Product Specifications PSS 2C-1A9 A 743C Series ™ FIELD STATION MICRO Controller The 743C is a self-contained, field-mounted, stand- alone, microprocessor-based controller with an integral power supply. It performs the standard proportional, integral, and derivative (PID) control functions of analog instruments. Additionally, it provides enhanced functions such as Foxboro’s patented EXACT® tuning algorithm, user- configurable control functions, a comprehensive calculation capability, and signal conditioning. Standard controller signals include: four analog inputs, two frequency inputs, two contact inputs, an optional platinum RTD direct input, two analog outputs, and two contact outputs. Optionally, one of the 4 to 20 mA analog outputs may be isolated. A fluorescent display is used to show the control variables in bargraph format, and to provide precision digital readout. It also displays an electronic loop tag, controller status, and alarm indication. A keypad, located on the front of the controller, is used for operator interface and configuration. The controller is housed in a field-mounted enclosure that meets IEC IP65 and that also provides the environmental and corrosion resistant protection of NEMA 4X Enclosure NEMA Type 4X. The enclosure can be mounted to a EXACT Control (Foxboro U.S. Patent RE 33267) surface or panel, or mounted to a nominal DN50 or 2 Fully Interactive Display in pipe. Standard Computer Interface for Operation and FEATURES Configuration Nonvolatile MemoryDynamic Compensation with Lead/Lag, Impulse, Transportable Configuration and Dead Time Functions Power Failure Recovery LogicAssignable Alarms Front Panel Keypad for Both Configuration and Algebraic Computation Operator InterfaceFlexible Configuration Blocks with Internal Signal Internal Signal Sources for Calibration Routing Passcode SecurityRS-485 Serial Communications Integral Field Power SupplyPulse Driven Input Boolean Logic Capability Configuration and Display of an Independent Variable Ratio Control Simple Batch Control Single Station Cascade Control ® PSS 2C-1A9 A Page 2 EXACT CONTROL Serial communications capability includes uploading/downloading of configuration, setting of EXACT control uses microprocessor technology to Auto/Manual (A/M) or Remote/Local (R/L) status and make ongoing controller adjustments based on the manual output and local setpoint values, polling of all actual, real time process dynamics. This is in direct inputs and the auxiliary output, and writing as well as contrast to other “self-tuning” controllers that establish reading of all configurable parameters. Both loops of the values of tuning parameters based on an arbitrary the single station cascade controller are process model. accommodated. The user can also select parity, stop While continuously scanning the process variables, bits, and panel or workstation (host) priority. EXACT control initiates corrective action upon sensing a process upset. The user selects the COMPUTATIONAL CAPABILITY desired response by specifying the desired damping This controller performs up to three independent and overshoot-to-load change, such as quarter calculations. The variables may include the results of amplitude damping. other calculation blocks, scaled and conditioned Values of EXACT can be read by the user. inputs, and other internal control signals. EXACT control functions as if your best operator is on An equation is entered from the keypad one character the job 24 hours a day. It can be turned on or off at at a time following the usual rules of algebra and a the keypad or by configuring logic functions, allowing few easy-to-learn rules. The result of this flexibility is these controllers to function as advanced PID exceptional computational capability in a single controllers. station controller. PULSE DRIVEN INPUT SIMPLIFIED CONFIGURATION AND OPERATION There is provision for two pulse inputs, forming a Because of its flexibility, this controller is easily pulse up/pulse down pair that can be assigned to any configured to meet the most exacting process scaled signal such as remote set point. This function requirements. All operating functions are examined is compatible with the signals used for older stepping and/or changed by keystrokes. Interactive