C Series Manual - Future Design Controls
Contents
1. P action PB too high Time F TI too high Set point action Perfect TI too low Time PV TD too low 1 Perfect Set point TD too high Time Figure 3 9 Effects of PID Adjustment 46 UMOC911A 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 types 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 Bit2. 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 moy be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded UMOC911A 3 2mm min 7 OMM max 15 7 2 0mm 0 08 max X 4 5 7 0 mm Figure 2 2 Lead Termination for C91 Figure 2 3 Lead Termination for C21 0 18 0 27 OP2 OP FAL dios g DO DO aS D L N Lo 90 250 VAC 24 240 VAC 2 240 VAC 47 63 Hz 10VA V mA V mA RE RE IC TC kl 1X2 PTA gt PTB COM TXD RXD O O 40 2 O 4 485 RS 232 n Figure 2 4 Rear Terminal Connection for C21 90 250 VAC 47 63Hz V 10VA Figure 2 5 Rear Terminal Connection for C91 22 UMOC911A 2 4 Power Wiring 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 C21 C91 Fuse L 6 ova 90 250 VAC or N 2 1
3. 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 would be setup as RELO O for 4 ma equals 0 F REHI 200 for 20 ma equals 200 F This output would typically go to a recorder PLC indicator etc UMOC911A 47 Chapter 5 Calibration A 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 lf 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 Make sure that if the system is allowable to apply calibration mode Equipments needed before calibration 1 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functions O 100 mV millivolf source with 0 005 accuracy O 10 V voltage source with 0 005 accuracy O 20 mA current source with 0 005 accuracy O 300 ohm resistant source with 0 005 accuracy 2 A test chamber providi
4. SV 1 5V 4 20 MA 0 20 MA 0 10V Special Order utput 1 None Relay rated 2A 240VAC Pulsed voltage to drive SSR 5V 30mA Isolated 4 20mA 20mA Isolated 1 5V 0 5V Isolated O 10V Triac output 1A 240VAC SSR C Pulsed voltage to drive SSR 14V 40mA 9 Special order N 0 0 PONO RWN O O1 S C UMOC911A 1 L o Display Color O Red color 1 Green color Communications None RS 485 interface for C21 RS 232 interface for C21 Retransmit 4 20 0 20 ma for C21 Retransmit 1 5V 0 5V for C21 5 Retransmit 0 10V for C21 9 Special order R OD Output 2 None Form A relay 2A 240VAC Pulsed voltage to drive SSR 5V 30mA Isolated 4 20mA 20mA Isolated 1 5V 5V Isolated O 10V Triac output 1A 240VAC SSR Isolated 20V 25mA transducer power supply Isolated 12V 40mA transducer power supply Isolated 5V 80mA transducer power supply A RS 485 interface for C91 C Pulsed voltage to drive SSR 14V 40mA B Special order NO OT AO N O 1 3 Programming Port Front Panel Access Hole Rear b Terminal C21 control board pin 1 Programming Port A HE Power board Top view of C91 with housing removed Figure 1 2 Programming Port Overview A special connector can be used to touch t
5. The unit under calibration is powered in a still air room with temperature 25A3 BC Stay at least 20 minutes for warming up Perform step 1 stated above then press scroll key until the display shows E JL a Press up down key to obtain 40 00 Press scroll key for at least 3 seconds The display will blink a moment anda 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 x Perform step 7 to calibrate gain of cold junction compensation if required Step 7 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 51 UMOC911A 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 it is recommended to use a Computer to perform the procedures Input modification and recalibration procedures for a linear voltage or a linear current input 1 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
6. UMOC9TIA 35 3 4 Alarm The output 2 can be selected as alarm output There are 6 types of alarm functions and one dwell timer can be selected and four kinds of alarm modes ALMD are available for each alarm function A process alarm sets two absolute trigger levels When the process is higher than SP2 a process high alarm PV HI occurs and the alarm is off as the process is lower than SP2 O2HY When the process is lower than SP2 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP2 O2HY 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 SP2 a deviation high alarm DE HI occurs and the alarm is off as the process is lower than SV SP2 02HY When the process is lower than SV SP2 a deviation low alarm DE LO occurs and the alarm is off as the process is higher than SV P2 O2HY 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 SP2 and SV SP2 for alarm When the process is higher than SV SP2 or lower than SV SP2 a 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 value for control which is different from SP1 as the
