T2750 Eurotherm PAC

User Guide
Firmware V6/0
HA030047 Issue 16
Date: 06/2020
T2750 Eurotherm PAC

Associated Documents
HA082375U003 LIN Blocks reference manual
HA082429 ELIN User guide
HA028014 Communications manual
HA028988 Modbus tools help manual (printable version of the on-line
Modbus tools help system)
HA029881 Store and Forward user guide
HA263001U055 LIN Help manual (printable version of the on-line LINtools
help system)
HA030272 PAC Systems alarm suppression user guide
HA030511 Raw Comms user guide
HA033151 File Synchronisation User Guide
HA033194 Batch and Recipe on T2750
Information is also to be found in the help systems associated with the various
software tools used with the product.

Software Effectivity
This manual relates to units with software version 5/0.

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 T2750 Eurotherm PAC

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T2750 Eurotherm PAC Table of Contents

Table of Contents
Table of Contents ........................................................................... 5
Safety Notes ................................................................................ 11
I/O Isolation Strategy........................................................................................ 12
EMC ................................................................................................................. 12
Symbols Used on the Instrument Labelling...................................................... 13
I/O Isolation Strategy........................................................................................ 13
Cybersecurity ............................................................................... 15
What's in this Chapter ...................................................................................... 15
Introduction ...................................................................................................... 15
Secure Network Topologies and Good Practices............................................. 15
Security Features ............................................................................................. 15
Instrument Password ................................................................................. 15
Whitelisting PCs and File Types ................................................................ 15
Legacy Mode ............................................................................................. 16
Principle of Secure by Default.................................................................... 16
Ethernet Security Features ........................................................................ 16
Configuration Backup and Recovery ......................................................... 17
Memory Integrity .............................................................................................. 17
Firmware .......................................................................................................... 17
Achilles® Communications Certification .................................................... 17
Decommissioning....................................................................................... 17
Introduction .................................................................................. 19
Physical Structure ............................................................................................ 19
Modules Available ............................................................................................ 19
Features ........................................................................................................... 20
LIN Communication ................................................................................... 20
ELIN Communication ................................................................................. 20
Profibus Master Communication................................................................ 20
Redundant Working ................................................................................... 20
Battery Backup........................................................................................... 21
Configuration.............................................................................................. 21
Data Recording .......................................................................................... 22
Store and Forward Software ...................................................................... 22
Time Localisation Support.......................................................................... 22
Health Monitoring....................................................................................... 23
Watchdog ................................................................................................... 23
IP (Intellectual Property) Protection ........................................................... 23
Front Panel Indicators................................................................................ 23
Installation .................................................................................... 25
Unpacking the Instrument ................................................................................ 25
Mechanical Installation..................................................................................... 25
Base Unit Mounting.................................................................................... 27
Terminal Unit Installation............................................................................ 28
Module Installation ..................................................................................... 28
Module Identification .................................................................................. 29
Installing the Optional netHOST Gateways ............................................... 30
Electrical Installation .................................................................................. 31
Controller Module (IOC) Terminal Unit ....................................................... 31
Two-channel Analogue Input (AI2)............................................................. 35
Three-channel Analogue Input (AI3) .......................................................... 37
Four-channel Analogue Input (AI4) ............................................................ 39
High Density Analogue Input (AI8)............................................................. 40
Two-channel Analogue Output (AO2) ........................................................ 42
Four-channel Digital Input (DI4)................................................................. 43

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Six-channel Digital Input Module (DI6) ...................................................... 44

Eight-channel Digital Input Module (DI8) ................................................... 45
16-Channel Digital Input Module (DI16)..................................................... 46
Four-channel Digital Output Module (DO4) ............................................... 47
Eight-channel Digital Output Module (DO8)............................................... 48
16-channel Digital Output Module (DO16)................................................. 50
Two-channel Frequency Input Module (FI2) .............................................. 51
Four Output Relay Module (RLY4)............................................................. 53
Eight Output Relay Module (RLY8) ............................................................ 55
Zirconia Input Module (ZI).......................................................................... 56
netHOST Profibus Master Gateway........................................................... 57
Hardware Configuration ................................................................................... 59
LIN Address ............................................................................................... 59
LIN Option Switch ...................................................................................... 60
IP Address Setting ..................................................................................... 60
USB Configuration ..................................................................................... 70
netHOST Profibus Master Configuration ................................................... 70
Operator Interface ........................................................................ 75
Introduction ...................................................................................................... 75
LED Interpretation...................................................................................... 75
Switches..................................................................................................... 76
Start-up ........................................................................................ 79
Redundancy Modes ......................................................................................... 79
Start-up Modes................................................................................................. 79
Hot Start..................................................................................................... 79
Cold Start ................................................................................................... 79
Hot/Cold Start ............................................................................................ 81
Startup Flowchart....................................................................................... 82
Starting the IOC Modules................................................................................. 83
Start-up Routine......................................................................................... 83
Power-up Decisions ................................................................................... 84
Autosynchronisation................................................................................... 87
ELIN Communication Modes ........................................................................... 88
Configuration ................................................................................ 89
Automatic I/O Build and Configuration Tools.................................................... 89
Automatic I/O Build .......................................................................................... 89
Preparing for the Automatic I/O Build......................................................... 90
LINtools ............................................................................................................ 91
Starting LINtools ........................................................................................ 92
MODBUS Tools ................................................................................................ 94
Introduction ................................................................................................ 94
Running Modbus Tools .............................................................................. 94
Configuring Modbus-TCP Slave Communications..................................... 95
Profibus Configuration...................................................................................... 96
Introduction ................................................................................................ 96
Launching the Profibus Master Configurator ............................................. 96
Control Loops ............................................................................. 101
Introduction .................................................................................................... 101
Temperature Control Loop Example ........................................................ 101
Loop PID Function Block ......................................................................... 102
Main Page................................................................................................ 102
Set Up Tab ............................................................................................... 105
Tuning Tab ............................................................................................... 108
PID Tab .....................................................................................................118
SP Tab...................................................................................................... 122
OP Tab ..................................................................................................... 125
Diag Tab................................................................................................... 131
Alarms Tab ............................................................................................... 132
Effect of Control Action, Hysteresis and Deadband ....................................... 133

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Control Action........................................................................................... 133

Hysteresis ................................................................................................ 133
Task Organisation ...................................................................... 135
Task Scheduling ............................................................................................. 135
Tasks........................................................................................................ 135
Priorities ................................................................................................... 135
Functions ................................................................................................. 135
User Tasks ..................................................................................................... 138
Terminology.............................................................................................. 138
Execution Times....................................................................................... 138
User Task Block Servers .......................................................................... 139
User Task Tuning ........................................................................................... 141
Usertask Block ......................................................................................... 141
Data Coherence ............................................................................................. 142
Data Flow Between Tasks........................................................................ 142
Event and Health Logs ............................................................... 145
Health Log...................................................................................................... 145
Event Log ....................................................................................................... 145
Status....................................................................................................... 146
Data Management ..................................................................... 147
Data Recording .............................................................................................. 147
Data Recording (*.uhh) File ..................................................................... 147
Data Recording Groups ........................................................................... 147
Data Archiving ................................................................................................ 147
File Transfer Protocol (FTP)..................................................................... 148
Data Management Configuration ................................................................... 148
Setpoint Programmer ................................................................. 151
Program Template Creation ........................................................................... 151
Template Creation.................................................................................... 151
Program Editor ............................................................................................... 154
Introduction .............................................................................................. 154
Editing Procedure .................................................................................... 156
Recipe Management .................................................................. 159
Batch Processing ....................................................................... 161
Error Conditions and Diagnostics .............................................. 163
Error Indication Types .................................................................................... 163
LED Displays.................................................................................................. 163
Instrument Failure Modes ........................................................................ 163
Power Failure........................................................................................... 164
Watchdog Failure ..................................................................................... 164
ICM Failure .............................................................................................. 164
LIN Failure ............................................................................................... 165
Decoupled Instruments ............................................................................ 166
Desynchronisation ................................................................................... 166
Power-up Failure............................................................................................ 167
Start-up Routine....................................................................................... 167
Power On Self Tests (POSTs) ........................................................................ 167
POST Failure LED Patterns ..................................................................... 168
SD Card Failure Detection ............................................................................. 168
Diagnostics Blocks ......................................................................................... 169
netHOST PROFIBUS Master Troubleshooting .............................................. 170
netHOST Fault Scenarios .............................................................................. 171
Fault Scenario 1: Ethernet Break between Primary’s T2750 and netHOST ..
171
Fault Scenario 2: Total failure of Primary’s netHOST............................... 172
Fault Scenario 3: Ethernet break between Secondary’s T2750 and netHOST
172

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Fault Scenario 4: Total failure of Secondary’s netHOST.......................... 173

Fault Scenario 5: Profibus break at Primary’s netHOST.......................... 173
Fault Scenario 6: Profibus Break at Secondary’s netHOST .................... 174
Fault Scenario 7: Profibus break in the middle of the Profibus network .. 174
Fault Scenario 8: Profibus Failure of All Slaves ....................................... 174
Service ....................................................................................... 177
Preventive Maintenance Schedule................................................................. 177
Replacement Procedures............................................................................... 177
Software/Firmware Upgrade .................................................................... 177
Live IOC Module Replacement ................................................................ 181
Appendix A Specification ............................................................ 183
A1 Installation Category and Pollution Degree .............................................. 183
A2 General Specification................................................................................ 183
A3 IOC Specification ...................................................................................... 184
A3.1 Terminal Unit.................................................................................... 184
A3.2 IOC Module ..................................................................................... 185
A3.2.1 Hardware ................................................................................ 185
A3.2.2 Software ................................................................................. 185
A4 I/O Module Specifications ......................................................................... 187
A4.1 AI2 Module....................................................................................... 187
A4.1.1 Thermocouple Input Variant ................................................... 187
A4.1.2 DC Input Variant ..................................................................... 187
A4.1.3 mA Input Variant ..................................................................... 189
A4.2 AI3 Module....................................................................................... 189
A4.3 AI4 Module....................................................................................... 190
A4.3.1 Thermocouple Input Variant ................................................... 190
A4.3.2 mV Input Variant ..................................................................... 190
A4.3.3 mA Input Variant ..................................................................... 191
A4.4 AI8 Module....................................................................................... 191
A4.4.1 mV Input Variant ..................................................................... 191
A4.4.2 Thermocouple Input Variant ................................................... 191
A4.4.3 mA Input Variant ..................................................................... 192
A4.4.4 RTD Input Variant ................................................................... 192
A4.5 AO2 Module..................................................................................... 192
A4.6 DI4 Module ...................................................................................... 193
A4.7 DI6 Module ...................................................................................... 193
A4.7.1 115V ac Input Variant ............................................................. 193
A4.7.2 230V ac Input Variant ............................................................. 194
A4.8 DI8 Module ...................................................................................... 194
A4.8.1 Logic Input Variant.................................................................. 194
A4.8.2 Contact Closure Input Variant................................................. 194
A4.9 DI16 Module .................................................................................... 195
A4.10 DO4 Module .................................................................................. 195
A4.11 DO8 Module................................................................................... 196
A4.12 DO16 Module ................................................................................ 196
A4.13 FI2 Module..................................................................................... 196
A4.14 RLY4 Module ................................................................................. 198
A4.15 RLY8 Module ................................................................................. 199
A4.16 ZI Module....................................................................................... 199
A4.17 netHOST Profibus Master Gateway .............................................. 200
A5 LIN Blocks Supported ............................................................................... 201
A5.1 Batch Blocks.................................................................................... 201
A5.2 Communications Blocks .................................................................. 201
A5.3 Condition ......................................................................................... 201
A5.4 Configuration Blocks........................................................................ 201
A5.5 Control Blocks ................................................................................. 201
A5.6 Convert Blocks ................................................................................ 202
A5.7 Diagnostics Blocks .......................................................................... 202
A5.8 IO Blocks ......................................................................................... 203
A5.9 Logic Blocks .................................................................................... 203
A5.10 Maths Blocks ................................................................................. 203

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A5.11 Organise Blocks............................................................................. 203

A5.12 Programmer Blocks ....................................................................... 203
A5.13 Recorder Blocks ............................................................................ 204
A5.14 Selector Blocks.............................................................................. 204
A5.15 Timing Blocks ................................................................................ 204
Appendix B Reference ............................................................... 205
B1 Frequency Input Module Details ............................................................... 205
B1.1 Terminal Connections, Links and Status LEDs................................ 205
B1.2 Specification .................................................................................... 205
B1.3 Application Details ........................................................................... 205
B1.3.1 Cable Selection ...................................................................... 205
B1.3.2 Cable Shield Connection ........................................................ 206
B1.3.3 Choosing the Appropriate Output Sensor Type ...................... 206
B1.3.4 FI2 General and LinTools Configuration ................................. 209
B1.4 Isolation Diagram............................................................................. 210
B1.5 Equivalent Circuits........................................................................... 210
B1.5.1 Magnetic Inputs ...................................................................... 210
B1.5.2 Voltage Inputs..........................................................................211
B1.5.3 Current Inputs..........................................................................211
B1.5.4 Contact Inputs ........................................................................ 212
B1.6 Fault Detection ................................................................................ 212
B1.6.1 Fault Diagnostics .................................................................... 212
B2 Zirconia Input Module Details ................................................................... 213
B2.1 Terminal Connections and Status LEDs .......................................... 213
B2.2 Specification .................................................................................... 213
B2.3 Application Details ........................................................................... 214
B2.3.1 Temperature Control............................................................... 214
B2.3.2 Carbon Potential Control ........................................................ 214
B2.3.3 Soot Alarm .............................................................................. 214
B2.3.4 Probe Cleaning....................................................................... 214
B2.3.5 Endothermic Gas Correction .................................................. 214
B2.4 Isolation Diagram............................................................................. 215
B2.5 Equivalent Circuits........................................................................... 215
B2.5.1 Analogue Inputs...................................................................... 215
B2.6 Fault Detection ................................................................................ 215
B2.6.1 Fault Diagnostics .................................................................... 216
B3 Glossary.................................................................................................... 217
B4 LIN Block Licences ................................................................................... 218
B4.1 Foundation Level ............................................................................. 219
B4.2 Standard Level ................................................................................ 219
B4.3 Control Level ................................................................................... 219
B4.4 Advanced Level ............................................................................... 220
Appendix C Battery Replacement Procedure (if Fitted) ............. 221
Appendix D System Variables .................................................... 225
Appendix E Recover Lost Password .......................................... 227

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10 HA030047 Issue 16
T2750 Eurotherm PAC Safety Notes

Safety Notes

WARNING
Any interruption of the protective conductor inside or outside the apparatus, or
disconnection of the protective earth ground terminal is likely to make the
apparatus dangerous under some fault conditions. Intentional interruption is
prohibited.

Note: In order to comply with the requirements of safety standard BS EN61010, the
instrument shall have one of the following as a disconnecting device, fitted within
easy reach of the operator, and labelled as the disconnecting device.

a. A switch or circuit breaker which complies with the requirements of IEC947-1

and IEC947-3.

b. A separable coupler which can be disconnected without the use of a tool.

c. A separable plug, without a locking device, to mate with a socket outlet in the
building.

1. Before any other connection is made, the protective earth ground terminal shall
be connected to a protective conductor. The mains (supply voltage) wiring to the
PSU must be terminated in such a way that, should it slip, the Earth wire would
be the last wire to become disconnected.

2. The protective earth ground terminal must remain connected (even if the
equipment is isolated from the mains supply), if any of the I/O circuits are
connected to hazardous voltages*.

3. Fuses are not user replaceable. If it is suspected that the fuse is faulty, the
manufacturer’s local service centre should be contacted for advice.

4. Whenever it is likely that protection has been impaired, the unit shall be made
inoperative, and secured against accidental operation. The manufacturer’s
nearest service centre should be contacted for advice.

5. Any adjustment, maintenance and repair of the opened apparatus under voltage,
should be avoided as far as possible and, if inevitable, shall be carried out only
by a skilled person who is aware of the hazard involved.

6. Where conductive pollution (e.g. condensation, carbon dust) is likely, adequate

air conditioning/filtering/sealing etc. must be installed in the recorder enclosure.

7. If the equipment is used in a manner not specified by the manufacturer, the

protection provided by the equipment might be impaired.

8. In order to comply with the requirements of BS EN61010 the voltage applied

across I/O terminals may not exceed the isolation voltage for those terminals. For
terminals specified as having ‘no isolation’, the maximum permissible voltage is
30V ac or 50V dc.

9. Under extreme shock along the axis of the backplane, the IOC is liable to reset.
Following this reset, the behaviour of the instrument is dependent upon the
configuration switches on the terminal unit. These switches determine whether
the instrument is allowed to reboot, and whether it should attempt to run the
strategy. See "LIN Option Switch" on page 60 for details on the LIN Options
Switch.

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Safety Notes T2750 Eurotherm PAC

10. The designer of any control scheme must consider the potential failure modes of
control paths and, for certain critical control functions, provide a means to
achieve a safe state during and after a path failure.

11. Separate or redundant control paths must be provided for critical control
functions.

12. System control paths may include communication links. Consideration must be
given to the implications of unanticipated transmission delays or failures of the
link.

13. Each implementation of this equipment must be individually and thoroughly

tested for proper operation before being placed into service.

* A full definition of ‘Hazardous’ voltages appears under ‘Hazardous live’ in BS

EN61010. Briefly, under normal operating conditions, hazardous voltages are defined
as being > 30V RMS (42.2V peak) or > 60V dc.

I/O Isolation Strategy

Isolation is implemented in the form of a double insulation (300V) barrier separating
all the I/O channels in a module from the rest of the system.

This prevents hazardous voltages on any one I/O channel from introducing hazards
on wiring associated with any other I/O module, or from putting the rest of the system
at risk.

Modules which provide channel-to-channel isolation further ensure safety and good
signal quality on all channels within such modules. Refer to the relevant section of
Appendix A for more details.

EMC
This instrument conforms with the essential protection requirements of the EMC
Directive 89/336/EEC, amended by 93/68/EEC. It also satisfies the emissions and
immunity standards for industrial environments.

The earthing strip at the lower edge of the backplane also provides termination
facilities for EMC, cable screens, etc.

To ensure compliance with the European EMC directive certain installation

precautions are necessary:

1. If the backplane is mounted on a DIN rail, the DIN rail must be in good
electrical contact with a grounded metal (aluminium or steel) sheet which is
part of the enclosure. If this contact is not possible, the ends of the DIN rail
must be connected at each end to the enclosure by two substantial earth
braids (10mm x 2mm) not more than 100mm in length.
2. If the backplane is mounted directly onto a panel, it must be in good
electrical contact with a grounded metal (steel or aluminium) sheet which is
part of the enclosure. If this contact is not possible, the protective earth
ground connections at the ends of the backplane must be connected to the
enclosure by two substantial earth braids (10mm x 2mm) not more than
100mm in length.
3. If these connections are not practical, ferrite clamps should be clipped over
the input leads, as near the terminal unit connector as possible. It is not
necessary to have one clamp for each input pair - several input pairs may
be inserted through a single clamp. Each clamp should have a minimum
200Ω impedance at 100MHz. A suitable clamp is Richco MSFC-13K.
General guidance For general guidance refer to the EMC Installation Guide
(Part no. HA025464).

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T2750 Eurotherm PAC Safety Notes

Relay outputs When using relay outputs it may be necessary to fit a filter
suitable for suppressing conducted emissions. The filter
requirements will depend on the type of load.
Routing of wires To minimise the pick-up of electrical noise, low voltage DC
connections and sensor input wiring should be routed
away from high-current power cables. Where it is imprac-
tical to do this, shielded cables should be used.
Power supply The instrument must be powered from a local power sup-
ply and must not be connected to a DC distribution net-
work. The power supply must be earthed according to
manufacturers instructions in order to give best EMC per-
formance for the system.

Symbols Used on the Instrument Labelling

One or more of the symbols below may appear as a part of the instrument labelling.

Refer to the user guide for instruction

Protective conductor terminal (protective earth ground)

Precautions against electrostatic discharge must be taken before handling

this unit or any electronic component of it.

This unit is RoHS compliant

For environmental reasons, this product must be recycled before its age
40 exceeds the number of years shown in the circle.

Underwriters Laboratories listed mark for the United States and Canada

This unit is CE compliant

RCM. Regulatory Compliance Mark for Australia and New Zealand.

Risk of electric shock

I/O Isolation Strategy

Isolation is implemented in the form of a double insulation (300V) barrier separating
all the I/O channels in a module from the rest of the system.

This prevents hazardous voltages on any one I/O channel from introducing hazards
on wiring associated with any other I/O module, or from putting the rest of the system
at risk.

Modules which provide channel-to-channel isolation further ensure safety and good
signal quality on all channels within such modules. Refer to the relevant section of
Appendix A for more details.

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Safety Notes T2750 Eurotherm PAC

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T2750 Eurotherm PAC Cybersecurity

Cybersecurity
What's in this Chapter
This chapter outlines some good practice approaches to cybersecurity as they relate
to use of the T2750 controller, and draws attention to several T2750 features that
could assist in implementing robust cybersecurity.

Introduction
When utilising Eurotherm T2750 controllers in an industrial environment, it is
important to take cybersecurity into consideration: in other words, the installation's
design should aim to prevent unauthorised and malicious access. This includes both
physical access (for instance via the T2750 front panel or USB connector), and
electronic access (via network connections and digital communications).

Secure Network Topologies and Good Practices

Overall design of a site network is outside the scope of this manual. The
Cybersecurity Good Practices Guide, Part Number HA032968 provides an overview
of principles to consider. This is available from www.eurotherm.com.

Typically, an industrial controller such as the T2750 together with any associated LIN
connected devices and controlled devices should not be placed on a network with
direct access to the public Internet. Rather, good practice involves locating the
devices on a fire-walled network segment, separated from the public Internet by a
so-called 'demilitarized zone' (DMZ).

Security Features
The sections below draw attention to some of the cybersecurity features of T2750
controllers.

Instrument Password
To help prevent unauthorized access to the instrument, every T2750 requires an
‘Instrument Password’ to be set. This must be set using Network Explorer. Until a
valid Instrument Password has been set, the instrument cannot be accessed for
configuration nor can it run any application.

Refer to "Setting Procedure (First Use)" on page 62 for details on setting the
Instrument Password.

Whitelisting PCs and File Types

It is necessary to ‘whitelist’ any PC that requires runtime data communications with
the instrument. By doing this, the PC will always be authorised for runtime data
access to the instrument for which it is whitelisted. Be aware that whitelisting does
not provide access to an instrument for configuration. To do this, it will always be
necessary to enter the Instrument Password. Whitelisting is carried out using the
Instrument Options Editor (part of LINtools).

Note: Runtime communications between controllers does not require whitelisting.

Whitelisting is only applicable to unattended PCs that wish to interact with an
instrument (for access to cached blocks or to exchange files).

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Cybersecurity T2750 Eurotherm PAC

It is also possible to whitelist specific file types for further security.

Refer to "Whitelisting a PC" on page 67 and "Whitelisting file types" on page 68 for
details.

Legacy Mode
Legacy Mode enables instrument behaviour that previously existed. It removes the
need to whitelist PC in runtime communication and allows configuration of the
instrument without entry of the Instrument Password. It can be used for operational
cases where the security provided by Instrument Passwords is not appropriate. For
example, when using instruments as spares in an existing system, prior to
implementing a more secure system solution requiring use of Instrument Passwords.

Notes:
1. To enable Legacy Mode, the Instrument Password must have been set.
2. Putting an instrument into Legacy Mode is NOT recommended unless there are
strong operational reasons to do so.

Refer to "Secure Mode" on page 69 for details.

Principle of Secure by Default

Some of the digital communication features on the T2750 can provide greater
convenience and ease-of-use (particularly in regards to initial configuration), but also
can potentially make the controller more vulnerable. For this reason, it is
recommended that features that are not being used are left disabled. This can
include the terminal configurator and the serial ports. Also, by default, LIN
communication does not allow cross-subnet working. Cross-subnet working should
only be enabled when it is really required.

Ethernet Security Features

Ethernet connectivity is always available on T2750 controllers. This connectivity is
vulnerable to cyberattacks. One form of cyberattack is to try to make a controller
process so much Ethernet traffic that this drains system resources and useful control
is compromised. For this reason, the T2750 includes an Ethernet rate protection
algorithm, which will detect excessive network activity and help to ensure the
controller's resources are prioritized on the control strategy rather than the Ethernet.
It is noted in '*.udz' files. This feature will also cause a break of synchronisation
(although units will auto re-sync once the rate protection ceases) - this happens
because Ethernet rate protection breaks the communications between left & right
units.

A 'broadcast storm' is a condition which may be created by cyberattack: spurious

network messages are sent to devices which cause them to respond with further
network messages, in a chain reaction that escalates until the network is unable to
transport normal traffic. The rate protection described in the previous paragraph also
provides protection against this type of attack.

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T2750 Eurotherm PAC Cybersecurity

Configuration Backup and Recovery

Eurotherm's LINtools software is used to configure a T2750 controller. This
configuration is stored locally on the PC running the tool. Thus it is available to be
copied onto another controller, or can be used to restore the original controller's
settings.

It is important that backups of the configurations are maintained.

Memory Integrity
When a T2750 controller powers up and attempts a 'hot start', it automatically
performs an integrity check on the contents of its internal non-volatile memory
devices. If this integrity check fails, the hot start fails. Nonvolatile memory is not used.

This is separate from the flash filing system, which is non-volatile storage.

Firmware
From time to time, to provide new functionality or address known issues, Eurotherm
may make new versions of the T2750 firmware available. T2750 uses a file
'upgrade.tgz' which includes self-consistency checks as well as the firmware. This file
is copied to the instrument which is then power-cycled. The instrument will detect the
presence of 'upgrade.tgz' and will verify its contents before attempting the upgrade.

WARNING
NON-SCHNEIDER ELECTRIC FIRMWARE
There is a potential risk that an attacker could upgrade a T2750 with non-genuine
firmware that contains malicious code. Care must be taken to ensure all firmware
updates are genuine.
Failure to follow this instruction can result in injury or equipment damage.

Achilles® Communications Certification

The T2750 controller has been certified at Level 1 under the Achilles®
Communications Robustness Test Certification scheme. This is an established
industry benchmark for the deployment of robust industrial devices recognized by
major automation vendors and operators.

Decommissioning
When a T2750 controller is at the end of its life and being decommissioned,
Eurotherm advises clearing the contents of the instrument's E: drive. This can help to
protect against subsequent data and intellectual property theft if the controller is then
acquired by another party.

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Cybersecurity T2750 Eurotherm PAC

18 HA030047 Issue 16
T2750 Eurotherm PAC Introduction

Introduction
The T2750 is a modular I/O controller which can be used either as a stand alone unit,
or as part of a complete control system. Modbus and Raw communications protocols
are supported, allowing simple connection with PCs, and other instruments. Profibus
master functionality is supported by using the optional netHOST gateways.

The control strategy is set up using LINTools software running on a PC.

Physical Structure
The unit consists of one or two Input/Output Controller (IOC) modules and a number
of Input/Output (I/O) Modules each of which clips into its own individual terminal unit
which provides termination for user wiring. The terminal units themselves are located
in a base unit which is mounted on a DIN rail or on a panel, as required. Base units
are available in different sizes to accommodate different numbers of I/O Modules
(maximum 16).

The lower front of the unit is covered by a removable flap which protects the wiring,
but leaves the status LEDs open to view.

Profibus master functionality, if required, is provided by the use of external netHOST

gateway units. Up to two netHOSTs are required, depending on whether one of two
IOC modules are installed.

Modules Available
AI2 Two universal analogue input channels
AI3 Three analogue input channels used for current loops,
either self powered or externally powered
AI4 Two pairs of isolated analogue input channels. Terminal
unit variants are available for particular applications (ther-
mocouples, mA or mV inputs).
AI8 High density analogue input module. Terminal unit variants
are available for eight channels of mA inputs (fast or
standard polling), eight channels of thermocouples with
cold junction compensation (also accepts mV inputs), or
four channels for platinum resistance thermometers
(RTD).
AO2 Two analogue output channels supplying 0 to 20mA or 0 to
10V signals
DI4 Four digital input channels (logic inputs)
DI6HV Six digital input channels (mains input 230VRMS)
DI6MV Six digital input channels (mains input 115VRMS)
DI8CO Eight digital input channels (contact closure inputs)
DI8LG Eight digital input channels (logic inputs)
DI16 16 digital input channels (universal inputs)
DO4LG Four digital output channels (0 to 10mA), externally
powered
DO424 Four digital output channels (0 to 100mA), externally
powered
DO8 Eight digital output channels (0 to 500mA per channel-
maximum 4 Amps per module), externally powered
DO16 16 digital output channels (0 to 700mA per channel)
FI2 Two frequency input channels (logic, magnetic and contact
closure up to 40kHz)

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Introduction T2750 Eurotherm PAC

RLY4 Four output relays arranged as one changeover relay and

three Normally Open relays
RLY8 Eight Normally Open relays
ZI2 One high impedance input channel and one thermocouple
input channel suitable for use with Zirconia oxygen probes

Features

LIN Communication
The unit is a Local Instrument network (LIN) instrument, where the ‘Local Instrument
Network’ is a collection of LIN instruments, that together form a control system. The
network communicates using ‘LIN Communication’ which is a proprietary system
used to connect each LIN instrument in the network.

ELIN Communication
ELIN Communication is LIN communication via Ethernet allowing peer-to-peer
communications between instruments and with the wider network via a standard
Ethernet infrastructure.

Profibus Master Communication

Profibus Master support is provided using the optional, externally mounted, netHOST
gateways. Interface from the netHOST to the T2750 is via IP over Ethernet. Up to two
netHOSTs are required depending on the number of IOCs installed into the T2750’s
base unit.

Redundant Working

Redundant Power Supply Connection

Two sets of power connections allow two Power Supply Units (PSUs) to be
connected so that the system can continue to run should one of the supplies fail. The
system monitors the supply voltages allowing alarms to be triggered should either or
both supply voltages drop below an acceptable value.

Redundant Instruments
When operating in redundant mode, a high speed data link between the primary and
secondary control modules provides exact tracking of the control database, allowing
bumpless automatic changeover to the secondary module should the primary module
fail. There is no loss of I/O states and no need to re-initialise I/O points. Revalidation
of all attached LIN nodes is automatic.

Live replacement of a failed control module can be carried out, without wiring
disconnections. Full hardware and software status indication allows rapid verification
and diagnostics. In Redundant mode operation either module can be removed
leaving the remaining module to drive the I/O modules. When a replacement control
module is fitted, it loads the control strategy and current status from the running
control module.

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Battery Backup
An internal ‘supercap’ supports hot start data, and the Real-Time Clock, for a
minimum of 1 hour. An external battery (3.3V ± 15%, 10μA max) can be connected in
order to extend this period. An option exists for the T2750 to contain a 3V ‘coin-cell’
style battery, mounted on a small board, fitted on the inside of the plastic side panel
adjacent to the IOC.

Configuration
Continuous strategies and Sequences are configured, downloaded and monitored
using LINtools.

The instrument is capable of creating its own LIN Database automatically (_auto.dbf
and _auto.run), this database including all the necessary module and I/O Function
Blocks based on the I/O modules detected.

Automatic Configuration is attempted after the instrument has determined the

Hot/Cold Start switch settings. If neither cold start nor hot start is selected, the
instrument detects the installed I/O, and then creates an operational database and
runs automatically.

Setpoint Program
Allows a setpoint program (*.uyy file) to be configured using the LIN Programmer
Editor. The Programmer

Wizard (available from LINtools Engineering Studio) is then used, automatically to

insert and to link all the

blocks needed to produce the generated Setpoint Program.

Sequential Function Chart (SFC)

The Sequential Function Chart (SFC) is the graphical way LINtools represents a LIN
Sequence (*.sfc file). A Sequence is employed when the process being controlled by
the LIN Database can adopt several distinct states - e.g. ‘Starting Up’, ‘Full Running’,
‘Shutting Down’, etc.

Ladder Configuration
A ladder diagram is a type of ‘Action’ represented graphically by a column of ‘rungs’.
Rungs are equivalent to program statements, with icons along them representing
digital or analogue fields, constants, and logical or arithmetic functions. Each rung
has only one ‘output’ or ‘objective’ - at its right-hand end - which is either a coil (digital
field), variable (analogue field), or a ‘jump’ to another labelled rung. Rungs can
include any number of input elements and use any complexity of wired or explicit
functions to perform the rung operation - subject only to screen space limitations.

Note: A single rung that evaluates TRUE or FALSE can also be used for a
Sequence Transition.

Sequential Text (ST) User Algorithms

Special Action blocks support user-algorithms written in Structured Text (ST).

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Software Blocks
Continuous strategies are built up using function blocks selected from a library of
analogue and logic elements. Diagnostic blocks are also available, for hardware and
software status reporting (See “Error Indication Types” on page 163.).

The LIN Blocks Reference manual contains descriptions of each block.

Blocks are ‘license protected’ into categories that define control levels (section B4
gives a full list):

1. Foundation blocks include I/O and Communications blocks, amongst

others.
2. Standard blocks include control, timing, basic maths and logic blocks.
3. Control blocks include control loop, advanced maths and sequence control
blocks.
4. Advanced blocks are natural gas concentration and AGA8 calculation
blocks.
Note: Generally, a combination of Standard license blocks can be used to provide a
level of instrument control equivalent to a single Control license block, but this has an
impact on the total number of available blocks remaining.

Data Recording
Data archive (*.uhh) files are saved in the unit’s flash memory (as configured in
LINtools) ready for automatic archiving to a host computer via FTP. Review software
can be used to display this data in chart or spreadsheet form. If ‘Store and Forward’
software is fitted at the host pc, then these data recording files can be interrogated to
read any data missing from the database as a result of a break in transmission.

Store and Forward Software

If there is a break in the transmission line, or if any other communications problem
arises, then data for the period of the break will be missing from the database. The
data remains in the instrument memory, and if the instrument is configured to archive
automatically to a ‘Review’ database, then ‘Store and Forward’ allows the missing
data to be retrieved from the Review database, once communications have been
restored. (It may take some time to download all the files, depending on the duration
of the break.)

More details are to be found in the ‘Store and Forward’ User Guide.

Time Localisation Support

Time Zone
Provides a means of configuring the instrument to use the local time zone.

Simple Network Time Protocol (SNTP)

Allows the instrument to receive time and date from an SNTP server over the
Ethernet connection.

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Health Monitoring
Automatic health checks, self-testing, and initialisation on power-up, with continuous
checking of I/O status and external communications.

Watchdog
A Watchdog switch on the control module allows the user to initiate a restart in the
event of a watchdog failure. If required, the Watchdog Relay connections can be
wired as shown in "Controller Module (IOC) Terminal Unit" on page 31.

Note: The watchdog relay can also be switched by the strategy, using the
‘Options.UsrAlm’ bit in the Tactician Header block. For synchronised systems, both
primary and secondary relays are switched.

IP (Intellectual Property) Protection

Specific application file types can be password protected. This prevents the loss of
the Intellectual Property to mis-use and duplication, e.g. using files on an instrument
for which they were not originally intended and the copying of files for use with
another instrument or process.

Front Panel Indicators

Status LEDs are provided to indicate communications and module I/O status. Control
switches are fitted on each control module.

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T2750 Eurotherm PAC Installation

Installation
Unpacking the Instrument
The instrument is despatched in a special pack, designed to give adequate protection
during transit. Should the outer box show signs of damage, it should be opened
immediately, and the contents examined. If there is evidence of damage, the
instrument should not be operated and the local representative contacted for
instructions. After the instrument has been removed from its packing, the packing
should be examined to ensure that all accessories and documentation have been
removed. The packing should then be stored against future transport requirements.

Mechanical Installation
Figure 2.1 gives dimensional details; Figure 2.2 gives fixing details.

132 mm (5.2 in)

70 mm (2.75 in)
0 module
profile

Primary Primary

180 mm (7.1 in)

DIN Rail

Cover catch

83.5 mm (3.29 in)

Open
cover

Max: 160 mm (6.3 in)

Base size

0 module 71.0 2.8

4 module 172.5 6.8
8 module 274.0 10.8
16 module 477.0 18.8

Figure 1 Overall dimensions

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Installation T2750 Eurotherm PAC

Protective Earth
Ground connection
(2 places)

26mm (0-module base) / 127.4mm (4-module base)

229mm (8-module base) / 432.2mm (16- module base)

DIN Rail

DIN Rail fixing clips

DIN Rail fixing
clips

Figure 2 Fixing details

Figure 3 No-module base details

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T2750 Eurotherm PAC Installation

Base Unit Mounting

This Base Unit is intended for DIN rail or bulkhead mounting within an enclosure, or
for IOCs at status level B2 or higher, in an environment suitable for IP20-rated
equipment.

WARNING
The equipment should not be operated without a protective earth ground conductor
connected to one of the earth terminals on the Base Unit. The earth cable should
have at least the current rating of the largest power cable used to connect to the
instrument.
The protective earth ground cable should be terminated with a suitable tinned
copper eyelet, retained by one of the screw and washer supplied with the base unit,
tightened to a torque of 1.2Nm (10.5lbin).
This connection also provides a ground for EMC purposes.

DIN Rail Mounting

For DIN rail mounting, symmetrical, horizontally-mounted 35×7.5 or 35×15 DIN rail to
BS EN50022 should be used.

1. Mount the DIN rail, using suitable bolts, ensuring that it makes good electrical
contact with the enclosure metal work either via the bolts or by means of a
suitable earthing cable.

2. Loosen the screws (‘A’ in Figure 2 and Figure 3) in the Base Unit, two or three
turns, and allow them, and the associated fixing clips to slide to the bottom of the
screw slot.

3. Lower the base unit on to the DIN rail such that the top edge of the rail fits into
the slot on the underside of the support bar (see Figure 2 and Figure 3).

4. Slide the screws (A) and associated clips as far as they will go towards the top of
the screw slots, ensuring that the top of each fixing clip locates behind the bottom
edge of the DIN rail.

5. Tighten the screws, and check that the base unit is fully secure on the rail.

Panel Mounting

WARNING
Bolt heads must not exceed 5mm in height, or there will be insufficient isolation
clearance between the bolt head and the relevant terminal unit(s).

1. Remove the screws (‘A’ in Figure 2 and Figure 3) and associated fixing clips.

2. Holding the base unit horizontally on the panel, mark the position of the two holes
on the panel.

3. Drill two suitable holes in the panel, and use two suitable bolts (M5
recommended) to secure the base unit to the panel, ensuring that good electrical
contact with the enclosure metal work is made either via the bolts or by means of
a suitable earthing cable.

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Installation T2750 Eurotherm PAC

Compliance with European EMC Directive

Please refer to the instructions given in the "Safety Notes" on page 11 at the front of
this manual which describe precautions which should be taken to conform with the
directive.

Terminal Unit Installation

1. Insert the tag at the top of the terminal unit printed circuit board into the relevant
slot in Base Unit (action ‘B’ in Figure 4).

2. Press on the bottom of the terminal unit until a ‘click’ confirms that the retention
clip has sprung back into position to secure the terminal unit (action ‘C’).

Note: If the base unit is not fully populated a blank Terminal Unit (supplied) must be
fitted immediately to the right of the final module position in order to maintain IP20
rating.

Terminal Unit Removal

1. Remove the terminal unit’s I/O module, if fitted ("Module Installation" on page 28,
below).

2. If necessary, remove all wiring from the terminal Unit.

3. Press the retention clip at the bottom of the terminal Unit and lift the terminal unit
out (action ‘D’).

Figure 4 Terminal unit installation/removal

Module Installation
Note:
1. It is recommended that the module’s channel blocks be placed in ‘Manual’ mode
(using LINtools) before an I/O module is replaced in a ‘live’ system.
2. Polarising keys prevent modules being fitted to unsuitable terminal units.

1. Pull the module retaining lever forwards into the unlocked position as shown in
Figure 5.

2. Offer the module up to the terminal unit and the backplane, and push home.

3. Return the retaining lever to the locked position.

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Module Removal
1. Pull the module retaining lever forwards into the unlocked position as shown in
Figure 5.

2. Disengage the module from the backplane connector and lift the module out of
the base unit.

Figure 5 Module installation

Module Identification
The inside of the cover contains locations (‘slots’) for labels which can be used to
identify the module fitted ‘above’ each slot.

A document template is supplied on the DVD which allows the user to print onto a
precut adhesive sheet (GA030486, supplied with the instrument). Once printed, the
relevant labels can be peeled-off the backing sheet and attached to the relevant
slots.

Label locations (1 per module)

Label locations
(1 per module)

Figure 6 Inside cover

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Installing the Optional netHOST Gateways

The optional netHOST gateways, which provide Profibus master functionality to the
T2750, are associated to an individual IOC installed on the T2750’s base unit. If only
one IOC is installed, only one netHOST is required. Similarly, if the T2750 is
configured with a redundant pair of IOCs, two netHOSTs are required.

Figure 7 shows the dimensions of the netHOST.

Figure 7 netHOST dimensions

It is recommended that the netHOSTs are mounted next to the T2750, although close
proximity is not enforced as communication between the T2750 and netHOST is via
standard Ethernet.

Mount the netHOST on a horizontally mounted DIN rail. The top hat rail must be
connected with the potential equalisation conductor (PE). With reference to Figure 8,
push the netHOST onto the top hat rail from above (1), and then press against the
mounting surface (2).
1

Figure 8 netHOST mounting

It is good practise to mount the two netHOSTs together, with the left netHOST being
associated with the left IOC, and the right netHOST being associated to the right
IOC.

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Electrical Installation

Controller Module (IOC) Terminal Unit

At both Con 3 and Con 4, Link

pins 2 and 3 for 5-wire, or link
pins 1 and 2 for 3-wire. Must
not be left open (as shown)
HS

OFF
CS
WR

‘P1’ terminals commoned  

Internal
‘P2’ terminals commoned wiring

All ‘C’ terminals commoned.

‘P1’ diode OR’d with ‘P2’

Watchdog Watchdog
relay (left) relay (right)

Internal Battery
wiring 3.3V ±15%
10μA max
Fuse: 0.5A
Type T

Fuse 4A Type T USB connector

(each PSU)
Note: Relays shown in alarm /
power off state.