prompting motor type devices. simplifies setting the adjustable parameters. ASSIGNABLE ALARMS COMPLETE SECURITY Four dual-level alarms, each with a dead band and The operator has keypad access to read the values of one Boolean output, are assignable to a wide variety inputs, alarm and limit settings, and the operating of signals, including non-control signals. High/High, configuration. However, the operator can adjust only High/Low, and Low/Low types; Latching, Nonlatching, those settings which were specified as operator- and Permissive action; and Absolute, Deviation, and adjustable when the controller was configured. A Rate-of-Change form are supported. Thus, virtually passcode must be entered from the keypad to enable any alarm application is accommodated. adjustment of the remaining parameters. In addition, a keypad disable jumper, accessible from inside the RS-485 SERIAL COMMUNICATIONS INTERFACE tamper resistant enclosure, is provided. This controller is equipped with an RS-485 serial port This passcode is determined by an authorized person for communication with most host computers, either at the time the controller is configured. Thus, only directly or via an RS-232/RS-485 converter or those who have been given this passcode can equivalent accessory. Protocol conforms to ANSI change any of the protected parameters. Specification X3.28-1976, Subcategory E3. Using the Foxboro Model F6501A converter, up to 30 controllers can be accommodated with a single host communication port. PSS 2C-1A9 A Page 3 BOOLEAN LOGIC CAPABILITY Table 1. Keypad Description There are five single gates and five dual gates. Each Key gate is configured by selecting the logic and then Name Usage of Key selecting the source of each input. Gates 0 through 4 Depression at any time will cause are the single input gates and are configured DIRECT Controller to exit FACEPLATE mode and or NOT by the user. Gates 5 through 9 are the dual enter the User Interface, provided the input gates and the user selects one of the following Controller is in PANEL (P). If Controller is logic types for each one: OR, NOR, AND, NAND, in WORKSTATION (W), the TAG key will XOR, or NXOR. be ignored. DYNAMIC COMPENSATION If an alarm has not been acknowledged, depression of ACK key will remove the The result of a dedicated calculation block can be alarm from the Alarm indicator flashing passed through a dynamic compensator, prior to queue and put alarm into the Alarm distribution. The dynamic compensator provides indicator steady queue. ACK is activated lead/lag, impulse, and dead time functions, each with whether in W or P. its individual follow switch. Functionally, dead time Short Depression (0.1 to < 0.3 s): precedes lead/lag and is the input to the lead/lag Moves through variables being function. displayed bargraphs, displaying each, in Utilizing the dynamic compensator and the follow turn, on lower alphanumeric display. switches, feedforward and other complex control Long Depression (≥0.3 s): applications are easily and efficiently handled. Toggles between faceplates of Primary FRONT PANEL and Secondary Controller provided the Cascade Controller is configured and The controller can be configured and operated active. Otherwise same action as if it entirely from the front panel without need for any were a Short Depression. external equipment. The panel consists of an The SEL key is independent of whether alphanumeric display, a graphics display, status Controller in W or P. indicators, an alarm (horn) symbol, and a keypad. Controller Status Switch; toggles between Refer to Figure 1. Workstation (W) and Panel (P) operation. The alphanumeric display at top of front panel has This key will be ignored if Controller is in two lines of nine characters each. The characters are “W” and configured to “W” priority, or if not 5 mm (0.196 in) high, and colored Blue-Green. configured to NONE. The graphics display consists of three bargraghs, Controller Status Switch; toggles between each having 50 segments plus a pointer on top and Auto (A) and Manual (M) operation. This bottom. The bars are 55.4 mm (2.18 in) long. The left key will be ignored if Controller is in “W”, and center bargraphs are 5 mm (0.196 in) wide, and or if in “P” when A/M not configured to the