User`s Manual
Contents
1. 3 62 E Panel Cutout 4000 Series Mes 92 mm 3 62 2 A 4 TE Panel SP g Cutout 8000 Series 2 7 1 45 mm 1 77 1 77 Panel 4 45 mm gt D 28 Cutout jj 6000 Series D D 104 8 4 12 20 UM60001A 2 3 Wiring Precautions Before wiring verify the label for correct model number and options Switch off the power while checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded t is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system Beware not to over tighten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 5 are not exceeded UM60001A 21 3 2mm min 7 0mm max2. 5 55V 11 1V min 0 22 2mA 0 20mA or 4 20mA 0 5 55V 0 5V 1 5V 0 11 1V 0 10V UM60001A User Interface Display Keypad Programming Port Communication Port Control Mode Output 1 Output 2 ON OFF P or PD PID Cycle Time Manual Control Auto tuning Failure Mode while Ramping Control Digital Filter Function Time Constant Dual 4 digit LED Displays 4 keys For automatic setup calibration and testing Connection to PC for supervisory control Reverse heating or direct cooling action PID cooling control cooling P band 50 300 of PB dead band 36 0 36 0 of PB 0 1 90 0 F hysteresis control band 0 0 100 0 offset adjustment Fuzzy logic modified Proportional band 0 1 900 0 F Integral time 0 1000 seconds Derivative time 0 360 0 seconds 0 1 90 0 seconds Heat MV1 and Cool MV2 Cold start and warm start Auto transfer to manual mode sensor break or A D converter damage 0 900 0 F minute or 0 900 0 F hour ramp rate First order 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UM60001A 57 Environmental amp Physical Operating Temperature 10 to 50 Storage Temperature 40 C to 60 C Humidity to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strengt 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m s for 2 hours Shock Resistance 200 m s 209
3. L 4 Figure 2 2 T Lead Termination for t 4000 Series amp 8000 Series 6 0mm max L Figure 2 3 Lead Termination 3 0mm piis for 6000 Series 90 250VAC 41 63 Hz 12VA OP1 UN TAE RE RS 485 TX RXD 14 RE Retransmission COM RS 232 OP2 ALM PTA TC V PTB mA TC V PTB mA TC V mA RTD Figure 2 4 Rear Terminal Connection for 4000 Series amp 8000 Series 22 UM60001A Retrans RS 232 TXD COM RS 485 TX1 TX2 13 14 15 LIZ 90 250 VAC 47 63 Hz ion 8 12V c 9 ra 1 2 10 RTD __ TC V PTB mA c 11 TC V 7 Ors BL PTB mA 12 Figure 2 6 Rear Terminal Connection for 6000 Series UM60001A 23 The controller is supplied to operate at 11 26 VAC VDC or 90 250 VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller 4000 Series 6000 Series 8000 Series 90 250 VAC or 90 250 VAC or 11 26 VDC 11 26 VAC VDC 111 ono gt 117 2 Fuse N 8 Fuse _ Figure 2 7 Power Supply Connections This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed
4. The low temperature coefficient resistors should be used for RA and RB Input Function RA T C RTD 0 60mV X 0 1V 61 9K 0 5V 1 5V 324K 0 10 649K 0 20mA 4 20mA 9 Perform Step 1 and Step 2 to calibrate the linear input zero Perform Step 3 but send a span signal to the input terminals instead of 60mV The span signal is 1V for 0 1 input 5V for 0 or 1 5V input 10V for 0 10 input and 20mA for 0 20 or 4 20mA input Final step Step 8 Set the LOCK value to your desired function 52 UM60001A Chapter 5 Specifications Power 90 250 47 63 Hz 12VA 5W maximum 11 26 VAC VDC 12VA 5W maximum Input Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 1 5uV for all inputs except mA input 3 0uV C for mA input Lead Resistance Effect T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads Burn out Current 200 mA Common Mode 120dB Normal Mode 55dB Sensor Break Detection Sensor open for TC RTD and mV inputs Sensor short for RTD input below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs UM6
5. Offset value for P control Low 0 High 100 0 96 25 0 0 nonE Ramp Function RAMP Ramp function selection 18 nr as 0 2 Hr Use unit hour as Ramp Rate 14 UM60001A eon Parameter Description Range Default RR Ramp rate Low 0 High 00 0 0 0 0 none Output 2 No Function 2 Deviation High Alarm 3 dEL o Deviation Low Alarm 6 PYH Process High Alarm 4 PYL p Process Low Alarm 8 Cooling PID Function or EL Relay output 155r Solid state relay drive output 2 55r 3 2 4 20 2 Output 2 signal type E module 0 4 70 a current LEES 0 54 0 8 0 ID voltage Select BPLS bumpless transfer o2FT Output 2 failure 0 gt tput 2 control function as the unit fails or select ON 0 or OFF 1 for alarm function Output 2 hysteresis O2HY Low 0 1 High 505 n function CYC2 Output 2 cycle time Low 0 1 High 90 0 sec 18 0 cpg Cooling proportional Low 50 High 300 100 UM60001A 15 Parameter in Default Notation Parameter Description Range Value Heating cooling dead DB band negative value Low 36 0 High 36 0 0 overlap 0 nanE No alarm function 1 E nr Dwell timer action 2 Deviation high alarm 3 dEl Deviation low alarm Alarm function for 4 dh H Deviation band out of ALEN alarm output ban
6. Consideration should be given to prevent from unauthorized person access to the power terminals Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed closed to the heater In a process where the heat demand is variable the probe should be closed to the work area Some experiments with probe location are often required to find this optimum position In a liquid process addition of a stirrer will help to eliminate thermal lag Since the thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes UM60001A Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process requirements In special processes the sensor might need to have different requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 degrees F 2 degrees or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection
7. mode Clear the message of communication error and auto tuning error Restart the dwell timer when the dwell timer has been time out Enter the manual control menu during failure mode occurs gt ENTER KEY Press for 3 seconds or longer Press for 3 seconds to 1 Ener setup menu The display shows SEE 2 Enter manual control mode during manual control mode is selected 3 Enter auto tuning mode during auto tuning mode is selected 4 Perform calibration to a selected parameter during the calibration procedure Press for 4 2 seconds to select manual control mode Press lt 2 for 5 4 seconds to select auto tuning mode Press for 6 6 seconds to select calibration mode UM60001A 9 Alarm Upper to display process value a Indicator menu symbol and error code etc Output 2 Process Unit Indicator Indicator Yon Output 1 OP1 OP2 ALM Indicator L1 I E wx sse Mode to display set point value Indicator riw rn nnn parameter value or Auto tuning 10 D D control output value etc Indicator A v 4 Buttons for ease of E EY control setup and 6000 set point adjustment Figure 1 3 Front Panel Description Table 1 1 Display Form of Characters Display program code of the product OP