Figure 9 Wiring and hardware configuration details for the IOC terminal unit

CAUTION
1. Input current must be limited to 4A or the IOC supply connector (CON8) may
overheat and be damaged.
2. If more than eight FI2 modules are fitted, and if these have an output channel
load of more than 5mA each, then an external power supply (additional to the main
power supply unit(s) shown above) must be used in order to avoid damage to the
backplane tracking.

Supply Wiring

CAUTION
Neither supply line may be allowed to rise above 30V with respect to protective
earth ground.

Note: Should the supply voltage fall below 19.2V during startup, the instrument will
not start successfully and will attempt repeatedly to restart.

The instrument supply voltage is 24Vdc ± 20%.

Typical power requirement is 150mA (3.6W) per control module, plus 1 Amp (24W)
for an eight-module unit or 2 Amps (48W) for a 16-module unit.

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Installation T2750 Eurotherm PAC

An external battery (3.3 ± 15%) may be connected in order to maintain power for the
SRAM and the real time clock when supply power is not available. Typical drain
current is 10μA maximum. An option exists for the T2750 to contain a 3V ‘coin-cell’
style battery, mounted on a small board, fitted on the inside of the plastic side panel
adjacent to the IOC.

Figure 3 shows the control module terminal unit with wiring details for the supply and
for the battery. A suitable battery and charger are available from the manufacturer
under part number LA030830.

Fuses
All positive supply lines must incorporate a fuse. Suitable types are 4A Type T for 24
Volt supplies and 0.5A Type T for an external battery.

Wire Sizes
Supply wiring: 0.25mm2 to 2.5mm2 (20 AWG to 14 AWG)

External battery: 0.14mm2 to 1.5mm2 (25 AWG to 16 AWG)

Note: The above diameters relate to the total cross sectional area of the
conductor(s) inserted into the terminal.

Terminal Details
Recommended screwdriver type: Supply power connector (Con8): 3mm flat blade.
Watch dog/battery connector (Con7): 2.5mm flat blade.

Maximum tightening torque: 0.6Nm for supply power terminals; 0.25Nm for battery
terminals

Maximum current carrying capability: 5A per pin for supply power terminals; 2A per
pin for battery terminals.

CAUTION
The maximum current carrying capacity should be considered when ‘daisy
chaining’.

Protective Earth Ground

Figure 2, above, and associated text gives protective earth ground details.

Watchdog Relays
Each control module (IOC) includes a ‘watchdog’ relay. At power up, for each IOC,
the relay remains de-energised (contacts open) until a number of health checks have
been completed successfully and a strategy has been loaded and is running, at
which point the relay is energised and the contacts close. If during operation one or
more health check fails, or if the strategy is stopped, the watchdog relay reverts to its
de-energised (contacts open) state.

Note: The watchdog relays can also be controlled by the ‘Options.UsrAlm’ bit in the
Tactician header block.

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T2750 Eurotherm PAC Installation

Figure 10, below, shows typical watchdog wiring. When wired in parallel, both IOCs
have to fail, before the alarm becomes valid. When in series, the alarm becomes
valid if either module fails. Figure 10 shows the relays wired in series to a 24V dc
‘healthy’ lamp, and wired in parallel, using an auxiliary relay to display both healthy
and fail states. The contact ratings (resistive loads) for the watchdog relays are
30Vac/60Vdc at 0.5A.

24V 24V

Healthy
Relays in parallel.
Fail ‘Healthy’ lamp is illuminated
whilst either IOC remains
healthy.
Healthy
‘Fail’ lamp is illuminated if both
Relays in Series. IOCs fail.
Lamp extinguishes if
either IOC fails

0V 0V

Figure 10 Typical watchdog relay wiring

Note: If the watchdog relay outputs are routed outside the cabinet in which the unit
is mounted, a clip- on ferrite should be fitted round all watchdog leads, and positioned
as closely as possible to the instrument. A suitable ferrite is available from the
manufacturer under part number CO025698.

Communications Connectors
A pair of parallel-wired RJ45 connectors, are used for EIA485 serial communications.
Figure 11 gives the pinout. Master / slave status is defined in ‘Modbus tools’ supplied
as a part of LINtools.

RJ45 plug: View on underside

Pin 5-wire 5-wire 3-wire

Master Slave Master/Slave
1 RxB TxB B
Pin 1
2 RxA TxA A

3 Common Common Common

4 NC NC NC
Pin 8
5 NC NC NC
RJ45 plug: View on underside 6 Common Common Common
7 TxB TxB NC
8 TxA TxA NC

Figure 11 RJ45 pinout (EIA485)

Note: The screen of the cable is connected to earth/ground via the RJ45
connectors. Best RFI performance is achieved if the screen is also earthed/grounded
at its other end.

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Installation T2750 Eurotherm PAC

WARNING
If the screen is earthed at both ends, it must be ensured that the earth potentials at
the ends of the cable are equal. If such is not the case, very large currents can flow
through the screen, causing the cable to become hot enough to harm personnel
who come into contact with it, and/or to cause fire.

USB Connector
A single Type-A USB connector, for redundant USB2.0 host communications, is
located on the IOC terminal unit between the supply power connector and the
battery/watchdog connector (Figure 9).

The connector is intended for use with USB memory sticks, and can supply up to
500mA. Attempts to draw more than 500mA causes the current limiting circuitry to
shut the USB power down until the fault is removed.

The IOC module contains a USB fuse which prevents the entire supply power system
from being affected in the unlikely event of a catastrophic failure in the USB
electronics. The fuse is not user replaceable, so if it fails, the relevant IOC Primary
must be returned to the supplier for service.

Note: If a USB extension cable is used to expose the USB port remotely, the
maximum length of this cable must not exceed 1.5m when the T2750 is configured
with a redundant pair of IOCs.

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Two-channel Analogue Input (AI2)

This module can be ordered as one of a number of variants to measure
thermocouple inputs, resistance thermometer inputs, Volts/mV or mA. Figure 12
gives pinout details

Thermocouple, millivolts Volts, Millivolts Resistance thermometers Milliamps

Thermocouple Thermocouple ‡150mV* ‡150mV* RTD (2-wire) RTD (2-wire) mA mA

Shunt resistors are factory fitted on
the back of the terminal unit

‡150mV ‡150mV 0 to 1.8V* RTD (3-wire) RTD (3-wire)

It is generally not recommended to
connect more than one input to a
single source, particularly
thermocouples, since this may
compromise the measurement and
sensor break action.
‡10V* ‡10V* RTD (4-wire) RTD (4-wire)
Similarly, it is generally not
recommended to connect
additional instruments to a single
input source.

Basic insulation

Note: When an input is configured as Volts or millivolts, the input circuit / terminal
connections are selected based on the configured range parameters HR_in and
LR_in as shown in the table.
Figure 12 AI2 module pinout

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Installation T2750 Eurotherm PAC

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Normal operation

On red Ch1 sensor break
Ch1 initialising
Flashing red/off Ch1 CJC fail
Ch1 bad cal data
Blinking red/off Ch1 Calibrating
As above but for channel

Note:

Flashing = 0.5 secs on, 0.5 secs off

Blinking = 0.2 secs on, 1.8 secs off

Figure 13 AI2 Status indicators

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Three-channel Analogue Input (AI3)

This module provides three isolated mA input channels. An isolated 24V (nominal)
supply is available across the ‘P’ and ‘C’ terminals for powering the current loop. If
the current loop is self powered, the ‘C’ and ‘I’ terminals should be used. Figure 14
shows the pinout.

Milliamps

Power supplied by module Current source inputs

T = two-wire 4 to 20mA transmitter

Basic insulation

Figure 14 AI3 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Normal operation

On red Ch1 sensor break
Ch1 initialising
Flashing red/off Ch1 CJC fail
Ch1 bad cal data
Blinking red/off Ch1 Calibrating
As above but for channel 2 and 3

Note:

Flashing = 0.5 secs on, 0.5 secs off

Blinking = 0.2 secs on, 1.8 secs off

Figure 15 AI3 Status indicators

Note: The number of AI3 modules must be restricted such that the total,
steady-state power consumption for all the modules in a base unit does not exceed
24 Watts for the eight module base or 48 Watts for the 16-module base.

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Installation T2750 Eurotherm PAC

Hart Compatibility
For each channel a 220 Ohm resistor is fitted in the input circuitry to the amplifier.
Normally, these resistors are by-passed by printed circuit links on the underside of
the terminal unit. In order to make the module Hart compatible, these links can be
cut, placing the resistors in series with the amplifier input.

Figure 16 shows the module equivalent circuit, and Figure 17 shows the location of
the links on the underside of the terminal unit.

Cuttable link (one per channel)

Ω 24V
Input
Current source
amplifier

Ω
amplifier

Figure 16 AI3 module equivalent circuit

Numbers are channel numbers

Figure 17 Link locations on underside of terminal unit

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Four-channel Analogue Input (AI4)

This module can be ordered as one of a number of variants to measure
thermocouple inputs, Volts/mV or mA. Figure 18 gives pinout details.

Volts, millivolts, milliamps

For mixed thermocouple and mV inputs, channel 1 For mA variants, 5Ω shunt resistors are factory fitted
must be a thermocouple input (to ensure correct CJC on the terminal unit.
operation).
mA variants must not have thermocouple or mV inputs
mV inputs can be converted to mA inputs if a 5Ω connected.
resistor is connected across the inputs.
For all variants, terminal 1- is internally connected to
It is generally not recommended to connect more than terminal 2-, and terminal 3- is internally connected to
one input to a single source, particularly terminal 4-
thermocouples, since this may compromise the
measurement and sensor break action.
Similarly, it is generally not recommended to connect
additional instruments to a single input source.

Thermocouple Thermocouple

Thermocouple Thermocouple

Basic insulation

Figure 18 AI4 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Normal operation

On red Ch1/2 sensor break
Ch1/2 initialising
Flashing red/off Ch1/2 CJC fail
Ch1/2 bad cal data
Blinking red/off Ch1/2 Calibrating

As above but for channel 3/4

Note:

Flashing = 0.5 secs on, 0.5 secs off

Blinking = 0.2 secs on, 1.8 secs off

Figure 19 AI4 status indicators

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Installation T2750 Eurotherm PAC

High Density Analogue Input (AI8)

This module can be ordered as one of four variants (each of which has a different
terminal unit):

• AI8-RT — four channels of isolated platinum resistance thermometer (RTD)

inputs, standard polling rate. See Figure 20 for terminal pin-out details.

For the following three variants, the channels are isolated in pairs.

• AI8-MA or AI8-FMA — eight isolated channels of current (mA) inputs, standard

polling rate and fast polling rate, respectively. See Figure 21 for terminal pin-out
details.

• AI8-TC — eight channels of thermocouple inputs (with cold junction

compensation) or voltage (mV) inputs, standard polling rate. See Figure 21 for
terminal pin-out details.

Platinum resistance thermometer inputs

Basic isolation between

all channels

RTDs

3-wire RTD connection shown.

2-wire and 4-wire RTDs can be used by
making the following connections:
For 2-wire RTDs link terminals b and c. AI8-RT
For 4-wire do not connect one of the
compensation leads.

Figure 20 AI8-RT terminal unit

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Thermocouple, millivolts, milliamps inputs

Thermocouple and millivolts (AI8-TC) milliamps (AI8-MA / AI8-FMA)

Basic isolation
between channel
pairs

Thermocouple

If thermocouple wiring needs to

mA and FmA
be extended use the correct modules have
compensating cable and
integral 3.33Ω
ensure that polarity is followed
resistors fitted
throughout

millivolts AI8-RT AI8-MA / AI8-FMA

If sensor break is enabled (see section 6.2.6), it is not

recommended to connect more than one input to a single
source (e.g. thermocouple or mV) since this may
compromise the measurement and sensor break action.

Also, it is not recommended to connect additional

instruments to a single input source.

Figure 21 Module pinout for thermocouple, mV and mA inputs

Status Indicators
As shown in Figure 22 below, the AI8 module’s status is shown by a single green
LED, whilst the status of each individual channel is shown by a red LED.

Off No power
unexpected module
On green normal operation - module
being polled
Flashing green error condition

Off Normal operation

On red error condition.
For example, sensor break,
over/under hardware range, bad
calibration
Repeated for each channel
For the RTD version only, LEDs 1 to 4 are used.
LEDs 5 to 8 are unused.

For the MA version only, LEDs 1 to 8 do not

indicate channel errors.

Figure 22 Status indicators

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Two-channel Analogue Output (AO2)

This module provides two isolated output channels which can be configured
independently (in software) as voltage or current source outputs. The specified
voltage output range (0 to 10V) can be expanded slightly (-0.3V to +10.3V) by limiting
the load to a minimum value of 1500Ω. Figure 23 gives the module pinout.

Voltage, milliamp outputs

0 to 10V 0 to 10V

0 to 20mA 0 to 20mA

Figure 23 AO2 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Normal operation

On red Ch1 saturated
Ch1 initialising
Flashing red/off Ch1 bad cal data
Blinking red/off Ch1 Calibrating

As above but for channel 2

Note:

Flashing = 0.5 secs on, 0.5 secs off

Blinking = 0.2 secs on, 1.8 secs off

Figure 24 AO2 module status indicators

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Four-channel Digital Input (DI4)

This module provides four digital inputs which support logic or contact closure inputs.
Types cannot be mixed in one module.

Logic inputs, Contact inputs

Invert logic by
swapping polarity
(any input)

Logic inputs (dc)

Link V+ to C
Off = -5V to +5V dc
On = 10.8V to 30V dc
Logic input Logic input Link Logic input Logic input

Contact inputs:
PSU 18 to 30V dc
Off = >7kΩ
18 to 30Vdc On = <1kΩ
Contact input Contact input PSU Contact input Contact input

Figure 25 DI4 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 26 DI4 module status indicators

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Six-channel Digital Input Module (DI6)

This module provides six isolated ac logic input circuits. The module is available in
two versions, one suitable for nominal 230V RMS, the other for nominal 115V RMS. It
is not possible for the user to change version.

Using the 115V version with 230V inputs causes power consumption higher than
specified, which can lead to overheating and eventual failure.

Using the 230V version with 115V inputs may cause intermittent switching as 115V
lies outside both the off and the on switching voltage ranges.

Status Indicators

115/230V AC logic inputs

On green Normal operation
Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

230V switching ranges:

AC logic AC logic Frequency range = 47 to 63Hz
Off = 0 to 70V RMS
On = 180V to 264V RMS

115V switching ranges:

AC logic AC logic
Frequency range = 47 to 63Hz
Figure 27 DI6 module status indicators (230V
Off = 0 to 35V RMS
version shown; 115V version similar)
On = 95V to 150V RMS

AC logic Basic insulation

AC logic

Figure 28 DI6 module pinout

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Eight-channel Digital Input Module (DI8)

This module provides eight digital inputs which support either logic inputs (DI8LG) or
contact closure (DI8-CO) inputs as specified at time of order.

Logic inputs Contact closure inputs

Logic inputs (dc) Contact inputs:

Off = -5V to +5V dc Off = >28kΩ
On = 10.8V to 30V dc On = <100Ω
Open cct. voltage
pins 1 to 8 = 9V nom.

Logic input Logic input Logic input Logic input Contact input Contact input Contact input Contact input

Logic input Logic input Logic input Logic input Contact input Contact input Contact input Contact input

Basic insulation

Figure 29 DI8 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 30 DI8 module status indicators

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16-Channel Digital Input Module (DI16)

This module provides 16 digital inputs which support either logic inputs or contact
closure inputs. Both input types may be freely mixed on each DI16 module.

Note: The ‘P’ terminals are internally connected together and the ‘C’ terminals are
internally connected together.

Logic/Contact closure inputs

Channel 1 shown; Channel 1 shown;

other channels other channels
similar similar

Logic input Contact input

Logic inputs (dc) Contact inputs:
Off = >7kΩ
Off = -30V to +5V dc
On = <1kΩ
On = 10.8V to 30V dc
Open circuit voltage
pins P = 18Vdc nom.

Figure 31 DI16 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 32 DI16 module status indicators

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Four-channel Digital Output Module (DO4)

This module provides four digital outputs. The module is available in two versions:
‘DO4 logic’ which can supply up to 8mA, and DO424 which can supply up to 100mA.

Voltage/mA digital outputs

Logic outputs:
Supply voltage (Vcs) = 18 to 30 Vdc
Logic 1 o/p voltage = Vcs - 3V (5mA
load)
Logic 1 o/p current = 8 mA

Voltage outputs:
Supply voltage (Vcs) = 12 to 30Vdc
Logic 1 o/p voltage = Vcs - 3V (full load)
Logic 1 o/p current = 100 mA (max.)

Load Load Load Load

Logic op Logic op Logic op Logic op

Fuse
All ‘C’ terminals are
4A connected together
internally
Voltage supply

Figure 33 DO4 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 34 DO4 module status indicators

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Eight-channel Digital Output Module (DO8)

This module provides eight high-current logic drive outputs.

CAUTION
1. If the module is inserted into a powered base unit, the outputs might turn on
fleetingly (up to 100ms). The DO8 module should not be inserted into a powered
base unit where such fleeting outputs could be damaging to the process being
controlled.
2. The maximum cumulative current for all eight channels must not exceed 4A.

Digital outputs

Supply voltage (Vcs) = 13 to 28.8Vdc

Logic 1 o/p voltage = Vcs - 3V (full load)
Logic 1 o/p current = 750mA (max.)
Logic 0 o/p voltage = <0.1V

Maximum module current (i.e total output

current for all eight channels) = 4A

Load Load Load Load

Digital op Digital op Digital op Digital op

Load Load Load Load

Digital op Digital op Digital op Digital op

Fuse
4A

Voltage supply

Figure 35 DO8 module pinout

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Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 36 DO8 module status indicators

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16-channel Digital Output Module (DO16)

CAUTION
If the module is inserted into a powered base unit, the outputs might turn on
fleetingly (up to 8ms). The module should not be inserted into a powered base unit
where such fleeting outputs could be damaging to the process being controlled,
unless the wiring has first been disconnected.

Note: Any ‘plant-side’ power supply connected to a DO16 module must be capable
of supplying an inrush current of 30A for 100μs.

This module provides 16 digital outputs of up to 700mA each. Two sets of power
supply inputs are included, with the ‘C’ terminals being internally connected. (The ‘P’
terminals are not internally connected.)

Digital outputs
Supply for Supply for
channels 1 to 8 channels 9 to 16
Fuse Fuse Fuse values should suit the
overall load. Fuse type
should be slow blow,
capable of withstanding an
inrush current of 30A for
24V ± 20% 24V ± 20%
100μs (max.).
Channel 1 shown;
other channels similar
Supply voltage (Vcs) = 24V ± 20%Vdc
Logic 1 o/p voltage = Vcs - 1V (full load)
Load

Logic 1 o/p current = 700mA (max.)

Logic 0 o/p voltage = <1V
Digital op Logic 0 o/p current = 10μA

Figure 37 DO16 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant input Off

On yellow Relevant input On

Figure 38 DO16 module status indicators

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Two-channel Frequency Input Module (FI2)

This module provides two isolated input channels used with a number of common
plant sensors.

Magnetic sensor inputs Voltage source inputs Contact inputs (closed = low) Contact inputs (closed = high)

Magnetic ip Magnetic ip Voltage ip Voltage ip Contact ip Contact ip Contact ip Contact ip

Set links to position ‘C’. Set links to position ‘C’. Set links to position ‘A’. Set links to position ‘A’.
Set ‘InType’ to ‘Magnetic’ in FI_UIO Set ‘InType’ to ‘V’ in FI_UIO Block. Set ‘InType’ to ‘V’ in FI_UIO Block. Set ‘InType’ to ‘V’ in FI_UIO Block.
Block If using the internal supply to power If using the internal supply to power the If using the internal supply to power
the sensor, set the output to 8V, 12V sensor, set the output to 8V (minimum the sensor, set the output to 8V
or 24V as required temp rise), 12V or 24V as required. (minimum temp rise), 12V or 24V as
Set ‘Thresh’ to 25% of supply voltage. required.
Set ‘Thresh’ to 75% of supply voltage.

Current sensor inputs

Chan 2

Chan 1

Current ip Current ip
To use the internal 1kΩ burden resistor, set
links to position ‘B’. Set ‘InType’ to ‘mA’ in
Link position A Link position B Link position C
FI_UIO block. If using the internal supply to (Contact) (Current) (Voltage, Magnetic)
power the sensor, set the output to 8V or
12V as required by the transducer.
The supply must not exceed 12V or the
burden resistor will be damaged. Set links independently for each channel
To use an external burden resistor, set
links to position ‘C’. Set ‘InType’ to ‘V’ in
FI_UIO block. If using the internal supply to
power the sensor, set the output to 8V, 12V
or 24V as required by the transducer.
Resistors are connected between 1+/C1
or 2+/C2 according to channel.

Basic insulation

Figure 39 FI2 module pinout (see also Figure 41 and associated cautionary note, be-
low)

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Note: ‘InType’, ‘Burden’, ‘Thresh’ are parameters associated with the LINtools
FI_UIO function block. The PSU value is also set in LINtools, using the ‘PSU’
parameter, and this sets, for each channel independently, the voltage appearing
across terminal pairs V1/C1 and V2/C2.

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off No activity Channel 1

Flashing yellow Activity Channel 1

Off Ch 1 Normal operation or frequency under range

On red Ch 1 hardware fault (Status.HwFlt)
Ch1 invalid software config. (Status: BadSetup)
Ch1 invalid hardware config. (Status: BadHWSet)
Flashing red Ch 1 sensor break or short circuit
Fast flashing red Ch 1 frequency over range

Note: As above but for channel 2

Flashing = 0.5 secs on, 0.5 secs off

Blinking = 0.2 secs on, 1.8 secs off

Figure 40 FI2 status indicators

CAUTION
If more than eight FI2 modules are fitted, and if these have an average output
channel load of more than 5mA each, then an external power supply must be used
to power the transducer (see Figure 41). Otherwise, if the internal supply is used,
damage will be caused to the base unit backplane tracking.

External power supply

Figure 41 External power supply wiring example

For more details of the Frequency input, see "B1 Frequency Input Module Details" on
page 205.

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Four Output Relay Module (RLY4)

This module provides four relay outputs, one with changeover (common, normally
open, normally closed) contacts, the remainder with common/normally open
contacts.

Relay outputs

Maximum current ratings:

2A at up to 240V RMS.
0.5A at 200V dc, increasing to 2A at 50V dc
Minimum current rating: 100mA at 12V.

Above ratings are for resistive loads.

See section A4.13 for further details.

Relays shown in
power off state.

Relay op Relay op Relay op Relay op

Figure 42 RLY4 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant output Off (de-energised)

On yellow Relevant output On (energised)

Figure 43 RLY4 status indicators

Snubber Circuits
Each set of relay contacts has an associated snubber Snubber
circuit (a 22nF capacitor in series with a 100Ω resistor) to
prolong relay life and to reduce radiated emissions when
switching inductive loads (e.g. solenoid coils).

This circuit passes a small current (approximately 1mA at

115V 60Hz; 2mA at 240V 60Hz) which can be sufficient to
cause problems when switching high impedance loads off.

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In order to prevent such problems, the resistor can be removed, rendering the
snubber open circuit.

CAUTION
Taking this action may shorten the life of the module, and may cause the system to
fail to meet CE requirements for radiated emissions.

Snubber Circuit Removal

Note: Suitable precautions against damage due to static electrical
discharge should be taken before the board is removed from the module.

1. Remove the module from its terminal unit.

2. With the module locking lever in the unlocked position*, use a small screwdriver,
inserted at points ‘A’ (Figure 44), to lever the card retaining strip gently out of the
module case. Attempting this with the lever in the locked position may result in
damage being caused to the module case.

3. Lift the board latch ‘B’ and pull gently on the lug ‘C’ to remove the circuit board
from the module moulding.

Retaining
strip

Figure 44 Removal of the relay board from the module

4. Once the board has been removed, and
placed in a suitable static safe area, the
relevant resistor leads can be cut, using a
suitable pair of side cutters or similar. Figure
45 shows the locations of the relevant
resistors numbered according to their
associated relay. The snubber circuits are
also identified on the circuit board.

5. When all the appropriate resistors have

been removed, the board can be returned to
the moulding, ensuring that it engages with
the board guides. The retaining strip should
then be refitted (module locking lever Figure 45 Snubber resistor
unlocked) and the module returned to its locations
terminal unit.

6. Ensure that the module label is marked appropriately.

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Eight Output Relay Module (RLY8)

This module provides eight relay outputs with common/normally open contacts. No
snubber circuitry is built into this module so it is the responsibility of the user to
incorporate such circuit elements as are necessary to protect the relay contacts from
undue wear, and to maintain CE compliance for the system.

Relay outputs

Maximum current ratings:

2A at up to 240V RMS.
0.5A at 200V dc, increasing to 2A at 50V dc
Minimum current rating: 100mA at 12V.

Above ratings are for resistive loads.

See section A4.14 for further details.

Relay op

Channel 1
shown; other
channels similar

Figure 46 RLY8 module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Relevant output Off (de-energised)

On yellow Relevant output On (energised)

Figure 47 RLY8 status indicators

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Zirconia Input Module (ZI)

This module consists of two input channels isolated both from each other and from
the system electronics, used to measure the Zirconia probe temperature
(thermocouple input to channel one) and the Zirconia probe output signal (channel
two). The cold junction compensation for the thermocouple input is provided by a
resistance temperature detector (RTD) mounted on the terminal unit.

Zirconia probe

Zirconia probe
T/C input input

Basic insulation

Figure 48 ZI Module pinout

Status Indicators

On green Normal operation

Off No power,
No communications
Incorrect module type

Off Ch 1 Normal operation

On red Ch1 sensor break, or initialising
Flashing red Ch1 CJC fail or bad cal. data 1
Blinking Red Ch1 calibrating

As above but for channel 2

Note:

Flashing = 50ms on, 50ms off

Blinking = 0.2s on, 1.8s off

Figure 49 ZI module status indicators

For further details of the Zirconia probe and its applications, see "B2 Zirconia Input
Module Details" on page 213.

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netHOST Profibus Master Gateway

Supply Wiring
The netHOST voltage and power requirements are sufficiently low that typically the
power can be obtained from the T2750’s power supply. However, always check that
sufficient capacity exists in the T2750’s power supply if this option is chosen.

The netHOST supply voltage is 24Vdc.

Typical power requirements for a single netHOST is 130mA (260mA for two).

Ethernet Wiring
The netHOST communicates with the T2750 using standard 100Mbps Ethernet
through either one of the integrated two-port switch RJ45 connectors. Consideration
to redundancy on the Ethernet network should be given when designing the system.

A typical configuration for Ethernet is shown in Figure 50 below. To implement this

setup, a total of four network feeds would be required – one for each of the
netHOSTs, and one for each IOC card on the T2750.

T2750

Ethernet

netHOST netHOST

Profibus DPv1

Figure 50 Typical netHOST Ethernet wiring

If the number of Ethernet feeds is severely limited, the netHOST’s integral switch can
be used to distribute a single feed to the netHOST and a single T2750 IOC.

Note: Using the netHost’s built-in 2-port switch to distribute an incoming Ethernet
feed introduces a single-point-of-failure and is therefore not recommended practice.

Profibus Wiring
The netHOST’s Profibus port is a single 9-way female D-connector. The pin out
details for this connector is shown in the following table.

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Profibus 9-way D Pin Signal Description

3 Rx/Tx + Receive / Transmit data positive

4 CNTR-P Control signal (direction control)

9
5 5 ISO GND Data ground
4
8
3
7
2
6 VP Powers supply +5V for terminating resistor. Max
6
1 current 100mA.
8 Rx/Tx - Receive / Transmit data negative
Shield PE Metal shell on PE

Status Indicators
Seven LEDs are situated on the front of a netHOST to show the current status, as
shown below.

1.SYS LED

2.APL LED

3.COM (Profibus DP Master) LED

4.Ethernet link channel 0 established

(green)

5.Ethernet activity at channel 0 (yellow)

6.Ethernet link channel 1 established

(green)

7.Ethernet activity at channel 1 (yellow)

Figure 51 netHOST status LEDs

The meaning of the SYS, APL and COM LEDs are outlined in the following tables.

SYS LED Description

Colour State Description

Green On netHOST is running in a healthy state

Yellow On The netHOST is starting up. This can take one minute or
longer. If this LED remains yellow permanently, then a
hardware failure is possible.
Yellow Flashing Hardware failure
Yellow/Green Flashing yellow/green Hardware failure
Off Off Power supply for the device is missing or hardware failure

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APL LED Description

Colour State Description

Green On Ethernet configured and Profibus communications running.

Green Flashing Ethernet configured, but Profibus not running.
Red On Configuration files are missing.
Red Flashing Configuration files in error, or not loaded.

Com LED Description

Colour State Description

Green On Profibus communication established to all slaves.

Green Flashing irregularly Configuration error.
Green Flashing regularly Profibus is configured, but communications not yet started
(this should only be a transient condition as the T2750
starts up).
Red Flashing Profibus communication to at least one or more slaves is
disconnected.
Red On Profibus communications to all slaves is disconnected.

Hardware Configuration

LIN Address
Each LIN instrument must have an address which is unique to the network. This
address is configured by means of a DIL switch (SW1) located on the IOC terminal
unit.

Setting an address at this switch automatically sets a pair of contiguous addresses

where the set address (e.g. 7A) is associated with the primary unit and the next
address (7B in this example) is associated with the secondary module. The primary
always takes the even address.

Figure 52 shows the detail.

HS
OFF

CS
WR

1 1
On (1 )

Figure 52 LIN Address setting

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LIN Option Switch

HS

Hot start Cold start HS

OFF
CS
WR
Watchdog re-try CS

OFF
WR

On (1 )
1 1

Figure 53 LIN option switch

A second DIP switch (SW2) on the IOC terminal unit allows the following settings:

Start Up Strategy
This is set by the Hot Start (HS) and Cold Start (CS) elements, as shown in Figure 54,
below.

HS CS

Off Off Automatically generate new database at each start-up.

Off On Attempt cold start. Halt if unsuccessful.

On Off Attempt hot start. Halt if unsuccessful

On On Attempt hot start. If unsuccessful attempt cold start. Halt if

unsuccessful.

Figure 54 Start up strategy setting switches

Cold start The instrument attempts to start up from a previous data-

base, using default parameter values.
Hot start The instrument attempts to start from where it stopped run-
ning.

Watchdog Retry
Setting this switch element ‘On’, causes the instrument to try to start again, after a
watchdog failure. Setting the switch ‘Off’ means that the instrument must be restarted
manually after any watchdog failure.

IP Address Setting
Each instrument must have an IP address set which is unique to the communications
network. The address is set using LINtools, and can be fixed, or automatically
allocated by the network. Each instrument uses a one-to-one mapping of LIN node
number and IP address, as defined in a file called the ‘network.unh’ file.

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It is normally necessary for the user to get advice from his or her IT department, or
network administrator before attempting to set IP addresses, as setting duplicate
addresses can cause severe communications problems.

Manual
The IP Address is explicitly defined in the ‘network.unh’ file. It is not recommended to
edit this file directly.

Instead, use LINtools or the Instrument Options Editor to make changes to this file.
Refer to "Setting Procedure" on page 61 for further details.

DHCP
A DHCP server is required that has been configured to respond correctly to IP
address requests. This configuration depends on the company network policy.

DHCP is a method whereby the instrument requests an IP Address from a DHCP

server. This happens at startup, but can be repeated during operation. DHCP
includes the concept of ‘leases’ (i.e. the assigned value will ‘expire’).

Using DHCP extends the processor restart time because it takes some time for the
DHCP server to respond.

BootP
BootP or Bootstrap Protocol is used by a network computer to obtain an IP Address
and other network information such as server address and Default Gateway. Upon
startup, the client station sends out a BOOTP request to the BOOTP server, which
returns the required information. A BootPtimeout period can be configured. If this
period elapses before the IP Address, Subnet mask, and Default Gateway address
are obtained, the values are automatically reset to 0.0.0.0.

Link-Local
Link-Local is used as a fallback to either DHCP or BootP, or can be used on its own
as the only IP Address configuration method. Link-Local always assigns an IP
Address in the range 169.254.X.Y. This IP Address range is reserved for use by
Link-Local and is explicitly defined as private and non-routable.

The Link-Local algorithm ensures that an instrument (IP host) on a network chooses
a unique IP Address from the Link-Local range.

To make a direct connection between a PC and the T2750 using Link-Local, the PC’s
network port must be configured to obtain an IP address automatically using the
standard Windows control panel.

Setting Procedure
It is assumed that LINtools has been started and a suitable project folder and
instrument folder have been created. It is also assumed that communications have
been successfully established between the instrument and the host PC. If this is not
the case (for example, a brand new instrument with no project or instrument folder
defined), refer to the next section, "Setting Procedure (First Use)" on page 62.

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1 Right click on the Instrument 3 Left click on ‘Network settings’ and enter IP address details or
folder select ‘DHCP’ etc. as required.
Use ‘Apply’ to download the new settings to the instrument.
Click on ‘Upload current...’ to view current settings

4 Left click on ‘LIN’ if required

2 Left click on ‘Properties’

Figure 55 Access to IP address setting in LINtools

Setting Procedure (First Use)

If the T2750 has not been used before and communication has not been established,
an alternative method of bringing up the Instrument Options Editor should be
followed, as outlined below.

If the T2750 is new, the default network settings (DHCP with Link-Local as a fallback)
will be been set at the factory. If DHCP is an acceptable method of initially assigning
the instrument with an IP address, then a DHCP server will be required to assign an
IP address. Ensure the PC is on the same network that the DHCP server will assign
in the instrument. Alternatively, the instrument can be connected directly to the PC
and the use of a Link-Local connection can be employed. If using the DHCP and/or
Link-Local method of communication, ensure the PC’s network port is set to obtain
an IP address automatically. Next, follow these steps shown in the next few pages.

1. Launch the LIN Network Explorer tool located in the Start menu. After a short
delay, the connected instruments should be displayed. An example is shown in
the following figure.

Note: The red padlock next to each instrument indicates that the Instrument
Password has not yet been set for that instrument. A password MUST be set before
the instrument can be accessed. A dedicated point-to-point Ethernet link should be
used when first setting the instrument password.

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2. Click on an instrument to highlight it and click ‘Set Password’. The Enter

Password dialog is displayed:

3. Enter New and Confirm the Instrument Password, then Click ‘Confirm’.

4. The padlock changes to Yellow for each instrument with a password.

Note: The yellow padlock next to an instrument indicates that the Instrument
Password has been set for that instrument.

5. The next step is to authorise the instrument. Click on the instrument to highlight it
and click ‘Authorise’.

6. In the Authorising dialog, Enter the Instrument Password’ and click ‘OK’. After a
short delay, the padlock changes to green. You can now access the instrument.

7. Click on the instrument in the left column to be configured to reveal the

instrument’s E: drive. An example is shown in the following figure.

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8. Double-click on the E drive folder for the instrument to view the contents of the
drive.

9. Locate the network.unh file and drag the file to the computer desktop (or other
memorable location).

10. Double-click on the network.unh file copied to the computer to launch the
Instrument Options Editor. Select the appropriate Instrument Type and Version.
An example of this is shown in the following figure.

11. Select the IP tab, and enter the network settings accordingly. An example is
shown in the following figure.

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12. Select the LIN tab and edit the LIN Protocol name if required.

13. Click the Save button and select No to the offer to download the new settings to
the instrument.

14. Drag the network.unh file from the computer to the instrument’s E: drive within
the Network Explorer tool, overwriting the existing version on the instrument. A
Current Transfer Status window displays the status of the file transfer (an
example is shown in the following figure).

After the above steps have been completed, power-cycle the T2750 for the changes
to take effect. Adjust the PC’s network configuration to match the new settings.

Recovery from an Unknown IP Address Configuration

To recover from an unknown IP address configuration, follow the procedure shown in
this section.

The IP Address and Subnet Mask for an instrument can be forced to a known value
by setting all of the LIN Address switches (SW1) “on” at the IOC terminal unit. Refer
to “LIN address” on page 52 for further details.

This sets the IP address of the left-hand IOC to 192.168.111.222, and of the
right-hand IOC (if installed) to 192.168.111.223, with a subnet mask of
255.255.255.0.

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A computer with a fixed IP address on this Subnet can now be connected directly to
the Ethernet port of the instrument and used to inspect and edit the IP Address of
each IOC module using the T2750’s terminal interface, which is accessed using
Telnet. Any Telnet client will suffice, provided it can support VT-100 emulation. Follow
the procedure outlined below.

1. Telnet to the left or the right IOC. A welcome page showing the current
configuration is displayed (an example is shown in the following figure).

Eurotherm T2750 3/0 69643 at 330 MHz

(Software Build: Mar 21 2015, 00:12:36)
(Hardware Build: RS485 - 2017Kbyte SRAM fitted at 0xA000000)
Serial Number = 115112
Ethernet (MAC) address = 00:0A:8D:01:C1:A8
IP address = 192.168.1.114
Subnet mask = 255.255.255.0
Default gateway = 0.0.0.0
POST result (0000) = SUCCESS
Hotstart failed because: Coldstart time was exceeded

Last shutdown because: Successful Power Down

T2750 3/0 (C) E8 69643

1 ANSI-CRT

>>>

2. Press ‘1’ to bring up the initial menu (an example is shown in the following
figure).

INIT Choose option

(Running)

Drag scroll
>DATABASE - General configurationbar down
GATEWAY - MODBUS configuration

3. Press the Enter key to select the database main menu. An example is shown in
the following figure.

MAIN MENU Select option

(Running)
MAKE - Create block

COPY - Copy block

DELETE - Delete block

INSPECT - Inspect block

NETWORK - Network setup

>UTILITIES- Engineering utilities

ALARMS - Current alarms

ALARM LOG- Alarm History Log

4. Use the cursor keys to scroll down to UTILITIES and press Enter to bring up the
utilities menu. An example is shown in the following figure.

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UTILITIES Select option

(Running)

START - Start runtime system

STOP - Stop runtime system
SAVE - Save database
LOAD - Load database
FILE - File page
TRY - Try Changes
UNTRY - Untry Changes
APPLY - Apply Changes
UNDO - Undo Changes
>ELIN - Elin Setup
DEBUG - Debug LIN Node
SERVICES - Available services

5. Use the cursor keys to scroll down to ELIN and press Enter to bring up the
configuration page for IP address. An example is shown in the following figure.

Elin Setup (network.unh file)

---------------------------------------------------------------------
----------
|
LIN PROTOCOL SETUP | REMOTE SUBNET NODE LIST
Protocol Name NET |
All Subnet Enable OFF |
Elin Only Enable OFF |
LOCAL IP SETUP |
Get Address Method Fixed |
IP Address 192.168.1.114 |
Subnet 255.255.255.0 |
Default Gateway 0.0.0.0 |
ELIN PARAMETERS |
Unack Timeout 200 msec |
Rmt Unack Timeout 1000 msec |
No of retries 5 |
EDB Timeout Used 5 sec |
EDB Timeout Unused 20 sec |
DBM Timeout TX conf 2000 msec |
|
| TELNET
| Login Id
| Password ********
Timeout 0 Secs

6. Enter the required configuration using the fields provided. When complete, press
the ESCAPE key. A pop-up will ask to confirm the changes. Press Y to save the
changes, or N if not.

7. Once the changes have been confirmed, turn off the T2750. The LIN Node
address should then be restored at SW1 on the IOC terminal unit. Finally,
re-power the T2750 for the IP address changes to take effect.

Note: If the Instrument Password is not known, or has been forgotten, refer to
Appendix E Recover Lost Password for details of resetting it.

Whitelisting a PC
It is necessary to ‘whitelist’ any PC that requires runtime data communications with
the instrument. By doing this, the PC will always be authorised for the instrument for
which it is whitelisted. Whitelisting is carried out using the Instrument Options Editor
(part of LINtools).

Notes:
1. Runtime communications between controllers does not require whitelisting.

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2. When a computer has more than one LIN Address then the correct address need
to be chosen to be added to the whitelist. Only the address (or addresses) that is
being used to communicate with the instrument needs to be added. It is possible
that more than one LIN Address from a single computer is being used to
communicate with an instrument, e.g. one address might be reserved for tools
access and another could be used for runtime access. In that scenario the LIN
Address being used for tools access would not be expected to be whitelisted. It is
also valid, if required, to add multiple addresses from the same computer (same
IP Address but different LIN Address) to the PC whitelist.

To whitelist a PC:

1. In LINtools, right-click on the instrument in the left-hand tree view.

2. Select Instrument Options from the context menu. The LIN Instrument
Options Editor is displayed.
3. Scroll down to display ‘Whitelisted PCs’.

4. Enter the required information. Check ‘Bridged’ if the PC communicates

with the T2750 via a LIN bridge, rather than via a direct connection).
Note: The aspects that can given access to are set in the ‘Allowed’ column and are:

• None - no access is allowed.

• DB - blocks can be cached and values can be read from and written to
blocks. For use with data servers in an HMI system.

• File - some files may be accessed (for example for use with File
Synchronisation), see next section: Whitelisting file types.

• DB+File - both blocks and files can be accessed (see previous points).

5. Click ‘Save’.

Whitelisting file types

You can additionally specify which file types a whitelisted PC can access. This may
be useful for File Synchronisation.

Note: It is only applicable if ‘File’ (or ‘DB+File’) is selected in ‘Allowed’, above.

To whitelist one or more file types:

1. Display the LIN Instrument Options Editor as described in the previous

section.

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2. Scroll down to display the Whitelisted Files.

3. The five file types as displayed above are always whitelisted by default.
4. Enter other file types as required, up to a maximum of 20.
5. If you wish the PC to be able to write to a certain file type, click in the
appropriate Writeable checkbox.
6. Click ‘Save’.

Secure Mode
You can implement Legacy Mode for an instrument which removes the need for
authorisation and you no longer need to enter the Instrument Password.

If not in Legacy Mode, you can specify the timeout period (in minutes) of how long the
system is left idle before authorisation (by Instrument Password) is removed.

