PID Controllers from Precision Digital
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The Nova PD540 series process and temperature controllers offer high accuracy with features such as auto-tuning PID, universal inputs, and multiple relay configurations for diverse applications. They support digital input set point selection and serial communication via RS-485, which can connect up to 30 controllers for monitoring and control. Additionally, these controllers are available in various DIN sizes and include a 3-year warranty.
PID Controllers from Precision Digital
- 1. Process & TEMPERATURE Controllers • Thermocouple, RTD, & Process Inputs • High Accuracy Auto-Tuning PID • Heating & Cooling Models • Universal Power Supply 100-240 VAC • Up to 3 Relays & 2 Analog Outputs • Digital Input Set Point Selection • RS-485 Serial Communications Option • Modbus® RTU/ASCII Communications • Free Operating & Data Logging Software • IP55 & IP65 Fronts • 1/16, 3/16, 1/8, 1/4 DIN Sizes • 3 Year Warranty NOVA PD540 Series Precision Digital Corporation www.predig.com
- 2. NOVA PD540 Series process & temperature controllers 2 Custom Operating Displays The Nova Digital Controller has dual four-digit LEDs and can display commonly used setup parameters defined by the user. All programming of a Nova Digital Controller is done through the front panel. No switches or jumpers are required. Front Panel Buttons Operating Display Navigation To access additional display information without the need to enter the setup menus, simply press the SET/ENT button. Main Operating Display • PV window displays process variable • SP window displays set point • Press the SET/ENT button to move to the next display window Percent Output Display • PV window displays process variable • SP window displays the operating level of the control outputs as % of full scale • Press the SET/ENT button to move to the next display window User Defined Display 1 • Display any setup parameter • Parameters are fully functional, and can be set through this display • Set by the user with parameter US1 • Press the SET/ENT button to move to the next display window User Defined Display 2 • Display any setup parameter • Parameters are fully functional, and can be set through this display • Set by the user with parameter US2 • Press the SET/ENT button to return to the main operating display Easy Setup & Programming • Press the SET/ENT button to confirm an entered value. Hold the button for 3 seconds to enter or exit the setup groups. Press the SET/ENT button to access the next parameter when in a setup group. • Press the Up arrow button to increase numerical values or scroll through parameter options and group menus. • Press the Down arrow button to decrease numerical values or scroll through parameter options and group menus. • Press the LEFT arrow button to move to the next digit during numerical value programming. Setup Group Menus For easy setup parameter navigation, all parameters are grouped by category. To access the group menus, press and hold the SET/ENT button for 3 seconds. Navigate through the group menus using the UP or DOWN arrow buttons as shown. To enter a group menu to access setup parameters, press the SET/ENT button. Button PV Display Group Definition q G.AT Auto-Tuning Group pq G.SP Set Point Group pq G.PID P.I.D. Group ENT PwD Password pq G.CTL Control Group pq G.IN Input Group pq G.oUT Output Group pq G.ALm Alarm Group pq G.RET Retransmission Group pq G.Com* Communications Group* Menu Password To prevent unauthorized changes to key parameters, a user defined lockout password must be entered to access the group menus that are not commonly used during operation. Enter the password at the prompt when navigating the group menus by pressing the SET/ENT button. The default password is 0. *This group menu appears only on models with the serial communications option. G.PID G.CTL R-S SPSL SP1 SP2 D.SLP G.SPG.AT SET/ENT SET/ENT SET/ENT SET/ENT SET/ENT SET/ENT P Du~ ENT Easy to Use Menu Structure Each parameter is located in an associated menu group. • Hold the SET/ENT button for 3 seconds to enter the group menu • Select the menu group using the p and q buttons • Press SET/ENT to access the parameters in the group • Set the value for the parameter, and press SET/ENT to select the next parameter • Hold the SET/ENT button for 3 seconds to return to the operating display For a complete list of setup parameters, their functions, and setting options, refer to the PD540 Series Instruction Manual.