8. 2 144 5 232 c TX1 Max 247 units can be linked 4000 Series 6000 Series 8000 jes TX1113 2 14 TX1 Terminator 220 ohms 0 5W Figure 2 19 RS 485 Wiring UM60001A 29 RS 232 4000 Series 6000 Series 8000 Series 13 RXD 14 coM 15 9 pin RS 232 port Wi CC94 1 Figure 2 20 RS 232 Wiring If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable PC must be modified according to the following circuit diagram 4000 Series 6000 Series 8000 Series 13 RXD 14 15 30 TX1 Figure 2 21 Female DB 9 Configuration of RS 232 UM60001A To DTE PC RS 232 Port 1 DCD 2RD 3 TD 4DTR 5 GND 6 DSR 7RTS 8 CTS 9 Chapter 3 Programming Press for 3 seconds and release to enter setup menu Press to select the desired parameter The upper display indicates the parameter symbol and the lower display indicates the selected value of parameter 3 1 Lockout There are four security levels can be selected by using LOCK parameter If NONE is selected for LOCK then no parameter is locked If SET is selected for LOCK then all setup data are locked If USER is selected for LOCK then all setup data as well as user data refer to section 1 5 except set point are locked to prevent from being changed If ALL is selected for LOCK then all parameters are locked to prevent from being changed 3 2
9. J type thermocouple thermocouple 2E EL thermocouple 3 E E type thermocouple 46_ amp C B type thermocouple 5 R type thermocouple 6 S EL S type thermocouple 7 C N type thermocouple 81 Ltype thermocouple 1 Input sensor selection 9 PE dn PT 100 ohms DIN 0 curve 10 Pk 16 100 ohms JIS curve 11 00 4 20 mA linear NOTE ae current input 12 0 20 0 20 mA linear Input Selection did current input 11 17 13 0 50 0 60 mV linear A millivolt inpu of Linear ma VDC 14 B 5 0 1V linear voltage Require input special order 15 1 59 0 27 linear voltage A inpu only See Matrix 16 6 1 5 linear voltage Page 8 9 10 0 10V linear voltage input 12 UM60001A eee Parameter Description Range Default 0 Of Degree C unit UNIT Input unit selection 1 Degree F unit m 2 P Process unit 0 mad No decimal point 1 1 19 1decimal digit DP Decimal point selection i ci 1 22 40 2decimal digits 3 gP 3decimal digits 17 8 INLO Input low sale value Low 19999 High 45486 DERE 93 3C INHI Input high scale value Low INLO 50 High 45536 299 0 F Low limit of set point T 17 8C SP1L value Low 19999 High 45536 High limit of set point ica 537 8C LOL P Low SP1L High 45536 1000 SHIF PV shift offset value Low 20005 High 38006 00 0 7 0
10. O CAN 2 in the user menu by using SEL1 SEL8 ae ALMD contained at the bottom of setup menu ALHY Se ALFT Release press again for 2 seconds ad RS 3 or longer but not longer than 3 seconds Cosa UD then release to enter the calibration menu 9 C pata PARI The user menu shown in the flow chart is E STOP corresponding to the default setting for ct SEE the SEL parameters SEL1 to SEL8 SP3 EC ic will be hidden if NONE is selected for ALFN SP2 will be hidden if alarm function 9 is not selected for OUT2 The unused a7 SEL6 parameter will be hidden even if it is SEL7 aH selected by SEL parameters UM60001A 11 1 6 Parameter Descriptions Parameter inti Default Notation Parameter Description Range Valie 4 ND 25 0C SP1 Set point for output 1 Low SP1L High SP1H 77 0 F Set point for output 2 10 00 SP2 when output 2 performs Low 19999 High 45536 18 0 F alarm function i Set point for alarm or UN 10 0C SP3 dwell timer output Low 19999 High 45536 18 0 F 0 nonE No parameter is locked 1 SEE Setup data LOCK Select parameters to be locked 0 locked 2 uSEr Setup data and User data except Set point are locked 3 ALL All data are locked 0 J_EL
11. Signal Input INPT Selects the sensor type or signal type for signal input Range thermocouple J 5 L RTD PT DN PT JS linear 4 20 0 20 0 60 0 1 0 5V 1 5V 0 10 UNIT Selects the process unit Range C F PU process unit If the unit is neither C nor F then selects PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 DP for linear NO DP 1 DP 2 DP 3 DP INLO Selects the low scale value for the linear type input INHI Selects the high scale value for the linear type input How to use INLO and INHI IA unit ordered with 4 20 mA is setup as INPT 4 20 then if SL specifies the input signal low ie 4 mA SH specifies the input signal high ie 20 mA S specifies the current input signal value the conversion curve of the process value is shown as follows UM60001A 31 process value INHI PV INL Figure 3 1 Conversion Curve for Linear Type Process Value input signal Formula PV INLO INHI INLO Example A 4 20 mA current loop pressure transducer with range 0 15 kg cm is connected to input then perform the following setup 4 20 INLO 0 00 INHI 15 00 DP 2 DP Of course you may select other value for DP to alter the resolution 3 3 Control Outputs There are 4 kinds of control modes can be configured as shown in Table 3 1 Table 3 1 Heat Cool Control Setup Value Control Modes OUT1 OUT
12. TI Instability or Ti Oscillations Slow Response or NER Decrease TD 3 Derivative Time TD Oscillations High Overshoot Increase TD Table 3 2 PID Adjustment Guide Figure 3 9 shows the effects of PID adjustment on process response 3 13 Manual Control Operation To enable manual control the LOCK parameter should be set with NONE then press for4 2seconds 47 4 Hand Control will appear on the display Release key and depress Press for 3 seconds then the MAN indicator will begin to flash and the lower display will Show The controller now enters the manual control mode 5 indicates output control variable for output 1 and i _ _ _ indicates control variable for output 2 Now you can use up down key to adjust the percentage values for the heating or cooling output The controller performs open loop control as long as it stays in manual control mode Exit Manual Control press R key the controller will revert to its normal display mode UM60001A 45 PB too low Set point P action PB too high Time TI too high PV Set point action TI too low Time PV TD too low Set point D action TD too high Time Figure 3 9 Effects of PID Adjustment 46 UM60001A 3 14 Data Communication The controllers support RTU mode of Modbus protocol for the data communication Other protocols are not available for the series Two t
13. and replacement 2 6 Sensor Input Wiring 4000 Series 6000 Series 8000 Series PTA 18 4 TC V TC V 9 PTB 5 V 20 TC V PTB Te mA RID Figure 2 8 Sensor Input Wiring 2 7 Control Output 1 Wiring 4000 Series 8000 Series 6000 Series 3 5 nim T 24 10 i 4120 240 Supply Figure 2 9 io AS SEPPI Output 1 Relay or Triac SSR to Drive Load External Device UM60001A 25 2 7 Control Output 1 Wiring Cont d External device 4000 Series 120 240V 8000 Mains Supply s ut 30mA 5V Pulsed Voltage Figure 2 10 Output 1 Pulsed 5 VDC Voltage to Drive SSR 4000 Series External device 8000 Series 6000 Series 3 ue 9 1 rmm 10 0 2 2 Load EE Maximum Load 500 ohms Figure 2 11 Output 1 Linear Current 4000 Series 8000 Series 6000 Series External device 3 0 1V 0 5V 9 0 1V 0 5V 4 1114 10 1 5 0 10 E Minimum Load 10K Figure 2 12 Output 1 Linear Voltage ohms 26 UM60001A Control Output 2 Wiring 4000 Series 8000 Series 6000 Series 5 11 omw at A 120 240 Mains Supply Figure 2 13 7 Output 2 Relay or SSR to Drive Load 4000 Series External device 8000 Series 6