To set these parameters:

1. Display the LIN Instrument Options Editor as described previously.

2. Scroll down to display the Secure Mode.

3. To set the instrument into Legacy Mode, click the checkbox.

4. If required, change the timeout period from the default 5 minutes.
5. Click Save.

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USB Configuration
The USB memory stick application can be set up as follows:

1. Access the instrument properties page as described in steps 1 and 2 above.

2. Click on ‘Instrument Options’, and use the scroll bar to locate the USB symbol.

3. Left click on the USB icon to reveal the configuration page and click on the
required items.

Left click on USB icon

USB Parameters
Media If ticked, the USB stick is supported; if not, none of the fol-
lowing items is configurable.
Upgrade If enabled, then the instrument performs an upgrade if the
correct files are found on the memory stick, when inserted.
The upgrade takes effect after the next power cycle.
Archive If enabled, all history files are archived to the memory stick
when it is inserted.
Support A support file is generated and saved to the memory stick
when it is inserted. The support file contains *.udd and
*.udz files as a minimum and can be used by the supplier
as a diagnostic tool.

netHOST Profibus Master Configuration

The optional netHOST gateways provide the T2750 with Profibus master
functionality. Where the T2750 runs in a duplex mode, one netHOST is assigned to
each processor (left and right). If the T2750 runs only in isolated mode (a single IOC
card), a single netHOST is assigned to the processor.

A netHOSTs identity consists of two parts:

- The “ADR” setting. This is the value set on the netHOST’s front panel decade
rotary switches. This value must be unique on the local subnet. Set the netHOST’s
front panel switches to match the value expected by the T2750.

- The IP address assigned to the netHOST (which must be unique and on the same
local subnet as the T2750). Note that this is not the T2750’s IP address, but a
unique address assigned to the netHOST.

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When the T2750 first starts the database file (*.dbf), it scans for all netHOSTs on the
local subnet. From the responses, it identifies the netHOST(s) with the correct ADR
setting and confirms the IP address is correct. If the IP address is unconfigured, the
T2750 will automatically configure the IP address as it starts up.

Setting the ADR Decade Switches

The netHOST’s address (ADR) is set
using the two decade switches on the
front of the netHOST. The value set
must be unique on the local IP subnet.
Use a small flatbladed screwdriver to set
the ADR switches.

The decade switches’ pointer is that

shown by the slot at the flat end of the
dial. Thus, in the example on the right,
the figure shows the decade switches
set to 74.

The T2750 must be set with the same

ADR details so it can locate and
associated the physical netHOST. Refer
to the next section, Setting the
netHOST’s IP address for details.

Setting the netHOST’s IP Address

The T2750 must be associated with a physical netHOST by means of physically
setting the address (using the ADR decade switches on the netHOST), and by
defining it in the T2750’s configuration. At the same time, the T2750 should be
configured to assign a specific IP address to the associated netHOST.

Both of these settings are performed using the Instrument Options Editor, which can
be invoked by rightclicking on the T2750’s instrument folder and selecting Properties
(and then clicking on the Instrument options tab), or from within LINtools (and clicking
on the instrument name and selecting Instrument Options).

The Instrument Options editor allows the Profibus settings to be configured. An

example is shown to the right and shows that the identity of both associated
netHOSTs can be defined through the fields:

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ADR: the netHOST instrument number. Set this to the same unique number as
physically set on the netHOST’s front-panel decade switches (00-99). Ensure this
setting is unique across all netHOSTs on the same IP subnet.

IP Address: Sets the IP address of the netHOST associated with the left or right IOC.
The netHOST is automatically assigned this IP address, which must be on the same
TCP/IP subnet as the T2750. Ensure this IP address is unique on the network.

In addition, the Timeout field specifies the maximum time (in milliseconds) before a
lack of response is treated as a communication failure.

The Simplex checkbox specifies the T2750 has only one IOC, and disables the
netHOST Right fields.

The Redundancy logic field are discussed in the following section.

Refer to the section below for information on the Redundancy logic, Desync and
Changeover fields.

Setting the Redundancy Logic

The behaviour of how the T2750 deals with Profibus health issues is definable using
the Redundancy Logic section of the Instruction Options Editor. Settings allow the
user to define how quickly (if at all) a Desync or Changeover occurs due to Profibus
communication failures. Further information can be found in the section, "Profibus
(netHOST) Redundancy Decisions" on page 86.

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Desync: This field determines how the T2750 reacts if the secondary IOC has a
worse view of the Profibus network than does the primary and when desync will
occur. This is only applicable in duplex IOC configurations (that is, if the Simplex field
is ticked, this field will not be editable). The functionality below also only applies if the
Stay Sync’d option is not selected in the Startup tab of the Instrument Options Editor
(if it is enabled, the T2750 will not desynchronise if the secondary IOC has a worse
view of the Profibus network than that of the primary. Instead, the SecWorse
parameter in the IDENTITY and RED_CTRL function blocks in the strategy - if they
exist - will be asserted. The Stay Sync’d option is available in T2750 v4/0 and later).
The three options, otherwise, are:

- 'Disable'. The T2750 ignores the situation (the IOCs never desync due to a
Profibus health issue).

- 'Fast'. This is the default operation. The T2750 desyncs if the situation persist for
1800ms. This allows the status of the secondary to be checked prior to
desynchronising. Selecting 'Fast' prioritises Profibus health over ELIN health for
desync decisions.

- 'Slow'. The T2750 desyncs if the situation persists for 8000ms. Selecting 'Slow'
prioritises ELIN health over Profibus health for desync decisions. Care should be
taken when setting the Desync option to 'Slow' if Profibus I/O is an essential part of
the strategy.

Changeover: This field determines how the T2750 reacts if the Primary cannot see
any of the configured nodes on the Profibus network and when an IOC changeover
will occur. This is only applicable in duplex IOC configurations (that is, if the Simplex
field is ticked, this field will not be editable). The four options are:

- 'Disable'. The T2750 ignores the situation (the IOCs never changeover due to a
Profibus health issue).

- 'Immediate'. This is the default operation. The primary IOC effects a changeover
as soon as it can no longer communicate to any of the configured Profibus slaves,
without checking whether the secondary IOC has a better view of the Profibus
network.

- 'Fast'. If the primary IOC is unable to communicate with any of the configured
Profibus slaves and the secondary IOC cannot view the primary on the Profibus
network, then the IOCs will changeover if this situation lasts for 250ms. This
prioritises Profibus health over ELIN health for changeover decisions.

- 'Slow'. If the primary IOC is unable to communicate with any of the configured
Profibus slaves and the secondary IOC cannot view the primary on the Profibus
network, then the IOCs will changeover if this situation lasts for 8000ms. This
prioritises ELIN health over Profibus health for changeover decisions.

Care should be taken when setting the changeover option to 'Slow' if Profibus I/O
is an essential part of the strategy.

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Operator Interface
Introduction
Figure 56 shows the IOC front panel LEDs and switches. Other modules’ LEDs are
described in "Electrical Installation" on page 31, above.

Status
Fault
Battery
Serial communications
IP resolution
Duplex

Watchdog switch

Primary
Standby
Sync switch
Desync switch
USB s/w
USB h/w
Ethernet speed
Ethernet activity

Figure 56 IOC LEDs and switches

LED Interpretation
See also "Power On Self Tests (POSTs)" on page 167 which describes Power On
Self Test (POST) failure LED patterns
LED Function
Status (green) On: Main power input valid
Off: Main power input failed
Fault (red) On: Module missing/faulty; incorrect type/base; any H/W
fault. Watchdog Failure if all other LEDs are extinguished.
Flashing: Database file unsaved, missing, or faulty. A *.dbf
and corresponding *.run file do not exist on the instrument.
Off: No H/W faults detected
Battery (green) On: Battery OK
Flashing: Battery failed or not fitted
Communications On: Instrument transmitting field communications
(yellow) Off: Instrument not transmitting field communications
IP Resolution On: IP address resolved successfully
(yellow) Flashing: IP address being resolved, or cable broken/dis-
connected
Off: IP address cannot be resolved. Invalid IP address or
DHCP failure.
Duplex (green) On: Primary and secondary modules are coupled
Flashing: Primary and secondary modules are not coupled
Off: Operating in isolation (no IOC in other slot).
Primary (green) On: The module is the primary module and it is running a
strategy.
Flashing: The module is the primary module and is either
loading a strategy, or is idle.
Off: The module is not the primary module.

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Standby (yellow) On: The module is the secondary module and it is synchro-
nised, ready to take over.
Flashing: Primary and secondary modules are synchronis-
ing.
Off: The module is not an active secondary module.
LED Function
USB s/w (green) On: USB being written to. USB device must not be re-
moved.
Flashing: Write failure has occurred. USB device may be
removed.
Off: USB device idle and may be removed.
USB h/w (yellow) On: an attempt is being made to draw too much current
(>500mA) from the USB socket. USB activity suspended.
Off: No hardware failure reported.
Ethernet speed On: 100MB
(green) Off: 10MB
Ethernet activity On: Connected to a live Ethernet network
(yellow) Flickering; Network traffic detected
Off: Ethernet connection invalid
All LEDs Flashing: A license violation has occurred within the cur-
rent loaded strategy. Modify the strategy to comply with the
license level, or contact the supplier to request an addition-
al license. Refer to Appendix B for details of function block
licence levels.
Note: If there is a "password error" then the Fault (red) LED will be steady on; and
the Battery, Comms & Duplex LEDs will be flashing. This has two possible meanings:
1. The instrument password is not set.
2. This is a duplex pair, and the partner is pre-V6/0 (i.e. does not support
Instrument Password). This would normally only occur whilst performing a
firmware upgrade of a duplex pair from pre-V6/0. Refer to "Upgrading Duplex
Systems" on page 179 for instructions for a hot upgrade of a duplex pair. You
will lose the security provided by Instrument Passwords if the partner is not
replaced.

Switches
Watchdog If the unit is in operating normally, or if the watchdog retry
switch (LIN Option Switch (page 60)) is set to ‘On’, then
this switch has no effect.
Otherwise, if the ‘fault’ LED is on, operating this push-but-
ton switch causes the module to reset and attempt to re-
start.
Sync switch If primary and secondary modules are synchronised:
Operation of the primary module ‘Sync’ switch has no ef-
fect.
Operation of the secondary module ‘Sync’ switch causes
the primary and secondary modules to swap.
If primary and secondary modules are not synchronised:
Operation of the primary module ‘Sync’ switch causes the
modules to start synchronising.
Operation of the secondary module sync switch has no ef-
fect.
Desync switch Operation of the primary module ‘Desync’ switch causes
synchronised modules to desynchronise, the Primary
module remaining in control.

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Operation of the secondary module ‘Desync’ switch for

longer than three seconds causes the secondary module
to shut down. When successfully shut down (all LEDs ex-
tinguished), the module can be safely removed from the
Terminal Unit.

Synchronisation
Synchronisation means the transfer of all relevant data from the primary module to
the secondary module, followed by the continuous maintenance of this data. This
allows the primary and secondary modules to change over should the primary
module fail.

This synchronisation process takes place automatically if both modules are

powered-up together, having been synchronised and powered down together
beforehand. Should either of these conditions not be met, then, at power-up the
primary and secondary modules adopt unsynchronised states and the secondary
module cannot change over to the primary in the event of failure. To synchronise the
modules, the primary module ‘Sync’ switch must be operated.

Once synchronisation has been achieved, the modules are said to be in primary
synchronised state and secondary synchronised state and the secondary can take
over the primary functions if required.

Time to Synchronise
The time taken to complete the synchronisation process varies according to the
complexity of the control strategy and on how heavily the file system is being used.
Typically, the ‘Load and Run’ part of the procedure takes a number of seconds, but if
the primary and secondary file systems are identical, synchronisation takes a few
seconds. If the file system contents are different, synchronisation can take much
longer whilst the files are copied. During the synchronisation period, the primary runs
the control process as normal.

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Start-up
Redundancy Modes
Two IOC modules (primary and secondary) are fitted and act in such a way that the
secondary can take over from the primary in case of failure. The left-hand module is
usually the ‘primary’ and the other the ‘secondary’. The secondary continuously
‘tracks’ the primary so that it can take over with minimum disturbance to the
controlled system. It also monitors communications to other nodes and the
input/output modules.

If there is only one IOC module, it acts in Duplex unsynchronised mode.

Start-up Modes
Note: The instrument will not load a database if the instrument password is not set;
it will enter the idle state.

The required start-up mode is selected using the ‘Options’ switch (SW2), described in
"LIN Option Switch" on page 60, above. This allows ‘Hot’, ‘Hot/Cold’, or ‘Cold’ to be
selected, using two elements of the switch. Figure 57 and Figure 58, below, shows a
simplified flow diagram for the different modes.

Hot Start
Hot start means that the instrument restarts from where it stopped running. A suitable
time period (Cold Start Time) is configured in the ‘Header’ block of the control
database, and if this period is exceeded after the database stops running, then a hot
start is not permissible. The Cold Start Time for any process can be defined as: A
pre-set duration, following power off or power failure (database stopped), after which
a Hot Start is not possible, and a Cold Start must be initiated instead.

A brownout time can be set in the ‘Header’ block, and if power to the instrument is
lost for this duration or longer, the brownout alarm is set (also in the ‘Header’ block).
This brownout time can be defined as an indication that a power variation or partial
power failure longer than the defined Brownout Time has occurred.

Any power variation or partial power failure shorter than the defined Brown out Time
allows the instrument to continue operating without interruption.

If the Hot start fails (because the database is corrupted or because the Cold Start
Time has been exceeded) the database is cleared and the instrument enters an ‘Idle’
state and remains there until physically restarted. See also "Hot/Cold Start" on
page 81 (Hot/cold start).

Cold Start
Cold start means that the instrument re-starts with the previous database loaded, but
with all parameter values set to starting values appropriate to the process (that is,
re-initialised). If the cold start fails the database is cleared and the instrument enters
an ‘Idle’ state and remains there until physically restarted.

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Cold Start Parameter File

In the event of a cold start, the instrument searches for a file with the same name as
the *.dbf file just loaded, but with the extension *.cpf, and if such a file is found it is
executed. This file is a parameter overlay file storing values that are initialised when a
cold start occurs. It is created using any text editor, and uses Structured Text (ST)
style comment lines, e.g. (* Comment *) and assignment statements (one complete
statement per line of text) that

(* Production plant Cold Start Initialisation --- .CPF file *)

(* Ensure no automatic control until started *)
PIC-023.Mode := “Manual”;
XCV-124.Mode := “Manual”;

(* Ensure vent valves open *)

XCV-124.Demand := “False”; (* Open *)
XCV-123.Demand := “False”; (* Open *)

(* Reset profile to default *)

Profile.A0 := 23.4; (* Start temp Deg C *)
Profile.A1 := 34.5; (* First target temp Deg C *)
Profile.A2 := 2.0; (* Ramp rate Deg C / min *)

(* Initialise totalisation block *)

>COUNT-01.NTotal := 10;
>COUNT-01.NTotFrac := 0.5;

1. Allocate the current cold start parameter values to database block fields

2. Define the Reset Data Set (Duplex)

Note: LINtools can interrogate this file to determine the cold start parameters. An
alarm is asserted in the instrument header block if any problem is encountered when
executing the *.cpf file.

If the ResetOfl alarm is enabled, it is asserted if one of these are TRUE:

1. The *.cpf file is missing, or

2. the maximum of 2560 parameters in the Reset Data Set supported by the *.cpf
file has been exceeded.

The only syntaxes that are supported by the *.cpf file are:

1. Block.Field[.Subfield]:=Value;
These are the defined default values used each time the instrument cold starts.
The instrument uses the specified value and overlays it on the defined (sub)field
regardless of what the (sub)field value is in the database, e.g. forcing a PID to
start in manual mode.

2. >Block.Field[.Subfield]:=Value;
This is used in the same manner as above but overlays a value on a (sub)field
which is normally read-only, e.g. setting a totalisation to a specific value. The
defined value is only used during the first scan of the database, after which the
(sub)field is updated at each block execution.

3. Block.Field[.Subfield];
This syntax adds the subfield to the Reset Data Set for this instrument. It is only
used during runtime and prevents the defined subfield being saved when
Options.SaveDBF in the header block is set TRUE. When the instrument next
cold starts, the value of the defined (sub)field will be read from the database in
the SD card.

4. -Block.Field[.Subfield];
This syntax removes the subfield from the Reset Data Set for this instrument. It is
only used during runtime to allow the value from the defined sub(field) to be
saved from RAM to SD card when Options.

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T2750 Eurotherm PAC Start-up

SaveDBF in the header block is set TRUE.

Example

If the syntax reads -PIC-023.SL; the online value is saved from RAM to SD card if
Options.SaveDBF in the header block is set TRUE during runtime.

Reset Data Set

The Reset Data Set is a list of parameters that remain unaltered in the database
when Options.SaveDBF in the header block is set TRUE during runtime. Any
parameter in the Reset Data Set can be omitted by preceding the parameter with ‘-’
(negative symbol). The Reset Data Set supports a maximum 2560 parameters but
three parameters are retained for Date, Time and Checksum, and used to validate
the data. The local setpoint (SL), Mode (MODE) and output (OP) from all PID,
PID_LINK or PID_CONN blocks in the database are allocated by default, but
additional parameters can also be added to the *.cpf file. This also applies to
LOOP_PID block but additional default parameters are included, i.e. AutoMan, SP1,
SP2, AltSPEn, ManOP and ReStrtOP.

Note: ReStrtOP is a hidden non-volatile parameter from which the volatile output
parameters are derived on power up. It is generally saved to the database with value
zero.

Hot/Cold Start
This setting causes the instrument to attempt a hot start. If the hot start fails,
however, instead of going straight into idle state as with ‘hot start’, the instrument
attempts to carry out a cold start. If the cold start fails the database will be cleared
and the IOC Modules enter an ‘Idle’ state and remain there until physically restarted.

Note: If the SD card is changed, a Hot Start for the current running database will not
be possible.

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Startup Flowchart

Power up

Instrument N Create empty

Idle
Password Set? database

HS & CS Y
switches both off? Database created

Was this unit Y Unsynchronised

secondary secondary
unsynch?

Valid shutdown N No database

last time? running last time

HS
Y

OFF
CS
WR

HS or HS & CS N Hot start

disabled On
switches on?
See Figure 2.53 for
SW2 location
Y
Extract last
known status
from memory

N Database
Does last loaded
database match mismatch
*.run file?
Y
Run Hot
Start routine CS or HS & Cold start
N
(Figure 4.2) CS switches disabled
on?
Y
Was hot start N
Get *.dbf file that
successful? matched *.run file
in flash
Y
Apply the values
saved in the cold
start parameter file

Was cold start N Create empty

successful? database

Y
Run database Run database Idle Run database
(Hot Start) (Cold Start)
Figure 57 Simplified start-up flow diagram

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Hot start called

(Figure 4.1)

Get *.dbf file that

matches *.run file in
flash

Attempt N
successful?

N
RAM OK?

Y
N
Is the root block
valid?

Is the real-time N
clock valid

Y
N
Is the root block
clock healthy?

Y
Extract last known
status from memory

Cold start time

N
exceeded?

N Set brownout alarm

Brownout time
exceeded? in root block

Return ‘Success’ Return ‘Fail’

Figure 58 Hot or Hot/Cold start flowchart

Starting the IOC Modules

Note: It is always possible to insert a second IOC module next to an isolated
module to convert the system into a duplex (redundant) system.

Start-up Routine
The Start-up routine is subject to the successful completion of the Power On Self
Tests (POSTs) (see "Power On Self Tests (POSTs)" on page 167 for details).

Off State
In the Off state, all LEDs are extinguished.

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Starting State
When power is applied, the relevant ‘Status’ LED illuminates green immediately.

The ‘Primary’ and ‘Standby’ LEDs flash intermittently until the modules are initialised,
at which point the ‘Primary’ LED is illuminated continuously on the primary module,
and the ‘Standby’ LED is illuminated continuously on the secondary module.

The start-up procedure concludes with the establishment of Ethernet (ELIN)

communications. During this period, the ‘Primary’ LED flashes on (600ms) and off
(600ms).

Operating State
When the start-up sequence is complete, then as a minimum, the ‘Status’ LED is
illuminated continuously green.

The ‘Primary’ (‘Standby’) LED is also illuminated green continuously if a database is

running, or it flashes if a database is loading or if the Module is idle.

The ‘Communications’ LEDs are illuminated yellow if the associated communications

links are operating correctly and flash intermittently when receiving messages.

The other LEDs operate as described in "LED Interpretation" on page 75.

Watchdog Relays
The Watchdog relays remain in their alarm state until the software has initialised.

Power-up Decisions
Figure 59 shows the states possible with a pair of modules in Redundant mode.

Off

Starting
Y
Power down N
status available?

Y
N
Primary?
Y
Auto N Auto N
synchronise? synchronise?

Primary Secondary
synching synching

Primary Primary Secondary Secondary Idle

synch unsynch synch unsynch
Illuminated LEDs: Illuminated LEDs: Illuminated LEDs: Illuminated LEDs: Illuminated
Status, Primary Status, Primary Status, Standby Status, Standby LEDs: Status

Figure 59 Power-up in redundant mode

CAUTION
If replacing an IOC module on a powered-down system (for example, during an
intentional site shutdown), there is a risk that an unwanted strategy on the new IOC
module will automatically run upon power-up. For this reason, always ensure when
replacing an IOC module from a stock of spare IOCs, that the run file (*.run) is
deleted from the device prior to installation on a production system. Caution should
also be taken if replacing both the primary and secondary IOC modules at the same
time.

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Primary/Secondary Criteria
When operating in redundant mode, it is necessary that one IOC module be defined
as the primary; the other as the secondary. As described in "Redundancy Modes" on
page 79 (Redundancy modes), above, the primary initially assumes control and the
secondary tracks the primary such that it can assume control should the primary
module fail.

Decisions as to which module starts up as primary are made using information held in
non-volatile memory, relating to which module was the primary prior to the last power
off. If both modules power-up as they last powered down, then they attempt to power
up with the same primary and secondary assignments. If the power down information
in the two modules is conflicting, or not available, because the battery is not
connected or the supercap has insufficient power to retain valid SRAM data, a cold
restart will be attempted (if configured). If a cold start is not configured, or fails, both
processor modules will enter an idle state (decoupled), and will not load or run a LIN
Database. The power down state is initialised so that the modules start with default
primary and secondary assignment at the next power cycle.

Redundancy Decisions
Normal redundant operation will take place only if the primary module believes that it
and the secondary module have an equal view of the ELIN network. The status of the
Stay Sync’d option (configured using the Instrument Options Editor, Startup tab) is
also taken into consideration. The Stay Sync’d option is available in T2750 v4/0 and
above.

When acting as a redundant pair, the primary and secondary modules independently
derive a communications status (indicated by the ‘IP Resolution’ LED).

The decision to remain synchronised, to desynchronise or to changeover, is always

made by the current primary module, and then only if the two units are synchronised.
The decision depends on which module has the best ‘view’ of the network. For
example:

1. If the primary module believes that both modules hold the same outlook of the
network, the primary and secondary modules remain synchronised.

2. If the primary module believes that it holds a better outlook of the network than
the secondary, and the instrument’s Stay Sync’d option is not enabled, then the
primary and secondary modules desynchronise and a changeover does not
occur. If the Stay Sync’d option is enabled, the primary and secondary modules
remain synchronised and the SecWorse parameter in the IDENTITY and
RED_CTRL blocks in the strategy (if they exist) are asserted to signify that the
subsystem health of the secondary IOC is worse.

3. If the primary module believes that the secondary module holds a better outlook
of the network, a changeover occurs. In addition, if the Stay Sync’d option is
enabled, an automatic resynchronisation occurs and the SecWorse parameter in
the IDENTITY and RED_CTRL blocks in the strategy (if they exist) are asserted.

If the communications status is unstable, the decision is debounced to prevent

spurious desynchronisations or changeovers occurring whilst faults are introduced to
or removed from the network. During this debounce period, there is no
desynchronisation or changeover operations.

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Profibus (netHOST) Redundancy Decisions

T2750 strategies that include Profibus I/O utilise the netHOST to communicate with
the Profibus network. Using the Instrument Options Editor, basic configuration can be
defined for both the identity of the netHOST and the redundancy logic. As mentioned
on page 61, each T2750 can be configured to handle redundancy for the Profibus
network with user-definable settings for desync and changeover logic. Refer to
“SETTING THE REDUNDANCY LOGIC” on page 61 for details on how to change
these settings. In addition, the Stay Sync’d option (configured using the Instrument
Options Editor, Startup tab) is taken into consideration as to whether a desync will
occur if the secondary Profibus health is worse. If this is not enabled, then the
functionality below will occur. If Stay Sync’d is enabled, the IOCs will remain
synchronised even if the Profibus health in the secondary IOC is worse. If this
happens, the SecWorse parameter in the IDENTITY and RED_CTRL blocks are
asserted.

The default behaviour of the Desync and Changeover settings make Profibus health
very high priority. This matches the functionality of the T940 and T940X in that a
changeover is immediate. If the Profibus I/O is an important element of the control
strategy, then this default behaviour is probably the most suitable. It has the
disadvantage, however, that if all Profibus slaves fail, the IOCs will changeover
(because it does not wait to check the secondary's view of the Profibus network).
This operation may not be desirable for control strategies where the Profibus health
is not top priority.

Setting both the Desync and Changeover settings to 'fast' will defer the
desync/changeover decision until the secondary's Profibus view can also be
checked. This avoids a changeover if the Profibus slaves will sill be unreachable after
a changeover. Note that 'fast' prioritises Profibus health over ELIN health for
desync/changeover decisions (if Profibus and ELIN health monitoring would result in
opposite decisions, the Profibus will ‘win’ and thus still treating Profibus as very
important). If the Stay Sync’d option is enabled, a Desync will not occur if the
subsystem health (Profibus or ELIN, for example) in the secondary IOC is worse. If
the subsystem health in the Primary is worse, a changeover occurs but then
automatically resynchronises (and asserts the SecWorse parameter).

Selecting 'Slow' has the effect of making ELIN health a higher priority than Profibus
health. This setting is only applicable where the Profibus I/O is not an essential part
of the strategy. Note that 'Slow' introduces a delay in the detection of the primary
Profibus Master failing, and there will be several seconds during which Profibus is not
operating before the changeover occurs. Similar to the ‘fast’ setting above, if the Stay
Sync’d option is enabled, a Desync will not occur if the subsystem health (ELIN or
Profibus, for example) in the secondary IOC is worse. If the subsystem health in the
Primary is worse, a changeover occurs but then automatically resynchronises (and
asserts the SecWorse parameter).

Finally, selecting 'Disable' stops all desync and changeover decisions based on the
health of Profibus. This should only be used where the Profibus is used for I/O
associated with very low priority monitoring, in cases where Profibus failures may be
not that important. With this option selected, no SecWorse enunciation is possible
(when the Stay Sync’d option is enabled) because the subsystem health is not
monitored and no decision can therefore be made.

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Autosynchronisation
Once the primary/secondary status of the modules has been determined, the system
must decide if synchronisation of the primary and secondary should be automatic or if
it should be initiated manually by means of the ‘Sync’ switch ("Switches" on page 76).
This decision is made as follows:

If the modules are powered-up within a short time of each other, and they were
running as a synchronised pair prior to power-down (data held in memory), then
synchronisation will take place without operator intervention.

If either of the above conditions is not met (or if the data held in memory is not
available) then both units will enter unsynchronised states in which case the
secondary cannot take over from the primary. This state will continue until the ‘Sync’
switch on the primary module is operated.

Synchronisation
During synchronisation (automatic or manual), the primary module:

1. Copies all the primary module’s strategy files to the secondary module.

2. The instrument password is copied from Primary to Secondary.

3. Instructs the secondary module to load the relevant database.

4. Transfers current block data to the secondary module.

During the synchronisation process, the ‘Standby’ LED on the secondary module
flashes. Once synchronisation is complete, the ‘Standby’ LED is continuously
illuminated yellow, and redundant operation starts with the IOC Modules in their
synchronised states.

Note: In redundant operating mode, the secondary module does not permit any LIN
database messages or any attempted writes to its filing system. It responds to all
other messages.

Time to Synchronise
The time taken to complete the synchronisation process depends on the complexity
of the control strategy and on how heavily the file system is being used. If the primary
and secondary file systems are identical, synchronisation takes just a few seconds. If
not, the ‘Load and Run’ part of the procedure can take a number of seconds, during
which period the primary runs the control process as normal.

Where primary and secondary filing systems have substantial differences (e.g. when
attempting synchronisation for the first time), multiple synchronisations may be
required to copy all the files to the secondary module. (The ‘Red_Ctrl’ block ‘sync’
fields can be viewed to determine the synchronisation status.)

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ELIN Communication Modes

Note: No configuration or cached block communication is possible until an
Instrument Password has been set.

The general principle is that access via any HMI (PC based) must be authenticated
but is otherwise unrestricted.

If, however, it is whitelisted, then DB connections are permitted when not

authenticated. Additionally some whitelisted PCs will have limited file system access.

Access from remote instruments does not need to be authenticated but is restricted
to those operations appropriate to strategy execution.

ELIN Mode is managed individually for each remote LIN node. For example, dual
redundant data servers are managed separately so both must be whitelisted. Each
computer where configuration tools are used is also managed separately and users
must enter the password at each computer as they use the tools

Initial

Remote ELIN
node identified

Password Not Set This is the ‘factory default’ state.

(red padlock) It will be possible to see the instrument in Network Explorer, and it is
possible to set the Instrument Password, but nothing else.

Factory Reset Password

Password Set
Once an Instrument Password is defined, ELIN operates in this mode by default.
Operation is restricted, depending on the Type of the Remote LIN device, as
Password follows:
not Set
• Instrument - ELIN operates sufficiently for strategy execution. Full cached block
Unauthorised access and limited file system access is provided (e.g. load a remote sequence
file). Management function requests (e.g. start/stop/etc.) are rejected.
(yellow padlock)
• PC (whitelisted) - cached block connections and limited file system access is
permitted depending on level of whitelisting. Management function requests are
rejected.

Comms • PC (not whitelisted) - cached block connections, file system access and
Management function requests (e.g. start/stop/etc.) are all rejected.
fail Remote device
authenticated
Remote device
Timeout unauthenticated

Remote device
identity changes Once a Remote LIN node has authenticated, full access to all LIN comms
features will be available.

Authorised Note: Because authorisation requires a user to enter a password,

authorisation is only possible from LIN nodes which are HMIs (PCs).
(green/grey padlock)
The Authorised state transitions to Unauthorised following an explicit
Unauthorise request. This can be due to an explicit ‘logout’ request, a
timeout, comms fail, or because the identity of the PC changes (for
example, if LINOPC/NTSE is restarted or a physically different PC takes
over the same LIN node address).

Figure 60 ELIN Mode State Machine

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Configuration
Automatic I/O Build and Configuration Tools
Note: This won’t work if the instrument password has not yet been set.

Most configuration will have been done before despatch but, at start-up, a basic LIN
Database and the communications parameters can be automatically generated by
setting the hot start (HS) and cold start (CS) elements of the LIN option switch to ‘Off’
("LIN Option Switch" on page 60).

LINtools also allows the creation of new LIN Databases, and the editing of existing
configurations on-site and on-line*, usually to accompany modifications to the
processing plant. LINtools Help should be referred to for details of the reconfiguration
procedures using the LINtools program.

The LIN Blocks Reference Manual gives full details of the software function blocks
available for control strategies, and how to configure their parameters.

Note: On-line reconfiguration is not permitted if the IOC Modules are synchronised.

All processed data in the LIN Database can be transferred via Modbus or Profibus
communications protocols (see Communications Manual). Modbus Tools (part of
LINtools) is used to configure the Modbus parameters, and Profibus Master
Configurator is used to configure Profibus.

Automatic I/O Build

If the hot and cold start switches are off, then at power up, the instrument detects
which I/O modules are fitted in the base unit. This information is used to create the
appropriate I/O channel blocks in a LIN Database, and configure them to match the
real hardware. This automatically generated LIN Database does not result in a
complete, usable, control strategy, because most I/O channel blocks require further
configuration, (e.g. thermocouple type requires a millivolt range).

Notes:
1. All existing *.run files are deleted.
2. The ‘FAULT’ LED (red) flashes whilst an unsaved LIN Database or changes to a
LIN Database exist in the instrument.
3. The Database name must be a unique 8-character string (it is recommended that
the name consists of the Instrument Type and the LIN Address, i.e. T2750_0F.
4. Each automatically generated I/O channel block is configured to match the real
hardware and is assigned a unique, meaningful 8-character name as shown in
Figure 61.
5. I/O channel blocks are assigned to the slowest I/O User Task, User Task 3.

Block Type Naming Convention Description

Header T2750_xx xx = LIN node address (hexadecimal)

Module Modyy_xx Mod = Module type; yy = module site
number; xx = LIN node address
Diagnostic [block template name]_xx xx = LIN node address
Calibration CALn_xx n = Task number; xx = LIN node
address

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Block Type Naming Convention Description

Analogue i/p channel index yyMzz_xx yy = Module site number; xx = LIN

node address; zz = channel number
Analogue o/p channel index yyPzz_xx yy = Module site number; xx = LIN
node address; zz = channel number
Digital i/p channel index yyXzz_xx yy = Module site number; xx = LIN
node address; zz = channel number
Digital o/p channel index yyYzz_xx yy = Module site number; xx = LIN
node address; zz = channel number
where site and channel numbers start at 1, and node addresses less than 10 include a leading ‘0’

Figure 61 Naming convention used by automatic I/O build

Preparing for the Automatic I/O Build

Before the Automatic I/O Build can be started, all power to the unit must be isolated,
the IOC Terminal Unit HS and CS switches must be ‘off’, as described in "LIN Option
Switch" on page 60, and all required I/O modules must be fitted in the appropriate
slots. Only then should power be applied to the instrument, initiating the automatic
generation of a LIN Database, and a corresponding ‘_auto.run’ file. The automatically
generated LIN Database includes appropriate Header, Module, Calibration, I/O, and
Diagnostic ("SD Card Failure Detection" on page 168) function blocks.

The LIN Database runs automatically. The database is unnamed until:

1. it is automatically saved, if the Options.SaveDBF bit in the TACTICIAN header

block is set

2. the ‘Save as’ command at the instrument level of the ‘Network Explorer’ is used

3. the LIN Database is open in LINtools and attached to the instrument via the
‘Online Reconfiguration’ command. The ‘Save’ command can then be used to
save the instrument LIN Database.

Block names are in the format ‘03X02_1A’, where:

03 represents the I/O Module location (slot 3 in this example).
X defines the channel type
(M = analogue input; P = analogue output; X = digital input; Y = digital out-
put; F = frequency input)
02 represents the channel number within the module (the second digital input
in this example).
1A is the LIN address for the base unit.

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Automatic I/O Generation Flow Diagram

HS off
CS off See section 2.4.2 for Hot start (HS) and
Cold start (CS) switch configuration.

All I/O modules

fitted

Power up instrument
(I/O database and *.run
files are automatically
created)

Configure and save

control strategy

Power down
instrument

Set HS and CS
switches as required

Power up instrument

Database Runs
Automatically

Figure 62 Automatic I/O generation routine

LINtools
LIN databases are edited using LINtools software. This provides:

1. A view of the instrument configuration

2. Build and Download functions

3. LIN names and node addresses for external databases (EDBs) (i.e LIN
databases running in other LIN instruments).

4. On-line Reconfiguration to a running LIN Database.

The strategy components can include one or more instances of the following items,
depending on the process being controlled:

1. I/O Modules Database file (file extension ‘.dbf’)

2. Database file(s) (Function Block Diagram - FBD, file extension ‘.dbf’)

3. Sequences (Sequential Function Chart - SFC, file extension ‘.sdb’)

4. Action block methods (Structured Text - ST, and Ladder, file extension ‘.stx’ and
‘.sto’)

5. Data Recording (file extension ‘.uxg’)

6. Setpoint Programs (Programmer Editor: file extension ‘.uyy’)

7. Modbus Gateway configurations (file extension ‘.ujg’ and ‘.gwf’).

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Starting LINtools
It is not within the scope of this document to describe the LINtools software in depth;
full details are to be found in the LINtools help system and in the LINBlocks reference
manual. If the user is already familiar with LINtools, the section may be ignored.

The following sections guide the user through the LINtools start-up, showing how to
create the required project folders, networks and instrument folders from scratch. It is
assumed that LINtools has already been installed successfully.

Note: For convenience, it is suggested that a ‘shortcut’ is created on the desktop.

1. Press Start/All Programs/..../LINtools Engineering studio....

2. ....or double-click on the desktop short cut.

LINtools starts

3. Click on ‘Create a LIN instrument folder’, then Click on ‘OK’.

4. Click on ‘Create a new Project’, then on ‘Next’.

5. Enter a project name, and if

necessary, browse for a file
location at which to store it.

6. Click on ‘Next’.

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Note: It is recommended that

‘Also Create on Desktop’ is clicked
on so that a short cut to the project
appears on the desktop.

7. Select a different icon from the

drop-down menu, if so desired.

8. Click on ‘Finish’.

9. Enter the name of the network on

which this instrument is to reside.

10. Click on ‘Next’.

11. Select the port name for this

network. (If it doesn’t yet exist, it
can be created by clicking on ‘Port
setup...’ and Adding the new port.)

12. Click on ‘Finish’.

13. Enter an instrument name.

Click on ‘Next’.

14. Select an instrument type from the

pull-down menu, then wait a few
seconds for the instrument version
to be displayed. (If this not the
required version, select the
required version from the
dropdown menu.)
Fill-in the remaining instrument
details.

15. Click on ‘Finish’.

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16. The LINtools worktop opens, allowing the user to configure a strategy as
required.

Connecting to a Computer
The instrument can be accessed over the Ethernet network via an Ethernet
hub/switch connected between the Ethernet Communications port on the underside
of the IOC modules and the Ethernet port on the Computer.

Note: that the correct LIN address must be set up on the instrument, as described in
"LIN Address" on page 59.

MODBUS Tools

Introduction
This instrument may be configured as a Modbus Master or as a Modbus Slave, and
the application supports up to three Modbus Gateway configurations.

Modbus configuration data is defined in a Modbus GateWay File (*.gwf), downloaded

with the LIN Database file into a LIN instrument. The data in the Gateway file is used
to define the transfer of data between LIN and Modbus instruments.

This data includes:

1. The operating mode (i.e. Master or Slave).

2. The serial line set-up (or TCP).

3. The mapping between fields in function blocks and the registers of a Modbus
instrument.

4. Modbus functions, Modbus register addresses and the format in which data is to
be transferred.

Connecting to a Computer
The instrument can be accessed over the Ethernet network via an Ethernet
hub/switch connected between the Ethernet Communications port on the underside
of the IOC modules and the Ethernet port on the Computer.

Running Modbus Tools

Refer to Modbus Tools Help for details of Modbus Configuration procedures using
Modbus Tools.

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An empty Modbus Tools window can be started

1. from the LINtools ‘Tools’ menu,

2. via the  Start > ... > LINtools Advanced > MODBUS Tools command.

The ‘Open’ command is used to open a browse window to help locate the required
*.ujg file.

Alternatively, double-click the LIN MODBUS Database file (*.ujg) from the required
Instrument folder.

Configuring Modbus-TCP Slave Communications

When this instrument is configured as a redundant pair and is communicating as a
Modbus-TCP Slave, the IP Addresses of the primary and secondary modules must
be entered in the ‘TCP properties’ configuration of whichever instrument is the
master.

With the relevant master’s *.ujg file open in the Modbus Tools window, click on the
TCP button to display the TCP Properties page and enter the IP Address of each
Modbus-TCP Slave which is to communicate with the Modbus-TCP Master.

Figure 63 shows the IP Addresses of both the primary and secondary modules of an
instrument configured as a redundant pair (the primary module taking the odd
address; the secondary the next highest address).

Figure 63 TCP properties

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Profibus Configuration

Introduction
This instrument may be configured as a Profibus master when used with the optional
external netHOST gateway units. Up to two netHOSTs are required, depending on
whether one or two IOC modules are installed.

Interface from the netHOST to the T2750 is via IP over Ethernet. Further information
about the netHOST can be found in the following places in this manual:

- For information about the physical installation of the netHOST, refer to "Installing
the Optional netHOST Gateways" on page 30.

- For information about the wiring of the netHOST, refer to "netHOST Profibus
Master Gateway" on page 57.

- For information about configuring the netHOST address, its IP address, and
redundancy logic, refer to "netHOST Profibus Master Configuration" on page 70.

The rest of this chapter will introduce how to launch the Profibus Master Configurator
from within LINTools.

Launching the Profibus Master Configurator

To configure the Profibus Master configuration tool, LINTools must be running with a
T2750 strategy loaded (an existing or a new blank one). Then follow the steps
outlined below:

1. Under the Contents pane on the left of the LINTools window, click the blue Add
button.

Click the
Add
button

2. The Add File to Configuration dialogue box appears as shown below. Click the
New LIN Profibus Master option from the list and click the OK button.

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3. A dialogue appears so the new Profibus master configuration file (*.upm file) can
be named. Enter an appropriate name and click the OK button.

4. The Profibus Master file is added to the strategy as shown in the Contents pane
on the left side of LINTools.

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5. Double-click the new Profibus Master file in order to start associating the
configuration to a valid Profibus network folder. The Select Network folder
dialogue appears.

6. Choose the Create a new network folder option and click the Next button to
proceed.

7. Enter the name of the network (the example has use ProfMast) and if need be,
use the Browse button to determine where the network folder is created. Then
click the Next button.

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8. From this context, the New Eurotherm Network Wizard knows we are creating a
Profibus network and has therefore selected the “PROFDP_1” option
automatically. Click the Finish button to complete the network setup. The
Profibus Master configuration tool appears.

Refer to LINTools help for further information with the configuration of Profibus.

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Control Loops
Introduction
The instrument can be configured to control and tune a control loop, via LINtools
Engineering Studio. This section discusses the use of the LOOP_PID block, but
similar Proportional Band, Integral Time, and Derivative Time, PID, principles are
also applicable to the 3_Term block and PID block.

Details of each block are to be found in the LIN Blocks Reference Manual.

Each control loop contains two outputs, Channel 1 and Channel 2, that can be
configured for PID, On/Off or Valve Position (bounded or unbounded) control. In a
temperature control loop Channel 1 is normally configured for heating and Channel 2
for cooling. Descriptions given here generally refer to temperature control but can
also apply to other process loops.

Temperature Control Loop Example

Simplified Loop Function Block Process Under

Control
PID Tuning
(PID page)

Control Setup Control

(Setup page) Output (OP Power
page) Regulator
PID/OnOff/VP

Error Control
SetPoint (SP
page) Loop
Generator
PV Status
Values
(Diag page)

Operating
Values
(Main page) Measured Heater
Temperature

Figure 64 Single Loop, Single Channel Control Loop Block schematic

The measured temperature (or Process Variable (PV)), is connected to a suitable
analogue input module. The PV is compared with the SetPoint (SP, or required
temperature). The difference between the SP and the PV (the error) is calculated and
a suitable heating or cooling demand output is generated, depending on the process
being controlled.