right bar graph is narrower at 2.5 mm (0.098 in). NONE. The bargraph pointer indicator will The bargraphs are colored Blue-Green. automatically preselect the Output The status characters (W/P, R/L, A/M) are 4 mm Bargraph when transferring to “M”, and (0.157 in) high and the alarm symbol (horn) is 5 mm the Measurement Bargraph when (0.196 in) high. The status characters are colored transferring to “A”. Blue-Green, and the alarm symbol is Red. Controller Status Switch; toggles between Remote (R) and Local (L) setpoint The keypad has eight keys as shown in Figure 1 and operation. This key will be ignored if identified in Table 1. The key switches are single Controller is in “W”, or if in “P” when R/L is pole, normally open contacts, all closing to a common not configured to NONE. On secondary lead. For actuation, keys must be depressed for a Faceplate, toggles between CASCADE minimum of 200 ms (0.2 s). and bypass control for a CASCADE function switch selection of NONE. Up and Down arrows are bidirectional movement requestors. Select menu items, functions, and reconfigure parameters. PSS 2C-1A9 A Page 4 COPY MEMORY FEATURE configured NOVRAM and a second NOVRAM (to be configured) into the copy accessory; then turn on the This optional copy memory feature permits the power and the second NOVRAM is copied for use in configuration of one controller to be duplicated for use another controller. With minimum effort, any number in another controller. This is accomplished using two of controllers can thus be configured with the same NOVRAMS (nonvolatile, random access memory parameter values as the original controller. Then modules) and a configuration copy accessory. Briefly, individual parameters in each controller are easily after turning off the power, the procedure is as changed to fit the particular loop. follows: remove the configured NOVRAM from the controller; install the copy accessory; plug the Figure 1. Controller Front Panel PSS 2C-1A9 A Page 5 OPERATING AND STORAGE CONDITIONS Reference Operating Normal Operating Transportation and Influence Conditions Condition Limits Operative Limits Storage Limits Ambient 23 ±2°C –10 and +60°C –10 and +60°C(a) –40 and +70°C Temperature (73 ±3°F) (14 and 140°F) (14 and 140°F)(a) (–40 and +158°F) Relative 50 ±10% 5 and 95% 5 and 95% 0 and 100% Humidity Supply 24, 120, 220 and V ac, +10, –15% V ac, +15, –20% – Voltage 240 V ac, ±1% V dc, +10, –15% V dc, +10, –15% – 24 V dc, ±1% Supply 50/60 Hz, ±0.1 Hz 50/60 Hz, ±3 Hz 40 and 65 Hz – Frequency 2 Vibration Negligible 5 and 500 Hz – 10 m/s (1 “g”) at an acceleration for 1 hour 2 of 10 m/s (1 “g”) Mechanical Negligible –– A 42 inch drop when in Shock shipping container. (a) Lower operative limit extends to –20°C (–4°F) with enclosure heater option. PERFORMANCE SPECIFICATIONS Accuracy at Numeric Display Resolution DISPLAY Numeric Display Accuracy Table ±0.1% of upper range value Parameter Accuracy BARGRAPH Set Point ±2% of upper range value ±0.1% of span Operator Ambient Temperature Effect ±0.1% of span External Maximum error in percent of span, except as noted, ±0.1% of span Ratio for a 30°C (55°F) change in temperature within Input normal operating limits. See table below. Analog ±0.1% of span Parameter Maximum Error Frequency ±0.1% of span RTD (Direct Meas.) ±0.5°C Set Point Local less than 0.1% Output Remote less than 0.5% Valve ±0.5% of span Retransmit (linear) ±0.25% of span Input Analog less than 0.5% Linearization Frequency less than 0.25% RTD ±0.5°C, reading only RTD less than 0.5°C Thermocouple ±0.5°C, reading only Output Control Modes Valve less than 0.5% Prop. Band ±5% of indicated value Retransmit less than 0.5% Integral & Deriv. ±5% of indicated value (setting ≥0.1 min) Humidity Effect ±0.5 s (setting <0.1 min) Maximum error in any conversion, calculation, or Alarm Settings setting is ±0.1% of span for a change from reference Absolute ±0.1% of span conditions to 95% R.H. at 30°C (85°F) wet bulb. Deviation ±0.1% of span Rate-of-Change ±0.1% of span Calculations ±0.1% of span PSS 2C-1A9 A Page 6 Frequency Response Supply Voltage Effect Analog input to output conversion is flat to 3 Hz. ±0.1% of span (maximum) for a +10% or –15% change in ac or dc voltage within normal operating Output Noise conditions. 