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ZEL-9100 User Manual - Zesta Engineering Ltd.

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1. 1 MA Kbits s baud rate 2 4 1902 19 2 Kbits s baud rate 5 288 28 8 Kbits s baud rate 6 FEY 38 4 Kbits s baud rate 1 DATA Data bit count of digital o ibi dam bits 1 communication 1 E 8 data bits o YE Even parity Parity bit of digital Odd parity PARI communication 2 odd parity bit 0 non E 7 Stop bit count of digital 0 Ibi E Onestop bit STOP 2 iati 1 Two stop bits 0 communication cbt Retransmission low m 0 0 LC RELO Low 19999 High 45536 G2 0LD Retransmission high SS 100 0 LC scale value Low 19999 High 45536 212 0 LF 0 mone No parameter selected 1 oc E LOCK is put ahead 2 n DE INPT is put ahead SELI Select I st parameter for 3 uni E UNIT is put ahead 1 4 DP is put ahead 5 GH F 5 put ahead 6 PB is put ahead 7 E Tl is put ahead UM91001D 18 Parameter Description Range Vtc 8 Ed TDis put ahead 9 p is put ahead 0 CYC is put ahead 11 oF SE OFST is put ahead z RR is put ahead SELI 2 for 13 G ZHY O2HY is put ahead 2 4 g CYC2 is put ahead 15 CPB is put ahead 6 DB is put ahead 17 Addr ADDR is put ahead 8 DI HO ALHY is put ahead sus sus Jensen SELS Select 8 th parameter Same as SEL 17 for user menu
2. 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 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 25 UM91001B 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 A4 degrees F A 2 degrees or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature oc
3. Three Phase No Fuse Delta Contactor Breaker Heater Load Relay Output to Drive Contactor Figure 2 20 Alarm Output to Drive Contactor UM 91001A 30 2 9 Data Communication ZEL 4100 ZEL 8100 RS 485 to RS 232 ZEL 9100 ZEL 7100 network adaptor TXI 13 0 XL SNAIOA or 5 10 TX2 14 1 RS 232 Twisted Pair Wire TXI G gt 251 4100 ZEL 8100 ZEL 9100 7 7100 TX1 13 0 TX2 14 1 Max 247 units can be linked 7814100 ZEL 8100 ZEL 9100 7 TXI 13 10 2 14 Terminator 220 ohms 0 5W Figure 2 21 RS 485 Wiring 31 UM 91001A 85 232 ZEL 4100 ZEL 8100 ZEL 9100 TXD PC Se OI 15 RS 232 port 01 7 94 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 ZEL 4100 ZEL 8100 ZEL 9100 1 DCD 2RD 3TD 4DTR 5 GND 6 DSR 7 RTS 8 CTS 9 Female DB 9 Figure 2 23 Configuration of RS 232 Cable UM 91001A 32 Chapter 3 Programming Press for 5 seconds and release to enter setup menu Press 9 to select the desired parameter The upper display indicates the parameter symbol and the lower display indicates the selected value of parameter
4. 5 Press for at least 5 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 manual control mode occurs UM91001D 46 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 H t E Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of f PB exceeds 9000 9000 PU 900 0 LF or 500 0 LC or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure Solutions to HE E 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 GEE 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
5. 300 96 100 band value UM91001A 16 Parameter Parameter Description Range Daule Heating cooling dead DB band negative value Low 36 0 High 36 0 0 overlap 0 AONE No alarm function I E Apr Dwell timer action 2 Deviation high alarm 3 dEL Deviation low alarm Alarm function for 4 db Hi Deviation band out of ALEN alarm output 1 band alarm R 2 5 d bL Deviation band in band alarm P Process value high 5 alarm TPYL o Process value low alarm 0 nor Normal alarm action 1 Lech Latching alarm ALMD Alarm operation mode action 0 2 Hold Hold alarm action 3 LtHo Latching amp Hold action Hysteresis control of 500LC 0 1 LC ALHY alarm Low 0 1 High 90 0 LF 0 2 LE 0 ON Alarm output ON as Alarm failure transfer unit fails ALFT 0 mode 1 oFF Alarm output OFF as unit fails Onon E No communication 1 n Ew Modbus RTU mode protocol 2 20 420mA retransmission output 201 0 issi Communication e 28 us COMM function 1 4 0 5 0 5 retransmission output 5 f GU 1 5 retransmission output 6 0 ig 0 10V retransmission output 17 UM91001D Parameter Description Range nas Address assignment of ADDR digital communication Low High 255 0 24 Kbits s baud rate 1 YG 4 8 Kbits s baud rate 2 QB 9 6 Kbits s baud rate Baud rate of digital
6. Figure 1 4 Display of Initial Stage 1 Figure 21 Mounting Dimensions Figure 2 2 Lead Termination for ZEL 4100 ZEL 8100 ZEL 7100 23 Figure 2 3 Lead Termination for ZEL 9100 23 Figure 2 4 Rear Terminal Connection for ZEL 4100 and ZEL 8100 23 Figure 2 5 Rear Terminal Connection for ZEL 7100 24 Figure 2 6 Rear Terminal Connection for ZEL 9100 24 Figure 2 7 Power Supply Connections m 25 Figure 2 8 Sensor Input Wiring 26 Figure 2 9 Output 1 Relay or Triac SSR to Drive Load 26 Figure 2 10 Output 1 Relay or Triac SSR to Drive Contactor 21 Figure 2 11 Output 1 Pulsed Voltage to Drive SSR 21 Figure 212 Output 1 Linear Current m 28 Figure 213 Output 1 Linear Voltage 8 Figure 2 14 Output 2 Relay or Triac SSR to Drive Load 28 Figure 2 15 Output 2 Relay or Triac SSR to Drive Contactor 29 Figure 2 16 Output 2 Pulsed Voltage to Drive SSR 29 Figure 217 Output 2 Linear Current m 29 Figure 2 18 Output 2 Linear Voltage m 30 Figure 2 19 Alarm Output to Drive Load 30 Figure 2 20 Alarm Output to Drive Contactor 30 Figure 2 21 RS 485 Wiring 31 Figure 2 22 RS 232 Wiring 32 Figure 2 23 Configuration of RS 232 Cable 32 Figure 3 1 Conversion Curve for Linear Type Process Value 34 Figure 3 2 Heat Only ON OFF Control 35 Figure 3 3 Output 2 Deviation High Alarm 38 3 4
7. Notes 0 SP1 Set point 1 4 4 R W 1 SP2 Set point 2 S 7 R W Set point 3 6 6 R W Lock code 0 65535 R W Input sensor selection 0 65535 R W Measuring unit 0 65535 R W Decimal point position 0 65535 R W Low scale value for linear input 4 4 R W High scale value for linear input 4 4 R W Low limit of SP1 4 4 R W High limit of SP1 4 4 R W V shift value 4 4 R W Filter time constant 0 65535 R W 3 DISP Display form for C21 0 65535 R W 4 PB proportional band 5 5 R W 5 TI Integral time 0 65535 R W 6 Derivative time 0 0 6553 5 R W 1 Output 1 function U 65535 R W 8 Output 1 signal type 0 65535 R W 9 Output 1 failure transfer 1999 9 4553 6 R W 20 Output 1 ON OFF hysteresis 5 5 W 21 Output 1 cycle time 0 0 6553 5 R W 22 Offset value for P control 00 6553 5 R W 23 Ramp function 0 65535 R W 24 Ramp rate 5 5 R W 25 OUT2 Output 2 function 0 65535 R W 26 Retransmission low scale value 4 4 R W 27 O2TY Output 2 signal type 0 65535 R W 28 Output 2 failure transfer 1999 9 4553 6 R W 29 Output 2 ON OFF hysteresis Ki 5 R W 69 UM91001D Register Parameter Scale Scale Address Notation Parameter Low High Notes 30 CYC2 Output 2 cycle time 0 0 6553 5 31 Cooling band 0 65535 SW 32 DB Heating cooling dead band 1999 9 4553 6 JW 33 Alarm function 0 65535 34 Re
