Novus N2000S Controller

1. SAFETY SUMMARY

The symbols below are used on the equipment and throughout this document to draw the user's attention to important operational and safety information.

⚠️ CAUTION OR WARNING: Read complete instructions prior to installation and operation of the unit.

⚡ CAUTION OR WARNING: Electrical Shock Hazard.

All safety related instructions that appear in the manual must be observed to ensure personal safety and to prevent damage to either the instrument or the system. If the instrument is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

2. INTRODUCTION

The N2000S is a controller for servo positioners with two control relays (open/close valve or damper). It features an analog output for control or retransmission of input/setpoint signals and a universal input compatible with most industry sensors and signals. Configuration is achieved via the keyboard, eliminating the need for circuit changes. Input/output types, alarm configurations, and special functions are accessed and programmed through the front panel. It is crucial to read this manual thoroughly before using the controller and ensure it matches your instrument's software version.

Key Features:

• Sensors break protection in any condition.
• Universal input for multiple sensors without hardware changes.
• Potentiometer input for current position reading.
• Auto-tuning of PID parameters.
• Relay control outputs.
• Automatic/Manual "bumpless" transfer.
• 2 alarm outputs with functions: minimum, maximum, differential (deviation), open sensor, and event.
• 2 alarm timers.
• 4-20 mA or 0-20 mA analog output for Process Variable (PV) or Setpoint (SP) retransmission.
• 4-function digital input.
• Ramp and soak functionality with 7 concatenable 7-segment programs.
• RS485 serial communication with RTU MODBUS protocol.
• Configuration protection.
• Dual voltage capability.

3. OPERATION

The controller's frontal panel is shown in Figure 1. This diagram identifies the PV/Programming Display, SP/Parameters Display, and various status indicators (COM, TUNE, MAN, RUN, OUT, A1, A2, A3, A4). The KEYBOARD section includes the PROG, BACK, Up/Down, Auto/Man, and F keys.

Figure 1: Front panel layout of the N2000S controller, showing displays for Process Variable (PV) and Setpoint (SP), status indicators (COM, TUNE, MAN, RUN, OUT, Alarms A1-A4), and the control keypad (PROG, BACK, Up/Down, Auto/Man, F).

Indicator Descriptions:

• COM: Flashes during data exchange with external environment.
• TUNE: Lights during automatic tuning operation.
• MAN: Indicates manual control mode.
• RUN: Indicates active control and enabled outputs.
• OUT: Constantly on when analog output is configured for control mode.
• A1, A2: Indicate respective alarm status.
• A3: Indicates valve (I/O3) opening output status.
• A4: Indicates valve/dumper (I/O4) closing output status.

Key Descriptions:

• PROG: Displays programmable parameters.
• BACK: Returns to the previous parameter.
• Up/Down Keys: Change parameter values.
• Auto/Man: Switches between Automatic and Manual control modes.
• F: Performs special functions.

Upon startup, the firmware version is displayed for 3 seconds, followed by normal operation with PV and SV values displayed. Outputs are enabled at this time. The valve closing relay activates for the duration required for complete valve closure to establish a known reference.

4. CONFIGURATION / RESOURCES

4.1 INPUT TYPE SELECTION

The input type must be selected using the keyboard via the 'Type' parameter. Table 2 lists the available input types, their codes, features, and measurement ranges, including various thermocouples, Pt100, 4-20mA, 0-50mV, and 0-5Vdc signals. All input types are factory calibrated.

Table 2: Input Type Selection - Details supported input types (Thermocouples J, K, T, N, R, S; Pt100; 4-20mA; 0-50mV; 0-5Vdc) with their respective codes, measurement ranges, and linearization options.

4.2 I/O CHANNELS CONFIGURATION

Controller input/output channels (I/O 1-6) can perform multiple functions including control output, digital input/output, alarm output, and PV/SP retransmission. Function codes are selected for each I/O.

