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ABB ECA06 Configuration And Installation

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ECA06/60/600 EMA60
Configuration and Installation
Version 1.05

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  • Page 1 ECA06/60/600 EMA60 Configuration and Installation Version 1.05...
  • Page 3 ECA06/60/600 EMA60 Configuration and Installation...
  • Page 4 Copyright © 2000 ABB Automation Technology Products AB. The contents of this document can be changed by ABB Automation Technology Products AB without prior notice and do not constitute any binding undertakings from ABB Automation Technology Products AB. ABB Automation Technology Products AB is not responsible under any circumstances for direct, indirect, unexpected damage or consequent damage that is caused by this document.

  • Page 5: Table Of Contents

    Contents Introduction 1.1 Warning and Information Symbols ....... . . 12 1.2 Process Safety .
  • Page 6 Contents SP Bar Graph Display ........50 Output Bar Graph Display .
  • Page 7 Contents Computer Interface ......... . . 203 Arithmetic Functions .
  • Page 8 C.1 ECA06 Configuration Tree ........
  • Page 9 Contents E.2 Protocol Description ..........288 Modbus Communication .
  • Page 10 Contents 493-0736-11 (6-2)

  • Page 11: Introduction

    Chapter 1 Introduction This Configuration and Installation Manual provides all the information required by trained installation and maintenance personnel to install the ECA06, ECA60, ECA600 and EMA60 process controllers and to configure them for use by system operators. Chapter 2, Installation, describes the mechanical and electrical installation procedures for the controllers.

  • Page 12: Warning And Information Symbols

    1.1 Warning and Information Symbols Chapter 1: Introduction Appendix F, Special Modes, contains details of operating modes where you can update the software or reset all the parameters in the configuration to their default settings • Installation and maintenance personnel should read chapters 3, 4 and 5 of this manual.

  • Page 13: Electrical Supplies

    • Always follow precautions for handling electrostatic sensitive devices when handling the ECA controllers. Version information Version 1.00 The first version. • Controller types ECA06, ECA60 and ECA600 Version 1.01 Changes and additions: • Absolute and Deviation Alarm block; The input connections are freely configurable.

  • Page 14: Version 1.02

    1.5 Version information Chapter 1: Introduction • Configuration via COMLI possible. Version 1.02 Changes and additions: • EMA60 is serial approved. • German menu language is introduced. Version 1.03 Changes and additions: • DOX 6 can be used in this version. Version 1.04 Changes and additions: •...
  • Page 15 Chapter 1: Introduction 1.5 Version information • The Three State Pulse function (with feedback) has been revised. • ISP and output signals are now writeable from a supervisory system via communication. • Support for the communication protocol MODBUS RTU has been added. •...
  • Page 16 1.5 Version information Chapter 1: Introduction 493-0736-11 (6-2)

  • Page 17: Installation

    ECA06, ECA60, ECA600 and EMA60 controllers and to make all the necessary electrical connections. The ECA06, ECA60, ECA600 and EMA60 controller units fit into a cutout in a vertical panel which allows high packing density. The panel must be between 2 mm and 4 mm thick.
  • Page 18 2.1 Panel Cutout Chapter 2: Installation Min. 76 67 + 1 138 + 1 Min. 180 Figure 1 Panel Cutouts. 493-0736-11 (6-2)

  • Page 19: Installation With Cassette

    Chapter 2: Installation 2.2 Installation with Cassette Installation with Cassette External Dimensions The external dimensions of the controller are shown below Figure 2 External Dimensions. Installation and Removal The mechanical installation is performed in two steps: Installation of the cassette in the panel cutout. Insertion of the controller unit in the cassette.
  • Page 20 2.2 Installation with Cassette Chapter 2: Installation Figure 3 Cassette and Springs. Installation of the Cassette Push the empty cassette into the panel cutout and let it hang down by its own weight with the upper edge pressing against the upper edge of the cutout. Figure 4 Empty Cassette Hanging in the Cutout.
  • Page 21 Chapter 2: Installation 2.2 Installation with Cassette Insert the lower retaining spring as shown in the figure below, holding the cassette with your thumb and pressing the spring down with your index finger or a screwdriver if necessary. Repeat step 2 for the upper retaining spring. Click! Figure 5 Mounting the Retaining Springs.
  • Page 22 2.2 Installation with Cassette Chapter 2: Installation Inserting the Controller Unit To insert the controller unit in the cassette proceed as follows: Gently slide the controller into the cassette unit as far as it will go. Press gently on the front until you can hear a distinct click. Take care not to press on the LCD display window or the push buttons.

  • Page 23: 2.3 Installation With Mounting Plates And Ip65 Gasket

    Chapter 2: Installation 2.3 Installation with Mounting Plates and IP65 Gasket Installation with Mounting Plates and IP65 Gasket To install the unit with mounting plates you need two mounting plates and four fixing nuts as shown in the figure below. For IP65 compliance you also need the gasket.
  • Page 24 2.3 Installation with Mounting Plates and IP65 Gasket Chapter 2: Installation Removal Removal is the reverse of installation. Note: To ensure IP65 sealing the IP65 gasket must be exchanged for a new one if the unit is reinstalled. Figure 8 Mounting the Gasket.

  • Page 25: Electrical Installation

    Chapter 2: Installation 2.4 Electrical Installation Electrical Installation Warning – Fuses: To prevent the risk of fire or injury to personnel in the event of a short-circuit the a.c. mains supply must be fitted with a 6 A slow blow fuse. No more than five units should be connected to the same supply.
  • Page 26 2.4 Electrical Installation Chapter 2: Installation 115VAC AC supply Ground shield Pin screw for connection mounting plates Jumper module 230VAC Pin screw for mount- ing plates – – – – 0 V (AI com.) – AO1+ DI1+ AO2+ DI2+ AO3+ DI3+ 0 V (AO com.) DI4+...

  • Page 27: Power Wiring

    Chapter 2: Installation 2.4 Electrical Installation Power Wiring The controller can operate from a direct current supply or an alternating current supply. 115VAC 230VAC 24V DC/ 19V AC 24V DC/ – 19V AC Figure 10 D.C. Power Supply Connections. 493-0736-11 (6-2)
  • Page 28 2.4 Electrical Installation Chapter 2: Installation 115VAC 230 VAC 230VAC Note. 230 VAC Figure 11 230 V AC Power Input Connections. 493-0736-11 (6-2)
  • Page 29 Chapter 2: Installation 2.4 Electrical Installation 115VAC 115 VAC 230VAC Note. 115 VAC Figure 12 115 V AC Power Input Connections. 493-0736-11 (6-2)
  • Page 30 2.4 Electrical Installation Chapter 2: Installation Jumper Open Closed Analog Input Differential Single Ended Voltage Current Differential Single Ended Voltage Current Differential Single Ended Voltage Current Differential Single Ended Voltage Current Differential Single Ended Voltage Current Table 1 Jumper Module Connections. A.C.

  • Page 31: I/O Signal Wiring

    Chapter 2: Installation 2.4 Electrical Installation Supply ground to ground terminal. Supply neutral to terminal 4. Supply live to terminal 1. Note: The ground connection must always be connected to ground when the controller is connected to the mains supply. When an AC supply is used a +24 V supply is available from terminals Z10 (+24 V) and Z2 (0 V) to supply external units, e.g.
  • Page 32 2.4 Electrical Installation Chapter 2: Installation Analog Inputs AI1 to AI5 have their positive and negative poles connected as shown in Figure 13. Cable screens must be connected to the chassis ground using lug connectors. Connection to the chassis ground is available at the four screws at the rear panel.
  • Page 33 Chapter 2: Installation 2.4 Electrical Installation Transmitter – signal – 250 Ω Figure 14 Two-wire connection with 24 v supply from the controller. Transmitter signal – 250 Ω supply – Figure 15 Separately supplied sensor with output signal electrically connected to ground. 493-0736-11 (6-2)
  • Page 34 2.4 Electrical Installation Chapter 2: Installation Transmitter signal – 250 Ω – supply +24 V Figure 16 Three-wire connection with 24 V supply from the controller. Transmitter signal – supply 250 Ω – Figure 17 Separately supplied sensor with output signal electrically isolated from ground. If an actuator potentiometer is used with a three-state pulse output it should be connected as shown in Figure 18.
  • Page 35 Chapter 2: Installation 2.4 Electrical Installation signal ground Figure 18 Actuator Potentiometer. If an analog output is not used the output terminals should be short-circuited, otherwise there is a risk of initiating an error message for open-circuit output. signal ground Figure 19 AO1 used / AO2 and AO3 not used.
  • Page 36 2.4 Electrical Installation Chapter 2: Installation Digital Inputs All digital input signals are connected via opto-couplers. The supply may be taken from the controller or from an external current source. DI COM +24V signal ground Digital Input Internal Supply DI COM z12 Digital Input External Supply Figure 20 Digital Input Internal and External Supplies.
  • Page 37 Chapter 2: Installation 2.4 Electrical Installation Digital Outputs Note: If an inductive load, e.g. a relay coil, is connected to a digital output the coil must be shunted by a diode, such as a 1N4003 or similar. The diode should be wired as close as possible to the coil.

  • Page 38: Communications Signal Wiring, Rs485

    2.4 Electrical Installation Chapter 2: Installation Communications signal wiring, RS485 For serial communications (RS485) screened twisted-pair cable must be used with the screen grounded at each device. RS485+ should be connected to terminal b8 and RS485- should be connected to terminal b6. The last device on the data bus must be terminated by a 120 Ω...
  • Page 39 Chapter 2: Installation 2.4 Electrical Installation Wrong Right Ground Rail Figure 22 Screening Connections. 2 3 4 2 3 4 analog digital power signals signals Figure 23 Controller Connections in an Enclosure with an Intermediate Terminal Block. 493-0736-11 (6-2)
  • Page 40 2.4 Electrical Installation Chapter 2: Installation Grounding and Common Mode Voltage (CMV) Ground loops can arise when the return wire or the sensor are grounded locally at their point of installation and the analog inputs have fixed reference grounds. The inputs should then be connected as differential inputs, i.e.
  • Page 41 Chapter 2: Installation 2.4 Electrical Installation Supply Unit Meter 20 mA 48V DC 250 Ω – – Controller CMV referenced 250 Ω to this point – Indicator 1 250 Ω – Indicator 2 250 Ω 28 V – – Sensor 4–20 mA Figure 25 Example of Single Controller Current Loop.
  • Page 42 2.4 Electrical Installation Chapter 2: Installation Figure 25 shows an example of a single controller current loop. It is assumed that all the units are isolated from supply ground. This type of current loop must always be grounded at one single point so that it does not float away from ground and introduce a large interference potential.

  • Page 43: Configuration

    Configuration This chapter is intended for trained personnel such as Process Control Engineers or Instrument Technicians who configure the ECA06, ECA60, ECA600 and EMA60 controllers. It describes the operator interfaces and features available in the Configuration Mode and includes full instructions for the configuration of the controllers.

  • Page 44: Configuration Trees

    3.1 Configuring the Process Value Chapter 3: Configuration Configuration Trees The Configuration trees in Appendix C show the path to take: Operator Process Value NumberOfDecimals (0 ≤ NumberOfDecimals ≤ 4) • MinValue (–99999 ≤ MinValue ≤ MaxValue ≤ 99999) • MaxValue (–99999 ≤...
  • Page 45 Chapter 3: Configuration 3.1 Configuring the Process Value Config 600 001.05-00 Enter Code 6845 Cancel If you enter the correct password you have read/write access to the Configuration mode. Config 600 001.05-00 Code correct Full access Return Press the OK key. Repeatedly press the Up or Down key until you reach the Operator Block.
  • Page 46 3.1 Configuring the Process Value Chapter 3: Configuration Repeatedly press the Up or Down key until you reach the Process Value section. PID1 Process Value Return Press the OK key to enter the Process Value section. Process Value NumberOfDecimals Return The first parameter displayed is NumberOfDecimals.
  • Page 47 Chapter 3: Configuration 3.1 Configuring the Process Value When the required MinValue –20 is displayed press the OK key. Process Value MinValue –20 Cancel Press the Up or Down key until the second line of the display shows MaxValue. Process Value MaxValue Return Press the OK key.
  • Page 48 3.1 Configuring the Process Value Chapter 3: Configuration Process Value Unit °C Cancel The Configuration is complete. Repeatedly press the Cancel key until you return to Operator Mode. 493-0736-11 (6-2)

  • Page 49: Controls And Indicators

    Chapter 3: Configuration 3.2 Controls and Indicators Controls and Indicators In Configuration Mode the functions of certain controls on the front panel are different from in Operator Mode. The controls and indicators are described below. Display Next Key Cancel Key OK Key Indication Manual Auto/Manual Key...