The output(s) from the instrument are connected to devices in the plant/system which
heat or cool the process, resulting in a change in the PV, that is again compared with
the SP, and the process is repeated continuously. This is referred to as closed loop
control.

In this instrument it is possible to select PID, On/Off, and Valve positioning

(Boundless or Bounded) algorithms.

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Loop PID Function Block

Note: Refer to the LIN Blocks Reference Manual for full block parameter details.

The instrument control loop is configured using the Loop function block and up to
seven additional Tune_-Set blocks, allowing a total of eight sets of tuning parameters
for an individual control loop.

Each set of PID tuning parameters provides specific tuning at different temperatures
so that (for example) initial heating can take place as quickly as possible (set 1),
followed by a controlled heating (set 2) and cooling (set 3) process, followed by a
rapid cooling period (set 4).

The LOOP_PID block parameters are divided into the following ‘tabbed’ sections’.
Main Sets up the operating parameters of the Control Loop such
as Auto/Manual select, current PV, current output de-
mand, selected SP value and working SP value. See "Main
Page" on page 102 for more details.
Setup Configures control type for each channel of the selected
loop (Main Page (page 102)).
Tune Set up and initiate the Auto Tune function (Tuning Tab
(page 108)).
PID Configures 3-term, Proportional Band, Integral Time, and
Derivative Time (PID) control parameters (PID Tab
(page 118)).
SP Select and adjust setpoint values, limits, and rates of
change (SP Tab (page 122)).
OP Set up output parameters such as limits, sensor break con-
ditions (OP Tab (page 125)).
Diag Control Loop status (Diag Tab (page 131)).
Alarms Alarm configuration (Alarms Tab (page 132)).
Parameters are software ‘wired’ using the LINtools Engineering Studio.

See "Control Loops" of the LINBlocks reference manual for full details of this block.

Main Page
The Main page of the Loop block provides an overview of parameters used by the
overall control loop. It allows the user:

1. To select ‘Auto’ or ‘Manual’ operation

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T2750 Eurotherm PAC Control Loops

2. To stop the loop from controlling, for commissioning purposes

3. To hold the integral action

4. To read PV and SP values

Automatic Mode
Automatic indicates that PV is continuously being monitored and compared with the
SP. The output power is calculated and used to minimise any difference.

If a sensor break occurs whilst the control loop is in automatic mode, a configured
sensor break output power (OP.SbrkOP or OP.SafeOP, if Main.Inhibit is configured),
can be output. The user can also switch to manual mode allowing the user to edit the
output power. When ‘Automatic’ is returned-to, the controller again checks for sensor
break.

Manual Mode
In manual mode:

1. If ‘On/Off’ control is configured, the output power may be edited by the user but
the only values available are: +100% (heat on, cool off) for positive value entries;
0% (heat off, cool off) for zero entry or - 100% (heat off, cool on) for negative
entries.

2. If PID control is selected, the output may be edited between =100% and (if cool is
configured) -100% but the actual output is subject to limiting (both absolute value
and rate-of-change of value).

3. For valve position control, the position of the valve can be adjusted by contact
closure inputs into a digital input module, driving the output relays directly, or by
using OP.NudgeUp or OP.NudgeDn. This control can also be achieved over
serial communications.

CAUTION
Manual control of valve position should be used with discretion, because, unless
some position feedback mechanism has been installed to provide an indication of
valve position, the operator is working ‘blind’, and might inadvertently leave the
valve in the fully open position.

During manual operation, the loop continues to be monitored, allowing a smooth

change when Automatic mode is subsequently selected.

If Auto Tune is enabled (Tune.Enable = Yes) it will remain in a reset state

(‘Tune.Stage’ shows ‘Reset’), until the control loop is switched to automatic control,
initiating the Auto Tune process.

To provide a strategy that allows both sensor break action (normally supported only
in Auto mode) and the ability to write to the output (only supported in manual mode)
‘ModeSel.FManSel’ can be wired to ‘SelMode.SelMan’. Then, if a sensor break
occurs the instrument operates in Forced Manual mode (‘Mode-Sel.FManSel’ is
‘True’ and ‘Mode’ is ‘F_Man’) and the required output can be written to OP.ManOP.

‘Main’ Tab Parameters

AutoMan Sets the operating mode of the loop as automatic or man-
ual
Inhibit No: Loop operates normally.
Yes stops the loop and sets the output to a ‘safe’ value
(SafeOP), this value being entered as a part of the Output

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configuration (OP Tab (page 125)). If an output rate limit is

set, then the output ramps to the safe level at that rate, oth-
erwise it performs a step change.
If setpoint or manual tracking is enabled (in setpoint con-
figuration (SP Tab (page 122)), Inhibit overrides tracking.
IntHold Select ‘Yes’ or ‘No’. ‘Yes’ freezes the integral term at its
current value. IntHold ensures that the power is reapplied
smoothly after the loop has been broken for service rea-
sons, for example.
ModeSel Read only value used to show requested modes. (Bit 0 is
at the top of the list.)
TrackSel. Bit 2 True = Loop output tracking is requested
(OP.TrackEn = On).
RemSel. Bit 3 True = Use alternative setpoint request
(SP.AltSpEn = Yes).
AutoSel. Bit 4 True = Automatic mode is requested
(Main.AutoMan = Auto)
ManSel. Bit 5 True = Manual mode is requested (Main.Au-
toMan = Man)
FmanSel. Bit 7 True = Forced manual mode is requested
because PV status is ‘Bad’
(Main.PVstat = Bad)
TuneSel. Bit 8 True = Autotune selected (Tune.Enable =
On)
PCalSel. Bit 9 True = Potentiometer calibration requested
(OP.PotCal = On)
InhibSel. Bit 10 True = Stop the loop running and output a
safe value (OP.SafeOP)
PV The value of the process variable input
PVStat ‘Good’ indicates that the PV is displaying a trusted value
derived from the process via an input block. ‘Bad’ indicates
that there has been a hardware failure or that the relevant
I/O module is missing.
SelMode Bitfields used to select controller modes via digital inputs
from the strategy. (Bit 0 is at the top of the list.)
EnaRem. Bit 3 True = Enable remote mode operation
SelAuto. Bit 4 True = Automatic mode unless SelMan =
True.
SelMan. Bit 5 True = Manual mode selected
TargetSP Target setpoint. This is the expected operating setpoint
value for the loop.
WrkOP The actual working output value before being split into
channels 1 and 2.
WSP Working Setpoint. The current setpoint being used by the
loop.

Alarms
See page 132 for a description of the alarms tab.
Combined Asserted if any block alarm is active.
DevHi, DevLo Asserted if the error signal value is greater than DevHi or
less than DevLo. Remains active until the signal returns
within the DevHi-DevLo band by more than the hysteresis
value. (DevHi and DevLo set in the Alarms tab.
Hi The alarm goes active if the PV value is greater than the
‘Hi’ value set in the Alarm tab and remains active until the
value is less than ‘Hi’ - ’Hyst’.

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Lo The alarm goes active if the PV value falls below the ‘Lo’
value set in the Alarm tab and remains active until the val-
ue exceeds ‘Lo’ + ’Hyst’.
HiHi (LoLo) As for Hi and Lo, above but use the HiHi and LoLo values
in the alarm tab.
LpBreak Active if Diag.LpBreak is ‘Yes’.
SensorB Asserted if Diag.SensorB is ‘Yes’.
Software Checksum error in the block’s RAM data.

Set Up Tab
Set Up configures the type of control required for each channel.

Figure 65 Setup tab

On/Off Control
This form of control turns heating power on when the process value is below the
setpoint, and turns it off when it is above the setpoint. If cooling is configured, cooling
power is turned on when the process value is above the setpoint, and turned off when
it is below the setpoint.

In Direct Acting mode, the behaviour is inverted.

Because of the thermal inertia of the load, a certain amount of oscillation takes place,
and this can affect the quality of the product. For this reason, On/Off control is not
recommended for critical applications.

Depending on the nature of the process being controlled, some hysteresis may have
to be included to prevent continuous operation (chatter) in the controlling device.

PID Control
Also known as ‘three term control’, this type of control continuously adjusts the output
demand, in order to control the process as closely as possible to requirements. PID
provides more stable control than On/Off control but is more complex to set up as the
parameters must match the characteristics of the process under control.

The three major parameters are: Proportional band (PB), Integral time (Ti) and
Derivative time (Td), the output from the controller being the sum of these three
terms. This output is a function of the size and duration of the error value and the
rate-of-change of the process value.

It is possible to disable the integral and/or derivative terms and control on

proportional only, on proportional plus integral (PI) or proportional plus derivative
(PD).

PI control is often used when the PV is noisy and/or subject to rapid variations, where
derivative action would cause the output power to fluctuate wildly.

PROPORTIONAL BAND (PB)

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The proportional band (PB) delivers an output which is proportional to the size of the
error signal. It is the range over which the output power is continuously adjustable in
a linear fashion from 0% to 100% (for a heat only controller). Below the proportional
band the output is full on (100%), above the proportional band the output is full off
(0%) as shown in Figure 67.

The width of the proportional band determines the magnitude of the response to the
error. If PB is too narrow (high gain) the system oscillates; if it is too wide (low gain)
control is sluggish. The ideal situation is when the proportional band is as narrow as
possible without causing oscillation.

Figure 66 also shows the effect of narrowing proportional band to the point of
oscillation. A wide proportional band results in straight line control but with an
appreciable initial error between setpoint and actual temperature. As the band is
narrowed the temperature gets closer to setpoint until eventually, it becomes
unstable.

The proportional band may be set in engineering units or as a percentage of the

controller range.

Wide
Narrow Proportional
band Setpoint
Temperature
Output

Increasing
proportional band

Temperature Time
SP

Figure 66 Proportional band action (reverse acting)

INTEGRAL TERM (TI)

In a proportional only controller, as seen in the

previous section, an error must exist between
setpoint and PV in order for the controller to
SP
deliver power. Integral is used to achieve zero
steady state control error.

The integral term slowly modifies the output

Temperature

level as a result of any error between setpoint

and measured value. If the measured value is
below setpoint the integral action gradually
increases the output in an attempt to correct
Time
the error. If it is above setpoint integral action
gradually decreases the output or increases Figure 67 Proportional + Inte-
gral Control
the cooling power to correct the error.

Figure 67 shows proportional plus integral

action.

The integral term is set in seconds. The longer the integral time constant, the more
slowly the output is modified and the more sluggish the response. Too small an
integral time causes the process to overshoot, and perhaps to start oscillating. The
integral action may be disabled by setting its value to Off.

DERIVATIVE TERM (TD)

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Derivative (or rate) action provides a sudden

change in output linked to the rate of change
in error, whether this is caused by PV alone SP
(derivative on PV) or by a change in the SP
as well (derivative on error selection). If the

Temperature
measured value falls quickly, derivative
provides a large change in output in an
attempt to correct the perturbation before it
goes too far. It is most beneficial in
recovering from small perturbations.
Time
Derivative is used to improve the
Figure 68 Proportional + Integral
performance of the loop. There are,
+ Derivative
however, situations where derivative may be
the cause of instability. For example, if the
PV is noisy, then derivative can amplify that noise and cause excessive output
changes, in these situations it is often better to disable the derivative and re-tune the
loop.

Derivative should not be used to curb overshoot in situations when the output is
saturated at Op High or Op Low for extended periods, such as process start up, since
to do so degrades the steady state performance of the system. Overshoot inhibition
is best left to the approach control parameters, High and Low Cutback.

If Derivative is set to Off, no derivative action will be applied.

Derivative can be calculated on change of PV or change of Error. If configured on

error, then changes in the setpoint will be transmitted to the output. For applications
such as furnace temperature control, it is common practice to select Derivative on PV
to prevent thermal shock caused by a sudden change of output as a result of a
change in setpoint.

In addition to the PID terms described above other parameters that determine the
control loop performance include Cutback terms, Relative Cool Gain and Manual
Reset.

Valve Position Control

Valve Position Control is designed specifically for controlling motorised valves and
can be specified either as boundless (VPU) or as bounded (VPB) mode.

Boundless VP (VPU) is a velocity mode algorithm that directly controls the direction
and velocity of the movement of the valve in order to minimise the difference between
the SP and the PV. It uses triac or relay outputs to drive the valve motor.

A feedback potentiometer is not required for VPU control, but can be used to provide
indication of the valve position.

Bounded VP (VPB) control requires a feedback potentiometer as part of the control

algorithm.

Control is performed by delivering a ‘raise’ pulse, a ‘lower’ pulse or no pulse in

response to the control demand signal via relay or triac outputs.

MANUAL MODE

Bounded VP controls in manual mode because the inner positional loop is still
running against the potentiometer feedback, so it is operating as a position loop.

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In boundless mode the algorithm is a velocity mode positioner. When manual is

selected then the up and down arrow produce +100% or –100% velocity respectively
for the duration of the key press.

In boundless mode it is essential that the motor travel time is set accurately in order
to allow the integral time to calculate correctly. Motor travel time is defined as (valve
fully open – valve fully closed). This is not necessarily the time printed on the motor
since, if mechanical stops have been set on the motor, the travel time of the valve
may be different.

Every time the valve is driven to its end stops the algorithm is reset to 0% or 100% to
compensate for any changes which may occur due to wear in linkages or other
mechanical parts.

This technique makes boundless VP look like a positional loop in manual even
though it is not. This enables combinations of heating and cooling e.g. PID heat, VPU
cool with manual mode working as expected.

Motorised Valve Output configuration automatically configures the second channel

once the first has been setup, e.g. if ‘OP.Ch2Outpt’ is wired and configured as
cooling, then ‘OP.Ch1Outpt’ is automatically wired and configured as heating.

Setup Tab Parameters

Ch1Ctrl Select Off/On, PID, VBU or VPB from the pull down table
for channel 1.
Ch2Ctrl As above, but for channel 2
CtrlAct ‘Rev’ = Reverse acting. This is the normal negative feed-
back mode of operation for heating, where the output is in-
creased when the PV is below SP.
Dir = Direct acting. This positive feedback mode is the op-
posite of reverse acting, the output being decreased when
the PV is below SP.
PB Units Select ‘Eng’ or ‘Percent’.
DerivTyp Select ‘PV’ or ‘Error’. for ‘PV’ the loop calculations occur
only when PV changes. For ‘Error’, the calculations occur
when either of PV or SP changes.

Tuning Tab

Figure 69 Tuning tab

The balancing of the P, I and D terms varies from process to process. In a plastics
extruder, for example, there are different responses to a die, casting roll, drive loop,
thickness control loop or pressure loop. In order to achieve the best performance
from an extrusion line all loop tuning parameters must be set to their optimum values.

Tuning involves setting the following PID tab parameters (PID Tab (page 118)):

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Proportional Band (PB), Integral Time (Ti), Derivative Time (Td), Cutback High
(CBH), Cutback Low (CBL), and Relative Cool Gain (R2G - applicable to heat/cool
systems only).

The recorder/controller is shipped with these parameters set to default values and in
many cases the default values give adequate, stable, straight-line control, but the
response of the loop may not be ideal. Because process characteristics vary it is
often necessary to adjust the control parameters to achieve best control. To
determine the optimum values for any particular loop or process it is necessary to
carry out a procedure called loop tuning. If significant changes are later made to the
process which affect the way in which it responds it may be necessary to retune the
loop.

Users have the choice of tuning the loop automatically or manually. Both procedures
require the loop to oscillate and both are described in the following sections.

Before the Tuning process begins, it is recommended that:

1. the tuning process is always started when PV and SP are not in close proximity.
This allows start up conditions to be measured and CutBack High (CBH), and
CutBack Low (CBL) values to be calculated more accurately.

2. tuning should be attempted only during dwell periods and not during ramp
stages. If a control loop is tuned automatically, set ‘Main.IntHold’ to Yes during
each dwell period while Auto Tune is active. It may be worth noting that tuning,
carried out in dwell periods that are at different extremes of temperature can give
different results owing to non linearity of heating or cooling. This can provide a
convenient way of establishing Gain Scheduling values.

3. the ‘OP.OutputHi’ and ‘OP.OutputLo’ parameters are configured, as required.

These overall output limit parameters apply both during tuning and during normal
operation.

4. the ‘Tune.HiOutput’ and ‘Tune.LoOutput’ parameters are configured, as required.

These output power limit parameters apply during the Auto Tune function.

Note: The ‘tighter’ power limit will always apply, e.g. if ‘Tune.HiOutput’ is set to 80%
and ‘OP.OutputHi’ is set to 70%, the output power will be limited to 70%. The
measured value must oscillate to some degree for the tuner to be able to calculate
values: the limits must be set so as to allow oscillation about the SP.

Loop Response
Ignoring loop oscillation, there are three categories of loop performance: Under
damped, Critically damped and Over damped, as described in the following
paragraphs:

UNDER DAMPED

In this situation the parameters are set to prevent oscillation but lead to an overshoot
of the Process Value (PV) followed by decaying oscillation until the PV finally settles
at the Setpoint. This type of response can give a minimum time to Setpoint but
overshoot may cause problems in certain situations and the loop may be sensitive to
sudden changes in PV, resulting in further decaying oscillations before settling once
again.

CRITICALLY DAMPED

This represents an ideal situation where noticeable overshoot to small step changes
does not occur and the process responds to changes in a controlled, non oscillatory
manner.

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OVER DAMPED

In this situation the loop responds in a controlled but sluggish manner which results in
a non-ideal and unnecessarily slow loop performance.

Initial Settings
In addition to the tuning parameters listed above, there are a number of other
parameters which can affect loop response. These parameters must be correctly
configured before tuning is initiated. Parameters include, but are not limited to:

SETPOINT

Before tuning, the loop conditions should be set as closely as practicable to the
actual conditions which will be met in normal operation. For example, in a furnace or
oven application a representative load should be included, an extruder should be
running, etc.

OUTPUTHI, OUTPUTLO

These OP tab heat and cool limits define the overall maximum and minimum power
which may be delivered to the process by the control loop. For a heat only controller
the default values are 0 and 100%. For a heat/cool controller the defaults are -100
and 100%. Although most processes are designed to work between these limits there
may be instances where it is desirable to limit the power delivered to the process.

REMOPL, REMOPH

If these Remote Output Limits parameters (OP tab) are used, they are effective only
if they lie within the Heat/Cool Limits above.

HEAT/COOL DEADBAND

Heat/Cool Deadband. If a second (cool) channel is configured, a parameter

‘OP.Ch2DeadB’ is also available in the Output tab which sets the distance between
the heat and cool proportional bands. The default value is 0% which means that
heating will cease to be available at the same time as cooling becomes available.

The dead band may be set to ensure that there is no possibility of the heat and cool
channels operating together, particularly when cycling output stages are installed.

MINIMUM ON TIME

If either or both of the output channels is fitted with a relay or logic output, the
parameter ‘Min On Time’ appears in the output menu. This is the cycling time for a
time proportioning output and should be set correctly before tuning is started.

RATESP

Sets the maximum PID rate-of-change. The output rate limit is active during tuning
and can affect the tuning results. RateSP is useful in preventing rapid changes in
output from damaging the process or heater elements. The parameter is found in the
‘SP’ tab (SP Tab (page 122)).

CH1TRAVT, CH2TRAVT

Valve Travel Time. If the output is a motor valve positioner the ‘Ch1TravT’ and
Ch2TravT’ Output tab parameters must be set correctly. The valve travel time is the
time taken for the valve to travel from 0% (closed) to 100% (open). This may be
different from the motor travel time limits because the mechanical linkage between
the motor and the valve, setting of limit switches, etc. can modify behaviour.

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Other Tuning Considerations

If a process includes adjacent interactive zones, each zone should be tuned
independently with the adjacent zones at operating temperature.

It is recommended that a tuning process be initiated when the PV and setpoint are far
apart. This allows start up conditions to be measured and cutback values to be
calculated more accurately. Cutback is not set for ‘Tune at setpoint’.

In a programmer/controller tuning should only be attempted during dwell periods and

not during ramp stages. If a programmer/controller is tuned automatically the
controller should be placed in ‘Hold’ during each dwell period whilst autotune is
active.

Note: Tuning, carried out in dwell periods which are at different extremes of
temperature may give different results owing to non linearity of heating (or cooling).
This may provide a convenient way to establish values for Gain Scheduling.

If an auto tune is initiated two further parameters (‘High Output’ and ‘Low Output’)
which must be set.
High Output Sets a high output limit to be imposed during autotune.
Must be = Output High, set in the Output menu.
Low Output Sets a low output limit to be imposed during autotune.
Must be = Output Low, set in the Output menu.
The above values must be set correctly, otherwise sufficient power to achieve SP
might not be available during tuning, and the tune will eventually fail.

Autotune
Autotune automatically sets the following PID tab parameters (PID Tab (page 118)):
PB Proportional band.
Ti Integral time. If previously set to ‘Off’ Ti will remain off after
an autotune.
Td Derivative time. If previously set to ‘Off’ Td will remain off
after an autotune.
CBH, CBL Cutback high and low values. If either is set to ‘Auto’, it will
remain so after auto tuning.
In order that Autotune set the cutback values for the user,
a value other than ‘Auto’ must be selected before Autotune
is initiated. Autotune never returns cutback values less
than 1.6 × PB.
R2G Calculated only if the unit is configured as Heat/Cool. Fol-
lowing an Autotune, R2G lies between 0.1 and 10. If the
calculated value lies outside this range, a ‘Tune Fail’ alarm
is set. See ‘Relative Cool Gain’ (PID Tab (page 118)) for
more details. From firmware 4/0, the automatic derivation
of R2G can be disabled by setting the R2G parameter on
the Tune tab to ‘No’.
LBT Loop break time. Following an autotune, LBT is set to 2 ×
Ti (if Ti was not previously set ‘Off’), or to 12 × Td (if Ti was
previously set to ‘Off’).
Autotune can be performed at any time, but normally it is performed only once, during
the initial commissioning of the process. However, if the process under control
subsequently becomes unsatisfactory (because its characteristics have changed), it
may be necessary to tune again for the new conditions.

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The auto tune algorithm reacts in different ways depending on the initial conditions of
the plant. The explanations given later in this section are for the following example
conditions:-

1. Initial PV is below the setpoint and, therefore, approaches the setpoint from
below for a heat/cool control loop

2. As above, but for a heat only control loop

3. Initial PV is at the same value as the setpoint (tune at setpoint). That is, within
0.3% of the range of the controller if ‘PB Units’ (Setup tab) is set to ‘Percent’, or
+1 engineering unit (1 in 1000) if the ‘PB Units’ is set to ‘Eng’. Range is defined
as ‘Range High’ – ‘Range Low’ for process inputs or the thermocouple or RTD
range defined in section A3 for temperature inputs. If the PV is just outside the
range stated above the autotune will attempt a tune from above or below SP.

Autotune and Sensor Break

When the controller is autotuning and sensor break occurs, the autotune aborts and
the controller outputs the sensor break output power ‘Sbrk OP’ set up in the OP tab
(OP Tab (page 125)). Autotune must be re-started when the sensor break condition is
no longer present.

Autotune and Inhibit

If the controller is in autotune when ‘Inhibit’ is asserted, the tune goes to the Off state
(Stage = Reset). On inhibit being released the controller will re-start autotune.

Autotune and Gain Scheduling

When gain scheduling is enabled and an autotune is performed, the calculated PID
values are written into the PID set that is active, on completion of the tune. Therefore,
the user may tune within the boundaries of a set and the values will be written into the
appropriate PID set. However, if the boundaries are close (because the range of the
loop is not large), then, at the completion of the tune, it cannot be guaranteed that the
PID values will be written to the correct set particularly if the schedule type is PV or
OP. In this situation the scheduler (‘Sched Type’) should be switched to ‘Set’ and the
‘active set’ chosen manually.

Initial Conditions
Configure the parameters described above.

Notes:
1. The ‘tighter’ power limit applies. For example, if ‘Tune.HiOutput’ is set to 80%
and ‘OP.OutputHi’ is set to 70% then the output power will be limited to 70%.
2. The PV must oscillate to some degree to allow the tuner to calculate the relevant
values. The limits must be set so as to allow oscillation about the setpoint.

Initiating the Autotune

In the Loop Tune tab for the relevant loop, set ‘TuneEn’ to ‘On’.

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Tuning from Below SP (Heat/Cool Control Loop)

The point at which automatic tuning is performed (Tune Control Point), is designed to
operate just below the Target SP (LOOP_PID block - Main.TargetSP) - the expected
operating value of the process. Using a Tuning Control Point configured below the
Target SP ensures the process is not significantly overheated or overcooled and is
calculated as:

Tune Control Point = Initial PV + 0.75 (Target SP – Initial PV) where the initial PV is
the PV measured after a settling period of 1 minute.

Example

If Target SP = 500°C and Initial PV = 20°C, the Tune Control Point is calculated at
380°C.

If Target SP = 500°C and Initial PV = 400°C, the Tune Control Point is calculated at
475°C.

Note: Any overshoot is likely to be smaller in the second example because the
process temperature is already close to the Target SP.

When automatically tuning a heat/cool control loop and the Initial PV is below the SP,
a number of cycles are run to calculate the PID tuning parameters.

1. Auto Tune is started, ‘Tune.Enable’ is set ‘On’ (A), but both heating and cooling
power remain off for 1 minute (A - B) to allow the algorithm to establish steady
state condition. Initial PV is then calculated.

2. First heat/cool cycle (B - D) establishes the first overshoot used to calculate

‘PID.CBL’ if it is not set to Auto.

3. Two cycles of oscillation (B - F) are produced to measure the peak to peak

response, the true period of oscillation, and calculate the PID terms.

4. An extra heat stage (F - G) is applied and all power is turned off to allow the plant
to respond naturally. During this period the ‘PID.R2G’ is calculated, then
‘PID.CBH ‘is calculated using the sum ‘PID.CBL x PID.R2G’.

5. Auto Tune is complete (‘Tune.Enable’ is set ‘Off ‘) (H). The control loop is now
operating at the Target SP using the automatically tuned PID term values.

Note: This operation also applies if the Initial PV is above SP, but in this case the
process starts with full cooling applied from (B), and not full heating.

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Temperature

Target SP First Overshoot peak to peak

(Main.TargetSP)

PV
Tune Control 12345678901234567890123456789012123456789012345678901234567890121234567890
12345678901234567890123456789012123456789012345678901234567890121234567890 Hysteresis
Point 12345678901234567890123456789012123456789012345678901234567890121234567890 (Alarms.Hyst)

OP
Initial PV
High Output
(Tune.HiOutput)
Zero Output

Low Output
(Tune.LoOutput) 1 min
A B C D E F G H
Time

Figure 70 Tuning from below SP - Heat/Cool control loop

Tuning from Below SP (Heat Only Control Loop)

When automatically tuning a heat only control loop and the Initial PV is below the SP,
a number of cycles are run to calculate the PID tuning parameters. The operation is
similar to the heat/cool control loop, but because a cooling channel does not exist, it
completes prematurely, ignoring the PID.R2G (set to ‘1’ for heatonly control loops).

1. Auto Tune is started (‘Tune.Enable’ set ‘On’) (A) but heating power remains off
for 1 minute (A - B) to allow the algorithm to establish steady state condition
‘Initial PV’ is then calculated.

2. First heat cycle (B - D) establishes the first overshoot used to calculate ‘PID.CBL’
(if it is not set to Auto). ‘PID.CBH’ is set to the same value.

3. Two cycles of oscillation (B - F) are produced to measure the peak to peak

response and the true period of oscillation. The PID terms are then calculated.

4. Auto Tune is complete (‘Tune.Enable’ is set ‘Off’) (F). The control loop is now
operating at the Target SP using the automatically tuned PID term values.

Note: This operation also applies if the Initial PV is above SP, but will start with full
cooling applied from (B), instead of full heating. ‘PID.CBH’ is calculated (not
PID.CBL), and ‘PID.CBL’ is set to the same value as ‘PID.CBH’.

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Temperature

Target SP First Overshoot peak to peak

(Main.TargetSP)

PV
Tune Control 12345678901234567890123456789012123456789012345678901234567890121234567890
12345678901234567890123456789012123456789012345678901234567890121234567890 Hysteresis
Point 12345678901234567890123456789012123456789012345678901234567890121234567890 (Alarms.Hyst)

Initial PV
OP
High Output
(Tune.HiOutput)
Zero Output

Low Output
(Tune.LoOutput) 1 min
A B C D E F
Time

Figure 71 Tuning from below SP - Heat only control loop

Tuning at SP (Heat/Cool and Heat Only)

When automatically tuning either type of control loop and the Initial PV is configured
at the same value as the SP, a number of oscillations are produced to calculate the
PID tuning parameters. This operation does not calculate ‘PID.CBH’ and ‘PID.CBL’
because there is not an initial start up response to the application of heating or
cooling.

Note: ‘PID.CBH’ and ‘PID.CBL’ will never return a value less than 1.6 x PB.

1. Auto Tune is started (‘Tune.Enable’ set ‘On’) (A). The output is frozen at the
current value for 1 minute (A - B), and the SP must remain within 0.3% of the
range of the control (if Setup.PB_Units is set to %), or ±1 engineering unit (if set
to ‘Eng’). Range is defined using the ‘SP.RangeHi’, and ‘SP.RangeLo’
parameters.

If during this period the PV drifts outside these conditions Auto Tune is aborted,
and resumed from above or below SP depending on which way the PV has
drifted.

A Tune Control Point is not used because the loop is already at SP.

2. Cycles of oscillation (C - G) are produced by switching the output between the

output limits. The peak to peak response and the period of oscillation are
measured, and the PID terms are calculated.

3. An extra heat stage (G - H) is applied and all power is turned off (H) to allow the
plant to respond naturally. During this period ‘PID.R2G’ is calculated.

4. Auto Tune is complete (‘Tune.Enable’ set ‘Off’) (I). The control loop is now
operating at the Target SP using the automatically tuned PID term values.

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Temperature

peak to peak
PV

Target SP 1234567890123456789012345678901212345678901234567890123456789012123456789012345678901234567890121234567890
1234567890123456789012345678901212345678901234567890123456789012123456789012345678901234567890121234567890
1234567890123456789012345678901212345678901234567890123456789012123456789012345678901234567890121234567890
(Main.TargetSP)

OP
High Output
(Tune.HiOutput)
Zero Output
Low Output
(Tune.LoOutput)
C D E F G H I
1 min
A B
Time

Figure 72 Tuning from below SP - Heat/Cool and Heat only control loop

Manual Tuning
If, for any reason, automatic tuning gives unsatisfactory results the controller can be
tuned manually. There are a number of standard methods for manual tuning, the
Zeigler-Nichols method being described here:

1. Adjust the setpoint to its normal running conditions (assumed to be above the PV
so that ‘heat only’ is applied.

2. Set the integral and derivative times (PID.Ti and PID.Td) to ‘Off’

3. Set High and Low cutback (PID.CBH and PID.CBL) to ‘Auto’.

4. If the PV is stable (not necessarily at the setpoint), reduce the proportional band
(PB) such that the PV just starts to oscillate, leaving time between adjustments to
allow the loop to stabilise. Make a note of the PB at this point (PB'), and also note
the oscillation period (‘T’).

If the PV is already oscillating measure the oscillation period (‘T’) and then
gradually increase PB to the point at which oscillation just ceases. Make a note of
the PB at this point (PB').

5. If the controller is fitted with a cooling channel, enable this now.

6. Observe the oscillation waveform and adjust ‘PID.R2G’ until a symmetrical wave
form is observed (Figure 6.11).

7. Set ‘PID.PB’, ‘PID.Ti’ and ‘PID.Td’ according to the table shown in Figure 73.

Control type PID.PB PID.Ti PID.Td

Proportional only 2 × PB' Off Off
P+I 2.2 × PB' 0.8 × T Off
P+I+D 1.7 × PB' 0.5 × T 0.12 × T

Figure 73 Calculate parameter values

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Setpoint

R2G correct

Temperature
R2G too large

R2G too small

Time

Figure 74 Relative Cool Gain waveform tuning

Cutback Values
The PID terms calculated from the table in Figure 6.10, above, should be entered
before the cutback values are set.

The above procedure sets up the parameters for optimum steady state control. If
unacceptable levels of overshoot or undershoot occur during start-up, or after large
step changes in PV, then the cutback parameters should be set manually, as follows:

1. Initially set the cutback values to one proportional bandwidth converted into
display units. This can be calculated by taking the value in percent that has been
installed into the parameter ‘PID.PB’ and entering it into the following formula:

PB/100 × Span of controller = Cutback High and Cutback Low

For example, if PB = 10% and the span of the controller is 0 to 1200°C, then

Cutback High = Cutback Low = 10/100 × 1200 = 120

2. If overshoot is observed following the correct settings of the PID terms increase
the value of ‘PID.CBL’ by the value of the overshoot in display units. If
undershoot is observed increase the value of the parameter ‘PID.CBH’ by the
value of the undershoot in display units.

Display Units

Adjust PID.CBH to reduce

Initial undershoot when tuning
Overshoot from above SP

Main.SP

Adjust PID.CBL to reduce

overshoot when tuning Initial Undershoot
from below SP
Time

Figure 75 CutBack High (PID.CBH) and CutBack Low (PID.CBL) manual tuning

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Tune Tab Parameters

See section 6 of the LINblocks reference manual for full details.
Enable ‘On’ initiates the autotune process.
HiOutput Specifies the maximum allowable percentage power level
to be output during the tuning process.
LoOutput Specifies the minimum allowable percentage power level
to be output during the tuning process.
State Shows the status of the autotune as Off, Running, Ready,
Complete,Timeout, Ti_limit or R2G limit
Stage Shows the progress of the autotune as: Reset, None, Mon-
itor, CurrentSP, NewSP, ToSP, Max or Min.
StageTim Shows the time since the latest change in ‘Stage’ oc-
curred.

PID Tab
The PID parameters are used to optimise the control of the loop.

Note: If the loop is configured for On/Off Control, only the PID.LBTn is available.

Left click to reveal

pull-down menu tab.

Figure 76 PID tab

PID Tab Parameters

Note: In the following list, the parameters with suffix ‘1’ refer to PID set 1. The
identical parameters for other PID sets are to be found in the associated ‘Tune_Set’
blocks, as is the parameter ‘Bound’ which sets the transition value from the previous
set.
ActivSet Shows which PID set is currently being used.
CBH1, CBL1 Cutback high and cutback low are values that modify the
amount of overshoot, or undershoot, that occurs as a re-
sult of a large step change in PV (under start-up conditions
for example). They are independent of other PID terms
which means that the PID terms can be set for optimal
steady state control, leaving it up to the cutback values to
control any overshoot. Described in more detail, below.
IntBal ‘On’ means that the integral balance calculation is applied
to prevent abrupt changes in output power.
LBT1 Loop Break Time. A loop break is deemed to have oc-
curred if the PV does not respond to a change in output
power within the Loop Break Time.

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MR1 Manual Reset. The output power setting required to elimi-

nate steady-state errors from proportional control mode
operation. This value is introduced into the output to force
the PV to equal the setpoint.
PB1 Specifies the proportional band value (Set Up Tab
(page 105)) for Set 1.
OPHi1, OPLo1 Maximum and minimum output limits for set 1.Num-
SetsSpecifies the number of PID sets to be used (maxi-
mum eight). Each additional set is configured in an
individual Tune_Set block and is associated using Set2 to
SetN (where N = NumSets value) A TuneSet block called
‘Heat2’ is being associated with Set3 in Figure 76). The rel-
evant Tune_Set blocks (‘Cool1’ and ‘Heat2’ in our exam-
ple) must exist before ‘NumSets’ parameters can be
edited.
R2G1 For loops where cooling has been configured, this ‘Rela-
tive Cool gain’ value compensates for the different heating
and cooling efficiencies of the process plant. Described in
more detail below.
RemInput If SchedTyp (above) is set to ‘Rem’, then this ‘RemInput’
value is used to determine which PID set is to be used.
SchedTyp Specifies a method for transferring from one PID set to the
next.
OffA PID set is not used.
ManualThe required PID set is selected by the operator
SPSelection of the PID set is controlled by the value of the
working setpoint value (Main.WSP). An internal
hysteresis value of 0.1% of loop span is included.
PVSelection of the PID set is controlled by the value of the
process variable value (Main.PV). An internal
hysteresis value of 0.1% of loop span is included.
ErrorSelection of the PID set is controlled by the difference
between the values of the working setpoint
(Main.WSP) and the process variable value
(Main.PV).
An internal hysteresis value of 0.1% of loop span
is included.
OPThe PID set selection is derived from the working out-
put value (Main.WrkOP) and includes an inter-
nally defined hysteresis of 0.5% of output span
RemPID set selection is derived from the value of a remote
input parameter (PID.RemInput). An internally
defined hysteresis of 0.1% of loop span is includ-
ed.
Ti1 Integral time ("Set Up Tab" on page 105) for Set 1. Off =
integrative action disabled
Td1 Derivative time ("Set Up Tab" on page 105) for Set 1. Off
= derivative action disabled

Relative Cool Gain (R2G)

Relative Cool Gain (R2G) is a tuning parameter corresponding to the gain of channel
2 control output, relative to the channel 1 control output.

R2G compensates for the different quantities of power available to heat, as opposed
to that available to cool, a process, e.g. water cooling applications might require an
R2G value of 0.25 because cooling is four times more effective than the heating
process.

R2G is set automatically when the Autotune process is performed.

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High and Low Cutback (CBH And CBL)

The CutBack High (PID.CBH), and CutBack Low (PID.CBL), are values that modify
the amount of overshoot, or undershoot, that occurs during large step changes in PV
(under start-up conditions for example). Cutback is independent of the PID terms,
which means that the PID terms can be set for optimal steady state response, while
the CBH and CBL are used to modify any overshoot that may be present.

Cutback involves moving the PB towards a cutback point nearest the measured
value whenever the latter is outside the PB and the power is saturated (at 0 or 100%
for a heat only controller). The PB moves downscale to the lower cutback point and
waits for the measured value to enter it. It then escorts the measured value with full
PID control to the SP. In some cases it can cause a ‘dip’ in the measured value as it
approaches SP, see below, but generally decreases the time needed to bring the
process into operation.

The action described above is reversed for falling temperature.

If PID.CBH and PID.CBL are set to Auto, the values are automatically configured to 3
x PB.

Temperature

CBH

0% output level
SP
100% output level

CBL

Time

Figure 77 High and Low Cutback (CBH and CBL) configuration

MANUAL RESET (MR)

In a PID control, ‘Ti’ automatically removes the steady state error from the SP. If the
PID control is changed to PD control, ‘Ti’ is set to ‘OFF’ and under these conditions
the measured value may not settle precisely at SP. The MR parameter represents the
value of the power output that will be delivered when the error is 0 (zero). To remove
the steady state error, the MR value must be configured manually.

LOOP BREAK

Loop Break attempts to detect loss of restoring action in the control loop by checking
the control output, the process value and its rate of change. Since response times
vary from process to process, the Loop Break Time (LBT) parameter allows a time to
be set before a Loop Break Alarm (LpBreak - see "Diag Tab" on page 131) becomes
active. LBT is set automatically in Autotune.

The Loop Break Alarm parameter has no direct effect on control. In order to define
behaviour under Loop Break conditions, the parameter must be wired, for example,
to a relay, which can then activate an external indicator.

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It is assumed that, so long as the requested output power is within the output power
limits of a control loop, the loop is operating in linear control and is therefore not in a
loop break condition. If, however, the output becomes saturated then the loop is
operating outside its linear control region. If the output remains saturated at the same
output power for a significant duration, then this might be symptomatic of a fault in the
control loop. The source of the loop break is not important, but the loss of control
could be catastrophic.

Since the worst case time constant for a given load is usually known, a worst case
time can be calculated over which the load should have responded with a minimum
movement in temperature. By performing this calculation the corresponding rate of
approach towards setpoint can be used to determine if the loop can no longer control
at the chosen setpoint. If the PV was drifting away from the setpoint or approaching
the setpoint at a rate less than that calculated, the loop break condition would be met.

If an autotune is performed the loop break time is automatically set to Ti × 2 for a PI

or PID loop, or to 12 × Td for a PD loop. For an On/Off controller loop break detection
is based on loop range settings as 0.1 × Span where Span = Range High – Range
Low. Therefore, if the output is at limit and the PV has not moved by 0.1Span in the
loop break time a loop break will occur.

If the loop break time is 0 (off) the loop break time can be set manually. Then, if the
output is in saturation and the PV has not moved by >0.5 × Pb in the loop break time,
a loop break condition is considered to have occurred.

Note: If the time configured in LBTn is 0 (off), loop break detection is disabled.

Gain Scheduling
In some processes the tuned PID set may be different at low temperatures from that
at high temperatures particularly in control systems where the response to the
cooling power is significantly different from that of the heating power, or when
changes in the process have occurred. Gain scheduling allows a number of PID sets
to be stored and provides automatic transfer of control between one set of PID values
and another. For this instrument, the maximum number of sets is three which means
that two boundaries are provided to select when the next PID set is used. When a
boundary is exceeded the next PID set is selected bumplessly. Hysteresis is used to
stop scheduling oscillation at the boundaries.

Gain scheduling is basically a look up table which can be selected using different
strategies or types. Auto tune tunes to the active scheduled PID set.

The following Gain Scheduled types are offered from parameter ‘SchedTyp’:
Set Required set selected by the user. Alternatively soft wiring
may be used to control the PID set selection
Setpoint Transfer between sets is dependent on the setpoint value
PV Transfer between sets is dependent on the process value
Error Transfer between sets is dependent on the Error value
Output Transfer between sets is dependent on the output demand
value
Remote A remote parameter may be wired into the scheduler. The
PID set is then selected according to the value of this input.

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PV (e.g.)

