll through various parameter sequences. In Manual mode this key
will cause the control action to move toward the Output 2 direction.
When used in the dual-key operation Shift/"down arrow" it accesses the
Programmer Status Display.
Usually used to increase the value of a digit in the data entry mode or
scroll through various parameter sequences. In Manual mode this key will
cause the control action to move in the Output 1 direction. When used in
the dual-key operation shift/"up arrow" an LED test is activated, where
every segment and decimal point should light in both displays. If any
segment or decimal point does not light a keyboard problem may exist,
contact a qualified MSI representative.
notes:
* full sequence of “IN A” repeats for inputs B and C.
: the screen repeats for numbers 0 - 8 decimal and hex and hex numbers 9 - f. This
indicates that the repeating screens have been left out between the first and last
numbers.
The following shows the order of configuration options set from the [Pr.Fact/CtlParm]
key and their range of values. Press [ENTER] to go forward to the next option, or
[Display] to back up to a previous option. The arrow keys are used to change the option
within its limits see the keys portion of this section for a complete description of how
they are used. Pressing [Cntl Parm] at any time will exit from this option setup
sequence.
CON menu
Process display Set display options Description
CONV This parameter sets the control process (and setpoint) the instrument
will use to control to setpoint.
Notes:
* thermocouple types are found in the specifications. Values and types are also
found in Maintenance and Troubleshooting.
AOUT menu
Process display Set display options Description
Analog out put 2 choices are the same menu items repeated.
PROG menu
Process display Set display Description
Password Entry
The password can be entered by pressing the Dual-key sequence [Display] + [Pr.FactCtl.
Parm] keys. Any order of keys, except for the [Display] or [ENTER] key, can be
entered as a password, up to nine keys maximum. Press [ENTER] to save the password.
The number in the set display will count the number of keys entered. Pressing
[ENTER] without pressing any other key (i.e. set display=0) will clear the password. So
to have no password the sequence [Display] + [Pr.Fact/Ctl Parm], [Enter], [Enter]
,[Enter] must be pressed.
EVTS menu
Process display Set display options Description
EXT NO, YES External event
boards active
Prob menu
Process display Set display options Description
PT I 0 to 9999 Probe test interval in
minutes
Thermocouple list:
NM
At this point, if there is no need for ALARM 2 to be set, press [Alarm Set] to exit alarm
parameters.
If ALARM 2 does need to be set, press [Enter]. Use the information starting at the top
of the table for ALARM 1. The process display will change only from a 1 to a 2. All
other information in the table remains accurate for ALARM 2.
Notes:
Variable Description
D This is DIRECT operation for alarm actuation (i.e. the contact is normally open until
it reaches the trigger limit specified in the ALARM VALUE then the contact closes).
R REVERSE operation (opposite of NORMAL) for ALARM actuation (i.e. the alarm
contact is normally closed until it reaches the trigger limit specified in the ALARM
VALUE then the contact opens).
O2 Alarm actuation is based on the analog signal at Input B inputs exceeding the
limit in the Alarm Value. Input B inputs is physically located at TBD-4, TBD-5, and
TBD-6 on the unit's rear connectors.
BND Alarm actuation uses BAND WIDTH control above and below a programmed
setpoint limit. (i.e. If the band is set by the ALARM VALUE to 0.10 and the
programmed setpoint is at 0.80, the alarm will trigger at 0.90 and 0.70.)
DEV Alarm actuation uses DEVIATION control above or below the programmed
setpoint. The + and - symbols determine if the deviation is allowed or if it is above (+)
the programmed setpoint or below (-) it. (i.e. If deviation of 0.10 is placed in the
ALARM VALUE and 0.80 is the programmed SETPOINT the alarm will trigger at 0.90
or 0.70, for -0.10.)
FLT An input FAULT, or a program alarm is to be used as basis for the actuation.
The ALARM VALUE is ignored.
[SETPT] key
Parameter entry under the [Setpt] key is the same procedure as under the other two keys
controlling parameters. [Enter] moves forward [Display] moves back and [arrow] keys
change the values in a parameter. [Setpt] exits and values are saved when changed.
Setpt key
Process display Set display options Description
Once installation and setup and configuration are complete, the day to day operation
needs of the CARBPRO depend upon the application. The basics are found in the
Quick Reference Guide.
Correct the problem or do what the programmed alarm indicates: see “Maintenance and
Troubleshooting”: the alarm messages for complete information on programmed alarms.
Then press [Enter] to continue the program.
[SETPT] is used to enter the setpoint, the Reference Number, and the Operator Inputs.
The first press of [SETPT] will allow the arrow keys to adjust the value of the setpoint.