  • Page 50: Lcd Display

    3.2 Controls and Indicators Chapter 3: Configuration LCD Display In Configuration Mode the display consists of four lines of text, each consisting of a maximum of 20 characters. Process Value Unit Cancel Figure 27 Typical Configuration Mode Display. • The top line of the display shows the previous selection or current block. •...

  • Page 51: Output Bar Graph Display

    Chapter 3: Configuration 3.2 Controls and Indicators Figure 28 PV, SP and Output Bar Graph Displays. Output Bar Graph Display The Output bar graph shows the output level as a percentage of the output signal. Control Keys In the Configuration Mode the function of the OK, Cancel and Next keys depends on the present position in the menu structure.
  • Page 52 3.2 Controls and Indicators Chapter 3: Configuration Cancel Key Press the Cancel key (red cross) to ascend one level in the tree structure without making any changes to the displayed parameter. Next Key The function of the Next key is shown on the bottom line of the display. Up Key Press the Up key to step up through a list of options for the currently selected parameter or to move to the previous parameter in the current branch of the tree.

  • Page 53: Entering Configuration Mode

    Return Figure 29 Configuration Mode Start-up Display. Where: XXX = Software type (06 for ECA06, 60 for ECA60, 600 for ECA600 and MI for EMA60). ZZZ.ZZ-ZZ = Software Version e.g. 001.05-00. Password Configured To enter Configuration Mode if a password has been configured: Press and hold the Next key.
  • Page 54 3.3 Entering Configuration Mode Chapter 3: Configuration Press the Up and Down keys to change the displayed number. When it is correct press the OK key. Config 600 001.05-00 Enter Code 6845 Cancel Figure 31 Password Prompt. If you enter the correct password you have read/write access to the Configuration mode.

  • Page 55: Exiting Configuration Mode

    Chapter 3: Configuration 3.4 Exiting Configuration Mode Exiting Configuration Mode To exit Configuration Mode and return to Operator Mode: Repeatedly press the Cancel key to move back up the Configuration Menu. When the display changes to show that the Operator Mode has been entered stop pressing the Cancel key.

  • Page 56: Setting The Configuration

    3.6 Setting the Configuration Chapter 3: Configuration Setting the Configuration Introduction This section describes the Configuration process. Configuration is the process of setting the parameters and making connections. Parameters are configured by means of a multi-level menu system (the Configuration tree) which is navigated by the use of four control keys on the front panel.
  • Page 57 Chapter 3: Configuration 3.6 Setting the Configuration The key sequence to set this parameter is given in full below but can be abbreviated to the form: Outputs → Analog Outputs → AO1 → Mode = Reversed To configure the mode parameter proceed as follows: Access the Configuration Menu as described in section 3.3.

  • Page 58: Menu Abbreviations

    3.6 Setting the Configuration Chapter 3: Configuration Mode Return Press the OK key. Press the Up or Down key until the third line of the display shows the required mode, e.g. Reverse. Mode Reversed Cancel Press the OK key. The Configuration is complete. Repeatedly press the Cancel key until you return to Operator Mode.
  • Page 59 Chapter 3: Configuration 3.6 Setting the Configuration Processing Blocks Comment Columns Input Analog Inputs Analog Input Communication Buffer Analog User Digital Input Digital Input Communication Buffer Digital User Input Function Arithmetic Function Logic Function Other Function Set Point Set Point Alarm Absolute Alarm Deviation Alarm...

  • Page 60: Naming Blocks

    3.6 Setting the Configuration Chapter 3: Configuration Naming Blocks You can give many of the blocks and parameters which you configure a twenty character name of your own choice. To use this feature proceed as follows: Select the option Identity. All names have a default setting. Select the character to change by pressing the Next key.
  • Page 61 Chapter 3: Configuration 3.6 Setting the Configuration • If an available block has no valid outputs, no outputs of that block are made available for connection. • If a valid output belongs to a block which is not available, it is not made available for connection.

  • Page 62: Overview

    3.6 Setting the Configuration Chapter 3: Configuration • Any digital input of any block type can be connected to any digital output of any block type. Overview The controllers each have six main configurable sections, called columns: • The Input column contains blocks that accept signals from direct wiring, or from the communication channels, or from values input by the user on the front panel.
  • Page 63 Chapter 3: Configuration 3.6 Setting the Configuration Input Control* Output Outputs Operator System Inputs Set Point Alarms Functions Functions *The EMA60 does not have a Control block Figure 35 Processing Columns. The inputs and outputs are not shown. Refer to “Configuration Work Sheets”, on page 277.
  • Page 64 3.6 Setting the Configuration Chapter 3: Configuration Analog Inputs Available in ECA06 ECA60 ECA600 EMA60 Analog Input Value Screw Terminals Block Each Analog Input Block (AI) can accept one external analog signal as an input and produces one analog output, Value. The type of input – current or voltage signal and single-ended or differential –...
  • Page 65 Chapter 3: Configuration 3.6 Setting the Configuration Outputs Name Type Value Analog Table 5 Analog Input Block Outputs. To select an analog input for use, configure the parameter Mode for the type of input which will be connected to the block. To deselect an analog input, set the parameter Mode to Off.
  • Page 66 3.6 Setting the Configuration Chapter 3: Configuration Terminal Input = Differential Pressure and Block Output = Flow Flow ∼ Differential Pressure The filter function of the analog Input block is activated by setting the parameter Filter Time to a non-zero value. The filter characteristic is shown below. time (FilterTime = 20 seconds) -t/FilterTime Block Output = e...
  • Page 67 Chapter 3: Configuration 3.6 Setting the Configuration • Each block may be given a twenty letter identification name by configuring the parameter Identity. Available in Analog Input Communication Buffers ECA06 ECA60 ECA600 EMA60 Analog Communication Input Value Comms Buffer Remote analog communication is provided by Analog Input Communications Buffers (AIC) via a two wire RS485 serial channel using a communication protocol.
  • Page 68 3.6 Setting the Configuration Chapter 3: Configuration Analog User Blocks Available in ECA06 ECA60 ECA600 EMA60 Analog User Value Front Keys Block Analog User Blocks (AU) can be configured so that the operator can enter analog values using the front panel keys. These user defined inputs are added to the operator option list if they are enabled during Configuration.
  • Page 69 Chapter 3: Configuration 3.6 Setting the Configuration Outputs Name Type Value Analog signal Table 9 Analog User Block Outputs. To enable an Analog User Block, set the parameter Mode to on. To disable the block set Mode to Off. To set the number of decimals displayed for the signal value configure the parameter NumberOfDecimals.
  • Page 70 3.6 Setting the Configuration Chapter 3: Configuration MaxValue MinValue LoLimit HiLimit Displayed Value Figure 38 The relationship between Displayed Value and Signal Range. The Signal Range is the range of the signal available on the output of the block. This range is MinValue ≤...
  • Page 71 The default values of LoLimit (0.0) and HiLimit (100.0) define the default (displayed) range –100.0 ≤ Displayed Value ≤ 100.0 LoLimit determines the value displayed for MinValue, and HiLimit determines the value displayed for MaxValue. Digital Inputs Available in ECA06 ECA60 ECA600 EMA60 Digital Input Status...
  • Page 72 3.6 Setting the Configuration Chapter 3: Configuration Each block may be given a twenty letter identification name by configuring the parameter Identity Digital Input Communications Buffers Available in ECA06 ECA60 ECA600 EMA60 Digital Communication Input Status Comms Buffer Remote digital communication is provided by Digital Input Communications Buffers (DIC).
  • Page 73 Chapter 3: Configuration 3.6 Setting the Configuration Digital User Blocks Available in ECA06 ECA60 ECA600 EMA60 Digital User Status Front Keys Block Digital User Blocks (DU) can be configured so that the operator can enter digital levels using the front panel keys. These user defined inputs are added to the operator option list if they are enabled during Configuration.

  • Page 74: Input Function Blocks

    Arithmetic Function Blocks Available in The input to any block may be connected to the output of any other block ECA06 ECA60 ECA600 EMA60 provided that they are of the same type, i.e. analog to analog or digital to digital.
  • Page 75 Chapter 3: Configuration 3.6 Setting the Configuration AddSub Available in ECA06 ECA60 ECA600 EMA60 Signal1 AddSub Value Signal2 Signal3 Value = Factor1 × Signal1 + Factor2 × Signal2 + Factor3 × Signal3 + Bias The AddSub function has three analog inputs, Signal1, Signal2 and Signal3, and one analog output, Value.
  • Page 76 Analog Table 19 AddSub Outputs. Note: The AddSub block in the ECA06 does not have the input Signal3 or the parameter Factor3 and hence the function is defined as: Value = Factor1 × Signal1 + Factor2 × Signal2 + Bias...
  • Page 77 –10.00 ≤ Bias ≤ 10.00 Bias None Table 21 MulDiv Parameters. Outputs Name Type Value Analog signal Table 22 MulDiv Block Outputs. Available in ECA06 ECA60 ECA600 EMA60 Signal Value Power Value = Factor × Signal + Bias 493-0736-11 (6-2)
  • Page 78 3.6 Setting the Configuration Chapter 3: Configuration The Exp function has one analog input, Signal, and one analog output, Value. It also holds three analog parameters – the exponential Power, a gain Factor and a Bias. Inputs Name Connection Signal Off, Analog Table 23 Exp Inputs.
  • Page 79 Chapter 3: Configuration 3.6 Setting the Configuration Comp Available in ECA06 ECA60 ECA600 EMA60 diff Comp Value × P abs P absMax P absMin P absMin T orifice – × × × ------------------------------------------------------------------------------------------------------------ - ----------------------------------------------------------------------------------- - Value Factor P diff ×...
  • Page 80 3.6 Setting the Configuration Chapter 3: Configuration Parameters Name Setting Unit –10.0 ≤ K ≤ 10.0 Factor none 0.0 ≤ P ≤ 10000.0 see note absMax absMax 0.0 ≤ P ≤ 10000.0 see note absMin absMin 0.0 ≤ P ≤ 10000.0 see note orifice orifice...
  • Page 81 Chapter 3: Configuration 3.6 Setting the Configuration Summary Term Type Unit Comment Factor Constant None Analog input None Differential pressure signal from diff differential pressure sensor. Signal not linearized. Analog input None Absolute pressure sensor signal. Set to Off if no absolute pressure compensation is required.

  • Page 82: Logic Function Blocks

    3.6 Setting the Configuration Chapter 3: Configuration Logic Function Blocks Available in The Logic Function Blocks (FL) perform logical operations on the digital input ECA06 ECA60 ECA600 EMA60 signals before their values are used in the control system. The available logic function blocks are summarised below.
  • Page 83 Outputs Name Type Status Digital Table 32 And Outputs. Note: If an input is not connected it represents the value True in the calculation. Available in ECA06 ECA60 ECA600 EMA60 Signal1 Signal2 Status Signal3 Signal4 Status = Signal1 OR Signal2 OR Signal3 OR Signal4 The Or block has four digital inputs, Signal1, Signal2, Signal3 and Signal4, and one digital output, Status.
  • Page 84 Type Status Digital Table 34 Or Outputs. Note: If an input is not connected it represents the value False in the calculation. Available in ECA06 ECA60 ECA600 EMA60 Signal1 Status Signal2 Status = Signal1 XOR Signal2 The Xor function has two digital inputs, Signal1 and Signal2, and one digital output, Status.
  • Page 85 Chapter 3: Configuration 3.6 Setting the Configuration Inputs Output Signal1 Signal2 Status False False False False True True True False True True True False Table 35 Xor Function. Inputs Name Connection Signal1 Off, Digital Signal2 Off, Digital Table 36 Xor Inputs. Outputs Name Type...
  • Page 86 3.6 Setting the Configuration Chapter 3: Configuration Available in ECA06 ECA60 ECA600 EMA60 Status Reset The S/R function has two digital inputs, Set and Reset, and one digital output, Status. The block performs the function of an S/R flip-flop as summarised in the table below.
  • Page 87 Type Status Digital Table 40 S/R Outputs. Note: If an input is not connected it represents the value False in the calculation. Available in ECA06 ECA60 ECA600 EMA60 Signal Status Status = NOT Signal The Not function has one digital inputs, Signal, and one digital output, Status.