14. odd ji 0 2 No parity bit j 1 stop Stop bit count of digital 0 b E stop bit communication 1 ei t Two stop bits PV Retranmission iah 17 8 C RELO rou Valge Low 19999 High 45486 1086 PV Retranmission igh 93 3 High Value Low 19999 High 45486 200 0 F 0 nan E No parameter selected 2 1 oct LOCK is put ahead 2 nFE INPT is put ahead SEL1 Select 1 st parameter for 3 uo UNIT is put ahead 4 dP DP is put ahead 5 SH SHIF is put ahead 6 PB is put ahead 7 LE Tisputahead 17 UM60001A Prameter Parameter Description Range Default Notation Value 8 E d TD is put ahead 95 O1HY is put ahead 10C CYC1 is put ahead 11 oF SE OFST is put ahead 12 RR is put ahead SEL1 2 135 gH S O2HY is put ahead 2 14 g CYC2 is put ahead 15 is put ahead 16 gh DB is put ahead 17 Add DDR is put ahead 18 HL H H ALHY is put ahead Sete Select end parameter Same as SEL1 3 SEL3 Select Ird parameter Same as SEL1 4 SEL4 Select 41 parameter Same as SEL1 6 SELs pelect Sth parameter Same SEL1 7 SEL6 Select 6th parameter Same as SEL1 8 seL7 Select 7th parameter Same as SEL1 10 SEL8 Select 8 th parameter Same as SEL1 17 for user menu 18 UM60001A AN Dangerous voltages capable of causing death are sometimes present in this instrum
15. required for input UM60001A 49 Step 4 E 100 ohms 19 100 ohms 5 20 6 Step 5 Step 6 50 Press scroll key until the display shows Send a 100 ohms signal to the RTD input terminals according to the connection shown below 4000 Series 8000 Series 6000 Series Figure 4 1 RTD Calibration Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails Press scroll key and the display will show Change the ohm s value to 300 ohms Press scroll key for at least 3 seconds The display will blink a moment and two values are obtained for RTDH and RTDL step 4 Otherwise if the display didn t blink or if any value obtained for RTDH and RTDL is equalto 199 9 or 199 9 then the calibration fails Perform step 6 to calibrate offset of cold junction compensation if required Setup the equipments according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used UM60001A Temperature Calibrator 4000 Series K TC 8000 Series 6000 Series K K H gt K 6 Stay at least 20 minutes in still air room room temperature 25 3C Figure 4 2 Cold Junction Calibration Setup The temperature calibrator is configured as K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration Step 7 The unit u
16. second time constant 1 02second time constant 2 0 5 second time constant 3 1 second time constant 4 2 seconds time FILT Filter damping time constant 2 constant of PV 5 5 5 time constant 6 10 seconds time constant 7 20seconds time constant 8 40 30 seconds time constant 9 60seconds time constant UM60001A 13 Parameter inti Default Notation Parameter Description Range Value PB Proportional band value Low 0 High 900 0 18 0 A TI Integral time value Low 0 High 1000 sec 100 TD Derivative time value Low 0 High 360 0 sec 25 0 Core heati Orble Galan 9 OUT1 Output 1 function E 0 1 Direct coolin e re Direct 0 EL Relay output 1 55 gd Solid state relay drive output 2 545 Solid state relay output 3 4 Pil 4 20 mA current module O1TY Output 1 signal type 4 1 BL 0 20 mA current 0 module 5 1 0 1V voltage module 6 1 50 0 5V voltage module 7 1 54 1 5 voltage module 8 m I 0 10V voltage U U module 4 Select BPLS bumpless transfer or 0 0 100 0 to o4rT Output 1 failure transfer continue output 1 control 0 mode function as the unit fails or select OFF 0 or ON 1 for ON OFF control Output 1 ON OFF control ws ais 0 1C O1HY hysteresis Low 0 1 High 50 0 90 0 0 2 F CYC1 Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST
17. the curve shown below Figure 3 5 RAMP Function 0 17 30 40 minutes Note When the ramp function is used the lower display will show the current ramping value However it will revert to show the set point value as soon as the up or down key is touched for adjustment The ramping value is initiated to process value either as power up or RR and or set point are changed Setting RR to zero means no ramp function at all UM60001A 39 3 7 Dwell Timer Alarm output can be configured as dwell timer by selecting TIMR for ALFN As the dwell timer is configured the parameter SP3 is used for dwell time adjustment The dwell time is measured in minute ranging from 0 1 to 4553 6 minutes Once the process reaches the set point the dwell timer starts to count down until zero time out The timer relay will remain unchanged until time out The dwell timer operation is shown as following diagram After time out the dwell timer will be restarted by pressing the RESET key The timer stops to count during the manual control mode failure mode calibration period and auto tuning period ALM l power off or touch RESET key Timer starts Figure 3 6 Dwell Timer Function If alarm is configured as dwell timer ALHY and ALMD are hidden 40 UM60001A 3 8 PV Shift In certain applications it is desirable to shift the controller display value from its actual value This can be easily accomplished by
18. the stability of process value This is particularly useful in certain application where the process value is too unstable to be read SEL Function The units have the flexibility for user to select those parameters which are most significant to him and put these parameters in the front of display sequence There are at most 8 parameters can be selected to allow the user to build his own display sequence 6 UM60001A 1 Power Input 0 1 C X Special Order Signal 0 Output 1 NO C X 2 Ordering Code 4900 LIO DI CI 80 90 250 VAC 50 60 HZ 11 26 VAC or VD Standard Input Thermocouple J S N L RTD PT100 DIN PT100 JIS None Relay rated 2A 240VAC Pulsed voltage to drive SSR 5V 30mA Isolated 4 20mA 0 20mA Isolated 1 5V 0 5V Isolated 0 10V Triac output 1 240VAC SSR Pulsed voltage to drive SSR 14V A0mA Special order LOptions 0 Panel mount IP50 standard 1 Panel mount IP65 water resistant rubber installed 2 DIN Rail mount with IP50 for 9100 only 3 DIN Rail mount with IP65 for 9100 only Communications None RS 485 interface RS 232 interface Retransmit 4 20mA 0 20 Retransmit 1 5 V 0 5V Retransmit 0 10V Special order Alarm 0 None 1 Form C relay 2A 240VAC 9 Special order Output 2 None Form A relay 2