Use the [LEFT ARROW] or [RIGHT ARROW] keys to select the character to be
altered. Once the character to be changed is flashing, use the [UP ARROW] or [DOWN
ARROW] keys to select the desired number or symbol. After all characters are as
desired, press [ENTER] to place the value in nonvolatile memory and to continue
paging through the parameters. Pressing [ENTER] again allows the Reference Number
to be changed. Pressing [Display] at any time allows the operator to “back up”to the to
the step before [ENTER] was pressed. An additional press of [ENTER] allows the
operator Input to be changed. Anytime during the setting of values [SETPT] may be
pressed to save the value and exit.
SETPOINT Parameters
PROG/AUTO/MAN
The Operation Mode for control of programs is selected by the [Prog/Auto/Man] key.
Pressing this key allows access to the operation mode selection controls.
The first selection, after pressing [Prog/Auto/Man], allows for control of the program to
be entered. The key presses that follow it depend upon the state of the program. If a
program is not running see “Running A Program” below.
Anytime during the selection process [Prog/Auto/Man] may be pressed to exit the
selection process. All of the parameters under this key have a Lock Level of 3.
MANual Mode.
In Manual mode the process variable is displayed in the PROCESS display, the SET
display shows the appropriate control value, and no control action is computed. The
arrow keys can also be used to activate the control output.
AUTOmatic Mode
In Automatic Mode the process variable is displayed in the PROCESS display, the
SETPOINT is displayed in the SET display, and control action is computed based upon
the PID parameters and the input(s). Pressing and holding the [LEFT ARROW] key will
cause the SET display to show the control action as described previously in "Manual
Mode.”
Running a Program
1. Press [PROG/AUTO/MAN] until the instrument's Prog LED lights.
2. The Program Number is displayed in the SET display, select the program to be run
using the arrow keys.
OPTIONAL: If beginning at a step other than 1 Repeatedly press the [SHIFT] key to
select the step upon which the program should start. The step number will appear in the
PROCESS display.
Stopping a Program
Press [PROG/AUTO/MAN] UNTIL either the Auto or Man LEDs begin to flash,
indicating a program is in HOLD. Press [ENTER] to cancel the program (flashing will
stop).
OR
Press the [PROG/AUTO/ MAN] key until the Auto or Man LED is flashing, indicating
a program is in HOLD. Return to the program mode by pressing [PROG/AUTO/MAN]
and the PROCESS window will display the word HOLd. The SET window indicates
the program number that is in hold. Press any of the arrow keys to cancel the program.
The hold symbol will be replaced by the run symbol.
Note
If the instrument is in Manual mode and a program is in HOLD, no automatic control is
taking place.
If the instrument is in Automatic mode and a program is in HOLD, automatic control is
continuing.
2. Do not alter the program number, otherwise, the program will start from the first step
and not where it had left off.
3. Press [ENTER] and the program will continue executing with the step where the HOLD
was initiated.
1. Press Display/Setpt
2. Select the program to be edited using the "arrow keys"(Edit / 0001)
3. Press Enter
* Note that the unit will allow editing of a program that might be running. This editing
will not affect the currently-running copy of this program until the program is actually
restarted, either manually or by a program jump.
1. Use the [LEFT ARROW] and [RIGHT ARROW] keys to select digits to be changed
(either the OPCODE or the data)
2. Use the [UP ARROW] and [DOWN ARROW] keys to change the selected digit
5. If at any point the program does not advance or back up, and the entire SET display
starts flashing, the data in the SET display is invalid for the OPCODE shown. Use the
[arrow keys] to enter the correct data and then press [ENTER].
To Insert A Step
1. 1. Go to the step of the desired insertion, using either the [ENTER] or [Display] keys
2. Press [Control Parm]
3. Enter the new step, OPCODE and data
4. Press [ENTER]
To Delete A Step
1. Press [Setpt ]at any time, the edited program is lost (the copy in non-volatile memory is
unchanged)
2. Press [ENTER]
3. Select the program number in the SET display using the [arrow keys] until the desired
program number is being displayed (SAVE / 0000)
4. Press [ENTER], the program stored in that location previously is now lost (SAVE /
Done)
Changing Parameters
All of the CARBPRO parameters, program numbers, OPCODES, and data values can
be altered using the following procedure:
Press [Pr. Fact./Ctrl. Param.]. The word MENU will appear in the PROCESS window.
The Parameter group will appear in the SET window. Press [ENTER]. The symbol for
the parameter is displayed in the PROCESS window while the current alterable data is
shown in the SET window. The flashing character is the one that can be altered.
Use the [LEFT ARROW] or [RIGHT ARROW] keys to select the character to be
altered.
Once the character to be changed is flashing, use the [UP ARROW] or [DOWN
ARROW] keys to select the desired number or symbol.
After all characters are as wanted, press the [ALARM SET] key to place the value in
memory and exit,
OR
press [ENTER] to save the value and continue (forward) editing other parameters,
OR
[Display] to save the value and continue (back) editing other parameters.
NOTE
If an entered number value is not within the acceptable data range, the
maximum/minimum value will flash in the SET display. Repeat the above procedure
until an acceptable value has been entered.