  • Page 88: Other Functions

    Note: If the input is not connected the output is given the value True. Other Functions Available in The Other Function Blocks (FO) perform logical and arithmetic operations on ECA06 ECA60 ECA600 EMA60 digital or analog input signals. Their outputs to the control system are also mixed analog and digital signals.
  • Page 89 Chapter 3: Configuration 3.6 Setting the Configuration Available in ECA06 ECA60 ECA600 EMA60 Signal1 Value Signal2 Signal3 LSBStatus Signal4 MSBStatus Value = Min(Signal1, Signal2, Signal3, Signal4) The Min function has four analog inputs Signal1, Signal2, Signal3, Signal4, one analog output, Value, and two digital outputs LSBStatus and MSBStatus.
  • Page 90 3.6 Setting the Configuration Chapter 3: Configuration Inputs Name Connection Signal1 Off, Analog Signal2 Off, Analog Signal3 Off, Analog Signal4 Off, Analog Table 45 Min Inputs. Note: If any input is set to Off it is not taken into account when making the selection.
  • Page 91 Chapter 3: Configuration 3.6 Setting the Configuration Available in ECA06 ECA60 ECA600 EMA60 Signal1 Value Signal2 Signal3 LSBStatus Signal4 MSBStatus Value = Max(Signal1, Signal2, Signal3, Signal4) The Max function has four analog inputs Signal1, Signal2, Signal3, Signal4, one analog output, Value, and two digital outputs LSBStatus and MSBStatus.
  • Page 92 3.6 Setting the Configuration Chapter 3: Configuration Note: If two inputs have the same value, LSBStatus and MSBStatus indicate the input with the smallest ordinal number. Inputs Name Connection Signal1 Off, Analog Signal2 Off, Analog Signal3 Off, Analog Signal4 Off, Analog Table 49 Max Inputs.
  • Page 93 Chapter 3: Configuration 3.6 Setting the Configuration Select Available in ECA06 ECA60 ECA600 EMA60 Signal1 Signal2 Signal3 Select Value Signal4 The Select function has four analog inputs Signal1, Signal2, Signal3, Signal4, and two digital inputs LSB and MSB. The single analog output is the same as the selected input.
  • Page 94 3.6 Setting the Configuration Chapter 3: Configuration This function can be used to select one input out of four or one input out of two to be used as the output. When using two inputs the LSB input is used to select the one to be copied to the output.
  • Page 95 Chapter 3: Configuration 3.6 Setting the Configuration Level Detector Available in ECA06 ECA60 ECA600 EMA60 Signal Level HiLimitSignal Status Detector LoLimitSignal The Level Detector function has three analog inputs Signal, HiLimitSignal, LoLimitSignal and one digital output Status. It holds two parameters, HiLimit and LoLimit.
  • Page 96 3.6 Setting the Configuration Chapter 3: Configuration Time Time Figure 39 Level Detector Function. 493-0736-11 (6-2)
  • Page 97 Outputs Name Type Status Digital Table 57 Level Detector Outputs. Delay Available in ECA06 ECA60 ECA600 EMA60 Delay Value Signal The Delay function has one analog input, Signal, and one analog output, Value. It also holds one analog parameter, DelayTime.
  • Page 98 Table 59 Delay Parameters. Outputs Name Type Value Analog Table 60 Delay Outputs. IncDec Available in ECA06 ECA60 ECA600 EMA60 IncSignal DecSignal IncDec Value TrackSignal TrackEnable The IncDec function has two digital inputs, IncSignal and DecSignal, and one analog output, Value. It also holds one analog parameter, Time.
  • Page 99 Chapter 3: Configuration 3.6 Setting the Configuration As long as IncSignal is active the output increases at a rate set by the parameter Time. As long as DecSignal is active the output decreases at a rate set by the parameter Time. When TrackEnable is false, the value of the Value output is controlled by the IncSignal and the DecSignal inputs.
  • Page 100 3.6 Setting the Configuration Chapter 3: Configuration Inputs Name Connection IncSignal Off, Digital DecSignal Off, Digital TrackSignal Analog input TrackEnable Digital input Table 61 IncDec Inputs. Parameters Name Setting Unit 0.1 ≤ Time ≤ 1000.0 Time seconds/100% 0.0 ≤ LoLimit ≤ LoLimit HiLimit ≤...
  • Page 101 Chapter 3: Configuration 3.6 Setting the Configuration Linear Available in ECA06 ECA60 ECA600 EMA60 Signal Linear Value The Linear function can be used to change the characteristic of an analog signal. It has one analog input, Signal and one analog output, Value. Ten breaking points are available for an accurate characterization.
  • Page 102 3.6 Setting the Configuration Chapter 3: Configuration In the example below, where (In1, Out1) = (20.0, 10.0), the function extends the characteristic with a horizontal line. If In10 < 100.0, the characteristic would also be extended with a horizontal line. Signal Input Figure 41 Linear Example.
  • Page 103 Chapter 3: Configuration 3.6 Setting the Configuration Signal Input Figure 42 Linear Example with Step Change. Note: If you set In > In , then In is adjusted to In = In . An automatic adjustment is made so that the successive entries are always greater than the preceding ones.
  • Page 104 3.6 Setting the Configuration Chapter 3: Configuration Parameters Name Setting Unit 0.0 ≤ In1 ≤ 100.0 0.0 ≤ Out1 ≤100.0 Out1 In1 ≤ In2 ≤100.0 0.0 ≤ Out2 ≤100.0 Out2 In2 ≤ In3 ≤100.0 0.0 ≤ Out3 ≤100.0 Out3 In3 ≤ In4 ≤100.0 0.0 ≤...
  • Page 105 Outputs Name Type Value Analog Table 66 Linear Outputs. Rate Limiter Available in ECA06 ECA60 ECA600 EMA60 Rate Signal Value Limiter The Rate Limiter function limits the rate of change of the input Signal connected to the block. The parameter Rate determines the limit.
  • Page 106 3.6 Setting the Configuration Chapter 3: Configuration Outputs Name Type Value Analog Table 69 Rate Limiter Outputs. Integrator Available in ECA06 ECA60 ECA600 EMA60 Signal Value Integrator Hold Overflow ResetSignal Pulse This block integrates the input signal over time and produces pulses, the number of which are in direct proportion to the integral.
  • Page 107 Chapter 3: Configuration 3.6 Setting the Configuration Pulse The output Pulse generates pulses. If the value of Signal is great, the pulses come often, and if the value of Signal is small, the pulses come seldomly. If the value of Signal is less than or equal to zero, no pulses are generated. An internal pulse pulse counter (IPC) keeps track of how many pulses have been generated.
  • Page 108 3.6 Setting the Configuration Chapter 3: Configuration Sub-zero Signals When Signal starts to drop below zero, the value of IPC is stored. As long as Signal is negative (or zero), no pulses are generated by the block, but IPC decreases with each passing of a gradation mark. When Signal turns positive again, no pulses are generated until IPC reaches the value stored.
  • Page 109 Chapter 3: Configuration 3.6 Setting the Configuration Hold and Reset By activating the digital input Hold, the block will behave as if Signal momentarily dropped to zero. No Pulses will be generated, and the Value output will freeze. Also, IPC is unchanged while Hold is active. By selecting the parameter Reset and pressing OK, the user can reset the block.
  • Page 110 3.6 Setting the Configuration Chapter 3: Configuration Outputs Name Type Value Analog output Overflow Digital output Pulse Digital output Table 72 Integrator Outputs. 493-0736-11 (6-2)
  • Page 111 Chapter 3: Configuration 3.6 Setting the Configuration Time Measurement Available in ECA06 ECA60 ECA600 EMA60 Time Signal Measurement The Time Measurement block measures the time that the input Signal has been active. The block measures time with a resolution of one second. The elapsed time is presented on the display in the form hours : minutes : seconds.
  • Page 112 3.6 Setting the Configuration Chapter 3: Configuration Timer Available in ECA06 ECA60 ECA600 EMA60 ActivateTimer TimerRunning Timer ResetSignal TimerDone This block provides functions to set the time, to start, to hold and reset a timer. The time can be set to a maximum of 86,400 seconds (1440 minutes = 24 hours).
  • Page 113 Chapter 3: Configuration 3.6 Setting the Configuration Parameters Name Setting Unit TimeUnit Seconds or Minutes 3xSampleTime ≤ TimerTime ≤ 86400 TimerTime Seconds Table 76 Timer Parameters. Outputs Name Type TimerRunning Digital TimerDone Digital Table 77 Timer Outputs. 493-0736-11 (6-2)
  • Page 114 3.6 Setting the Configuration Chapter 3: Configuration Counter Available in ECA06 ECA60 ECA600 EMA60 ActivateCounter CounterRunning CountSignal Counter CounterDone ResetSignal The block is used to count pulses. When the preset number of pulses on the input CountSignal (the value in the parameter NbrOfPulses) is reached, the output CounterDone is set to 1.
  • Page 115 Chapter 3: Configuration 3.6 Setting the Configuration Inputs Name Connection ActivateCounter Off, Digital CountSignal Off, Digital ResetSignal Off, Digital Table 78 Counter Inputs. Parameters Name Setting Unit 1 ≤ NbrOfPulses ≤ 999 999 NbrOfPulses None Table 79 Counter Parameters. Outputs Name Type CounterRunning...