19. value for control which is different from SP1 as the ramp function is performed There are four types of alarm modes available for each alarm function these are Normal alarm Latching alarm Holding alarm and Latching Holding alarm They are described as follows UM60001A 37 Normal Alarm ALMD NORM When a normal alarm is selected the alarm output is de energized in the non alarm condition and energized in an alarm condition Latching Alarm ALMD LTCH If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the alarm condition is cleared The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Holding Alarm ALMD HOLD A holding alarm prevents an alarm from power up The alarm is enabled only when the process reaches the set point value Afterwards the alarm performs same function as normal alarm Latching Holding Alarm ALMD LT HO A latching holding alarm performs both holding and latching function The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Alarm Failure Transfer is activated as the unit enters failure mode Alarm will go on if ON is set for ALFT and go off if OFF is set for ALFT The unit will enter failure mode when sensor break or if the A D converter of the unit fails 3 5 Configure User Menu This series has the flexibility for you to select those par
20. value will be varied and eventually coincide with set point Using the P control set to 0 the auto tuning is disabled Refer to section 3 12 manual tuning for the adjustment of PB and TD Manual reset adjust OFST is not practical because the load may change from time to time and often need to adjust OFST repeatedly The PID control can avoid this situation Heat only PID control Selecting REVR for OUT1 PB and TI should not be zero Operate auto tuning for the new process or set PB TI and TD with historical values See section 3 11 for auto tuning operation If the control result is still unsatisfactory then use manual tuning to improve the control See section 3 12 for manual tuning The unit contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned Cool only control ON OFF control P PD control and PID control can be used for cool control Set OUT1 to DIRT direct action The other functions for cool only ON OFF control cool only P PD control and cool only PID control are same as descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat control NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation process value from the set point It is recommended to use PID contr
21. 000 Series ND EMEN Mena Hr 5 5 VDC 30 ma 11 Pulsed Voltage 6 12 120 240 Internal Circuit Mains Supply 30mA 5V 5V Pulsed Voltage 33 33 Figure 2 14 Output 2 Pulsed Voltage to Drive SSR 4000 Series External device 8000 Series 6000 Serjes e m 6 4 20 Maximum Load 500 ohms Figure 2 15 Output 2 Linear Current TAM UM60001A 27 Control Output 2 Wiring Cont d 4000 Series i External device 8000 Series 6000 Series NEN 5 0 1V 0 5V 11 0 1V 0 5V 6 1 5V 0 10V 12 TOM OE T0V ss Minimum Load Figure 2 16 Output 2 Linear Voltage 410 K ohms 2 8 Alarm Wiring 2 2 2 2 4000 Series 8000 Series 6000 Series LOAD 8 420V 240VAC Figure 2 17 Alarm Output to Drive Load Mains Supply External device 2 9 Process Retransmission 4000 Series 6000 Series 8000 Series Output to Re 13L Recorder 0 20 4 20ma 0 5 4 5VDC 0 10vpc PLC Etc Re 1A Load Resistance 0 500 ohms for current output 10 K ohms minimum for voltage output Figure 2 18 Retransmission Output Wiring m UM60001A 2 10 Data Communication 4000 Series 6000 Series RS 485 to RS 232 8000 Series network adaptor naa or SNA10B 2 14 Twisted Pair Wire 4000 Series 6000 Series 8000 Series TX1113
22. 0001A 53 Characteristics 54 Accuracy Input Tes Range 25 C Impedance 120 1000 ESSE p 1832 ew 00 C 1870 328 2498 p 2 22 250 400 418 F752 pj 5 22 100 C 900 C P denar eo 0 C 1800 C Q 32 3272F 0 1767 8 32 3214F 2 2 MQ 0 1767 8 32BF 3214 2A MO 250 C 1300 C 418 F 2372 F 2 2 200 900 328 F 1652 F 2 2 210 700 346 1292 teka 200 600 328 F 1112 F 1 3 2 2 mA 3mA 27mA 0 05 70 50 V 1 3 11 5V 0 05 650 UM60001A Output 1 Output 2 Relay Rating for 2A 240 VAC life cycles 200 000 resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Linear Output Characteristics Zero Span Load Type Tolerance Tolerance Capacity 4 20 mA 3 8 4 mA 20 21 mA 5000 max 0 20 mA 0 mA 20 21 mA 5000 max 0 5 OV 5e 5 25 V 10 KO min 15V 0 95 1V 555 V 10 KO min 0 10V OV 10 10 5 V 10 KO min Linear Output Resolution 15Bits Output Regulation Output Settling Time Isolation Breakdown Voltage Temperature Effect Triac SSR Output Rating Inrush Current Min Load Current Max Off state Leakage Max On state Voltage Insulation Resistance Dielectric Strength 0 02 for full load change 0 1 sec stable to 99 9 1000
23. 1 OP2 ALM for 2 5 seconds The left diagram shows program no 6 for 6000 Series with version 12 The program no for 4000 Series is 12 and the number for the 8000 Series is 11 Figure 1 4 Display of Initial Stage 10 UM60001A 1 5 Menu Overview User Setu Manual Auto tunin Calibration menu inen Mode Mode i Mode A 3 sec 4 2 sec 5 4 sec 6 6 sec 7 8 sec 37 SEE 0 8 a a ja Release c9 3 i A li A H peas mc ac for 3 seconds re cc oer to start RESTI pP auto tuning C pg mode 9 CNH CI Spi Es co 9C Press ca seconds press for ADDR 3 seconds to PB manual control EUM perform calibration OUT1 Corus pply these modes will break the control 214 loop and change some of the previous 8 setting data Make sure that if the system ER is allowable to apply these modes OFST fey cLRAMP 1 The flow chart shows a complete listing of all parameters For actual application Scary the number of available parameters depends on setup conditions and should ae O2HY be less than that shown in the flow chart eq c CC ad e __ You can select at most 8 parameters put
24. 2 O1HY O2HY CPB DB Heat only REVR Cool only DIRT Heat PID Cool ON OFF REVR Heat PID Cool PID REVR COOL x x X Don t care yx Required if ON OFF control Adjust to met process is configured requirements 32 UM60001A Heat Only ON OFF Control Select REVR for OUT1 Set PB to 0 O1HY is used to adjust dead band for ON OFF control The output 1 hysteresis O1HY is enabled in case of PB 0 The heat only on off control function is shown in the following diagram PV SP1 Dead band O1HY SP1 O1HY OUT1 Action Time Time Figure 3 2 Heat Only ON OFF Control The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set ie PB 0 TD CYC1 OFST CYC2 CPB DB will be hidden and have no function to the system The auto tuning mode and bumpless transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI to 0 OFST is used to adjust the control offset manual reset O1HY is hidden if PB is not equal to 0 OFST Function OFST is measured by with range 0 100 0 96 In the steady state ie process has been stabilized if the process value is lower than the set point a definite value say 5 LC while 20 LC is used for PB that is lower 25 96 UM60001A 33 then increase OFST 25 and vice versa After adjusting OFST value the process