0.25% maximum, peak-to-peak. FUNCTIONAL SPECIFICATIONS Proportional Input Signals Any combination of the following proportional inputs. All input signals are converted ten times per second and can be characterized or combined in a variety of calculations. See table below. Proportional Type Input Maximum Signal Number Details 4 to 20 mA dc 4 4 to 20 mA dc input is standard. Inputs are across 250 Current Input resistors located on terminal block at lower left, inside of enclosure. 1 to 5 V dc 4 Controllers will accept 1 to 5 V dc by removing the input Voltage Input resistor(s) used with the current input. Thermocouple Input 1 Linearization of displayed value is provided, as follows: (requires 893 Temperature Thermocouple Temperature Range Transmitter, or equivalent) Type J –20 to +760°C (–4 to +1400°F) Type K –20 to +1380°C (–4 to +2500°F) Type E –130 to +540°C (–200 to +1000°F) 1 to 9999 Hz Frequency 2 Input pulse rates, voltage levels, and field power are Input compatible with Foxboro E83 Series Vortex Flowmeter, and with Foxboro 81 and 82 Series Turbine Flowmeter having a preamplifier input. Input impedance is 250Ω. 1 to 9999 Hz Pulse Up/ 1 Pair 1 to 9999 Hz pulse up/pulse down pair of inputs driven Pulse Down Inputs by external contact closure or voltage pulse. Contact closure/open times and pulse voltage level are compatible with older stepping motor devices. Resistance Temperature 1 Platinum, per IEC 100 or SAMA* 100 (RC 21-4) Detector (RTD) Input, temperature curves. Linearization of displayed value is Direct or Temperature provided, as follows: Difference Measurement. IEC 100 SAMA 100 See Model Code section to Range –200 to +850°C –200 to +600°C select this optional RTD (–330 to +1560°F) (–330 to +1100°F) input. Span 110 to 1000°C 110 to 800°C (198 to 1800°F) (198 to 1440°F) *Scientific Apparatus Makers Association PSS 2C-1A9 A Page 7 Two Discrete Inputs Other Control Functions Two nonisolated contact or transistor switch inputs, Input bias, gain, and output bias available for 5 V dc nominal open circuit voltage, 1 mA maximum every input. current. For remote status changes such as A/M, Characterizers (two available, 10 and 15 R/L, W/P, EXT ACK, and tracking functions. segments, assignable). Boolean Gate Logic {DIRECT and NOT (single Output Signals input); OR, NOR, AND, NAND, XOR, and NXOR TWO NONISOLATED ANALOG OUTPUTS (dual input); 18 function switches. Inputs Control Output Signal: 4 to 20 mA nominal into selectable from contact inputs, alarm output 500 O maximum; isolation provided as an option. states, status indicator outputs, EXACT state, Auxiliary: 1 to 5 V dc nominal into 2 kΩ minimum, gate outputs, and three fixed states.} or 4 to 20 mA nominal into 500Ω maximum, Signal Conditioning (square, square root, jumper selectable. Can be assigned by user for characterizer). measurement, set point, control, or conditioned Toggle Mode input signals. Configuring the TOGGLE mode allows a user to TWO DISCRETE OUTPUTS toggle (switch) between a menu level and the Two nonisolated open collector transistor (NPN) normal front panel display and back to the same switch outputs, diode clamped at 62 V ±5%. For menu level utilizing the TAG key. status indication of A/M, R/L, W/P, and alarms, or can be configured as the destination for any two of Alarms the Boolean Gate Inputs. Contact ratings are 50 V Four dual-level alarms, each with a dead band and dc maximum, 250 mA maximum. Leakage current one Boolean output are available. Each alarm is is 100 µA maximum. configurable for Absolute, Deviation, Rate-of- Change, High/Low, High/High, Low/Low, Latching, Control Functions Nonlatching, or Permissive. Each alarm can be Within this controller are two interconnected configured to act on any one of a number of user- controllers with individual built-in options that can be selected points. configured. Thus, the 743CA is an advanced single The alarm status is indicated by a combination of station cascade controller. The Secondary controller alphanumeric display, the bar graphs, an alarm can be disabled to provide a single controller having symbol, and the contact outputs. the functions of the Primary. The alarm dead band is adjustable between 0 PRIMARY CONTROLLER and 100% of span. Standard algorithms are P, I, PD, PI, PID, and