7. the 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 UMOC9TIA 3 7 Dwell Timer Output 2 can be configured as dwell timer by selecting TIMR for OUT2 As the dwell timer is configured the parameter SP2 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 Time E Spa power off or touch RESET key ALM Timer starts Figure 3 6 Dwell Timer Function If output 2 is configured as dwell timer ALMD will be hidden 39 UMOC911A 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 using the PV shift function The SHIF function will alter PV only Here is an example A process is equipped with a heate
8. EC EC 2 k l c k l c k C k C 20 o c 2 2 k EC 2 EC EC k l 4 2 sec GI el El z AJ 000 0000000000 0000000 0000000000 00000000 00060 UMOC911A 5 4 sec CAL 2 SEC Presse for 3 seconds to perform calibration A Apply these modes will x N Value break the control loop and change some of the previous setting data Make sure that if the system is allowable to apply these modes The flow chart shows a complete listing of all parameters For actual application the number of available parameters depends on setup conditions and should be less than that shown in the flow chart Release 2 press again for 2 seconds or longer but not longer than 3 seconds then release to enter the calibration menu 1 6 Parameter Descriptions Default Parameter Parameter Description Range YUS Set point for output 1 Low SPIL High SP1H Set point for output 2 when output 2 performs Low 19999 High 45536 alarm function or dwell timer No parameter is locked Setup data are Select parameters to be locked locked Setup data and User data except Set point are locked All data ar
9. Low 0 High 100 0 25 0 UMOCO11A Parameter Notation Parameter Description Range Default Value nonE No Ramp Function Ramp function 1 RAMP selection nenE bi Ar a EH dELo ohh So m6 OUT2 Output 2 function 5 dbia 6 PYH 8 Lool n ft 2 Heer Use unif minufe as Ramp Rate Use unit hour as Ramp Rate 500 0 C High 900 0 F Output 2 No Function Dwell timer action Deviation High Alarm Deviation Low Alarm Deviation band out of band Alarm Deviation band in band Alarm Process High Alarm Process Low Alarm Cooling PID Function 0 0 O2TY Output 2 signal type Relay output Solid state relay drive output Solid state relay output 4 20 mA current module O 20 mA current module 0 1V voltage module O 5V voltage module 1 5V voltage module O 10V voltage module O2FT Output 2 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 to continue output 2 control function as the unit fails or select ON 0 or OFF 1 for alarm and dwell timer function UMOC91 1A Parameter Notation Parameter Description Range Output 2 hysteresis value when output 2 performs alarm function Low 0 1 Default Value 0 1 C 0 2 F 50 0 C High 90 0 F Output 2 cycle time Low 0 1 High 90 0 sec 18 0 Cooling proportional band
10. SP1 for DISP in the normal condition Examples If LOCK is set with NONE OUT2 is set with DEHI DISP is set with PV set SEL SHIF 5 12 SEL3 PB SEL4 SEL8 NONE then the display for C21 becomes sp yk sro E H E Sm Gr If LOCK is set with NONE OUTI is set with REVR nonzero value is set for PB and Tl OUT2 is set with COOL DISP is set with SP1 set SEL1 INPT SEL2 PB 5613 1 SEL4 SEL8 NONE then the display scrolling for C21 becomes SP1 PE HE H E a pa LU Fb ara 37 UMOC911A Example for C91 Set OUT2 PVLO LOCK NONE SEL1 INPT SEL2 UNIT SEL3 DP SEL4 SEL8 NONE then the display scrolling for C91 becomes HER Fs je 1 2 S an Ga fra 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 LC for UNIT selects 1 DP for DP Set RR 10 0 SV is set to 200 LC initially and changed to 100 LC after 30 minutes since power up The starting temperature is 30 LC After power up the process is running like the curve shown below Figure 3 5 RAMP Function minutes Note When the ramp function is used
11. anti vibration antiseptic etc Standard sensor limits of error are 4 degrees F 2 degrees C 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 and replacement 2 6 Sensor Input Wiring C21 91 PTA PTB MA 9 POD B Pa ma 10 15 Jat TC V mA RID Figure 2 8 Sensor Input Wiring 2 7 Control Output Wiring C21 C91 Po 120V 240VAC o El El Mdins Supply Figure 2 9 Output 1 Relay or Triac SSR to Drive Load 24 UMOC911A C21 C91 F or 120V 240V 6 Mains Supply F 30mA 5V 5V Pulsed Voltage 33 I I 33 i vv 1 OV L 4 Figure 2 11 Output 1 Pulsed Voltage to Drive SSR C21 C91 O 20mA DD loaa Maximum Load 6 9 4 20mA EI 500 ohms Figure 2 12 Output 1 Linear Current C21 C91 O 1V 0 5V Load Minimum Load 9 1 5V 0 10V 10 K ohms Figure 2 13 Output 1 Linear Voltage C21 C91 R 120V 240VAC 14 Mains Supply Figure 2 14 Output 2 Relay or Triac SSR fo Drive Load 25 UMOC911A C21 C91 T l E al 16 120V 240V Mains Supply ozu z TED q 30mA 5V 5V Pulsed Voltage 33 EE I 33 i nN um ayn Figure 2 16 Output 2 Pulsed Voltage to Drive SSR C21 C91 F O 20mA Load Maximum Load 4 2
