Bulletin No.

PCU-E
Drawing No. LP0338
Released 1/05
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net

MODEL PCU - PROCESS CONTROL UNIT

G SELF-DIAGNOSTICS
G FULL PID CONTROL WITH REDUCED OVERSHOOT
G OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE
G OPTIONAL DUAL ALARM OUTPUTS (USES OUTPUT MODULES)
G OPTIONAL SECONDARY OUTPUT (USES OUTPUT MODULE)
G OPTIONAL LINEAR 4 to 20 mA OR 0 to 10 VDC OUTPUT FOR
CONTROL OR PROCESS VALUE RE-TRANSMISSION
G OPTIONAL MOTORIZED VALVE POSITION CONTROL AND
VALVE FAIL ALARM
G OPTIONAL SECOND ANALOG INPUT FOR REMOTE SETPOINT
AND CASCADE CONTROL
G OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL
G STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES

C UL
R US LISTED
G PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED
FLEXIBILITY
IND. CONT. EQ.
G MANUAL/AUTOMATIC AND LOCAL/REMOTE SETPOINT
51EB
CONTROL MODES
G 100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY
G SETPOINT RAMPING FOR PROCESS STARTUP
G ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS
G PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS
G DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF G FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
PROCESS VALUE AND SETPOINT OR SECOND ANALOG INPUT MODULES (Relay, Logic/SSR Drive and Triac)
G ACCEPTS EITHER 0 to 10 VDC OR 0 to 20 mA DC INPUTS

DESCRIPTION
The PCU Controller accepts either 0 to 10 VDC or a 0 to 20 mA DC input Dual 4-digit displays allow viewing of the process value and setpoint
signal, precisely scales the process signal according to programmable scaling simultaneously. Front panel indicators inform the operator of the controller and
points, and provides an accurate output control signal (time proportional, linear, output status. Replaceable and interchangeable output modules (Relay,
or valve position) to maintain a process at the desired control point. A Logic/SSR Drive, or Triac) can be installed for the main control output, alarm
comprehensive set of easy to use program instructions allows the controller to output(s) and secondary output.
solve various applications.
The controller can operate in the PID control mode for both the main output
and optional secondary output, with on-demand auto-tune, that establishes the
tuning constants. The PID tuning constants may be fine-tuned by the operator
at any time and then locked-out from further modification. The controller
employs a unique overshoot suppression feature, which allows the quickest
response without excessive overshoot. The unit can be transferred to operate in
the manual mode, providing the operator with direct control of the output. The
controller may also be programmed to operate in the ON/OFF control mode
with adjustable hysteresis.

DIMENSIONS In inches (mm)

Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.