  • Page 116: Set Point Block

    3.6 Setting the Configuration Chapter 3: Configuration Set Point Block Available in ECA06 ECA60 ECA600 EMA60 PVValue SPValue PVSignal RampDone Controllers ESPSignal Set Point RampActive ESPEnable ESPMode RampHold PVValue SP Value PVSignal EMA60 RampDone Set Point RampActive RampHold The Set Point block (SP) processes the Set Point data. The Control Block is permanently connected to the Set Point block.
  • Page 117 Chapter 3: Configuration 3.6 Setting the Configuration • In the text and tables below, any features which are not available in the EMA60 are identified by a “*” character. Inputs Name Connection PVSignal Off, Analog ESPSignal* Off, Analog ESPEnable* Off, Digital Table 81 Set Point Block Inputs.
  • Page 118 3.6 Setting the Configuration Chapter 3: Configuration Outputs Name Type 0 ≤ PVValue ≤ 100 PVValue 0 ≤ SPValue ≤ 100 SPValue ESPMode * Digital RampDone Digital RampActive Digital RampHold Digital Table 83 Set Point Block Outputs Process Value PVSignal should be connected to the process value. This is usually an Analog Input block (AI), but can also be a Function block (FA, FO) or an Analog Input Communication Buffer block (AIC).
  • Page 119 Chapter 3: Configuration 3.6 Setting the Configuration The ESPSignal input to the block allows you to specify an External Set Point from different analog sources for use with the controller. Depending on the analog source type, different indicators are displayed on the top row of the LCD display. Source Type External Set Point Type Indicator...
  • Page 120 3.6 Setting the Configuration Chapter 3: Configuration ESPEnable * The ESPEnable input to the block enables switching between ESP and ISP and can be connected to any digital source. Whenever the ESPEnable input is connected to a source switching between ESP and ISP can be made either from the front panel of the controller or by using the ESPEnable input.
  • Page 121 Chapter 3: Configuration 3.6 Setting the Configuration For example, setting SPLoLimit to 2.00m /min and SPHiLimit to 7.00m /min limits the Set Point to values within the range 2.00 < SP < 7.00. The limits are indicated on the SP bar graph by brighter segments. It is not possible to set these parameters beyond the following limitations: •...
  • Page 122 3.6 Setting the Configuration Chapter 3: Configuration The following parameters apply to both the Simple Set Point Ramp and the Advanced Set Point Ramp. Parameters Name Setting Unit RampMode Off, Simple, Advanced None Hold Off, On None TimeUnit Minutes, Seconds None RampStart StartFromPV, StartFromStartValue...
  • Page 123 TrackMode in the table is used for either TrackOneMode or TrackTwoMode. TrackMode Triggers Simple Set Point Ramp InAutoWDeltaU WhenEnabled WhenEnabledWDeltaU InAutoBumpless Table 86 Simple Set Point Ramp Triggering*. Simple Set Point Ramp * Available in ECA06 ECA60 ECA600 EMA60 Parameters Name Setting Unit ≤ RampSpeed ≤ RampSpeed RampSpeed...
  • Page 124 3.6 Setting the Configuration Chapter 3: Configuration The lowest speed makes the Set Point travel the whole span in 86 400 seconds (24 hours). RampSpeed is hence defined by (if TimeUnit = seconds): span Unit/second RampSpeed Min -------------- - 86400 or if TimeUnit = minutes: span Unit/minute...
  • Page 125 Chapter 3: Configuration 3.6 Setting the Configuration Hold Both the Simple and Advanced Set Point Ramp functions offer a hold feature. It is activated by setting the parameter Hold to On. As described below, the ramps are activated by a Non-Auto to Auto transition. When the ramp is running (RampDone = False) an Auto to Non-Auto transition can either reset the ramp and put it on hold (Hold = Off), or just put it on hold (Hold = On).
  • Page 126 3.6 Setting the Configuration Chapter 3: Configuration Time AutoStatus Input RampActive Output RampDone Internal Timer Active Figure 47 Simple Set Point Ramp Timing and Function Example. At t = 1 the control Mode changes from non Auto (Manual, Tracking, or Forced Output) to Auto and the ramp starts.
  • Page 127 Chapter 3: Configuration 3.6 Setting the Configuration The time 9 – (minus) 7 ≥ TimerTime and therefore the ramp is complete. Note: It is not possible to toggle between ISP and ESP when RampDone is False. If ESPEnable = True and RampMode = On then ESP is the target value of the Simple Set Point Ramp.
  • Page 128 Set Point at the current value. At the same time RampActive is set to False, and RampDone is set to True. Advanced Set Point Ramp Available in ECA06 ECA60 ECA600 EMA60 The Advanced Set Point Ramp function is only available on the ECA600 and EMA60 controllers.
  • Page 129 Chapter 3: Configuration 3.6 Setting the Configuration When the ramp reaches the first Breaking Point, it immediately starts to ramp towards to second Breaking Point, and so on. Notes: • Pressing the Up/Down keys while RampDone is False has no effect. •...
  • Page 130 3.6 Setting the Configuration Chapter 3: Configuration Advanced Set Point Ramp Example In the example below the Time and Value parameters are set according to the table below. Note: Each Time parameter is relative to the previous Time parameter. All Value parameters are absolute.
  • Page 131 Chapter 3: Configuration 3.6 Setting the Configuration –2 Time AutoStatus Input RampActive Output RampDone Output Figure 48 Advanced Set Point Ramp Example. 493-0736-11 (6-2)

  • Page 132: Alarms

    3.6 Setting the Configuration Chapter 3: Configuration Alarms Available in The Alarm blocks holds alarm limits and generates alarm signals when these ECA06 ECA60 ECA600 EMA60 limits are transgressed. Note: The ECA600 is configurable as PID1/Master or as PID2/Slave. The functions described here are duplicated for PID1 and PID2.
  • Page 133 Chapter 3: Configuration 3.6 Setting the Configuration Disabling Selected Alarms You may selectively disable these alarms as follows: LoLoAlarm: Set the LoLoLimit to 0.0. LoAlarm and LoLoAlarm: Set the LoLimit and the LoLoLimit to 0.0. HiHiAlarm: Set the HiHiLimit to 100.0. HiHiAlarm and HiAlarm: Set the HiLimit and the HiHiLimit to 100.0.
  • Page 134 Hi Alarm Digital HiHiAlarm Digital Alarm Digital Table 92 Absolute Alarm Outputs. Note: The Absolute Alarm block is freely configurable. Deviation Alarm Block Available in ECA06 ECA60 ECA600 EMA60 NegAlarm Signal1 Deviation PosAlarm Alarm Signal2 Alarm The Deviation Alarm block handles relative alarms. The block observes the difference between the Signal1 and Signal2 input values: Diff = Signal2 –...
  • Page 135 Chapter 3: Configuration 3.6 Setting the Configuration PosAlarm = Diff > PosDeviationLimit NegAlarm = Diff < NegDeviationLimit Alarm = PosAlarm OR NegAlarm. Disabling Alarms You may selectively disable the deviation alarms as follows: NegAlarm: Set NegDeviationLimit to –100.0. PosAlarm: Set PosDeviationLimit to 100.0. Inputs Name Connection...

  • Page 136: Control

    Deviation Alarm Outputs. Note: The Deviation Alarm block is freely configurable. Control Available in Combination ECA06 ECA60 ECA600 EMA60 Setting combination to Cascade or DualLoop opens a second Control block for configuration. Select Cascade when you want to connect the Control blocks in a Master/Slave configuration.
  • Page 137 Chapter 3: Configuration 3.6 Setting the Configuration Parameters Available in The Control block (CO) encapsulates PID control and related functions. ECA06 ECA60 ECA600 EMA60 The following connections are permanently made to the Set Point block – they cannot be changed: •...
  • Page 138 3.6 Setting the Configuration Chapter 3: Configuration The controller can be configured to perform different types of control: • PID control with fixed parameters. If the process has dynamic characteristics which are independent of the working point (a linear process) and do not change with time, PID control with fixed parameters may be used.
  • Page 139 Offset parameter. The control parameters should be commissioned via the Autotuner function on installation. However the parameters can also be set manually. The ECA06 has only one set of PID parameters – K1, TI1 and TD1. 493-0736-11 (6-2)
  • Page 140 3.6 Setting the Configuration Chapter 3: Configuration Gain Scheduling Available in ECA06 ECA60 ECA600 EMA60 Gain Scheduling is used to improve the control of non-linear processes where the non-linearity is fixed, i.e. not time-dependent. Processes with time-dependent non-linearity must be controlled by a PID controller with adaptive PID settings.
  • Page 141 Chapter 3: Configuration 3.6 Setting the Configuration Parameters Name Setting Unit Mode Off, On None 0.0 ≤ Limit1 ≤ Limit2 ≤ 100.0 Limit1 0.0 ≤ Limit1 ≤ Limit2 ≤ 100.0 Limit2 Reset None Table 101 Gain Scheduling Parameters. GainSchedulingSignal PID Parameter Set 0.0 ≤...
  • Page 142 3.6 Setting the Configuration Chapter 3: Configuration When tuning is first performed, or after the Autotuner has been reset, not only the set selected by GainSchedulingSignal (here 0.0–Limit1) is filled but also the rest of the table. GainSchedulingSignal Limit2–100.0 Tuning 1 Tuning 1 Tuning 1 Limit1–Limit2...
  • Page 143 Chapter 3: Configuration 3.6 Setting the Configuration Feed Forward Available in The Feed Forward function block has one analog input, FeedForwardSignal, and ECA06 ECA60 ECA600 EMA60 three parameters – Mode, Gain and Reset. Inputs Name Connection FeedForwardSignal off, Analog Table 106 Feed Forward Inputs.
  • Page 144 3.6 Setting the Configuration Chapter 3: Configuration The Feed Forward block in the figure below holds the factor Gain. This factor is either static (does not change over time, Mode = StaticGain), or adaptive (changes with Control Loop dynamics, Mode = AdaptiveGain). Select the desired behaviour by setting the Mode parameter.
  • Page 145 • Feed Forward (Mode = StaticGain) can be used with Three State Pulse with no actuator feedback. • Adaptive Gain will not work together with pPI control. Autotuner Available in ECA06 ECA60 ECA600 EMA60 Autotuning is an aid which permits automatic setting of the controller PID parameters.
  • Page 146 3.6 Setting the Configuration Chapter 3: Configuration The Autotuner even incorporates a form of intelligence. In situations where the D element should not be used, for example in level control, the Autotuner automatically identifies the process and eliminates the D element. Tune Σ...
  • Page 147 Chapter 3: Configuration 3.6 Setting the Configuration pPi Controller The pPi (predicting PI) controller is a specially designed dead time controller. It should be used when the dead time is longer than twice the dominant process time constant. If the dead time is varying, for example with flow or conveyor speed, the pPI controller can be combined with gain scheduling.
  • Page 148 3.6 Setting the Configuration Chapter 3: Configuration By determining the four key parameters L, T, ∆ y and ∆u from a step response, the three process parameters static gain K , dominant time constant T and dead- time L can be determined according to the expressions below: ∆...
  • Page 149 Chapter 3: Configuration 3.6 Setting the Configuration TD = L = 20 s Note: When setting the controller parameter TD you actually set the value of the Lp (Dead-time) parameter, not the Derivative Time. In the menu system however, the notation TD is used for the dead-time of the pPI controller. Notes: •...
  • Page 150 3.6 Setting the Configuration Chapter 3: Configuration • The Tuning process can be interrupted by pressing the Hand key. In this case no changes are made to the controller’s parameters. √ To Tune Press Tune Temp Tank 4 21.7 °C I Tuning Init Temp Tank 4 21.7 °C...
  • Page 151 Output Figure 53 Autotuning Graphs Showing SP and PV During Output Signal Changes. Adapt Available in ECA06 ECA60 ECA600 EMA60 Adaptive control automatically alters the PID parameters if the process changes. The pPI controller cannot be used with adaptive control.
  • Page 152 3.6 Setting the Configuration Chapter 3: Configuration When the Reset parameter is set to OK the internal parameters for the Adapt function are reset. Parameters Name Setting Unit Mode Off, On None 0.0 < CriticalGain ≤ 100.0 CriticalGain None 0.0 ≤ CriticalPeriod < 10000.0 CriticalPeriod seconds Reset...
  • Page 153 Chapter 3: Configuration 3.6 Setting the Configuration • Ringing in the process (disturbances with the same time constant as the process) can cause problems with adaptive controlling. If these disturbances cannot be eliminated the controller must be set for adaptive feed forward. Critical Gain and Critical Period In a very few cases (like very noisy processes), the AutoTuner may not be able to determine the control loop characteristics (CriticalGain and CriticalPeriod)
  • Page 154 3.6 Setting the Configuration Chapter 3: Configuration Miscellaneous Functions The Miscellaneous section contains two parameters – ControllerAction, and ESPStepBehavior. If the controller action is known you can set it using the parameter ControllerAction parameter. Otherwise the Autotuner will determine and set the correct value.

