TINY 48 Model 4830 Installation Instructions and User Guide

CONTENTS 1.0 (1.1) 2.0 3.0 (3.1) (3.2) (3.3) (3.4) 4.0 (4.1) (4.2) (4.3) (4.4) (4.5) 5.0 6.0 (6.1) (6.2) (6.3) (6.4) GENERAL DETAILS Options MECHANICAL INSTALLATION ELECTRICAL INSTALLATION General Precautions Instrument Electrical Supply Connections (Terminals 7,8) Input Signal Connections (Terminals 14,15 and 16) Outputs FRONT PANEL FUNCTIONS Setting the control temperature Interrogation of control parameters Adjusting control parameters Setting the Alarms Preventing adjustment of control parameters and alarm settings INTERROGATION OF CONFIGURATION OF THE TINY 48 RECONFIGURATION OF THE TINY 48 .Software reconfiguration Hardware reconfiguration analogue output board Reconfiguration details Input sensor range configuration information

PAGE 2 2 2 3 3 3 3 4 5 5 5/6 6 7 8 8 9 9 9 10 11

Newtronic Controls International Ltd Rockfield House 512 Darwen Road Bromley Cross, Bolton, BL7 9XD

Tel :+44(0)1204 401105 Fax:+44(0)1204 401105 e-mail Newtronicontrols@AOL.COM www.newtronic-controls.co.uk

2 1.0 GENERAL DETAILS The Newtronic TINY 48 is an 1/16 DIN (48 x 48) it is the latest 16 bit Microprocessor based temperature / process controller, designed and manufactured by : Newtronic Controls International Ltd. Old Trafford, Manchester. M16 9NN The unit(s) supplied to you will have been configured (Both Software & Hardware) by Newtronic or your local agent or distributor as specified. The setpoint will be set at minimum for safety purposes. The power supply is universal 85 / 264 Volts 50 / 60 Hz. 1.1 Options The TINY 48 can be supplied with additional relay outputs for channels 2 and 3 in addition to the output specified for channel 1 (Logic Relay or Isolated Analogue). 2.0 MECHANICAL INSTALLATION The TINY 48 requires a panel cut-out of 45 x 45 mm. The unit is secured from the rear using the mounting clamp supplied with each unit. The overall dimensions of the unit are 48 x 48 x 112 mm behind panel depth. 6.4

11 INPUT SENSOR RANGE CONFIGURATION INFORMATION(A)

45mm + 0.5 -0.0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

K J R S N T K J T B

NiCr/NiAl Iron Constantan Pt 13% Rh Pt 10% Rh Nicrosil / Nisil Copper / Constantan NiCr/NiAl Iron/Constantan Copper / Constantan Pt 6% 30% Rh

-200 -200 0 0 -200 -260 0.0 -199.9 -199.9 +40

to to to to to to to to to to

+1300 +800 +1700 +1700 +1300 +400 999.9 +800.0 +400.0 +1800

Pt100 Platinum Resistance -200 Pt100 Platinum Resistance -199.9

to to

+800 +800.0

4-20 mA Linear 4-20 mA Linear 4-20 mA Linear 4-20 mA Linear 0-20 mA Linear 0-20 mA Linear 0-20 mA Linear 0-20 mA Linear 0 -10 Volts Linear 0 -10 Volts Linear 0 -10 Volts Linear 0 -10 Volts Linear 0 -5 Volts Linear 0 -5 Volts Linear 0 -5 Volts Linear 0 -5 Volts Linear 1 -5 Volts Linear 1 -5 Volts Linear 1 -5 Volts Linear 1 -5 Volts Linear 2 -10 Volts Linear 2 -10 Volts Linear 2 -10 Volts Linear 2 -10 Volts Linear

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

4000 4.000 40.00 400.0 4000 4.000 40.00 400.0 4000 4.000 40.00 400.0 4000 4.000 40.00 400.0 4000 4.000 40.00 400.0 4000 4.000 40.00 400.0

PANEL CUT-OUT

45mm +0.5 - 0.0

10 6.3 Reconfiguration Details See table on page 11 3.0 ELECTRICAL INSTALLATION

InP Inputs

CH1 Channel 1 (Output 1) OFF H.LF H.r1 H.r2 H.r3 H.r4 H.An Output non active Heat output fast cycle LOGIC/RELAY Heat output slow cycle LOGIC/RELAY 40 secs. Heat output slow cycle LOGIC/RELAY 20 secs. Heat output slow cycle LOGIC/RELAY 10 secs. Heat output slow cycle LOGIC/RELAY 5 secs. Heat output analogue Anlg H0-5 HEAT 0-5V / 0-10V / 0-20mA Anlg H0-5 HEAT 1-5V / 2-10V / 4-20mA Anlg H5-0 HEAT 5-0V / 10-0V / 20-0mA Anlg H5-1 HEAT 5-1V / 10-2V / 20-4mA Output configured as an ALARM