12. parameter during the calibration procedure Press for 4 2 seconds to select calibration mode UMOC911A Output 2 Indicator Output 1 Indicator Deviation Indicator Output 1 Indicator Output 2 ma Indicator Process Unit Indicator Auto tuning Indicator Manual Mode Indicator 3 Silicone Rubber Buttons 4 Buttons for ease of for ease of control setup control setup and and set point adjustment set point adjustment Figure 1 3 Front Panel Description Table 1 1 Display Form of Characters A R E E IT IN In s _ Blaft F U OTolT E Y M 2 ice ic H H L L Q Did hiR M A R V r Confused Character OP1 OP2 Display program code of the product o0 go for 2 5 seconds a l LI m The left diagram shovvs program no 34 V 2 L LI for C91 vvith version 16 The program no for C21 is 33 PV SPT SP2 MAN AT lal Ly tr C91 Display of Initial Stage Figure 1 4 UMOC911A 1 5 Menu Overview User menu 1 Setup menu 1 Calibration Moda N 11 3 sec dy User Menu 1 575 5 v so r es Mode Fat 3880 ee s 3566 Mode Auto tuning 3 ses Mode k l C 2 E cC EC EC 2 EC 2 EC 2 EC 2 k l k l c 22 22 c EC 22 2 EC 2 EC
13. to factory for repair Cold junction compensation for Belum to taclo f rte alr thermocouple malfunction y p Input sensor break or input current below 1 mA if 4 20 mA is 39 selected or input voltage below REPIacE 0 25V if 1 5V is selected A to D converter or related 40 Bag componenftis malfunction Return to factory for repair UMOC911A z Warranty Future Design Controls warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or use of Future Design products is the Purchaser s responsibility 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 Future Design reserves the right to make changes without notification to Purchaser to materials or processing that do not affect compliance with any applicable specification Future Design products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use An extended period is available with extra cost upon request Future Design s sole responsibility under this warranty at Future Design 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 transporta
14. 0mA 500 ohms Figure 2 17 Output 2 Linear Current C21 C91 7 1 5V 0 10V 10 K ohms Figure 2 18 Output 2 Linear Voltage 2 6 Alarm Wiring C21 C91 m E Ar ary ains Supply Figure 2 19 Alarm Output to Drive Load 26 UMOC911A 2 9 Data Communication RS 485 to RS 232 C21 C91 network adaptor x SNAIOA or SNATOB RS 232 PC Twisted Pair Wire C21 491 1 112 TX2 13 Mox 247 units can be linked C21 C91 T 112 1X2 13 Figure 2 21 RS 485 Wiring Terminator 220 ohms 0 5W 27 UMOC911A RS 232 CC94 1 Figure 2 22 RS 232 Wiring If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable Must be modified according to the following circuit diagram To DTE PC RS 232 Port 1 DCD 2 RD 3 TD 4 DIR 5 GND 6 DSR 7 RIS 8 CTS Female DB 9 ORI Figure 2 23 Configuration of RS 232 Cable UMOCO11A 2 10 Process Retransmission C21 Only C21 we 0 20mA i Load Maximum Load C21 57 0 1V 0 5V Minimum Load RE 1 5V 0 ov G 10 ohms Figure 2 24 Process Retransmission UMOCO11A 29 Chapter 3 Programming Press for 3 seconds and release to enter setup menu Press to select the desired parameter The display indicates the parameter symbol Press 4 orlv to view or adjust the value of the selected parameter 3 1 Lockout There are four security levels can be selected by using LOCK parameter If NONE is selected for LO
15. 1 26 VAC VDC Figure 2 7 Power Supply Connections A 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 Consideration should be given to prevent from unauthorized person access to the power terminals 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system The probe should be placed so that if 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 UMOC911A 23 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
16. 1 6 Parameter Descriptions 12 Appendix A 1 Error Codes 59 A 2 Warranty 60 Chapter 2 Installation 2 1 Unpacking 19 2 2 Mounting 19 2 3 Wiring precautions 2 2 4 Power Wiring 23 2 5 Sensor Installation Guidelines 23 2 6 Sensor Input Wiring 24 2 7 Control Output Wiring 24 2 8 Alarm Wiring 26 2 9 Data Communication 27 2 10 Process Retransmission 29 Chapter 3 Programming 3 1 Lockout 30 3 2 Signal Input 30 3 3 Control Outputs 31 3 4 Alarm 36 3 5 Configure Display 37 3 6 RAMP 38 3 7 Dwell Timer 39 3 8 PV Shift 40 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 PV Retransmission 47 UMOC911A 3 Chapter 1 Overview 1 1 General The Fuzzy Logic plus PID microprocessor based controller series incorporate a bright easy to read 4 digit LED display indicating process value or set point value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest t