See “Setup and Configuration” for the Menu table and parameter definitions. The
Alarms are also found there.
Programmer Operations
3) less information needs to be saved for each step therefore more programs can be
stored.
The step approach is very similar to what an operator would do if he were manually
controlling the process.
Some of the features in the OPCODEs may not be obvious as to how they would be
used until more experience is gained. However, with a little practice and
experimentation the Programmer can soon be mastered.
Each program in the CARBPRO consists of nineteen steps (one OPCODE per step).
Some OPCODEs allow programs to be linked together. The CARBPRO can store up to
200 programs in non-volatile memory.
Description of OPCODEs
The following "alphabet" lists all of the available OPCODEs for the CARBPRO
Programmer.
Note:
The P and = OPCODEs are used together as shown in the following example which
enters values for the Pb=150, Reset=.3, Rate=.05, LOPO=20 and HIPO=95
01 P 0150 Pb=150
02 = 0030 Reset=.30
03 = 0005 Rate=.05
04 = 0020 Minimum %Output=20%*
05 = 0095 Maximum %Output=95%*
cycle Time=16
Note:
The execution of a JUMP or a GOSUB statement always loads the program into
working memory whereas an unconditional BRANCH statement does not reload the
program.
Note that the Programmer counts time in hours, tenths of hours (=6 minutes) and
hundredths of hours (=36 seconds) rather that in hours, minutes, and seconds.
A-ALARM
b-BRAN
C-AUXCN
d-ADREF
E-EVENT
F-FSOAK
G-GOSUB
H-TEMPS
h-TEMPI
I-DELAY
J-JUMP
L-LIMIT
n-REF#S
O-OUTPUT
o-OXINQ
P-PID
r-RAMP
S-SOAK
T-TIMES
t-TIMEI
U-TOUTI
Y-AUXI
=-PIDEQ
--NOP
Limit Statements
There are various ways to force a program to wait for something to happen. Although it
may seem that the specified condition should be easily satisfied, it is still wise to put
realistic time limits on how long the wait should be.
The following chart summarizes the effect the LIMIT statement has on each OPCODE.
The operation of a limit statement after the following OPCODEs is described in more detail
below:
E (EVENT) (INPUT) - A limit statement here will cause the program to wait for the
specified event INPUT (normally event numbers 8-15) to switch to the specified state (ON
OR OFF, 1 OR 0), before proceeding. If this does not occur within the specified limit time, a
limit time-out alarm will occur.
Note: The event INPUT must be held in the trip state for at least 30 seconds to make sure
that the Programmer will acknowledge it. Thus, a momentary push button could not be
used as an event INPUT unless some type of latching scheme is employed. If a limit
statement is not used, the program may wait indefinitely.
H (TEMPS) A limit statement here will cause the program to wait for the measured
temperature to come to within +10 F (or +10 C) of the specified Setpoint. If this does not
occur within the specified limit time, a limit time-out alarm will occur. If no limit statement
is used, the Programmer simply sets the specified Setpoint and goes on to the next step. The
maximum time that a limit statement will accept is 40 hours. Use the Programmer Status
Display during a wait operation to reveal the time left before a limit time-out alarm will
occur.
Branch Statements
Branch statements are best utilized when placed after inquiry statements. If neither a branch
A limit statement between an inquiry and a branch just sets a definite time to wait for the
inquiry to become true. It has no effect on the outcome of the inquiry or where the program
branches to. It only effects the length of the time delay.
If a branch statement is not preceded by an inquiry, or any conditional statement, the branch is
automatically assumed TRUE.
An unconditional branch is one in which the steps specified for true and false are the same. An
unconditional branch to step 1 (b 01.01) will cause a program to loop back to the beginning of
the program every time the above statement is encountered. The difference between a b 01.01
and a J 0000 is that the jump reloads the program and would therefore pick up any changes
edited into the program after it was initially started.
Writing
Before a program can ever be written into the CARBPRO, the author must understand and
perform the following process:
The Programmer Editor can be used to create a new program or modify an already existing
program. While in Program Edit mode, the unit continues to control the furnace (as long as
the Auto LED is on), and a running program continues if the program LED is on.
To get the unit into the editor mode, perform the dual-key operation [Display][Setpt.] The
PROCESS window will have the message EDIT displayed and the SET window will have a
XXXX displayed signifying the program number to be edited. At this point any of the 200
programs can be called into the edit space using the arrow keys to change the necessary
At any point, a step can be inserted or deleted. To insert a step, press Control Parm, this
forces the OPCODE at step 19 to be lost and a -(NOP) will appear. To delete a step, press
[Alarm Set key], this causes a - NOP to be pulled in at step 19.
Use the [left arrow] or [right arrow] keys to determine whether the OPCODE or DATA is to
be changed. If a data character is flashing move left or right in the data by using the arrows. If
the OPCODE needs to flash press the [left arrow] until the OPCODE character flashes the
[right arrow] does not allow access to the OPCODE. If the OPCODE is to be changed, the
[up arrow] or [down arrow] keys can be used to scroll through the OPCODES alphabetically.