Channel1 Channel2 Output Output Logic/mA/Volts + _ RELAY RELAY C NONCC NO 1 2 3 4 5 6

SUPPLY 85-264V 50/60 Hz L N 7 8

Made in the U.K. 9 10 11 12 13 14 15 16 + TC _ NO C RELAY Pt100 Channel3 Output

3.1 General Precautions The TINY 48 has a universal power supply (terminals 7, 8) and will operate at any voltage between 85 and 264 Volts 50 / 60 Hz.

indirect acting indirect acting direct acting direct acting

A.L3

mA/mV + _

CH2 Channel 2 (Output 2) OFF C.LF C.r1 C.r2 C.r3 C.r4 A.L2 Output non active Cool output fast cycle LOGIC/RELAY Cool output slow cycle LOGIC/RELAY Cool output slow cycle LOGIC/RELAY Cool output slow cycle LOGIC/RELAY Cool output slow cycle LOGIC/RELAY Output configured as an ALARM

40 secs. 20 secs. 10 secs. 5 secs.

. Check the controller outputs are compatible with the application by examining the output board label. Please note The TINY 48 will be damaged if output channels fitted with logic or analogue are wired as if they were fitted with relay outputs.

Sb Sensor Break Sb.0 Sb.1 Sb.2 Sb.3 Sb.4 Standard zero Heat zero Cool zero Heat zero Cool zero Heat zero Cool Automatic power control on Heat Automatic power control on Cool 3.2 Manual power control on Heat Manual power control on Cool Instrument Electrical Supply connections (terminals 7 & 8). Connect the neutral to terminal 8. Connect the line to terminal 7. (via a 1 Amp protection fuse). Power wiring should be run separately from all signal wiring. Input Signal connections (terminals 14,15 and 16). Thermocouple Input / millivolts Input Connect 15 (+ve) and 16 (-ve) as shown, the thermocouple must be connected directly to the TINY 48 or the correct thermocouple compensating cable must be used. The correct polarity must be observed throughout. If in doubt consult your supplier. RTD Input The TINY 48 is designed to use 3 wire RTD's. The connections should be made as shown to terminals 14, 15, and 16. Each wire must be the same length and gauge or errors will result. If a 2 wire RTD is used connect the RTD to terminals 15 and 16 and wire link terminals 14 and 15 Note Some Zero error will result if a 2 wire RTD is used

SUPPLY 85-264V 50/60 Hz L N 6 7 8

Note Sd Sensor Replacement Detection 3.3 no YES no automatic recovery when sensor replaced automatic recovery when sensor replaced

PU Power Up and Feature option St.An HoLd FULL SoFt rAtE Standard Commence control at the output operative when the unit was last switched off Full power for 15 secs then as HoLd Programme power from 0 to 100% over defined time allows maximum rate of change of temperature to be programmed

14 15 16 + TC _ Pt100 mA/mV + _

SEC Soft Start Time Interval The interval time to program power from 0 to 100% on Power up, 0 - 600 seconds AP Approach Release Point This determines the point at which the proportional band is released on initial start up. AP range 0.0 to 5.0 times the proportional band setting.

14 15 16 + TC _ Pt100 mA/mV + _

4 Milliamp Input (0-20mA, 4-20mA) Connect the 3R3 1% resistor provided between terminals 15 (+ve) and 16 (-ve), connect the milliamp input between terminals 15 (+ve) and 16 (-ve). If in doubt consult your supplier.

14 15 16 + TC _ Pt100 mA/mV + _

6.0 6.1

RECONFIGURATION OF THE TINY 48 Software Reconfiguration Turn the supply to the TINY 48 off. Remove the TINY 48 from its sleeve by pulling the unit towards you. Locate the manufacturers (configuration) link header on the rear of TINY 48 mpu pcb. Reposition the link so that it shorts the two pins together.

3.4

Outputs

Channel 1 (Output 1) Relay (Connections 1, 2 and 3) The relay is rated at 2A 264 volts. 50/60Hz it is a changeover. It is suggested the supply to terminal 1 (common) is fused at 2 Amps. Terminal 2 is the normally open (N.O) contact and is made (energised) when heat is required. Terminal 3 is normally closed (N.C).