17. 5536 No parameter selected LOCK is put ahead INPT is put ahead UNIT is put ahead DP is put ahead SHIF is put ahead PB is put ahead Tl is put ahead TD is put ahead OTHY is put ahead CYC1 is put ahead OFST is put ahead RR is put ahead 2 is put ahead CYC2 is put ahead CPB is put ahead DB is put ahead ADDR is put ahead 100 0 C 212 0 F Parameter Default Notation Value 12 Select 6 th parameter for user Menu Parameter Description Range Same as SEL Select 7 th parameter for user menu Same as SEL Select 8 th parameter for user menu SEL8 same as SEL UMOC911A Chapter 2 Installation A Dangerous voltages capable of causing death are sometimes present in this instrument 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 service person only A 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 temper
18. 800 C 32F 3272F 0 C 1767 8 C Brae 0 C 1767 8 C 32BF 3214F 2 22 0 250 C 1300 C 2002 ET 3289F 1652 F 2C 2 2 MQ PT100 210 C 700 C DIN 346 F 1292F 7046 r 00 2009C 600 C 828 F Tivoey 4086 oa zama ee Tee UMOC911A Output 1 Output 2 Relay Rating 2A 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage SV current limiting resistance 66 Q Linear Output Characteristics Zero Span 4 20 mA 3 8 4 mA 20 21 mA 0 20 mA 20 21 mA 095 V 6 525V Linear Output Resolution 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 UMOCO11A Load Capacity 500 max 500 max 10K min 10K min 10K min 1 5Bits 0 02 for full load change 0 1 sec stable to 99 9 1000 VAC 0 01 of SPAN LC TA 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 55 DC Voltage Supply Characteristics Installed at Output 2 Max Output Ripple 1 Isolation Output 2 Function Relay Form A Relay N O Contact 2A 240VAC 200 000 cycles for resistive load Functions PID Cool Dwell timer PV High Low A
19. CK 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 Signal Input INPT Selects the sensor type or signal type for signal input Range thermocouple J K T E B R S N L RTD PT DN PT JS linear 4 20ma 0 20ma 0 60Mv 0 1 O 5V 1 5V 0 10 UNIT Selects the process unit Range LC LF PU process unit If the unit is neither LC nor LF then selects PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 for linear NO DP 1 DP 2 DP 3 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 If 4 20 mA is selected for INPT let 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 UMOC911A process value INHI Figure 3 1 PV Conversion Curve for INLO Linear Type Process Value input signal S SL Formula PV INLO INHI INLO SH SL Example A 4 20 mA current loop pressure transducer with range 0 15 kg cm is connected to in
20. EMC EN61326 58 UMOC911A Table A 1 Error Codes and Corrective Actions Displa nur Sabo Error Description Corrective Action Illegal setup values been used Check and correct setup values of Before COOL is used for OUT2 OUT2 PB Tl and OUT1 IF OUT2 DIRT cooling action has already is required for cooling control the been used for OUTI or PID mode control should use PID mode PB 4 is not used for OUT1 that is PB 0 TI 0 and OUT1 should use reverse mode heating action otherwise don t use OUT2 for cooling control Communication error bad Correct the communication 10 function code software to meet the protocol requirements Communication error register Don t issue an over range 1 address out of range register address to the slave Communication error attempt 1 Don t write a read only data or a 14 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 value which is out of range to a to the slave register register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value 26 Fail to perform auto tuning during auto tuning procedure 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 Tl 6 Push RESET key to cancel E E EE EEPROM can t be written correctly Return
21. User s Manual FDC C21 C91 Auto Tune Fuzzy PID Process Temperature Controller q FuTUREDESIGN N T R OL Warning Symbol A 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 e Installers Read Chapter 1 2 e System Designer Read All Chapters e User Read Page 13 NOTE It is strongly recommended that a process should incorporate a LIMIT CONTROL like the FDC L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this user s manual is subject to change without notice Copyright February 2004 Future Design Controls 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 Future Design Controls UMOC911A Contents Page No Page No Chapter Levelview Chapter 5 Calibration 48 1 1 General 4 1 2 Ordering Code 7 1 3 Programming Port 8 ifjagti M Ee and Dam 9 Chapter 6 Specifications 49 1 5 Menu Overview 1