If either the "up arrow" or "down arrow" keys are held down, the OPCODEs will
automatically be displayed with each flash of the display. When entering data, the "up arrow"
and "down arrow" keys can be used to select 0 through 9 (or negative sign, if applicable).
If at any point [Enter] or [Shift] is pressed and the SET display starts flashing, the data is not
valid for the OPCODE shown. Use the arrow keys to alter the data as required and press
[Enter] or [Display] to continue entering or editing the program.
Exiting
Once all 19 steps have been entered or modified as needed and the editor is sitting at step 19,
press [Enter] one more time to get the message SAVE displayed in the PROCESS window.
The program number, the number of the program originally pulled into the edit space, will
appear in the SET display but can be changed using the arrow keys.
If the program number is changed at this point, however, the edited program will be stored as
the new number. For example, it is possible to call up program #29, edit it, and store it back
as program #4. The original #29 is still intact, and whatever was in program #4 is now
replaced with the edited #29.
If, while entering data an error is made, or it is desired to exit the editing routine without
making any changes, press Setpt and the unit will continue normal operation. The edited
information will be lost.
NOTE:
It is recommended that program #200 be kept as a "garbage" program location
to temporarily store programs as required.
Programmer messages are displayed when inputting data and using the Editor, refer to the
table shown below:
The two start-up options described in "Start-Up Procedures" affect the Programmer
significantly.
If a Shift-Shift-Enter start-up was used, the program running at the time of power was lost
will pick up where it left off. This includes events and soak times.
If a simple Enter-Enter start-up sequence was used, the program is canceled. All events will
return to the rest position (OFF) and the setpoint is lost.
Alarm Messages
Messages #01-79:
Indicate a programmed alarm (from an "A-ALARM" OPCODE in the program) has occurred.
The response should be to carry out whatever task the message code indicates. For example,
Message #37 might mean put test pins in furnace, while #28 might mean to manually change
the temperature setpoint to 1550`F. These codes should be assigned for the particular
installation involved.
Message #80-#81:
The A(Alarm) OPCODE in this case should be followed by the L(Limit) OPCODE that sets
Also, after the Deviation Alarm 81 occurs, clearing the alarm also clears the inb and flag;
therefore, the process must reach setpoint before the alarm can sound again. The alarm is
automatically disarmed at the end of a program.
Message #82-90:
Not assigned.
Message #91:
Reserved
Message #92:
Indicates a problem on the Events Buss. This error may occur at any point in a program
that attempts to use events statements.
One of the following conditions possibly exists:
a. The OPTOMUX board of interest is not present, is disconnected, or is turned off.
b. The jumpers on the events board are improperly set.
Should be configured for:
-2 pass format
-1200 baud
-Address #1
-Multidrop Mode
c. There is severe disruption of communication due to the use of wrong cable, too
long a cable run, routing of cable in non-recommended termination schemes (i.e.
WYE), or improper or missing termination resistor connections.
Message #93:
Indicates a limit statement has timed out. This must be interpreted in the particular situation,
but if the limit time specified in the program was realistic, then a flaw in the system is
indicated, or an instrumentation or operator error has occurred.
Message #94:
Not assigned.
Message #95:
Indicates an illegal ramp, the r OPCODE is not followed by the H OPCODE in the currently
running program.
Message #96:
Indicates that a power failure has occurred and the CARBPRO started up again in the AUTO
Message #97:
Indicates that a subroutine is calling a subroutine which is illegal with the MSI Programmer.
Message #98:
Indicates that a jump from one program to another was attempted but not implemented due to
memory disruption or a J201 to reference number too large.
Message #99:
Not assigned.
Message #101:
Indicates that a recipe has attempted to change the instrument set point when the remote
setpoint selection (SETP) has been changed from LOC (local) to IN C (input C).
3. After taking the required action based upon the alarm message, there are several possible
courses of action:
a. Press Enter again to continue with the program (after
either correcting the problem with the temperature or events buss in the case of
error message #92, or taking the prescribed action in the case of programmable
messages 01 through 89).
b. Abort the program by pressing PROG/AUTO/MAN.
c. In the case of a timed-out limit statement, (message #93), it is normally desirable
to continue the program by re-executing the offending limit statement to be sure it
is satisfied. To do this, simply press Enter. A setpoint will cause the LIMIT
statement to be skipped and the program to continue on the next step.
The status display is broken into “pages” and “paragraphs” the “pages” are
represented here by columns and the” paragraphs”, by the individual cells. See
“Setup And Configuration” for the values displayed here most of the status
pages correspond to the setup menus.
Press [Display]+[Down Arrow] to enter the page display table. Press [Right
Arrow] or [Left Arrow] to move from one column to the next in the display.
Press [Up Arrow] or [Down Arrow] to move down a column.