25. 3 Chapter 1 Overview 1 1 General The Fuzzy Logic plus PID microprocessor based controller series incorporate two bright easy to read 4 digit LED displays indicating process value and set point value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance SERIES 6000 is a 1 16 DIN size panel mount controller SERIES 4000 is a 1 4 DIN size panel mount controller SERIES 8000 is a 1 8 DIN size panel mount controller These units are powered by 11 26VAC VDC or 90 250 VAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control or an alarm Both outputs can select triac 5V logic output linear current or linear voltage to drive external device There are six types of alarm plus a dwell timer can be configured for the third output The units are fully programmable for PT100 and thermocouple types T S L with no need to modify the unit The input signal is digitized by using a 18 bit A to D converter Its fast sampling rate 5 scans second allows the unit to control fast processes Digital communications RS 485 or RS 232 are available as an additional option These options allow the units to be integrated with supervisory control system and software A programming port is available for automatic configuration calibration and testing wit
26. A 240VAC Pulsed voltage to drive SSR 5V 30mA Isolated 4 20 0 20 Isolated 1 5V 0 5V Isolated 0 10V Triac output 1 240VAC SSR Isolated 20V 25mA transducer power supply Isolated 12V 40mA transducer power supply Isolated 5V 80mA transducer power SUP Pulsed voltage to drive SS 40 Special order o N NO UM60001A 7 1 3 Programming Port 1 Rear gt Front Terminal E Panel E Figure 1 2 Programming Port Overview Le Access Hole A special connector can be used to touch the programming port which is connected to a PC for automatic configuration also can be connected to an ATE system for automatic calibration and testing The programming port is used for off line automatic setup and testing procedures only Do NOT attempt to make any connection to these pins when the unit is in normal operation 8 UM60001A 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY 4 This key is used to increase the value of selected parameter DOWN KEY v This key is used to decrease the value of selected parameter RESET KEY R This key is used to 1 Revert the display to display the process value 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and calibration
27. User s Manual PROHEAT Controls OP1 OP2 ALM WIC 4000series JAREZ 4000 Series 1 4 DIN 0000 Series 1 16 DIN 8000 Series 1 8 DIN Auto Tune Fuzzy PID LEE Lv Le Process Temperature Controller marr Industrial Heaters Sensors amp Controls 117 East Adam Street LaGrange KY 40031 502 222 1402 Fax 502 222 0714 www proheatinc com Warning Symbol N This Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual Installers Read Chapter 1 2 e System Designer Read All Chapters e User Read Page 12 NOTE Itis strongly recommended that a process should incorporate a LIMIT CONTROL which will shut down the equipment at a preset process condition in order preclude possible damage to products or system Information in this user s manual is subject to change without notice Copyright January 2005 Proheat Inc all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of Proheat Inc 2 UM60001A Cont
28. VAC 0 01 of SPAN LC 1A 240 VAC 20A for 1 cycle 50 mA rms 3 mA rms 1 5 V rms 1000 Mohms min at 500 VDC 2500 VAC for 1 minute UM60001A 55 DC Voltage Supply Characteristics Installed at Output 2 Type Tolerance 20V 12V 5V 0 5 V 0 3 V 0 15 V Alarm Alarm Relay Alarm Functions Isolation Barrier Form C Rating 2A 240VAC 200 000 cycles for resistive load Dwell timer PV High Low Alarm Deviation High Low Alarm Deviation Band High Low Alarm Alarm Mode Normal Latching Hold Latching Hold Dwell Timer 0 1 4553 6 minutes Data Communications Interface Protocol Address Baud Rate Data Bits Parity Bit Stop Bit Comm Buffer RS 232 1 unit RS 485 up to 247 units Modbus Protocol RTU mode 1 247 2 4 38 4 Kbits sec 7 or 8 bits None Even or Odd 1 or 2 bits 160 bytes Analog Retransmission Functions Output Signal Resolution Accuracy Load Resistance Regulation Settling Time Breakdown Volts Linearity Error Temp Effect Saturation Low Saturation High Output Range 56 Process Variable 4 20 mA 0 20 mA 0 5V 1 5V 0 10V 15 bits 0 05 of span 0 0025 C 0 500 ohms for current output 10 K ohms minimum for voltage output 0 01 96 for full load change 0 1 sec stable to 99 9 1000 VAC min 0 005 of span 0 0025 of span C 0 mA or OV 22 2 mA
29. al control mode occurs UM60001A 43 Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warm Start After the auto tuning procedures are completed the AT indicator will cease to flash and the unit revert to PID control by using its new PID values The PID values obtained are stored in the nonvolatile memory Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases e f PB exceeds 9000 9000 PU 900 0 F or 500 0 e or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t set zero value for PB and TI 4 Use manual tuning instead of auto tuning See section 3 12 5 Touch RESET key to reset message 3 12 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning If the control performance by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 44 UM60001A ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB 1 Proportional Band PB High overshoot or BB Oscillations Helene Slow Response Decrease TI 2 Integral Time
30. ameters which are most significant to your application These parameters are able to be put in the front of display sequence for ease of access SEL1 SEL8 Selects the parameter for view and change in the user menu Range LOCK INPT UNIT DP SHIF PB TI TD O1HY CYC1 OFST RR O2HY CYC2 CPB DB ADDR ALHY When using the up down key to select the parameters you may not obtain all of the above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are also deleted from the SEL selection 38 UM60001A Example OUT2 selects DE LO PB 100 0 SEL1 selects INPT SEL2 selects UNIT SEL3 selects PB SEL4 selects TI SEL5 SEL8 selects NONE Now the upper display scrolling becomes Sel 9 3 6 Ramp The ramping function is performed during power up as well as any time the set point is changed Choose MINR or HRR for RAMP the unit will perform the ramping function The ramp rate is programmed by adjusting RR The ramping function is disabled as soon as the failure mode the manual control mode the auto tuning mode or the calibration mode occurs Example without Dwell Timer Select MINR for RAMP selects C for UNIT selects 1 DP for DP Set RR 10 0 SV is set to 200 C initially and changed to 100 C after 30 minutes since power up The starting temperature is 30 C After power up the process is running like