- 3. NOVA PD540 Series process & temperature controllers 3 Input Bias Adjustment Up to five bias points can be used to provide precise offset adjustments at specific input values. The controller will use the offset to create a smooth input value curve leading up to the bias points. On/Off Timers The start timer delays control output operation from power- up. The process timer determines how long the control outputs will run after starting. These timers may run up to 99 hours 59 minutes, or be turned off. Digital Input Set Point Selection Two digital inputs can be added as an optional feature. Digital inputs are activated by closing contacts or low logic levels. The configuration of the two inputs can select which of the 4 programmable set points to run or turn the control outputs on and off while selecting one of two programmable set points. Serial Communications & Adapters Nova controllers with the serial communications option can be used for data acquisition, master/slave set point control, or Modbus communication (RTU and ASCII). Nova controllers transmit via RS-485. The PDA7485 RS-232 to RS-485 and PDA8485 USB to RS-485 converters are available for use with the Nova Multi-Monitoring software or other PC applications. PDA7485 Process & Temperature Inputs Nova Controllers use a single universal input that accepts process and temperature inputs. Thermocouple: J, K, T, E, R, B, S, L, N, U, W, Platinel II RTD: Pt100 (0.00385), JPt100 (0.00392) Process: -10 to 20 mV, 0 to 100 mV 0.4 to 2 V, 1 to 5 V, 0 to 10 V 4 to 20 mA input with a resistor shunt VERSATILE OPERATION Powerful standard and optional features such as universal inputs, up to three relays and two analog outputs, two digital inputs, and serial communications make this controller applicable for most process or temperature control applications. Programmable Relays All PD540 Series controllers have a standard 3 A Form C (SPDT) relay. Up to two additional 1 A Form A (SPST) relays. All relays can be programmed for numerous control or alarm functions. • Time-Proportional PID Control • On/Off Control • High/Low Alarms • Set Point Deviation Alarms • Fail-Safe and Standby Alarms • Alarm Delays and Deadbands Analog Output Configurations Up to two analog outputs are available on all PD540 Series controllers. Each analog output can be programmed independently, and numerous output types are selectable. • 4-20 mA PID Control • 4-20 mA Retransmitting • Time-Proportional PID Voltage Pulse • Transmitter Loop Power Supply Auto-Tuning PID A high accuracy auto-tuning function using Fuzzy Logic calculates the PID values for your system with the push of a button, eliminating the need for complex PID calculations and time consuming setup. After several on/off cycles, the PID values will be setup automatically. Gain Adjustment Adjustments to system control characteristics can be done after auto-tuning with the programmable Gain function. Increasing the Gain will increase accuracy and reduce overshoot. Lowering the Gain will let the system reach the set point faster. Gain < 1 Gain = 1 Gain > 1 PV Reactions to SP Change Based on Gain PDA8485 STOP RUN STOP Start Time Process Time POWER ON u DI Selection Normally open switches (external excitation not required) or open collector transistor Input 1 Input 2 Function
- 4. NOVA PD540 Series process & temperature controllers 4 Sync Master/Slave Set Point Control PD540 Series Digital Controllers with the serial communications option can use Sync set point control. By connecting controllers together using the RS-485 serial communication capability, one controller can control the set point of an entire string. RS-485 Sync Master Slave 1 Slave 4Slave 3Slave 2 Changing the set point of the Sync Master controller will change the set points on all Sync Slave controllers. Nova PC Software Any Nova Controller with the serial communications option can be configured to interface with the Nova Multi-Monitoring PC software. Up to 30 controllers can be monitored and operated, and each can use independent data logging. • Easy to Set Up and Use • Connect up to 30 Nova Controllers • View PV, SP, and Alarm Status Simultaneously • Control Set Points • Log, View, and Save Data in