PROCESS & TEMPERATURE CONTROLLERS NOVA PD540 Series • Thermocouple, RTD, & Process Inputs • High Accuracy Auto-Tuning PID • Heating & Cooling Models • Universal Power Supply 100-240 VAC • Up to 3 Relays & 2 Analog Outputs • Digital Input Set Point Selection • RS-485 Serial Communications Option ® • Modbus RTU/ASCII Communications • Free Operating & Data Logging Software • IP55 & IP65 Fronts • 1/16, 3/16, 1/8, 1/4 DIN Sizes • 3 Year Warranty PRECISION DIGITAL CORPORATION www.predig.com NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS Setup Group Menus CUSTOM OPERATING DISPLAYS For easy setup parameter navigation, all parameters are The Nova Digital Controller has dual four-digit LEDs and can grouped by category. To access the group menus, press and display commonly used setup parameters defined by the user. hold the SET/ENT button for 3 seconds. Navigate through Operating Display Navigation the group menus using the UP or DOWN arrow buttons as shown. To enter a group menu to access setup parameters, To access additional display information without the need to press the SET/ENT button. enter the setup menus, simply press the SET/ENT button. Main Operating Display Button PV Display Group Definition • PV window displays process variable G.AT Auto-Tuning Group • SP window displays set point  • Press the SET/ENT button to move to G.SP Set Point Group  the next display window P.I.D. Group G.PID  ENT Password PwD Percent Output Display G.CTL Control Group • PV window displays process variable  • SP window displays the operating level Input Group G.IN  of the control outputs as % of full scale G.oUT Output Group  • Press the SET/ENT button to move G.ALm Alarm Group to the next display window  G.RET Retransmission Group  User Defined Display 1 Communications Group* • Display any setup parameter G.Com*  • Parameters are fully functional, and can *This group menu appears only on models with the serial communications option. be set through this display • Set by the user with parameter US1 Menu Password • Press the SET/ENT button to move to To prevent unauthorized changes to key parameters, a user the next display window defined lockout password must be entered to access the group menus that are not commonly used during operation. Enter User Defined Display 2 the password at the prompt when navigating the group menus • Display any setup parameter by pressing the SET/ENT button. The default password is 0. • Parameters are fully functional, and can be set through this display Easy to Use Menu Structure • Set by the user with parameter US2 Each parameter is located in an associated menu group. • Press the SET/ENT button to return to    ENT  the main operating display u G.AT G.SP G.PID P D G.CTL SET/ENT EASY SETUP & PROGRAMMING R-S • Hold the SET/ENT button for All programming of a Nova Digital Controller is done through SET/ENT 3 seconds to enter the group menu the front panel. No switches or jumpers are required. SPSL • Select the menu group using Front Panel Buttons SET/ENT the  and  buttons SP1 • Press SET/ENT to access the • Press the SET/ENT button to confirm an entered value. SET/ENT parameters in the group Hold the button for 3 seconds to enter or exit the setup • Set the value for the parameter, groups. Press the SET/ENT button to access the next SP2 and press SET/ENT to select parameter when in a setup group. SET/ENT the next parameter • Press the Up arrow button to increase numerical values or D.SLP SET/ENT scroll through parameter options and group menus. • Hold the SET/ENT button for 3 seconds to return to the • Press the Down arrow button to decrease numerical values or operating display scroll through parameter options and group menus. • Press the LEFT arrow button to move to the next digit For a complete list of setup parameters, their functions, and during numerical value programming. setting options, refer to the PD540 Series Instruction Manual. 