EXACT control. The following options may be Calculations configured: nonlinear extender, ratio, There are three calculation functions, designated measurement and set point tracking, output CALC 1, CALC 2, and CALC 3. The variables in tracking, remote/local set point, output each calculation can be any combination of direct multiplication or summing, external reset, external inputs to the controller, configured constants, and limits for output, and simple batch control. results of other calculation blocks. The available SECONDARY CONTROLLER operators are +, –, /, *, >, <, and ten Boolean gates. This controller is enabled by configuring Open and close brackets are also available for CASCADE in the user interface menu. The grouping variables. standard algorithms are P and PI. Ratio and external limits for output are configurable options. Transmitter Power Supply Nominal 27 V dc minimum, 30 V dc maximum power supply with a 250Ω limiting resistor at each transmitter connection. Provides field power for two 4 to 20 mA transmitters with a maximum series resistance of 350Ω in each current loop, including the 250Ω input resistor. PSS 2C-1A9 A Page 8 Dynamic Compensation Execution Rate The result of CALC 3 may be passed through the Ten times per second. May be five times per second dynamic compensator function prior to distribution. for some complex configurations. This block provides lead/lag, impulse, and dead time Memory functions, each with its individual follow switch. All configuration and operating parameters (not Functionally, dead time precedes lead/lag and is the status data) are stored in a nonvolatile RAM device input to the lead/lag function. having a ten year data retention capability. Should a Dead time allows the input to be delayed by a power failure occur, essential control settings and configured time before making it available at the last operating conditions are saved indefinitely. No output. The lead/lag function allows the output to batteries are used. dynamically lead or lag the input by a configured time. Both functions can be enabled or by-passed Input Filter selectively utilizing the follow switches. Second order Butterworth filter. Adjustment time: 0 The impulse can be positive, negative, or bi-polar to 10 minutes. and is part of the lead/lag function. Signal Distribution Dynamic Compensation Adjustment Limits Twenty-five signals are available for internal routing. DEAD TIME These are the conditioned and scaled inputs, 0 and 200 minutes unconditioned inputs, control inputs and outputs, LEAD/LAG TIME and calculation results. 0 and 200 minutes Power On/Off Switch A rocker type ON/OFF power switch is provided within the enclosure. PHYSICAL SPECIFICATIONS Enclosure Black for background. The case is a glass fiber reinforced polyester Display molding, compounded for superior corrosion Vacuum fluorescent lamps in glass enclosure having resistance. The door is glass fiber reinforced, a glass frit seal and tin plated copper pin outs. Horn modified polyphenylene oxide. The overall symbol (for alarms) is Red, and bargraphs and construction meets IEC IP65, and provides the alphanumeric characters are Blue/Green. environmental and corrosion resistant protection of NEMA Type 4X. Electronic Packaging The electronic circuitry is mounted on two 1.6 mm Electrical Connections (0.062 in) thick, glass-based epoxy, wiring boards. Electrical conduit holes, located on bottom of These electronic printed wiring assemblies (PWA's) enclosure, accommodate 1/2-in conduit (see are interconnected using 20-pin connectors. “Dimensions—Nominal” section). User signal wires, 2 with a maximum size of #14 AWG (2.50mm ), are Mounting terminated at a 32-terminal block at the lower rear Enclosure can be mounted to a panel, to a flat surface of the case. Power wires, ranging in size surface, or to a DN50 or 2 in pipe. For enclosure and 2 from #22 to #12 AWG (0.5 to 4 mm ), terminate at a mounting dimensions, see “Dimensions-Nominal” 3-terminal block (having a protective cover) at the section. bottom of the case. Approximate Mass Keypad 6.4 kg (14 lb) The contacts are stainless steel snap domes trapped between an upper and lower silver contact. Overlay colors are Red for ACK; Blue for ¦, Ø, and SEL; Light Gray for