  • Page 155: Output Configuration

    Chapter 3: Configuration 3.6 Setting the Configuration Output Configuration Available in ECA06 ECA60 ECA600 EMA60 ManualStatus ManualEnable DDCIncrease ControlSignal DDCDecrease Output AutoStatus Configuration TrackOneSignal TrackOneEnable TrackOneStatus TrackTwoSignal TrackTwoStatus TrackTwoEnable ForcedEnable ForcedStatus The Output Configuration (OC) block supervises the output of the controller. The block has four different modes of operation: •...
  • Page 156 3.6 Setting the Configuration Chapter 3: Configuration The Manual Mode LED is only lit in the Manual Mode. Inputs Name Connection ManualEnable Off, digital DDCIncrease Off, digital DDCDecrease Off, digital TrackOneSignal Off, Analog TrackOneEnable Off, Digital TrackTwoSignal Off, Analog TrackTwoEnable Off, Digital ForcedEnable Off, Digital...
  • Page 157 Chapter 3: Configuration 3.6 Setting the Configuration TrackOne. TrackTwo. Auto. Manual Mode The ManualBehavior parameter, the ManualEnable input and the Hand key at the front panel determine the status of the output ManualStatus. When ManualBehavior is set to Normal the ManualEnable input and the Hand key signal have equal priority.
  • Page 158 Manual Figure 55 ManualBehavior = TrueManual. Available in The DDC function has two digital inputs, DDCIncrease and DDCDecrease, and ECA06 ECA60 ECA600 EMA60 one parameter DDCTime. The DDCIncrease and DDCDecrease inputs only control the ControlSignal when the ControlMode is Manual.
  • Page 159 Table 115 DDC Parameters. Tracking Available in ECA06 ECA60 ECA600 EMA60 The ECA60 and EMA60 have the function TrackOne; the ECA600 has the functions TrackOne and TrackTwo. TrackOne and TrackTwo perform identical functions but TrackOne has a higher priority than TrackTwo.
  • Page 160 3.6 Setting the Configuration Chapter 3: Configuration Note: The DeltaU signal can take negative or positive values. The EMA60 does not have a Control Block and therefore the signal DeltaU does not exist. This means that the modes InAutoWDeltaU and WhenEnabledWDeltaU do not exist in the EMA60.
  • Page 161 Chapter 3: Configuration 3.6 Setting the Configuration Parameters Name Setting Unit TrackOneMode InAutoBumpless, None InAutoWDeltaU, WhenEnabled, WhenEnabledWDeltaU 1 ≤ TrackOneBumpSpeed ≤ 1440 TrackOneBumpSpeed s/100% TrackTwoMode InAutoBumpless, None InAutoWDeltaU, WhenEnabled, WhenEnabledWDeltaU 1 ≤ TrackTwoBumpSpeed ≤ 1440 TrackTwoBumpSpeed s/100% Table 117 Tracking Parameters. If both TrackOneEnable and TrackTwoEnable are active, the Controller Output will track TrackOneSignal.
  • Page 162 When the controller is tracking, the word “Tracking” is displayed on the top line of the display. Forced Output Available in ECA06 ECA60 ECA600 EMA60 The PID output can be forced to a preset value by activating the ForcedEnable input. When the Mode parameter is set to Off, forced control is disabled. The value to which the control output is forced is defined by the parameter ForcedValue.
  • Page 163 Chapter 3: Configuration 3.6 Setting the Configuration When Mode is set to AutoToAny it is possible for the operator to change the control mode to Manual. If the ForcedEnable input changes from True to False when the controller is in Manual Control mode, the Control Mode remains unchanged.
  • Page 164 3.6 Setting the Configuration Chapter 3: Configuration Miscellaneous Available in A group of parameters affecting the output are grouped together under the ECA06 ECA60 ECA600 EMA60 heading miscellaneous. Parameters Name Value Unit RestartBehavior PrevValPrevMode, None PrevValManMode, PrevValAutoMode RestartValManMode RestartValAutoMode RestartValPrevMode 0.0 ≤...
  • Page 165 LoLimit and HiLimit. Even if LimitMode is set to InAutoAndTracking or AlwaysExceptForced, the Control Signal limiting is not functional if ForcedEnable is True. Note: The ECA06 does not have the Control Signal Limit function and hence does not have the parameters related to this function (LimitMode, LoLimit and HiLimit).

  • Page 166: Output Functions

    Analog None ThreeStatePulse TwoStatePulse SplitRange Table 121 Available Output Functions. Analog Available in ECA06 ECA60 ECA600 EMA60 Analog Value Signal Value = Signal This block has no actual functionality but merely transports the signal at the input to the output.
  • Page 167 Chapter 3: Configuration 3.6 Setting the Configuration The active time of the output Pulse is proportional to the value of the input Signal. When the input is 0%, the output signal is active for the minimum time period, which is equal to the parameter SampleTime found in the System Block settings. When the input signal is 100%, the output signal is equal to the parameter CycleTime.
  • Page 168 The Pulse output is active for 30 seconds and then inactive for 20 (50–30) seconds. True False –10 Time Figure 56 Two State Pulse Example. Three State Pulse Available in ECA06 ECA60 ECA600 EMA60 Three Signal Increase State Pulse Decrease Feedback Signal The Three State Pulse output has two analog inputs, FeedbackSignal and Signal, two digital outputs, Increase and Decrease.
  • Page 169 Chapter 3: Configuration 3.6 Setting the Configuration The ControlSignal changes (DeltaU) are buffered internally in the Three State Pulse block. When the sum of the accumulated changes becomes greater than the buffer threshold mentioned above, the block activates one of the outputs (Increase or Decrease).
  • Page 170 3.6 Setting the Configuration Chapter 3: Configuration Note: The inputs identified as fixed connections cannot be changed. They are listed for information only. Parameters Name Setting Unit 0.0 < Deadband ≤ 10.0 DeadBand 0.5 ≤ Hysteresis ≤ 3.0 Hysteresis 15 ≤ ActuatorPosTime ≤ 1000 ActuatorPosTime 0.3 ≤...
  • Page 171 Chapter 3: Configuration 3.6 Setting the Configuration • Adaptive Control • Tuning • Control Signal Limit Non Auto Mode Non-Auto mode comprises the following Control modes: • Manual • Forced Output No Feedback In Non-Auto mode with no feedback, the Out bar graph is 0.0% and the display shows Inc/Dec signal.
  • Page 172 DeltaU = DeltaU When switching from Auto to Non-Auto control modes a bumpless transfer is ensured by setting: ControlSignal = FeedbackSignal Split Range Available in ECA06 ECA60 ECA600 EMA60 Value1 Split Signal Range Value2 The Split Range output has one analog input, Signal, and two analog outputs, Value1 and Value2.
  • Page 173 Chapter 3: Configuration 3.6 Setting the Configuration This type of output splits the Control Block output signal into two signals, Value1 and Value2. The linear relationships between the input and the two outputs Value1 and Value2 can be configured via the parameters. Value2 Value1 Control Signal...
  • Page 174 3.6 Setting the Configuration Chapter 3: Configuration The coordinates are entered according to the table below. Parameter Name Value Name Value MinIn1 20.0 MinIn2 40.0 MaxIn1 50.0 MaxIn2 90.0 MinOut1 70.0 MinOut2 10.0 MaxOut1 20.0 MaxOut2 90.0 Table 128 Split Range Example. For values that fall outside the range defined by the coordinate pairs, the function extends the characteristic with a horizontal line.
  • Page 175 Chapter 3: Configuration 3.6 Setting the Configuration Note: The input is a fixed connection and cannot be changed. It is listed for information only. Parameters Name Setting Unit 0.0 ≤ MinIn1 ≤ 100.0 MinIn1 0.0 ≤ MinIn1 ≤ MaxIn1 ≤ 100.0 MaxIn1 0.0 ≤...

  • Page 176: Outputs

    The Mode parameter is used to select the block for operation and whether it operates in the Direct or Reverse modes. Note: The ECA06 and EMA60 do not have the Fixed mode. In the text and tables below, any features which are not available in the ECA06 and EMA60 are identified by a “*”...
  • Page 177 Chapter 3: Configuration 3.6 Setting the Configuration Signal input Figure 58 Direct Mode Characteristic. With the block configured to Mode = Reverse, the block has the characteristic shown in Figure 59. 493-0736-11 (6-2)
  • Page 178 3.6 Setting the Configuration Chapter 3: Configuration Signal input Figure 59 Reverse Mode Characteristic. With the block configured to Mode = Fixed, the block produces a constant current on the terminal outputs, regardless of the value on the Signal input. The constant current is defined by the parameter FixedCurrent.
  • Page 179 Analog Output Block Parameters. Stiction Compensation Available in This function is to be used with analog output signals which control pneumatic ECA06 ECA60 ECA600 EMA60 regulating valves with high friction components. The stiction compensation adds short pulses of equal amplitude and duration to the analog output signal. This significantly reduces the control error during stick-slip motion compared with standard control without stiction compensation.
  • Page 180 3.6 Setting the Configuration Chapter 3: Configuration The stiction compensation function detects the signal direction of the analog output signal and adds positive or negative pulses, depending on the signal direction, see figure below. a = Pulse amplitude τ τ = Pulse width h = Hysteresis n = Pulse period factor...
  • Page 181 This means, for example, that the function can be added to an external input signal and then be distributed as an output signal with the stiction compensation pulses superimposed. Analog Output Communication Buffers Available in ECA06 ECA60 ECA600 EMA60 Analog Output...
  • Page 182 3.6 Setting the Configuration Chapter 3: Configuration Digital Outputs Available in ECA06 ECA60 ECA600 EMA60 Digital Signal Screw Terminals Output Each Digital Output Block (DO) has one digital input, Signal and provides one digital signal to the external terminals of the controller. Each block also holds two parameters –...
  • Page 183 Chapter 3: Configuration 3.6 Setting the Configuration Digital Output Communication Buffers Available in ECA06 ECA60 ECA600 EMA60 Digital Output Signal Comms Communication Buffer Remote digital communication is provided by Digital Output Communications Buffers (DOC) via a two wire RS485 serial channel using the COMLI protocol.

  • Page 184: Eca Operator Block

    Chapter 3: Configuration ECA Operator Block Available in The Operator Block (OP) handles the presentation of all information on the ECA06 ECA60 ECA600 EMA60 controller front panel. The displayed process value can be scaled using the function “ProcessValue” and a selected signal value can be shown on the display using the function “AltDisplay”.
  • Page 185 Chapter 3: Configuration 3.6 Setting the Configuration Parameters Name Setting Unit 0 ≤ NumberOfDecimals ≤ 4 NumberOf None Decimals –99999 ≤ MinValue ≤ MaxValue ≤ 99999 MinValue None –99999 ≤ MinValue ≤ MaxValue ≤ 99999 MaxValue None %, °C, °F, K, W, kW, MW, J, kJ, MJ, rpm, Pa, Unit None kPa, MPa, bar, mbar, bara, l, l/s, l/min, l/h, Psi,...
  • Page 186 3.6 Setting the Configuration Chapter 3: Configuration AltDisplay Available in ECA06 ECA60 ECA600 EMA60 Signal AltDisplay The AltDisplay function is used to select a signal, scale and present its value on the display. The selected signal value is shown using “Next Key” (in Operator Mode).
  • Page 187 Chapter 3: Configuration 3.6 Setting the Configuration Parameters %, °C, °F, K, W, kW, MW, J, kJ, Unit None MJ, rpm, Pa, kPa, MPa, bar, mbar, bara, l, l/s, l/min, l/h, Psi, Psig, Psia, mmWG, ”WG, mmvp, mvp, mmH O, mmHg, ”Hg, kp/cm , N/m , kg/cm...
  • Page 188 3.6 Setting the Configuration Chapter 3: Configuration Bar Graphs The Bar Graphs section contains four parameters, LeftBargraphMode, CenterBargraphMode, RightBargraphMode and LeftBargraphAlarm. Parameters Name Value Unit LeftBargraphMode Bar, ReversedBar, Point, None ReversedPoint CenterBargraphMode Bar, ReversedBar, Point, None ReversedPoint RightBargraphMode Bar, ReversedBar, Point, None ReversedPoint LeftBargraphAlarm...
  • Page 189 Chapter 3: Configuration 3.6 Setting the Configuration × 30 = 12 segments. For reversed indication the number of segments lit is given by: 100–40 × 30 = 18 segments. This is shown in the figures below for LeftBargraph set to Bar, ReversedBar, Point and ReversedPoint modes.

  • Page 190: Ema60 Operator Block

    3.6 Setting the Configuration Chapter 3: Configuration Figure 63 Segments Lit in Point Mode (Left) and Reversed Point Modes (Right). EMA60 Operator Block Available in ECA06 ECA60 ECA600 EMA60 Signal1 EMA60 Signal2 Operator Signal3 The Operator Block (OP) handles the presentation of all information on the controller front panel.
  • Page 191 Chapter 3: Configuration 3.6 Setting the Configuration Connection to the analog source is made via the input Signalx (where x = 1, 2 or 3). If Signalx is off then the corresponding bar graph is turned off. The text “Off” is shown on the display instead of a numerical value when the signal is accessed from the Operator option List.
  • Page 192 3.6 Setting the Configuration Chapter 3: Configuration Bar Graphs Each bar graph displays the corresponding input value. Alarm indicators can also be shown on the bar graphs. The parameter BargraphAlarm determines which alarm indication is presented on the bar graph. This is selectable from the available Absolute Alarms and Deviation Alarms.