31. by step manual procedures Since it needs 30 minutes to warm up an unit before calibration calibrating the unit one by one is quite inefficient An automatic calibration system for small quantity as well as for unlimited quantity is available Consult factory 48 UM60001A Manual Calibration Procedures Perform step 1 to enter calibration mode Step 1 Step 2 Step 3 Set the Lock parameter to the unlocked condition LOCK NONE Press and hold the scroll key until 2 4 appears on the display then release the scroll key Press the scroll key for 2 seconds then release the display will show AdL the unit enters calibration mode Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter Short the thermocouple inpt terminals then press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Press scroll key until the display shows HdH Send a 60 mV signal to the thermocouple input terminals in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform both steps 4 and 5 to calibrate RTD function if
32. d alarm 2 5 dhLa Deviation band in 6 muH value high alarm 7 Process value low 2 alarm 0 morn Normal alarm action 1 LEch Latching alarm ALMD _ Alarm operation mode action 0 2 Het d Hold alarm action 3 LEHo Latching amp Hold action ALHY Hysteresis control of Low 0 1 High 50 0 C 0 1C alarm ba 90 0 0 2 F 0 orm Alarm output ON as ALFT A failure transfer unit fails 0 mode 1 Alarm output OFF as OFF unit fails 0 monE communication Communication COMM function 1 r E u Modbus RTU mode 1 protocol 24 21 4 20mA eu PV Retransmission 71 0 20mA au e PV retransmission 0 5 0 40 5 7 PV Retransmission Cu 1 5VDC Toy 5 PV Retransmission me 0 10 VDC PV Retransmission 16 UM60001A Parameter infi Default Notation Parameter Description Range Value Address assignment of SEN ADDR digital communication Low 1 High 255 0 2 4 Kbits s baud rate 1 4 8 Kbits s baud rate 2 GE 9 6 Kbits s baud rate Baud rate of digital 3 14 4 Kbits s baud rate BAUD communication HH di PM 2 4 Hg 19 2 Kbits s baud rate 5 28 8 Kbits s baud rate 6 FAY 38 4 Kbits s baud rate 7 2 DATA Data bit count of digital 0 16 E 7 data bits 1 communication 1 L 8 data bits 0 E E n Even parity Parity bit of digital Odd parit PARI communication
33. data or a 14 E 1 to write a read only data or a protected data to the slave protected data Communication error write a Don t write an over range data 15 E 15 value which is out of range toa to the slave register 7 register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value as eee Fail to perform auto tuning during auto tuning procedure mee function 3 Use manual tuning instead of auto tuning 4 Don t set a zero value for PB 5 Don t set a zero value for 6 Touch RESET key 29 EEPROM can t be written correctly Return to factory for repair ic Cold junction compensation for 30 Jtr Er thermocouple malfunction Return to factory for repair Input sensor break or input current below 1 mA if 4 20 mA is 39 55tr selected or input voltage below Replace input sensor 0 25V if 1 5V is selected 40 HAE A to Diconverter or related Return to factory for repair component s malfunction UM60001A 59 Warranty Proheat Inc makes no warranty or representations of any sort regarding the fitness for use merchantability fitness for a particular purpose or the application of its products by the purchaser The selection application or use of Proheat Inc products is the purchaser s responsibility Proheat Inc products are warranted to be free from functional defects in material and workmansh
34. elected and four kinds of alarm modes ALMD are available for each alarm function ALFN Besides the alarm output the output 2 can also be configured as another alarm But output 2 only provides 4 kinds of alarm functions and only normal alarm mode is avaiable for this alarm A process alarm sets two absolute trigger levels When the process is higher than SP3 a process high alarm PV HI occurs and the alarm is off as the process is lower than SP3 ALHY When the process is lower than SP3 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP3 ALHY A process alarm is independent of set point A deviation alarm alerts the user when the process deviates too far from set point When the process is higher than SV SP3 a deviation high alarm DE HI occurs and the alarm is off as the process is lower than SV SP3 ALHY When the process is lower than SV SP3 a deviation low alarm DE LO occurs and the alarm is off as the process is higher than SV SP3 ALHY Trigger level of deviation alarm is moving with set point A deviation band alarm presets two trigger levels relative to set point The two trigger levels are SV SP3 and SV SP3 for alarm When the process is higher than SV SP3 or lower than SV SP3 deviation band high alarm DB HI occurs When the process is within the trigger levels a deviation band low alarm DB LO occurs In the above descriptions SV denotes the current set point
35. ent Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only IN To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture A Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 5 Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due to transit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of control Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout UM60001A 19 Figure 2 1 Mounting Dimensions
36. ents Page No Chapter 1 Overview 1 1 General 4 1 2 Ordering Code 7 1 3 Programming Port 8 1 4 Keys and Displays 9 1 5 Menu Overview 11 1 6 Parameter Descriptions 12 Chapter 2 Installation 2 1 Unpacking 19 2 2 Mounting _ 19 2 3 Wiring precautions 21 2 4 Power Wiring 24 2 5 Sensor Installation Guidelines 24 2 6 Sensor Input Wiring 25 2 7 Control Output Wiring 25 2 8 Alarm Wiring 28 2 9 Process Retransmission 28 2 10 Data Communications 29 Chapter 3 Programming 3 1 Lockout 31 3 2 Signal Input 31 3 3 Control Outputs 32 3 4 Alarm 37 3 5 Configure User Menu 48 3 6 Ramp 49 3 7 Dwell Timer 40 3 8 PV Shift 41 3 9 Digital Filter 41 3 10 Failure Transfer 42 3 11 Auto tuning 43 3 12 Manual tuning 44 3 13 Manual Control 45 3 14 Data communication 47 3 15 Retransmission 47 UM60001A Page No Chapter 4 Calibration Chapter 5 Specifications 53 Appendix A 1 Error Codes 59 A 2 Warranty 60