PANEL CUT-OUT

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OPTIONS “....” - Appears when display values exceed + display range.
Optional dual alarms can be configured to activate according to a variety of “-...” - Appears when display values exceed - display range.
“SLid” - Appears when loss of slidewire signal is detected.
actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT and Valve “VALV” - Appears when valve actuator error is detected.
Fail Detect) with adjustable hysteresis. A standby feature suppresses the output 2. POWER: Switch selectable 115/230 VAC (+10%, -15%) no observable line
during power-up until the process stabilizes outside the alarm region. An variation effect, 48 to 62 Hz, 10 VA.
optional secondary output is available (for processes that require cooling) that 3. ANNUNCIATORS:
provides increased control accuracy and response. LED Backlight Status Indicators (Model dependent):
A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface %PW - Lower auxiliary display shows power output in (%).
with actuators, chart recorders, indicators, or other controllers. The output DEV - Lower auxiliary display shows deviation (error)
signal can be digitally scaled and selected to transmit one of the following: % from process setpoint.
output power, measurement value, process measurement value deviation or OP1 - Main control output is active.
AL1 - Alarm #1 is active.
setpoint value. Valve Positioner and Second Analog Input Models have the AL2 - Alarm #2 is active (for Dual Alarm Option).
adjustable output demand dampening, output deadband and output update time OP2 - Secondary output is active
parameters to expand the versatility of the PCU to control devices. (for Secondary Output Option).
The optional Motorized Valve Positioner directly controls the position of a OPN - Valve positioner OPEN output is active
valve by the use of twin outputs (open and close) to control the direction of (for Valve Positioner Option).
CLS - Valve positioner CLOSE output is active
motor rotation. The motor position defines the opening position of the valve. (for Valve Positioner Option).
Two control modes are possible: position control, that makes use of the SEC - Lower auxiliary display shows second analog input
slidewire feedback signal supplied with the positioner and velocity control, in (for Second Analog Input Option).
which no slidewire feedback signal is used. Parameters are provided to adjust MAN - Flashing: Controller is in Manual control mode.
the operation of the valve. These include: REM - ON: controller is in remote setpoint mode
(Second Analog Input Option).
- Valve activity hysteresis - OFF: controller is in local setpoint mode
- Valve update time (Second Analog Input Option).
- Variable control dampening - Flashing: controller is in Manual control mode
- Slidewire signal fail action (Second Analog Input Optional).
- Adjustable valve position limits 4. CONTROLS: Four front panel push buttons for modifying and setup of
controller functions and one external input for parameter lockout or other
The Valve Positioner PCU achieves tight process control, yet minimizes functions.
unnecessary valve activity. An alarm event output or display alarm can be 5. SIGNAL INPUT:
programmed under loss of slidewire feedback or under valve fail detection. Sample Period: 100 msec typ.
The optional Second Analog Input (0 to 20 mA DC) can be configured as a Response Time: 300 msec typ. (to within 99% of final value w/step input)
remote setpoint signal or as a secondary process signal. Configuration of the Signal Overdrive Threshold:
second analog input as a remote setpoint signal allows ratio control, master 10 V Range: 13 V typ.
setpoint/multiple slave operation, and the ability to cascade the PCU with 20 mA Range: 26 mA typ.
another controller (external cascade). Configuration of the second input as a Signal Overdrive Response:
secondary process signal allows operation as a two-process cascade controller Main Control Output: Programmable preset output
within a single unit (internal cascade). In either control mode, parameters are Display: “SENS”
provided to scale, configure, communicate and monitor the activity of both Alarms: Upscale drive
analog inputs. A square law linearizer function can be used to linearize signals DC Linear: Programmable preset output
derived from flow transmitters. Normal Mode Rejection: 40 dB typ. @ 50/60 Hz (improves with increased
The optional RS485 multidrop serial communication interface provides two- digital filtering).
way communication between a PCU unit and other compatible equipment such Common Mode Rejection: 100 dB typ., DC to 60 Hz
as a printer, a programmable controller, or a host computer. In multipoint Protection: Input overload 120 VAC for 30 seconds.
applications the address number of each unit on the line can be programmed Range And Accuracy:
from zero to ninety-nine. Up to thirty-two units can be installed on a single pair SIGNAL
ACCURACY (%
MAXIMUM INPUT
of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be OF UNSCALED RESOLUTION
RANGE INPUT IMPEDANCE
READING)
interrogated or changed by sending the proper command code via serial
communications. Alarm output(s) may also be reset via the serial 0 to 10 VDC ±(0.15% + 3 mV) 300 VDC 1 MΩ 10 mV
communications interface option. 0 to 20 mA DC ±(0.15% + 6 µA) 200 mA DC 10 Ω 10 µA
An optional NEMA 4X/IP65 rated bezel is available for wash down and/or
6. OUTPUT MODULES [Optional] (For All Output Channels):
dirty environments, when properly installed. Modern surface-mount
Relay:
technology, extensive testing, plus high immunity to noise interference makes
Type: Form-C (Form-A with some models. See Ordering Information.)
the controller extremely reliable in industrial environments. Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @
120 VAC (inductive load) max.
SAFETY SUMMARY Life Expectancy: 100,000 cycles at max. load rating. (Decreasing load
All safety related regulations, local codes and instructions that appear in the and/or increasing cycle time, increases life expectancy).
manual or on equipment must be observed to ensure personal safety and to Logic/SSR Drive: Can drive multiple SSR Power Units.
prevent damage to either the instrument or equipment connected to it. If Type: Non-isolated switched DC, 12 VDC typ.
equipment is used in a manner not specified by the manufacturer, the protection Drive: 45 mA max.
provided by the equipment may be impaired. Triac:
Do not use the PCU to directly command motors, valves, or other actuators Type: Isolated, Zero Crossing Detection
not equipped with safeguards. To do so, can be potentially harmful to persons Rating:
Voltage: 120/240 VAC
or equipment in the event of a fault to the unit. An independent and redundant
Max. Load Current: 1 Amp @ 35°C
limit indicator with alarm outputs is strongly recommended. Red Lion Controls
0.75 Amp @ 50°C
offers various units (such as an IMP, IMD1 or IMD2) that may be used for this Min. Load Current: 10 mA
purpose. The indicators should have input sensors and AC power feeds Off State Leakage Current: 7 mA max. @ 60 Hz
independent from other equipment. Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused
SPECIFICATIONS 7. MAIN CONTROL OUTPUT:
1. DISPLAY: Dual 4-digit Control: PID or ON/OFF
Upper Process Display: 0.4" (10.2 mm) high red LED Output: Time proportioning or linear DC
Lower Auxiliary Display: 0.3" (7.6 mm) high green LED Hardware: Plug-in, replaceable output modules
Display Messages (Model dependent): Cycle time: Programmable
“OLOL” - Appears when measurement exceeds +105% input range. Auto-tune: When selected, sets proportional band, integral time, and
“ULUL” - Appears when measurement exceeds -5% input range. derivative time values.
“SENS” - Appears when measurement exceeds “OLOL” & “ULUL” Signal Overdrive Action: Programmable
range.