W/P, R/L, and A/M; Gray for TAG; and PSS 2C-1A9 A Page 9 MODEL CODE Description Model FIELD STATION MICRO Controller 743CA Nominal Supply Voltage and Frequency 120 V ac, 50/60 Hz –A 220 V ac, 50/60 Hz –B 240 V ac, 50/60 Hz –C 24 V dc –D 24 V ac, 50/60 Hz –E 100 V ac, 50/60 Hz –J Mounting Pipe Mounting F Panel or Surface Mounting P Optional Selections Output Isolation, 4 to 20 mA –1 Platinum RTD Input(a) –2 Enclosure Heater (Not Available with 743CA–D, 24 V dc Supply) Required for Operating –3 Temperature below –10°C (+14°F) down to a lower limit of –20°C (–4°F) Examples: 743CA–AP, 743CA–BF–2, 743CA–AF–123 (a)Minimum span with platinum RTD is 111°C (200°F) PRODUCT SAFETY SPECIFICATIONS Electrical Classification Testing Laboratory, Types of Electrical Certification Protection, and Area Classification Conditions of Certification Specification CSA: Certified for use in ordinary – CS–E/CGZ (non-hazardous) locations. CSA: Suitable for Class I, Groups A, Without Enclosure Heater: CS–E/CNZ B, C, and D, Division 2 hazardous Temperature Code T4. locations. With Enclosure Heater, Optional Code “—3”: Temperature Code T3. FM: Nonincendive for Class I, Groups Not available with enclosure heater, CS–E/FNZ A, B, C, and D, Division 2 hazardous Optional Code “—3”. Temperature locations. Code T4. PSS 2C-1A9 A Page 10 OPTIONAL FEATURES AND ACCESSORIES Output Isolation Surge Suppressor This option replaces the nonisolated control output A surge suppressor is optionally available for use signal by an isolated 4 to 20 mA nominal signal with serial communication input when external wiring is located near transient producing sources such as (500Ω load maximum). Select Model Code Optional meters, solenoids, high voltages, etc. Specify AS Suffix “–1”. Code SURSUP. Platinum RTD Input Configuration Copy Accessory This option provides for accepting a platinum RTD All of the operating configuration is stored in a calibrated per IEC 100 or SAMA 100 temperature NOVRAM. The copy accessory permits the entire curves. Each curve is linearized for digital readout contents of the memory module to be quickly copied over the ranges and spans listed below: to another NOVRAM, either a spare or one from IEC 100 (Direct or _T Measurement) another controller. Specify Part Number K0143DV Range: –200 to +805°C (–330 to +1560°F) for the copy accessory, and Part Number K0141LA Span: 110 to 1000°C (198 to 1800°F) for a spare NOVRAM. SAMA 100 (Direct or ΔT Measurement) Range: –200 to +600°C (–330 to +1100°F) Computer Based Training Package Span: 110 to 800°C (198 to 1440°F) Consists of a software program that operates on any Specify by selecting Model Code Optional IBM-compatible personal computer that has a Suffix “–2”. 256K RAM (minimum) and MS-DOS 2.0 release. The package includes a keyboard overlay so that Enclosure Heater designated keys on the computer clone the function A thermostatically controlled enclosure heater option of the controller front panel keyboard. Specify Part is required when operating at ambient temperatures Number L0121AA for 5 1/4-inch diskette, or Part below –10°C (+14°F). By using the heater, Number L0121AB for 3 1/2-inch diskette. operation of the controller is extended down to – 20°C (–4°F). This heater is not available with the 24 V dc supply (743CA–D). Specify by selecting Model Code Optional Suffix “–3”. ORDERING INSTRUCTIONS 1. Model Number 2. Optional Features 3. Accessories 4. User Tag Data PSS 2C-1A9 A Page 11 DIMENSIONS – NOMINAL PSS 2C-1A9 A Page 12 DIMENSIONS – NOMINAL (Cont.) PATENT NOTICE This product and its components are protected by one or more of the following U.S. Patents, and other patents pending: 4, 616, 332; 4, 658, 348; 4, 704, 676; RE 33267; and corresponding foreign patents. The Foxboro Company Foxboro, EXACT, and FIELD STATION MICRO are trademarks of The Foxboro Company. 33 Commercial Street Invensys is a trademark of Invensys plc. Foxboro, MA 02035-2099 All other brand names may be trademarks of their respective companies. United States of America http://www.foxboro.com Inside U.S.: 1-888-FOXBORO (1-888-369-2676) Outside U.S.: Contact your local Foxboro representative. Copyright 1992-1993 The Foxboro Company Facsimile (508) 549-4492 All rights reserved An Invensys company MB 010 Printed in U.S.A. 0294