NOTES:
---- The item displayed in the box above this repeats through the full cycle of
options. For example:
Exterior Analog has 16 displays and Slave Instrument has 8.
** Items displayed above this repeat in sequence through the full cycle of options. For
example: Slave Instrument will display data for HSP, HAC, And HPO for each option in the
cycle before going to the next option.
: The Generic table (the title of this page does not display) displays the parameters in hex
for all the programs loaded into the CARBPRO 3.5 . These are for engineering
troubleshooting purposes only. The operator should not try to use these.
The first column displays the firmware version number. The 3.5 c indicates that the
instrument is a version 3.5 Carbpro. The number following the ‘r’ is the actual frimware
version.
EVNT Events
This display should be used by advanced users and Marathon service personnel. The
memory map or generic display shows values as they are stored in various memory
locations. Both value and memory location addresses are in hexadecimal notation. In the
upper row the display shows XX=Y, where XX is the memory address and Y is the memory
table. The memory addresses range from 00 to FF. The table is fixed at 0. The lower row
shows the data stored in the memory location shown.
Pressing the [Enter] key advances the address by x10 memory locations. Pressing the
[Enter] and [Setpt] keys at the same time will allow changes to the lower value for the
displayed memory location.
CALIBRATION PROCEDURES
The CARBPRO instrument is shipped completely pre-calibrated. The drift
characteristics of the input circuits are excellent but from time to time adjustment may
be necessary in order to maintain high accuracy.
When operating in the calibration mode, the displays and front panel keys take on
special assignments. The PROCESS display shows the value of the input being
calibrated with a flashing digit. This flashing digit shows the relative sensitivity of the
arrow keys, as described following the key descriptions. The SET display shows which
input is being calibrated and whether the zero value or the span value is being modified.
Message Description
NOTE
It is very important to be sure the SET display is showing the proper mode
before making an adjustment or the wrong value will be changed.
Adjustment Sensitivity
The adjustment sensitivity works in the following manner. If the digit farthest right in
the process display is flashing, then each press of the [Up Arrow] or [Down Arrow] key
will change the calibration value shown by one unit. This is the least sensitive position.
If the digit farthest left is flashing, then each press of the [Up Arrow] or [Down Arrow]
key will change the calibration value by a thousand units. The middle digits will show
sensitivities of a hundred and ten units respectively. It is not important to know the
relative worth of one calibration unit. Understanding that the location of the flashing
digit affects change that one key press will make on the calibration value is necessary.
By observing the degree of sensitivity one key press makes at each flashing digit
location, you can quickly see how to use this feature.
Before placing the CARBPRO into calibration mode, check to be sure that for each
input:
The proper thermocouple type has been selected, and
Cold Junction compensation has been selected, if required. Cold Junction compensation
can be selected by using the [Setup] key. The option is below the corresponding input
type selection.
This calibration procedure assumes that a thermocouple has been selected and internal
cold junction compensation is being used. If this is not true, follow the procedure for the
auxiliary board using a 0 to 40 millivolt signal. The calibration procedure is as follows:
Using the [Display] key, select the proper input to be calibrated (input A, if standard
configuration).
Using the [Enter] key, select the zero mode (IE: if for input A, Z-A).
Set the calibrator output to the recommended zero value for the thermocouple type
selected. See the table below.
Using the Arrow keys, adjust the process value to equal the calibrator output.
Press the [Enter] key to select the span mode (IE: S-A, for input A).
Set the calibrator output to the recommended span value in for the thermocouple type
selected.
Using the arrow keys, adjust the process value to equal the calibrator output.
Repeat steps f. through j. until no additional change is needed.
Press the [Enter] key one more time to be sure the calibration factors are stored. Go to
the next input to be calibrated or exit calibration mode by removing the calibration
jumper or pressing [Setup] .
The usable ranges of the thermocouple types are shown in The table above. If having a
high accuracy over a specific operating range is desirable then the input should be
calibrated over that range. Follow the calibration procedure for normal calibration with
the following changes. Use the low end of the desired range as the zero value and the
high end as the span value. There will be more interaction between zero and span with
this method. The desired operating range must fit with the limits of the table.
Short the input by putting a banana plug shorting block into the simulator. Short the
jumper (switch) wired into 17 and 18 to calibration mode.
This will produce some value in the PROCESS window and Z-A in the SET window.
Use the left and right arrow keys to change the adjustment from coarse to fine in the
PROCESS window, and the up and down arrow keys to change the value. Adjust the
PROCESS window value to zero (0), or as close as possible.
Press the [Display] key to change the SET window to Z-B or Z-C and repeat steps 4 and
5 for inputs B and C.
After all the values are stored, press the [Display] key to return the SET window to Z-A
Using a meter to check your input voltage on the O2 side, enter 1400 or 1500 mV from
the simulator, and turn ON the simulator.
Set the span values at 1400 or 1500 (depending on what the simulator generated) using
the arrow keys to adjust the values.