8. OM964 Isolated 1 5V 0 5V Analog Output Module 96 5 Isolated 0 10V Analog Output Module 94 1 Isolated RS 485 Interface Module for ZEL 8100 4100 7100 CM942 Isolated RS 232 Interface Module for ZEL 8100 4100 CM94 3 Isolated 4 20 mA 0 20 mA Retrans Module for ZEL 8100 4100 7100 CM944 Isolated 1 5V 0 5V Retrans Module for ZEL 8100 ZEL 4100 ZEL 7100 CM94 5 Isolated 0 10V Retrans Module for ZEL 8100 4100 7100 97 1 Isolated 115485 Interface Module for ZEL 9100 CM972 Isolated RS 232 Interface Module for ZEL 9100 CM97 3 Isolated 4 20 mA 0 20mA Retrans Module for ZEL 9100 CM974 Isolated 1 5V 0 5V Retrans Module for ZEL 9100 97 5 Isolated 0 10V Retrans Module for ZEL 9100 DC94 1 7 Isolated 20V 25mA DC Output Power Supply DC942 Isolated 12V 40mA DC Output Power Supply DC94 3 Isolated 5V 80mA DC Output Power Supply CC94 1 RS 232 Interface Cable 2M 91 1 Programming Port Cable RK91 1 Rail Mount kit for ZEL 9100 Related Products SNAIOA Smart Network Adaptor for third party software which converts 255 channels of RS 485 or RS 422 to RS232 Network SNAIOB Smart Network Adaptor for ZE Net software which converts 255 channels of RS 485 or RS 422 to RS 232 network SNA12A Smart Network Adapter for programming port to RS 232 interface ZE Set Configuration Software UM91001C 81 1 3 Programming Port Front Panel
9. Rear Terminal Figure 1 2 Programming Port Overview 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 Don t attempt to make any connection to these pins when the unit is used for a normal control purpose 9 UM 91001A 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter be viewed or adjusted UP KEY NEN 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 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 Stop the manual control mode auto tuning mode and calibration 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 w ENTER KEY Press Press for 5 seconds or longer for 5 seconds to 1 Ener setup menu The display shows 2 Enter manual control mode during manual control mode HAnd is selected 3
10. Setup data are Select parameters to be locked E 0 LOCK locked 2uSEr Setup data and User data except Set point are locked 3 ALL All data are locked O JEC J type thermocouple ID EU type thermocouple 2 T type thermocouple 3 ELEC E type thermocouple 4 b EU thermocouple 5 EL type thermocouple 6 S EC S type thermocouple 7 n EE N type thermocouple 8L EC L type thermocouple INPT Input sensor selection PE dn PT 100 ohms DIN curve 10 PE JS PT 100 ohms JIS curve 11 4 gg 4 20 mA linear current input 12 2 20 0 20 mA linear current input 13 0 0 0 60 mV linear millivolt input 14 Q 1 9 0 linear voltage input 15 0 6 0 5 linear voltage input 16 41 50 1 5V linear voltage input 17 Q 10 0 10V linear voltage input 13 UM91001A Parameter Parameter Description Range pee 0 or Degree C unit UNIT Input unit selection 1 or Degree F unit Ai 2 Pu Process unit 0n odP No decimal point 1 fe 1 decimal digit DP Decimal point selection Wi 1 2 e dP 2 decimal digits 3 gP 3 decimal digits m 11 8 LC INLO Input low sale value Low 19999 High 45486 OLE INHI Input high scale value Low INLO 50 High 45536 Geet SPIL Low limit of set point Low 19999 High 45536 17 8 LC value 0 LF High limit of set point 2 AM 537 8 LC SPIH value Low SPIL High 45536 1000 SHIF PV shift offset value Low ran H
11. then the calibration fails Press scroll key until the display shows Send a 60mV signal to the thermocouple input terminals in correct polarity Press scroll key for at least 5 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 required for input UM91001D 56 Step 4 Press scroll key until the display shows J Send a 100 ohms signal to the RTD connection shown below t terminals according to the ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 100 ohms 18 12 4 5 5 20 4 6 Figure 5 1 RTD Calibration Press scroll key for at least 5 seconds The display will blink a moment otherwise the calibration fails Step 5 Press scroll key and the display will show Change the ohm s value to 300 ohms Press scroll key for at least 5 seconds The display will bli nk 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 equal to 199 9 or 99 9 then the calibration fails Perform step 6 to calibrate offset of cold junction compensation if required Step 6 Setup the equipments accor ing to the following diagram for calibrating the cold junctio
12. 0111 RR O2HY and ALHY Nonlinear Linear input Linear input Linear input Linear input Conditions input DP 0 DP 1 DP 2 DP 3 Scale low 0 0 0 0 0 00 0 000 Scale high 6553 5 655 35 65 535 6 The scale high low values are defined in the following table for SP3 Conditions Scale low 1999 9 Scale high ALFN 1 4553 6 londinear input 4553 6 Linear input DP 0 1999 9 19999 1999 9 199 99 45536 4553 6 DP 1 Linear input Linear input DP 2 455 36 Linear input DP 3 19 999 45 536 7 The scale high low values are de For C21 and C91 fined in the following table for Sp2 007251 Nonlinear Linear input Linearinput Linear input Linear input Conditions TIMR input DP 0 DP 1 DP 2 DP 3 Scale low 1999 9 1999 9 19999 1999 9 199 99 19 999 Scale high 4553 6 4553 6 45536 4553 6 455 36 45 536 UM91001D 72 For ZEL 9100 ZEL 8100 ZEL 7100 and ZEL 4100 SS Non linear Linear input Linear input Linear input Linear input Conditions input DP 0 DP 1 DP 2 DP 3 Scale low 1999 9 19999 1999 9 199 99 19 999 Scale high 4553 6 455 36 45 536 7 4 Data Conversion The word data are regarded as unsigned positive data in the Modbus message However the actual value of the parameter may be negative value with decimal point The high low scale values for each parameter are used for the pu