  • Page 193: System Block

    HandKey Normal, LockInManual None Table 146 EMA60 Operator Block Parameters. Note: The “x” character in the BargraphMode and BargraphAlarm parameters represents “Left”, “Center” or “Right”. System Block Available in ECA06 ECA60 ECA600 EMA60 Computer Mode Computer System Mode Block Enable ErrOrWarn The System Block (SY) monitors the controller communications and status.
  • Page 194 3.6 Setting the Configuration Chapter 3: Configuration Outputs Name Type Computer Mode False = Local, True = Computer ErrOr Warn Refer to Appendix B for more information Table 148 System Status Outputs. COM Setup There are five parameters associated with communications: •...
  • Page 195 Chapter 3: Configuration 3.6 Setting the Configuration If WriteEnable is set to On, the Communication Mode has no impact on a supervisory system’s ability to write to the controller’s registers. The Communication Mode simply locks the front panel. Communication Write Operations Operator Front Panel Mode Access...
  • Page 196 3.6 Setting the Configuration Chapter 3: Configuration Miscellaneous The system block contains a number of miscellaneous parameters whose functions are summarised in the table below. Parameters Name Setting Unit Setup Please refer to the booklet “Preset None Configurations” for details. 0.030 ≤...
  • Page 197 Chapter 3: Configuration 3.6 Setting the Configuration Display Language The Display Language section contains two parameters, Select and Edit. Parameters Name Setting Unit Select English, Svenska, Deutsch None Edit Please refer to the Edit section below None Table 153 System Block Miscellaneous Parameters. The language in which all messages appear on the display is selected by setting the parameter Select.

  • Page 198: Status Signals

    3.7 Status Signals Chapter 3: Configuration Status Signals The various status signals and their locations within the controller are listed in the table below. Status Signal Block Location Ramp Set Point Block Absolute Alarms Absolute Alarm Block Deviation Alarms Deviation Alarm Block Computer/Local Mode System Block ErrorOrWarningActive...

  • Page 199: Maintenance

    Chapter 4 Maintenance This chapter contains maintenance instructions to ensure the continued safe operation of the ECA06, ECA60, ECA600 and EMA60 controllers. General The operation of the controller should be checked once a year. The controllers require no other special maintenance or any periodic calibration.
  • Page 200 4.2 Annual Check Chapter 4: Maintenance 493-0736-11 (6-2)

  • Page 201: Technical Data

    Chapter 5: Technical Data 5.1 Type Chapter 5 Technical Data Type • Electronic controller with configurable functions. Control Functions Selectable from: • PID controller with fixed parameters (conventional controller). • PID controller with continuously adaptive parameters settings. • PID controller with gain scheduling (combined with adaptive control). •...

  • Page 202: Process Value

    5.4 System Functions Chapter 5: Technical Data • Internal/External Set Point, selected via the front panel or an external digital signal. All operating mode switching is normally bumpless. Process Value • Selectable signal range. • Arithmetic functions can be configured. Set Point •...

  • Page 203: Computer Interface

    Chapter 5: Technical Data 5.4 System Functions Computer Interface • Can be used for control and/or data logging. • Can be configured remotely. Arithmetic Functions • Addition/Subtraction (AddSub). • Multiplication/Division (MulDiv) • Exponent (Exp). • Pressure/Temperature compensation (COM). • Selection of minimum signal (MIN). •...

  • Page 204: Miscellaneous

    5.5 Input Signals Chapter 5: Technical Data • Integrator • Time Measurement • Rate Limiter • Timer • Counter Miscellaneous • Remote reading of selectable internal signals. • Password to protect configuration. • Fault Indications. • Controller and/or configuration resetting. •...

  • Page 205: Output Signals

    Chapter 5: Technical Data 5.6 Output Signals • Inactive = 0 to 5 V, active = 16 to 30 V Output Signals AO1, AO2, AO3 • Three analog outputs, 0–20 mA or 4–20 mA. Loading 0 to 650 Ω. • Load dependence < 0.2 % for a change from 0 to 60 Ω. DO1, DO2, DO3, DO4, DO5, DO6 •...

  • Page 206: 5.10 Mains Supply

    5.10 Mains Supply Chapter 5: Technical Data • Bar graph also shows actuator position with increase/decrease output. Alarms • Flashing segment on bar graph and message on display. Set Point Indication • Digital Set Point value indicated on the display. Cascade Control (Internal) •...

  • Page 207: 5.11 Transmitter Power Supply

    Chapter 5: Technical Data 5.11 Transmitter Power Supply 5.11 Transmitter Power Supply • 24 V d.c., 100 mA. • Potentiometer feedback when three-state pulse output, maximum 20 mA at 650 Ω. 5.12 Environment Ambient Operating Temperature • +5 to +55°C. Sealing Classification •...

  • Page 208: 5.16 Physical Characteristics

    5.16 Physical Characteristics Chapter 5: Technical Data 5.16 Physical Characteristics • Width 72 mm. • Height 144 mm. • Length 235 mm. • Weight 2.5 kg. 493-0736-11 (6-2)

  • Page 209: Application Examples

    Appendix A: Application Examples Appendix A Application Examples This appendix contains application examples which demonstrate how to configure the controllers for a number of typical applications. The examples are: Level Control with Feed Forward and Gain Scheduling. Temperature Control and Communication with COMLI. Furnace Pressure Control with Three State Pulse Output and Position Potentiometer.

  • Page 210: Level Control With Feed Forward And Gain Scheduling

    A.1 Level Control with Feed Forward and Gain Scheduling Appendix A: Application Examples Inspect the default parameter settings of each block, and determine what changes need to be made. Write down all parameter changes on paper. Configure the controller using your filled out Configuration Work Sheet and parameter changes sheet.

  • Page 211: Preset Configurations

    Appendix A: Application Examples A.1 Level Control with Feed Forward and Gain Scheduling LICA1 Figure 1 Example of Level Control with Feed Forward and Gain Scheduling. To solve this problem an ECA60 or an ECA600 controller may be used. The Set Point is to be set at the front panel of the controller. Preset Configurations Is there a preset configuration available that solves this application? Look in the Preset Configuration booklet.

  • Page 212: Electrical Installation

    A.1 Level Control with Feed Forward and Gain Scheduling Appendix A: Application Examples • One analogue input from the flow transmitter. • One analogue output to control the valve (Control Output). For the level transmitter choose AI1 (as in the Default Configuration) and for LV1 choose AO1 (as in the Default Configuration).
  • Page 213 Appendix A: Application Examples A.1 Level Control with Feed Forward and Gain Scheduling LICA1 jumpers 1, 2, 3, 4 closed – AI2+ – AI1+ AO1+ – +24 V DC out Figure 2 Connection diagram. 493-0736-11 (6-2)

  • Page 214: Configuration

    A.1 Level Control with Feed Forward and Gain Scheduling Appendix A: Application Examples Configuration Preset Configuration Select the default setup from the Preset Configurations. System → Miscellaneous → Setup = Default. Miscellaneous SetUp Default Cancel Inputs AI1 is set by default to 4–20 mA current input so there is no need to change it, but it can be given a suitable name.
  • Page 215 Appendix A: Application Examples A.1 Level Control with Feed Forward and Gain Scheduling Identity Flow Cancel Filtering Set the time constant for AI1 to 12 seconds and AI2 to 13 seconds: Inputs → Analog Inputs → AI1 → FilterTime = 12 seconds. AI1: Level FilterTime Cancel...
  • Page 216 A.1 Level Control with Feed Forward and Gain Scheduling Appendix A: Application Examples Process Value MaxValue 10.0 Cancel Operator → (PID1 – ECA600 only →) Process Value → Unit = mvp. Process Value Unit Cancel Absolute Alarms Set the absolute low alarm to 2 mvp (i.e. 20%) and the high alarm to 8 mvp (i.e. 80%).
  • Page 217 Appendix A: Application Examples A.1 Level Control with Feed Forward and Gain Scheduling Absolute Alarm 1 HiLimit Cancel Feed Forward The Feed Forward mode must be set to StaticGain. The signal that is fed forward is the flow measured by the transmitter FT1, which is connected to AI2. The Gain must be tested by trial and error but in this example it is set to 2.
  • Page 218 A.1 Level Control with Feed Forward and Gain Scheduling Appendix A: Application Examples Control → Parameters → Gain Scheduling → Mode = On. Gain Scheduling Mode Cancel Control → Parameters → Gain Scheduling → Limit1 = 40%. Gain Scheduling Limit1 Cancel Control →...

  • Page 219: Startup

    Appendix A: Application Examples A.1 Level Control with Feed Forward and Gain Scheduling Identity ValveControl Cancel Configuration Complete When Configuration is complete repeatedly press the Cancel key until you return to Operator Mode. Startup The controller starts automatically as soon as you leave the configuration mode, using the values you have just configured.

  • Page 220: Temperature Control And Communication With Comli

    A.2 Temperature Control and Communication with COMLI Appendix A: Application Examples A.2 Temperature Control and Communication with COMLI Description This example describes a control loop for temperature control of a medium which is heated by a hot water heat exchanger. Definition of the Control Problem The object is to regulate the temperature of one medium by controlling the flow of another.

  • Page 221: Mechanical Installation

    Appendix A: Application Examples A.2 Temperature Control and Communication with COMLI Mechanical Installation Please refer to chapter 2 of this manual for details of the mechanical installation. Preset Configurations Is there a Preset Configuration available that solves this application? Look in the Preset Configuration booklet.
  • Page 222 A.2 Temperature Control and Communication with COMLI Appendix A: Application Examples TICA1 jumpers 3, 4 closed – AI1+ AI2+ AI1– – +24 V DC out AO1+ – DI1+ DI com +24 V DC in –24 V DC RS485 TR– DO1+ –...

  • Page 223: Configuration

    Appendix A: Application Examples A.2 Temperature Control and Communication with COMLI Configuration Preset Configuration Select the Default Setup from the Preset Configurations. System → Miscellaneous → Setup = Default. Miscellaneous SetUp Default Cancel Inputs The TT1 output signal range is 0–5V (for 0–400ºC) and the FT1 output signal range is 0–20 mA: Inputs →...
  • Page 224 A.2 Temperature Control and Communication with COMLI Appendix A: Application Examples AI2: Ana In 2 Identity Flow Cancel Process Value The required temperature range is 0–400ºC, with no decimal places. There is no need to change PVMinValue as its default value is zero: Operator →...
  • Page 225 Appendix A: Application Examples A.2 Temperature Control and Communication with COMLI Computer Communications To configure the COMLI communications, give the signal an identity number and select a suitable communications protocol and Baud rate for the transmission: System → Com Setup → Com Protocol → COMLI Com Setup Com Protocol COMLI...

  • Page 226: Startup

    A.2 Temperature Control and Communication with COMLI Appendix A: Application Examples AO1: Ana Out 1 Identity ValveControl Cancel Outputs → Digital Outputs → DO1 → Mode = PositiveLogic. DO1: Dig Out 1 Mode PositiveLogic Cancel Outputs → Digital Outputs → DO1 → Signal = DIC1[Status]. DO1: Dig Out 1 Signal DIC1[Status]...

  • Page 227: Furnace Pressure Control With 3-State Pulse Output

    Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output A.3 Furnace Pressure Control with 3-State Pulse Output Description This example shows how to control the pressure in a steam boiler furnace with a draught valve motor at the flue duct. High and low pressure alarms are required at 0.000 kPa and +0.500 kPa respectively.