2 ~ NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS Input Bias Adjustment PROCESS & TEMPERATURE INPUTS Up to five bias points can be used to provide precise offset Nova Controllers use a single universal input that accepts process adjustments at specific input values. The controller will use the and temperature inputs. offset to create a smooth input value curve leading up to the bias Thermocouple: J, K, T, E, R, B, S, L, N, U, W, Platinel II points. RTD: Pt100 (0.00385), JPt100 (0.00392) On/Off Timers Process: -10 to 20 mV, 0 to 100 mV The start timer delays control output operation from power- 0.4 to 2 V, 1 to 5 V, 0 to 10 V up. The process timer determines how long the control outputs 4 to 20 mA input with a resistor shunt will run after starting. These timers may run up to 99 hours 59 minutes, or be turned off. VERSATILE OPERATION Powerful standard and optional features such as universal inputs, Start Time Process Time up to three relays and two analog outputs, two digital inputs, and  serial communications make this controller applicable for most STOP RUN STOP process or temperature control applications. POWER ON Programmable Relays All PD540 Series controllers have a standard 3 A Form C Digital Input Set Point Selection (SPDT) relay. Up to two additional 1 A Form A (SPST) relays. Two digital inputs can be added as an optional feature. Digital All relays can be programmed for numerous control or alarm inputs are activated by closing contacts or low logic levels. functions. The configuration of the two inputs can select which of the 4 • Time-Proportional PID Control programmable set points to run or turn the control outputs on • On/Off Control and off while selecting one of two programmable set points. • High/Low Alarms • Set Point Deviation Alarms • Fail-Safe and Standby Alarms DISelection Input1 Input2 Function • Alarm Delays and Deadbands Analog Output Configurations Up to two analog outputs are available on all PD540 Series controllers. Each analog output can be programmed independently, and numerous output types are selectable. • 4-20 mA PID Control • 4-20 mA Retransmitting • Time-Proportional PID Voltage Pulse Normallyopenswitches(externalexcitationnotrequired) • Transmitter Loop Power Supply oropencollectortransistor Auto-Tuning PID A high accuracy auto-tuning function using Fuzzy Logic Serial Communications & Adapters calculates the PID values for your system with the push of a Nova controllers with the serial communications option can button, eliminating the need for complex PID calculations and be used for data acquisition, master/slave set point control, or time consuming setup. After several on/off cycles, the PID Modbus communication (RTU and ASCII). Nova controllers values will be setup automatically. transmit via RS-485. The PDA7485 RS-232 to RS-485 and Gain Adjustment PDA8485 USB to RS-485 converters are available for use with Adjustments to system control characteristics can be done after the Nova Multi-Monitoring software or other PC applications. auto-tuning with the programmable Gain function. Increasing the Gain will increase accuracy and reduce overshoot. Lowering the Gain will let the system reach the set point faster. Gain < 1 Gain = 1 PDA7485 Gain > 1 PV Reactions to SP Change Based on Gain PDA8485 3 NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS Sync Master/Slave Set Point Control PD540 Series Digital Controllers with the serial communications option can use Sync set point control. By connecting controllers together using the RS-485 serial communication capability, one controller can control the set point of an entire string. ����������� Changing the set point of the Sync Master controller will change the set points on all Sync Slave controllers. Simultaneously View Up to 30 Nova Controllers Remotely Control Set Points Program each of the 4 set points through a detailed operation screen available for every connected controller. In addition, control outputs can be set to run or stop, auto