• 4.2.1 I/O 1 AND I/O2 – USED AS ALARM OUTPUTS: Two SPDT relays (terminals 7-12) can be assigned as Alarm 1 or Alarm 2.
• 4.2.2 I/O 3 AND I/O4 – USED AS CONTROL OUTPUTS: Two SPST relays (terminals 3-6) are assigned as control outputs.
• 4.2.3 I/O 5 – ANALOG OUTPUT: This 0-20 mA or 4-20 mA channel supports retransmission of PV/SP, digital input functions (Manual/Auto switch, Run/Stop control, program control, program selection), and analog control output.
• 4.2.4 I/O 6 – DIGITAL INPUT: Supports functions like Manual/Auto switching, Run/Stop control, program execution control, and program selection. Note that when a function is assigned to a digital input, it overrides the frontal keypad command for that function.

4.3 POTENTIOMETER INPUT

A potentiometer input (typically 10 kΩ) is available for reading the valve's current position. This reading is for information only and does not affect control action. The 'Pot' parameter must be enabled to display the potentiometer position on the Manipulated Variable (MV) screen.

4.4 ALARM CONFIGURATION

The controller features 2 independent alarms that can be programmed with various functions as detailed in Table 3.

• 4.4.1 OPEN SENSOR: Activates if the input sensor is broken or disconnected.
• 4.4.2 EVENT ALARM: Activates alarms in specific segments of a program.
• 4.4.3 RESISTANCE FAIL: Detects heater failure by monitoring load current (requires an optional device).
• 4.4.4 MINIMUM VALUE: Triggers when the measured value falls below a setpoint.
• 4.4.5 MAXIMUM VALUE: Triggers when the measured value exceeds a setpoint.
• 4.4.6 DIFFERENTIAL (OR BAND): Triggers based on deviation from the main Setpoint (SP).
• 4.4.7 MINIMUM DIFFERENTIAL: Triggers when the measured value is below (SP – Deviation).
• 4.4.8 MAXIMUM DIFFERENTIAL: Triggers when the measured value is above (SP + Deviation).

Table 3: Alarm Functions - Lists available alarm types (Disabled, Sensor Break, Event, Resistance Fail, Min/Max Value, Differential, Min/Max Differential) and their operational logic.

4.5 ALARM TIMER

Alarms can be programmed with timer functions for delayed activation, single pulses, or sequential pulses using parameters A1t1, A1t2, A2t1, A2t2. Table 4 describes these temporization functions.

Table 4: Alarm Temporization Functions - Describes timer modes (Normal, Delayed, Pulse, Oscillator) for alarms, specifying the use of t1 and t2 time parameters.

4.6 ALARM INITIAL BLOCKING

The Initial Blocking option prevents alarms from triggering if an alarm condition exists at power-up. The alarm will only activate after a non-alarm condition is followed by a new alarm occurrence. This is disabled for the Open Sensor function.

4.7 PV AND SP ANALOG RETRANSMISSION

The analog output (I/O 5) can retransmit PV or SP values proportionally (0-20 mA or 4-20 mA). Retransmission is scalable via SPLL and SPxL parameters. Voltage retransmission requires a shunt resistor.

4.8 KEY FUNCTIONS

The front panel 'F' key can be assigned functions similar to Digital Input I/O 6 (except function 6), as defined by the 'FFunc' parameter. These include controlling outputs/alarms, holding programs, or selecting programs.

4.9 KEY

Designated as 'No function'.

5. INSTALLATION / CONNECTIONS

The controller is designed for panel mounting. Follow the steps: create panel slot, remove brackets, insert controller, and secure with clamps. Rear panel terminals do not need to be disconnected for removal.

Figure 2: N2000S Controller Back Panel Terminal Layout - Illustrates the physical arrangement of terminals for power supply, inputs (T/C, Pt100, mA, mV, Vdc), control outputs (Relays I/O1-I/O4), analog output (I/O5), digital input (I/O6), and RS485 communication.