Spreadsheet Files • Free Download from www.predig.com Specifications System Requirements: Windows® 9598ME2000XP Communications: An RS-232 to RS-485 or USB to RS-485 converter may be used for communication with a PC and Nova Multi-Monitoring Software. Number of Units: Up to 30 Nova Controllers Baud Rate: 9,600 to 19,200 bps Data Logging: Graph and save data as .hdr format. Each controller saves graphs independently. Data exportable in spreadsheet format. Logging Interval: 1 second to 24 hours Simultaneous Monitoring Simultaneously monitor up to 30 Nova Controllers and view the PV, SP, and alarm status for all connected controllers. The main view screen also displays the basic model numbers of all connected units. Any series of Nova Controllers with the serial communications option may be monitored with this software. Simultaneously View Up to 30 Nova Controllers Remotely Control Set Points Program each of the 4 set points through a detailed operation screen available for every connected controller. In addition, control outputs can be set to run or stop, auto tuning enabled, and automatic or manual control established. Data Acquisition PV and SP data can be logged independently for each unit. This data can be graphed using the Data Viewer for quick and clear analysis. Logged data can be exported into spreadsheet format. Monitor and Control Common Parameters View Logged Data Graphs and Export Data
- 5. NOVA PD540 Series process & temperature controllers 5 CONNECTIONS NO switches (external excitation not required) or open collector transistor Open circuit voltage: approximately 5 VDC Logic levels: LO = 0 to 0.8 VDC HI = 4.7 to 28 VDC MAX: 19200bps Rating: 250 VAC @ 3 A 30 VDC @ 3 A 100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A 4-20 mADC or Voltage Pulse - - 12345678910 11121314151617181920 NO switches (external excitation not required) or open collector transistor Open circuit voltage: approximately 5 VDC Logic levels: LO = 0 to 0.8 VDC HI = 4.7 to 28 VDC MAX: 19200bps Rating: 250 VAC @ 3 A 30 VDC @ 3 A 100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A Rating: 250 VAC @ 1 A 30 VDC @ 1 A PD542 & PD543 PD540 & PD541
- 6. NOVA PD540 Series process & temperature controllers 6 PD546 & PD547 PD544 & PD545 NO switches (external excitation not required) or open collector transistor Open circuit voltage: approximately 5 VDC Logic levels: LO = 0 to 0.8 VDC HI = 4.7 to 28 VDC MAX: 19200bps Rating: 250 VAC @ 3 A 30 VDC @ 3 A 100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A - NO switches (external excitation not required) or open collector transistor Open circuit voltage: approximately 5 VDC Logic levels: LO = 0 to 0.8 VDC HI = 4.7 to 28 VDC MAX: 19200bps Rating: 250 VAC @ 3 A 30 VDC @ 3 A 100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A Rating: 250 VAC @ 1 A 30 VDC @ 1 A -
- 7. NOVA PD540 Series process & temperature controllers 7 PD548 & PD549 NO switches (external excitation not required) or open collector transistor Open circuit voltage: approximately 5 VDC Logic levels: LO = 0 to 0.8 VDC HI = 4.7 to 28 VDC MAX: 19200bps Rating: 250 VAC @ 3 A 30 VDC @ 3 A 100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A 30 VDC @ 1 A Rating: 250 VAC @ 1 A 30 VDC @ 1 A - 0 - 6 R A - 0 0P D 5 4 Size - DIN Cutout 0, 1 = 1/16 DIN 2, 3 = 1/8 DIN (H) 4, 5 = 3/16 DIN 6, 7 = 1/8 DIN (V) 8, 9 = 1/4 DIN Power 6 = 100-240 VAC Display R = Red LED Digital Controller Main Control Outputs PD540, PD541, PD544, PD545: A = 1 relay & 1 analog output PD542, PD543, PD546 to PD549: B = 1 relay & 2 analog outputs Notes: 0, 2, 4, 6, 8 = Heating or Cooling 1, 3, 5, 7, 9 = Heating & Cooling Options 00 = None PD540, PD541: 11 = 1 relay & 2 digital inputs 14 = 1 relay & RS-485 31 = 1 analog output & 2 digital inputs 34 = 1 analog output & RS-485 PD544, PD545: 04 = RS-485 51 = 2 relays, 1 analog output & 2 digital inputs 54 = 2 relays, 1 analog output & RS-485 PD542, PD543, PD546 to PD549: 21 = 2 relays & 2 digital inputs 24 = 2 relays & RS-485 Model Number Guide The following guide describes the possible PD540 Series Nova Digital Process & Temperature Controller model numbers. Refer to the price list for the complete list of models and accessories.