Press the [Enter] key twice to save the values and press the [Display] key to change the
input type.
Repeat steps 1-5 for each input (A, B, and C), pressing [Enter] twice to save the values
each time. Wait 5 to 10 seconds to allow the reading to record, then take it out of
calibration mode by throwing the switch.
Remove the banana plugs from the simulator (remove the load from the line) and wait
for the instrument to "max out" at 3500.
Let the reading settle at maximum (another 5 to 10 seconds) hen reinsert the banana
plug into the simulator to see if the instrument returns to a steady 1500 at all inputs.
Vary the input millivoltage down and verify that 1500 reduces to 1000 at a steady level
for each input setting.
Check the reference voltage on TBD-5 and 6 (for input B) and 8 and 9 (for input C).
Should read around +2 mV (between 1.8 and 2.2 is considered good).
Initial Settings
The following steps set up the parameters necessary to calibrate the Linear board.
Verify these settings before proceeding with this calibration.
Zero
Turn off the power at the simulator.
Short the input by putting a banana plug shorting block into the simulator. Short the
jumper (switch) wired into 17 and 18 to calibration mode.
This will produce some value in the PROCESS window and Z-A in the SET window.
Change Z-A to Z-C by pressing the [Display] key.
Use the left and right arrow keys to change the adjustment from coarse to fine in the
PROCESS window, and the up and down arrow keys to change the value. Adjust the
PROCESS window value to zero (0), or as close as possible.
Span
Put the meter leads into the banana plugs to measure Volts.
Using a meter to check your input voltage on the O2 side, enter 10V for the simulator,
and turn ON the simulator.
Set the span values at 10.00 (depending on what the simulator generated) using the
arrow keys to adjust the values.
Press the [Enter] key twice to save the values and press the [Display] key to change the
input type (if required).
Wait 5 to 10 seconds to allow the readings to record, then take it out of calibration
mode by throwing the switch.
Remove the banana plugs from the simulator (remove the load from the line).
It may be necessary to change the ICOF and ICSP values to scale the input C signal to a
particular process value. For example it would be necessary to change ICSP to 2.00 if
input C was going to used as a carbon setpoint source. A 0V to 10V input would
indicate a 0% to 2% carbon.
Zero
Turn off the power at the simulator.
Short the input by putting a banana plug shorting block into the simulator. Short the
jumper ( switch) wired into 17 and 18 to calibration mode.
This will produce some value in the PROCESS window and Z-A in the SET window.
Use the left and right arrow keys to change the adjustment from coarse to fine in the
PROCESS window, and the up and down arrow keys to change the value. Adjust the
PROCESS window value to zero (0), or as close as possible.
Press the [Display] key to change the SET window to Z-B or Z-C and repeat steps 4 and
5 for inputs B and C.
After all the values are stored, press the [Display] key to return the SET window to Z-A
and press the [Enter] key to change it to S-A (span).
Span
Put the meter leads into the banana plug to measure mV (300----).
Using a meter to check your input voltage on the O2 side, enter 1.4 or 1.5 mV from the
simulator, and turn ON the simulator.
Set the span values at 1400 or 1500 (depending on what the simulator generated) using
the arrow keys to adjust the values.
Press the [Enter] key twice to save the values and press the [Display] key to change the
input type.
Repeat steps 1-5 for each input (A, B, and C), pressing [Enter] twice to save the values
each time. Wait 5 to 10 seconds to allow the readings to record, then take it out of
calibration mode by throwing the switch.
Remove the banana plugs from the simulator (remove the load from the line) and wait
for the instrument to "max out" at 3500.
Let the reading settle at maximum (another 5 to 10 seconds) then reinsert the banana
plug into the simulator to see if the instrument returns to a steady 1500 at all inputs.
Vary the input millivoltage down and verify that 1500 reduces to 1000 at a steady level
for each input setting.
Check the reference voltage on TBD-5 and 6 (for input B) and 8 and 9 (for input C).
Should read around +2 mV (between 1.8 and 2.2 is considered good).
The two Analog Output signals can be configured for the following ranges: 0 to 5 V or
4 to 20 mA. The output modes for each of the Analog Outputs are determined by the
two separate DIP switches on the ANALOG OUTPUT board.
Any time the mode of operation is switched between current and voltage, the outputs
must be re-calibrated. The outputs do not have to be re-calibrated when switching
between output mode i.e.: if the output is calibrated for 0 to 5 volts, and it is necessary
to change from Process Variable to Proportional Output 1, then no re-calibration is
necessary (5 volts will be equal to 100%).
To set the desired mode, find the proper switch that corresponds to the output to be
used. Select the voltage mode by pushing the rocker switch down at the bottom edge
of the switch. Select the current mode by pushing the rocker switch down at the top of
the switch. Repeat procedure for the other output.