13. 13 Output 1 Linear Voltage ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 5 5 6 11 Load 6 d 7 12 Mains Supply Figure 2 14 Output 2 Relay or Triac SSR to Drive Load UM 91001A 28 ZEL 4100 ZEL 8100 781 7100 ZEL 9100 p 5 6 120V 240V 6 1 T o Mains Supply 5 2 lt Three 6 oe o Phase lt Heater Power Three Phase No Fuse Delta Contactor Breaker Heater Load Figure 2 15 Output 2 Relay or Triac SSR to Drive Contactor ZEL 4100 ZEL 8100 781 7100 ZEL 9100 SSR 5 6 120V 240V 1 ul Be Mains Supply Internal Circuit C 7 1 30mA 5V 05V 1 Pulsed Voltage 33 1 1 3 i AA iT Figure 2 16 Output 2 Pulsed Voltage to Drive SSR ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 5 6 0 20mA Maximum Load 6 7 12 4 20mA 500 ohms Figure 2 17 Output 2 Linear Current 29 UM 91001A ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 0 1 0 5V L 1 5V 0 10V pa Figure 2 18 Output 2 Linear Voltage 5 6 6 7 Minimum Load 10 K ohms d 2 8 Alarm Wiring ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 7 3 3 ia 120V 240VAC Mains Supply 8 4 1 9 5 2 Figure 2 19 Alarm Output to Drive Load ZEL 4100 ZEL 8100 781 7100 ZEL 9100 7 3 3 120V 240V M 4 1 Mains Supply 9 5 2 ES 9
14. 19 UM91001A Chapter 2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any cleaning or 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 A This instrument is protected throughout by Double Insulation n To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture AN 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 6 A Remove stains from this instrument using a soft dry cloth Don t use harsh chemicals volatile solvent such as thinner or strong detergents to clean the instrument in order to avoid deformation or discoloration 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
15. 3 1 Lockout There are four security levels can be selected by using LOCK parameter f NONE is selected for LOCK then no parameter is locked f SET is selected for LOCK then all setup data are locked f 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 f 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 TC T TC E TC B TC TC S TC N RTD PT DN PTJS inear 4 20 0 20 0 60 0 1 0 5 1 5 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 I 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 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 33 UM91001D process value Figure 3 1 Conversion Curve for Linear Type Process Value input signal 5 51 Formula
16. 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 is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of 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 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 36 096 to 36 0 96 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 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 th
17. PV INLO INHI INLO SH SL Example 4 20 mA current loop pressure transducer with range 0 15 kg cm is connected to input then perform the following set p 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 oun ourz DB Heat only REVR x Cool only DIRT x REVR x 0 REVR COOL x x 0 X i Don t care Required if ON OFF control is configured Adjust to met process requirements UM 91001A 34 Heat Only ON OFF Control Select REVR for OUTI Set PB to 0 OILHY 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 Dead band SP1 OLHY Time Action ON OFF 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 TI TD CYC1 OFST CYC2 CPB DB will be hidden and have no function to the system The auto tuning mode and bumpless transf
18. 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 If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable should be modified for proper operation of RS 232 communication according to Section 2 9 3 15 PV Retransmission The controller can output retransmit process value via its retransmission terminals RE and RE provided that the retransmission option is ordered A correct signal type should be selected for COMM parameter to meet the retransmission option installed RELO and are adjusted to specify the low scale and high scale values of retransmission UM 91001A 50 Chapter 4 Applications 4 1 Heat Only Control with Dwell Timer An oven is designed to dry the products at 150 ZEL for 30 minutes and then stay unpowered for another batch A ZEL 8100 equipped with dwell timer is used for this purpose The system diagram is shown as follows Set SP1 150 0 SP3 30 0 Oven Figure 4 1 T C Heat Control Example Mains Supply Timer ALM To achieve this function set the following parameters in the setup menu INPT K_TC UNIT LC DP 1_DP OUTI REVR OITY RELY 18 0 OIFT BPLS ALFN TIMR ALFT ON Auto Tuning is performed at 150 LC for a new oven 51 UM91001A 4 2 Cool Only Control A ZEL 8100 is used to control a refrigerator at temperature belo
19. 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 ALM power off or touch RESET key poc OFF Timer starts Figure 3 6 Dwell Timer Function If alarm is configured as dwell timer ALHY and ALMD are hidden UM 91001A 42 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 heater 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 LC and the desired temperature at the subject to be heated is 200 LC the controlling value or the temperature at t
20. by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 47 UM 91001A ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB 1 Proportional Band PB High overshoot or Oscillations Increase PB Slow Response Decrease TI 2 Integral Time Instability or Oscillations Increase Slow Response or 3 Derivative Time TD Oscillations High Overshoot Increase TD 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 Hand Control will appear on the display Press for 5 seconds then the NONE then press for 6 2 seconds MAN indicator will begin to flash and the lower display will show H The controller now enters the manual control mode 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 R key the controller will revert to its normal display mode UM91001D 48 PB too low Set point P action PB too