2
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SPECIFICATIONS (Cont’d) Signal Overdrive Action: Upscale
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
8. SECONDARY OUTPUT (Optional): with secondary output or motorized valve position option.)
Control: PID or ON/OFF 15. ENVIRONMENTAL CONDITIONS:
Output: Time proportioning or linear DC Operating Temperature Range: 0 to 50°C
Hardware: Plug-in, replaceable output modules Storage Temperature Range: -40 to 80°C
Cycle time: Programmable Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input
Proportional Gain Adjust: Programmable Zero Drift (maximum):
Deadband Overlap: Programmable 4 to 20 mA DC Range: 0.5 µA/°C
9. LINEAR DC OUTPUT (Optional): With digital scale and offset, 0 to 10 VDC Range: 0.2 mV/°C
programmable deadband and update time. Second Input: 2 µA/°C
4 to 20 mA: Relative Humidity: Less than 85% RH (non-condensing)
Resolution: 1 part in 3500 typ. Altitude: Up to 2000 meters
Accuracy: ±(0.1% of reading + 25 µA) 16. ISOLATION BREAKDOWN RATINGS:
Compliance: 10 V (500 Ω max. loop impedance) All inputs and outputs with respect to AC line: 2300 VMIN
0 to 10 VDC: Analog Outputs, Second Analog Input or Slidewire Input with respect to
Resolution: 1 part in 3500 typ. main input: 500 VMIN
Accuracy: ±(0.1% of reading + 35 mV) 17. CERTIFICATIONS AND COMPLIANCES:
Min. Load Resistance: 10 KΩ (1 mA max.) SAFETY
Source: % output power, setpoint, deviation, or process value
UL Listed, File #E137808, UL508, CSA C22.2 No. 14-M95
(Available for OP1 or OP2, but not both.)
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
10. MOTORIZED VALVE POSITIONER (Optional):
Two Outputs: Valve open and valve close or Linear DC (optional) UL Recognized Component, File # E156876, UL873, CSA C22.2 No. 24
Hardware: Plug-in, replaceable output modules Recognized to U.S. and Canadian requirements under the Component
Three Inputs: Slidewire feedback, signal fail detect (Isolated from main Recognition Program of Underwriters Laboratories, Inc.
input) Type 2 or 4X Enclosure rating (Face only), UL50
Slidewire Resistance: 100 Ω to 100 KΩ IECEE CB Scheme Test Certificate #UL1239-156876/USA,
Slidewire Exciting Voltage: 0.9 VDC typ. CB Scheme Test Report #96ME50279-070794
Slidewire Fail Action: programmable Issued by Underwriters Laboratories, Inc.
Control Mode: Position mode (with slidewire) and velocity mode (w/o IEC 1010-1, EN 61010-1: Safety requirements for electrical equipment
slidewire). for measurement, control, and laboratory use, Part 1.
Control Deadband: 1% to 25.0% (position mode) IP65 Enclosure rating (Face only), IEC 529
0.1 to 25.0 seconds (velocity mode) ELECTROMAGNETIC COMPATIBILITY:
Update Time: 1 to 250 seconds Immunity to EN 50082-2
Motor Time (open, close): 1 to 9999 seconds Electrostatic discharge EN 61000-4-2 Level 2; 4 Kv contact
Position Limits: Adjustable 0.0 to 100.0% of valve stroke Level 3; 8 Kv air
Valve Fail Time: Off to 9999 seconds Electromagnetic RF fields EN 61000-4-3 Level 3; 10 V/m1
Alarm mode: Dual acting; loss of slidewire feedback signal and valve fail 80 MHz - 1 GHz
detection
Fast transients (burst) EN 61000-4-4 Level 4; 2 Kv I/O
11. SECOND ANALOG INPUT:
Range: 0 to 20 mA (Isolated from main input) Level 3; 2 Kv power
Overload: 100 mA MIN (steady state) RF conducted interference EN 61000-4-6 Level 3; 10 V/rms2
Input Resistance: 10 Ω typ. 150 KHz - 80 MHz
Voltage Drop (@ 20 mA): 0.2 V typ. Power frequency magnetic fields EN 61000-4-8 Level 4; 30 A/m
Accuracy: 0.15% of reading ±10 µA ±1 LSD Emissions to EN 50081-2
Scale Range: -999 to 9999 RF interference EN 55011 Enclosure class A
12. SERIAL COMMUNICATION: Power mains class A
Type: RS485 Multi-point, Balanced Interface Notes:
Communication Format: 1. Self-recoverable loss of performance during EMI disturbance at 10 V/m:.
Baud Rate: Programmable from 300 to 9600 Process and/or analog output signals may deviate during EMI
Parity: Programmable for odd, even, or no parity disturbance.
Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit For operation without loss of performance:
Unit Address: Programmable from 0 to 99, max. of 32 units per line Install power line filter, RLC #LFIL0000 or equivalent.
Transmit Delay: 100 msec min., 200 msec max. 2. Self-recoverable loss of performance during EMI disturbance at 10 Vrms:
RS485 Common: Isolated from signal input common Process and/or analog output signals may deviate during EMI disturbance.
Auto Print Time: Off to 9999 seconds between print-outs For operation without loss of performance:
13. USER INPUT (Optional): Internally pulled up to +5 VDC. Install power line filter, RLC #LFIL0000 or equivalent and 1 ferrite
VIN = 5.25 VDC MAX, VIL = 0.85 VMAX; VIH = 3.0 VMIN, core 1 turn, RLC #FCOR0000 or equivalent, to cable at unit.
Available on all second input (MVP & ANA) models, and on models with Refer to the EMC Installation Guidelines section of the manual for additional
RS485. information.
Response Time: 100 msec max. 18. CONNECTION: Jaw-type terminal block
Functions: Program Lock Wire Range: 12-30 AWG copper wire
Integral Action Lock Torque: 5-7 inch-lbs (56-79 N-cm)
Auto/Manual Mode Select 19. CONSTRUCTION: NEMA 2 For Standard Models.
Setpoint Ramp Select Front Panel: Flame and scratch resistant tinted plastic
Reset Alarms Case: High impact black plastic. (Mounting collar included)
Print Request NEMA 4X/IP65 model only: Sealed bezel utilizing two captive mounting
Local/Remote Setpoint Select screws (panel gasket included) This unit is rated for NEMA 4X/IP65
14. ALARMS (Optional): indoor use. Installation Category II, Pollution Degree 2
Hardware: Plug-in, replaceable output module 20. WEIGHT: 1.3 lbs (0.6 kgs)
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Valve fail
Second Analog Input monitoring
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable

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BASIC OPERATION Programmable dampening output hysteresis and output update time parameters
The PCU controls a process by measuring the input signal and then calculating can dramatically reduce actuator activity without degrading control accuracy.
a control output power value by use of a modified PID control algorithm. The unit The RS485 Communication option allows the user to access various
controls the system with the new output power value to keep the process at controller parameters such as the setpoint, % output power, % proportional
setpoint. The PID control algorithm incorporates features that provide for high band, etc. The controller may be set up to transmit various parameters at a
control accuracy and low overshoot from process disturbances. programmable automatic print rate.

FRONT PANEL FEATURES AUTO-TUNE

In the normal operating mode, the unit displays the scaled process value in the The PCU has an auto-tune feature that, on demand, automatically determines
upper display. One of four other parameters can be viewed in the lower display: the PID control parameters for a particular process. After completion of auto-
- Setpoint tune, the PID parameters are automatically optimized for that process and
- % Power Output loaded into nonvolatile memory. The operator may view and modify the
- Deviation parameters as desired.
- Second Input Process Value Auto-tune may be invoked either at start-up or at setpoint, depending on the
process requirements. An auto-tune programmable dampening factor produces
The parameters can be scrolled through by pressing the DSP button. If
various levels of process control and response characteristics.
enabled, the control setpoint or power output (manual mode only) can be
directly modified in this mode.
In the normal operating mode, parameters are selected by use of the PAR OPTIONS
button and modified by use of the UP and DOWN buttons. Parameters are then RATIO CONTROL
entered by the PAR button, which advances the user to the next parameter.
Pressing the DSP button immediately returns the controller to the normal
operating mode when making a parameter change. The controller’s configuration
and parameter settings are stored in an internal E2PROM device.