2 - 3 boundary
1 - 2 boundary

Time
Set 1 Set 2 Set 3

Figure 78 Gain scheduling

SP Tab

Figure 79 SP tab parameters

The SetPoint (SP) tab provides parameters for configuring the control loop setpoint.
The control SP, defined as the Working SetPoint (Main.WSP), is the value used to
control the PV in a control loop, and can be:

1. SP.SP1 or SP.SP2 (configured by the user and switched into use by an external
signal or via a user interface).

2. SP.AltSP, an external (remote) analogue source.

SP.RateDone
SP.SPSelect SP.AltSPEn SP.SPRateDs
Yes
SP.RangeHi/ SP.RateSP Value used in
SP.SP1 No SP.RangeLo, Yes control algorithm
SP.SPHiLim/ No
SP.SP2 SP.SPTrim
SP.SPLoLim,
SP.AltSP Yes SP.SPTrimHi/ No
SP.SPTrimLo

Main.TargetSP Main.WSP
Ramp Max
Ramp
Other Inputs, i.e. PV, Ramp
rate, Servo, SP changed Ramp Status
Ramp Min

Figure 80 Set Point page block diagram

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When the control loop is configured, changes to the Target setpoint can cause abrupt
changes to the output value. By configuring Setpoint Integral Balance (‘SP.SPIntBal’),
abrupt changes, can be prevented, and the output power gradually changed in
accordance with the demand by a user via a User Screen.

This page also provides the facility to limit the rate of change of the setpoint before it
is applied to the control algorithm and provides upper and lower setpoint limits
(‘SP.SPHiLim’ and ‘SP.SPLoLim’), for the local setpoints ‘SP.SP1’ and ‘SP.SP2’.

‘SP.RangeHi’ and ‘SP.RangeLo’ provide range information for the control loop in the
control calculation to generate the Proportional Bandwidth (Span = SP.RangeHi -
SP.RangeLo). These parameters affect all SP values.

User configurable methods for tracking are available, providing smooth transfers
between SP values and between operational modes.

Maximum
Display Units
+Span

SP.RangeHi

SP.SPTrimHi

SP.SPHiLim

Main.WSP
SP.AltSP SP.SP1 SP.SP2 Main.TargetSP Alarms.all SP.SPTrim

SP.SPLoLim

SP.SPTrimLo

SP.RangeLo

-Span
Minimum
Display Units

Figure 81 Setpoint Limits

Setpoint Rate Limit (‘RateSP’)

‘RateSP’, allows the rate of change of setpoint to be limited to prevent step changes
in the setpoint. The parameter is a symmetrical rate limiter including any configured
Setpoint Trim (SPTrim) applied to the Working SP (Main.WSP).

RateSP’ is enabled by the Setpoint Rate Limit Disable parameter ‘SPRateDS’. If

‘RateSP’ is set Off, any change made to the SP will be effective immediately, but
when a value is set, any change in the SP will be take place at ta maximum rate of
RateSP. (in units per minute). ‘RateSP’ applies to ‘SP1’, ‘SP2’ and ‘AltSP’.

When ‘RateSP’ is active ‘RateDone’ will display ‘No’. When the setpoint has been
reached the value configured in this parameter, ‘RateDone’ will change to ‘Yes’, but
will reset to ‘No’ if the Target Setpoint, (TargetSP), is changed.

When ‘RateSP’ is set to a value other than Off, ‘SPRateDS’ can be used to
enable/disable ‘RateSP’, thus avoiding the necessity to switch this parameter
between Off and a value.

Setpoint rate limiting is suspended and ‘Main.WSP’ is set to zero if the PV is in

sensor break, (‘Diag.SensorB’ set ‘Yes’ and ‘Alarms.SBreak’ set ‘True’. When the
sensor break is cleared, ‘Main.WSP’ returns to the defined setpoint at the rate
configured in ‘RateSP’.

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Setpoint Tracking (‘SPtrack’)

Setpoint Tracking ensures that the Local setpoint (SSP1 or SSP2), follows the
Alternative Setpoint value (‘Alt-SP’), whilst ‘AltSP’ is selected. This ensures a
bumpless transfer when returning to ‘SP1’ or ‘SP2’. Bumpless transfer does not take
place when changing from Local to Remote.

If a setpoint rate limit value is configured, the change in setpoint value will take place
at the value set (in units per minute) when changing from ‘SP1’ or ‘SP2’ to ‘AltSP’.

The setpoint used by the control can be:

1. Local setpoint ‘SP1’ or ‘SP2’, selected using ‘SPSelect’, via serial

communications or by a digital input. SP1 and SP2 may be used, for example, to
switch between normal running conditions and standby conditions. If ‘RateSP’ is
set OFF, the new setpoint value is adopted immediately when the switch is
changed.

2. A remote analogue source. The source could be an input to an analogue input

module wired to ‘AltSP’ or it might be a User Value wired to ‘AltSP’. The Alternate
Setpoint is used when the ‘AltSPEn’ is set to ‘Yes’.

MANUAL TRACKING

When the control loop is operating in manual mode the currently selected setpoint
(‘SP.SP1’ or ‘SP.SP2’) tracks the PV. When the control loop resumes automatic
control there will be no step change in the resolved setpoint. Manual tracking does
not apply to the Alternate Setpoint (‘SP.AltSP’).

Servo to PV
After power cycling the instrument, the time taken to obtain the ‘Main.WSP’ can be
increased by configuring ‘SP.ServToPV’. When ‘SP.ServToPV’ shows ‘On’, the
measured PV (‘Main.PV’), is used as a start point for the Main.WSP. This decreases
the time required for the WSP to arrive at the TargetSP.
Value

Main.WSP
Main.PV

Main.TargetSP

ServToPV ServToPV
set Off set On Time

Figure 82 PV starting point

SP Tab Parameters
AltSP The value derived from the Alternative (remote) setpoint,
wired into the loop via an analogue input channel.
AltSPEn When ‘Yes’, the setpoint is taken from ‘AltSP’ input.
ManTrack ‘On’ enables manual tracking, allowing the currently se-
lected SP1 or SP2 to follow the value of the PV, so there is
no step change when automatic control resumes. ‘Off’ dis-
ables manual tracking.
Range Hi (Lo) High (Low) range limits for all setpoints within the control
loop
RateDone ‘Yes’ indicates that the setpoint rate limit has achieved its
target (i.e. the working setpoint has reached the target set-
point). ‘No’ implies that ramping is continuing.
RateSP Specifies the maximum rate-of-change for the setpoint.

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ServoToPV When ‘Yes’, the measured PV is used as the starting point

for the working setpoint.
When ‘No’, the working setpoint is reset and restarted.
SPRateDS ‘Yes’ allows the working setpoint to carry out step chang-
es. When ‘No’, the maximum rate-of-change is limited to
the RateSP value.
SPSelect Allows SP1 or SP2 to be selected as the current setpoint.
Read only if wired.
SP1 (2) Setpoint 1 (2) value
SPHiLim, SPLoLim Maximum and minimum values allowable for the setpoints.
SPIntBal When ‘On’, the setpoint integral balance calculation is ap-
plied when TargetSP is changed in order to ensure a
smooth response. When ‘off’ the calculation is not applied.
SPTrack ‘On’ enables setpoint tracking, allowing the currently se-
lected SP1 or SP2 to follow the value of the alternative set-
point, so there is no step change when switching from the
alternative setpoint to the local setpoint. ‘Off’ disables set-
point tracking.
SPTrim An offset value that can be applied to the setpoint.
SPTrimHi (Lo) The maximum and minimum values for ‘SPTrim‘
TrackPV The tracked PV value when tracking enabled.
TkPVStat The tracked PV status. ‘Good’ indicates that the PV is dis-
playing a trusted value derived from the process via an in-
put block. ‘Bad’ indicates that there has been a hardware
failure or that the relevant I/O module is missing.

OP Tab

Figure 83 Output (OP) tab

The Output (OP) function selects the correct output sources to be used, determines
whether to heat or to cool and then applies power feed forward, non-linear cooling
and limit values.

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The outputs, ‘OP.Ch1Outpt’ and ‘OP.Ch2Outpt’, are normally connected to an output

module and converted into an analogue or time proportioned signal for electrical
heating, cooling or valve movement. These parameters are limited using the upper
and lower output limits ‘OP.OutputHi’ and ‘OP.OutputLo’. The following additional
configuration may also be required,:

1. Individual output limits can be configured for each set of PID parameters when
gain scheduling is used.

2. ‘Diag.SchdOPHi’ and ‘Diag.SchdOPLo’ can be set to values that override the

gain scheduling output values.

3. Limits (‘OP.RemOPH’ and ‘OP.RemOPLo’) can be applied from an external

source. These parameters are wireable, e.g. they can be wired to an analogue
input module so that a limit can be applied through an external strategy.
However, if these parameters are not wired, ±100% limit is applied every time the
instrument is powered up.

The ‘tightest’ set, out of Remote and PID, is applied to the output if an overall limit
is applied using parameters ‘OP.OutputHi’ and ‘OP.OutputLo’.

4. ‘Diag.WrkOPHi’ and ‘Diag.WrkOPLo’ are read-only parameters showing the

overall working output limits.

Notes:
1. Tune limits are a separate part of the algorithm and are applied to the output
during the tuning process. The overall limits OP.OutputHi and OP.OutputLo
always have priority.
2. Each ‘OPHin’ and ‘OPLon’ is derived from a Tune_set block identified by the ‘n’,
where ‘n’ equals the PID set number.

PID page Diag page

PID.OPHi1 Diag.SchdO OP page Diag page

pHi (read only)
Diag.SchdO
OP.OutputHi
pLo (not Min Diag.WrkOpHi
PID.OPLo1 wireable) Working
Output
Diag.WrkOpLo
Tune_Set block OP page OP.OutputLo

OPHin OP.RemOpL

Output
limiting to +ve
OPLon OP.RemOpH

Tune page

Tune.HiOutput

Tune.LoOutput

Figure 84 Output Limits

Output Rate Limit (‘OP.RateOP’)

Output Rate Limit, allows the rate of change of output to be controlled in order to
prevent step changes in the output value. The limit is a symmetrical rate limiter
applied to the Working output (‘Main.WrkOP’), and is active in both auto and manual
modes. The limit is performed by determining the direction the output is changing,
and incrementing or decrementing the Working Output until it is equal to the required
Target Output.

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The incremental or decremental value is calculated based on the sampling (update)

rate of the algorithm, i.e. 100ms, and the configured OP.RateOP value. Any change
in output less than the rate limit increment will take effect immediately. The direction
and size of increment is calculated on every execution of the rate limit, so if the rate
limit is changed during execution, the new value takes effect immediately. If the
output is changed while rate limiting is taking place, the new value takes effect
immediately in the direction of the rate limit.

The limit is self-correcting so that if the increment is small and is lost in the floating
point resolution, the increment will be accumulated until it takes effect.

‘OP.RateOP’ is switched on and off by the Output Rate Limit Disable parameter
‘OP.RateDis’. If the limit is disabled (Off), any change made to the output takes effect
immediately, but when a value other than ‘Off’ is set, any change in the output will
take place at the set rate, in % per second.

When the limit is set to a value other than ‘Off’, ‘OP.RateDis’ can be used to disable
and enable the limit avoiding the necessity to switch the parameter between Off and
a value.

Sensor Break Mode (SBRKMode)

The Sensor Break Mode parameter determines the response of the control loop
when a Sensor Break is detected by the measurement system. When a sensor break
is detected, the output can be configured to adopt a pre-set value (‘OP.SbrkOP’), or
to remain at its current value (‘OP.SbrkMode’ set to ‘Hold’).

When ‘OP.SbrkMode’ = ‘SbrkOP’, the output ramps to the preset value at the rate
defined in ‘OP.RateOP’, (unless ‘OP.RateOP’ = ‘Off’, in which case output steps to
the preset value. When ‘OP.SbrkMode’ = ‘Hold’, the output of the loop remains at its
last good value. If an ‘OP.RateO’P value other than ‘Off’, has been configured, a
small step might be seen, because ‘Main.WrkOP’ limits to the two-second-old value.

When a Sensor Break has been cleared, the power output ramps from the current
value and transfers smoothly to the control value.

Forced Output (FORCEDOP)

This feature enables the user to specify what the output of the loop should do when
moving from automatic control to manual control. The default is that the output power
is maintained but it is then adjustable by the user.

If Manual Mode is set to ‘Step’, the user can set a manual output power value and on
transition to manual the output will be forced to that value.

If Manual Mode is set to ‘Track’ the output steps to the forced manual output and then
subsequent edits to the output power are tracked back into the manual output value.

If Manual Mode is set to ‘Last Man. Out’ then when moving from automatic to manual
mode, the output adopts the last manual output value.

Power Feedforward
Power feed forward (PFF) is used when driving an electrical heating element. It
monitors the line voltage and compensates for fluctuations before they affect the
process temperature, providing better steady state performance when the line
voltage is not stable.

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PFF is mainly used for digital type outputs which drive contactors or solid state
relays. Because it only has value in this type of application it can be switched off
using the parameter ‘OP.PwrffEnb’. It should be disabled for any non-electric heating
process.

Example

Consider a process running at 25% power, with zero error and then the line voltage
falls by 20%. The heater power would drop by 36% because of the square law
dependence of power on voltage. A drop in temperature would result. After a time,
the thermocouple and controller would sense this fall and increase the ONTIME of
the contactor just enough to bring the temperature back to set point. Meanwhile the
process would be running a bit cooler than optimum which may cause some
imperfection in the product.

With power feed forward enabled the line voltage is monitored continuously and
ON-TIME increased or decreased to compensate immediately. In this way the
process need never suffer a temperature disturbance caused by a line voltage
change.

Power FeedForward should not be confused with Feed Forward described below.

Cool Type
Cooling methods vary from application to application. For example, an extruder barrel
may be cooled by forced air (from a fan), or by circulating water or oil around a jacket.
The cooling effect will be different depending on the method. CoolType is used to
accommodate different types of cooling methods as follows:
Linear The cooling algorithm may be set to linear where the con-
troller output changes linearly with the PID demand signal.
Oil ‘OP.CoolType’ = ‘Oil’. As oil is essentially non-evaporative,
oil cooling is pulsed in a linear manner.
Water If the area being cooled is running well above 100°C, then
the first few pulses of water flash into steam giving greatly
increased cooling due to the latent heat of evaporation.
When the area cools, less (or even no) evaporation takes
place and the cooling is less effective.
Setting ‘OP.CoolType’ to ‘Water’ delivers much shortened
pulses of water for the first few percent of the cooling
range, when the water is likely to be flashing into steam.
This compensates for the transition out of the initial strong
evaporative cooling.
Fan ‘OP.CoolType’ = ‘Fan’. Fan cooling is much gentler than
water cooling and not so immediate or decisive (because
of the long heat transfer path through the process mechan-
ics). With fan cooling, a cool gain setting of three upwards
is typical. Delivery of pulses to the blower is non linear, this
non-linearity being caused by a combination of forced air
movement and fan efficiency as a function of air velocity
(e. g. the efficiency of a fan when producing a low speed
(laminar) air flow is different from its efficiency when pro-
ducing a high-speed, turbulent flow.

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Feedforward
Feed forward is a method of adding an extra scalable component to the PID output,
before any limiting. It can be used, for example, in the implementation of cascade
loops and constant head control or it can be used to pre-load the control signal with a
value close to that which is required to achieve the setpoint, thus improving system
response. Feed forward (FF) is applied such that the PID output is limited by trim
limits (OP.FFTrimLim) and acts as a trim on the FF value (OP.FFOP). This value is
derived either from the PV or setpoint by scaling the PV or SP by the ‘OP.FFGain’
and ‘OPFFOffset’. Alternatively, if OP.FFOP = Remote, a remote value may be used
for the FF value, but this is not subject to any scaling. The resultant FF value is added
to the limited PID OP and becomes the PID output as far as the output algorithm is
concerned. The feedback value then generated must then have the OP.FFOP
contribution removed before being used again by the PID algorithm. The diagram
below shows how feed forward is implemented.

OP.FFOffset OP.FFType
OP.FFType

Remote
SP
+
PV OP.FFGain +

- Feedback
+

SP.SP1 or OP.FFTrimLm
SP.SP2 Hi
+ Output Output
PV PID + Algorithm
Lo

Figure 85 FeedForward block diagram

OP Tab Parameters
C1OnOfHs Channel 1 hysteresis value in PV units.
C1PotBrk A potentiometer input module must be fitted, and the chan-
nel 1 wiper value wired directly to OP.C1PotPos. ‘Good’
shows that the input signal is valid. ‘Bad’ indicates that a
break has been detected in the circuit.
C1PotPos The value from a valve positional feedback potentiometer
associated with channel 1.
C1TravT Channel 1 valve travel time in seconds from closed (0%)
and fully open (100%).
C2OnOfHs Channel 2 hysteresis value in PV units.
C2PotBrk A potentiometer input module must be fitted, and the chan-
nel 2 wiper value wired directly to OP.C2PotPos. ‘Good’
shows that the input signal is valid. ‘Bad’ indicates that a
break has been detected in the circuit.
C2PotPos The value from a valve positional feedback potentiometer
associated with channel 2.
C2TravT Channel 2 valve travel time in seconds from closed (0%)
and fully open (100%).
Ch1Outpt The output value of channel 1
Ch2Outpt The output value for channel 2. When operating as a part
of a heat/cool process, this negative value is inverted to
give a positive value for driving a time-proportioning or dc
output.

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Ch2DeadB Deadband percentage value specifying the gap between

channel one going off, and channel 2 coming on, and
vice-versa. Used to ensure that heating and cooling are
not on simultaneously. For on-off control, the value is a
percentage of the hysteresis value.
CoolType The type of cooling mechanism used in the process, as de-
scribed above. Select from ‘Linear’, ‘Oil’, ‘Water’ or ‘Fan’
FFGain A scaling factor for the feedforward signal.
FFOffset An offset value for the feedforward signal.
FFOP Shows the calculated feedforward signal.
FFRem An alternative value to be applied as the feedforward sig-
nal. Gain and offset are not applied to this input.
FFTrimLim Defines symmetrical limits about the PID output which are
applied to the scaled feedforward signal.
FFType Feedforward type:
None Feedforward disabled.
Remote The feedforward input comes from a remote
source.
SP The feedforward value is derived from the
working setpoint, scaled by FFGain and FFOff-
set.
PV The feedforward value is derived from the pro-
cess variable, scaled by FFGain and FFOffset.
ForcedOP The output power value to be adopted in manual mode op-
eration when man-Mode=Step.
ManMode Specifies the power output during manual mode:
Track The output is derived from last control output.
Step The output is the value set in ‘ForcedOP’.
LastMOP the output is the value last configured by the
operator in ‘ManOp’.
ManOP Manual output power. Used in manual mode when Man-
Mode = LastMOP or Track. ManOp follows the control out-
put in Auto mode.
ManStart If ‘On’, then Auto/Man (Main tab) is set to Man at startup.
If ‘Off’ Auto/Man remains as configured.
NudgeUp (Dn) Used to open (NudgeUp) or close (NudgeDn) a valve by
one minimum on time, allowing the valve position to be
controlled over a serial link, or by contact closure inputs to
a digital input module.
OutputHi (Lo) The maximum output power values delivered by channels
one and two. ‘Outputlo’ would normally be set to 0% for
heat only processes.
PBrkMode Defines the action to be taken in a bounded valve position-
ing system if the feedback potentiometer status is ‘Bad’.
Raise The output raises the actuator.
Lower The output lowers the actuator.
Rest The actuator remains where it is.
Model The output uses a model to predict actuator
position.
PotCal Controls automatic calibration of the specified channel po-
sition input. A potentiometer input module must be fitted,
and the wiper values wired directly to OP.C1PotPos for
channel 1 or to OP.C1PotPos for channel 2.
Off: Automatic pot calibration disabled.
CalibrateCh1. Automatic calibration of channel 1 pot ena-
bled.
CalibrateCh2. Automatic calibration of channel 1 pot ena-
bled.

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PwrffEnb Enables Power Feed forward. Must be disabled for any

load other than electric heaters. Power feed forward allows
fluctuations in line voltage to be compensated for before
they can affect the process.
PwrffIn Instantaneous value of the supply voltage. See ‘Power
feed forward’, above.
RateOP Output rate limiting. The maximum rate at which the PID
output may change in % per minute. Effective only if
‘OPRateDis’ is ‘Off’. Can be disabled by setting its value to
zero.
RateDIS Enables/disables output rate limiting.
RemOPH, REMOPL The high and low limits for loop output, derived from a re-
mote source or calculation.
SafeOP Defines the output power to be adopted if ‘Inhibit’ is ena-
bled in the Main tab ("Main Page" on page 102).
SbrkMode Defines the output action if the PV is ‘bad’.
SbrkOP The output adopts the value entered in
SbrkOP.
Hold The output is maintained at the last good PV
value.
SbrkOP Specifies the output value to be adopted if a sensor break
is detected, and ‘SbrkMode’ = SbrkOP.
TrackEn When ‘On’, the loop output follows the track output value.
TrackOP Shows the current tracked value if TrackEn = On.

Diag Tab

Figure 86 Diag tab

The Diagnostic tab provides parameters that assist in the commissioning of the
control loop. The parameters are generally read only, but can be wired from to
produce an application specific strategy. For example, ‘Diag.

LpBreak’ can be wired to an output module to produce a physical output if the Loop
Break Time, ‘PID.LBT’, is exceeded.

Additional gain scheduling parameters are also provided. These display the current
values of the control time constants as set by the active PID list and determined by
Gain Scheduling.

DIAG Tab Parameters

DerivOP The percentage contribution that the derivative term is
making to the control output.
Error The calculated error signal showing the difference be-
tween the working setpoint and the PV.

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InOP The percentage contribution that the integral term is mak-

ing to the control output.
LPBreak Yes = a loop break has occurred (i.e. the PV has not re-
sponded to a change in output within the Loop break time
for the current PID set). No = a loop break has not oc-
curred.
PropOP The percentage contribution that proportional band is mak-
ing to the control output.
SchdLPBrk The loop break time value for the current PID set.
SchdOPHi (Lo) The current output high and low values for the current PID
set.
SchedCBH (CBL) Cutback High and Low values for the current PID set. ‘Au-
to’ = 3 x proportional band.
SchedMR The manual reset value for this PID set.
SchedPB The proportional band setting for the current PID set.
SchedR2G The relative cool gain value for the current PID set
SchedTd The derivative time for the current PID set.
SchedTi The integral time for the current PID set
SensorB ‘Yes’ = sensor break has been detected.
TargetOP The requested control output.
WrkOPHi (lo) High and low power output limits.

Alarms Tab

Figure 87 Alarms tab

The Alarms tab of the Loop block provides parameters that define the alarm limits
applied during the operation of the control loop.

ABSOLUTE ALARMS

The following absolute alarm types are available:

1. High High Absolute (Alarms.HiHi). HiHighAl = True when PV>’HiHigh’

2. High Absolute (Alarms.Hi). HighAl = True when PV>’High’

3. Low Absolute (Alarms.Lo). LowAl = True when PV<’Low’

4. Low Low Absolute (Alarms.LoLo). LoLowAl = True when PV<’LoLow’

The action of these four multipurpose parameters depends on which type of alarm
function is selected (via the Type parameter):

An alarm is not reset immediately that PV returns to a ‘safe’ value - the PV must be
inside the level by a margin equal to the hysteresis parameter (Alarms.Hyst) before
the alarm resets. Hysteresis permits clean transitions into and out of the alarm
condition. The configured Hysteresis value will be applied.

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DEVIATION ALARMS

The following deviation alarm types are available:

1. High Deviation (Alarms.DevHi) HighAl = True when PV-Setpoint >’High’

2. Low Deviation (Alarms.DevLo) LowAl = True when Setpoint -PV >’Low’

The high alarms are set when the positive deviation exceeds the defined levels. The
low alarms are set when the negative deviation exceeds the levels:.

Hysteresis is applied to deviation values as it is to PV in absolute alarms.

HYSTERESIS

A hysteresis value (Alarms.Hyst) in engineering units, is applicable to the High

Absolute and Low Absolute Alarm limits and the High Deviation, Low Deviation Alarm
limits. This value provides a band that defines when the alarm limits are set TRUE.
Once an alarm has been annunciated, it is not cleared until the value causing the
alarm has returned inside the limit by an amount specified by this parameter.

Effect of Control Action, Hysteresis and Deadband

Control Action
When configuring temperature control, the parameter ‘Setup.CtrlAct’ should be set to
‘Rev’. If using PID control this means the heater power decreases as the PV
increases, but if using on/off control, output 1 (usually heat), is full on when PV is
below the SP and output 2 (usually cool), is full on when PV is above the SP.

Hysteresis
Hysteresis (Alarms.Hyst) applies to on/off control only and is configured in the units
of the PV. In heating applications the output turns off when the PV is at SP and turns
on again when the PV falls below SP by the hysteresis value, see below.

Hysteresis is used to prevent the output from repeatedly switching on and off as the
PV drifts around the control SP. If Hysteresis is set to 0, any change in the PV, when
operating at SP, will change the output, possibly causing unacceptable chatter.
Hysteresis should be set to a value that provides acceptable life for the output
contacts, but does not cause unacceptable oscillations in the PV.

Note: If this performance is unacceptable, it is recommended that PID control be

attempted instead.

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Display Units

Strategy Configuration
Hyst.C (Cooling Heat/Cool type On/Off Control
Hysteresis) Setpoint (SP) 300°C
SP 300°C Control Action Reverse
Heating Hysteresis 8°C
Hyst.H (Heating Cooling Hysteresis 10°C
Hysteresis) Channel2 Deadband Off

Timing
A SP + Hyst.C = 300°C,
OP1 On
Heating turned off
(Heating 100%) B SP + Hyst.C = 310°C,
Cooling turned on
No OP C SP - Hyst.H = 300°C,
Cooling turned off
OP2 On D SP - Hyst.H = 292°C,
(Cooling 100%) Heating turned on
A B C D Time

Figure 88 Hysteresis applied, Deadband not applied

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Task Organisation
Task Scheduling
All in-built and user-programmed instructions are performed serially (i.e. one after the
other).

Tasks
A Task is a unit of software that is responsible for carrying out particular duties at
certain times, usually while the Database is running. There are multiple tasks, and
some of the more principle ones are discussed here.

Most Tasks are fixed and cannot be varied by the user. Others, the user tasks, are
programmable, as described in ‘USER TASKS 1 TO 4’, below.

Priorities
Each task has a priority based on its importance to efficient and safe operation. A
task, once started, will run to completion unless it is interrupted at any time by a task
of higher priority. In such a case, the lower priority task suspends activities until the
higher priority task has finished, at which point it resumes running. These
interruptions are hierarchical; several tasks may be suspended by higher priority
tasks at any one time.

Functions
A list of Task functions is given in the table shown in Figure 89, below.

The following six tasks are the block servers and are under the control of the
configuration engineer.

User Tasks 1 to 4
User Task 1, Fast I/O task (10ms) and User Task 3, Slow I/O Task (110ms) are
synchronised with the I/O modules and are module type specific (Figure 90, below).
The associated I/O blocks can be assigned to User Task 1 or User Task 3, as
applicable.

Any blocks added to the database are automatically assigned to User Task 3 by
default. If the SFC_CON block (and associated Sequences) were assigned to
operate on User Task 4, the configured strategy must take into account that data may
be missed when reading and writing values between Sequences and the I/O blocks.
For example, consider the case where User Task 3 is updated at 110ms intervals and
User Task 4 is updated at 250ms intervals. A possible order of task execution is:

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Other Tasks ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

User Task 3 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

User Task 4 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Data from this execution of User task 3 is not

available for the next execution of User Task 4

Cache Sync Server

This Task is used to maintain synchronisation of cached blocks. The task is repeat
driven every 110ms, but this may be extended depending on the amount of CPU time
remaining after User Tasks have been serviced.

Cache Conn Server

This Task is responsible for processing LIN field writes into and out of cached blocks.
The task is repeat driven every 110ms, but this may be extended depending on the
amount of CPU time remaining after User Tasks have been serviced.

Task Schedule Function

Tick Every 5ms Provides system check

netHOST (x6) Event driven Profibus Master communication is
managed via a netHOST gateway
device. A total of six tasks are
devoted to the management of, and
communication to, the netHOST
device.
Rx_ICM Event driven Processes messages received over
the ICM
Rx_LIN Event driven Processes messages received over
the LIN
ICM_Mgr Every 50ms Monitors ICM link low level status.
Applies timeouts to transmitted
messages.
Re-programs ICM hardware if errors
detected.
PRMT Event driven <100ms Process redundancy management
task. Responsible for effecting and
maintaining synchronisation between
redundant processors.
Pr_Px Every 100ms (approx.) Processes messages received using
port resolution protocol (PRP) over
ELIN
EDBserv (x2) Every 10ms (approx.) Manages ELIN communications with
external databases via cached blocks.
Network Event driven ‘Housekeeping’ for all LIN
transactions
File sync Event driven Responsible for maintaining
synchronisation of filing systems on
redundant systems

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Task Schedule Function

Mod_Rx (x3) Event driven Processes messages received via

Modbus Gateway. There are three
tasks devoted to this.
Profibus Master (x4) Periodic Tasks associated with various
aspects of managing Profibus data
(cyclic, acyclic and diagnostic tables
and general communications
management). There are four tasks
devoted to this.
ModServ (x3) Periodic Modbus database management.
There are three tasks devoted to this.
User task (x4) Every TskRptn secs Runs User task 1 and User task 3
synchronised with fast and slow I/O
task modules respectively. Both user
tasks 1 and 3 run at integer multiples
of the repeat rate. That is User task
one runs at multiples of 10ms and
user task 3 runs at multiples of
110ms. User tasks 2 and 4 run at the
repeat rate set in the header block.
Cache Sync Server Min default 100ms Maintains synchronisation of cached
blocks
Cache Conn Server Min default 100ms Responsible for LIN field writes into
cached blocks
LLC Every 110ms (approx.) Monitors LIN link low-level status.
Applies timeouts to transmitted
messages.
Re-programs LIN hardware if errors
are detected.
NFS Event driven Network Filing System. Processes
LIN filing requests.
TTermcfg Event driven Runs the terminal configurator
accessed via a Telnet session
Pr_Maint Every 500ms (approx.) PRP database management
Load Event driven Loads a database as a result of a
remote request
Panel Event driven Runs the operator interface
Config Event driven Runs the terminal configurator via the
serial port
BatLoad Event driven Responsible for batch load operations
(e.g. loading/unloading SFCs)
Bgnd (scan) Event driven Collates alarm information. Performs
database checksum testing
Idle Event driven ‘Null’ task. Provides an environment
for CPU execution whilst no other
tasks run.

Figure 89 Task scheduling

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Slow task rate Fast task rate Slow task rate Fast task rate
Module type Module type
(110ms) 10ms (110ms) 10ms
AI2 yes no AI3 yes no
AI4 yes no AI8 (TC) yes no
AI8 (MA) yes no AI8 (RT) yes no
AI8 (FMA) yes yes AO2 yes yes
DI4 yes no DI6 yes no
DI8 yes yes DI16 yes yes
DO4 yes yes DO8 yes yes
DO16 yes yes RLY4 yes yes
RLY8 yes yes FI2 yes yes
ZI yes no

Figure 90 Module task rate applicability

User Tasks

Terminology

User Task
A User Task is a defined set of function blocks in a database that are updated at a
specific tick rate. The blocks are normally associated with instrument control.

Block Server
A Block Server is a fixed software task, within this instrument, that executes a User
Task, or processes cached blocks.

Execution Times
User Task execution times are repeat driven. User Task 1, and User Task 3 are
synchronised to the fast and slow I/O task modules respectively. Both run at an
integer multiple of the repeat rate, i.e. User Task 1 runs at N × 10ms, and User Task 3
runs at M × 110ms, where N and M are integers.

User tasks 2 and 4 run at rates defined in the header block.

User task 1 has the highest priority, followed (in descending order) by User Task 2,
User Task 3 and User Task 4 (lowest priority).

Note: All I/O blocks must be configured to User Task 1 or User Task 3.

Each of the 4 User Tasks has a ‘requested repeat rate’. This can be configured using
LINtools (Task n Period) or the Terminal Configurator (Block Full Description page).

Each function block has a Task field used to allocate it to one of the four available
User Tasks. This field can also be used to configure the ‘requested repeat rate’ of the
User Tasks. If the ‘requested repeat rate’ is changed via a function block allocated to
a particular User Task, this change is made to the User Task, not the function block,
and it affects all other function blocks assigned to that User Task.

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If using the LINtools Database Editor, selecting the Task field from the function block
Object Properties Pane reveals the Task dialogue which permits changes to the Task
Number associated with the function block. To enable changes to the Task Period
(i.e. to the ‘requested repeat rate’), click the right (next) arrow button to display the
Task Period dialogue.

If the requested repeat rate is not configured (LINtools Task n Period dialogue or
Terminal Configurator Rate ms field set to 0) the default request repeat rate is applied
i.e.10ms for User Task 1 and User Task 2, and 110ms for User Task 3 and User Task
4.

Note: Tasks must not be configured to use a faster requested repeat rate than any
higher priority task. Any such configuration will be ignored by the instrument, but will
be run according to the rules stated in "Usertask Block" on page 141, below.

User Task Block Servers

Block Server Interactions

There are six block servers in this instrument, one for each of the User Tasks, and
two for the cached blocks (see Figure 89). The block servers are prioritised,
repeat-rate driven, and fully coherent, (see "Data Coherence" on page 142, below).

The instrument’s block structured LIN Database supports cached blocks by showing
local ‘image’ of a remote function block, i.e. a function block running in another
instrument on the LIN. The cached function block allows interaction with the remote
function block. In a cached function block, the DBase field specifies the name of the
remote LIN Database containing the ‘real’ function block.

Block Server 1 has the highest priority, and block server 6 the lowest. Interruption of
one block server by another of higher priority (see "Priorities" on page 135, above).
The User Task block servers will only start at intervals specified by the corresponding
Task repeat rate. If the task continues beyond the task repeat time, it will be
suspended until the next task repeat time, e.g. User Task 1 is set to repeat every 10
ms, but lasts 10.25 ms, it will start again at the next scheduled repeat time.

Figure 91 shows how the block servers interact with one another according to their
priorities. The darker bars represent running tasks and the paler bars represent
suspended tasks.

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User Task 1
Synchronised to start every 10ms
User Task 3
Task running
Synchronised to start every 110ms
Task suspended T1used T3used

User Task 1 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

User Task 2
Priority

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

User Task 3 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

User Task 4 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Cached sync server ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Cached conn server ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Time

Figure 91 User task block server interactions

User Task Block Server Operation

A higher priority user task block server always interrupts the running of a lower
priority user task block server.

Thus, whenever a given user task is running, all higher priority user tasks must have
run to completion.

Figure 92 shows, schematically, the sequence of events that occurs during the
running of a user task block server. These are as follows:

1. The user task is marked as ‘busy’. During this ‘busy’ period lower priority tasks
are suspended.

2. All connections sourced from higher priority tasks are copied into their
destination blocks in this user task. This occurs as a single, indivisible, operation.

3. The blocks and their associated intra-task connections are then executed in
order.

4. All connections sourced from this user task are now copied into their destination
blocks in all higher priority user tasks, as a single, indivisible, operation.

5. The task ‘busy’ flag is removed.

This structure results in the least work being carried out by the highest priority task.

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Connection
Connection

Mark Input connects Output connects Mark task

task as from higher from higher as
‘busy priority tasks Execute blocks priority tasks ‘unbusy

Coherent task body

Figure 92 User task block server operation

User Task Tuning

At Database start-up, various checks are performed on the requested task repeat
rates. Starting with the highest priority task, each block server check to ensure that:

1. Any requested repeat rate is not higher than any higher priority block server task.
Any lower priority block server task configured with a higher repeat rate is
adjusted to match the next highest priority task.

2. The repeat rate for the I/O synchronised block servers (User Task 1 and User
Task 3) is an integer multiple of the I/O repeat rate (10ms for task 1; 110ms for
task 3).

Usertask Block

Figure 93 USERTASK block

In order to ensure smooth running, the amount of time used in executing all the
blocks in all the tasks must not exceed 90% of the time available, otherwise there is
insufficient time for non-task events (e.g. FTP transfers) to take place.

The LINtools USERTASK diagnostic block includes two read only parameters for
each task: ‘T1used’ to ‘T4 used’ and’ T1period’ to ‘T4 period’. When online to an
instrument, these allow the user to calculate the percentage usage for each task and
then to add them together. In the example above, task 1 is used for 1ms out of 10 ms
(10%) and task 3 for 4ms out of 110ms = approximately 3.6%, giving a sum total of
something less than 14%.

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If the usage is more than 90%, the user has two choices - either to move some blocks
to slower tasks, or to increase the repeat period for the relevant task.

Stretch
If the above precautions are not taken, and the usage time attempts to exceed 90%
of the time available, the period is automatically extended by a stretch factor, to
ensure block execution can be achieved within 90% of the adjusted period.

Notes:

1. The stretch factor is applied only when it is >1 (i.e for stretch values of = 1, the
tasks run at their configured rates).

2. The ‘Stretch’ parameter should ideally be 0.5 or less.

Data Coherence

Data Flow Between Tasks

Data coherence is an important aspect of those control strategies which involve more
than one user task. Data flow is defined as being coherent if, during any single
execution of a task, the data input to it from outside the task is a ‘snapshot’ -
unchanging during the execution of the task - and represents the values output from
other tasks that have completed their execution.

Data coherence, by definition, refers to connections that are ‘remote’ (i.e. linking
different tasks). Connections that are limited to within a task (i.e. ‘local’), are copied
from source to destination immediately before executing the destination function
block.

For any task, there are three types of remote connection. These types, and the way
in which data coherence is ensured, are as follows.

Connections from Other Tasks in the Same Instrument (Node)

In order to ensure that multiple uses (in this task) of the same value (from another
task) always use the same iteration of the value, such values are copied prior to the
execution of all the executable blocks of this task -i.e. a ‘snapshot’ is taken of all
values external to this task.

Two types of connection apply - those from higher priority tasks to lower priority
tasks, and those from lower priority tasks to higher priority tasks:

1. Higher to lower priority. For coherence, whenever connections out of a task are
used, all their values must result from the same iteration of that task. Owing to
the priority structuring of the tasks, any connections from a higher priority task
into a lower priority task meet this requirement because a lower priority task
cannot interrupt a higher priority task, which therefore always runs to completion.
Hence, these connections are dealt with by a ‘snapshot’ copying at the start of
the lower priority task.

2. Lower to higher priority. A low priority task may be interrupted by a higher priority
task before completion, and so be ‘caught’ with an incoherent set of output
values. To avoid such invalid values being passed on, the last action of task
execution is for the lower priority task to copy its set of coherent connections as a
‘snapshot’ to the higher priority task. In this way, the values passed on are always
the last set of coherent values from a complete task execution.

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Connections from Tasks in Another Instrument

Connections between nodes are effected by the use of cached blocks. The process
of cached block transmission, and reception at the destination end, is coherent for all
the data within that function block.

At the destination end, the cached block exists on a cached block server.
Connections from this cached block to other blocks effectively become inter-server
connections within the same node, the coherence of which is guaranteed (as
described in 'Connections into tasks...', immediately above).

Connections Out of this Task to Another Instrument

This type of connection results in data flow that is not coherent, because the data is
transmitted across the network as individual field writes, rather than complete block
updates. If coherence is required, the block(s) can be cached in the opposite
direction, via an AN_CONN block for example. This is illustrated in Figure 94, where
block A coherently connects to block B across the LIN via the AN_CONN block (bold
lines), but the connection is non-coherent when routed via cached block B. The
coherent method is preferred as this is more efficient (in terms of communications
throughput and impact on local user task execution).

NODE 1 Coherent Block NODE 2

Update
Coherent
A AN_CONN AN_CONN
<local> <cached>

Non-coherent
field write
Non-coherent B B
<cached> <local>

Figure 94 Coherent and non-coherent data flow across network

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144 HA030047 Issue 16

T2750 Eurotherm PAC Event and Health Logs

Event and Health Logs

As of T2750 v4/0, there are two primary event and health logs that are generated in
the instrument to aid the diagnosis of problems within the system. The Event Log
(EVENT.UDZ) records and store individually time stamped (real-time clock and
instrument internal time) events generated in the instrument, and provides an
indication of the impact of an event on the system. It contains a comprehensive log of
events, and as such, may require assistance from Eurotherm to aid analysis. The
Health Log (HEALTH.UDZ), however, introduced in T2750 v4/0, provides a
user-friendly, plain language log, with messages from both the left and right IOC in a
single file.

Health Log
The Health Log is the recommended log to examine in the first instance to aid
diagnostics. The file can be retrieved (using LIN Network Explorer or directly from the
instrument’s SD card if the instrument is powereddown and the SD card is inserted in
a separate card reader) from either the left or right IOC (if running in a duplex
configuration) as the file includes entries from both processors. The records are
stored as an ASCII format using a single line for each event and written in the local
language selected via the Instrument Options Editor. The Health Log also includes
three header lines at every power-up or reset making the file contents easier to read.

As from T2750 v4/0, the log includes information concerning duplex operation and
general status information. A ‘!’ symbol in the first column indicates a condition which
needs attention; all other messages are normal operation. "Health Log" on page 145
shows an example Health Log.

T2750 4/0 (Revision: 88066) Created: Jun 01 2017, 22:55:40; Bootrom: 3.0 ; Hardware: 1; Serial no:
217439
LIN Node: 0x0004; Protocol Name: "NET"; IP Address: 192.168.1.85; Subnet Mask: 255.255.255.0
Hot Start: enabled; Cold Start: enabled; Time Zone UTC Offset: 0 (Minutes); DST: Inactive

Status,Time (UTC) ,Side ,Role ,Class ,Message

,04/05/17 09:28:50,Left ,Secondary,Status ,Power on / reset
,04/05/17 09:28:50,Right,Secondary,Status ,Power on / reset
,04/05/17 09:28:54,Left ,Primary ,Status ,ELIN health status changed = healthy
,04/05/17 09:28:55,Left ,Primary ,Status ,Power up start result: cold started
,04/05/17 09:28:55,Left ,Primary ,Status ,Started database: FERMENT.DBF
,04/05/17 09:28:55,Left ,Primary ,Redundancy,Start of changeover following: normal Primary database
start
,04/05/17 09:28:55,Left ,Primary ,Redundancy,Changeover completed (units not synchronised): strategy
is running
,04/05/17 09:28:53,Right,Secondary,Status ,ELIN health status changed = healthy
,04/05/17 09:28:54,Right,Secondary,Status ,Power up start result: empty
!,04/05/17 09:30:31,Left ,Primary ,Redundancy,Relative view of ELIN health has changed:Primary is
better

Figure 95 Health.udz log example

Event Log
Event records are stored in a ASCII text file, using a single line for each event. An I/O
Subsystem with provision for two Processors use two Event Log files, ‘event_l.udz’
and ‘event_r.udz’ for left and right processors respectively. Eventually, as more event
records are automatically added, the oldest event records are removed from the file.
The file indicates the impact of the event on the system using the ‘!’ character. Status,
Warning, Error, and Major Error, are represented by 0, 1, 2 or 3 ‘!’ characters
respectively.