21. 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 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 UM91001B 20 Figure 2 1 Mounting Dimensions 92 mm Panel Cutout 21 mm gt 92 Panel Cutout Hmm Panel 68 mm Panel Cutout 68 mm Panel 65 mm UM 91001A ZEL 4100 ZEL 8100 ZEL 7100 Panel mm 45 mm gt 45 ZEL 9100 Panel Cutout Panel Mount 2 1 5mm f 104 8mm 75 gt 62 0mm 48 0mm ZEL 9100 Rail Mount lL5mm 104 8 6 5mm 3 W Before wiring verify the label for correct model number and options Switch off the power while checking ring Precautions 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 sh
22. 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 J K T E 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 RS232 excluding ZEL 7100 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 UM91001B PID control with properly tuned PID trol Temperature WEN point Figure 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 measuremen
23. 0 1 Protective Class 65 for panel with additional option 50 for panel without additional option IP20 for terminals and housing with protective cover All indoor use EMC EN61326 65 UM91001D Chapter 7 Modbus Communications This chapter specifies the Modbus Communications protocol as RS 232 or RS 485 interface module is installed Only RTU mode is supported Data is transmitted as eight bit binary bytes with 1 start bit 1 stop bit and optional parity checking None Even or Odd Baud rate may be set to 2400 4800 9600 14400 19200 28800 and 38400 7 1 Functions Supported Only function 03 06 and 16 are available for this series of controllers The message formats for each function are described as follows Function 03 Read Holding Registers Query from master Slave address 0 255 Function code 3 Starting address of register Hi 0 Starting address of register Lo 0 79 128 131 No of words Hi 0 No of words Lo 1 79 CRC 16 Hi CRC16 Lo Function 06 Preset single Register Query from master Slave address 0 255 Function code 6 Register address Hi 0 Register address Lo 0 79 128 131 Data Hi Data Lo CRC16 Hi CRC16 Lo UM91001B Response from slave Byte count Data Hi Data 1 Lo Data 2 Hi Data 2 Lo D CRC16 Hi CRC16 Lo Response from slave 66 Function 16 Preset Multiple Registers Query from master S
24. 00 is 11 and for ZEL 4100 is 12 1 5 Menu Overview User Setup Manual Auto tuning Calibration menu menu Mode Mode Mode 5 sec 74 sec bo 9 8 sec Hand A AL Release 3 a hen pre 5 2 LOCK for 5 secon ADLO Elie C rr C ADHI mer eq UNIT auto tuning co RIDL CI or Ec mode El s DP ae INLO GLO Sc PB ef INHI SPIL ace Ge Lel 5 cL el to start Press for ADDR mc manual control 5 seconds to S perform calibration Sm perform calibrati TD q SC Apply these modes will break the control and change some of the previous OT loop and g f the p setting data Make sure that if the system ES is allowable to apply these modes q OFST 9 1 The flow chart shows a complete listing of all parameters For actual application ce Ca f all ters For actual a
25. 35 70 Operation mode amp alarm status 2 0 65535 71 140 rogram code 3 0 00 655 35 72 Command code 0 65535 R W 73 ob code 0 65535 R W 74 ob code 0 65535 R W 75 ob code 0 65535 R W 16 Cold Junction Temperature 199 99 455 36 R 77 eserved 0 65535 R 78 eserved 0 65535 R 79 eserved 0 65535 R 51 The error code is show in the first column of Table A 1 2 Definition for the value of MODE register H 000X Normal mode H OIOX Calibration mode H O20X Auto tuning mode H 030X Manual control mode H 040X Failure mode 71 7 910010 H 0X00 Alarm status is off H 0x01 Alarm status is on The alarm status is shown in MV2 instead of MODE for models C21 and C91 3 The PROG Code is defined in the following table Model No ZEL 9100 7EL 8100 ZEL 4100 ZEL 7100 PROG Code 6 XX 11 XX 12 XX 13 XX Where XX denotes the software version number For example PROG 34 18 means that the controller is C91 with software version 18 4 The scale high low values are defined in the following table for SP1 INLO INHI SP1L SP1H SHIF PV SV RELO and REHI Nonlinear Linear input Linear input Linear input Linear input Conditions input DP 0 DP 1 DP 2 3 Scale low 1999 9 19999 1999 9 199 99 19 999 Scale high 4553 6 45536 4553 6 455 36 45 536 5 The scale high low values are defined in the following table for PB
26. 4163 Hz OPI to l RE 10 Missi NT RETRANSMISSION A PTA 12 d RTD 13 11 d gt TC V B vi ma 14 TC V mA RID 50LC max air ambient Use copper conductors except on T C input Figure 2 5 Rear Terminal Connection for ZEL 7100 RETRANSMISSION RE RS232 TXD RXD COM RS 485 TX TX2 E oi 3 15 No LI 90250VAC 4163 Hz NA ALM N 2 Ine 8 Clo OPI A 4 PTA NO 10 RTD V pre mas O lei TC V x 6 PTB mA 12 50LC max air ambient Use copper conductors except on T C input Figure 2 6 Rear Terminal Connection for ZEL 9100 UM91001B 24 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 Near the controller a fuse and a switch rated at 2A 250VAC should be equiped as shown in the following diagram ZEL 4100 ZEL 7100 ZEL8100 ZEL 9100 a Ne L 1 L 7 90 7250 VAC or 2A 250VAC 11 VAC VDC NI NIS8 Figure 2 7 Power Supply Connections AN This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground
27. 91001A Output 1 Output 2 Relay Rating 2A 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Linear Output Characteristics Type Zero Span Load olerance Tolerance Capacity 4720 mA 3 6 4 mA 20 21 mA 500W max 0720 mA O0 mA 20 21 mA 500W max 075 OV 575250 10 0971 872225 V 10 KW min 07 10V OV 10 10 5V 10 KW min Linear Output esolution 15 bits Output Regulation 0 02 96 for full load change Output Settling Time 0 1 sec stable to 99 9 solation Breakdown Voltage 1000 VAC Temperature Effect AO 01 96 of SPAN LC Triac SSR Output ating 1A 240 VAC nrush Current 20A for 1 cycle Min Load Current 50 mA rms Max Offstate Leakage 3 mA rms Max Onstate Voltage 1 5 V rms nsulation Resistance 1000 Mohms min at 500 VDC Dielectric Strength 2500 VAC for 1 minute UM91001B 62 DC Voltage Supply Characteristics Installed at Output 2 Tolerance Max Output Current Ripple Voltage Isolation Barrier 20V ALV 25 mA 0 2 Vp p 500 VAC 12V 06 40 mA 0 1 Vpp 500 VAC 5V A025V 80 mA 0 05 Vp p 500 VAC Alarm Alarm Relay Form C Rating 2A 240VAC life cycles 200 000 for resistive load Alarm Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV High Low Alarm Alarm Mode Normal Latc