Channel1 Output RELAY C NONC 1 2 3

Replace the controller in its sleeve and switch on the supply. (The memory will be wiped clean). Ensure that an input sensor is connected to the correct terminals. The upper display shows LinK the lower display shows in Then the upper display shows InP with the bottom left hand bar flashing (to show configuration mode) the lower display shows 1. The and buttons are used to select the required inputs 1 to 8 (see Section 6.4 Reconfiguration Details) for the various input options. When the correct input has been selected use button to proceed to the next parameter rH. rH is the maximum range of the instrument. When adjustment of rH is complete press button to proceed to the next parameter rL. rL is the minimum range of the instrument, adjust as required. This procedure is repeated through the following CH1, CH2, Sb, Sd and PU for complete details of the various options including temperature ranges please refer to Section 6.4 Reconfiguration Details. When PU option has been set the upper display will show measured temperature and the lower display minimum setpoint. Switch the power to the TINY 48 off. Remove the unit from its sleeve and move the configuration link from shorting the 2 pins and park on one of the pins. Replace the unit in the sleeve and the unit is ready for operation. 6.2 Hardware reconfiguration analogue output board Remove the unit from its sleeve and look at the rear of the analogue output board, check the board is labelled CH1 analogue. The analogue output board hardware is configurable depending on the position of three shorting links on the header situated on the rear of board. These links configure the output to be 5 Volts, 10 Volts, or 20 millliamps, whether the zero is live i.e 4mA or not and whether the output action is direct or indirect is determined by the software configuration set in CH1 H.An.( see section 6.3 reconfiguration details for options)

Channel 1 (Output 1) Logic (Connections 1 and 2) The logic output is for use with solid state relays and logic input thyristor units. Terminal 2 is negative and Terminal 1 is positive. These terminals are not isolated from the sensor circuit. The output is 5 volts at 40 mA.

Channel1 Output Logic + _ 1 2 3

Channel 1 (Output 1) mA / Volts (Connections 1 and 2) Terminal 2 is negative and terminal 1 is positive. These terminals are isolated from the sensor circuit.

Channel1 Output Logic + _ 1 2 3

Channel 2 (Output 2) Relay (Connections 4 and 5) The relay is rated at 2A 264 volts 50/60Hz it is factory supplied as normally open. It is suggested the supply to terminal 4 is fused at 2 amps. Terminal 5 (N.O) is made (energised) when cool is required or the alarm is activated. Note Channel 2 is not fail-safe when used as an alarm, as the relay is energised in the alarm condition. For a fail-safe alarm use Channel 3.

Channel2 Output RELAY C NO 4 5

8 x - 10V

Channel 3 (Output 3) Relay (Connections 9 and 10) The relay is rated at 2A 264 Volts 50/60Hz it is factory supplied as normally open. It is suggested the supply to terminal 10 is fused at 2 Amps. Terminal 2 (N.O) is open (de-energised) when the alarm is activated i.e. fail-safe.

9 10 NO C RELAY Channel3 Output

1 8

x - 5V

x - 20mA

8 4.5 Preventing Adjustment of Control Parameters and Alarm Settings( Setting the LOCK to ON) When all necessary adjustments to the control parameters and alarm settings have been finalised, it may be advantageous to prevent further unauthorised adjustments. The procedure is quite simple. Press button LOCK OPEN is displayed. Press button LOCK ON is displayed Press button The unit proceeds to automatically scan the various control parameters and alarm settings. 5.0 INTERROGATION OF THE CONFIGURATION OF THE TINY 48 It is possible to read the configuration of any particular TINY 48 in order to check whether a unit is configured correctly for a particular application. Procedure Remove power from the unit. Press button whilst power is off and keep pressed. Apply power. Release button. The unit then scans through the configuration. InP rH rL CH1 CH 2 Sb Sd PU AP Input type Max range Min range Channel 1 output type Channel 2 output type Sensor break option Sensor detect option Power up/ramp option Approach release point UP BUTTON 4.0 FRONT PANEL FUNCTIONS

UPPER DISPLAY

LOWER DISPLAY

DOWN BUTTON

I INTERROGATE BUTTON 4.1 Setting the Control Temperature ( )

When the unit is switched on for the first time the setpoint will be at minimum. The upper display shows the measured temperature and the lower display the setpoint. Use the to increase the setpoint and to reduce the setpoint. 4.2 Interrogation of Control Parameters ( )