HARDWARE FEATURES
The fast 100 msec input sampling rate provides quick controller response to
a process disturbance, thus providing excellent process control. Measurement
accuracy of 0.15% or better, provides closer process control conforming to the
desired control setpoint value. The unit accepts either a 0 to 10 VDC or a 0 to
20 mA DC input signal. The AC input power is switch selectable, allowing the
unit to operate from either 115 VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the output modules may be easily
changed or replaced without disturbing the wiring behind the panel. No re-
programming is required when changing or replacing modules.
The optional NEMA 4X/IP65 rated model utilizes two bezel securing screws The PCU configured for ratio operation controls a process as a ratio of
and a neoprene gasket to guarantee a water tight seal, when properly installed. another process or to another variable. Ratio control is commonly used for flow
The standard model simply requires pressing a latch to remove the unit. applications, however, any two process variables can be controlled in a
Low-drift, highly stable circuitry ensures years of reliable and accurate ratio mode.
process control. The recommended two-year re-calibration interval is easily Ratio Control Configuration Parameters
accomplished via the programming menu. “OPEr” - Select ratio mode
“root” - Select second input square root linearization
“dPt2” - Select second input decimal point
SETPOINT FEATURES “dSP1”
The controller setpoint can be protected from out of range values by “INP1”
- Enter scaling units of second input
programming the setpoint range limit values. Additionally, safeguards from “dSP2”
“INP2”
inadvertent data entry can be programmed.
“SPtr” - Local/Remote Select options
The setpoint ramp feature ramps the setpoint value at start-up or any time a “InPt” - Program User Input for Local/Remote
setpoint change is made, at a user programmable rate. This feature reduces Setpoint selection
shock to the process and helps to minimize overshoot. The setpoint may also be Ratio Control Operational Parameters
transmitted by the optional linear DC output for slave control loops. “rtio” - Remote setpoint ratio
The second analog input may be configured as a remote setpoint. As such, the “bIAS” - Remote setpoint bias
controller is easily switched from local/remote setpoint operation via the front
panel or user input. Ratio and bias parameters provide on-line scaling of the MOTORIZED VALVE POSITIONER
remote setpoint. Absolute limit values and maximum rate of change of the
remote setpoint further enhance controller flexibility.

INPUT FEATURES
A programmable input filter can be used to stabilize readings from a process
with varying or oscillating characteristics, helping to provide better process
control. Programmable scaling points allow the controller to display in any
engineering unit; flow, level, pressure, etc. Scaling points are used in
conjunction with the programmable rounding increment to stabilize a jittery or
otherwise hard to read process signal for better indication.
The programmable User Input can be used to control a variety of functions,
such as auto/manual transfer of the controller, reset alarm output(s), etc.
The second analog input has independent scaling parameters to match the
units of other processes or transmitters, or to match the controller’s range.

The motorized valve positioner controls the position of a valve directly, by

OUTPUT FEATURES use of “open” and “close” control outputs. The slidewire feedback signals of
Programmable output power limits provide protection for processes where
the valve may optionally be connected to the controller. Alternatively, the
excessive power can cause damage. Automatic signal overdrive detection, for
controller may be configured for linear input valve control using the 4 to 20 mA
fail-safe operation, causes the controller to default to a programmed output
DC output.
power (upscale or downscale burnout). With adjustable time proportioning
cycle time, and programmable DC linear output, the controller can satisfy a
wide variety of output requirements.

4
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 Motorized Valve Positioner Configuration Parameters Internal Cascade Operational Parameters
Position mode: “VPS1” - Enter or measure valve closed position “SP-2” - View secondary setpoint value
“VPS2” - Enter or measure valve open position “Pb-2” - Enter secondary proportional band
“VUdt” - Enter Valve update time “It-2” - Enter secondary integral time
“VPdb” - Enter valve control deadband “dt-2” - Enter secondary derivative time
“VFAL” - Enter valve fail detect time
“Act1” - Program alarm as valve fail output
Velocity mode: “VUdt” - Enter Valve update time EXTERNAL CASCADE
“VOPt” - Enter valve open time
“VCLt” - Enter valve close time
“VOnt” - Enter valve control deadband
(minimum on time)