5.1 INSTALLATION RECOMMENDATIONS

• Route input signal conductors away from high-tension/current conductors, preferably through grounded conduits.
• Use a dedicated electrical power supply network for instruments.
• Consider potential system failure consequences in control/monitoring applications; internal relay alarms do not provide total protection.
• RC filters are recommended for inductor charges (contactors, solenoids).

5.2 POWER SUPPLY CONNECTIONS

Figure 3: Power Supply Connection Diagram - Shows how to connect the main power supply (100-240 Vac/dc) or optional 24 Vdc/ac supply to the controller.

5.3 INPUT CONNECTIONS

Ensure sensor wires are securely connected to the rear panel terminals.

• 5.3.1 THERMOCOUPLE (T/C) AND 50 mV: Wiring diagrams are provided (Figure 4). Use proper compensation cables if thermocouple extension is needed.
• 5.3.2 RTD (PT100): Wiring diagram for 3-wire Pt100 (Figure 5). Ensure equal wire resistance for compensation. For 4-wire sensors, leave one wire loose. For 2-wire Pt100, short terminals 22 and 23.
• 5.3.3 4-20 mA: Wiring diagram shown in Figure 6.
• 5.3.4 0-5 VDC: Wiring diagram shown in Figure 7.
• 5.3.5 ALARM AND OUTPUT CONNECTION: Ensure output channel capacities are respected.

Figure 8: Potentiometer Connection Diagram - Details how to connect a potentiometer for valve position feedback.

Note: It is recommended to disable/suspend control (run = NO) when changing device settings.

6. CONFIGURATION PARAMETERS

6.1 OPERATION CYCLE

PV and SP Indication: The upper display shows the current PV, and the lower display shows the SP in automatic control mode. The display shows "----" if PV exceeds the maximum range or if there is no input signal.

MV Indication: The upper display shows PV, and the lower display shows the MV (control output percentage). MV flashes intermittently to distinguish it from SP display. In manual control, MV can be changed; in auto mode, it's for visualization only.

Pr n (Program): Selects the ramp and soak program to be executed (0 for none, 1-6 for specific programs). When control is enabled, the selected program runs immediately.

run: Enables control and alarms (YES) or disables them (NO).

6.2 TUNING CYCLE

atvn (Auto-tune): Enables or disables the auto-tuning process for PID parameters.

Pb (Proportional band): Sets the P term value (0-500%). If set to zero, control is ON/OFF.

Hysteresis: Control hysteresis for ON/OFF control (only shown when Pb=0).

Ir (Integral rate): Sets the I term value (0-24.00) in repetitions per minute.

dt (Derivative time): Sets the D term value (0-250 s).

sert (Servo time): Time for servo excursion (fully open to fully closed), programmable from 15 to 600 s.

serr (Servo resolution): Determines the dead band for servo activation. Low values (<1%) can make the servo "nervous".

serF (Servo filter): PID output filter time in seconds; output is activated after this time. Recommended value: > 2 s.

act (Action): Sets control action: 'rE' for Reverse (heating), 'dir' for Direct (cooling).

6.3 PROGRAM CYCLE

tbas (Time base): Selects time base for ramp and soak programs (0 for seconds, 1 for minutes).

Pr n (Program): Selects the ramp and soak program to be edited.

Ptol (Program tolerance): Maximum deviation between PV and SP. If exceeded, program execution halts until deviation is within tolerance. Set to zero to disable.

Psp0 to Psp7 (Program SetPoints): Define up to 8 setpoints for the program profile.

Pt1 to Pt7 (Program time): Define the duration (seconds or minutes) for each program segment.

Pe1 to Pe7 (Program event): Define which alarms trigger during specific program segments.

Lp (Link to program): Specifies the next program to run, allowing profiles of up to 49 segments.

6.4 ALARM CYCLE

Fva1/Fva2 (Alarm function): Defines the alarm functions as per Table 3.

bla1/bla2 (Alarm blocking): Enables or disables initial alarm blocking.

