easyTermo Manual English 05_2012
Contents
1. digital inputs digital relay outputs temperature sensor input LCD display keyboard power supply working temperature working humidity case protecition 8 voltage type inputs 230V AC each 8 relay type outputs 250V AC 5A max each 1 K type thermocouple 2 lines x 16 characters with backlight 8 keys 9V AC 250mA max 0 20 45 C 40 85 non condensing IP20 Thermal afterburner controller2. 20 21 22 host controller communication link mini I O expansion inputs and outputs connectors for afterburner control Contact number Control signal oreheating signal input from chamber number 5 afterburning signal input from chamber number 5 flap number 2 of chamber number 5 smoke flap output Nee per West 8s Se ee 9 10 11 12 host controller communication link blocking signal input from chamber number 5 Thermal afterburner controller 13 Instead of midi I O expansion module 4 digital inputs and 4 digital outputs you can also use mini expansion modules combo one mini In module 4 digital inputs and one mini Out module 4 digital outputs Assignment of signals for this configuration of modules is shown in the following tables mini In expansion inputs connectors for afterburner control Contact number Control signal blocking signal input from chamber number 3 afterburning signal input from chamber number 4 blocking signal input from chamber number 4 eee 9 10 11 12 host controller communication link 1 2 3 4 5 6 7 8 3 4 preheating signal input from chamber number 4 78 O mini Out expansion outputs connectors for afterburner control Contact number Control signal flap number 1 of chamber number 3 exhaust flap output flap number 2 of chamber number 3 smoke flap output flap number 2 of chamber number 4 smoke flap output Be a e BM flap number 1 of chamber number 4 exha
3. connect the signal source to the digital input Digital inputs Umax 230V AC 2 2222222 1 2 On request the digital inputs can also be factory adjusted to other operating volatages Active input state corresponds to the nominal voltage value at the input terminals CONNECTING THE RELAY OUTPUTS easyTermo controller is equipped with 8 digital relay outputs 250V AC 5A each The following figure shows how to connect the load to the relay output Relay outputs Umax 250V Imax 5A A The outputs are independent and isolated from each other Safeguarding against burning the relay contacts should be provided within the load circuit Each relay output is also individually protected with a varistor of nominal voltage of 250V AC CONNECTING THE TEMPERATURE SENSOR easyTermo controller is equipped with one dedicated input for a K type thermocouple temperature sensor The controller accepts temperatures in the range of 0 1023 C with measurement error typically no more than 3 C over the measurement range Connect the thermocouple to the controller as shown in the following figure 19 20 21 Terminal number 21 allows connecting the thermocouple wire to the temperature measurement circuit analog ground which in turn makes possible detection of a thermocouple open circuit As in some very specific cases external connections to the easy Termo ground may cause controller malfunction this connection
4. the LCD display To change the mode use the 4 and keys An approval of the selected mode occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen External modules Allows you to adjust the controller configuration to the number of chambers serviced optional input output expansion modules 1 to 2 chambers or two input output expansion modules 8 to 5 chambers Selecting the controller configuration compatible with the current electrical system protects against malfunctions due to reading of non existent digital inputs or attempting to control not connected relays Therefore despite the security measures included in the afterburner control program it is highly recommended to always set the number of O expansion modules conforming to the electrical installation of the control system MIDI MODUL v OK or ESC The currently selected modules configuration is shown in the first line of the LCD display You you can change it with the 4 and keys An approval of the selected configuration mode occurs when you press the OK key or press the ESC key to return Thermal afterburner controller 8 to the service menu without any changes Pressing the ESC key again brings back the main screen Connecting O expansion modules to the easyTermo controller is described in detail later in this manual Typical parame
5. 7 Jacket fan delay Allows you to set the measured temperature additional filtration depth within the temperature range below the jacket off threshold thus making possible adjusting it to the level of interference in your electrical network This is achieved by setting the time in seconds during which the measured temperature must be lower than the jacket off temperature T1 in the previously described service function used to set temperature thresholds before the afterburner control algorithm considers this condition as met and takes the appropriate action Tk lt 60 during 5s AV OK or ESC Current value of the jacket off temperature threshold is shown in the first line of the LCD display and the measured temperature filtration time near this threshold flashes on the right side of the display Using the 4 4 keys you can change the value of filtration time in the range of 1 60 seconds in 1s increments An approval of the time set occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Power on autostart Allows you to select one of two modes of the controller operation after power up automatic startup mode of the afterburner control program manual start mode of the afterburner control program using the START key AUTOMATIC START v OK or ESC The current controller operating mode after power up is shown in the first line of