  • Page 228: Selection Of I/O

    A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples Selection of I/O The potentiometer can be connected to AI1 and AO1. Jumper 1 must therefore be closed. The pressure transmitter PT1 does not have its own power supply and therefore must be fed from the controller.
  • Page 229 Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output PICA1 jumper 1 closed AI1+ AI2+ AI1– AO1+ DO3+ – DO4+ – +24 V DC – DO2+ High pressure Alarm DO1+ Low pressure Alarm Figure 6 Connection of Transmitter, Actuator Potentiometer, and Increase/Decrease Motor. 493-0736-11 (6-2)

  • Page 230: Configuration

    A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples Configuration When configuring the functions only those parameters with unsuitable default values have to be changed, therefore only these points are described below. Preset Configuration Select the default setup from the Preset Configurations. System →...
  • Page 231 Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output AI2: Ana In 2 Mode 4–20mA Cancel Inputs → Analog Inputs → AI2 → Identity = Pressure. AI2: Ana In 2 Identity Pressure Cancel Filtering Set the time constant for AI2 to 2seconds: Inputs →...
  • Page 232 A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples Process Value PVMinValue –1.0 Cancel Operator → (PID1 – ECA600 only →) Process Value → PVMaxValue = 1. Process Value PVMaxValue Cancel Operator → (PID1 – ECA600 only →) Process Value → Unit = kPa. Process Value Unit Cancel...
  • Page 233 Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output Absolute Alarm 1 Mode Cancel Alarms → Absolute Alarm → Absolute Alarm 1 → LoLimit = 0. Absolute Alarm 1 LoLimit Cancel Alarms → Absolute Alarm → Absolute Alarm 1 → HiLimit = 50. Absolute Alarm 1 HiLimit Cancel...
  • Page 234 A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples Output Functions Type ThreeStatePulse Cancel Output Functions → (PID1, ECA600 only) → ThreeStatePulse → ActuatorPosTime = 120s. ThreeStatePulse ActuatorPosTime 120 s Cancel Output Functions → (PID1/Master, ECA600 only) → ThreeStatePulse → ActuatorMinPulseLen = 1%.
  • Page 235 Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output ThreeStatePulse Feedback AI1[Value] Cancel Outputs The feed to the potentiometer should be set to 5.0mA which gives 0–5V output since the potentiometer resistance is 1000Ω: Outputs → Analog Outputs → AO1 → Mode = Direct. AO1: Ana Out 1 Mode Direct...
  • Page 236 A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples DO1: Dig Out 1 Mode PositiveLogic Cancel Outputs → Digital Outputs → DO1 → Signal = AA1 [LoAlarm]. DO1:Dig Out 1 Signal AA1 [LoAlarm] Cancel Outputs → Digital Outputs → DO1 → Identity = LoAlarm. DO1:Dig Out 1 Identity LoAlarm...
  • Page 237 Appendix A: Application Examples A.3 Furnace Pressure Control with 3-State Pulse Output DO2:Dig Out 2 Identity HiAlarm Cancel Configure the controller to provide a three state pulse output from DO3 and DO4 for the motor increase/decrease signal: Outputs → Digital Outputs → DO3 → Mode = PositiveLogic. DO3:Dig Out 3 Mode PositiveLogic...

  • Page 238: Startup

    A.3 Furnace Pressure Control with 3-State Pulse Output Appendix A: Application Examples DO4:Dig Out 4 Signal OF1[Decrease] Cancel Configuration Complete When Configuration is complete repeatedly press the Cancel key until you return to Operator Mode. Startup The controller starts automatically as soon as you leave the configuration mode, using the values you have just configured.

  • Page 239: Error, Warning And Information Messages

    Appendix B: Error, Warning and Information Messages B.1 Message Types Appendix B Error, Warning and Information Messages Message Types Four types of messages can be shown on the display. In order of priority these are: • System Errors, Errors and Warnings. •...

  • Page 240: Information Messages

    B.2 Controller Reaction Appendix B: Error, Warning and Information Messages E AI1 Int 21.7 °C Figure 8 Display – Error Message. Information Messages This category of messages appears flashing on the bottom line of the display. If the Information Message is an Absolute or Deviation Alarm, the associated alarm limit indication on the bargraphs also flashes.

  • Page 241: Error And Warning Descriptions

    Appendix B: Error, Warning and Information Messages B.4 Error and Warning Descriptions Make sure you are in Operator Mode. Access the Message List by multiple pressing of the Next key. Acknowledge the Error or Warning by pressing the OK key. √...

  • Page 242: Sample Time Error

    B.4 Error and Warning Descriptions Appendix B: Error, Warning and Information Messages Sample Time Error If the time it takes to complete a full cycle of processing is greater than the Sample Time configured, this error is set. The Sample Time is automatically increased so that the system can complete a full cycle of processing without errors.

  • Page 243: Arithmetic Error

    Appendix B: Error, Warning and Information Messages B.5 Information Messages Arithmetic Error If the calculations done in the Input Function Blocks result in a divide by zero or an arithmetic overflow, this error is set. CLPM Osc LoopX If the CLPM (Control Loop Performance Monitor) detects abnormal oscillation in the control loop, this warning is set.

  • Page 244: Summary Of Messages

    B.6 Summary of Messages Appendix B: Error, Warning and Information Messages Summary of Messages The messages which appear on the display are summarised in the tables below. 493-0736-11 (6-2)

  • Page 245: System Error, Error And Warning Messages

    Appendix B: Error, Warning and Information Messages B.6 Summary of Messages System Error, Error and Warning Messages Prior. Condition Warn Display Comment Sys Err HW Hardware Error FLASH Write Sys Err FLASH Write Write Error in FLASH memory FLASH Erase Sys Err FLASH Erase Erase Error in FLASH memory...
  • Page 246 B.6 Summary of Messages Appendix B: Error, Warning and Information Messages Prior. Condition Warn Display Comment DA Source off W DA Source off Output or Source off when called AA Source off W AA Source off Output or Source off when called SP Source off W SP Source off...

  • Page 247: Information Messages

    Appendix B: Error, Warning and Information Messages B.6 Summary of Messages Note: For Errors/Warnings numbers 7 to 14, the leading character in the display is “E” for Errors and “W” for Warnings. In the table above, the “E” is chosen as an example.
  • Page 248 B.6 Summary of Messages Appendix B: Error, Warning and Information Messages Tuning Phase 5 I Tuning Phase 5 Self explanatory Tuning Phase 4 I Tuning Phase 4 Self explanatory Tuning Phase 3 I Tuning Phase 3 Self explanatory Tuning Phase 2 I Tuning Phase 2 Self explanatory Tuning Phase 1...

  • Page 249: Configuration Tree Diagrams

    Configuration Tree Diagrams The following pages show the Configuration menu tree structures for each of the controllers: ECA06, ECA60, ECA600 and EMA60. The different tabulation levels indicate the different levels in the configuration tree. This means that all items on the same tabulation level are on the same tree level.

  • Page 250: A.1 Eca06 Configuration Tree

    A.1 ECA06 Configuration Tree Appendix A: Configuration Tree Diagrams A.1 ECA06 Configuration Tree Inputs Analog Inputs AI1–AI2 • Mode • RootExtraction • FilterTime • Alarm • Identity Analog In Com AIC1–AIC4 • Mode • Identity Digital Inputs • Mode •...
  • Page 251 Appendix A: Configuration Tree Diagrams A.1 ECA06 Configuration Tree Absolute Alarm 1 • Mode ⇒ Signal • LoLimit • HiLimit • LoLoLimit • HiHiLimit Control Parameters PID Parameters • • • • Offset Tuner • Mode • FirstStep • ControllerDynamics •...
  • Page 252 A.1 ECA06 Configuration Tree Appendix A: Configuration Tree Diagrams • Pulse Width • PulsePeriodFactor • Hysteresis Analog Out Com AOC1–AOC4 • Mode ⇒ Signal • Identity Digital Outputs DO1–DO2 • Mode ⇒ Signal • Identity Digital Out Com DOC1–DOC4 •...
  • Page 253 Appendix A: Configuration Tree Diagrams A.1 ECA06 Configuration Tree DisplayLanguage • Select • Edit • Password 493-0736-11 (6-2)

  • Page 254: A.2 Eca60 Configuration Tree

    A.2 ECA60 Configuration Tree Appendix A: Configuration Tree Diagrams A.2 ECA60 Configuration Tree Inputs Analog Inputs AI1–AI3 • Mode • RootExtraction • FilterTime • Alarm • Identity Analog In Com AIC1–AIC8 • Mode • Identity Analog User Blocks AU1–AU2 • Mode •...
  • Page 255 Appendix A: Configuration Tree Diagrams A.2 ECA60 Configuration Tree • Factor3 • Bias MulDiv • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒ Signal4 • Factor • Bias Logic Func Blocks FL01–FL02 • Type • Identity ⇒ Signal1 ⇒ Signal2 ⇒...
  • Page 256 A.2 ECA60 Configuration Tree Appendix A: Configuration Tree Diagrams ⇒ Signal3 ⇒ Signal4 Select • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒ Signal4 ⇒ LSBSignal ⇒ MSBSignal IncDec • Identity ⇒ IncSignal ⇒ DecSignal • Time ⇒ TrackSignal ⇒ TrackEnable •...
  • Page 257 Appendix A: Configuration Tree Diagrams A.2 ECA60 Configuration Tree Set Point Process Value ⇒ PVSignal Set Point ⇒ ESPSignal ⇒ ESPEnable ⇒ ESPLock • SPLimitMode (Off, On) • SPLoLimit • SPHiLimit • SPTrackMode Set Point Ramp • RampMode • Hold •...
  • Page 258 A.2 ECA60 Configuration Tree Appendix A: Configuration Tree Diagrams • • Offset Gain Scheduling • Mode ⇒ GainSchedulingSignal • Limit1 • Limit2 • Reset Feed Forward • Mode ⇒ FeedForwardSignal • Gain Tuner • Mode • FirstStep • ControllerDynamics • Reset Miscellaneous •...
  • Page 259 Appendix A: Configuration Tree Diagrams A.2 ECA60 Configuration Tree Outputs Functions • Type Analog ThreeStatePulse • DeadBand • Hysteresis • ActuatorPosTime • ActuatorMinPulseLen ⇒ FeedbackSignal TwoStatePulse • CycleTime Outputs Analog Outputs AO1–AO2 • Mode ⇒ Signal • MinCurrent • MaxCurrent •...
  • Page 260 A.2 ECA60 Configuration Tree Appendix A: Configuration Tree Diagrams • NumberOfDecimals • MinValue • MaxValue • Unit AltDisplay ⇒ Signal • NumberOfDecimals • MinValue • MaxValue • Unit • Bargraphs • LeftBargraphMode • CenterBargraphMode • RightBargraphMode • LeftBargraphAlarm System Status ⇒...

  • Page 261: Eca600 Configuration Tree

    Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree A.3 ECA600 Configuration Tree Inputs Analog Inputs AI1–AI5 • Mode • RootExtraction • FilterTime • Alarm • Loop • Identity Analog In Com AIC1–AIC12 • Mode • Identity Analog User Blocks AU1–AU8 •...
  • Page 262 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams • Factor2 • Factor3 • Bias MulDiv • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒ Signal4 • Factor • Bias • Identity ⇒ Signal • Factor • Power • Bias Comp •...
  • Page 263 Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree ⇒ Signal4 • Identity • Signal1 • Signal2 • Identity ⇒ ⇒ Reset • Identity ⇒ Signal Other Func Blocks FO01–FO16 • Type • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒...
  • Page 264 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams ⇒ TrackSignal ⇒ TrackEnable • LoLimit • HiLimit LevelDetector • Identity ⇒ Signal ⇒ LoLimitSignal ⇒ HiLimitSignal • LoLimit Value • HiLimitValue Linear • Identity ⇒ Signal • • Out1 • •...
  • Page 265 Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree ⇒ ResetSignal TimeMeasurement • Identity ⇒ Signal Timer • Identiy ⇒ Activate Timer • TimeUnit • TimerTime ⇒ ResetSignal Counter • Identity ⇒ Activate Counter • NbrOfPulses ⇒ ResetSignal Set Point PID1/Master Process Value ⇒...
  • Page 266 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams • Value5 PID2/Slave Process Value ⇒ PVSignal Set Point ⇒ ESPSignal ⇒ ESPEnable ⇒ ESPLock • SPLimitMode • SPLoLimit • SPHiLimit • SPTrackMode Set Point Ramp • RampMode • Hold • TimeUnit •...
  • Page 267 Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree • LoLoLimit • HiHiLimit Deviation Alarm Deviation Alarm 1 • Mode ⇒ Signal1 ⇒ Signal2 • NegDeviationLimit • PosDeviationLimit Deviation Alarm 2 • Mode ⇒ Signal1 ⇒ Signal2 • NegDeviationLimit • PosDeviationLimit Control •...
  • Page 268 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams Adapt • Mode • CriticalGain • CrititalPeriod • Reset Miscellaneous • ControllerAction • ESPStepBehavior • CLPM Output Configuration Manual ⇒ ManualEnable • ManualBehavior ⇒ DDCIncrease ⇒ DDCDecrease • DDCTime Tracking • TrackOneMode •...
  • Page 269 Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree • • • • Offset Gain Scheduling • Mode ⇒ GainSchedulingSignal • Limit1 • Limit2 • Reset Feed Forward • Mode ⇒ FeedForwardSignal • Gain • Reset Tuner • Mode • FirstStep •...
  • Page 270 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams • Mode ⇒ ForcedEnable • ForcedValue Miscellaneous • RestartBehavior • RestartValue • ErrorBehavior • ErrorValue • LimitMode • LoLimit • HiLimit Output Functions PID1/Master • Type Analog ThreeStatePulse • DeadBand • Hysteresis •...
  • Page 271 Appendix A: Configuration Tree Diagrams A.3 ECA600 Configuration Tree • MaxOut1 • MinIn2 • MaxIn2 • MinOut2 • MaxOut2 Outputs Analog Outputs AO1–AO3 • Mode ⇒ Signal • MinCurrent • MaxCurrent • FixedCurrent • Alarm • Loop • Identity Stiction Comp •...
  • Page 272 A.3 ECA600 Configuration Tree Appendix A: Configuration Tree Diagrams ⇒ AltDisplaySignal • Bargraphs • LeftBargraphMode • CenterBargraphMode • RightBargraphMode • LeftBargraphAlarm PID2/Slave Process Value • NumberOfDecimals • MinValue • MaxValue • Unit AltDisplay ⇒ Signal • NumberOfDecimals • MinValue • MaxValue •...