- 8. NOVA PD540 Series process & temperature controllers 8 Dimensions and Panel Cutouts 1.89 1.89 0.43 3.92 2.17 1.76x1.76 2.76 2.76 1.77 1.77 1.89 x N 1.77 (48) (55.2) (44.8x44.8) (70) (45 )+0.6 0 (45)+0.6 0 (48) (10.9) (99.6) (70) (45)+0.6 0 (48xN-3 )+2 0 3.78 1.89 3.92.45 1.76x3.61 3.62 1.77 4.72 2.76 (48) (44.6x91.6) (45)+0.6 0 (70) (96) (99.6)(11.4) (120) (92 )+0.6 0 2.83 2.83 0.45 3.92 2.65x2.65 2.68 2.68 3.54 3.54 2.68 2.80xN (72) (67.2x67.2) (90) (68)+0.6 0 (68)+0.6 0 (72) (11.4) (99.6) (90) (68 )+0.6 0 (71xN-3 )+2 0 1.89 3.78 4.23 3.61x1.76 0.45 3.92 1.77 2.76 4.72 3.62 1.89xN 3.62 (96) (107.5) (91.6x44.6) (120) (92)+0.6 0 (92)+0.6 0 (48) (11.4) (99.6) (70) (45 )+0.6 0 (48xN-3 )+2 0 (92)+0.6 0 3.78 0.45 3.92 3.78 4.23 3.61x3.61 4.72 4.72 3.62 3.62 3.78xN 3.62 (96) (107.5) (91.6x91.6) (120) (92)+0.6 0 (92 )+0.6 0 (96xN-4 )+0.2 0 (120) (99.6)(11.4)(96) inches (mm) Units: PD540 & PD541 1/16 DIN (48 x 48) PD548 & PD549 1/4 DIN (96 x 96) PD546 & PD547 1/8 DIN (V) (48 x 96) PD544 & PD545 3/16 DIN (72 x 72) PD542 & PD543 1/8 DIN (H) (96 x 48)
- 9. NOVA PD540 Series process & temperature controllers www.predig.com Precision Digital Corporation 233 South Street • Hopkinton MA 01748 USA • Tel (800) 343-1001 • Fax (508) 655-8990 LDS540_D 12/15 SPECIFICATIONS Except where noted all specifications apply to operation at +25°C. General Display: Dual 4 digits, red LED, -1999 to 9999 DIN Sizes PV Display Inch (mm) SP Display Inch (mm) Weight oz (g) 1/16 0.45 (11.3) 0.37 (9.5) 7.0 (198) 3/16 0.55 (14.0) 0.47 (12.0) 11.4 (324) 1/8 (H) 0.78 (19.8) 0.45 (11.5) 10.8 (306) 1/8 (V) 0.54 (13.6) 0.41 (10.5) 10.7 (304) 1/4 0.81 (20.5) 0.43 (11.0) 13.7 (389) Front Panel: Panel gasket provided. 1/16 & 1/8 DIN: IP65, 3/16 & 1/4 DIN: IP55 Programming Methods: Four front panel buttons and Modbus Number of Set Points: Four programmable set points Noise Filter: Programmable 1 to 120 seconds or off Display Update Rate: 4/second Password: Restricts modification of programmed settings. Non-Volatile Memory: Settings stored for a minimum of 10 years. Power: 100-240 VAC, 50/60 Hz, 10 W Required Fuse: UL Recognized, 1 A, 250 V, slow-blow Isolation: 2300 V input/output-to-power line; 4 kV relay output-to-input/ output/power line. Operating Temperature: 10 to 50°C Storage Temperature: -40 to 85°C Relative Humidity: 20 to 90% non-condensing Enclosure: 1/16, 3/16, 1/8(H), 1/8(V), 1/4 DIN; impact-resistant plastic; color: black Approvals: UL & C-UL Recognized, CE Compliant UL File Number: E244207; Process Control Equipment Warranty: 3 years parts & labor Extended Warranty: 1 or 2 years, refer to Price List for details. Temperature Inputs Inputs: Factory calibrated, field selectable: J, K, T, E, B, R, S, L, U, N, W, Platinel II thermocouples, and 100 Ω platinum RTD (0.00385 or 0.00392 curve) Cold Junction Reference: Automatic or off Offset Adjustment: Four programmable input bias zones Sensor Break: Up or down scale, user selectable; display reads S.OPN; alarm relays will follow the up or down scale selection. Type Range (ºC) Range (ºF) Accuracy* Thermocouple K1 -200 to 1370 -300 to 2500 >0ºC: ±0.1% FS ±1 count <0ºC: ±0.2% FS ±1 count K2 -199.9 to 999.9 0 to 2300 J -199.9 to 999.9 -300 to 2300 T -199.9 to 400.0 -300 to 750 E -199.9 to 999.9 -300 to 1800 B 0 to 1800 32 to 3300 >400ºC: ±0.15% FS ±1 count <400ºC: ±5% FS ±1 count R 0 to 1700 32 to 3100 ±0.15% FS ±1 count S 0 to 1700 32 to 3100 L -199.9 to 900.0 -300 to 1600 >0ºC: ±0.1% FS ±1 count <0ºC: ±0.2% FS ±1 countU -199.9 to 400.0 -300 to 750 N -200 to 1300 -300 to 2400 >0ºC: ±0.1% FS ±1 count <0ºC: ±0.25% FS ±1 count W 0 to 2300 32 to 4200 ±0.2% FS ±1 count Platinel II 