INTERNAL CASCADE

Cascade control allows the process to be divided into two control loops: the Similar to internal cascade control, external cascade control differs by the
primary control loop and the secondary control loop. The secondary loop receives employment of two controllers, one of which is equipped with a second analog
its setpoint from the primary loop to control an intermediate variable (steam input configured as a remote setpoint. A PCU controls the secondary loop, while
pressure). The control level of the intermediate variable is the input to the primary a TCU controls the primary loop.
process. The primary loop (main input) controller maintains loop regulation by External Cascade Configuration Parameters
manipulating the setpoint of the secondary controller. The setpoint of the “OPEr” - Select ratio mode
secondary controller, in turn, changes the intermediate variable. The secondary “root” - Select second input square root linearization
loop can react faster to disturbances of the intermediate variable, thereby “dPt2” - Select second input decimal point
“dSP1”
minimizing the effects to the primary control loop. Control loops cascaded in such “INP1”
a manner provide greater control quality than would be possible with single loop - Enter scaling units of second input
“dSP2”
control. A single PCU can accomplish two-process cascade control. “INP2”
“SPtr” - Local/Remote select options
Internal Cascade Configuration Parameters
“OPEr” - Select cascade mode External Cascade Operational Parameters
“root” - Select second input square root linearization “rtio” - Remote setpoint ratio
“dPt2” - Select second input decimal point “bIAS” - Remote setpoint bias
“dSP1”
“INP1”
- Enter scaling units of second input
“dSP2”
“INP2”
“OPd2” - Output dampening of secondary

SETPOINT MASTER CONTROL

Setpoint Master Control allows automatic setpoint changes to slave
controller units (up to 50 units total) from a master PCU controller. The
linear DC output of the master is looped with the second analog input
of the slave PCU controllers. Each slave unit can have unique remote
setpoint ratio and bias values.
Setpoint Slave Configuration Parameters
“OPEr” - Select remote setpoint mode
“root” - Select second input square root
linearization
“dPt2” - Select second input decimal point
“dSP1”
“INP1”
- Enter scaling units of second input
“dSP2”
“INP2”
“SPLO”
- Limit range of remote setpoint
“SPHI”
“SPrP” - Limit rate of change of remote
setpoint
Setpoint Slave Operational Parameters
“rtio” - Second input ratio
“bIAS” - Second input bias

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CONTROLLER PROGRAMMING Configuration 3, Parameter lock-outs
“SP” - Select degree of setpoint access
The PCU has been designed to reduce the operator interaction with the
“OP” - Select degree of power access
controller while still maintaining a high degree of control accuracy and user “dEv” - Enable deviation display *
flexibility. Front Panel Program Disable allows all of the controller’s set-ups to be “IN-2” - Enable second input display *
locked-out from further operator intervention after the initial parameter set-up. “bdSP” - Enable blank display
The programming of the controller is divided into four sections: “CodE” - Enter parameter access code
“PId” - Select degree of PID access
Unprotected Parameter Mode “PId2” - Select degree of secondary PID access *
Configuration Parameter Mode “rtbS” - Select degree of ratio/bias access *
Protected Parameter Mode “AL” - Select degree of alarm access *
Hidden Function Mode “ALrS” - Enable alarm reset access *
“SPSL” - Enable local/remote setpoint selection *
These four programming modes allow the controller to adapt to any required “trnF” - Enable auto/manual mode selection
user-interface level. “tUNE” - Enable auto-tune invocation