6. clock allows time and day triggered actions or recording time stamps of selected control system events OPERATOR PANEL The operator panel allows the afterburner user to modify the controller operating parameters to start and stop the afterburner control program and to watch its current status The panel view is shown in the following figure 141 IN amp xAC LI5 SUE 112345678 easyTermo 912345678 04 OUT8x5A Q5 On the left side of the panel you will find an LCD display 2 lines of 16 characters each showing information about the current state of the control system The right part of the panel forms the keyboard with the following dedicated keys START press to start the afterburner control program STOP press to stop the afterburner control program ESC press to enter the service mode or return to the previous function without approval of the changes made so far OK press to return to the previous function with approval of the changes up down arrows V press to increase decrease the current parameter or select a function from the service menu left right arrows gt press to select the field with parameter to be adjusted When in the service mode some keys act in a specific way described in detail in the section devoted to this mode You will find a bi color LED between START and STOP keys which indicates the current status of the controller If the afterburner control program i
7. easyTermo THERMAL AFTERBURNER CONTROLLER 555 9 10 71 12 13 14 15 16 17 18 19 20 a AN LI5 l6 18 iC 9V 30 31 32 33 34 35 36 37 USER MANUAL Rex Pol Version 05 2012 EN CONTENTS GETTING STARTED CONTROLLER APPLICATION AND FEATURES OPERATOR PANEL CONTROLLER CONFIGURATION BASIC SERVICE FUNCTIONS EXTENDED SERVICE FUNCTIONS INSTALLATION OF THE CONTROLLER TECHNICAL SPECIFICATIONS 10 12 17 GETTING STARTED The easyTermo industrial controller is an electronic device For safety reasons please carefully read and follow the manual instructions WARNING Personal injury may result from improper operation CAUTION The easyTermo controller may be damaged by improper operation PRECAUTION FOR INSTALLATION Compliance with the installation instructions and the user manual is absolutely necessary Failure to comply could lead to improper operation equipment damage or in extreme cases even death serious bodily injury or considerable damage to property When installing the controller insure that no wiring or foreign materials can fall into the openings Damage to equipment fire or considerable damage to property could result Always switch off power before you wire connect install or remove any module The wiring for the easyTermo controller is open and exposed for this reason it is recommended that the controller be installed in an enclosure or cabinet to prevent accidental contact or exposure to the
8. ectrical network This is achieved by setting the time in seconds used as a base for averaging temperature measurements before beeing used by the afterburner control program Longer filtration gives temperature measurements free from short term disruptions but may cause adverse delays in the response to the changes Shorter filtration time affects the temperature measurements in the opposite direction tf 5s Tk 25 AV OK or ESC Current value of the temperature sensor filtration time flashes in the first line of the LCD display while on the right side the currently measured temperature is shown using present filtration time selected With the 4 keys you can change the value of filtration time in the range of 1 10 seconds in 1s increments Approval of the filtration time set occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Digital inputs filtering Input filtering Allows you to set the controller digital inputs filtration depth thus making possible adjusting it to the type of the input signals delivered or to the level of interference in your electrical network This is achieved by setting the time in seconds during which the input 0 state must remain stable before the change from state 1 state 0 will be accepted by the afterburner control program Longer filtration removes the short term disruptions on the d