Hysteresis (Alarms): Defines the differential range for alarm activation/deactivation.

A1t1, A1t2, A2t1, A2t2 (Alarm times): Define the ON and OFF durations for alarms 1 and 2.

6.5 INPUT CONFIGURATION CYCLE

Type: Selects the signal type for the PV input.

dPpo (Decimal point position): Sets the decimal point position for PV and SP values.

unit: Selects temperature unit (°C or °F).

Offs (Offset): PV offset value to compensate for sensor error (-400 to 400).

SPll (Setpoint low limit): Defines the minimum value for indication, adjustment, and retransmission of PV/SP.

SPxl (Setpoint high limit): Defines the maximum value for indication, adjustment, and retransmission of PV/SP.

Pot: Selects whether to display the potentiometer value (YES) or PID output (NO) on the MV screen.

Baud: Sets the communication Baud Rate for RS485 (1200, 2400, 4800, 9600, 19200 bps).

Addr (Address): Sets the controller's unique communication address for RS485 (1-247).

6.6 I/O CYCLE (INPUTS AND OUTPUTS)

Defines functions for I/O channels 1-6. I/O 1-2 are for alarm outputs, I/O 3-4 for control outputs, I/O 5 for analog output (0-16 functions), and I/O 6 for digital input (0, 7-10 functions).

F.Func: Maps the front panel 'F' key to specific functions.

6.7 CALIBRATION CYCLE

All input/output types are factory calibrated. Recalibration is not recommended for inexperienced users. If necessary, use specialized personnel.

• InLC (Input offset calibration): Calibrates PV offset.
• InHC (Input span calibration): Calibrates PV gain.
• OuLL (Output Offset calibration): Calibrates current control output offset.
• OuHC (Output high calibration): Calibrates current output high value.
• CUL (Cold joint Offset calibration): Adjusts cold junction temperature offset.
• PotL/PotH (Potentiometer calibration): Calibrates potentiometer low and full scale values.

7. RAMP AND SOAK PROGRAM

This feature allows creating behavior profiles for the process. Each program consists of up to 7 segments, defined by SP values and time intervals. The controller automatically generates the SP according to the program. Upon completion, the control output turns off.

Figure 9: Ramp and Soak Program Example (Full Segments) - Visual representation of a program profile with setpoints (SP0-SP7) and corresponding time durations (T1-T7).

Figure 10: Ramp and Soak Program Example (Reduced Segments) - Shows a program profile where unused time segments are set to zero.

Ptol (Tolerance Function): Defines maximum PV-SP deviation; exceeding it halts program execution until tolerance is met. Setting to zero disables this check.

7.1 LINK OF PROGRAMS

Programs can be linked to create complex profiles with up to 49 segments. The 'Lp' parameter in the program cycle determines if another program follows.

Figure 11: Program Linking Example - Demonstrates how to connect multiple ramp and soak programs sequentially to create longer profiles.

7.2 EVENT ALARM

Alarms can be programmed to activate during specific program segments. Alarms must be set to 'Event Alarm' function and programmed in PE1 to PE7 according to Table 5.

Table 5: Event Values for Ramps and Soaks - Maps alarm codes (0-3) to specific program segments for triggering alarms.

To configure a ramp and soak program with event alarms: set tolerance, SPs, time, and event; set alarm function to 'Event Alarm'; set control mode to automatic; enable program execution.

8. PID PARAMETERS AUTO-TUNING

Auto-tuning controls the process in ON/OFF mode at the programmed SP. It may take several minutes and can cause oscillations. The recommended procedure involves disabling control output, selecting automatic mode, setting a non-zero proportional band, disabling Soft Start and ramp/soak functions, setting an appropriate SP, enabling auto-tuning, and then enabling control.

The 'TUNE' flag remains active during auto-tuning. For relay or pulse outputs, auto-tune calculates the highest PWM period value.

Table 6: PID Manual Tuning Suggestions - Provides guidance on adjusting Proportional Band, Integral Rate, and Derivative Time to resolve issues like slow response or large oscillations.