UNPROTECTED PARAMETER MODE *

Configuration 4, Alarms *
“Act1” - Select operation mode of alarm #1
The unprotected parameter mode is accessible when program disable is “rSt1” - Select reset mode of alarm #1
inactive or when the proper access code number from the protected mode is “Stb1” - Enable activation delay of alarm #1
entered. The configuration parameter modes can be accessed only from this mode. “AL-1” - Enter value for alarm #1
“SP” - Enter Setpoint “Act2” - Select operation mode of alarm #2
“OP” - Enter output power “rSt2” - Select reset mode of alarm #2
“Prop” - Enter proportional band “Stb2” - Enable activation delay of alarm #2
“Intt” - Enter integral time “AL-2” - Enter value for alarm #2
“dErt” - Enter derivative time “AHYS” - Enter hysteresis value for both alarms
“rtio” - Enter Remote Setpoint ratio value
“bIAS” - Enter Remote Setpoint bias value
Configuration 5, Secondary Output *
“CYC2” - Enter time proportioning cycle time
“SP-2” - View internal cascade secondary setpoint
“GAN2” - Enter relative gain
demand
“db-2” - Enter deadband or overlap
“Pb-2” - Enter internal cascade, secondary
proportional band Configuration 6, Serial Communications *
“It-2” - Enter internal cascade, secondary integral “bAUd” - Select baud rate
time “PArb” - Select parity bit
“dt-2” - Enter internal cascade, secondary derivative “Addr” - Enter unit address number
time “Abrv” - Select abbreviated or full mnemonic
“AL-1” - Enter value for alarm #1 transmissions
“AL-2” - Enter value for alarm #2 “PrAt” - Enter automatic print rate
“CNFP” - Select basic configuration mode “PoPt” - Select parameters to be included in print-out
“End” - Return to normal display mode
Configuration 7, Second Input *
“OPEr” - Select remote setpoint or internal cascade
CONFIGURATION PARAMETER MODE
mode
The configuration parameter mode allows the operator to set up the basic “root” - Select second input square root linearization
requirements of the controller. It is divided into sections which group together “dPt2” - Select second input decimal point
related programming steps, such as inputs, outputs, alarms, etc. Upon “dSP1”
completion of each section, the program returns to the configuration selection “INP1”
- Entering scaling parameters of second input
stage allowing the user to return to the normal display mode. “dSP2”
“INP2”
“SPtr” - Enter local/remote select options
“OPd2” - Enter Secondary output control dampening
Configuration 1, Inputs
“tYPE” - Select input signal type Configuration 8, Motorized Valve Positioner *
“root” - Select square root linearization of main Position mode: “VPS1” - Enter or measure valve closed position
input * “VPS2” - Enter or measure valve open position
“dCPt” - Select scaled display decimal point position “VUdt” - Enter valve update time
“rnd” - Enter rounding increment and trailing zeroes “VPdb” - Enter valve control deadband
for scaled display “VFAL” - Enter valve fail detect time
“FLtr” - Select level of input filtering Velocity mode: “VUdt” - Enter valve update time
“dSP1” “VOPt” - Enter valve open time
“INP1” “VCLt” - Enter valve close time
- Scale main input
“dSP2” “VOnt” - Enter valve control deadband
“INP2” (minimum on time)
“SPLO” - Enter setpoint lower limit
“SPHI” - Enter setpoint higher limit
“SPrP” - Enter setpoint ramp rate
HIDDEN FUNCTION MODE *
“InPt” - Select user input function *
The hidden function mode is accessible from the normal operating mode. The
Configuration 2, Outputs four functions in this mode may be locked-out individually in configuration 3
“CYCt” - Enter time proportioning cycle time parameter lock-out section.
“OPAC” - Select control action
“OPLO” - Enter output power low limit
“OPHI” - Enter output power high limit “SPSL” - Select Local/Remote Setpoint
“OPFL” - Enter signal overdrive power preset “trnF” - Transfer between automatic (PID) control
“OPdP” - Enter output control dampening and manual control
“CHYS” - Enter ON/OFF control hysteresis “tUNE” - Invoke/cancel PID Auto-tune
“tcod” - Select auto-tuning dampening “ALrS” - Reset latched alarms
“ANAS” - Select linear DC output assignment *
“ANLO” - Enter linear DC output low scaling value *
“ANHI” - Enter linear DC output high scaling value * * These parameters may not appear due to option configuration or other
“ANdb” - Enter linear DC output control deadband * programming.
“ANUt” - Enter linear DC output update time *

6
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PROTECTED PARAMETERS MODE *
The protected parameters mode is enabled when program disable is active.
This mode prevents access to the configuration modes without the proper access
code number. Only the parameters that are selected in the configuration 3
parameter lock-out section can be accessed.
“ProP” - Enter Proportional band “AL-1” - Enter value for alarm #1
“Intt” - Enter integral time “AL-2” - Enter value for alarm #2
“dErt” - Enter derivative time “CodE” - Enter access value to unprotected
“rtio” - Enter remote setpoint ratio value parameters & configuration parameters
“bIAS” - Enter remote setpoint bias value
“SP-2” - Enter internal cascade, secondary setpoint
“Pb-2” - Enter internal cascade, secondary
proportional band * These parameters may not appear due to option configuration or other
“It-2” - Enter internal cascade, secondary integral programming.
time
“dt-2” - Enter internal cascade, secondary derivative
time

OUTPUT MODULES
TYPICAL CONNECTIONS

Relay: Triac:
Type: Form-C (Form-A with some models. See ordering information.) Type: Isolated, Zero Crossing Detection
Rating: 5 amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120 Rating:
VAC (inductive) maximum. Voltage: 120/240 VAC
Life Expectancy: 100,000 cycles at maximum load rating. Max. Load Current: 1 ampere @ 35°C
(Decreasing load and/or increasing cycle time, increases life expectancy). 0.75 ampere @ 50°C
Min. Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 400 Hz
Protection: Internal Transient Snubber, Fused

Logic/SSR Drive: Can drive multiple SSR Power Units.