22. ature of the areas should not exceed the maximum rating specified in Chapter 6 2 1 Unpacking 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 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take the mounting clamp away and insert the controller into panel cutout Install the mounting clamp back UMOC911A Figure 2 1 Mounting Dimensions 2 2 2 45mm MOUNTING A CLAMP 1 77 2 2 i 22 2mm 875 21 2 y 2 j 5 T Panel 49 1 3 5 12 5mm 39 98 0mm 10 0mm 45mm Z F 2 2 E ER O 5 5 C91 2 2 91 Cutout Panel 86 mm uU 3 38 3 70 94 mm 2 UMOC911A 2 3 Wiring Precautions x Before wiring verify the label for correct model number and options Switch off the power while checking x Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded x It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible
23. 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 UMOCO11A ADJUSTMENT SEQUENCE SYMPTOM SOLUTION High overshoot or Oscillations 1 Proportional Band PB Increase PB Slow Response Decrease Tl 2 Integral Time TI indented Oscillations Increase TI Slow Response or 3 Derivative Time TD Oscillations Decrease 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 for several times then Heating output or Cooling output will appear on the display Press for 3 seconds then the MAN indicator for C91 and C92 or the display for C21 will begin to flash The controller now enters the manual control mode H _ indicates output control variable for output 1 and 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 To press key the controller will revert to its normal display mode 45 UMOC911A PV PB too low Perfect Sef poini
24. d 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 control for the Heat Cool control to produce a stable and zero offset process value Other Setup Required O1TY CYC1 O2TY CYC2 O1FT O2FT 1 amp O2TY are set in accordance with the types of OUT amp OUT2 installed CYCI amp CYC2 are selected according to the output 1 type OTTY 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 OITY and CYC1 is ignored if linear output is used Similar condition is applied for CYC2 selection 33 UMOC9TIA You can use the auto tuning program for the new process or directly set the appropriate values for PB Tl 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 of PB with range 50 300 Initially set 100 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 adj
25. e locked J type thermocouple K type thermocouple T type thermocouple E type thermocouple B type thermocouple R type thermocouple S type thermocouple m m 1 m 1 rr mn F 1 In N type thermocouple 8 LE Ltype thermocouple Input sensor selection Fk PT 100 ohms DIN curve 10 PE 75 PT 100 ohms JIS curve zili 4 20 mA linear current input 20 mA linear current input Linear INPUT Li 0 60 mV linear millivolt input MUST BE Special m O IV linear voltage Ordered i 0 5V linear voltage see matrix 7 input input O 10V linear voltage input UMOC911A Parameter ti Default Notation Parameter Description Range Degree C unit Input unit selection Decimal point selection Degree F unit Process unit No decimal point 1 decimal digit 2 decimal digits 3 decimal digits Input low sale value Low 19999 High 45486 6 A 93 3 C Input high scale value Low INLO 50 High 45536 200 0 F Low limit of set point value LOW 19999 High 45536 17 8 C O F SPIL SP1H SHIF PV shift offset value Low 0 De FILT High limit of set point value Filter damping time constant of PV Low SPIL C F High 45536 200 0 C High 360 0 F second time constant 0 2 second time UMOC911A constant 0 5 second time con
26. following table The low temperature coefficient resistors should be used for RA and RB 2 Perform Step 1 and Step 2 to calibrate the linear input zero 3 Perform Step 3 but send a span signal to the input terminals instead of 60MV The span signal is 1V for O 1V input 5V for O 5V or 1 5V input 10V for O 10V input and 20mA for 0 20mA or 4 20MA input Final step Step 8 Set the LOCK value to your desired function 52 UMOC911A Chapter 6 Specifications Power 90 250 VAC 47 63 Hz 10VA SW maximum 11 26 VAC VDC 10VA SW 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 C for all inputs except MA input 3 0UV C for M input Sensor 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 nA Common Mode Rejection Ratio CMRR 120dB Normal Mode Rejection Ratio NMRR 55dB sensor Break Detection Sensor open for TC RTD and MV inputs Sensor short for RTD input below 1 M for 4 20 M 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 UMOC911A 53 Characteristics cian ss Fe Heg 0 C 1
27. 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 the stability of process value This is particularly useful in certain application where the process value is too unstable to be read UMOC911A 1 2 Ordering Code c21 0 1 C91 Power Input 4 90 250 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input 1 Standard Input Thermocouple J K T E B RS NL RTD PT100 DIN PTI OO JIS 60 MA 0 1V