The unit is supplied pre-programmed with initial control parameters. To interrogate these, press . The upper and lower displays no longer indicate measured value and setpoint but are used to automatically scan the various control parameters. The upper display is used to identify the parameter and the lower display indicates its value. The sequence and initial values are as follows. LOCK ON SPH Max operator setpoint high limit SPL Min operator setpoint low limit PbHt Proportional Band (Heat) Int Integral action time dt Derivative action time Ar Approach rate LtHt Limit Heat output channel If a cool channel is configured, the scan continues (PbC CdB LtCo) PbCo Cdb LtCo AL1 COdE Proportional Band (Cool) Heat/Cool deadband or crossover Limit Cool output channel Alarm 1 (Channel 3) Software version number

For various options and definitions see Section 6.0 Reconfiguration.

Max Range Min Range 5.0% 5.0 mins .20 mins 1.0 100%

5.0% 00C 100% OFF 2.0

6 4.2 Interrogation of Control Parameters (cont.) If Channel 2 of the instrument is configured as an alarm (Alarm 2) the scan continues. AL2 COdE Alarm 2 (Channel 2) Software version number OFF 2.0 Note

7 Adjustment can be made at each stage using the and t buttons, at the end of the sequence the upper display shows the measured temperature and the lower display, the setpoint value. It is not necessary to go through all the parameters when a particular adjustment has been made just press v , the new value will be loaded and the displays will show the measured temperature and setpoint. Setting the alarms The TINY 48 is supplied with alarms not active i.e. OFF. To set the alarms proceed as per Method 4.3 Adjusting Control Parameters until the upper display shows AL1 / tYPE and lower display shows OFF Setting Alarm 1 (Output 3) Press button the upper display still shows AL1 / tYPE but the lower display now shows Hi (To give a true temp high alarm) Press button again the lower display shows Lo (To give a true low alarm) Press button again the lower display shows Err H (To give error alarm above setpoint) Press button again the lower display shows Err L (To give error alarm below setpoint) Press button again the lower display shows Err (To give alarm band about setpoint) Press Note button then press buttons to set alarm value

If these parameters are considered unsuitable for the application or some fine tuning is required in order to achieve optimum control performance proceed to Section 4.3 . Adjusting the control parameters If the (optional) alarms require setting proceed to Section 4.4 Setting the alarms 4.3 Adjusting the Control Parameters (Setting the LOCK to OPEN) The TINY 48 is supplied with the parameter LOCK ON to prevent unauthorised adjustment. In order to adjust the Control Parameters the LOCK has to be set to OPEN Procedure to set the LOCK to OPEN Remove power from the unit. Press whilst power is off and keep pressed. Apply power. keep pressed until LOCK KEY is displayed Release button, LOCK OPEN is displayed momentarily. To adjust the parameters proceed as follows. Press button LOCK OPEN is displayed. Press button again. The upper display shows SPH and the lower display the max range of the instrument, use the and buttons to limit the maximum operator setpoint i.e. perhaps 3200C on a 4000C instrument. When the adjustment is complete press to move on to the next parameter. The upper display shows SPL and the lower display the min range of the instrument, use the and buttons to raise the minimum operator setpoint i.e. to give the operator a limited operational setpoint adjustment range. Note It is possible to lock the setpoint for the operator completely by setting SPH and SPL to the required temperature The procedure then continues by pressing sequence continues: PbHt Int dt Ar LtHt PbCo Cdb LtCo AL1 COdE to move on to the next parameter, the

4.4

Alarm 1 (Output 3) is fail-safe ie. the alarm relay is de-energised and open in the alarm condition Setting Alarm 2 (Output 2) when fitted and configured as an alarm Press t buttons the upper display still shows AL2 / tYPE but the lower display now shows Hi(To give a true temp high alarm) Press button again the lower display shows Lo(To give a true low alarm) Press button again the lower display shows Err H(To give error alarm above setpoint) Press button again the lower display shows Err L(To give error alarm below setpoint) Press button again the lower display shows Err (To give alarm band about setpoint) Press button then press buttons to set alarm value

Proportional Band (Heat) Integral action time Derivative action time . Approach rate Limit Heat output channel Proportional Band (Cool) Heat Cool deadband or crossover Limit Cool output channel Alarm 1 (Channel 3) - (To adjust Alarm see Section 4.4 Setting the alarms) Software version number 1.6