Because the Event Log can be very detailed, assistance from Eurotherm may be
required in order to interpret the output. Figure 96 shows part of a typical event log.

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Event and Health Logs T2750 Eurotherm PAC

T2750 4/0 (Revision: 88066) Created: May 01 2017, 22:55:40; Bootrom: 3.0 ; Hardware: 1; Serial no:
217439
LIN Node: 0x0004; Protocol Name: "NET"; IP Address: 192.168.1.85; Subnet Mask: 255.255.255.0
Hot Start: enabled; Cold Start: enabled; Time Zone UTC Offset: 0 (Minutes); DST: Inactive

Stat Time (UTC) (XEC time :hires ) Code Message

04/01/00 05:52:49 (0x0000007E:1F898272) 81FF Power On / Reset
! 04/01/00 05:52:50 (0x00000107:2135A7AF) 81F1 POST result = SRAM is not initialised
! 04/01/00 05:52:50 (0x00000107:2135ACD8) 815A Last Shutdown Msg 1: Unknown
04/01/00 05:52:50 (0x00000109:213C205A) 92E3 Read Red Power Data = 0
04/01/00 05:52:50 (0x00000127:219B8BC1) 81FC Attempt to check for licence file E:00217439.UTL
04/01/00 05:52:50 (0x0000012F:21B4C7B9) 81F9 Licence file not found
!! 04/01/00 05:52:50 (0x00000130:21B6F71E) 81FA _system.opt: COM3 invalid hardware
!! 04/01/00 05:52:50 (0x00000130:21B706A8) 81FA _system.opt: COM4 invalid hardware
!! 04/01/00 05:52:50 (0x00000130:21B71DB9) 81FA _system.opt: PROFIBUS1 invalid timeout
!! 04/01/00 05:52:50 (0x00000130:21B72BFB) 81FA _system.opt: PROFIBUS2 invalid timeout
04/01/00 05:52:50 (0x00000139:21D3BFAE) 92EE Waiting for other CPU to initialise = 0
04/01/00 05:52:50 (0x00000143:21F2557F) 92E9 Time waited to establish ICM comms = 10
04/01/00 05:52:51 (0x000001D3:23B7F221) 92E5 Successfully coupled
04/01/00 05:52:51 (0x000001D3:23B7F69C) 92EC ICM communications established - so attempt to
resolve mode
04/01/00 05:52:51 (0x000001D3:23B7F978) 92FB Instrument initial mode SECONDARY

Figure 96 Event.udz log example

Status
The Event Log file, supports the recording of the following events:

No ‘!’ Characters
This indicates normal operation events such as: power up, database start, database
stop, Online Reconfiguration operations, normal synchronisation of a redundant pair,
etc.

One ‘!’ Character (Warning)

Single ‘!’ characters indicate minor abnormalities, e.g. hot start fails due to power off
time exceeded, controlled changeover of a redundant pair, etc.

Two ‘!’ Characters (Error)

Double ‘!’ characters indicate real faults on the system, for example, automated
changeover of a redundant pair due to a detected fault, or the running of serial
communications on unsupported versions of this instrument causing corruption of
communications bus on power-up.

If any Error is written to the Event Log file, the ‘Alarms.EventLog’ and
‘Status.EventLog’ fields of the database Tactician header block are set True and this
provides an output that can be linked to a display to provide immediate identification
of a problem that can have an effect on the system.

Three ‘!’ Characters (Major Error)

Three ‘!’ characters, indicate real faults in the execution of the instrument that must
be investigated before continuing. If any Major Error is written to the Event Log file,
the ‘Alarms.EventLog’ and ‘Status.EventLog’ fields of the database header block are
set True and this provides an output that can be linked to a display to provide
immediate identification of a problem that can have an effect on the system.

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T2750 Eurotherm PAC Data Management

Data Management
Data Management records selected parameters’ values derived during run-time and
saves them as .uhh files in the flash memory of the instrument. These files can then
be archived automatically to a maximum of three FTP (File Transfer Protocol)
Servers, or if the USB application is so configured ("USB Configuration" on page 70),
to a memory stick inserted into the USB connector on the I/O controller module
terminal unit (Figure 9).

Data recording is configured using LINtools and this configuration is downloaded to

the instrument along with the database (.dbf) file.

Instrument flash memory problems can be investigated by inspecting the

‘RMEMDIAG’ block. Archiving problems may be investigated by inspecting the
‘RARCDIAG’ block. Both of these blocks are described in "Data Management" of the
LINBlocks reference manual.

Data Recording

Data Recording (*.uhh) File

The *.uhh file is an electronic tamper-resistant file that is used to record the values
derived from the instrument. The file is saved in a proprietary format, that can be
interpreted only by ‘Review’ software. Review can be configured to display files from
different groups and different instruments on the same ‘chart’ or spreadsheet.

Data Recording Groups

Data Recording Groups provide a method of organising recorded data. For example,
a single group can be created for each individual area of a plant/system. Each
relevant LINblock field is assigned to a group, identified by an ‘RGROUP’ block, each
group recording the configured field value at a specified rate. Fields may be assigned
to multiple groups, allowing them to be recorded at different rates.

It is possible to record up to eight groups simultaneously, i.e. one ‘RGROUP’ block

per recording group, with a maximum of 127 data values per group.

Data Archiving
Data archiving is the process of copying recorded data from the internal flash
memory to up to three FTP Servers or to a USB memory stick. The archived *.uhh file
can then be replayed using an off-line tool (‘Review’ software).

FTP servers are configured as follows:

1. Right click on Instrument folder.

2. Left click on ‘Properties’.

3. Left click on the Instrument options tab.

4. Left click on the ‘Archiving’ icon.

5. Click in the ‘False’ field and select ‘True’ from the pulldown menu.

6. Click in the 0.0.0.0 field and type-in the IP address of the relevant host computer.

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7. Fill in the remaining Directory, user name and password information as required.

File Transfer Protocol (FTP)

File Transfer Protocol (FTP) is a commonly used Server/Client transfer mechanism. It
allows the instrument to act as a FTP client to up to three FTP Servers for the
purpose of transferring recorded files from the flash memory to a remote computer.
When multiple FTP Servers can be configured to provide a back-up service for
archiving, and in such cases, the *.uhh files are archived to all defined FTP Servers.

It is necessary that each relevant host computer be configured to act as an FTP

server and the services of the user’s IT department or the Network Administrator may
be needed in order to achieve this, particularly if there are company ‘firewalls’ or
other security systems in place.

Data Management Configuration

Data Management is configured using LINtools.
Groups of recorded fields are defined in the instrument
database, and can be individually customised using the
Data Recording Configurator accessed by clicking on
‘Data Recording’ in tree view. Configuring individual
fields provides a clear identification of each recorded
field when displayed in Review.

To configure data management,

1. Define the data recording configuration using LINtools. There must be as many
‘RGROUP’ blocks on the worktop as the required number of groups.

2. Define the data archiving configuration using the Instrument Properties in

LINtools.

3. Define the data visualisation configuration using Review.

4. Configure the FTP server(s).

Note: Review can import files directly from the instrument, as configured in the
‘Review’ Auto-Backup + Transfer facility. A User Name, (‘history’), and a Password
(‘history’) are required.

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LINtools data
recording
configuration

FTP server

Archive files to
FTP server Primary Primary
Download
strategy from
LINtools

Display data on T2750PAC

Review ‘chart’.

‘Review’ chart

Figure 97 Data management overview

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T2750 Eurotherm PAC Setpoint Programmer

Setpoint Programmer
The Setpoint Programmer creates a profile consisting
of Ramp and hold segments. The output or current
setpoint (PROGCHAN.Monitor.CurrSP) of the channel
is the demand value, and should be wired to the
setpoint of a control loop, e.g. LOOP_PID.SP.AltSP,
together with the loop PV itself, so the loop can control
an output, typically via an AO_UIO block, to drive the
process.

A program template is first created using the

‘Programmer Wizard’, accessed from the LINtools
‘Tools’ menu. This contains basic information such as
the number of Channels and their names, the number
of Digital Events, Wait Conditions, Exit Conditions,
User Values, the maximum number of segments the
Figure 98 Tools menu
channels are to have, etc.

Once the program template has been created, a Program file can be generated,
using the Programmer Editor, which allows the user to enter segment details.

Program Template Creation

As mentioned above, program template (*.uyw) files are created using the
Programmer Wizard. Once created, such files may be edited only via the wizard.

The wizard creates a PROG_WIZ compound in the database file, containing:

1. One PROGCTRL block, used to control the overall execution of the Setpoint
Program

2. Up to eight PROGCHAN blocks, one for each profiled setpoint in the compound,

3. Up to eight SEGMENT blocks per channel, each SEGMENT block offering four
program segments

The wizard can also be used to specify the maximum number of digital event outputs,
user values and segments allowed in the Program. The total number of digital event
outputs, user values and Wait/Exit conditions is limited by the size of the Database
file and the remaining number of PROGCHAN blocks available.

Additional PROGCHAN blocks are automatically created if more than 16 digital event
outputs and four user values are requested, but a maximum of eight PROGCHAN
blocks can exist in a PROG_WIZ compound.

The Program Template file can be referenced by a local instrument or any other
instrument on the same network allowing the same file to apply to multiple
instruments.

Template Creation
The following sequence illustrates the creation of a simple setpoint program
template, with three channels having a maximum of eight segments each. The
screen ‘Help’ has been disabled in order to save space.

1. With LINtools running, click on the Tools menu, then on ‘Programmer wizard’
(Figure 98, above).

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Setpoint Programmer T2750 Eurotherm PAC

2. The PROGCTRL Name display page appears. Enter a four-character name for
the block and click on ‘Next’.

3. The ‘Program Template’ File page appears. Enter a name for the Program
template, and click Next.

4. The ‘Program Segments’ page appears.

Select a value for the maximum number of segments the program is to have.
There are four segments per block, so the available values are in increments of
four.

Click on ‘Next’.

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5. The ‘Profiled Channels’ page appears, allowing details of the required channels
to be entered.

For this example, we have entered three channels: ‘Lower’, Mid’ and ‘Upper’.

Click on ‘Next’.

6. Enter any necessary user values and click on ‘Next’.

User values (and digital events - below) can be associated with particular
segments, such that they are output to a wired destination when that segment
becomes active.

7. In a similar way, enter any Events, Wait Conditions, Exit Conditions and Power
Fail recovery action.

User values (above) and digital events can be associated with particular segments,
such that they are output to a wired destination when that segment becomes active.

Wait conditions must be fulfilled before the next segment can be advanced-to.

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Exit conditions must be fulfilled before the program can terminate.

8. The configuration can be checked by viewing

the Summary page, before clicking on ‘Finish’.

Note: The ‘quicklink’ headings on the left side of the pages can be used to jump to
the relevant page.

Program Editor

Introduction
The Chart pane in the Programmer editor shows a maximum of three Profiled
Channels, the first two showing the first two Profiled Channels the third being the
channel currently selected in the Segment grid. The lowest Chart position can also
show a Digital Event Output, or User Values by selecting it from the Properties pane

Any Program Template file can be used to construct many different Programs that
can be run by each Programmer instance.

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To configure a Setpoint Program:

1. In LINtools, create (edit) the instrument Program Template file using the
Programmer Wizard as described in "Template Creation" on page 151, above.

To prevent erroneous template file configurations only the wizard may be used to
edit the blocks in the PROG_WIZ compound. Changing the number of Profiled
Channels, Digital Events, or User Values invalidates any Program file created
with the previous version.

2. Wire the control loop configuration (LOOP_PID block) to the Programmer

configuration (PROGCHAN block) and return the current setpoint from the
Programmer configuration (PROGCHAN block) to the control loop configuration
(LOOP_PID block). This provides the setpoint control for the control loop
configuration. Wire the input values (AI_UIO.PV) from the plant/system to the
control loop (LOOP_PID.Main.PV).

3. Wire any Digital Events and User Values to appropriate output blocks.

4. Wire to the required Wait conditions and Exit conditions from appropriate input
blocks.

5. When wiring is complete, save the Database file. Add the Program Template file
and the Program file to the List of files to be Downloaded.

6. Create and/or open a Program file. This can be done either by using the context
menu available when selecting the ‘PROGCTRL.File.ProgFile (block.page.field)’
in the LINtools Object Properties pane, after providing the Program name, or by
opening the Programmer Editor, and selecting File > New (Open), and choose
the Program Template file that matches the blocks of a PROG_WIZ compound in
the database.

7. Configure the Program, setting each Segment type, Duration, and Target
Setpoint in the Segment grid as required. Then configure the Digital Event
Outputs, User Values, Exit and/or Wait conditions in the Program Properties
Pane.

8. Download all relevant files to the instrument from the Programmer Editor to
control the running Program.

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Editing Procedure
The following sequence shows typical steps in an imaginary segment creation
procedure. Refer to "Installation" of the PAC Tutorial user guide for fuller details.

One way of opening the program editor is to right-click on the PROGCTRL block on
the LINtools work area, and selecting ‘Open program File (UYY)’ from the pull-down
menu. Another way, for existing files, is to select ‘Program Editor’ from the LINtools
‘Tools’ menu’, and using the browser to search for the program file (must have been
saved previously).

If this is a new file, the program editor page opens, with an empty program display,
based on the program template settings. If the file is pre-existing, then the previous
configuration appears, but this part of the manual is concerned only with new files.

1. Click on the ‘End’ segment; then on ‘Insert segment’.

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2. A new (dwell) segment appears. Edit the values as required. The traces respond
to the new values.

3. In the right hand pane, edit program parameters as required.

4. Continue to add new parameters, by highlighting the parameter to the right of

where the new parameter is to be located, then clicking on ‘Insert Segment’.

5. When all the segments have been correctly entered, and all wait conditions,
digital events, user values, etc. correctly allocated, save the file, and close the
editor.

6. Carry out a ‘Build’ and Download the program.

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T2750 Eurotherm PAC Recipe Management

Recipe Management
The Recipe functionality is used to control the parameters that change based on the
product or formula, e.g. reaction time.

Recipes provide a set of LIN function block field names (‘variables’) with a particular
value assigned to each, e.g. if the recipe is for one or more identical cake baking
lines, it would include setpoint values representing the amounts of each flavouring in
the mixture needed for a particular cake. In use, the recipe is downloaded to the LIN
database controlling a particular plant line, i.e. each recipe value is copied to the
corresponding LIN block field to achieve the required control.

It will usually be required to run several related recipes on a given plant line at
different times, with the same set of variables but with different assigned values, e.g.
for different cake types. These recipes constitute a recipe set, that are stored in a
single comma-separated text file with extension ‘.uyr’.

Refer to Batch and Recipe on T2750 (HA033194) for further details.

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T2750 Eurotherm PAC Batch Processing

Batch Processing
Batch Production is a manufacturing method in which the product in question is
created stage by stage and small quantities of identical products are made. Each
batch having a unique identifier to enable quality control and any potential future
investigations. Batch Production is in contrast to Continuous Production which is a
flow production method used to manufacture, produce, or process materials without
interruption.

Batch production is most common in bakeries and in the manufacture of foodstuffs,

pharmaceutical ingredients, inks, paints, and adhesives or for any manufacturing
process where a controlled number of products needs to be treated as a distinct
manufacturing set.

Within the T2750, Batch Production is controlled and monitored by the Batch Engine.
This control is referred to as ‘Batch Processing’. The Batch Engine is a State
Machine that controls processes which have a defined Start and End. The engine has
interfaces to the HMI (Human-Machine Interface) and the Data Recording Engine (for
data logging).

Refer to Batch and Recipe on T2750 (HA033194) for further details.

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T2750 Eurotherm PAC Error Conditions and Diagnostics

Error Conditions and Diagnostics

This chapter describes the various ways to tell if a fault has occurred in the PAC
instrument, (not in the process being supervised).

The various subsections are:

1. Error indication types ("Error Indication Types" on page 163)

2. LED error displays ("LED Displays" on page 163)

3. Power-up failures ("Power-up Failure" on page 167)

4. Power On Self Tests (POSTs) ("Power On Self Tests (POSTs)" on page 167)

5. SD Card failure detection ("SD Card Failure Detection" on page 168)

6. Diagnostic blocks ("Diagnostics Blocks" on page 169)

7. netHOST Profibus master troubleshooting ("netHOST PROFIBUS Master

Troubleshooting" on page 170)

8. netHOST fault scenarios ("netHOST Fault Scenarios" on page 171)

Error Indication Types

Error indications include:
LEDs. The LEDs are the most immediate source of error and in-
strument status information concerning Basic I/O System
(BIOS) start, watchdog functions and normal running. Dur-
ing BIOS start, the LEDs are momentarily illuminated to in-
dicate the BIOS status. If an IOC Module start fails, the
pattern that these LEDs adopt prior to the failure is helpful
to service engineers, so it is recommended that this pat-
tern is recorded (along with the unit serial number) before
a service call is made. Note that if the Watchdog triggers,
the LEDs can adopt a different pattern, so it is helpful to re-
cord the LED pattern prior to this.
POSTs. The results of Power On Self Tests (POSTs) can be used
to pinpoint error conditions in the instrument. Refer to Pow-
er On Self Tests (POSTs) And Error Numbers section.
Diagnostic blocks. A range of function blocks can be included in the running
Strategy Database to provide diagnostic information on
various topics, including the redundancy mechanism, the
ICM (Inter-processor Communications Mechanism), the
I/O interface, and others.

LED Displays
The IOC LEDs are the primary method of displaying error, and an overview
description is to be found in "Operator Interface".

Additional information is included in the following subsections.

Instrument Failure Modes

The LEDs directly indicate the following IOC Module failure or potential failure
modes:

1. Loss of Power

2. Watchdog

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Error Conditions and Diagnostics T2750 Eurotherm PAC

3. Communications failure

4. Loss of primary status

5. Decoupling

6. Desynchronisation

7. Instrument Password issues (either not set, or duplex partner is running pre v6/0
firmware and does not support an Instrument Password). If possible, replace the
partner instrument with one that does support Instrument Passwords. You will
lose the security provided by Instrument Passwords if the partner is not replaced.

When either or both IOC modules, running as one of a redundant pair, fail, it usually
changes its redundancy state in response to the failure, e.g. from primary to
secondary, or from synchronised to desynchronised and sometimes, coupled to
decoupled.

Power Failure
In the event of a power failure, the IOC Modules enter a ‘Power fail’ state and the
‘Status’ LED on the Module is extinguished. Hot Start and Real-Time Clock data are
maintained if a back-up battery is fitted. An internal ‘super-capacitor’ also maintains
this data (for approximately 1 hour) should power fail without a working backup
battery being fitted.

Watchdog Failure
In the event of a Watchdog failure, the affected IOC Module enters a ‘Watchdog fail’
state. Initially, the ‘Fault’ LED flashes, but becomes permanently illuminated after
some seconds.

If the Watchdog Retry switch ("LIN Option Switch" on page 60) is set ON, the IOC
module automatically attempts to restart the CPU. If the Watchdog Retry switch is set
Off, the CPU will attempt to restart only after an operation of the ‘Watchdog’ switch
(Figure 56 shows the switch location).

Note: It is suggested that the OFF position be used for systems operating in duplex
mode, whereas the ON position be used for a single unit operating in isolation.

On watchdog failure in redundant mode, the surviving IOC module adopts (or
maintains) the PRIMARY UNSYNCHRONISED state. The database can run only if
the modules were synchronised before changeover, otherwise, the database halts.

ICM Failure
Note: An ICM failure is not associated with any single IOC Module, and so is not
classed as either primary or secondary fault.

An Inter-processor Communications Mechanism (ICM) failure occurs when the

primary and secondary modules can no longer communicate with each other across
the internal link, making database synchronisation impossible to maintain. An ICM
failure causes the primary and secondary modules to decouple, but does not permit a
changeover.

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Action in the Event of ICM Failure

In the event of an ICM failure, the IOC Module decouples (indicated by the flashing of
the ‘Duplex’ LEDs on both IOC modules). See "Decoupled Instruments" on page 166
for details of decoupling. The process strategy must be designed to send the
supervisory system an appropriate alarm to annunciate this ICM failure state, (e.g.
use the ‘RED_CTRL’ block’s ‘PrHWstat.ICM_Ok’ and ‘SeHWstat.ICM_Ok’ bits).

If the ICM does fail, the cause of the failure should be eliminated by replacing the
secondary module. If this solves the problem the modules should be resynchronised
by use of the primary ‘Sync’ button.

If the fault persists, the primary module is the most likely cause and should be
replaced and the original secondary should be re-fitted as it is unlikely also to be
faulty.

If appropriate, the existing database should be restarted by powering down and then
up again. Otherwise, a ‘default’ database should be loaded and started in the new
primary.

This last option is a Cold Start and requires manual supervision of the plant during
the transition.

Note: A fault in the Terminal Unit is also a possible cause of ICM failure.

LIN Failure
A LIN failure occurs when an IOC Module is not communicating over the LIN,
perhaps because the cable is damaged or disconnected or because there is a
hardware (electronics) failure or there is a network communications failure. A LIN
failure causes the relevant ‘Ethernet (Activity)’ LED associated with the affected IOC
Module to extinguish and the yellow ‘IP’ LED to flash. In redundancy configurations
with two IOC modules installed, the status of the Stay Sync’d option (set using the
Instrument Options Editor, Startup tab) is also taken in consideration.

A LIN failure in a synchronised primary Module causes primary/secondary

changeover and loss of synchronisation, i.e. Primary synchronised adopts Secondary
unsynchronised, and Secondary synchronised adopts Primary unsynchronised, if the
Stay Sync’d option is disabled. If the Stay Sync’d option is enabled, then a
desync/changeover occurs but then an automatic resynchronisation occurs to make
the ‘better’ unit the primary. The SecWorse parameter in the IDENTITY and
RED_CTRL blocks (if in the strategy) are then asserted.

If an unsynchronised primary module suffers a LIN failure no changes of state occur.

If a LIN failure occurs in a synchronised secondary module and the Stay Sync’d
option is disabled, the module adopts the Secondary unsynchronised state (‘Standby’
LED off), and the primary module desynchronises to the Primary unsynchronised
state. If the Stay Sync’d option is enabled, and the secondary LIN health is
determined to be worse than that of the primary, no desynchronisation occurs. The
SecWorse parameter in the IDENTITY and RED_CTRL blocks (if in the strategy) are
then asserted. In both cases, if the secondary was unsynchronised at the time of the
failure, no change of state occurs.

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Effect of LIN Failure on Redundancy Mode Control

LIN failure affects the ability of Primary and Secondary modules to synchronise. For
example, if Stay Sync’d is not enabled, a LIN-failed secondary IOC module cannot be
synchronised successfully with the primary by pressing the primary’s ‘Sync’ switch
(synchronisation will be attempted, but then fail). However, if the Stay Sync’d option is
enabled, the secondary IOC module may be able to be synchronised with the primary
by pressing the primary’s ‘Sync’ switch. Having synchronised, however, if there is a
fault other than worse secondary subsystem health, the two IOCs may immediately
desync again (or changeover).

Decoupled Instruments
Decoupling occurs when communication between unsynchronised primary and
secondary modules is aborted because of a conflict regarding the unsynchronised
state. This causes the IOC modules to become decoupled. Such decoupling can be
caused by a number of faults, but generally it is due to a serious error, causing the
modules to assume they should be more than unsynchronised.

A decoupled state is indicated by the ‘Duplex’ LED flashing on both IOC modules.
Such a state can occur on power up if the two IOC modules conflict in their outlook of
how they both powered down, i.e., if the two modules power down, both as
synchronised secondary modules, when powered up together, they may decouple -
because the dual power up cannot resolve the differences between them.

The strategy must be designed to send the supervisory system an appropriate alarm
to annunciate this state, using, for example, the ‘RED_CTRL’ block’s
‘PrSWstat.Decoupld’ and ‘SeSWstat.Decoupld’ bits.

In the event of the primary and secondary modules becoming decoupled, the IOC
modules are already unsynchronised. This can be rectified by operation of the ‘Sync’
switch on the primary module, and if this is successful, both ‘Duplex’ LEDs illuminate
continuously. Should the decoupled modules not re-synchronise after using the
‘Sync’ switch, further investigation must be made in order to locate and rectify the
cause of the fault.

Inter-processor Communications Mechanism (ICM) faults will cause a decouple of

occur, but a decouple does not necessarily mean an ICM fault has occurred.

Desynchronisation
Desynchronisation occurs when there is a mismatch in health between the Primary
and Secondary IOC modules. When this happens, the two IOC modules
desynchronise. No changeover occurs and attempts to resynchronise are inhibited
by the redundancy control software until the health mismatch is resolved.

Only when the decision to changeover has been accepted, can the secondary IOC
module assume control. Changeover occurs when a synchronised pair determines
that the secondary’s health is better than the primary’s health. The changeover
occurs to result in the better unit ending up as primary. The process of performing a
changeover is shown in Figure 13.1 below. The changeover is complete when the
database on the previously primary module is stopped.

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Database running
Database running Becomes secondary
Becomes secondary
Unsynchronised
OldOld primary
primary Primary LED off
Primary LED off Database stopped
Database stopped Unsynchronised
Changeover
Changeover 
request
request Time
Time

Old secondary
Old secondary Becomes primary
Becomes primary Primary LED on
Primary LED on New primary
New primary
Standby LED off
Standby LED off
Database running
Database running

Figure 99 Changeover time line

Power-up Failure

Start-up Routine
A number of error conditions can occur during the power-up phase. This start-up
routine is described earlier ("Start-up"), and should be referred-to for detailed
information. Various messages are generated by the IOC Module during power-up
and these messages can be displayed by running a ‘Telnet’ session on a Computer
via the ELIN network.

Power On Self Tests (POSTs)

At switch on, the Basic I/O system (BIOS) checks that the Central Processor Unit is
operating correctly. This stage of power-up is apparent by the lighting of all LEDs on
the front of the IOC (shown in Figure 56).

The start-up process initiates the Power On Self Tests (POSTs) with the loading of
the application and system code from the SD card on the underside of the IOC
Module.

Firstly the Boot ROM is checked, running each POST to ensure the SD Card is
functioning correctly.

If all LEDs are dimly lit, this indicates a boot ROM failure, and the IOC must be
returned to the factory for repair.

Then the IOC Module is checked, again running each POST to ensure the application
is operating correctly.

Should any POST fail, the LEDs display a pattern (see below). The pattern is
displayed for approximately 11 seconds before the instrument enters a watchdog
state. The location of the POST failure is indicated by the ‘Standby’ LED. If
illuminated, an Application POST has failed, whereas if it remains extinguished a
Boot ROM POST has failed.

If the POSTs are concluded successfully, the instrument attempts to start the
software. The primary/secondary status of each module is decided according to the
criteria described in "Primary/Secondary Criteria" on page 85 using ‘signature’ data
relating to last-time’s power down, automatic synchronise states and so on.

The primary module continues its power up sequence according to the mode
selected. A check is made to ensure that the ICM communications are valid, and if
synchronisation is permitted, the ‘Standby’ LED starts flashing on and off when the
primary module starts to transfer data to the secondary.

If the ICM test fails, or if non-redundant working is required, the module continues the
power up sequence, according to the mode selected.

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POST Failure LED Patterns

As mentioned above, if the POST procedure fails, a ‘pattern’ of LEDs is illuminated at
front of the relevant IOC. The three patterns shown below are the only failure modes
that the user can correct. All other modes require that the IOC be returned to the
factory for repair.

Code 13: No SD card fitted: Code 14: SD card write protected: Code 30: IOC not fully pushed
Fit SD card ("Replacement Slide write protect tab to home and secured:
Procedures" on page 177) ‘unlocked’ position. Ensure that the module is
correctly fitted and secured using
the quarter turn fastener.

Figure 100 POST failure LED displays

SD Card Failure Detection

The T2750 uses an SD card for its local file storage, which includes the user-defined
strategies, SFCs, and configuration data. A defective SD card is therefore potentially
highly significant and can manifest itself as a gradual corruption of the file system
contents, or stop the T2750 working completely. A corruption of contents could lead
to unexpected behaviour or the watchdog triggering.

As of version 3.3 of the T2750 firmware, monitoring of the health of the SD card is
performed, and if issues are detected, the card is placed into quarantine mode to
help protect against the above possible scenario. Once in quarantine mode, the
T2750’s local filing system is no longer accessible, though the control strategy
continues to function. Any aspects of the control strategy configuration which require
access to the filing system (RECORD blocks, load of SFCs, or Modbus or Profibus
communications, for example) fail gracefully with the appropriate alarms being
raised.

If the file system is quarantined, FilSysEr (bit 8) in the TACTICIAN header block is set
to TRUE. For further information, refer to the TACTICIAN block in the LIN Blocks
Reference Manual, HA082375U003.

When operating as a duplex pair, if the SD card on one side of the pair enters
quarantine mode, the units will change over or desynchronise as necessary so as to
ensure the good unit is the Primary. The UDZ file of the good unit will log the reason
for any change over or desynchronisation.

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Diagnostics Blocks
Several diagnostic function blocks are available from the DIAG category, that can be
installed in the LIN Database at configuration time to help in diagnosing any error
conditions that may arise in the running strategy. The LINtools program can then be
used, via the LIN network, to investigate these fields.

Figure 101 shows a list of diagnostic blocks that are generated as part of the
automatically created LIN Database, when the Options switches are set correctly
("LIN Option Switch" on page 60).

Note: All function blocks are described in the LIN Blocks Reference Manual.

Block Function

DB_DIAG Database diagnostic block. Shows actual and

maximum resource levels of the database being used
by the current application. Displayed parameter values
are valid only at run time.

EDB_DIAG External database diagnostics block. Shows

connection information relating to an external database
running in remote instruments, and monitors the
cached block update rate tuning algorithm.

EIO_DIAG Eurotherm I/O system diagnostic block. Shows the

current state (Healthy or Unhealthy) of the expected
and actual I/O modules at each site. A maximum of 16
I/O sites can be displayed on one screen.

ELINDIAG ELIN diagnostics block. Statistics on the operation of

the Ethernet Local Instrument Network.

XEC_DIAG Task diagnostic block. Displays information on the

tasks within the instrument’s operation system (XEC).

GWProfM_ CON Profibus master gateway block. Provides gateway

diagnostics and standard Profibus communication
diagnostic parameters for a device at a defined slave
address. Only relevant if Profibus master functionality
is used.

ICM_DIAG ICM diagnostics block. Statistics related to the

numbers and types of message passing between
redundant IOC modules.

IDENTITY IDENTITY diagnostics block. Identifies the instrument

containing this block and its status.

LIN_DEXT LIN high-level diagnostics extension block. Statistics

relating to operation of the Local Instrument Network
(LIN).

NETHOST netHOST diagnostic block containing information

regarding the associated netHOST Profibus gateway.
Only relevant if Profibus master functionality is used.

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Block Function

OPT_DIAG Options/License control system diagnostics block. This

block shows the user system attributes that may
impose some limit of operation, or cause a license
violation alarm. The block is not essential to the
running of the LIN database, and can be added whilst
on line, if required.

RED_CTRL Redundancy Control Block. If redundant systems are

configured, this block shows Processor Redundancy
Management Task (PRMT) parameters. The block can
also be used to trigger processor module
synchronisation and primary/secondary swap.

SD_DIAG SD Card Diagnostic Block. Provides basic information

about the installed SD card, its performance, and other
advanced real-time diagnostic information.

SFC_DIAG Sequential Flow Chart diagnostics block. If SFC is

enabled, this block shows actual and maximum
resource levels of the sequence used by the current
application. Displayed parameter values are valid only
at run time.

TACTTUNE Tactician Tuning Block. System task monitoring in

priority order.

USERTASK User task diagnostic block. Strategy task performance

monitoring.

Figure 101 Typical diagnostic blocks

netHOST PROFIBUS Master Troubleshooting

When the T2750 first starts the database file (*.dbf), and if Profibus Master is
configured, it scans for all netHOSTs on the local subnet. From the responses, it
identifies the netHOST with the correct ADR setting and confirms the IP address is
correct. If the IP address is unconfigured, the T2750 will automatically configure the
IP address as it starts up.

There are several potential failures:

1. No netHOST with the correct ADR found

2. A netHOST with the correct ADR is found, but it is already assigned a different IP
address to that expected (implying another T2750 may be using it).

3. A netHOST with the correct ADR is found but no IP address assigned and
netIdent fails to correct set the IP address.

These failures can be diagnosed by any of the following:

- Alarm and status data in the GWProfM_CON block

- Status data in the NETHOST diagnostics block

- Error messages written to the UDZ file. This is a text file and can be copied from
the instrument’s drive using the Network Explorer tool

- Status LEDs on the front of the netHOST gateway (refer to "Status Indicators" on
page 58.

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netHOST Fault Scenarios

This section considers various fault scenarios that could occur on a redundant
Profibus system using T2750 and netHOST devices. The scenarios are described in
terms of this example system:

T2750
T2750 T2750T2750
(Primary)
(Primary) (Primary)
(Primary)

netHOST
netHOST netHOST
netHOST
(Primary)
(Primary) (Primary)
(Primary)

Profibus
Profibus Profibus
Profibus
Slave
Slave 11 Slave
Slave 22

Note: This section does not consider the failure of a T2750, as failures of this nature
are detected elsewhere and cause the surviving T2750 to adopt an isolated,
unsynchronised primary state virtually immediately, with no impact from the Profibus
health monitoring.

The action taken during a fault scenario depends upon the redundancy logic defined
for the T2750. Refer to the "Setting the Redundancy Logic" on page 72 for details.

Fault Scenario 1: Ethernet Break between Primary’s T2750 and

netHOST
In this scenario, the Ethernet connection between the Primary T2750 and its
netHOST breaks. The secondary T2750 therefore has a better view of the Profibus
network (because the primary has no view at all of the Profibus network). The figure
below shows a timeline of the events which will result in a changeover of the T2750s.
If the redundancy logic for Changeover events is set to “Disable”, then the T2750 will
not change over due to Profibus failures.

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Error Conditions and Diagnostics T2750 Eurotherm PAC

Ethernet break occurs TCP Timeout: Primary reports “Profibus dead”

Ethernet break occurs  TCP Timeout:
between Primary’s T2750 Secondary reports “Profibus minor fault”
between Primary’s 
and the netHOST Primary reports “Profibus dead”
T2750 and the netHOST Secondary reports “Profibus minor fault”

0mS
0mS 1000mS
1000mS 1250mS 8000mS
8000mS

“Immediate”
“Immediate” Fast”
“Fast” “Slow”
changeover
“Slow”
changeover changeover
changeover changeover changeover

Fault Scenario 2: Total failure of Primary’s netHOST

In this scenario, the Primary’s netHOST fails completely (a power failure, for
example). In this scenario, clearly the secondary T2750 has a better view of the
Profibus network (because the primary has no view at all of the Profibus network).
The figure below shows a timeline of the events which will result in a changeover of
the T2750s. If the redundancy logic for Changeover events is set to “Disable”, then
the T2750 will not change over due to Profibus failures.

netHOST fails completely

netHOST fails  TCP Timeout: Primary reports “Profibus dead”
TCP Timeout:
(power failure, for Secondary reports “Profibus minor fault”
completely (power  Primary reports “Profibus dead”
example)
failure, for example) Secondary reports “Profibus minor fault”

0mS
0mS 1000mS
1000mS 1250mS
1250mS 8000mS
8000mS

“Immediate”
“Immediate” Fast”
“Fast” “Slow”
“Slow”
changeover changeover changeover
changeover changeover changeover

Fault Scenario 3: Ethernet break between Secondary’s T2750 and

netHOST
In this scenario, the Ethernet connection between the Secondary T2750 and its
netHOST breaks. The primary T2750 therefore has a better view of the Profibus
network (because the secondary has no view at all of the Profibus network). The
figure below shows a timeline of the events which will result in a desync of the
T2750s. If the redundancy logic for desync events is set to “Disable”, then the T2750
will not desync due to Profibus failures.

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Ethernet break occurs

Ethernet break occurs  TCP Timeout: Primary reports “all
TCP Timeout:
between Secondary’s healthy” Secondary reports “dead”
between Secondary’s 
T2750 and the netHOST
Primary reports “all healthy”
T2750 and the netHOST Secondary reports “dead”

0mS
0mS 1000mS
1000mS 2800mS
2800mS 8000mS
8000mS

“Fast” “Slow”
“Fast” “Slow”
desync desync
desync desync

Fault Scenario 4: Total failure of Secondary’s netHOST

In this scenario, the Secondary’s netHOST fails completely (a power failure, for
example). Clearly the primary T2750 has a better view of the Profibus network
(because the secondary has no view at all of the Profibus network). The behaviour is
identical to those to that for an Ethernet break between the Secondary’s T2750 and
associated netHOST (see "Fault Scenario 3: Ethernet break between Secondary’s
T2750 and netHOST" on page 172).

Fault Scenario 5: Profibus break at Primary’s netHOST

In this scenario, the Profibus connection fails at the Primary’s netHOST. Clearly the
Secondary’s T2750 has a better view of the Profibus network (because the primary
has no view at all of the Profibus network). The primary T2750 will report “dead”
virtually immediately as it has lost contact with all the Profibus slaves.

The secondary T2750 will report “minor fault” almost immediately. However, it takes a
small, but finite, time for this information to propagate from the secondary to the
primary. The figure below shows a timeline of the events which will result in a
changeover of the T2750s. If the redundancy logic for changeover is set to “Disable”,
then the T2750 will not changeover due to the Profibus network failure.

Profibus failure at the

Profibus failure at the 
Primary’s T2750
Primary’s T2750  Primary reports “dead” virtually immediately
Primary reports “dead” virtually immediately
netHOST
netHOST
Secondary reports “minor fault” very quickly afterwards
Secondary reports “minor fault” very quickly afterwards

A few
A few
0mS
0mS mS ~250mS
~250mS 8000mS
8000mS
mS

“Immediate” Fast” “Slow”

“Immediate” “Fast” “Slow”
changeover changeover changeover
changeover changeover changeover

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Error Conditions and Diagnostics T2750 Eurotherm PAC

Fault Scenario 6: Profibus Break at Secondary’s netHOST

In this scenario, the Profibus connection fails at the Secondary’s netHOST. Clearly
the Primary’s T2750 has a better view of the Profibus network (because the
secondary has no view at all of the Profibus network). The secondary T2750 will
report “minor fault” virtually immediately because it has lost contact with the Primary.

The figure below shows a timeline of the events which will result in a desync of the
T2750s. If the redundancy logic for desync is set to “Disable”, then the T2750 will not
desync due to the Profibus network failure.

Profibus failure at the

Profibus failure at the 
Secondary’s T2750 Secondary reports “minor fault” virtually immediately
Secondary’s T2750  Secondary reports “minor fault” virtually immediately
netHOST
netHOST

0mS
0mS 1800mS
1800mS 8000mS
8000mS

“Fast” desync “Slow” desync

“Fast” “Slow”
desync desync

Fault Scenario 7: Profibus break in the middle of the Profibus network

In this scenario, the Primary’s netHOST is connected to some of the Profibus slaves,
and the Secondary’s netHOST is connected to the remaining Profibus slaves. The
Profibus link between the Primary and Secondary is broken.

There is no count of the number of slaves connected to each netHOST, so there is no

way of knowing whether the Primary or Secondary has the “better” view of the
Profibus network.

Both the Primary and Secondary T2750 will report “minor fault”, but a desync or
changeover will not occur.

Fault Scenario 8: Profibus Failure of All Slaves

In this scenario, the Primary and Secondary’s netHOSTs are still connected via the
Profibus network, but all slaves are missing. The figure below shows a timeline of the
events which will result in a changeover of the T2750s. If the redundancy logic for
changeover is set to “Disable”, then the T2750 will not changeover due to the
Profibus all-slave failure.

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All Profibus slaves are

All Profibus slaves are  Primary reports “minor fault” virtually immediately
Primary reports “minor fault” virtually immediately
missing missing Secondary reports “all OK” as it can still see the Primary
Secondary reports “all OK” as it can still see the Primary

A few
A few
0mS
0mS mS 250mS
250mS 8000mS
8000mS
mS

“Immediate” “Fast”
“Immediate” “Fast” “Slow”
“Slow”
changeover changeover changeover
changeover changeover changeover

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Service
This section describes the regular preventive changing of back-up batteries etc., and
shows how to replace the IOC SD card and live operating Modules.

For details of how to update and change the instrument’s system software, boot ROM
and libraries, please contact the manufacturer’s nearest service centre.

CAUTION
All circuit boards associated with this unit are susceptible to damage due to static
electrical discharges of voltages as low as 60V. All relevant personnel must be
aware of correct static handling procedures.

Preventive Maintenance Schedule

The following periods are recommended to guarantee maximum availability of the
instrument, for use in what the manufacturer considers to be a normal environment.
Should the environment be particularly dirty, or particularly clean, then the relevant
parts of the schedule may be adjusted accordingly.

Whenever preventive maintenance is performed, it is recommended that a visual

inspection of the instrument be made, and any deposits of dirt or dust removed using
a low-pressure compressed ‘air duster’ such as are available from most electronics
distributors.

Replacement Procedures

Software/Firmware Upgrade
The T2750 software/firmware can be upgraded by putting an upgrade file onto the
T2750 and cycling the power. From the T2750 V3/3 onwards, the upgrade file also
contains the bootrom image, which will be updated at the same time as the main
firmware. Bootrom upgrade is skipped if the bootrom in the instrument is already the
latest version.

There are three ways to perform an upgrade, as outlined in this section.

Note: If the system being upgraded is configured as a duplex system, refer to the
section, "Upgrading Duplex Systems" on page 179 first, and then determine which of
the three upgrade options to follow.

Option 1 – Upgrading by Copying onto the SD Card

Perform the following steps to perform an upgrade by copying the upgrade files
directly onto the SD card within the instrument:

1. Extract the files from the upgrade zip file. The zip file contains upgrade.tgz,
upgrade.bat and upgrade.txt.

2. With the power off, remove the SD card form the T2750 (refer to the “SD CARD
REPLACEMENT PROCEDURE” on page 151 for details).