28. he 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 Don t attempt to make any connection to these pins when the unit is used for a normal control purpose UMOC911A 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY This key is used to increase the value of selected parameter DOWN KEY This key is used TO decrease the value of selected parameter RESET KEY press LR for C91 press a LY for C21 This key is used to 1 Revert the display to display the process value or set point value if DISP is set with SP1 for C21 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and calibration mode 4 Clear the message of communication error and auto tuning error 5 Restart the dwell timer wnen the dwell timer has been time out 6 Enter the manual control menu during failure mode occurs ENTER KEY Press for 3 seconds or longer Press for 3 seconds to 1 Ener setup menu The display shows 2 Enter manual control mode during manual control mode or is selected 3 Enter auto tuning mode during auto tuning mode AT for C91 Or for C21 is selected 4 Perform calibration to a selected
29. igure 1 1 Fuzzy Control Advantage Warm Up Load Disturbance Time High Accuracy The series 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 units 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 UMOC9TIA 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
30. ime with the minimum of overshoot during power up Or external load disturbance C21 isa 1 32 DIN size panel mount controller C91 is a 1 16 DIN size panel mount controller These units are powered by 11 26 or 90 250 VDC VAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control an alarm or dwell timer Both outputs can select triac SV 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 second output The units are fully programmable for PT100 and thermocouple types J K T E B R S N 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 allows the unit to control fast processes Digital communications RS 485 or RS 232 for C21 C91 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 without 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 UMOC911A PID control with properly tuned PID Fuzzy control Temperature Set point F
31. ized by the following diagram PV FILT 30 1 sec 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 41 UMOC911A 3 10 Failure Transfer The controller will enter failure mode as one of the following conditions OCCUIS 1 SBER occurs due to the input sensor break or input current below 1mA if 4 20 M 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 PB 6 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 If output 1 is configured as proportional control PB 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 If output 1 is configured as ON OFF control PB 0 then output 1 will transfer to off state if OFF is set for O1FT and transfer to on s
32. larm 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 RS 232 1 unit RS 485 up to 247 units Protocol Modbus Protocol RTU mode Address 1 247 Baud Rate 2 4 38 4 Kbits sec Data Bits 7 or 8 bits Parity Bit None Even or Odd Stop Bit 1 or 2 bits Comm Buffer 160 bytes Analog Retransmission Model C21 ONLY Functions Process Variable Output Signal 4 20 mA 0 20 mA 5V 1 5V 10V Resolution 15 bits Accuracy 0 05 of span 0 0025 C Load Resistance Regulation Settling Time Breakdown Volts Linearity Error Temp Effect Saturation Low saturation High Output Range 56 O 500 ohms for current output 10 K ohms minimum for voltage output 0 01 for full load change 0 1 sec stable to 99 9 1000 VAC min 0 005 of span 0 0025 of span C O mA or OV 22 2 mA or 5 55V 11 1V min 0 22 2mA 0 20mA or 4 20mA 0 5 55V 0 SV 1 5V 0 11 1V 0 10V UMOCO11A 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 Ramping Control Digital Filter Function Time Constant single 4 digit LED Displays 4 keys for C91 3 keys for C21 For automatic setup calibratio
33. n 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 P band 0 O 100 0 offset adjustment Fuzzy logic modified Proportional band 0 1 900 0 F Integral time 0 1000 seconds Derivative time O 360 0 seconds 0 1 90 0 seconds Heat MV1 and Cool MV2 Cold start and warm start Auto transfer to manual mode while sensor break or A D converter damage O 900 0 F minute or O 900 0 F hour ramp rate First order 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UMOC911A 57 Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity O to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strength 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m s for 2 hours shock Resistance 200 m s 20 g Moldings Flame retardant polycarbonate Dimensions FDC C21 50mm W X 26 5mmiH X 110 98 mm depth behind panel FDC C91 48mm W X 48mm H X 94mm D 86 mm depth behind panel Weight FDC C21 120 grams FDC C91 140 grams Agency Approvals UL Pending CSA Pending Protective Class IP65 Front panel for C21 lp30 Front panel for C91 All indoor use 1520 for terminals and housing with protective cover