9. CALIBRATION

9.1 INPUT CALIBRATION

Detailed steps are provided for calibrating input offset ('InLC') and span ('InHC'). This involves applying known signals and adjusting parameters to match expected values.

9.2 ANALOG OUTPUT CALIBRATION

Steps for calibrating the analog output ('OuLL', 'OuHC') involve configuring I/O 5, connecting a mA meter, setting MV limits, and adjusting output values.

9.3 POTENTIOMETER CALIBRATION

Steps for calibrating the potentiometer ('PotL', 'PotH') involve setting input type, adjusting the potentiometer to minimum/maximum values, and setting the corresponding parameters.

10. SERIAL COMMUNICATION

An optional master-slave RS485 serial communication interface is available for communication with supervisor machines. The controller acts as the slave.

10.1 FEATURES

Supports RS485 standard with two-wire connection for up to 31 instruments. Features include electrical isolation, selectable speed options (1200-19200 bps), 8 data bits, 1 stop bit, and a response time of max 100 ms. Uses MODBUS RTU protocol.

Table 7: RS485 Communication Signals - Lists the signals (D1, D0, C) and their respective terminal assignments for serial communication.

10.2 SERIAL COMMUNICATION CONFIGURATION

Requires configuration of two parameters: 'Baud' (communication speed) and 'Addr' (controller address).

11. PROBLEMS WITH THE CONTROLLER

Connection errors and inadequate programming are common issues. The controller displays messages to help identify problems.

Table 8: Controller Error Messages - Details common error messages displayed by the controller (e.g., Err1) and their probable causes, such as open input or connection problems.

A visual alarm (display flashing) indicates when the PV value is out of the range defined by SPxL and SPll.

12. SPECIFICATIONS

Dimensions: 48 x 96 x 92 mm (1/16 DIN).

Approximate weight: 250 g.

Panel Cut-out: 45 x 93 mm (+0.5 -0.0 mm).

Power: 100 to 240 Vac/dc (±10%), 50/60 Hz. Optional 24 Vdc/ac.

Max. Consumption: 3 VA.

Environmental Conditions: 5 to 50 °C, 80% relative humidity up to 30 °C. Decreases 3% per °C above 30 °C. Indoor use, Installation category II, Pollution degree 2. Altitude < 2000 m.

Input: T/C, Pt100, voltage, and current, configurable.

Internal resolution: 19500 levels.

Display resolution: 12000 levels (-1999 to 9999).

Input sample rate: 5 per second.

Accuracy: Varies by input type (e.g., Thermocouples J, K, T: 0.25% of span ±1 °C; Pt100: 0.2% of span).

Input impedance: Varies by input type (e.g., >10 MΩ for mV, Pt100, T/C; >1 MΩ for 0-5V; 15 Ω for 4-20mA).

Pt100 measurement: 3-wire circuit, cable resistance compensation (a=0.00385), Excitation current: 0.170 mA.

Digital Input (I/O6): Dry contact or NPN open collector.

Analog Output (I/O5): 0-20 mA or 4-20 mA, 550 Ω max., isolated, control output or PV/SP retransmission.

Control Output: 2 SPDT relays (3 A / 240 Vac), 2 SPST-NO relays (1.5 A / 250 Vac), Voltage pulse for SSR (10 V max. / 20 mA).

Auxiliary Voltage Supply: 24 Vdc, ±10%; 25 mA.

EMC: EN 61326-1:1997 and EN 61326-1/A1:1998.

Safety: EN61010-1:1993 and EN61010-1/A2:1995.

Front Panel: IP65, polycarbonate UL94 V-2.

Housing: IP20, ABS+PC UL94 V-0.

Certifications: CE, UL and UKCA.

Programmable PWM Cycle: 0.5 to 100 seconds. Starts operation 3 seconds after power up.

13. WARRANTY

Warranty conditions are available on the Novus Automation website: www.novusautomation.com/warranty.