9. electrical circuits and components Never install the product in an environment beyond the limits specified in this user manual such as high temperature humidity dust corrosive gas vibration etc PRECAUTION FOR WIRING Improper wiring and installation could lead to death serious bodily injury considerable damage to property The easyTermo controller should only be installed and wired by properly experienced and certified personnel Make sure the wiring of the easyTermo controller meets all applicable regulations and codes including local and national standards and codes Be sure to properly size cables for the required current rating Always separate AC wiring DC wiring with high frequency switching cycles and low voltage signal wiring PRECAUTION FOR OPERATION To insure safety with the application of the easyTermo controller complete functional and safety testing must be conducted Run the easyTermo controller only after all testing and confirming safe and proper operation is complete Any potential faults in the application should be included in the testing Failure to do so could lead to improper operation equipment damage or in extreme cases even death serious bodily injury or considerable damage to property When the power is on never contact the terminals exposed conductors or electrical components Failure to comply could lead to improper operation equipment damage or in extreme cases even death serious bodily injury o
10. es Displays the easyTermo controller technical support phone numbers REXPOL 322459034 INLOG 322507600 Pressing any key returns you to the service menu and pressing the ESC key again brings back the main screen Language setup Allows you to select the language version of the the LCD display messages JEZYK POLSKI Av OK or ESC The currently selected language version is shown in the first line of the LCD display Change the version from Polish to English and vice versa using the 4 and keys An approval of the selected language occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen EXTENDED SERVICE FUNCTIONS Working mode simulation Simulation mode This function sets the controller in a specific operating mode where the state of digital inputs and temperature sensor readings are set using the keyboard calculated output states are shown on the LCD display just like during a normal program execution but the controller does not activate any of its outputs This special mode allows to dry test the control algorithm and to make sure it is working according to the requirements set SIMULATE OK BACK TO MENU ESC To start the controller simulation mode press the OK key or press the ESC key to return to the service menu without simulation Pressing the ESC key again brings back the main screen Thermal afterburner con
11. es may require an additional power supply If the controller and expansion modules are placed in the same enclosure next to each other the cable connecting them can be made of practically any four wire electrical cable In case of a longer distance between the two devices or strong electrical interferences the cable should be made of shielded twisted pair cable SF UTP with the shield grounded at one of the cable ends One cable pair should be used for signal lines TRX and TRX two pairs for power supply and ground and the fourth is reserved Connect the next expansion modules in an identical manner The symbol shown on the display to the right of the current time indicates the detection of expansion modules and establishing correct communication link to them Lack of this symbol indicates the configuration without expansion modules and the symbol signals failure of the communication link between the controller and modules In this case using the previously described External modules service function check the expansion modules configuration mode and if it is correct the cable connecting the controller and the modules Expansion modules signal their error free communication with the easyTermo controller with slow flashing of the STATUS lamp while continuous illumination indicates lack of communication between the module and the controller Thermal afterburner controller 16 TECHNICAL SPECIFICATIONS
12. igital inputs but may cause adverse delays in the response to the changes Shorter filtration affects the interpretation of digital inputs in the opposite direction 0 VALID AFTER 5s v OK or ESC The current value of digital inputs O state filtration time flashes in the first line of the LCD display Using the 4 4 keys you can change the value of filtration time in the range of 1 60 seconds in 1s increments Approval of the filtration time set occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Flaps delay Sets the operation delay of flap number 2 with regard to flap number 1 Flap 2 changes its state to a state identical with flap 1 state after the time delay set by using this function This applies to both switching on and off for each pair of flaps and to all the chambers where the catalytic combustion process is supervised by easyTermo controller DELAY TIME 5s AV OK or ESC Current value of the flap 2 operation delay time flashes in the first line of the LCD display Using the 4 keys you can change the value of flap number 2 delay time in the range of 1 60 seconds 1s increments Approval of the delay time set occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Thermal afterburner controller