34. ng 25 C 50 C temperature range 3 A switching network SWU16K optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software BC Net and Smart Network Adaptor SNATOB optional for automatic calibration The calibration procedures described in the following section are a step by step manual procedures 48 UMOC911A Manual Calibration Procedures Step 1 Step 2 Step 3 Perform step 1 to enter calibration mode Set the Lock parameter to the unlocked condition LOCK NONE Press and hold the scroll key until Z AL appears on the display then release the scroll key Press the scroll key for 2 seconds then release the display will show Ad o land 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 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 dis
35. oting beyond the normal process value is likely to cause damage Press several times until appears on the display for C21 or AT indicator is lit for C91 Press for at least 3 seconds The AT indicator for C91 or the display for C21 Jwill 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 manual control mode occurs UMOC911A 4 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 display in cases of f PB exceeds 9000 9000 U 900 0 F or 500 0 C 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 Dont 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
36. play 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 RID function if required for input 49 UMOC911A Step 4 Press scroll key until the display showsl Send a 100 ohms signal to the RID input terminals according to the connection shown below C21 C91 100 ohms H Figure 5 1 RTD Calibration Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails Step 5 Press scroll key and the display will shoh EdH 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 RIDL step 4 Otherwise if the display didn t blink or if any value obtained for RTDH and RIDL is equal to 199 9 or 199 9 then the calibration fails x Perform step 6 to calibrate offset of cold junction compensation if required Step 6 Setup the equipments according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used 50 UMOC911A 5520A Calibrator C21 C91 K TC K ET lo Stay at least 20 minutes in still air room room temperature 25 3C Figure 5 2 Cold Junction Calibration Setup The 5520A calibrator is configured as K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration
37. put then perform the following setup INPT 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 PID Heat PID x Dont care Yr Required if ON OFF control O Adjust to met process is configured requirements UMOC911A Heat Only ON OFF Control Select REVR for OUT1 Set PB to O OTHY is used to adjust dead band for ON OFF control The output 1 hysteresis OTHY is enabled in case of PB 0 The heat only on off control function is shown in the following diagram PV SP Dead band O1HY SP1 O1HY OUTI Action 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 Tl 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 OUTI set TI to O OFST is used to adjust the control offset manual reset OTHY is hidden if PB is not equal to 0 OFST Function OFST is measured by with range O 100 0 In the steady state ie process has been stabilized if the process value is lower than the set point a definite
38. r a sensor and a subject to be warmed up Due to the design and position of the components in the system the sensor could not be placed any closer to the part Thermal gradient different temperature is common and necessary to an extent in any thermal system for heat to be transferred from one point to another If the difference between the sensor and the subject is 35 C and the desired temperature at the subject to be heated is 200 C the controlling value or the temperature at the sensor should be 235 C You should input 35 C as to subtract 35 C from the actual process display This in turn will cause the controller to energize the load and bring the process display up to the set point value Subject Heater Subject Heater Subject Heater Heat Transfer o Heat Heat Transfer Transfer 0C 35 C temperature Adjust SHIF Display is stable difference is observed SHIF 35 SHIF 35 SHIF 0 Supply more heat PV SV Figure 3 7 PV Shift Application 40 UMOC911A 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 O to 60 seconds 0 second represents no filter is applied to the input signal The filter is character
39. 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 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 LICH 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 36 UMOCO11A 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 O2FT and go off if OFF is set for O2FT The unit will enter failure mode when sensor break occurs or if the A D converter of the unit fails 3 5 Configure Display C21 can be configured to display the process value by selecting PV for DISP or to display the set point value by selecting