tuning enabled, ������� ������� ������� ������� and automatic or manual control established. NOVA PC SOFTWARE Any Nova Controller with the serial communications option can be configured to interface with the Nova Multi-Monitoring PC software. Up to 30 controllers can be monitored and operated, and each can use independent data logging. • Easy to Set Up and Use • Connect up to 30 Nova Controllers • View PV, SP, and Alarm Status Simultaneously • Control Set Points • Log, View, and Save Data in Spreadsheet Files • Free Download from www.predig.com Monitor and Control Common Parameters Specifications ® System Requirements: Windows 95\98\ME\2000\XP Data Acquisition Communications: An RS-232 to RS-485 or USB to RS-485 PV and SP data can be logged independently for each unit. This converter may be used for communication with a PC and Nova data can be graphed using the Data Viewer for quick and clear Multi-Monitoring Software. analysis. Logged data can be exported into spreadsheet format. Number of Units: Up to 30 Nova Controllers Baud Rate: 9,600 to 19,200 bps Data Logging: Graph and save data as .hdr format. Each controller saves graphs independently. Data exportable in spreadsheet format. Logging Interval: 1 second to 24 hours Simultaneous Monitoring Simultaneously monitor up to 30 Nova Controllers and view the PV, SP, and alarm status for all connected controllers. The main view screen also displays the basic model numbers of all connected units. Any series of Nova Controllers with the serial communications option may be monitored with this software. View Logged Data Graphs and Export Data 4 ������ NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS CONNECTIONS PD540 & PD541 NOswitches(externalexcitationnotrequired)oropencollectortransistor Opencircuitvoltage: approximately5VDC Logiclevels: LO=0to0.8VDC HI=4.7to28VDC - 4-20mADCorVoltagePulse MAX:19200bps Rating:250VAC@3A 30VDC@3A 100-240VAC50/60Hz 4-20mADCorVoltagePulse Rating:250VAC@1A 30VDC@1A PD542 & PD543 �������������������������� ���������������������� ��������������������� ������������ ������������������������������ �������������������� ������������������������������� 20 19 18 17 16 15 14 13 12 11 ��������������������������� ������������������ 10 9 8 7 6 5 4 3 2 1 ���������������������������������������������� ���������������������������� � ������������� ��������������������� ��������������������� ������������ ������������ 5 NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS PD544 & PD545 NOswitches(externalexcitationnotrequired)oropencollectortransistor Opencircuitvoltage: approximately5VDC Logiclevels: - LO=0to0.8VDC HI=4.7to28VDC MAX:19200bps Rating:250VAC@3A 30VDC@3A Rating:250VAC@1A 30VDC@1A 4-20mADCorVoltagePulse Rating:250VAC@1A 30VDC@1A 100-240VAC50/60Hz 4-20mADCorVoltagePulse PD546 & PD547 Rating:250VAC@1A 30VDC@1A Rating:250VAC@3A 30VDC@3A Rating:250VAC@1A 30VDC@1A - 4-20mADCorVoltagePulse MAX:19200bps Opencircuitvoltage: approximately5VDC 100-240VAC50/60Hz Logiclevels: LO=0to0.8VDC HI=4.7to28VDC NOswitches(externalexcitationnotrequired)oropencollectortransistor 6 NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS PD548 & PD549 Rating:250VAC@1A 30VDC@1A Rating:250VAC@3A 30VDC@3A Rating:250VAC@1A 30VDC@1A - 4-20mADCorVoltagePulse MAX:19200bps 100-240VAC50/60Hz Opencircuitvoltage: approximately5VDC Logiclevels: LO=0to0.8VDC HI=4.7to28VDC NOswitches(externalexcitationnotrequired)oropencollectortransistor MODEL NUMBER GUIDE The following guide describes the possible PD540 Series Nova Digital Process & Temperature Controller model numbers. Refer to the price list for the complete list of models and accessories. � � � � � � � � � � � � ������������������ ����������������� ������� ��������������� � ��������� ������ ������������������ ������������� ��������������������������������������� ��������������� � ������������������������������� �������������������������������������� ������������������ � ��������������������� �������������� � ��������������������������������������� ����� � ����������������������������� ��������������� ������������� ������� � ����������� ����������� � ������������������������������������������������� � ��������������������������������������� �������������������� ����������������������������� ��������������������������� � �������������������������������� � ����������������������������� � ���������������������� ����������������������������� � ������������������������������ 7 NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS Units: inches DIMENSIONS AND PANEL CUTOUTS (mm) PD540 & PD541 2.76 1/16 DIN (48 x 48) (70) 1.89 x N +2 (48xN-3 ) 0 1.89 0.43 3.92 1.77 (48) (10.9) (99.6) +0.6 (45 ) 0 PD542 & PD543 4.72 1/8 DIN (H) (96 x 48) (120) 3.78 .45 3.92 (96) (11.4) (99.6) 3.62 +0.6 PD544 & PD545 (92 ) 0 3.54 3/16 DIN (72 x 72) (90) 2.80xN +2 (71xN-3 ) 0 2.68 2.83 0.45 3.92 +0.6 (68 ) (72) (11.4) (99.6) 0 2.76 PD546 & PD547 (70) 1/8 DIN (V) (48 x 96) 1.89xN +2 (48xN-3 ) 0 1.89 0.45 3.92 (11.4) (99.6) 1.77 (48) +0.6 (45 ) 0 PD548 & PD549 4.72 (120) 1/4 DIN (96 x 96) 3.78xN +0.2 (96xN-4 ) 0 3.78 0.45 3.92 (96) (11.4) (99.6) 3.62 +0.6 (92 ) 0 8 2.83 1.89 1.89 (72) (48) 3.78 (48) (96) 3.78 (96) 2.17 4.23 (55.2) 4.23 ( ) 107.5 2.65 x 2.65 1.76 x 1.76 (107.5) 3.61 x 3.61 (67.2 x 67.2) 3.61 x 1.76 (44.8 x 44.8) (91.6 x 91.6) (91.6 x 44.6) 1.76 x 3.61 (44.6 x 91.6) 4.72 (120) 4.72 2.76 (120) 3.54 (70) (90) 1.77 +0.6 (45 ) 0 3.62 +0.6 1.77 (92 ) 3.62 0 +0.6 +0.6 (45 ) 0 (92 ) 0 2.68 +0.6 (68 ) 0 1.77 2.68 2.76 +0.6 (45 ) 3.62 +0.6 0 3.62 (70) (68 ) 0 +0.6 +0.6 (92 ) (92 ) 0 0 NOVA PD540 SERIES PROCESS & TEMPERATURE CONTROLLERS Process Inputs SPECIFICATIONS Inputs: Field selectable: 0.4 to 2.0 V, 1 to 5 V, 0 to 10 V, Except where noted all specifications apply to operation at +25°C. -10 to 20 mV, 0 to 100 mV. 4-20 mA input requires 100 Ω resistor connected across input terminals (order P/N: PDX-RES1). General Accuracy: ±0.1% FS ±1 count Display: Dual 4 digits, red LED, -1999 to 9999 Decimal Point: Up to 3 decimals: 9.999, 99.99, 999.9, or 9999 DIN PV Display SP Display Weight Calibration: All inputs are calibrated at the factory Sizes Inch (mm) Inch (mm) oz (g) Scale Range: User programmable over entire range 1/16 0.45 (11.3) 0.37 (9.5) 7.0 (198) Transmitter Supply: 14 to 18 VDC @ 20 mA; available at terminals OUT2 or 3/16 0.55 (14.0) 0.47 (12.0) 11.4 (324) OUT3, instead of retransmitting analog output; selection through front panel. 1/8 (H) 0.78 (19.8) 0.45 (11.5) 10.8 (306) Relays 1/8 (V) 0.54 (13.6) 0.41 (10.5) 10.7 (304) Ratings: 1 Form C (SPDT) standard; rated 3 A @ 30 VDC or 3 A @ 250 VAC resistive load. 1 or 2 Form A (SPST) optional; rated 1/4 0.81 (20.5) 0.43 (11.0) 13.7 (389) 1 A @ 30 VDC or 1 A @ 250 VAC resistive load. Front Panel: Panel gasket provided. Relay Operation: Time proportional PID control, on/off control, forward or 1/16 & 1/8 DIN: IP65, 3/16 & 1/4 DIN: IP55 reverse (fail-safe) alarm, or run status Programming Methods: Four front panel buttons and Modbus Cycle Time: 1 to 300 seconds; time proportional PID control only Number of Set Points: Four programmable set points On/Off Hysteresis: For standard models, 0-10.0% of sensor range for Noise Filter: Programmable 1 to 120 seconds or off independent high and low hysteresis limit. For heating & cooling models, 0- Display Update Rate: 4/second 10.0% of sensor range full hysteresis band. Password: Restricts modification of programmed settings. High/Low Alarm: User may program any alarm for absolute high or low Non-Volatile Memory: Settings stored for a minimum of 10 years. trigger values. Power: 100-240 VAC, 50/60 Hz, 10 W Deviation Alarm: User may program any relay for high, low, or high/low Required Fuse: UL Recognized, 1 A, 250 V, slow-blow range set point deviation alarm. Isolation: 2300 V input/output-to-power line; 4 kV relay output-to-input/ Alarm Deadband: 0-100% FS, user selectable output/power line. Alarm Delay: 0 to 99 