  • Page 273: Ema60 Configuration Tree

    Appendix A: Configuration Tree Diagrams A.4 EMA60 Configuration Tree A.4 EMA60 Configuration Tree Inputs Analog Inputs AI1–AI3 • Mode • RootExtraction • FilterTime • Alarm • Identity Analog In Com AIC1–AIC4 • Mode • Identity Analog User Blocks AU1–AU4 • Mode •...
  • Page 274 A.4 EMA60 Configuration Tree Appendix A: Configuration Tree Diagrams • Factor3 • Bias MulDiv • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒ Signal4 • Factor • Bias • Identity ⇒ Signal • Factor • Power • Bias Comp • Identity ⇒...
  • Page 275 Appendix A: Configuration Tree Diagrams A.4 EMA60 Configuration Tree • Signal1 • Signal2 • Identity ⇒ ⇒ Reset • Identity ⇒ Signal Other Func Blocks FO01–FO08 • Type • Identity ⇒ Signal1 ⇒ Signal2 ⇒ Signal3 ⇒ Signal4 • Identity ⇒...
  • Page 276 A.4 EMA60 Configuration Tree Appendix A: Configuration Tree Diagrams LevelDetector • Identity ⇒ Signal ⇒ LoLimitSignal ⇒ HiLimitSignal • LoLimit Value • HiLimitValue Linear • Identity ⇒ Signal • • Out1 • • Out2 • • Out3 • • Out4 •...
  • Page 277 Appendix A: Configuration Tree Diagrams A.4 EMA60 Configuration Tree Timer • Identity ⇒ ActivateTimer • TimeUnit • TimerTime ⇒ ResetSignal Counter • Identity ⇒ ActivateCounter ⇒ CountSignal • NbrOfPulses ⇒ ResetSignal Set Point Process Value ⇒ PVSignal Set Point Ramp •...
  • Page 278 A.4 EMA60 Configuration Tree Appendix A: Configuration Tree Diagrams • LoLimit • HiLimit • LoLoLimit • HiHiLimit Absolute Alarm 3 • Mode ⇒ Signal • LoLimit • HiLimit • LoLoLimit • HiHiLimit Deviation Alarms Deviation Alarm 1 • Mode ⇒ Signal1 ⇒...
  • Page 279 Appendix A: Configuration Tree Diagrams A.4 EMA60 Configuration Tree • RestartValue • ErrorBehavior • ErrorValue • LimitMode • LoLimit • HiLimit Outputs Analog Outputs • Mode ⇒ Signal • MinCurrent • MaxCurrent • Alarm • Identity Stiction Comp • Mode •...
  • Page 280 A.4 EMA60 Configuration Tree Appendix A: Configuration Tree Diagrams • Signal 2 ⇒ Signal • NumberOfDecimals • MinValue • MaxValue • Unit • CenterBargraphMode • CenterBargraphAlarm • Signal 3 ⇒ Signal • NumberOfDecimals • MinValue • MaxValue • Unit • RightBargraphMode •...

  • Page 281: Configuration Work Sheets

    Appendix A: Configuration Work Sheets Appendix A Configuration Work Sheets This appendix contains a Configuration Work Sheet for each controller to assist you in configuration planning. Make a photocopy of one of the default sheets and add the configuration required for the control application.

  • Page 282: Eca06, Default

    Appendix A: Configuration Work Sheets 493-0736-11 (6-2)

  • Page 283: Eca60, Default

    Appendix A: Configuration Work Sheets 493-0736-11 (6-2)

  • Page 284: Eca600, Default

    Appendix A: Configuration Work Sheets 493-0736-11 (6-2)

  • Page 285: Ema60 Default/Triple Ind

    Appendix A: Configuration Work Sheets 493-0736-11 (6-2)
  • Page 286 Appendix A: Configuration Work Sheets 493-0736-11 (6-2)

  • Page 287: E Communication

    Appendix A: Communication A.1 Communication setup Appendix A Communication This appendix describes how to establish ECA communication with a supervisory control system. A.1 Communication setup The information below facilitates the communication setup. • Serial communication interface RS485 (point to point or multidrop) or RS232 (point to point) is available.

  • Page 288: A.2 Protocol Description

    A.2 Protocol Description Appendix A: Communication Recommended max number of units per master system is 10 slaves. This is due to the response time when cyclically requesting information from all slaves. A.2 Protocol Description Modbus Communication Function Codes ECA can only work as a MODBUS slave and supports the following MODBUS function codes.

  • Page 289: Comli Communication

    Appendix A: Communication A.2 Protocol Description Code Name Illegal data address Illegal data value Examples of MODBUS Master Requests Here are some examples of read/write operations in a MODBUS Master system. The syntax is an example and differs between different master systems. Operation Syntax in Master Operation in ECA...
  • Page 290 A.2 Protocol Description Appendix A: Communication information. The basic format always starts with the STX (start of text) as shown, followed by bytes for: • The destination address • A stamp (indicating if the message is a retransmission) • The message type •...
  • Page 291 Appendix A: Communication A.2 Protocol Description The destination address would appear as: Message byte number 24=18H= Stamp – A character that changes value between message so that the slave station can determine if it is a retransmission. The first message after starting must have the value 30H.

  • Page 292: A.3 Communication Facilities

    A.3 Communication Facilities Appendix A: Communication 24=18H= Data Characters – This section of the message contains the transmitted characters specified by the Number of Characters. The value in the 16 bit registers are sent in two bytes. Byte 1 which is sent second is the data character with the lowest number.
  • Page 293 Appendix A: Communication A.3 Communication Facilities • Analog and digital signal values can be written to the controller. The signals must be connected via communications buffers of type AIC (Analog Input Communication) and DIC (Digital Input Communication). • All status bits, such as Alarm, Tuning phase, Auto/Manual mode, etc., can be read by a supervisory system.

  • Page 294: Changing Communication Mode

    A.3 Communication Facilities Appendix A: Communication Example The example below illustrates the interconnections for switching the controller setpoint from internal mode (ISP) to external mode (ESP) on command from the supervisory control system. The setpoint is then determined by the control system.

  • Page 295: Changing Loops

    Appendix A: Communication A.4 Front Panel Usage Changing Loops You can select loops by pressing the Next key until the display shows “Loop”, and then selecting the desired loop. A.4 Front Panel Usage If the Communication Mode is Local, the front panel is operable as usual. If the Communication Mode is Computer, the operator can inspect all posts in the list of operator choices.
  • Page 296 A.5 Communication Area Mapping Appendix A: Communication Variable Access Address Bit Position Errors Read 0058 0130 0088 AI5 Int AI4 Int AI3 Int AI2 Int AI1 Int AO3 Int AO2 Int AO1 Int Warnings Read 0060 0140 0096 AI5 Int AI4 Int AI3 Int AI2 Int...

  • Page 297: Register Map

    Appendix A: Communication A.5 Communication Area Mapping Note 2. For ‘Controller Action’, the value 0 (zero) denotes Reversed, and the value 1 (one) denotes Direct. The value 0 (zero) is also used for Unknown (Read only). Note 3. A supervisory system, e.g. SattGraph 5000, can conveniently increase or decrease the output value of the ECA controller by use of two bits in the variable Control 00D0 .
  • Page 298 A.5 Communication Area Mapping Appendix A: Communication Variable Access Register AOC1 Read AOC2 Read AOC3 Read AOC4 Read AOC5 Read AOC6 Read AOC7 Read AOC8 Read AOC9 Read AOC10 Read AOC11 Read AOC12 Read Control Signal of OC1 block Read/Write R29 Control Signal of OC2 block Read/Write R30 Read...
  • Page 299 Appendix A: Communication A.5 Communication Area Mapping Variable Access Register Sample Time Read Process Value of SP1block Read Set Point of SP1block Read Internal Set Point of SP1 block Read/Write R52 External Set Point of SP1 block Read Control Signal of OC1 block Read/Write R54 Process Value of SP2 block Read...

  • Page 300: Writing K

    A.5 Communication Area Mapping Appendix A: Communication Variable Access Register Limit1, Loop 1 Read/Write R112 Limit2, Loop 1 Read/Write R113 K1, Loop 2 Read/Write R128 TI1, Loop 2 (hi Read/Write R129 TI1, Loop 2 (lo Read/Write R130 TD1, Loop 2 (hi Read/Write R131 TD1, Loop 2 (lo Read/Write R132...

  • Page 301: Writing Ti And Td

    Appendix A: Communication A.5 Communication Area Mapping The registers only hold integer values. To be able to write and read K using communication, a simple conversion must be made: = K*100 COMLI which means that 1 ≤ K ≤ 10000 COMLI Example Send the value K1 = 0.87 to loop one.
  • Page 302 A.5 Communication Area Mapping Appendix A: Communication Procedure: 1. Convert the value in milliseconds into hexadecimal format: (2 600 = 0000 0A28 2. Split the hexadecimal value into two 16-bit words: (0000 and 0A28 3. Write the MSW (most significant word) to the first register of TD2... (Write 0000 , or 0 to R136)

  • Page 303: Special Modes

    Appendix B: Special Modes B.1 Total Reset Appendix B Special Modes Total Reset To reset all parameters in the configuration to factory default settings pressing the Cancel and Down keys simultaneously on the front panel of the controller when powering the unit up. 493-0736-11 (6-2)
  • Page 304 B.1 Total Reset Appendix B: Special Modes 493-0736-11 (6-2)

  • Page 305: Index

    Index AddSub Configuration Tree Diagrams Comp ECA60 Configuration AA Source off MulDiv Tree Absolute Alarm ECA600 Configuration Acknowledge Tree AU Source off Adapt warn Loop1 EMA60 Configuration Autotuning Adapt warn Loop2 Tree Adaptive control Configuration Work Sheet Control Block Bar graphs AI Source off Control Keys Output bar graph...
  • Page 306 Index Digital User Communications signal EMA60 wiring Display Other Function Blocks Electrical Delay gasket DO overload IncDec I/O Signal Wiring Level Detector In an Electrically Noisy DOC (Digital Output Com- Linear munication) Environment IP65 DU Source off Rate Limiter Mounting Plates Select Panel Cutout Engineering Units...
  • Page 307 Index Sample Time Sample Time Error SattGraph 5000 Set Point Block Slave SP Source off Special Modes Status signals Supervisory control system System Block Technical Data Test Mode Total Reset Tracking True Manual Tune abort Loop1 Tune abort Loop2 Tune PVNoise Loop1 Tune PVNoise Loop2 Tuner Tuning Init...
  • Page 308 Index 493-0736-11 (6-2)
  • Page 310 ABB Automation Technology Products AB Instrumentation SE-191 85 Sollentuna, Sweden Phone: +46 8 658 80 00 Fax: +46 8 658 80 21 e-mail: instrumentation@se.abb.com www.abb.se 493-0736-11 Specifications subject to change without notice. 0230 Printed in Sweden. © 2000 ABB Automation Technology Products AB.

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