• Consideration must be made at this time about which type of output, current or
voltage, is to be used. Check the two rocker switches on the Analog Output board
to confirm that the desired mode is selected for each output.
• Remove the FRONT PANEL by loosening the black knurled knob in the
counterclockwise direction. Remove the panel from the chassis and support it near
the instrument.
• To calibrate the outputs using the following method, both Analog Outputs must be
set to the Proportional Output (PO) control mode. This is done by:
1. Pressing [Pr. Fact / Ctl. Parm] and selecting AOUT from the menu. Press [Enter]
to move forward through the menu.
2. At the AO 1 display, change the control mode in the lower window to PO.
3. Press [Enter] repeatedly.
4. At the AO 2 display, change the control mode in the lower window to PO.
5. Press [Setup] to exit the menu.
• *Remove any wires at the Analog Output terminals (TBD-13, TBD-14, TBD-15
and TBD-16).
• *Attach the leads of a digital multi-meter (DMM) to the terminals that correspond
to the output to be calibrated (TBD-13(+) and TBD-14(-) for Analog Output #1.
TBD-15 (+) and TBD-16(-) for Analog Output #2).
• *Set the Percent Output to 0% using the [Left Arrow] key.
• *Find the OFFSET POT for the output to be adjusted. Adjust the pot until the
DMM reads 4 mA current output or 0 V.
NOTE: Make sure your meter is setup for the appropriate measurement. If you are
reading >20VDC then the output is probably setup for current output and the meter
should be configured to read DC Current.
• To get the full SPAN output value, press the [right arrow] until 100 is displayed in
the PROCESS Window indicating 100 percent is being applied.
• With the DMM connected at the proper output terminal connection, adjust the
GAIN pot of the corresponding output until the DMM reads the required output (5
V max) or 20 mA).
• Move the meter leads to the other Analog Output and repeat the previous step for
the SPAN output.
• Repeat the Zero and Span process until no further adjustments are required.
• Reset PO1 to its original setting, if it was changed in the *l offset pot step above,
to their desired values. Reattach any wires removed from the Analog Output
terminals.
• Reattach the FRONT PANEL to the chassis. The Analog Output Calibration
procedure is now complete.
DIGITAL INTERFACES
Host Communications
The Host communications are able to be set from the front panel: see “Setup and
Configuration”. The CARBPRO is suitable for connection to a host computer for
intelligent overall process monitoring or supervision. Terminal connections are made
on the rear panel: See the connections label on the instrument. Twisted pair wire with
or without a shield must be used for all communications wiring. Conventional RS-232
cable is required along with a half-duplex RS-232/422 convertor (P/N FG/500-0501).
With a 9-Pin or 25-Pin female connector depending on Host Computers connector,
some of the pins on the computer end of the connector should be jumpered together as
follows: 9-Pin: 1,4,6,8 or 25-Pin: 5,6,8,20. The CARBPRO never initiates
communications, and is always in receive mode unless responding to a question.
"X" Protocol
The "X" protocol software involves a Parameter Table, a Program Run Buffer, a
Program Edit Buffer, and a Serial I/O Program Buffer. The CARBPRO can be written
to using a "1TXparameternumber$data" format. This entry would place the data value
in the proper location as determined by the parameter number. Any parameter can be
read back from the CARBPRO using the following format "1Txparameternumber".
Therefore, to write a value to the CARBPRO for a specific parameter use an "X" or to
read a specific parameter from the CARBPRO, use an "x".
All of the parameters are listed below along with a short description. The numbers in
the parenthesis are in Hexadecimal.*
Parameter Table
(0H-2FH) & (72H-79H)
CHSTAT (0) -Status Word
SETPT(1) -Setpoint of Process Variable
SETPTOS (2) -Setpoint Offset
GAIN (3) -PID Proportional Band
RESET (4) -PID Reset
RATE (5) -PID Rate
CYCTIM (6) -PID Cycle Time
ALARM1 (9) -ALARM1 Value and Type
ALARM2 (0AH) -ALARM2 Value and Type
(0H-2FH) & (72H-79H)
REFNUM (0CH) -Reference Number
PRGNUM (0DH) -Program Number and Step
PRGSTK (0EH) - Program Stack (Number and Step)
PRGMT (0FH) -Master Timer Bit 15 is DIR Flag
PRGRTIM (10H) -Programmer Course Remaining
The Alarm Queue works on a READ & CLEAR basis. If the Alarm Queue is read with the "x"
parameter FF (Hex), the storage location will return a word comprised of a HI byte and a LO
byte. The LO byte is the first alarm appearing in memory while the HI byte is the second alarm
appearing in memory (thus creating the FIFO effect). If both bytes are non-zero, then the Host
will look again to see if any non-zero values have been stored. Once the bytes are read from
the Queue, they are cleared out of the memory block.