0 to 1390 32 to 2500 ±0.1% FS ±1 count RTD PtA -199.9 to 850.0 -300 to 1560 ±0.1% FS ±1 count PtB -199.9 to 500.0 -199.9 to 999.9 PtC -19.99 to 99.99 -4.0 to 212.0 ±0.2% FS ±1 count JPtA -199.9 to 500.0 -199.9 to 999.9 ±0.1% FS ±1 count JPtB -150.0 to 150.0 -199.9 to 300.0 Process Inputs Inputs: Field selectable: 0.4 to 2.0 V, 1 to 5 V, 0 to 10 V, -10 to 20 mV, 0 to 100 mV. 4-20 mA input requires 100 Ω resistor connected across input terminals (order P/N: PDX-RES1). Accuracy: ±0.1% FS ±1 count Decimal Point: Up to 3 decimals: 9.999, 99.99, 999.9, or 9999 Calibration: All inputs are calibrated at the factory Scale Range: User programmable over entire range Transmitter Supply: 14 to 18 VDC @ 20 mA; available at terminals OUT2 or OUT3, instead of retransmitting analog output; selection through front panel. Relays Ratings: 1 Form C (SPDT) standard; rated 3 A @ 30 VDC or 3 A @ 250 VAC resistive load. 1 or 2 Form A (SPST) optional; rated 1 A @ 30 VDC or 1 A @ 250 VAC resistive load. Relay Operation: Time proportional PID control, on/off control, forward or reverse (fail-safe) alarm, or run status Cycle Time: 1 to 300 seconds; time proportional PID control only On/Off Hysteresis: For standard models, 0-10.0% of sensor range for independent high and low hysteresis limit. For heating & cooling models, 0-10.0% of sensor range full hysteresis band. High/Low Alarm: User may program any alarm for absolute high or low trigger values. Deviation Alarm: User may program any relay for high, low, or high/low range set point deviation alarm. Alarm Deadband: 0-100% FS, user selectable Alarm Delay: 0 to 99 minutes and 59 seconds Reverse Operation (Fail-Safe): Programmable, independent for each alarm. Relay coils are energized in non-alarm condition. In case of power failure, relays will go to alarm state. Forward Operation: Relay coils are energized in alarm condition. In case of power failure, relays will go to non-alarm state. Auto Alarm Initialization: Normal and standby operation independent for each alarm. Normal alarms will reflect the state of the input to the controller at all times. Standby alarms will not trigger if the change to alarm state is a result of power up cycle, set point change, or alarm configuration change. Run Status: Relays will energize when PID outputs are running. Analog Outputs Scaling Range: Retransmitting 4-20 mA outputs can be scaled for any display range. Accuracy: ±0.1% FS Availability: 1/16 & 3/16 DIN: 1 standard, 1 optional 1/8 & 1/4 DIN: 2 standard Output Operation: 4-20 mA PID control, time proportional voltage pulse PID control, or 4-20 mA retransmitting Ratings: Continuous 4-20 mA PID or retransmitting: 600 Ω max Time Proportional PID: 15 VDC pulse high, less than 0.1 VDC pulse low; 600 Ω minimum, current limited at 30 mA Cycle Time: 1 to 300 seconds; time proportional PID control only Power: Internally powered 4-20 mA output Isolation: 500 V input-to-output Output Loop Resistance: 600 Ω max Digital Inputs Configuration: Two contacts, two operating modes Contacts: Normally open switches (external excitation not required) or open collector transistor Open Circuit Voltage: Approximately 5 VDC Logic Levels: LO = 0 to 0.8 VDC, HI = 4.7 to 28 VDC Operation Modes: Mode 1: Control output run or stop, selection of set point 1 or 2. Mode 2: Selection of set points 1 to 4. Serial Communications Compatibility: EIA-485 Protocol: PC, Modbus (ASCII, RTU), Sync (Master/Slave SP Control) Address: 1 to 99 (Max 31 units connected) Baud Rate: 600 to 19,200 bps Transmit Time Delay: 0 to 100 ms Data: 7 or 8 bit, automatic when using Modbus protocol Stop Bit: 1 or 2 Parity: None, even, or odd