3. On a PC with a suitable card reader, copy the upgrade.tgz file into the root folder
on the SD card.

4. Replace the SD card in the T2750.

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5. Power up the T2750. Once the power has been restored, the upgrade will be
applied and the LEDs on the T2750 will cycle. Please be patient as this takes
some time to complete. At the end of the upgrade, the T2750 will reset by means
of a watchdog.

6. If the watchdog reset switch is in the off position, then it will be necessary to
manually reset the T2750 by pressing the watchdog switch once the red fault
light (X) is on constantly, indicating that the upgrade is complete.

7. If upgrading from pre V6/0 to V6/0 (or above), set the Instrument Password if this
is a simplex instrument or if this is the first processor of a duplex redundant pair
being upgraded.

Option 2 – Upgrading Over a Network

Note: These Notes apply to firmware v6/0 (or above).

Notes:
1. Prior to V6/0 the FTP server supported an account where both the username and
password were "DEVT2750".
2. From V6/0, the FTP server password must be configured via the Instrument
Options Editor.
3. The file upload.txt contains the password (‘DEVT2750’) - replace this with the
password you have configured.

Perform the following steps to perform an upgrade using FTP (assuming the T2750’s
IP address is known).

1. Extract the files from the upgrade.zip file. The zip file contains upgrade.tgz,
upgrade.bat and upgrade.txt.

2. Copy the upgrade.tgz file onto the SD card using FTP by issuing the command
“upload <ip_address>” where <ip_address> is the IP address of the T2750 to be
upgraded.

3. Power cycle the T2750.

4. Once the power has been restored, the upgrade will be applied and the LEDs on
the T2750 will cycle. Please be patient as this takes some time to complete. At
the end of the upgrade, the T2750 will reset by means of a watchdog.

5. If the watchdog reset switch is in the off position, then it will be necessary to
manually reset the T2750 by pressing the watchdog switch once the red fault
light (X) is on constantly, indicating that the upgrade is complete.

6. If upgrading from pre V6/0 to V6/0 (or above), set the Instrument Password if this
is a simplex instrument or if this is the first processor of a duplex redundant pair
being upgraded.

Option 3 – Upgrading Using a USB Memory Stick

In order to upgrade using a USB memory stick, the T2750 must be configured to
enable upgrades via USB. Refer to "USB Configuration" on page 70 for details. Then
perform the following steps:

1. Extract the files from the zip file. The zip file contains upgrade.tgz, upgrade.bat
and upgrade.txt.

2. Copy the upgrade.tgz file onto the root of a compatible USB memory stick.

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3. Plug the memory stick into the USB connector on the T2750 terminal unit. The
green USB LED should illuminate indicating that the file is being copied. Once
the green LED has gone out, the USB memory stick can be removed. If the
amber USB LED illuminates, there is an error trying to read the USB memory
stick.

4. Power cycle the T2750.

5. Once the power has been restored, the upgrade will be applied and the LEDs on
the T2750 will cycle. Please be patient as this takes some time to complete. At
the end of the upgrade, the T2750 will reset by means of a watchdog.

6. If the watchdog reset switch is in the off position, then it will be necessary to
manually reset the T2750 by pressing the watchdog switch once the red fault
light (X) is on constantly, indicating that the upgrade is complete.

7. If upgrading from pre V6/0 to V6/0 (or above), set the Instrument Password if this
is a simplex instrument or if this is the first processor of a duplex redundant pair
being upgraded.

Note: If a USB extension cable is used to expose the USB port remotely, the
maximum length of this cable must not exceed 1.5m when the T2750 is configured
with a redundant pair of IOCs.

Upgrading Duplex Systems

Note: These Notes apply to firmware v6/0 (or above).

Notes:
1. If both units are V6/0 (or above) there is no need to set the instrument password
in the new secondary (it will be copied as part of the synchronisation process).
2. When upgrading from pre-V6/0 to V6/0 (or above) it will be necessary to set the
instrument password in the newly upgraded secondary before attempting to run it
as a secondary.
3. Whilst the units with pre-V6/0 and V6/0 (or above) are operating as a duplex pair,
the unit running V6/0 (or above) will flash its LEDs to indicate "password error"
(see "LED Interpretation" on page 75). Once you have changed over so that the
new unit is Primary, the units will refuse to resynchronise (i.e. step 8, below, is
skipped).
4. It is essential that firmware is updated on both sides of a duplex pair, rather than
continuing to run with a pair mixed - one running pre-V6/0 and one running V6/0
(or above).

To upgrade a duplex configured system, upgrade Option 2 – Upgrading Over a

Network or Option 3 – Upgrading Using a USB Memory Stick above can be followed
without interrupting control. To do this, the following additional instructions should be
followed:

1. Begin by de-synchronising the processors by pressing the Desync button on the

primary controller.

2. Follow the above instructions (Option 2 or Option 3) up to, but not including the
power cycling.

3. Press and hold the Desync button on the secondary until all but the Ethernet
LEDs go out.

4. Remove and the replace the secondary processor into the backplane.

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Service T2750 Eurotherm PAC

5. Continue following the instructions (option 2 or option 3) above, from after the
power cycling step.

6. Synchronise the processors by pressing the Sync button on the primary

controller.

7. Changeover primary and secondary by pressing the Sync button on the

secondary controller.

8. Wait for the secondary to re-synchronise, indicated by the Standby LED being
steady on.

9. Repeat the process to upgrade the other processor by repeating steps 1-7 in this
procedure.

SD CARD REPLACEMENT PROCEDURE

Figure 12.2.1 shows the location of the SD card. The replacement procedure allows
databases, user configurations, IP address and Network name, to be transferred
from one module to another, allowing the ‘Mean Time to Replace’ to be reduced to a
minimum.

Note: The Node address is set using the base unit switches and is therefore not
transferred when replacing the SD card.

1.For convenience, remove the relevant IOC

IOC underside
module as follows:

a.Disconnect the Ethernet cable from the

relevant IOC module.
SD card Push to release
b.Release the module by rotating its 1/4 turn
fastener 90 degrees anti-clockwise.

c.Pull the IOC Module away from its Terminal

Unit.
Left hand face
2.At the underside of the IOC Module, push on
the edge of the SD card, to release it, then
carefully pull it out of its connector.

IOC top 3.Ensure that the replacement card is not write

protected (Figure 103), then insert it into the slot
Figure 102 SD card re-
placement and gently push it home.

4.Re-fit the Module to its terminal unit and

secure it by turning the 1/4 turn fastener 90
degrees clockwise. Refit the Ethernet cable.

Figure 103 Write protect tab

SD CARD PRECAUTIONS

The following ‘rules’ should be observed to protect user databases, etc:

1. Folders and / or system files must not be deleted.

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T2750 Eurotherm PAC Service

2. The card must not be removed from the reader without the correct removal
procedure having first been followed. This procedure varies according to the
version of Windows being used.

3. It is recommended that a backup copy of all files and folders be made so that
they may be restored in the event of accidental removal.

The SD card is a high-capacity card (SDHC) which might not be readable with older
(SD) readers.

Note: If the SD card is changed, a Hot Start for the current running database will not
be possible.

Live IOC Module Replacement

Note: It is recommended that a backup of the strategy is made before replacing any
IOC module.

Live replacement of a failed IOC Module can be carried out, without wiring
disconnections. When operating in Redundant mode, either of the IOC modules can
drive the I/O modules allowing the replacement module to load its strategy and status
from the current primary Module. To replace the module:

1. Ensure the IOC Module to be replaced is not the current primary module. If the
failed Module is the primary, press the ‘Sync’ switch to initiate the
synchronisation process. This will ensure that both modules are synchronised
allowing the primary and secondary modules to changeover.

On occasions, it may be necessary to operate the primary module’s ‘Desync’

switch in order to desynchronise the modules and ensure the failed module is
operating as the secondary.

2. Shut down the secondary module by pressing its ‘Desync’ switch for longer than
three seconds.

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Appendix A Specification
A1 Installation Category and Pollution Degree
This product has been designed to conform to BS EN61010 installation category II
and pollution degree 2.

These are defined as follows:

INSTALLATION CATEGORY II

The rated impulse voltage for equipment on nominal 230V ac mains is 2500V.

POLLUTION DEGREE 2

Normally, only non-conductive pollution occurs. Occasionally, however, a temporary

conductivity caused by condensation shall be expected.

A2 General Specification

Physical
Base unit dimensions 0 module: 61.25mm wide x 180mm high x 132mm deep (2.41in x 7.1in x 5.2in)
See Figure 1 and
4 module: 172mm wide x 180mm high x 132mm deep (6.79in x 7.1in x 5.2in) Figure 2 for dimen-
8 module: 274mm wide x 180mm high x 132mm deep (10.8in x 7.1in x 5.2in) sional details.
16 module: 477mm wide x 180mm high x 132mm deep (18.8in x 7.1in x 5.2in)
Base Unit fixing centres 0 module: 26mm (1.023in)
4 module: 127.4mm (5.02in)
8 module: 229mm (9.016in)
16 module: 432.2mm (17.016in)
Weight
0-way 0.7kg (1.54lb), including controller module.
4-way: No modules = 0.7kg (1.54lb). Including 2 x IOC and 4 x I/O modules = 1.65kg (3.64lb) max.
8-way: No modules = 0.98kg (2.16lb). Including 2 x IOC and 8 x I/O modules = 3.1kg (6.83lb) max.
16-way: No modules = 1.6kg (3.53lb). Including 2 x IOC and 16 x I/O Modules = 5.24kg (11.55lb) max.

Electrical
Protective earth ground Earth terminal strip at lower front flange of base unit
connections
Supply voltage 24V dc (±20%) If the supply voltage falls below 19.2V dc during
startup, the instrument can enter a continuous
Supply power (max.) 82 Watts (16 module base) cycle of attempted re-starts.
80 Watts (8 module base)
34 Watts (4 module base)
18 Watts (0 module base)
Surge current (max.) 8 Amps
Back-up supplies 3.3V ±15%, 10μA max. (Figure 2.9)

Environmental Maximum RH with dewpoint of 50°C


Temperature Storage: -20 to +85°C
Relative Humidity (RH) %

'
Operation: 0 to +55°C &
Humidity Storage/Op- 5 to 95% RH (dewpoint 50°C) (see graph) %
eration: $
#
Atmosphere Non-corrosive, non-explosive "
Altitude (max.) 2000m !

Environmental protection Panel: BS EN60529:IP20 


RFI EMC emis- BS EN61326-1:2006 Class A 
sions:           

EMC immuni- BS EN61326-1:2006 Industrial locations Temperature

ty:
Electrical Safety Specifi- BS EN61010-1: 2001 (see section ‘A1’, above); UL61010
cation
Vibration / shock To BS EN61131-2 (9 to 150Hz @ 0.5g; 1 octave per minute)
15g static shock

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Appendix A Specification T2750 Eurotherm PAC

Impact with- BS EN61010 (Corner drop test 100mm)

stand
Packaging BS EN61131-2 section 2.1.3.3
Free fall: BS EN60068-2-32, proc. 1 (five x 1 metre drops for each of six faces)
Flammability of plastic UL746 UL V0
materials
RoHS compliance EU; China

Approvals
CE; cUL (UL61010); GOST

Ethernet Communications
Connectors: One RJ45 connector on the underside of each IOC Module
Network medium: Ethernet Category 5 cables
Protocols: LIN over Ethernet / IP (ELIN), Modbus-TCP RTU slave, FTP
Speed: 100Mbps
Network Topology: Star connection to a hub
Line length (max): 100 metres, extendible by repeater
Allocation of IP address: Manual, DHCP, Link-Local or BootP
Isolation: 50V dc; 30V ac. (IEEE 802.3)

Modbus Communications
Connector: Parallel pair of RJ45 connectors on the Terminal unit
Network medium: EIA485, link selectable as 3-wire or 5-wire
Protocols: MODBUS/JBUS RTU master and slave
Isolation: None

A3 IOC Specification

A3.1 Terminal Unit

Physical
Dimensions (approx.) 50mm wide x 110mm high
Weight (approx.) 0.1kg

Switches
SW1, segment 2 to 8: Instrument Address
SW2, segment 3: Hot start switch
SW2, segment 2: Cold start switch and Automatic Database Generation
SW2, segment 1: Watchdog retry (trip and try again mode)

Links
LK1 and LK2 Link pins 1 and 2 for three-wire communications; link pins 2 and 3 for five-wire. (Figure 9)

User Connectors
Supply power Two x four-way terminal block for supply power. Supplies separately monitored by the IOC modules
Watchdog Relay Two x three-way terminal block, shared with back-up battery
Backup battery Shares connectors with Watchdog relays
Modbus Two RJ45 sockets, wired in parallel
USB Type A connector

USB
Connector type Type A located on IOC terminal unit (Figure 2.9)

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T2750 Eurotherm PAC Appendix A Specification

USB standard USB2.0 host communications

Source current 500mA max (current limited)
Fuse Within primary IOC. Non-user replaceable
USB extension cable length Maximum 1.5m permissible with redundant IOCs

A3.2 IOC Module

A3.2.1 Hardware

General
Dimensions 25mm wide x 114.3mm high x 110mm deep
Flash memory 32MB
SD card Factory formatted. Removable from underside of the IOC module

LED Indicators Status (24V dc nominal - Main supply), Fault indicator, Battery, Communications, IP Resolution, Du-
plex (redundant mode), Primary processor, Standby processor, Ethernet (speed), Ethernet (activity),
USB hardware and USB software

Control switches
Watchdog Reset
Synchronise/changeover
Desynchronise

User Connections
Ethernet Communications One RJ45 connector mounted on the underside of each IOC module

Note: Section 3 gives details of all IOC LEDs and control switches.

A3.2.2 Software

LIN BLOCK LIBRARIES

Batch: Sequencing recipe/record and discrepancy checking
Communications: Instrument Communication blocks. Specific blocks MUST be included in the database to permit com-
munications
Conditioning: Dynamic signal-processing and alarm collection
Configuration (Header): Instrument identity (Header) blocks
Control: Analogue control, simulation and communications
Convert: Convert dissimilar database field types, particularly enumerated values
Diagnostic: Diagnostics
I/O: Analogue and digital input output manual override
Logic: Boolean, latching, counting and comparison
Maths: Mathematical functions and free-format expressions
Organise: Organise system screens and grouping data for logging
Programmer: Control, monitor and schedule programs generated by the SetPoint Programme Editor
Recorder: Control and manage data recording
Selector: Selection, switching, alarm and display page management
Timing: Timing, sequencing, totalisation and events

Continuous database resources

Number of function blocks (maximum) 2048

Number of templates (maximum) 170

Number of template libraries (max.) 32
Number of EDBs (maximum) 32

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Appendix A Specification T2750 Eurotherm PAC

Number of FEATTs (maximum) 4096

Number of TEATTs (maximum) 1024
Number of server tasks (maximum) 6
Number of field-to-field connections 4096
Control database size (maximum) 800kB

Sequence Control Resources

Program data: 400kB
Nº of independent sequence tasks: 36 simultaneously active
SFC Roots: 31
Steps: 420
Action associations: 1680
Actions: 840
Transitions: 630

Modbus
Configuration Tools: The Serial parameters of the instrument must be configured using ‘Modbus Tools’ software. The in-
strument parameters can be configured using ‘Instrument Properties’.
Memory Size: 51,672 bytes
Maximum Tables: 250
Diagnostics Registers: 16 general purpose registers + 1 register for each table
Operating Mode: Master, Slave
Transparent Modbus Access
(TMA/TalkThru): Via Modbus Gateway file
Format: Direct 32 bit, Reverse 32 bit (D, and S)
Tick Rate: 5ms
Number of facilities: 3 Modbus Gateway facilities
Redundancy: Full control
Interface: Serial interface can communicate with a maximum of 64 slave devices, one per register in the gate-
way file. TCP can communicate with 16 slave devices and 16 additional master devices, via the EN-
ET3 and ENET4 ports.

I/O Block non supported software features

Some features are valid only in certain block configurations, and in such cases, unavailable options are ‘greyed out’ (non-editable). In addition to
these, the following general exclusions apply.

AI_UIO block Alarms.OctDel not supported

Options.OCDelSt not supported
Options.OCDelEnd not supported
Status.BrkDtctd not supported
AO_UIO block Alrms.OvrDrive not supported
Status.OvrDrive not supported
DI_UIO block All status bits and alarms are supported
DO_UIO block Alarms.CctFault not supported
Status.OverTemp supported only by DO16 module
FI_UIO All status and alarm bits supported
TPO_UIO block Status.OverTemp supported only by DO16 module
VP_UIO block Status.OverTemp supported only by DO16 module

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A4 I/O Module Specifications

A4.1 AI2 Module

Note: Sensor Break Protection is controlled using an associated AI_UIO block.

General specification, common to all variants

Power consumption 2W max.
Common mode rejection (47 to 63Hz) >120dB
Series mode rejection (47 to 63Hz) >60dB
Isolation Channel to chan- 300V RMS or dc (basic insulation)
nel:
to system: 300V RMS or dc (double insulation)
Max voltage across any channel 10.3V dc

A4.1.1 Thermocouple Input Variant

mV inputs, Thermocouple inputs

Input range -150mV to +150mV
Input impedance >100MΩ (sensor break detect circuit ‘Off’)
Input leakage current <100nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±10μV
Noise <28μV peak-to-peak with filter off: <4μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 2μV with 1.6s filter
Linearity Better than 5μV
Temperature coefficient <40ppm of reading per °C
Sensor break protection Switchable as ‘High’, ‘Low’ or ‘Off’. Sensor current: 125nA

Cold Junction
Temperature range: -10°C to +70°C
CJ Rejection: >30:1
CJ accuracy: ±0.5°C typical (±1.0°C max.)
Sensor type Pt100 RTD, located beneath the input connector

High impedance input (channel two only)

Input range 0.0V to 1.8V
Input impedance >100MΩ (sensor break detect circuit ‘Off’)
Input leakage current <100nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±20μV
Noise <100μV peak-to-peak with filter off: <15μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 7μV with 1.6s filter
Linearity Better than 50μV
Temperature coefficient <40ppm of reading per °C

A4.1.2 DC Input Variant

mV inputs
Input range -150mV to +150mV
Input impedance >100MΩ (sensor break detect circuit ‘Off’)
Input leakage current <100nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±10μV
Noise <28μV peak-to-peak with filter off: <4μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 2μV with 1.6s filter
Linearity Better than 5μV
Temperature coefficient <40ppm of reading per °C

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Appendix A Specification T2750 Eurotherm PAC

Sensor break protection Switchable as ‘High’, ‘Low’ or ‘Off’. Sensor current: 125nA

High impedance input (channel two only)

Input range 0.0V to 1.8V
Input impedance >100MΩ (sensor break detect circuit ‘Off’)
Input leakage current <100nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±20μV
Noise <100μV peak-to-peak with filter off: <15μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 7μV with 1.6s filter
Linearity Better than 50μV
Temperature coefficient <40ppm of reading per °C

Voltage inputs
Input range -10.3V to +10.3V
Input impedance 303kΩ
Calibration accuracy ±0.1% of measured value ±2mV
Noise <2mV peak-to-peak with filter off: <0.4mV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 0.2mV with 1.6s filter
Linearity Better than 0.7mV
Temperature coefficient <40ppm of reading per °C

Resistance inputs
Input range 0Ω to 560Ω (includes support for 2-, 3- or 4-wire RTD connection)
Lead resistance 22Ω maximum each lead (total resistance to be within range limits)
Sensor current 320μA maximum
Calibration accuracy ±0.1% of measured value, ±0.1Ω
Noise <0.08Ω peak-to-peak with 1.6s filter (better with longer time constants)
Resolution Better than 0.04Ω with 1.6s filter
Linearity Better than 0.05Ω
Temperature coefficient <30ppm of reading per °C

High Resistance input

Input range 0 to 6kΩ (includes support for 2-, 3- or 4-wire RTD connection)
Lead resistance 22Ω maximum each lead (total resistance to be within range limits)
Sensor current 320μA maximum
Calibration accuracy ±0.1% of measured value, ±0.6Ω
Noise <0.5Ω peak-to-peak with 1.6s filter (better with longer time constants)
Resolution <0.25Ω with 1.6s filter
Linearity Better than 0.1Ω
Temperature coefficient <30ppm of reading per °C

Potentiometer inputs
Input range 0 to 100% rotation
End-to-end resistance 100Ω (min.) to 6kΩ (max.)
Drive current 310μA maximum
Calibration accuracy ±0.1% of rotation value, ±0.1%
Noise <0.01% peak-to-peak with 1.6s filter (5kΩ pot.); <0.3% peak-to-peak with 1.6s filter (100Ω pot.)
Resolution Better than 0.001% with 1.6s filter and 5kΩ pot
Linearity Better than 0.01%
Temperature coefficient <20ppm of reading per °C

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T2750 Eurotherm PAC Appendix A Specification

A4.1.3 mA Input Variant

4 to 20mA loop
inputs
Input range -25mA to +25mA with 5Ω burden resistor in terminal
unit
Calibration ±0.25% of measured value plus ±2μA max offset
accuracy
Noise <1μA peak-to-peak with 1.6s filter (better with longer
time constants)
Resolution Better than 0.5μA with 1.6s filter
Linearity Better than 1μA
Temperature coefficient <50ppm of reading per °C

A4.2 AI3 Module

Notes:
1. The number of AI3 modules must be restricted such that the total, steady-state
power consumption for all the modules in a base unit does not exceed 24W for
the eight module base or 48W for the 16 module base.
2. Sensor Break Protection is controlled using an associated AI_UIO block.

General specification
Power consumption Current i/p: 2.2W
Three powered loops: 4W max.

Common mode rejection (47 to 63 Hz) >120dB

Series mode rejection (47 to 63 Hz) >60dB
Isolation Channel to chan- 50V RMS or dc (basic insulation)
nel:

to system: 300V RMS or dc (double insulation)

Hart Compliance
Cutting printed circuit links (one per channel) on the underside of the terminal unit places 220Ω re-
sistors in the input circuits within the AI3 module (section 2.3.3)

Channel inputs
Input range -28mA to +28mA
Calibration accuracy ±0.1% of measured value
Noise <1μA peak-to-peak with 1.6s filter (better with longer time constants)
Resolution Better than 0.5μA with 1.6s filter
Linearity Better than 1μA
Temperature coefficient <50ppm of reading per °C
Burden resistor 60Ω nominal; 50mA maximum current
Channel PSU 20V to 25V
PSU protection: 30mA (nominal) current trip, auto resetting

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Appendix A Specification T2750 Eurotherm PAC

A4.3 AI4 Module

Note: Sensor Break Protection is controlled using an associated AI_UIO block.
Channels 1 and 3 support sensor break actions ‘Up’, ‘Down’ and ‘None’; channels 2
and 4 support ‘Up’ only.

General specification (applies to all AI4 variants)

Power consumption 2W max.

Common mode rejection (47 to 63 Hz) >120dB
Series mode rejection (47 to 63 Hz) >60dB
Isolation Channel 1 to chan- No isolation
nel 2:
Channel 3 to channel 4: No isolation
Ch1 or Ch2 to Ch3 or Ch4: 300V RMS or dc (basic insulation)
to system: 300V RMS or dc (double isolation)
Max. voltage across any channel 5V dc

A4.3.1 Thermocouple Input Variant

Thermocouple inputs
Input range -150mV to +150mV
Input impedance >20MΩ (sensor break detect circuit ‘Off’)
Input leakage current <125nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±10μV
Noise <28μV peak-to-peak with filter off; <6μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 2μV with 1.6s filter
Linearity Better than 5μV
Temperature coefficient <40ppm of reading per °C
Sensor break protection Fixed pull-up. Sensor current: 125nA

Cold Junction
Temperature -10°C to +70°C
range:
CJ Rejection: >30:1
CJ accuracy: ±0.5°C typical (±1°C maximum)
Sensor type Pt100 RTD, located beneath the input connector

A4.3.2 mV Input Variant

Thermocouple inputs
Input range -150mV to +150mV
Input impedance >20MΩ (sensor break detect circuit ‘Off’)
Input leakage current <125nA (sensor break detect circuit ‘Off’)
Calibration accuracy ±0.1% of measured value ±10μV
Noise <28μV peak-to-peak with filter off; <6μV peak-to-peak with 1.6s filter (better with longer time con-
stants)
Resolution Better than 2μV with 1.6s filter
Linearity Better than 5μV
Temperature coefficient <40ppm of reading per °C

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A4.3.3 mA Input Variant

Input range -25mA to +25mA

Calibration accuracy ±0.25% of measured value plus ±2μA max offset
Noise <1μA peak-to-peak with 1.6s filter (better with longer time constants)
Resolution Better than 0.5μA with 1.6s filter
Linearity Better than 1μA
Temperature coefficient <50ppm of reading per °C
Burden Resistor 5Ω ±0.1% (fitted to terminal unit)

A4.4 AI8 Module

General specification (applies to all AI8 variants)
Number of channels 8 (4 for AI8-RT)
Module power consumption <1.8W
Common mode rejection (47 to 63 Hz)
w.r.t. system, i.e. across galv. isolation >140dB
Series mode rejection (47 to 63 Hz) >60dB
Isolation To system: Reinforced for <300V ac/dc mains networks - Installation category II
Between channels: Galvanic isolation in pairs (channels 1 & 5, 2 & 6, 3 & 7 and 4 & 8)
Basic isolation for <300V ac/dc mains networks - Installation category II
Differential isolation within ±1V range between two channels of each pair in thermocouple, mV, mA
and FmA modules
RTD provides basic isolation (<300V ac/dc) between channels

A4.4.1 mV Input Variant

Suitable transmitter types mV sources with output impedance <1KΩ (floating or grounded)
Input range ±80mV
Input impedance 10MΩ differential, 2.5MΩ common
Input leakage current ±25nA (@ <1V common)
Calibration accuracy Example.
±0.1% of mV reading for values outside -8mV to +8mV (at 25°C ambient temperature)
±8μV for values inside -8mV to +8mV Calibration accuracy using type K
thermocouple at 500°C
DC common mode rejection 500°C = 20.644mV
(w.r.t. other channels of same pair) >105dB for source impedance mismatch <100Ω ±0.1% of 20.644mV = ±20.644μV
Resolution/Noise >17 bit with 1.6s filter (±1.5μV) Thermocouple sensitivity at 500°C =
43μV per °C
16 bit of span with no filter (±3μV) Calibration error is ±20.644/43°C =
Linearity 10ppm of input range ±0.48°C
Temperature coefficient <±30ppm per °C
Zero offset <±3μV
Offset drift <20pV/°C
Sensor break detection within 250ms using 25μA pulse. Thresholds >50kΩ

A4.4.2 Thermocouple Input Variant

Thermocouple inputs
Suitable thermocouples B, C, D, E, G2, J, K, L, N, R, S, T, U, NiMo/NiCo, Platinel, Ni/NiMo, Pt20%Rh/Pt40%Rh
As mV input, with:
Calibration accuracy as for mV input, divided by chosen thermocouple sensitivity
(mV/temperature unit) at measurement temperature
Linearity of linearisation ±0.1°C (deviation from defined curves)
Sensor break detection within 250ms using 25μA pulse. Thresholds >50kΩ
Cold Junction CJ Rejection >50:1 typical (depending upon thermocouple sensitivity)
Internal CJ accuracy ±0.8°C typical

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Appendix A Specification T2750 Eurotherm PAC

A4.4.3 mA Input Variant

Suitable transmitter types 4-20mA sensors (floating or grounded)

As mV input, with:
Input range ±24mA with 3.33Ω burden resistors fitted in the terminal unit
Calibration accuracy ±0.15% of mA reading for values outside -2.4mA to +2.4mA (at 25°C ambient temperature)
Resolution/Noise >17bit with 1.6s filter (±0.5μA)
16bit of span with no filter (±1.0μA)
DC common mode rejection
(w.r.t. other channels of the same pair) >105dB for source impedance mismatch <100Ω
Linearity 10ppm of span
Temperature coefficient <±40ppm per °C (using 10ppm burden resistor)
Zero offset <±1μA
Offset drift <±8pA/°C)
Sensor break detection Not detectable in hardware (software can detect under range current)

A4.4.4 RTD Input Variant

Connection scheme 3-wire, 2-wire connected to terminals A and B, with link between terminals B and C. 4-wire by leaving
one wire disconnected
Number of channels 4
Suitable RTD types Pt100, Pt1000
Input ranges 0Ω to 500Ω and 0Ω to 5kΩ (including lead resistance)
Calibration accuracy 500Ω range ±0.1% of resistance reading above 10% of range (>50Ω) (at 25°C ambient temperature)
±50mΩ below 10%
5kΩ range ±0.1% of resistance reading above 10% of range (>500Ω) (at 25°C
ambient temperaturee
±500mΩ below 10%
Resolution/Noise >17bit (±8mΩ) with 1.6s filter
16bit (±16mΩ) with no filter
Linearity 20ppm of input range
Temperature coefficient <±20ppm per °C
Sensor break detection Within 125ms by high resistance detection

A4.5 AO2 Module

General specification
Power consumption 2.2W max.
Isolation Channel to chan- 300V RMS or dc (basic insulation)
nel:
to system: 300V RMS or dc (double insulation)

Current outputs
Output range -0.1 to +20.5mA
Load limits 0 to 500Ω
Calibration accuracy Better than ±0.1% of reading
Linearity 0.03% range (0.7μA)
Resolution Better than 1 part in 10000 (1μA typical)

Voltage outputs
Output load limits
-0.1 to 10.1V range: 550Ω min.
-0.3V to +10.3V range: 1500Ω min.
Calibration accuracy Better than 0.1% of reading
Linearity 0.03% range (0.3mV)
Resolution Better than 1 part in 10000 (0.5mV typical)

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A4.6 DI4 Module

Note: Inputs must be either all logic inputs (link ‘V+’ and ‘C’ terminals together) or all
contact inputs (apply 24V supply across ‘V+’ and ‘C’ terminals).

General specification
Power consumption 0.5W max.
Isolation Channel to chan- Channels share ‘common’ (‘C’) connections
nel:
to system: 300V RMS or dc (double insulation)
Voltage supply 24±6V dc external supply required for contact inputs
Minimum pulse width 10ms, or de-bounce value whichever is longer
De-bounce time 0ms to 2.55s (as configured by the user)
Max. voltage across any channel 30V dc

Logic inputs (see note above)

Off (logic 0) voltage -5V to +5V dc
On (logic 1) voltage 10.8V to 30V dc
Input current 2.5mA approx. at 10.5V; 10mA max. at 30V

Contact inputs (see note above)

Off (0) resistance >7kΩ
On (1) resistance <1kΩ
Wetting current >8mA
Wetting voltage >9V (12V typical measured open circuit)

A4.7 DI6 Module

Note:

1. This module is ordered either as a 115V version or as a 230V version. One type
cannot be converted into the other.

2. Each input is fitted with a 470pF capacitor for EMC purposes. This causes an
earth leakage current of approximately 0.04mA at 115Vac 60Hz or 0.08mA
230Vac 60Hz.

General specification
Power consumption 0.5W max.
Detectable pulse width Three mains cycles
Isolation Channel to system: 300V RMS or dc (Double insulation)
Channel to channel: 300V RMS or dc (Basic insulation)

A4.7.1 115V ac Input Variant

115V inputs
Off (logic 0) voltage 0 to 35V ac The result of applying RMS voltages
On (logic 1) voltage 95V to 150V ac
between 35V and 95V is not defined.
Input current Maximum: 8mA at 150V RMS
Minimum: 2mA
Max voltage across any channel 150V RMS

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Appendix A Specification T2750 Eurotherm PAC

A4.7.2 230V ac Input Variant

230V inputs
Off (logic 0) voltage 0 to 70V ac
On (logic 1) voltage 180V to 264V ac The result of applying RMS voltages
Input current Maximum: 9mA at 264V RMS between 70V and 180V is not defined.
Minimum: 2mA
Max voltage across any channel 264V RMS

V ac
V ac

On On
mA

mA
Off Undefined
Off Undefined

Voltage/current curves for 230V module Voltage/current curves for 115V module

A4.8 DI8 Module

Note: This module is ordered either as a ‘logic’ version or as a ‘contact closure’
version. One type cannot be converted into the other.

General specification
Power consumption Contact i/p: 1.9W max.
Logic i/p: 0.6W max.
Isolation Ch1 to Ch 2: Channels share ‘common’ (‘1C2’) connection
Ch3 to Ch 4: Channels share ‘common’ (‘3C4’) connection
Ch5 to Ch 6: Channels share ‘common’ (‘5C6’) connection
Ch7 to Ch 8: Channels share ‘common’ (‘7C8’) connection
Ch1/2 to other channels: 50V RMS or dc (Basic insulation)
Ch3/4 to other channels: 50V RMS or dc (Basic insulation)
Ch5/6 to other channels: 50V RMS or dc (Basic insulation)
Ch7/8 to other channels: 50V RMS or dc (Basic insulation)
to system: 300V RMS or dc (Double insulation)
Minimum pulse width 5ms (Task 1), or 10ms (Task 3), or de-bounce value whichever is longer
De-bounce time 0ms to 2.55s (as configured by the user)
Max. voltage across any channel 30V dc

A4.8.1 Logic Input Variant

Logic inputs (see note above)
Off (logic 0) voltage -5V to +5V dc The result of applying voltages between
On (logic 1) voltage 10.8V to 30V dc +5V and +10.8V is not defined.
Input current 2.5mA approx. at 10.5V; 8mA max. at 30V

A4.8.2 Contact Closure Input Variant

Contact inputs (see note above) The result of applying contact resistances
Off (0) resistance >7kΩ between 1kΩ and 7kΩ is not defined.
On (1) resistance <1kΩ
Wetting current 4mA typical

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T2750 Eurotherm PAC Appendix A Specification

A4.9 DI16 Module

General specification
Power consumption Logic mode: 0.75W max.
Contact mode: 2.0W max.
Isolation Channel to chan- Channels share ‘common’ (‘C’) connections
nel:
to system: 300V RMS or dc (Double insulation)
Minimum pulse width 5ms, or de-bounce value whichever is longer
De-bounce time 0ms to 2.55s (as configured by the user)
Max. voltage across any channel 30V dc

The result of applying voltages between

Logic inputs
+5V and +10.8V is not defined.
Off (logic 0) voltage -30V to +5V dc
On (logic 1) voltage 10.8V to 30V dc
Input current 3.8mA approx. at 12V dc; 2.8mA approx. at 24V dc

Contact inputs
Off (0) resistance >7kΩ The result of applying inputs between 1kΩ
On (1) resistance <1kΩ
and 7kΩ is not defined.
Wetting current 4mA min.
Module internal isolated power supply (terminal P voltage)
16V to 18V dc
Wetting voltage (effective) 12V dc min.

A4.10 DO4 Module

General specification
Power consumption 0.5W max.
Isolation Channel to chan- Channels share ‘common’ (‘C’) connections
nel:
to system: 300V RMS or dc (Double insulation)

Logic outputs
Voltage supply (VCS) 24±6V dc
Logic 1 o/p voltage (Vcs - 3)V for a 5mA load
Logic 0 o/p voltage <1V dc
Logic 1 o/p current 8mA per channel (current limited)
Off state leakage <0.1mA

Voltage outputs
Voltage supply (VCS) 12V to 30V dc
Logic 1 o/p voltage (Vcs - 3)V for a 5mA load
Logic 0 o/p voltage <1V dc
Logic 1 o/p current 100mA per channel (current and temperature limited)

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Appendix A Specification T2750 Eurotherm PAC

A4.11 DO8 Module

CAUTION
A 4 Amp fuse must be fitted in the voltage supply line in order to ensure against
connector overheat.

General specification
Power consumption 0.6W max.
Isolation Channel to Channels share ‘common’ (‘C’) connections.
channel:
to system: 300V RMS or dc (Double insulation)
Refer to "Electrical Installation" on page 31
for precautions to be taken when fitting DO8
Input specification
modules
Voltage supply (VCS) 18V to 30V dc
Supply protection Internally limited at 4A (reaction time 4ms max.)
Automatically resets 150ms after the cause of the fault has been rectified
Logic 1 o/p voltage (Vcs - 3)V for a full load
Logic 0 o/p voltage <0.1V

Logic 1 o/p current 0.75A max. per channel; 4A max. per module

A4.12 DO16 Module

General specification
Power consumption Module: 0.6W
(max.)
Plant side: 850W
Isolation Channel to chan- Channels share ‘common’ (‘C’) connections
nel:
to system: 300V RMS or dc (Double insulation)

Refer to "Eight-channel Digital Input Module

Input specification
(DI8)" on page 45 for precautions to be
Voltage supply (VCS) 24V dc ±20%
Logic 1 o/p voltage (Vcs - 1)V for a full load taken when fitting DO16 modules
Logic 0 o/p voltage <1V
Logic 1 o/p current 0.7A max. per channel
Logic 0 output current 10μA
Short circuit protection 0.7A to 1.7A per channel
Module thermal cut-off (55°C ambient) 90±3°C (restart at 88±3°C)

A4.13 FI2 Module

CAUTION
If more than eight FI2 modules are fitted, and if these have an average output
channel load of more than 5mA each, then an external power supply must be used
to power the transducer (Figure 41). Otherwise, if the internal supply is used,
damage will be caused to the base unit backplane tracking.

General specification

Power consumption 3.7W max.

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Isolation Channel to chan- 100V RMS or dc (Basic insulation)

nel:
Channel to system: 300V RMS or dc (Double insulation)
Max terminal voltage ‘+’ to ‘-’ 100V peak-to-peak
‘+’, ‘-’ and ‘C’ are terminal
‘+’ to ‘C’ 50V dc
identifiers

Channel general specification

Frequency measure- Ranges: Logic: 0.01Hz to 40kHz (de-bounce off)
ment
Magnetic: 10Hz to 40kHz
Resolution: <60 ppm of reading for square wave input
Accuracy: ±100 ppm of reference ± 160ppm overall ± 0.05% drift (five years)
Pulse counting Ranges: Logic: DC to 40kHz (de-bounce off)
Magnetic: 10Hz to 40kHz
Resolution <600 ppm of reading for square wave input
Max-frequency derating, due to de-bounce
Setting = 5ms: Max frequency = 100Hz
Setting = 10ms: Max frequency = 50Hz
Setting = 20ms: Max frequency = 25Hz
Setting = 50ms: Max frequency = 10Hz

Magnetic sensor inputs

Input range 10mV to 80V peak-peak
Absolute maximum ±100V
input
Input impedance >30kΩ

Logic inputs
Minimum pulse width 1.2μs
(de-bounce off)

Voltage Input range: 0 to 20V dc

Absolute maximum 50V dc
input:
Input impedance: >30kΩ
Threshold: Settable range: 0 to 20V ±0.2V hysteresis
Accuracy ±0.4V or ±7% of range, whichever is the greater
Sensor break level: 50mV to 310mV ±10%. Active for threshold settings between 200mV
and 7.4V

Current Input range: 0 to 20mA

Absolute maximum 30mA dc
input:
Input impedance: 1kΩ
Threshold: Settable range: 0 to 20mA ±0.2mA hysteresis
Accuracy: ±0.4mA or ±7% of range, whichever is the greater
Sensor break level: 0.05mA to 0.31mA ±10%. Active for threshold settings between
0.2mA and 7.4mA
Sensor short cir- when <100Ω; restored when >350Ω. Active for threshold settings be-
cuit: tween 0.2mA and 7.4mA

Contact Input impedance: 5kΩ

Threshold: Settable range: 0 to 20V ±0.2V hysteresis
Accuracy ±0.4V or ±7% of range, whichever is the greater

PSU Output specification

Voltage Selectable as 8, 12 or 24V dc at 10mA
Maximum current 25mA
Accuracy ±20%

Voltage drop 1V at 25mA

Current limiting Output short circuit causes temporary failure of pulse input circuit

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Appendix A Specification T2750 Eurotherm PAC

A4.14 RLY4 Module

Note: Snubber circuits (22nF+100Ω) are fitted internally to this module. They may
be removed as described in "Two-channel Frequency Input Module (FI2)" on
page 51. Leakage across the snubber at 240V ac 60Hz = approx. 2mA.

General specification
Power consumption 1.1W max.
Isolation Channel to chan- 300V RMS or dc (Basic insulation)
nel:
Channel to system: 300V RMS or dc (Double insulation)
Contact life (resistive 240Vac, 2A: >6x105 operations
load)
240Vac, 1A: >107 operations
Contact life (induc- As per derating curves
tive load)
Mechanical life >3x107 operations

Relay specification
Contact material AgCdO
Maximum current rating 2A at up to 240V ac; 0.5A at 200Vdc, increasing to 2A at 50V dc (re-
sistive)
Minimum current rating 100mA at 12V

Contact format
Channels 1 to 3: Common and normally open contacts. (Open circuit with relay not en-
ergised)
Channel 4: Common, normally open and normally closed contacts.
Common and normally closed contacts are short circuit with relay not
energised

AC inductive load derating curves

Reduction Factor F

Power factor (cos φ)

F1 = Measured results
F2 = Typical values
Life = Resistive life x reduction factor

DC inductive load breaking capacity

derating curves

Resistive
DC Amps

DC Volts

The above derating curves apply to the relays

in both RLY4 and RLY8 modules.

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A4.15 RLY8 Module

Note: Each input is fitted with a 100pF capacitor for EMC purposes. This causes an
earth leakage current of approximately 0.02mA at 240Vac 60Hz per relay.