minutes and 59 seconds Operating Temperature: 10 to 50°C Reverse Operation (Fail-Safe): Programmable, independent for each alarm. Storage Temperature: -40 to 85°C Relay coils are energized in non-alarm condition. In case of power failure, Relative Humidity: 20 to 90% non-condensing relays will go to alarm state. Enclosure: 1/16, 3/16, 1/8(H), 1/8(V), 1/4 DIN; impact-resistant plastic; Forward Operation: Relay coils are energized in alarm condition. In case of color: black power failure, relays will go to non-alarm state. Approvals: UL & C-UL Recognized, CE Compliant Auto Alarm Initialization: Normal and standby operation independent for UL File Number: E244207; Process Control Equipment each alarm. Normal alarms will reflect the state of the input to the controller at Warranty: 3 years parts & labor all times. Standby alarms will not trigger if the change to alarm state is a result Extended Warranty: 1 or 2 years, refer to Price List for details. of power up cycle, set point change, or alarm configuration change. Run Status: Relays will energize when PID outputs are running. Temperature Inputs Inputs: Factory calibrated, field selectable: J, K, T, E, B, R, S, L, U, N, W, Analog Outputs Platinel II thermocouples, and 100 Ω platinum RTD (0.00385 or 0.00392 curve) Scaling Range: Retransmitting 4-20 mA outputs can be scaled for any display Cold Junction Reference: Automatic or off range. Offset Adjustment: Four programmable input bias zones Accuracy: ±0.1% FS Sensor Break: Up or down scale, user selectable; display reads S.OPN; alarm Availability: 1/16 & 3/16 DIN: 1 standard, 1 optional relays will follow the up or down scale selection. 1/8 & 1/4 DIN: 2 standard Output Operation: 4-20 mA PID control, time proportional voltage pulse PID Type Range (ºC) Range (ºF) Accuracy* control, or 4-20 mA retransmitting Ratings: Continuous 4-20 mA PID or retransmitting: 600 Ω max K1 -200 to 1370 -300 to 2500 Time Proportional PID: 15 VDC pulse high, less than 0.1 VDC pulse low; K2 -199.9 to 999.9 0 to 2300 >0ºC: ±0.1% FS ±1 count 600 Ω minimum, current limited at 30 mA J -199.9 to 999.9 -300 to 2300 <0ºC: ±0.2% FS ±1 count Cycle Time: 1 to 300 seconds; time proportional PID control only Power: Internally powered 4-20 mA output T -199.9 to 400.0 -300 to 750 Isolation: 500 V input-to-output E -199.9 to 999.9 -300 to 1800 Output Loop Resistance: 600 Ω max >400ºC: ±0.15% FS ±1 count B 0 to 1800 32 to 3300 <400ºC: ±5% FS ±1 count Digital Inputs R 0 to 1700 32 to 3100 Configuration: Two contacts, two operating modes ±0.15% FS ±1 count Contacts: Normally open switches (external excitation not required) or S 0 to 1700 32 to 3100 open collector transistor L -199.9 to 900.0 -300 to 1600 >0ºC: ±0.1% FS ±1 count Open Circuit Voltage: Approximately 5 VDC <0ºC: ±0.2% FS ±1 count U -199.9 to 400.0 -300 to 750 Logic Levels: LO = 0 to 0.8 VDC, HI = 4.7 to 28 VDC Operation Modes: Mode 1: Control output run or stop, selection of >0ºC: ±0.1% FS ±1 count N -200 to 1300 -300 to 2400 <0ºC: ±0.25% FS ±1 count set point 1 or 2. Mode 2: Selection of set points 1 to 4. W 0 to 2300 32 to 4200 ±0.2% FS ±1 count Serial Communications Platinel II 0 to 1390 32 to 2500 ±0.1% FS ±1 count Compatibility: EIA-485 PtA -199.9 to 850.0 -300 to 1560 Protocol: PC, Modbus (ASCII, RTU), Sync (Master/Slave SP Control) ±0.1% FS ±1 count Address: 1 to 99 (Max 31 units connected) PtB -199.9 to 500.0 -199.9 to 999.9 Baud Rate: 600 to 19,200 bps PtC -19.99 to 99.99 -4.0 to 212.0 ±0.2% FS ±1 count Transmit Time Delay: 0 to 100 ms JPtA -199.9 to 500.0 -199.9 to 999.9 Data: 7 or 8 bit, automatic when using Modbus protocol ±0.1% FS ±1 count Stop Bit: 1 or 2 JPtB -150.0 to 150.0 -199.9 to 300.0 Parity: None, even, or odd *Performance within recommended operating conditions (10 to 50 ºC, 20 to 90% RH) LDS540_B 06/05 PRECISION DIGITAL CORPORATION www.predig.com 19 Strathmore Road • Natick MA • 01760 • USA • Tel: (800) 343-1001 • Fax: (508) 655-8990 RTD Thermocouple