13. is marked as optional but highly recommended Thermal afterburner controller 15 If any errors in the temperature measurement system are detected then a non typical temperature of 1100 C is simulated by the controller program which in turn leads to emergency stop of the afterburner To distinguish this erroneous state the measured temperature flashes on the LCD display then POWER SUPPLY easyTermo controller power supply comes from a 230V 9V transformer delivered along with the controller which provides enough power supply for both the controller and the optional I O expansion modules Power supply voltage of 9V AC value must be connected to the controller terminals number 17 and 18 CONNECTING THE EXPANSION MODULES easyTermo inputs and outputs can optionally be extended using the expansion modules to allow monitoring of more complex control systems requiring an increased number of inputs and outputs Detailed description of the expansion modules is contained in modules manuals The following diagram shows a typical cable connecting midi I O expansion module to the easyTermo controller Connecting easyTermo controller and midi I O expansion module easyTermo midi I O module terminal number terminal number 38 GND 19 39 TR 41 12V In the standard configuration an expansion module does not require a separate power supply as it is supplied via the MASTER connector of the easyTermo controller 2 or more expansion modul
14. ital input number 4 igital input number 6 d d digital input number 5 d expansion module option Thermal afterburner controller 12 easyTermo inputs and outputs connectors for afterburner control Contact number Control signal preheating signal input from chamber number 1 blocking signal input from chamber number 1 blocking signal input from chamber number 2 ees ee eee ee flap number 2 of chamber number 1 smoke flap output flap number 1 of chamber number 2 exhaust flap output pere uM 8 4 afterburning signal input from chamber number 1 E 4 6 8 1 3 5 7 If easyTermo controller is intended to supervise a catalytic combustion process for more than two smoking or maturing chambers the I O expansion modules must be connected to it For three or four chambers a standard midi I O 4 digital inputs and 4 digital outputs expansion module is needed for five chambers you must also use the specialized version of the mini 3 digital inputs and 1 digital output expansion module Assignment of signals for I O expansion modules is shown in the tables below midi I O expansion inputs and outputs connectors for afterburner control blocking signal input fom chamber number 4 pcr cmd ee WOMEN 13 14 flap number 2 of chamber number 3 smoke flap output 15 16 flap number 1 of chamber number 4 exhaust flap output 17 18 flap number 2 of chamber number 4 smoke flap output Ramee Nese et 19
15. ommended to adjust the sensor temperature after inserting the sensor into the water with ice 0 C or into a vessel of possibly high thermal capacity and stable temperature measured by a reference instrument Temperature thresholds Allows you to set specific temperature thresholds and hysteresis used by the afterburner control program to turn on and off the flaps T1 jacket off temperature threshold default 60 C T2 flaps on temperature threshold default 400 C T3 burner off temperature threshold default 800 C Th flaps off hysteresis linked with T2 default 25 C T1 60 T2 400 T3 800 Th 25 To change the pulsing temperature field press the 48 and keys to select another field use the and gt keys An approval of the temperatures values set occurs when you press the OK key Press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen The allowed range of values is set to 0 995 C for temperature thresholds and 0 50 C for the hysteresis both in 5 C increments While the operator enters the threshold temperatures the controller interactively checks if the limits are not exceeded not allowing to set the incorrect values Thermal afterburner controller 6 Tk measurements filtering Temp filtering Allows you to set the measured temperature filtration depth thus making possible adjusting it to the level of interference in your el
16. pansion modules With the OK key you can change the output state of the controller and expansion modules simultaneously to the opposite state To finish the test and return to the service menu press the ESC key Pressing the ESC key again brings back the main screen All outputs will automatically be turned off after the test Setting the time Clock time setup Use this function to set the astronomical time currently shown on the LCD display 12 00 00 lt gt OK ESC Using the 48 and 4 keys you can change the state of currently flashing time field The and gt keys allow you to select the time field hours minutes seconds which is to be changed An approval of the selected time occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Thermal afterburner controller 9 Setting the date Clock date setup Use this function to set the date currently shown on the LCD display 01 01 2006 lt OK ESC Using the 4 and keys you can change the state of currently flashing date field The and gt keys allow you to select the date field year month day which is to be changed An approval of the selected date occurs when you press the OK key or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen Service phon