28. DB at 4 0 96 Apply Auto tuning at 120 LC for a new system to get an optimal PID values See Section 3 11 Adjustment of CPB is related to the cooling media used If water is used as cooling media instead of oil the CPB is set at 250 96 If air is used as cooling media instead of oil the CPB is set at 100 96 Adjustment of DB is dependent on the system requirements More positive value of DB will prevent unwanted cooling action but will increase the temperature overshoot while more negative value of DB will achieve less temperature overshoot but will increase unwanted cooling action UM 91001A 54 Chapter 5 Calibration A Do not proceed through this section unless there is a definite need to recalibrate 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 recalibrate 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 0 100 mV millivolt source with A0 005 96 accuracy 0 10 V voltage source with 0 005 96 accuracy 0 20 mA current source with 0 005 96 accuracy 0 300 ohm resistant source w
29. Enter auto tuning mode during auto tuning mode selected 4 Perform calibration to a selected parameter during the calibration procedure for 6 2 seconds to select manual control mode for 7 4 seconds to select auto tuning mode for 8 6 seconds to select calibration mode UM91001D 10 Alarm r Upper Display to display process value bol and error code etc Indicator menu sym Output 2 Indicator T Output 1 OPI A t Y Indicator 9c SE Manual w em Manu DD H H Indicator gt Autotuning 1 1 AT B H H Indicator ZESTA v BI ZEL 9100 g Figure 1 3 Front Panel Description Table 1 1 Display Form of Characters Process Unit Indicator Lower Display to display set point value parameter value or control output value etc 1 4 Buttons for ease of control setup and set point adjustment 5 A ojvioj z lt Confused Character OPI ALM 4 v R ZESTA ZEL 9100 U Figure 1 4 Display of Initial Stage 910010 Display program code of the product for 2 5 seconds The left diagram shows program no 6 for ZEL 9100 with version 24 The program no for ZEL 7100 is 13 for ZEL 81
30. NL RTD PT100 DIN PT100 JIS 60 mV 0 0 0 d 4 0 0 5 pecial Order Output 1 0 None 1 Relay rated 2A 240VAC 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20mA 4 Isolated 1 5V 0 7 5 Isolated 0 10V 6 Triac output 1A 240VAC SSR C Pulsed voltage to drive SSR 14V 40mA 9 Special order Options 0 Panel mount 50 standard 1 Panel mount IP65 water resistant rubber installed 2 DIN Rail mount with IP50 for ZEL 9100 only 3 DIN Rail mount with 5 for ZEL 9100 only Communications 0 None 1 RS 485 interface 2 RS 232 interface not available for ZEL 7100 3 Retransmit 4 20mA 0 20mA 4 Retransmit 1 5 V 0 5V 5 Retransmit 0 10V 9 Special order Alarm 0 None 1 Form C relay 2A 240VAC 9 Special order Output 2 0 None Form A relay 2A 240VAC ulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20 4 Isolated 1 5V 0 5V 5 6 ye solated 0 10V Triac output 1A 240VAC SSR 7 Isolated 20V 25mA transducer power supply ated 12V 40mA transducer power supply ated 5V 80mA transducer power supply Pulsed voltage to drive SSR 14V 40mA Special order 5 5 gt UM91001C 94 6 Isolated 1A 240VAC Triac Output Module SSR OM94 7 14 40mA SSR Drive Module OM963 Isolated 4 20 mA 0 20 mA Analog Output Module
31. Output 2 Process Low Alarm 38 3 5 RAMP Function 41 3 6 Dwell Timer Function 42 3 7 PV Shift Application 43 3 8 Filter Characteristics 44 3 9 Effects of PID Adjustment 49 4 1 Heat Control Example 7 M 51 4 2 Cooling Control Example 52 4 3 HeatCool Control Example 5 1 RTD Calibration 5 2 Cold Junction Calibration Setup 58 Table 1 1 Display Form of Characters 1 Table 3 1 HeatCool Control Setup Value 34 Table 3 2 PID Adjustment Guide 48 Table A l Error Codes and Corrective Actions D I 4 UM 91001A Chapter 1 Overview 1 1 General The Fuzzy Logic plus PID microprocessorbased 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 ZEL 9100 is a 1 16 DIN size panel mount controller It can also be used for rail mount by adding a rail mount kit ZEL 7100 is a 72X72 DIN size panel mount controller ZEL 8100 is a 1 8 DIN size panel mount controller and ZEL 4100 is a 1 4 DIN size panel mount controller These units are powered by 11 26 or 90 250 VDC NAC supply incorporating a 2 amp control relay
32. PID Fuzzy logic modified Proportional band 0 1 900 0 LF Integral time 0 1000 seconds Derivative time 0 360 0 seconds Cycle Time 0 1 90 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warm start Failure Mode Auto transfer to manual mode while sensor break or A D converter damage Ramping Control 0 900 0 LF minute or 0 900 0 LF hour ramp rate Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UM 91001A 64 Environmental amp Physical Operating Temperature 10 ZE to 50 ZE Storage Temperature 40 ZE to 60 ZE umidity 0 to 90 RH non condensing Ititude 2000m maximum Pollution Degree 2 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 s2for 2 hours Shock Resistance 200 m s2 20 g Moldings Flame retardant polycarbonate Dimensions ZEL 4100 96mm W X 96mm H X 65mm D 53 mm depth behind panel ZEL 7100 72mm W X 72mm H X 78 2mm D 65 mm depth behind panel ZEL 8100 48mm W X 96mm H X 80mm D 7 gt 65 mm depth behind panel EL 9100 48mm W X 48mm H X 116mm D 105 mm depth behind panel Weight ZEL 4100 250 grams ZEL 7100 200 grams ZEL 8100 210 grams ZEL 9100 150 grams Approval Standards Safety UL61010C 1 CSA C22 2 No 24 93 EN61010 1 IEC101
33. User s Manual DIN EN ISO 9001 Certificate 01 100 98505 ZEL 4100 ZESTA ZEL 4100 7100 8100 9100 Auto Tune Fuzzy PID Process Temperature Controller Cu ZESTA ENGINEERING LTD Warning Symbol The 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 System Designer Read All Chapters Expert User Read Page 12 NOTE It is strongly recommended that a process should incorporate LIMIT CONTROL like 191 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 This manual is applicable for the products with software version 23 and later version Copyright February 2002 ZESTA ENGINEERING LTD 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 ZESTA ENGINEERING LTD 2 UM91001D Contents Chapter 1 Overview 1 1 General 5 12 Ordering Code 8 1 3 Prog
34. and a value of 0 to 100 0 96 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 w 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 45 UM91001A 3 11 Auto tuning A 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 The 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 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 w and hold until _A E appears on the display