37. f 4 20 mA is selected or input voltage below 0 25V if 1 5 V is selected 2 ADER occurs due to the A D converter of the controller fails The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode Output 1 Failure Transfer if activated will perform 1 If output 1 is configured as proportional control PB70 and BPLS is selected for O1FT then output 1 will perform bumpless transfer Thereafter the previous averaging value of MV1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB70 and a value of 0 to 100 0 is set for O1FT then output 1 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 1 3 If output 1 is configured as ON OFF control PB 0 then output 1 will transfer to off state if OFF is set for OTFT and transfer to on state if ON is set for OTFT Output 2 Failure Transfer if activated will perform 1 If OUT2 is configured as COOL and BPLS is selected for O2FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 is configured as COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O2FT will be used for controlling output 2 3 If OUT2 is configured as alarm function and OFF is set for O2FT then output 2 will transfer t
38. g Moldings Flame retardant polycarbonate Dimensions 4000 Series 96mm W X 96mm H X 65mm D 53 mm depth behind panel 6000 Series 48mm W X 48mm H X 116mm D 105 mm depth behind panel 8000 Series 48mm W X 96mm H X 80mm D 65 mm depth behind panel Weight 4000 Series 250 grams 6000 Series 150 grams 8000 Series 210 grams Agency Approvals UL Pending CSA Pending Protective Class 65 for panel with additional option IP50 for panel without additional option 1 20 for terminals and housing with protective cover EMC EN61326 58 UM60001A Table A 1 Error Codes and Corrective Actions Displ Syrnbol Error Description Corrective Action lllegal setup values been used Check and correct setup values of Before COOL is used for OUT2 OUT2 PB TI and OUT1 IF OUT2 DIRT cooling action has is required for cooling control the alreadybeen used for OUT1 control should use PID mode PB 4 E nul PID mode is not used for OUT1 5 0 TI 2 0 and OUT1 should t thatisPB 0 and orTI 20 rev rse mode heating action otherwise don t use OUT2 for cooling control Communication error bad Correct the communication 10 1 1 function code software to meet the protocol B B requirements o Communication error register Don t issue an over range 11 Er 1 f address out of range register address to the slave Communication error attempt Don t write a read only
39. hout the need to access the keys on front panel By using proprietary Fuzzy modified PID technology the control loop will minimize the overshoot and undershoot in a shortest time The following diagram is a comparison of results with and without Fuzzy technology 4 UM60001A PID control with properly tuned PID Fuzzy control Temperature Set point Figure 1 1 Fuzzy Control Advantage Warm Up Disturbance Time High Accuracy This Series controllers are manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1 F resolution for thermocouple and PT100 and a 15 bit D to A converter for linear current or voltage control output The ASIC technology provides improved operating performance low cost enhanced reliability and higher density Fast Sampling Rate The sampling rate of the input A to D converter reaches 5 times second The fast sampling rate allows this series to control fast processes Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes The results is to enable a process to reach a predetermined set point in the shortest time with the minimum of overshoot and undershoot during power up or external load disturbance Digital Communication The u
40. ip for two years after delivery to the first purchaser for use Proheat Inc s sole responsibility under the warranty at Proheat Inc s option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse No claims will be allowed for any damages or losses whether direct indirect incidental special or consequential Specifications are subject to change without notice In addition Proheat Inc reserves the right to make changes without notification to purchaser to materials or processing that do not affect compliance with any applicable specifications There are no expressed or implied warranties extending beyond the warranty herein and above set forth RETURN MATERIAL AUTHORIZATION Please contact Proheat Inc for Return Material Authorization Number prior to returning to factory Proheat Inc 117 EastAdam Street LaGrange KY 40031 Main Office Phone 502 222 1402 Fax 502222 0714 Technical Support Phone 800 626 2142 www proheatinc com E mail sales proheat net 60 UM60001A
41. ld be setup as RELO 0 for 4 ma equals 0 F 200 for 20 ma equals 200 F This output would typically go to a recorder PLC indicator etc UM60001A AT Chapter 4 Calibration Do not proceed through this section unless there is a definite need to re calibrate the controller Otherwise all previous calibration data will be lost Do not attempt recalibration unless you have appropriate calibration equipment If calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to re calibrate the controller A Entering calibration mode will break the control loop Verify that the system is acceptable to apply calibration mode Equipments needed before calibration 1 Ahigh accuracy calibrator Fluke 5520A Calibrator recommended with following functions 0 100 mV millivolt source with 0 005 accuracy 0 10 V voltage source with 0 005 accuracy 0 20 mA current source with 0 005 accuracy 0 300 ohm resistant source with 0 005 96 accuracy 2 Atest chamber providing 25 C 50 C temperature range 3 A switching network SWU16K optional for automatic calibration 4 Acalibration fixture equipped with programming units optional for automatic calibration 5 APC installed with calibration software FDC Net and Smart Network Adaptor SNA10B optional for automatic calibration The calibration procedures described in the following section are a step
42. nder calibration is powered in a still air room with temperature 25 3 C Stay at least 20 minutes for warming up Perform step 1 stated above then press scroll key until the display shows Press up down key to obtain 40 00 Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 5 00 or 40 00 then the calibration fails Perform step 7 to calibrate gain of cold junction compensation if required Setup the equipments same as step 6 The unit under calibration is powered in a still air room with temperature 50 3 C Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode UM60001A 51 Perform step 1 stated above then press scroll key until the display shows Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails This setup is performed in a high temperature chamber hence itis recommended to use a computer to perform the procedures Input modification and recalibration procedures for a linear voltage or a linear current input Remove R60 3 3K and install two 1 4 W resistors RA and RB on the control board with the recommended values specified in the following table