40. stant 1 second time constant 2 seconds time constant 5 seconds time constant 10 seconds time constant 20 seconds time constant 30 seconds time constant 60 seconds time constant 537 8 C 1000 F Parameter eve Default Notation Parameter Description Range Value Display process DISP Normal display selection value normally 0 Display set point 1 value normally Proportional band value Low O High 900 0 4 n 0 5 r a In 1 Um Integral time value Low 0 High 1000 sec 100 TD Derivative time value Low 0 High 360 0 sec 25 0 D Reverse heating OUT Output 1 function control action 0 z me Direct cooling control action 0 EL 4 Relay output 5 5 z Solid state relay drive output 2 hm Solid state relay output 34 41 4 20 mA current module OlTY Output 1 signal type 4 ii H 0 20 mA curent 0 Module 5 15 0 1Vvoltage Module 6 H 55 0 5V voltage Module 7 1 5 1 5V voltage Module 8 m1 IM 0 10V voltage x module Select BPLS bumpless transfer or 0 0 100 0 to 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 0 1 C hysteresis Low 0 1 High 50 0 C 90 0 F 0 2 F CYC Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST Offset value for P control
41. tate if ON is set for O1FT 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 If OUT2 is configured as COOL and a value of O 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 If OUT2 is configured as alarm function and OFF is set for O2FT then output 2 will transfer to off state otherwise Output 2 will transfer to on state if ON is set for O2FT 42 UMOC911A 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 x Initial setup for a new process The set point is changed substantially from the previous auto tuning value x The control result is unsatisfactory Operation 1 2 The system has been installed normally 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 Set the set point to a normal operating value or a lower value if oversho
42. tion alteration misuse or abuse RETURN MATERIAL AUTHORIZATION Please contact Future Design Controls for Return Material Authorization Number prior to returning to factory Future Design Controls 7524 West 98th Place Bridgeview IL 60455 Main Office Phone 888 751 5444 Fax 888 245 2883 Technical Support Phone 866 342 5332 Www futuredesigncontrols com E mail csr futuredesigncontrols com og UMOC911A
43. ust 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 Adjustment 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 A negative 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 6 kinds of alarm functions can be selected for output 2 these are DE HI deviation high alarm DE LO deviation low alarm DB HI deviation band out of band alarm DB LO deviation band in band 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 with normal alarm mode NORM is set for ALMD 34 UMOC911A PV OUT2 DE HI SV SP2 SV SP2 O2HY OUT2 Action Figure 3 3 Output 2 Deviation Time High Alarm SP2 O2HY SP2 OUT2 Action Figure 3 4 Output 2 Process Low Alarm
44. value Low 50 High 300 COMM ADDR BAUD 16 Heating cooling dead band negative value overlap Alarm operation mode Communication function Address assignment of digital communication Baud rate of digital communication 0 1 2 3 Low 36 0 narn Lech Hold LE Ha Hign 36 0 Normal alarm action Latching alarm action Hold alarm action Latching amp Hold action No communication Modbus RTU mode protocol 4 20mA retransmission output 0 20mA retransmission output 0 5V retransmission output 1 5V retransmission output 0 10V retransmission output High 255 2 4 Kbits s baud rate UMOC911A 4 8 Kbits s baud rate 9 6 Kbits s baud rate 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate Parameter Notation DATA PARI STOP Data bit count of digital communication Parity bit of digital communication Stop bit count of digital communication 7 data bits 8 data bits Even parity Odd parity No parity bit One stop bit Two stop bits Retransmission low i iz RELO aoas Hide 15536 REHI Retransmission high scale value Select 1 st parameter for user menu Low 19999 LurE nPE umi E dP SH F Ph E Ed o IHY Tol YE 1152 56 12 m 1352 TAL LE 15 16 dh 17 ddr 2 3 4 5 6 7 8 9 UMOC9I11A High 4
45. value say 5 C while 20 C is used for PB that is lower 25 ig UMOC911A then increase OFST 25 and vice versa After adjusting OFST value the process value will be varied and eventually Coincide with set point Using the P control TI 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 OUTI PB and TI should not be zero Operate auto tuning for the new process or set PB Tl 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 OUTI 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 an
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