17. r considerable damage to property It is strongly recommended to add safety protection such as an emergency stop in case the easyTermo controller operation must be shut down immediately EXAMINATION BEFORE INSTALLATION Every easyTermo controller has been carefully tested and examined before shipment Please carry out the following examination procedures after unpacking your easyTermo controller check to see if the model number of the easyTermo controller matches the model number that you ordered check to see whether any damage occurred to the easyTermo controller during shipment Do not connect the easyTermo controller to the power supply if there is any sign of damage Thermal afterburner controller 3 CONTROLLER APPLICATION AND FEATURES Microprocessor based controller of easyTermo family presented here with dedicated firmware version for thermal afterburner allows monitoring of catalytic combustion process for up to 5 smoking or maturing chambers with optional I O expansion modules Fitted with digital inputs voltage type relay outputs temperature measurement input K type thermocouple and a connector for optional I O expansion modules easyTermo controller can easily be adapted to other control tasks by simply replacing its firmware Operator interface consists of a built in front panel LCD display 2x16 characters 8 keys keypad buzzer and one bi color LED signalling the current operating mode Battery backed real time
18. r delivered along with it are both intended to the standard DIN 35 mm rail mounting in the afterburner electrical enclosure Note the following requirements for the safety of the controller installation the installation and controller connection should be done by qualified personnel only all connections should be made with controller power turned off before removing the controller from the DIN rail unplug all signal connectors place all controller signal cables as far away from power cables as possible do not supply the controller from the power rail used to supply devices that generate large disturbances especially of pulse type protect the controller relay outputs with external fuses 5A max easyTermo external connectors are shown in the following figure Digital inputs 230V AC standard iei cd K type Thermocouple 2662529 Ooo0006655 58 9 10 11 12 13 14 15 16 17 18 19 20 21 027 Uist UiaTinexac A list 016 077 Ciel AC 9V NIC GRUB 112345678 A CPAN e 14112 T ea ub easyTermo 012345678 v Q3 Q4 OUT 8x5A 95 96 97 98 MASTER 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Expansion Relay outputs 230V AC 5A modules easyTermo connectors and signal types Contact number Signaltype digital input number 1 digital input number 2 Contact number Signal type igital input number 3 ig
19. s no expansion modules connected or some malfunction in controller 1 modules connection while the symbol indicates inconsistency between the number of modules connected and the I O modules number set during the controller configuration In such a case you must first verify the correct controller configuration for operation with I O expansion modules using the External modules service function described hereinafter LCD display backlight switches off automatically after approximately 3 minutes of controller keyboard inactivity This in turn reduces controller power consumption which leads to lower level of controller interference emitted and raises its immunity to momentary power supply interruptions or brown outs Pressing any key in this state causes the immediate turning on of the display backlight The first key press is ignored in this case so there is no fear of unintended change of the controller state In the event of emergency in the controllers environment e g the thermocouple damage the display is automatically turned on until the cause of the failure is gone to signal the erroneous state to the user Additional acoustic signal and an error message on the LCD display may also acompany this state CONTROLLER CONFIGURATION easyTermo controller configuration usually consists of a one time setting up of the working parameters using the service mode functions described below The parameters
20. s stopped the LED lights in red and if the program is running it lights in green Thermal afterburner controller 4 Depending on the current condition of the controller one of the two specific screens appears on its LCD display Program stopped Program running INPUTS 112345678 PROGRAM STOP 150 NODONUNDOUG 12 00 150 12 00 OuTPUTS 12345678 The display constantly shows the Aside from the temperature and time temperature measured and the current the state of the controller inputs and time After pressing the OK key current outputs is also shown The mand date is displayed instead of time Press symbols on the display correspond to the OK key again to return to the time the I O numbers placed on the panel display mode The ESC key activates The m symbol represents the I O the service mode activity the symbol its inactivity The red LED is on The green LED is on Pressing the START key will activate Pressing the STOP key will halt the the control program execution control program execution The symbol displayed to the right of the current time informs you of a successful detection of I O expansion modules and of establishing connection to them by the easyTermo controller The I O expansion modules let you connect up to three additional smoking or maturing chambers which allows controlling the catalytic combustion process for up to 5 chambers Lack of the symbol indicate