If there is no Host Software used, the Alarm Queue is never read, but the Queue is still written
to by the instrument. Once the Queue is filled, it cannot be written to until a location has been
cleared. Considering the fact that Host Software is not used, the Queue will never be cleared
and will never store any of the alarms that occur after the Queue has been filled. This does not
cause a problem considering the fact that the Queue is only used with Host Software and if the
software is not used, we do not care if it is filled or not. Message Protocol Format
A I C dddd D L E
HOST SOFTWARE
The CARBPRO will emulate the 10PRO temperature controller command set. The commands
which are emulated are:
Command Set
The MSI command set supports the extensive capabilities of the CARBPRO when used with a
supervisory computer software system such as MMI's Process Master. The command set consists
of the following characters:
OPTOMUX Protocol
The OPTO 22 format is RS-422, Full-Duplex, 1200 BAUD, 8 bit, no parity, and 1 stop bit. The
message format follows the OPTOMUX two pass protocol. The CARBPRO sends messages to
set up the events board per the events partition, activate the appropriate outputs, and reads the
input conditions. The CARBPRO initiates messages on this buss and waits ½ second for a reply.
The Events Buss allows the Controller to receive and/or transmit discrete events in time. The
XMT and REC LEDs indicate whether the OPTOMUX is transmitting or receiving data. (These
LEDs should never be on at the same time.) This actual input/output switching is executed by
the OPTOMUX board: see “Setup and Configuration” or “Programmer Operations” or the
OPTO22 manual for specific details.
Slave Buss
The slave buss is a broadcast only communications buss.
Broadcast Mode
The slave buss broadcasts the CARBPRO setpoint using the 10PRO broadcast protocol. The
broadcast protocol format is similar to the message protocol format. Its form is
?AIddddDLE
where ?= 10PRO address symbol
A= Using 10PRO
I= Sending Setpoint
dddd= Data for Setpoint
Passwords
In “Setup and Configuration” the Password is introduced. Password protection for certain
operator functions is provided for security. We do not preset passwords at the factory.
SPECIFICATIONS
Ambient 0 to 130 F
Temperature 0 to 5 volts for 0-4000 F
Analog 0 to 5 volts for -99 to +99 control
Outputs output
Serial
Interface
Host RS-422, 1200 BAUD, Half Duplex
MMI protocol and 10PRO emulation
Events RS-422, 1200 BAUD, Full Duplex
OPTOMUX protocol
PID Constants
Proportional 1 to 999% of Range
Band
Signal Display
Range -300 to 4000 (+4)
Depends on
thermocouple
type
Thermocouple
L: Linear
E: Chromel-Constantan
J: Iron-Constantan
K: Chromel-Alumel
Tungsten 5% Rhenium vs.
C: Tungsten 26% Rhenium
Platinum vs. Platinum l3%
R: Rhodium
Platinum vs. Platinum 10%
S: Rhodium
T: Copper-Constantan
GLOSSARY
Load Line
Load line (LdLn) is a manual offset to the control output (manual reset). The load line
can be set from 0 to 100%. Load line must be set to zero when using ON/OFF control.
ON/OFF control
In ON/OFF control Output l is turned ON whenever the percent output exceeds l0% and
Output 2 is turned ON whenever the percent output goes below -l0%. Therefore the
proportional band is used to set the deadband. If the proportional band is set at 5% then
an error of 5 will produce a l0% output; therefore, the deadband is 5. Reset and Rate
would normally be set to zero; however, experimentation could improve the control
response. Load Line must be set to zero.
Proportional Band
The proportional band is based upon a range of l000. Therefore, if the proportional
band is set at 10% and the error is 100 (10% of range) then the output would be 100%
(presuming reset=0).
Rate
The rate setting is in minutes and is settable from 0 to 9.99 minutes in .0l steps.
Reset
The reset setting is in repeats per minute. The range is 0 to 99.99 repeats per minute in
.0l steps.
Time Proportion
In time proportion mode Output l is ON for the percent of the cycle time when the
percent output is plus. When the percent output is minus, Output 2 is ON for the
percent of the cycle time.
Appendix A
Hexadecimal Code
Decimal BinaryHexadecimal
System System System
0 0000 0
1 0001 1
2 0010 2
3 0011 3
4 0100 4
5 0101 5
6 0110 6
7 0111 7
8 1000 8
9 1001 9
10 1010 A
11 1011 B
12 1100 C
13 1101 D
14 1110 E
15 1111 F
2. Analyze each set of four separately for the equivalent hexadecimal digit
determined from the chart above.
i.e. 1100 1111 0011 1101
C F 3 D
* For further explanation, consult any college digital systems text, such as
Microcomputer-Based Design by John B. Peatman.
3. Put all of the separate HEX digits together to form the numerical word.
i.e. CF3DH*
UNIT #1
BANK 1 1234 5678
BANK 2 1234
UNIT #2
BANK 1 1234 5678
BANK 2 1234
UNIT #3
BANK 1 1234 5678
BANK 2 1234
UNIT #4
BANK 1 1234 5678
BANK 2 1234