43. nits are equipped with RS 485 or RS 232 interface card to provide digital communication By using the twisted pair wires there are at most 247 units can be connected together via RS 485 interface to a host computer UM60001A 5 Programming Port A programming port is used to connect the unit to a hand held programmer or a PC for quick configuration also can be connected to an ATE system for automatic testing amp calibration Auto tune The auto tune function allows the user to simplify initial setup for a new system A clever algorithm is provided to obtain an optimal set of control parameters for the process and it can be applied either as the process is warming up cold start or as the process has been in steady state warm start Lockout Protection According to actual security requirement one of four lockout levels can be selected to prevent the unit from being changed abnormally Bumpless Transfer Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks Hence the process can be well controlled temporarily as if the sensor is normal Soft start Ramp The ramping function is performed during power up as well as any time the set point is changed It can be ramping up or ramping down The process value will reach the set point with a predetermined constant rate Digital Filter A first order low pass filter with a programmable time constant is used to improve
44. nt of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of PB Anegative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither output is active Output 2 ON OFF Control Alarm function The output 2 can also be configured as alarm function There are 4 kinds of alarm functions can be selected for output 2 these are DE HI deviation high alarm DE LO deviation low alarm PV HI process high alarm and PV LO process low alarm Refer to Figure 3 3 and Figure 3 4 for the description of deviation alarm and process alarm UM60001A 35 PV OUT2 DE HI SV SP2 SV SP2 O2HY OUT2 Action Time e e n n m _ Figure 3 3 Output 2 Deviation Time High Alarm PV SP2 O2HY SP2 OUT2 Action Figure 3 4 Output 2 Process Time Low Alarm 36 UM60001A 3 4 Alarm The controller has one alarm output There are 6 types of alarm functions and one dwell timer can be s
45. o off state otherwise output 2 will transfer to on state if ON is set for O2FT Alarm Failure Transfer is activated as the controller enters failure mode Thereafter the alarm will transfer to the ON or OFF state which is determined by the set value of ALFT 42 UM60001A 3 11 Auto tuning The auto tuning process is performed at set point The process will oscillate around the set point during tuning process Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of Initial setup for a new process The set point is changed substantially from the previous auto tuning value control result is unsatisfactory Operation 1 The system has been installed normally 2 Set the correct values for the setup menu of the unit But don t use a zero value for PB and TI otherwise the auto tuning program will be disabled The LOCK parameter should be set at NONE 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press and hold until appears on the display 5 Press for at least 3 seconds The AT indicator will begin to flash and the auto tuning procedure is beginning NOTE The ramping function if used will be disabled once auto tuning is proceeding The auto tuning mode is disabled as soon as either failure mode or manu
46. ol for the Heat Cool control to produce a stable and zero offset process value Other Setup Required O1TY CYC1 O2TY CYC2 O1FT O2FT O1TY amp O2TY are set in accordance with the types of OUT1 amp OUT2 installed CYC1 amp CYC2 are selected according to the output 1 type O1TY amp output 2 type O2TY Generally selects 0 5 2 sec for CYC1 if SSRD or SSR is used for O1TY 10 20 sec if relay is used for O1TY and is ignored if linear output is used Similar condition is applied for CYC2 selection 34 UM60001A You can use the auto tuning program for the new process or directly set the appropriate values for PB TI amp TD according to the historical records for the repeated systems If the control behavior is still inadequate then use manual tuning to improve the control See section 3 12 for manual tuning CPB Programming The cooling proportional band is measured by 96 of PB with range 50 300 Initially set 10096 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of CPB is related to the cooling media used For air is used as cooling media adjust CPB at 100 For oil is used as cooling media adjust CPB at 125 For water is used as cooling media adjust CPB at 250 DB Programming Adjustme
47. using the PV shift function The SHIF function will alter PV only Example If process variable is reading a value of 195 degrees and needs to match another indicator reading 200 The value of 5 can be installed in the SHIFT parameter This will now ADD a 5 degree value to current reading allowing controller to read 200 degrees A negative value can also be used to subtract from controller current reading 3 9 Digital Filter In certain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from 0 to 60 seconds 0 second represents no filter is applied to the input signal The filter is characterized by the following diagram PV FILT 0 1 sec FILT 30 1 sec Time Figure 3 8 Filter Characteristics Note The Filter is available only for PV and is performed for the displayed value only The controller is designed to use unfiltered signal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process UM60001A 41 3 10 Failure Transfer The controller will enter failure mode as one of the following conditions occurs 1 SBER occurs due to the input sensor break or input current below 1mA i
48. ypes of interface are available for Data Communication These are RS 485 and RS 232 interface Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS 232 RS 485 is less sensitive to the noise and suitable for a longer distance communication RS 485 can communicate without error over 1 km distance while RS 232 is not recommended for a distance over 20 meters Using a PC for data communication is the most economic way The signal is transmitted and received through the PC communication Port generally RS 232 Since a standard PC can t support RS 485 port a network adaptor such as SNA10A has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication Multiple RS 485 units up to 247 units can be connected to one RS 232 port Setup Enters the setup menu Select RTU for COMM Set individual address as for those units which are connected to the same port Set the Baud Rate BAUD Data Bit DATA Parity Bit PARI and Stop Bit STOP such that these values are accordant with PC setup conditions 3 15 Process Retransmission The controllers support a optional ma VDC output retransmit of the process variable The program parameters to scale the ma VDC signal are RELO and REHI respectively for low and high scale For example using a 4 20 ma retransmission option to represent a temperature of 0 200 F unit wou
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