21. set are stored in the controlller s nonvolatile memory so they don t get lost after switching off the power Due to the necessary knowledge of the controller operation details and the need to protect its proper functioning against unauthorized Thermal afterburner controller 5 user tampering the service functions are divided into two groups coded with different access passwords Entering the service mode is possible only when you press the ESC key while the afterburner control program is stopped Using the 48 i gt and OK keys you may enter one of the two password codes 1983 for basic service functions set 1994 for extended service functions set After entering the correct password you will be presented with a list of service functions which you can select using the 4 V keys and finally accept your selection by pressing the OK key BASIC SERVICE FUNCTIONS Sensor correction Temp correction Allows the adjustment of the sensor temperature the range of 50 C 1 Tk 100 v OK or ESC In the first line of the display the present value of the sensor correction flashes while on the right side the currently measured temperature including correction set is shown With the 4 keys you can change the value of the correction Press the OK key to approve the adjustments made or press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main screen It is rec
22. ters Factory defaults Use this function to set typical values of the controller s programmable parameters This function may be useful for a rapid preparation of the controller to resume its function after losing some settings as a result of a strong interference or after user error while setting the parameters TYPICAL PARAMETERS OK STORE ESC BACK After pressing the OK key all the controller programmable parameters will be set to the typical values and an automatic restart will follow Press the ESC key to return to the service menu without any changes Pressing the ESC key again brings back the main Screen Digital I O test Shows the status of digital inputs and allows the user to manually control the controller relays This function is especially useful for faults location during controller installation or servicing ESC or moomsomogo gt OK meomsoomag Controller inputs state is shown in the first line of the LCD display and controller outputs status in the second line The m and a display symbols correspond to the numbers of inputs and outputs placed on the frontpanel The m symbol indicates the activity of a given input or output while the o symbol the lack of activity The selection of the relay output to be tested is done using the and gt keys and a dot symbol is placed over the currently selected output To change the selected output state press the 4 and keys for the controller and the START STOP keys for the ex
23. troller 10 The individual keys have the following meaning in the simulation mode i selection of the simulated input simulation of input status change from inactive to active and vice versa mi simulation of the measured temperature change 10 C respectively START a hint with the name of the input currently selected for the simulation ESC a hint with the name of the output corresponding to the current input STOP end of the simulation mode Firmware upgrade This function is reserved exclusively for the controller manufacturer It allows to change the controller internal software by means of a specialized programmer or an external memory module Factory number Displays the factory number of the easyTermo controller which may be needed for service purposes or for upgrading the controller firmware Factory number 034 0710 4 NOREL Pressing any key returns you to the service menu Diagnostics info Displays the status of the easyTermo controller internal parameters whose values may be useful in diagnosing the state of the controller by the manufacturer s technical support PF 0000 RST 0001 WD 0000 BOD 0002 After pressing the OK key all parameters are cleared Press the arrow keys to show additional diagnostic information or press any other key to return to the service menu Thermal afterburner controller 11 INSTALLATION OF THE CONTROLLER easyTermo controller and the 230V 9V transforme
24. ust flap output S 9 10 11 12 host controller communication link mini Out expansion module 4 digital outputs must be properly set to work in this configuration To do this remove carefully the plastic cover of the lower connector MASTER connector set the jumper number 2 the jumper closer to the connector next to the green LED and finally place the connector cover back in its place Lack of the jumper no 2 will cause malfunction of the mini Out mini In modules set Using the previously described External modules service function you must also choose the correct modules configuration and confirm the selection with the OK key MODUL MINI MINI Y OK or ESC After that a set of mini In 4 digital inputs and mini Out 4 digital outputs expansion modules is correctly configured as the equivalent of a midi I O module 4 digital inputs and 4 digital outputs In all of the expansion modules configurations described above namely midi I O module up to 4 chambers a pair of mini In and mini Out modules up to 4 chambers a pair of midi I O and mini I O modules up to 5 chambers a separate power supply for the expansion modules is not required because they are powered via the MASTER connector of an easyTermo controller Thermal afterburner controller 14 CONNECTING THE DIGITAL INPUTS easyTermo controller is equipped with 8 galvanically isolated 230V AC digital inputs The following figure shows how to
Download Pdf Manuals
Related Search