35. currence 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 00 00 7281 7100 ZEL 9100 18 12 V PTB mA419 13 TC V PTB mA 2n 14 TC V MA RTD Figure 2 8 Sensor Input Wiring 2 7 Control Output Wiring ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 D 3 8 9 120V 240VAC 9 4 m Mains Supply Figure 2 9 Output 1 Relay or Triac SSR to Drive Load UM 91001A 26 ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 ZEE 8 9 ON 7 14 9 10 Mains Supply oto o Three Phase No Fuse Ze mE Contactor Breaker Heater Load Figure 2 10 Output 1 Relay or Triac SSR to Drive Contactor ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 SSR 5 3 8 9 py Mains Supply 4 9 10 e o Internal Circuit 30mA 5V i 5V 1 Pulsed i i Voltage 33 1 33 i a a Figure 2 11 Output 1 Pulsed Voltage to Drive SSR 27 UM 91001A ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 P 0 70 4 20mA 2 Loa Figure 2 12 Output 1 Linear Current Maximum Load 500 ohms ZEL 4100 ZEL 8100 ZEL 7100 ZEL 9100 3 8 0 1 0 5V Minimum Load 1 5V 0 10V 10 K ohms 4 9 10 Figure 2
36. e description of deviation alarm and process alarm 37 UM91001A SV SP2 O2HY OUT2 Action ON OFF SP2 O2HY SP2 OUT2 Action ON OFF PV OUT2 DE HI A 1 1 1 1 1 1 1 1 eck 1 1 1 1 1 1 1 a A 1 1 1 1 1 Time Figure 3 3 Output 2 Deviation High Alarm PV A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 t A 1 1 1 1 1 Time Figure 3 4 Output 2 Process Low Alarm UM 91001A 38 3 4 Alarm The controller has one alarm output There 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 ALEN 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 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 occ
37. er will be disabled too Heat only P or PD control Select REVR for OUTI set TI to 0 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 96 with range O 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 then increase OFST 25 96 and vice versa 35 UM 91001A 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 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 c
38. he 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 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 UM 91001A 1 2 Ordering Code zL 400 QLOOOOOOO ZEL 7100 ZEL 8100 ZEL 9100 Power Input 4 90 250 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input 1 Standard Input Thermocouple B S
39. he sensor should be 235 LC You should input 35 LC as to subtract 35 LC 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 Bises Subject Subject Hcr Heat Heat Heat Transfer Transfer Transfer 165 C 165 C 200 C 200 Sensor 200 Sensor 35 C temperature Adjust SHIF Display is stable difference is observed SHIF 35 C SHIF 35 C SHIF 0 Supply more heat PV SV Figure 3 7 PV Shift Application 43 UM 91001A 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 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 c
40. high Time TI too high PV Set point Laction TI too low Time TD too low Perfect Set point D action TD too high Time Figure 3 9 Effects of PID Adjustment 49 UM 91001A 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 SNAIOB has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication But there is no need to be sad Many RS 485 units up to 247 units can be connected to one RS 232 port therefore a PC with 4 comm ports can communicate with 988 units It is quite economic Setup Enters the setup menu Select RTU for COMM Set individual address as for those units which are connected to the same port
41. hing Hold Latching Hold Dwell Timer 0 1 4553 6 minutes Data Communication 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 Communication Buffer 160 bytes Analog Retransmission Output Signal 4 20 mA 0 20 mA 0 5V 1 5 0 7 Resolution 15 bits Accuracy 0 05 96 of span 0 0025 LC Load Resistance 0 500 ohms for current output 10 K ohms minimum for voltage output Output Regulation 0 01 for full load change 63 UM91001D Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC min Integral Linearity Error 0 005 of span Temperature Effect A0 0025 of span LC Saturation Low 0 mA or OV Saturation High 22 2 mA 5 55V 11 1V min Linear Output Range 0 22 2mA 0 20mA or 4 20mA 0 5 55V 0 5V 1 5V 0 111 0 10 User Interface Dual 4 digit LED Displays Keypad 4 keys Programming Port For automatic setup calibration and testing Communication Port Connection to PC for supervisory control Control Mode Output 1 Reverse heating or direct cooling action Output 2 PID cooling control cooling P band 50 300 of PB dead band 36 0 36 0 of PB ON OFF 0 1 90 0 LF hysteresis control band 0 P or PD O 100 0 96 offset adjustment
42. igh 2000 0 0 0 Osecond time constant 1 Ge 0 2 second time constant 2 05 0 5 second time constant 3 1 time constant 4 seconds time Filter damping time constant FILT constant of PV 5 5 2 5 seconds time 2 constant 6 8 10 seconds time constant 7200 20seconds time constant 8 30 30 seconds time constant 9 60 seconds time constant UM91001A 14 Parameter Notation Parameter Description Range Default Value PB Proportional band value 500 0 LC Low 0 900 0 LF High 10 0 LC 18 0 LF Integral time value Low 0 High 1000 sec 100 TD Derivative time value Low 0 High 360 0 sec 25 0 OUTI Output 1 function Reverse heating control action lor rk Direct cooling control action Output 1 signal type Relay output Or ELY 1 55rd 2 2 3 4 20 0 20 mA current 22 module 0 IV voltage 5 7 1 50 8 n in L7 Solid state relay drive output Solid state relay output 4 20 mA current module 4 5 module 0 5 voltage module DD 6 1 5 voltage module 0 10V voltage module OIFT Output 1 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 96 to continue output 1 control function as the unit fails or select OFF 0 or ON 1 for ON OFF control OIHY Output 1 ON OFF co