Type: Non-isolated switched DC, 12 VDC typical
Drive: 45 mA maximum.

APPLICATION
A chemical company would like to
maintain the level of an acid solution tank to
insure constant availability for their process.
They have chosen a PCU controller which
has a continuous level probe with a 4 to 20
mA output proportional to tank level,
connected to the input terminals. The tank is
filled by controlling the position of a
proportional control valve. The control valve
is controlled by a 3 to 15 PSI air signal.
The PCU uses the level control input as its
feedback. The 4 to 20 mA input signal is
scaled so that 4 mA equals 0% and 20 mA
equals 100%.
The 4 to 20 mA output of the PCU is taken
to an I/P converter to convert the 4 to 20 mA
output to a 3 to 15 PSI signal for the control
valve. The relay outputs of the PCU are used
for high and low level alarms.

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 ORDERING INFORMATION
MODELS WITHOUT SECOND INPUT OPTIONS
NEMA 4X/IP65 4 to 20 mA 0 to 10 VDC ALARM COOLING
RS485 COM PART NUMBER
BEZEL ANALOG OUTPUT ANALOG OUTPUT OUTPUTS OUTPUT
NO YES NO NO NO NO PCU01000
NO YES NO 2 NO NO PCU01001
YES NO NO NO NO NO PCU10000
YES NO NO 2 NO NO PCU10001
YES NO NO 1 YES NO PCU10002
YES YES NO NO NO NO PCU11000
YES YES NO 2 NO NO PCU11001
YES YES NO 1 YES NO PCU11002
YES YES NO 2 NO YES PCU11004
YES YES NO 1 YES YES PCU11005
YES NO YES 2 NO NO PCU12001
YES NO YES 2 NO YES PCU12004
YES NO YES 1 YES YES PCU12005
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common terminals (Form A Type). As a result,
these outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.

SECOND ANALOG INPUT MODELS (RSP)

4 to 20 mA 0 to 10 VDC
NEMA 4/XIP65 ALARM COOLING
ANALOG ANALOG RS485 COM PART NUMBER
BEZEL OUTPUTS OUTPUT
OUTPUT OUTPUT
YES NO NO 2 NO YES PCU10104
YES YES NO 2 NO NO PCU11108
YES NO YES 2 NO NO PCU12108
These models have dual alarm outputs, or single alarm with secondary outputs, with shared common
terminals (Form A Type). As a result, these outputs should be fitted with the same type of output module.
The main output (OP1) may be fitted with any type of output module.

MOTORIZED VALVE POSITIONER MODELS (MVP)

4 to 20 mA 0 to 10 VDC
NEMA 4/XIP65 ALARM COOLING
ANALOG ANALOG RS485 COM PART NUMBER
BEZEL OUTPUTS OUTPUT
OUTPUT OUTPUT
YES NO NO 1 NO YES PCU10307
YES YES NO 1 NO NO PCU11306
YES NO YES 1 NO NO PCU12306

ACCESSORIES
DESCRIPTION PART NUMBER

Relay Module OMD00000

Triac Module OMD00001
Logic/SSR Drive Module OMD00003
SSR Power Unit RLY50000
Single Phase 25 A DIN Rail Mount Solid State Relay RLY60000
Single Phase 40 A DIN Rail Mount Solid State Relay RLY6A000
Three Phase DIN Rail Mount Solid State Relay RLY70000

Note: Output Modules are NOT supplied with the controller. When specifying the controller, be sure to
purchase the appropriate output module for the Main Control Output and if necessary, the alarm output(s),
the secondary output, and valve positioner outputs.
The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an SSR power unit.
It should never be connected to line voltage.
All modules are packaged separately and must be installed by the user.

Red Lion Controls AP

Red Lion Controls Red Lion Controls BV 31, Kaki Bukit Road 3,
20 Willow Springs Circle Basicweg 11b #06-04/05 TechLink
York PA 17402 NL - 3821 BR Amersfoort Singapore 417818
Tel +1 (717) 767-6511 Tel +31 (0) 334 723 225 Tel +65 6744-6613
Fax +1 (717) 764-0839 Fax +31 (0) 334 893 793 Fax +65 6743-3360

For Sales and Support, Contact Walker EMD • Toll-free: (800) 876-4444 • Tel: (203) 426-7700 • Fax: (203) 426-7800 • www.walkeremd.com