General specification
Power consumption 2.5W max.
Isolation Channel to chan- 300V RMS or dc (Basic insulation)
nel:
Channel to system: 300V RMS or dc (Double insulation)
Contact life (resistive 240Vac, 2A: >6x105 operations
load)
240Vac, 1A: >107 operations
Contact life (induc- As per derating curves
tive load)
Mechanical life >3x107 operations

Relay specification
Contact material AgCdO
Maximum current rating 2A at up to 240V ac; 0.5A at 200Vdc, increasing to 2A at 50V dc (re-
sistive)
Minimum current rating 100mA at 12V

Contact format
Channels 1 to 8: Common and normally open contacts. (Open circuit with relay not en-
ergised)

A4.16 ZI Module

General specification
Power consumption 1.8W max
Common mode rejection >80dB (48 to 62Hz)
Series mode rejection >60dB (48 to 62Hz)
Isolation ZI Channel to T/C 300V RMS or dc (Basic insulation)
channel:
Channel to system: 300V RMS or dc (Double insulation)
Max. voltage across any channel 10V dc
Thermocouple input (channel 1)
Input range -77mV to +100mV
Input impedance 10MΩ
Calibration accuracy ±0.1% of reading ±10μV
Noise <5μV peak-to-peak with 1.6s filter
Better than 2μV with 1.6s filter
Linearity ±0.1°C
Temperature coefficient <±30ppm/°C
Sensor break protection 250nA break high, low or off

Cold Junction
Temperature range: -10°C to +70°C
CJ Rejection: >30:1
CJ accuracy: ±0.5°C (typical); ±1.3°C max. (automatic CJC)
Sensor type Pt100 RTD, located beneath the input connector

Zirconia input (channel 2)

Input range -10mV to +1800mV
Input impedance >500MΩ
Calibration accuracy ±0.2% of input
Noise <0.1mV peak-to-peak with 1.6s filter
Resolution <50μV with 1.6s filter
Sensor impedance measurement 0.1kΩ to 100kΩ ±2%
Input leakage current ±1nA (typical) ±4nA (max.)

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A4.17 netHOST Profibus Master Gateway

Electrical specification
Supply voltage 24V dc ±6V dc (with reverse voltage protection)
Current consumption at 24V (typically) 130mA
Power consumption 3.2W
Power connector Mini-COMBICON, 2-pin

Environmental
Temperature range 0 to 60°C
Humidity No condensation permitted

Diagnostic interface
LED status for SYS (System), APL (Application), COM (Communication) and Ethernet link and activity
Diagnostic LIN blocks NETHOST and GWProfM_CON

Physical
Dimensions (L x W xH) 100mm x 52mm x 70mm (without connector)
Weight 150g (approx)
Mounting on DIN rail EN60715
Protection class IP 20

Profibus
Max number of Profibus DP slaves 125
Max number of total cyclic input data 3584 bytes
Max number of total cyclic output data 3584 bytes
Max number of cyclic input data 244 bytes/slave
Max number of cyclic output data 244 bytes/slave
Configuration data Max 244 bytes per slave
Parameterisation data per slave 7 bytes/slave standard parameters

max 237 bytes/slave application specific parameters

Supported baud rates 9.6kbit/s
19.2kbit/s
31.25kbit/s
45.45kbit/s
93.75kbit/s
187.5kbit/s
500kbit/s
1.5Mbit/s
3Mbit/s
6Mbit/s
12Mbit/s
Auto baud rate detection is not supported
Data transport layer PROFIBUS FDL
Limitations DP V1 services class 1 and 2 are not supported
DP V2 services are not implemented
Interface type ISO 11898, optically isolated
Connector Sub D female, 9-pin

Ethernet
Transmission rate 100Mbit/s
Half duplex / Full duplex Supported
Connector RJ45 x 2

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T2750 Eurotherm PAC Appendix A Specification

A5 LIN Blocks Supported

A5.1 Batch Blocks

See LIN Blocks reference manual chapter 2 for block details.
DISCREP Discrepancy block
RECORD Record block
SFC_CON Sequential function chart control block
SFC_DISP Sequential function chart display block
SFC_DISP_EX Sequential function chart display extension block
SFC_MON Sequential function chart monitor block

A5.2 Communications Blocks

See LIN Blocks reference manual chapter 3 for block details.
GW_CON Gateway configuration block
GW_TBL Gateway table block
GW_ProfM_CON Gateway Profibus Master configuration block
RAW_COM Raw communications block

A5.3 Condition
See LIN Blocks reference manual chapter 4 for block details.
AGA8DATA AGA8 Calculation block
AN_ALARM Analogue alarm block
CHAR Characterisation block
DIGALARM Digital alarm block
FILTER Filter block
FLOW_COMP Compensated flow block
GASCONC Natural gas concentration data block
INVERT Analogue inversion block
LEAD_LAG Lead/lag filter block (for feed-forward calculations, etc.)
LEADLAG Lead/lag block
RANGE Range block
TC_LIFE Thermocouple life-expectancy block
TC_LIFE_EX Thermocouple life-expectancy extension block
TC_SEL Thermocouple selector block
UCHAR Data storage for ‘CHAR’ block
ZIRCONIA Zirconia block

A5.4 Configuration Blocks

See LIN Blocks reference manual chapter 5 for block details.
PROGRAM Program configuration (header) block
TACTICIAN Tactician configuration (header) block

A5.5 Control Blocks

See LIN Blocks reference manual chapter 6 for block details.
3-TERM Incremental PID block
AN_CONN Analogue connections block
AN_DATA Analogue data block

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Appendix A Specification T2750 Eurotherm PAC

ANMS Analogue manual station block

DG_CON Digital connections block
DGMS Digital manual station block
LOOP_PID Loop proportional, integral, derivative block
MAN_STAT Manual station block
MODE Mode block
PID PID Block
PID_LINK PID linking block
SETPOINT Setpoint block
SIM Simulation block
TUNE_SET PID tuning set block

A5.6 Convert Blocks

See LIN Blocks reference manual chapter 7 for block details.
REALTIME Real-time converter block

A5.7 Diagnostics Blocks

See LIN Blocks reference manual chapter 9 for block details.
AGA8DIAG AGA8 diagnostic block
ALH_DIAG Alarm history diagnostic block
DB_DIAG Database diagnostic block
EDB_DIAG External database diagnostic block
EDB_TBL External database table block
EIO_DIAG Eurotherm I/O diagnostic block
ELINDIAG ELIN MAC and LLC diagnostic block
EMAP_DIAG ELIN mapping diagnostic block
ETH_RT_LIM Ethernet rate limit diagnostic block
FSM_DIAG File system management diagnostic block
FTQ_DIAG Processor redundancy management task (PRMT) queues
diagnostic block
ICM_DIAG Inter-processor communications mechanism statistics
block
IDENTITY Instrument identification/status diagnostic block
LIN_DEXT LIN high level diagnostic extension block
LINMAPD LIN mapping diagnostic block
LLC_DIAG Logical link control (LLC) diagnostic block
NETHOST netHOST diagnostic block
OPT_DIAG Options diagnostic block
PRP_DIAG Port resolution protocol diagnostic block
RARCDIAG Data record archive diagnostic block
RMEMDIAG Data record memory diagnostic block
ROUTETBL Routing table block
RSRCDIAG Resource diagnostic block
RTB_DIAG Routing table diagnostic block
SD_DIAG SD card diagnostic block
SFC_DIAG Sequential function chart diagnostic block
SUM_DIAG Summary diagnostic block
TACTTUNE Tactician task summary block
TOD_DIAG Time-of-day diagnostic block
USERTASK User task diagnostic block

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T2750 Eurotherm PAC Appendix A Specification

A5.8 IO Blocks
See LIN Blocks reference manual chapter 11 for block details.
AI_UIO Analogue input block
AO_UIO Analogue output block
CALIB_UIO Analogue I/O calibration block
DI_UIO Digital input block
DO_UIO Digital output block
FI_UIO frequency input block
MOD_DI_UIO Multi-channel digital input module block
MOD_DO_UIO Multi-channel digital output block
MOD_UIO Module I/O block
TPO_UIO Time proportioning output block
VP_UIO Valve positioner block

A5.9 Logic Blocks

See LIN Blocks reference manual chapter 12 for block details.
AND4 Four-input logical AND block
COMPARE Compare block
COUNT Input pulse count block
LATCH D-Type flip-flop block
NOT Logical invert block
OR4 Four-input logical OR block
PULSE Monostable pulse generator block
XOR4 Four-input logical exclusive OR block

A5.10 Maths Blocks

See LIN Blocks reference manual chapter 13 for block details.
ACT_2A2W3T Action block with gated down timers
ACTION Action block
ADD2 Add block
DIGACT Digital action block
DIV2 Divide block
EXPR Expression block
MUL2 Multiply block
SUB2 Subtract block

A5.11 Organise Blocks

See LIN Blocks reference manual chapter 15 for block details.
AREA Area block
GROUP Group block

A5.12 Programmer Blocks

See LIN Blocks reference manual chapter 16 for block details.
PROGCHAN Setpoint programmer channel block
PROGCTRL Setpoint programmer control block
SEGMENT Setpoint programmer segment block
SPP_RAMP Setpoint programmer local ramp block

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Appendix A Specification T2750 Eurotherm PAC

A5.13 Recorder Blocks

See LIN Blocks reference manual chapter 17 for block details.
RGROUP Data recording group block

A5.14 Selector Blocks

See LIN Blocks reference manual chapter 19 for block details.
2OF3VOTE Best average block
ALC Alarm collection block
SELECT Selector block
SWITCH Switch block

A5.15 Timing Blocks

See LIN Blocks reference manual chapter 21 for block details.
DELAY Delay block
DTIME Dead time block
RATE_ALM Rate alarm block
RATE_LMT Rate limit block
SEQ Sequence block
SEQE Sequence extension block
TIMEDATE Time/date event block
TIMER Timer block
TOT_CON Totaliser connections block
TOTAL Totaliser block
TOTAL2 Totaliser block
TPO Time proportioning output block

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Appendix B Reference
B1 Frequency Input Module Details
This module provides two input channels to be used for data gathering and signal
conditioning from a range of common plant sensor types, including magnetic, voltage
input, current input and contact closure inputs.

The module includes internal power supplies which can provide loop or wetting
currents, transducer power as required.

B1.1 Terminal Connections, Links and Status LEDs

"Two-channel Frequency Input Module (FI2)" on page 51 gives full pinout, link setting
and status LED details. For the sake of clarity, Figure 39 shows the links set in the
same position for both channels, but as the channel acts independently, the links
should be set as appropriate for each channel.

CAUTION
If more than eight FI2 modules are mounted in a base unit, and the channel output
at 24V is greater than 5mA per channel, then an external power supply must be
used. Using the normal base unit supply in such a situation can cause damage to
the backplane.

B1.2 Specification
"A4.13 FI2 Module" on page 196 gives the FI2 module specification

B1.3 Application Details

B1.3.1 Cable Selection

The selection of appropriate cabling to connect the encoder to the FI2 is dependent
upon a number of factors. In all cases, it is recommended that sensor cabling does
not exceed 30m, otherwise high energy surges (IEC61000-4-5) may be picked-up
and applied to the module terminals. The choice of cable depends on how electrically
noisy the area is, the length of cabling required, and the frequency being used.
Typical cabling choices include:

a. Short cable length in low-noise environments: Basic shielding (a foil jacket

and a drain wire) should provide moderate noise protection for cost-sensitive
applications.

b. Noisier environments and/or longer (more than 3m) cable runs: In potentially
high-noise environments, or for cable runs >3m, it is recommended that each
channel is connected to the FI2 using a lowcapacitance (<20pF/foot)
shielded cable.

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Appendix B Reference T2750 Eurotherm PAC

c. High-frequency inputs and/or longer cable runs: For high frequency

applications (>5kHz), both a foil and braided shielding in a low-capacitance
(<20pF/foot) cable is recommended. A foil-wrapped twisted shielded pair in a
braided shielded cable can deliver good performance over long distances
(depending on the type of output driver used).

d. Best immunity to noise and long cable runs: A multi-conductor cable with 22
and 24 AWG stranded tinned copper conductors, individually foil shielded
(100% coverage) and an overall tinned copper braid with a capacitance of
12pF/foot or less should be considered for longer distances. A cable similar
to the Belden 3084A could be used, for example.

B1.3.2 Cable Shield Connection

Typically, noise immunity can be achieved by connecting the cable shield to the
relevant FI2 common connection (C1/C2). However, in some cases connecting the
shielding to the common signal return path at the encoder end may achieve better
noise immunity. Under no circumstances, connect the shield at both ends.

B1.3.3 Choosing the Appropriate Output Sensor Type

The choice of input type is heavily dependent on the distance from the encoder to the
FI2 and the noiseenvironment it is operating in.

Open Collector/Drain
An open collector or open drain output is commonly used in single-ended incremental
encoders to provide a simple, economical solution for low-end applications like
counters. The FI2 provides a programmable output voltage of 8V, 12V or 24V
(maximum 25mA) which can be used as either the encoder power supply (max
current output is 25mA) or as the pull-up supply, or both. There is also a dedicated
5kΩ pull-up/pulldown resistor network built into the FI2’s terminal unit connected to
the programmable power supply. This can be activated by setting the links on the
terminal unit to position A.

Refer to "B1.5.4 Contact Inputs" on page 212 for a diagram showing the external and
effective internal circuit representation for open collector/drain configurations. The
figure below shows the connections for this type of configuration on the FI2’s terminal
unit.

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Figure 104 FI2 terminal unit connectors for open collector/drain configuration
Note that when the links are set to position A on the terminal unit, then half the supply
voltage is applied to the 1+ terminal via a voltage divider of 2 x 5KΩ resistors. The
input would then have a 5kΩ pull-up to the channel supply and a 5kΩ pull-down to
channel 0V. Thus an NPN device (or contacts) would switch between 0V and half the
channel supply, and a PNP device (or contacts) would switch between the channel
supply and half the channel supply. The threshold will appear in volts and will need to
be set according to which connection had been made.

If the FI2 is used in this way, ensure that the PSU setting in LinTools is set to the
correct voltage (8V, 12V or 24V) for the appropriate FI2 block. The user may enter
any voltage in this parameter, but the block will edit the value to 8, 12 or 24,
whichever is the nearest to the entered value.

Figure 105 FI2 block properties page

It should be noted that these types of encoders can be vulnerable to noise and
should only be used for cable runs of 3m or less.

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Appendix B Reference T2750 Eurotherm PAC

Push-pull Totem-Pole Output

For higher noise environments, a push-pull or totem-pole output driver provides a far
superior solution. Using an encoder with a Push-Pull output will make the design far
more noise tolerant and can work well for distances of up to 10m when used in
conjunction with a screened cable. Refer to "B1.5.2 Voltage Inputs" on page 211 for a
diagram showing the external and effective internal circuit representation for
Push-pull Totem-Pole configurations. The figure below shows the connections for
this type of configuration on the FI2’s terminal unit.

Figure 106 FI2 terminal unit connectors for Push-pull Totem-Pole input configuration

Ensure the threshold (Thresh parameter) in LinTools is initially set to 50% of the input
signal. For example, if using the FI2 supply set to 12V as the pull-up supply, set the
Thresh parameter to 6V.

When the Links are set in the Voltage (position C) or Current (position B), the
Threshold must be set, as close to the midpoint between the peak to peak values as
is possible, in order to achieve good pulse detection, best repeatability, and to help
prevent detection of noise spikes.

If the FI2 power supply output is used as the pull-up supply then note the following:

a. Set the links to position C on the terminal unit. This is clearly marked on the
silk screen of the terminal unit.

b. The maximum current that should be drawn from the FI2 supply is 25mA on
any selected voltage range.

c. If the FI2 power supply is set to 12V and a 1/4 watt resistor is to be used for
the pull-up, the minimum value of resistor that should be used is 1kΩ.

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d. If the FI2 power supply is set to 24V and a 1/4 watt resistor is to be used for
the pull-up, the minimum value of resistor that should be used is 4.3kΩ.

e. If the FI2 power supply is set to 8V and a 1/4 watt resistor is to be used for
the pull-up, the minimum value of resistor that should be used is 470Ω.

B1.3.4 FI2 General and LinTools Configuration

When configuring the FI2 for the first time, it is worth considering the following:

1. Ensure the link positions are set correctly on the terminal unit. See "Two-channel
Frequency Input Module (FI2)" on page 51 for details.

2. The settings for the FI2 inputs can be found in the FI_UIO block within LinTools.
Ensure that the correct InType is selected for the FI2 channel being configured.

3. Consider using the OPC scope which can be found on the LinTools top menu
under Tools > OPC Scope, to monitor the output. If noise spikes are still an issue,
consider adding a software filter in the Filter field of the appropriate FI_UIO block.

It is possible, if the application permits it to apply a ‘debounce’ value of 0ms (off),

5ms, 10ms, 20ms, or 50ms, with the algorithm ensuring that pulse edges closer than
the set time, are excluded.

An OverRange warning is not displayed for signals approaching the maximum

frequency allowed by the Debounce algorithm. Control loops based on a frequency
PV are not recommended, when debounce is applied, without provision for protecting
against the consequences should the frequency exceed this upper limit.

It may be necessary to disable the Sensor Break and Sensor Short Circuit detection
(via the Options.SBreak and Options.SCct fields in the associated FI_UIO block) to
prevent inappropriate alarms. The Sensor Break alarm is set if the Input value falls
below 0.05V or 0.05mA. The Sensor Short circuit alarms is set if the Input value rises
above 91% of the output supply (Volts or milliamps).

A NAMUR Input on a module configured in the Current (position B), must be set to 8V
output supply, and the threshold must be set to 1.65mA. Sensor Break and Sensor
Short circuit detection can be enabled, if required.

14
12
10
Magnitude (V)
(Min to Peak)
Input Signal

8
6
4
2
0
0 5 10 15 20 25

Threshold Setting (V)

Figure 107 Input signal versus Threshold

Note: To allow for Hysteresis and Threshold accuracy with temperatures and
between modules that have been swapped, the input signal must have sufficient
amplitude. The graph in Figure B.4 may be used as a guide to the size of signal for a
given Threshold setting.

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Appendix B Reference T2750 Eurotherm PAC

When the Links are set in the Contact Inputs (position A) position, 5kΩ biasing
resistors are connected that provides a wetting current. If more wetting current is
required, additional resistors can be fitted to the Terminal Unit, or an external biasing
supply can be connected, and the threshold configured accordingly.

Sensor Break and Sensor Short circuit detection must be disabled) via the
‘Options.SBreak’ and ‘Options.SCct’ fields in the associated FI_UIO block).

B1.4 Isolation Diagram

Isolation is implemented in the form of a double insulation (300V) barrier separating
all the I/O channels in a module from the rest of the system.

This prevents hazardous voltages on any one I/O channel from introducing hazards
to wiring associated with any other I/O module, or from putting the rest of the system
at risk.

Modules which provide channel-to-channel isolation further ensure safety and good
signal quality on all channels within such modules. Refer to the relevant section of
Appendix A for more details.

V1
1+
Channel 1 1-

C1 I/O Bus
and IOC

V2
Channel 2 2+
2-
C2

Figure 108 Isolation Diagram

B1.5 Equivalent Circuits

B1.5.1 Magnetic Inputs

1+ or
2+

Sensor

1+ or
2-
Internal View

Figure 109 Magnetic Input

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T2750 Eurotherm PAC Appendix B Reference

B1.5.2 Voltage Inputs

V1 or V2

V
1+ or 2+

Voltage
Source
Threshold
C1 or C2
Internal View

Figure 110 Voltage Inputs

B1.5.3 Current Inputs

V1 or V2
Voltage
Source V
1+ or 2+

1kΩ
Threshold
C1 or C2
Internal View

Figure 111 Current Inputs

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Appendix B Reference T2750 Eurotherm PAC

B1.5.4 Contact Inputs

V1 or V2

5kΩ
V
1+ or 2+

5kΩ
Threshold
C1 or C2

Internal View

Figure 112 Contact Inputs (PNP) or Volt-Free

V1 or V2

5kΩ
V
1+ or 2+

5kΩ

Threshold
C1 or C2
Internal View

Figure 113 Contact Inputs (NPN) or Volt-Free

B1.6 Fault Detection

Detected faults can be defined as Field, Setup, or Hardware faults, but any reaction
will depend on the Input configuration of the associated FI_UIO block. These faults
are indicated via the LEDs on the Module (Figure 40), and the Status and Alarms bits
of the corresponding FI_UIO block.

B1.6.1 Fault Diagnostics

The Status and Alarms bits of the associated FI_UIO block can be inspected in order
to locate a fault.
Status Interpretation
Missing The associated MOD_UIO block has not been found,
caused by an incorrectly configured Strategy, i.e. the
MOD_UIO block does not exist in the Strategy. This sets
the Alarms.ModBlock field True. To resolve the problem,
ensure that the Strategy contains the required MOD_UIO
block.
BadType The Channel configured in the block, does not correspond
to the module. Ensure the block and the module corre-
spond.
Ranging The Input value is not measurable by the hardware, but a
fault is not detected, i.e. the Input is currently being ranged
or configured.

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BadSetup An invalid setup is detected, caused by an incorrect ‘LR_in’

or ‘HR_in’ field configuration. This sets ‘Alarms.OutRange’
to True.
To resolve the problem, ensure ‘LR_in’ and ‘HR_in’ fields
correspond to the range used by the installed hardware.
HwFlt A fault in the output supply is detected caused by output
supply overload. This sets the Alarms.Hardware field to
True.
NotAuto The module is not operating in Automatic mode. This sets
the ‘Alarms.NotAuto’ field to True
OverRng An input value greater than the measurement circuit range
is detected, generally caused by an input value greater
than 40kHz, but less than 80kHz.
UnderRng An Input value less than the measurement circuit range is
detected. Can be caused by input values less than 10Hz,
for a Magnetic Sensor configuration, or less than 0.01Hz
for the Voltage, Current, or Contact configuration.
OpenCct An Open circuit fault in the Logic Sensor is detected, set-
ting the ‘Alarms.CctFault’ field to True.
ShortCct An Short circuit fault in the Logic Sensor is de-
tected, setting the ‘Alarms.CctFault field’ to True.
BadHwSet The hardware configuration does not correspond to the In-
put Type configured in the FI_UIO block. To resolve the
problem, ensure the Link configuration (Figure 2.39) corre-
sponds with the ‘InType’ field of the FI_UIO block.
Cutoff A measured frequency value below the low threshold val-
ue (CutOff) is detected, setting ‘Alarms.CutOff’ True. The
measured frequency value adopts the value defined in the
‘Default’ field.
Badtask Task Rate configured in the block does not correspond to
the Task Rate of the module, this situation setting the
Alarms.Hardware field to True.
To resolve the problem, configure the Task rate of the
module and the Task rate in the block to the slow task rate
(Task 3: 110ms).

B2 Zirconia Input Module Details

The Zirconia input module contains two input channels, isolated both from each other
and from the system electronics, and intended to be used to measure the
temperature at the measuring tip of a Zirconia probe (channel 1) and the voltage
generated across a Zirconia pellet (channel 2).

User Calibration allows the ‘permanent’ factory calibration to be modified in order to:

1. Calibrate the controller to reference standards

2. Match the calibration of the controller to that of a particular transducer or sensor

3. Calibrate the controller to suit the characteristics of a particular installation

B2.1 Terminal Connections and Status LEDs

"Zirconia Input Module (ZI)" on page 56 gives full pinout and status LED details.

B2.2 Specification
"A4.16 ZI Module" on page 199 gives the ZI module specification.

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B2.3 Application Details

This module is used to control the temperature of the process on one channel (loop)
and carbon potential on the other. The module, in conjunction with the strategy,
generates temperature and carbon potential profiles synchronised to a common
timebase.

Channel one is a thermocouple input with automatic Cold Junction Compensation.

Channel two (connected to the Zirconia pellet) offers the high-impedance low
leakage 2V range used to output a voltage measurement allowing simple offset and
scaling.

To comply with EMC regulations, it is recommended that the Zirconia Probe be

connected to Channel 2 of the module using screened cable with a maximum length
of 30m.

B2.3.1 Temperature Control

The sensor input of the temperature channel (loop) may come from the Zirconia
Probe but it is common for a separate thermocouple to be used. The strategy can
then control an output which is connected to heating elements (e.g. gas burners or
thyristors) to control the temperature. In some applications a cooling output may also
be connected to a circulation fan or exhaust damper.

B2.3.2 Carbon Potential Control

The Zirconia probe generates a millivolt (mV) signal based on the ratio of oxygen
concentrations on the reference side of the Probe (outside the furnace) to the amount
of oxygen in the furnace. The temperature and carbon potential millivolt values, read
into the related block, are used to calculate the percentage of carbon in the furnace.

B2.3.3 Soot Alarm

An alarm can be triggered when the atmospheric conditions within the furnace are
such that carbon will be deposited as soot on all surfaces inside the furnace.

B2.3.4 Probe Cleaning

A Probe clean and recovery strategy can be configured either to occur between
batches or to be triggered manually. A short blast of compressed air is used to
remove any soot and other particles that may have accumulated on the probe. Once
cleaning is complete, the time taken for the probe to recover is measured.

If the recovery time is too long this indicates that the probe is ageing and replacement
or refurbishment is due. During the cleaning and recovery cycle, the %C reading is
frozen, ensuring continuous furnace operation.

B2.3.5 Endothermic Gas Correction

A gas analyser may be used to determine the CO or H2 concentration of the
endothermic gas. If a 4 to 20mA output is available from the analyser, it can be
connected to the module and used to generate a display of the calculated % carbon
reading. Alternatively, this value can be entered manually via the ‘GasRef.CO_Local
and ‘GasRef.H2_Local’ fields.

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B2.4 Isolation Diagram

In isolation strategy is implemented throughout the base unit, which takes the form of
a barrier separating all I/O channels in any I/O module from the rest of the system.
This prevents hazardous voltages on any one I/O channel introducing hazards on
wiring associated with any other I/O module, or put at risk the rest of the system.
Modules providing isolation channel-to-channel ensure safety and good signal quality
on all channels.

1+
ADC1
Channel 1 CJC
1- I/O Bus
and IOC

2+
Channel 2 ADC2
2-

Figure 114 Isolation Diagram

B2.5 Equivalent Circuits

B2.5.1 Analogue Inputs

VRef
20kΩ

Volt Source
2+
10kΩ 0 to 2Vdc
1+
Sensor
CJC High impedance High
Health
Thermocouple input amplifier impedance
Check

1-
2-
Internal View

Figure 115 Equivalent circuit

B2.6 Fault Detection

Detected faults can be defined as Field, Setup, or Hardware faults, but any reaction
depends on the input configuration of the associated Zirconia block. Faults are
indicated via the LEDs on the Module (Figure 40), and the Status and Alarms bits of
the corresponding Zirconia block.

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Appendix B Reference T2750 Eurotherm PAC

B2.6.1 Fault Diagnostics

The Fields and related Alarms bits of the associated ZI block can be inspected in
order to locate a fault.
Status Interpretation
ProbeSt The Probe Input value is not measurable by the hardware
(possibly caused by a Probe failure). The fault sets the
‘Alarms.ProbeSt’ field to True.
TempSt The Probe Temperature Input value has failed (possibly
due to a Probe failure). This fault sets the ‘Alarms.TempS’
field to True.
CarbPotSt The Carbon Potential value is not measurable by the hard-
ware. This might be, for example, if the furnace tempera-
ture is below the configured minimum calculation
temperature value. To resolve the problem, wait until the
furnace achieves the configured minimum calculation tem-
perature value, MinCalcT.
DewPntSt The Dewpoint value is not measurable by the hardware.
This might be, for example, if the furnace temperature is
below the configured minimum calculation temperature
value. To resolve the problem, wait until the furnace to
achieve the configured minimum calculation temperature
value, MinCalcT.
Oxygen.St The Oxygen value is not measurable by the hardware.
This might be, for example, if the furnace temperature is
below the configured minimum calculation temperature
value.
To resolve the problem, wait until the furnace to achieve
the configured minimum calculation temperature value,
MinCalcT.
SootWrn The Probe has detected atmospheric conditions that
would cause the deposit of soot on all surfaces inside the
furnace. This sets the ‘Alarms.SootWrn’ field to True. To
resolve the problem, launch the probe clean sequence and
ensure that it completes successfully.
ClnRcvWn The performance of the probe is degrading, as evidenced
by a failure to regain 95% of its original value within the
specified time. This sets the ‘Alarms.ClnRcvWn’ field to
True.
To resolve the problem, launch the probe clean sequence
and ensure that it completes successfully. If alarms contin-
ue to be generated, replace the probe.
LastClnmV The probe clean sequence failed, due (for example) to a
fault in the probe. This fault sets the ‘Alarms.ClnRcvWn’
field to True.
CO_remSt The Remote CO Gas value is not measurable by the hard-
ware due (for example) to a Probe failure. This fault sets
the ‘Alarms.CO_Remte’ field to True.
H2_RemSt The Remote H2 Gas value is not measurable by the hard-
ware due (for example) to a Probe failure. This fault sets
the ‘Alarms.H2_Remte’ field to True.
MxCnRcvT The Probe cleaning sequence is not permitted due (for ex-
ample) by a failure to achieve 95% of the Input value be-
fore the defined maximum recovery time after cleaning has
expired. This fault sets the ‘Alarms.ClnRcvWn’ field to
True. To resolve the problem, launch the cleaning process
and ensure that it completes successfully. If alarms contin-
ue to be generated, replace the probe.
MxImRcvT The Probe impedance measurement recovery time has
been exceeded, possibly caused by a Probe failure. This

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fault sets the’ Alarms.ImpRcWrn field’ to True. To resolve

the problem, launch the probe clean sequence and ensure
it completes successfully. If alarms continue to be gener-
ated, replace the probe.
PrbImpHi The maximum probe impedance threshold value has been
exceeded, possibly caused by a Probe failure. This will set
the Alarms.PrbImpHi field to True. To resolve the problem,
ensure the Probe impedance measurement sequence
completes successfully or reset the impedance measure-
ment message field (‘ImpMsgRt’ to True).
ImpRcvWn The Probe impedance measuring sequence could not be
performed. This fault sets Alarms.ImpRcvWn field to True.
To resolve the problem, launch the impedance measuring
process and ensure that the Probe impedance measuring
completes successfully.

B3 Glossary
This section contains explanations of abbreviations and other terms used within this
document.
Abbrev/Term Meaning/Description
AMC Application Master Comms
Duplex Another term for ‘Redundant’, meaning that dual systems
are in place, such that one system can take over from the
other in the event of failure.
ELIN LIN protocol running over UDP/IP.
ICM Inter-processor Communications Mechanism. Used to
communicate between control modules.
IOC Input/Output Controller. Contains the programs to control
the Input/Output modules, and thereby, the process.
IP Internet Protocol. This is the communications protocol of
the public Internet, many wide area networks (WANs) and
most local area networks (LANs). The Internet Protocol is
part of the TCP/IP protocol suite, and the terms ‘IP net-
work’ and ‘TCP/IP network’ are often used synonymously
despite this being untrue.
LAN Local Area Network
LIN Local Instrument Network. Generally, LIN refers to re-
al-time software for running control strategies, the commu-
nications system (LIN communications) between
instruments, and to the suite of tools that configures them
(LINtools).
LLC Logical Link Control
MAL Machine Architecture Library
MMC Master Modbus Communications
Mutex Mutually exclusive
PRMT Processor Redundancy Management Task
PRP Port Resolution Protocol
PSU Power Supply Unit
PV Process Variable. This is the displayed value of the varia-
ble being measured.
Redundant This means that two parallel systems are in place, such
that if one fails, the other can take over without interrupting
the process being controlled. Also known as ‘Duplex’.
Review A proprietary software option which allows archive data to
be stored in a database, this data then being available for
display in chart or spreadsheet format. If Store and For-
ward is enabled, the data in the review database can be

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Appendix B Reference T2750 Eurotherm PAC

used to replace missing data in the EurothermSuite data-

base.
Reviewer A proprietary software option, similar to Review, which al-
lows archive data to be stored in a database. Reviewer is
available in a number of different variants which range
from local installations on a desktop PC (similar to Review)
to a cloud-based solution allowing data to be gathered and
shared from multiple instruments in multiple sites, and
viewed anywhere on any device.
RTC Real-time Clock. A clock used to control sequencing, to
provide time and date information, etc.
Simplex Non-redundant working - not applicable to this instrument.
See ‘Duplex’.
SDHC High Capacity Secure Digital Card used, in this applica-
tion, to store the user’s strategy and license.
SFC Sequential Function Chart.
SNTP Simple Network Time Protocol. An SNTP server transmits
local time and date. SNTP clients receive this data and use
it to control their instrument time and date. A simple way of
synchronising multiple instruments.
SP Setpoint. The target value to be reached.
ST Structured Text.
Store and Forward A feature which allows missing data in the EurothermSuite
database to be retrieved from the Review database. This
makes use of the fact that archive date is stored in the in-
strument, which can be configured to archive these files on
a regular basis. If the transmission line fails for any reason,
the data continues to be saved until communications are
restored, when all the unarchived data is transmitted.
TCP Transfer Control Protocol. The reliable transport protocol
within the TCP/IP protocol suite. TCP ensures that all data
arrives accurately and 100% intact at the other end.
UDP User Datagram Protocol. A communications protocol pro-
viding a direct way to send and receive datagrams over an
IP network but with few error recovery resources.
USB Universal Serial Bus. Type of serial bus that allows periph-
eral devices (disks, modems, printers, digitizers, data
gloves, etc.) to be connected to a computer. A
“plug-and-play” interface, it allows a device to be added
without an adapter card and without rebooting the comput-
er (the latter is known as hot-plugging). The USB standard,
developed by several major computer and telecommuni-
cations companies, supports data transfer speeds up to
480 megabits per second.
WAN Wide Area Network

B4 LIN Block Licences

This section shows which blocks are included at each licence level.

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T2750 Eurotherm PAC Appendix B Reference

B4.1 Foundation Level

Input/Output Communications AN_CONN Diagnostic

AI_UIO GW_CON DG_CONN All diag blocks
AO_UIO
DI_UIO GW_TBL Timing RGROUP
DO_UIO Conditioning TIMER Programmer
FI_UIO CHAR TIMEDATE PROGCTRL
MOD_UIO
MOD_DI_UIO UCHAR TPO
MOD_DO_UIO
TPO_UIO FILECHAR RATE_ALM
VP_UIO AN_ALARM Selector
CALIB_UIO
DIGALARM ALC

ZIRCONIA

Control

B4.2 Standard Level

Standard level includes all the foundation level blocks, and the following additional
blocks:

Control modules
Conditioning Control (Cont.) Selector Maths
(Cont.)
INVERT MAN_STAT SELECT ADD2 AN_ALM_2
FILTER MODE SWITCH SUB2 Programmer
LEAD_LAG PID_LINK 2OF3VOTE MUL2
RANGE TUNE_SET Logic DIV2 PROGCHAN
FLOWCOMP EXPR SEGMENT
Timing PULSE ACT_2A2W3T
Control DELAY AND4 Batch
RATE_LMT OR4
ANMS XOR4 Control modules RECORD
DGME TOTAL DISCREP
TOTAL2 NOT VLV1IN
SIM LATCH VLV2IN SFC_MON
SETPOINT TOT_CON SFC_DISP
DTIME COUNT VLV3WAY
TC_SEL COMPARE MTR3IN SFC_CON
SEQE
DUTYSTBY

B4.3 Control Level

Control level includes all the foundation and standard level blocks, together with the
following additional blocks:

Control Maths Communications

TC_LIFE ACTION RAW_COM
PID DIGACT
3_TERM ACT15A3W
LOOP_PID ACTUI818
Timing Batch
SEQ SFC-CON

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Appendix B Reference T2750 Eurotherm PAC

B4.4 Advanced Level

Includes all the above blocks plus Conditioning blocks: GASCONC and AGA8DATA

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T2750 Eurotherm PAC Appendix C Battery Replacement Procedure (if Fitted)

Appendix C Battery Replacement Procedure (if

Fitted)

Personnel One engineer, who shall be a suitably qualified person.

Time required to 10 minutes.
complete
Parts required Battery board (contains battery, soldered onto the board)
Order Code T2750A/BAT
For sales contacts see www.eurotherm.com/global
Tools required Magnetized Pozidrive #1 Screwdriver
When to carry out If the controller module battery LED (labelled with an icon)
goes out, or every 12 months, whichever is sooner.

The T2750 has an option to include a 3 V ‘coin-cell’ style battery, mounted on small
board, fitted on the inside of the plastic side panel adjacent to the controller module.

The purpose of the battery is to maintain the contents of the controller module
terminal unit’s volatile memory when the T2750 is powered off.

Note: The T2750 can be left powered up while the battery is being replaced. This
ensures the volatile memory contents will be retained.

The battery is soldered to its board, and the two are replaced as a single unit.
Proceed as follows:

1. Open the hinged plastic front cover of the T2750, so that the terminal units can
be seen.

2. Locate the back of battery board (Figure 116): It is on the inside of the plastic side
panel to the left of the controller module, and is fixed in place by two screws. A
two-wire cable runs from the front of the battery board to the controller module
terminal unit; the red wire connects to the B+ terminal, the black wire connects to
the B- terminal. It is recommended leaving these wires connected to the
terminals whilst replacing the battery.

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Appendix C Battery Replacement Procedure (if Fitted) T2750 Eurotherm PAC

Fixing screws

Rear side of
battery board

Two-wire battery cable IOC Terminal Unit

Figure 116 Battery board in place

3. Using a magnetised Pozidrive #1 screwdriver, unscrew the two fixing screws
holding the battery board in place.

4. Carefully manoeuvre the battery board of from the plastic side panel. Unplug the
two-wire cable from the board end (Figure 117).

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T2750 Eurotherm PAC Appendix C Battery Replacement Procedure (if Fitted)

Lug
Two-wire battery
cable plug

Figure 117 Battery board removed

WARNING
Do not touch the battery itself using metal pliers or tweezers, as this could cause a
short circuit possibly resulting in an explosion of the battery.

5. Take the new battery board (Figure 118), and plug the two-wire battery cable into
it.

Notch on top edge

Battery

Socket for 2-wire

battery cable

Figure 118 New battery board

6. Manoeuvre the new battery board into position in the left-hand plastic side panel.
Note the lug on the panel which fits into the notch on the top end of the battery
board.

7. Using a magnetized Pozidrive #1 screwdriver, screw in the two fixing screws to

hold the battery board in place.

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Appendix C Battery Replacement Procedure (if Fitted) T2750 Eurotherm PAC

8. Close the plastic top cover of the T2750.

9. Ensure the old battery board is disposed of appropriately.

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T2750 Eurotherm PAC Appendix D System Variables

Appendix D System Variables

The following tables lists all the system variables used on the T2750 instrument.

Variable Name Usage Notes

"DATE" current date In the format: dd/mm/yy
"TIME" current time In the format: hh/mm/ss
"TZ_DST" TRUE is DST is active 0 = False
1 = True
"RCP_ID" ID of currently selected
recipe (or 0 if none)
"BAT_ID" ID of currently selected
batch (or 0 if none)
"ALM_ACT" Total number of active
alarms
"ALM_NAK" Total number of
unacknowledged alarms
"ALM_LVL" Alarm level alarm level is bit encoded:
1 = there is at least one
active alarm
2 = there is at least one
unacked alarm
"ALM_SUP" Total number of
suppressed alarms
"ALM_STA" Alarm statistics: NumActive/NumUnack{/N
umSuppressed}
"ALM_URG" Most urgent alarm Most urgent entry in alarm
history log:
Block_Name Alarm_Name
"PROG_ID" ID (name) of current
programmer
"SYSDATE" System (UTC) date In the format: dd/mm/yy
"SYSTIME" System (UTC) time In the format: hh/mm/ss
"APP_NAME" Database name
"RCP_FILE" Name of currently loaded
recipe file
"RCP_NAME" Name of currently loaded
recipe
"RCP_RECN" Number of currently
loaded recipe
"BAT_FILE" Name of currently loaded
batch file
"PROG_END" Estimated end time or date
of program
"PROG_REM" Estimated time remaining In the format: hh/mm/ss
in program
"PROG_ERR"
"PROG_SCH"
"TZ_SUFFIX" Time suffix as configured e.g.’GMT+1’
"RCP_STATE" State of current recipe

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Appendix D System Variables T2750 Eurotherm PAC

Variable Name Usage Notes

"RCP_STATE" State of current recipe
"BAT_STATE" Batch state
"BAT_PHASE" Name of current phase
PROG_NAME Program name
"RCP_LINE_S" Name of current recipe
line
"RCP_LINE_N" Index of current recipe line
"UNRESOLVED" Count of unresolved The function which derives
references this always returns 0 for
the T2750
"PROG_STATE" Program state
"PROG_SEG_N" Current segment number
"PROG_SEG_S" Current segment name
"PROG_HBACK"
"TZ_SUFFIX1" Time suffix: name only e.g. ‘Paris’
"TZ_SUFFIX2" Time suffix: name + 'DST'
if active
"TZ_SUFFIX3" Time Suffix: GMT offset
"BAT_PHASE_N" Phase number of current
batch
"PROG_SEG_ID" ID of current segment
"PROG_SEG_REM" Segment time remaining
"PROG_CYC_NUM" Program cycle number
"PROG_CYC_REM" Program cycles remaining
"PROG_CYC_TOT" Total program cycles
"PROG_CYC_PCT" Program cycles executed
as a percentage
"PROG_CYC_FRC" Program cycles executed
as a fraction

226 HA030047 Issue 16

T2750 Eurotherm PAC Appendix E Recover Lost Password

Appendix E Recover Lost Password

Note: A lost password does not affect a running controller even if power fails.

If the instrument password is not known or has been forgotten, then it can be
recovered by the following procedure:

1. This procedure requires physical access to the instrument, it must be

powered down, the SD Card removed, and inserted to a card reader on a
PC.
2. Edit the file IDENTITY.USA (use a simple text editor – e.g. notepad).
Sample IDENTITY.USA contents:

SerialNumber=115112
ResetToFactoryDefault=NO

Notes:
a. DO NOT touch or edit any other file otherwise normal operation may be
adversely affected.
b. This file is specific to an instrument and must only be edited for that
instrument. Do not attempt to copy this file from one instrument to
another.

3. Replace the string “ResetToFactoryDefault=NO” with

“ResetToFactoryDefault=YES”
4. Replace the SD Card into the instrument and power it up. The instrument
will revert to ‘no instrument password set’. The ‘ResetToFactoryDefault’
line is reset to ‘No’ so does not need to be copied and edited again.
5. All user configuration files remain intact – a new instrument password must
be set before any runtime operation or configuration is possible.
6. Normal instrument functioning is restored.
Note: For a duplex pair, if the password is forgotten, both will need to be powered
off together – this means control will be lost during this process.

HA030047 Issue 16 227

Appendix E Recover Lost Password T2750 Eurotherm PAC

228 HA030047 Issue 16

Scan for local contents

Eurotherm Ltd
Faraday Close
Durrington
Worthing
West Sussex
BN13 3PL
Phone: +44 (0) 1903 268500
www.eurotherm.com

As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication.

© 2020 Eurotherm Limited. All rights reserved.

HA030047 CN38400