43. ion same effect as pressing R key Query Data Hi Lo Addr Func Register Addr Example 4 Enter Auto tuning Mode Query 06 Addr Func Register Addr Data Hi Lo CRCI6 Example 5 Enter Manual Control Mode Query H 68 7 CRC16 Addr Func Register Addr Data Hi Lo Example 6 Read Parameters Query 03 00 Lo Addr Func Starting Addr No of words CRC16 Example 7 Modify the Calibration Coefficient Preset the CMND register with 26669 before attempting to change the calibration coefficient H 2D Hi Lo 06 00 48 H 68 Addr Func Register Addr Data Hi Lo CRCI6 75 UM91001D Table A 1 Error Codes and Corrective Actions Bree ee Error Description Corrective Action Illegal setup values been used Check and correct setup values of Before COOL is used for OUT2 OUT2 PB TI and OUTI IF OUT2 DIRT cooling action has already required for cooling control the been used for OUTI or PID mode control should use PID mode 4 Ee fils not used for OUTI that is PB TIA O and OUTI should 1 0 and or TI 0 use reverse mode heating action otherwise don t use OUT2 for cooling control Communication error bad function Correct the communication 10 Ee iff code software to meet the protocol requirements Communication error register Don t issue an overrange 11 Er i I addres
44. ith 0 005 96 accuracy 2 A test chamber providing 25 ZE 50 ZE temperature range 3 A switching network SWUI6K optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software ZE Net and Smart Network Adaptor 5 101 optional for automatic calibration The calibration procedures described in the following section are a step 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 upon request 55 UM 91001A 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 CAL appears on the display then release the scroll key Press the scroll key for 2 seconds then release the display will 5 Agl 5 and the unit enters calibration mode Perform step 2 to calibrate Zero of A to 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 5 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
45. lave address 0 255 Function code 16 Starting address of register Hi 0 Starting address of register Lo 0 79 128 131 No of words Hi 0 No of words Lo 1 79 Byte count 2 158 Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo 67 UM91001B Response from slave E 34 amp CRC16 Hi CRC16 Lo 7 2 Exception Responses If the controller receives a message which contains a corrupted character parity check error framing error etc or if the CRC16 check fails the controller ignores the message However if the controller receives a syntactically correct message which contains an illegal value it will send an exception response consisting of five bytes as follows slave address offset function code exception code 6 Hi CRC16 Lo Where the offset function code is obtained by adding the function code with 128 ie function 3 becomes H 83 and the exception code is equal to the value contained in the following table Exception Code Name Cause Function code is not supported 1 Bad function code by the controller 2 Illegal data address Register address out of range Data value out of range or attempt to write a read only or 3 Illegal data value data UM 91001A 68 7 3 Parameter Table Parameter fale IER
46. n compensation Note that a K type thermocouple must be 57 used UM91001D 5520A Calibrator ZEL4100 KTC ZEL 8100 ZEL 7100 ZEL 9100 K 19 13 5 20 14 6 K Stay at least 20 minutes in stillair room room temperature 25 A 3 LC Figure 5 2 Cold Junction Calibration Setup The 5520A calibrator is configured as type thermocouple output with internal compensation Send a 0 00 LC signal to the unit under calibration Step 7 The unit under calibration is powered in a still air room with temperature 25A3 ZE 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 obtain40 00 ress scroll key for at least 5 seconds The display will blink a moment and 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 erform 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 50A3 ZE Stay at east 20 minutes for warming up The calibrator source is set at 0 00 ZE with internal compensation mode UM91001D 58 Step 8 59 Perform step 1 stated above then press scroll key until the display shows LC ZH J Press scroll key for at least 5 seconds The display will blink a moment and a new value is
47. ntrol hysteresis Low 0 1 High 50 0 BC 90 0BF 0 116 02 1 Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST Offset value for P control Low 0 High 100 0 25 0 RAMP Ramp function selection 0 mon Ramp Function 1 Use unit minute as Ramp Rate 2 Her Use unit hour as Ramp Rate Dr 15 UM91001A Parameter Parameter Description Range Drail RR Ramp rate Low 0 High See 5 0 0 0 NONE Output 2 No Function 2 dEH Deviation High Alarm 3 dEL Deviation Low Alarm OUT2 Output 2 function 2 6 PYH Process High Alarm 7 PYL x Process Low Alarm 8 Cool Cooling PID Function orEL Relay output 1 5 Sr d Solid state relay drive output 2 5 Sr Solid state relay output 3 4 0 4 20 mA current 5 Outed goe module 4 0 e 0 20 mA current 9 module 5 g IU voltage 7 module 6 D 5 0 5V voltage 7 module 7 1 50 1 5 voltage module 8 0 ig 0 10 voltage module Select BPLS bumpless transfer or 0 0 100 0 to continue O2FT Output 2 failure output 2 control function as the 0 transfer mode unit fails or select ON 0 or OFF 1 for alarm function Output 2 hysteresis value when output 2 50 0 LC O 1LC O2HY performs alarm Low 0 1 High 90 0 LF 0 2 LF function CYC2 Output 2 cycle time Low 01 High 90 0 sec 18 0 CPB Cooling proportional Low 50 High
48. 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 following table The low temperature coefficient resistors should be used for RA and RB Input Function RA RB R60 T C RTD 0 60mV X 33K 071 61 9K 3 92K X 07 5 1 AN 324 3 92K X 07 10V 649K 3 92K X 0720 4 20mA 39W 3 01W X 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 IV for 0 1V input 5V for 075V or 175V input 10V for O 10V input and 20mA for 0720mA or 4 20m input Finalstep Set the LOCK value to your desired function UM91001D Chapter 6 Specifications Power 90 250 VAC 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 Al 5uV ZE for all inputs except mA input A3 0uV ZE for mA in
49. ontrol may produce an unstable process UM 91001A 44 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 if 4 20 mA is selected or input voltage below 0 25V if 1 5 V is selected 2 ADER occurs due to the AD 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 If output 1 is configured as proportional control PB O and BPLS is selected for 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 PBZO and a value of 0 to 100 0 96 is set for OIFT 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 0 then output 1 will transfer to off state if OFF is set for and transfer to on state if ON is set for OFT N 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
50. ontrol 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 control for the Heat Cool control to produce a stable and zero offset process value Other Setup Required OITY CYCI O2TY CYC2 OIFT O2FT OITY amp O2TY are set in accordance with the types of OUTI amp OUT2 installed amp CYC2 are selected according to the output 1 type OITY amp output 2 type O2TY Generally selects 0 5 2 sec for if SSRD or SSR is used for OITY 10 20 sec if relay is used for OITY and is ignored if linear output is used Similar condition is applied for CYC2 selection UM 91001A 36 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 of
51. ould be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human ands 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 The torque should not exceed 1 N m 8 9 Lb in or 10 2KgF cm UM91001D 22 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 6 are not exceeded Except the thermocouple wiring all wiring should use stranded copper conductor with maximum gauge 18 AWG 3 2mm min SC Omm max yt Figure 2 2 Lead Termination for mA ZEL 4100 ZEL 8100 and ZEL 7100 6 0mm max Figure 2 3 Lead Termination for ZEL 9100 SS 3 0mm min 90 250VAC 1 1 50LC max air ambient 4163 Hz Use copper conductors 12VA 2 2 except on T C input 13 RE TXI TXD 13 85 485 4 RE TX2 14 RETRANSMISSION DI COM 15 RS232 OP2 6 6 7 7 ALM 8 PTA 18 TC V FH 9 PTB mA 19 TC V 19 PTB m 20 V mA RID Figure 2 4 Rear Terminal Connection for ZEL 4100 and ZEL 8100 23 UM91001D 90 250VAC 8
52. pplicati Soon the number of available parameters OZIY depends on setup conditions and should ER lepend tup lit 1 should OFT be less than that shown in the flow chart ae I than that sh the flow chart 5 e 2 2 You can select most 8 parameters put c CPB in the user menu by using SEL SEL8 contained at the bottom of setup menu ee tained at the f setup ALEN lt CL AMD 3 Release 2 press 9 again for 2 seconds or longer but not longer than 3 seconds ec g t not longer than 3 d tom then release to enter the calibration menu ADDR 4 The user menu shown in the flow chart is 1 para corresponding to the default setting for cp A the SEL parameters SEL to SELB SP3 stop will be hidden if NONE is selected for c CAELO ALEN SP2 will be hidden if alarm function Cram is not selected for OUT2 The unused El C Sec parameter will be hidden even if it is 6 SEL2 selected by SEL parameters SEL3 S SEL4 LSE c cL 506 SELT UM91001D 12 1 6 Parameter Descriptions t Ee Parameter Description Range Defan SPI Set point for output 1 Low SP1L High SP1H UI Set point for output 2 10 0 BC SP2 when output 2 performs 19999 High 45536 ou 18 0BF alarm function Set point for alarm or 2199 sedi 10 0 BC SP3 dwell timer output Taie 13329 Migne 18 0 BP OnonE No parameter is locked 1 SEE
53. put Sensor Lead Resistance Effect T C 0 2uV ohm 3 wire RTD 2 6 LC ohm of resistance difference of two leads 2 wire RTD 2 6 LC ohm of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 1204 Normal Mode Rejection Ratio NMRR 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 UM91001B 60 Characteristics Accuracy Input Type Range 25 C Impedance 120 C 100 C J 184 F 1832 F A2LC 22MQ 200 C 6 K 328 F 2498 F 2 22 0 250 C 400 C T 418 F 752 F A2 LC 22 0 100 C 900 C E 148 F 1652 F A2 LC 22M Q A2LC 0 C 1800 C o 200 C 32 3272 BF 1800 C 2 2M 0 C 1767 8 C m 32 3214 BF e 22 1 1767 8 S 32 BF 3214 BF 22 0 250 C 1300 N 418 F 2372 F A2 LC 22 0 200 900 C L 328 F 1652 F A2 LC 22 PT100 210 C 700 C DIN 346 129208 0416 13K 80 PTIOO 200 C 600 C JIS 328 F 1112 F A0 4 LC LIE D mV 8mV 70mV 0 05 96 20M O mA JmA 27mA A0 05 96 705 V 43V 15V 0 05 96 650K Q 6l UM
54. ramming Port 9 1 4 Keys and Displays 10 1 5 Menu Overview 12 1 6 Parameter Descriptions 13 Chapter 2 Installation 2 1 Unpaking 2 2 Mounting 2 3 Wiring precautions 2 4 Power Wiring 2 5 Sensor Installation Guidlines 25 26 Sensor Input Wiring 26 2 7 Control Output Wiring 26 2 8 Alarm Wiring 30 29 Data Communication 31 Chapter 3 Programming 3 1 Lockout 33 3 2 Signal Input 33 33 Control Outputs 34 34 Alarm 39 3 5 Configure User Menu 40 3 6 Ramp 41 37 Dwell Timer 42 38 PV Shift 43 39 Digital Filter 44 3 10 Failure Transfer 45 3 1 Auto tuning 46 3 12 Manual tuning 47 3 13 Manual Control 48 3 14 Data Communication 50 3 15 PV Retransmission 50 Page No Chapter 4 Applications 4 1 Heat Only Control with Dwell Timer 51 42 Cool Only Control 52 4 3 Heat Cool Control 53 Chapter 5 Calibration 55 Chapter 6 Specifications 60 Chapter 7 Modbus Communications 66 Functions Supporte 66 Exception Responses 7 1 7 2 7 3 Parameter Table 7 4 7 5 Data Conversion Communication Examples Appendix A 1 Error Codes 76 A 2 Warranty 77 UM 91001A E Figures amp Tables Page No Figure 1 1 Fuzzy Control Advantage 6 Figure 1 2 Programming Port Overview H Figure 1 3 Front Panel Description 1
55. rpose of such conversion Let Value of Modbus message Actual value of the parameter SL Scale low value of the parameter SH Scale high value of the parameter The conversion formulas are as follows 65535 A SL SH SL SHSL M SL 65535 7 5 Communication Examples Example 1 Down load the default values via the programming port The programming port can perform Modbus communications regardless of the incorrect setup values of address baud parity stop bit etc It is especially useful during the first time configuration for the controller The host must be set with 9600 baud rate 8 data bits even parity and 1 stop bit The Modbus message frame with hexadecimal values is shown as follows 73 UM 91001A o o 00 o 4D 6D 51 INLO 17 8 CYC1 18 0 OFST 25 0 RAMP 0 00 1 o o 00 00 64 4 ir O2TY 0 O2FT 0 O2HY 0 1 CYC2 18 0 CPB 100 ALFN 2 REHI 100 0 ALMD 0 ALHY 0 1 ALFT 0 COMM 1 DATA 1 PARI 0 STOP 0 SEL1 2 00 o Hi Lo SEL8 17 CRCI6 UM91001D SEL7 10 74 Example 2 Read PV SV MV1 2 Send the following message to the controller via the COMM port or programming port 03 00 00 04 Addr Func Starting Addr No of words CRCI6 Example 3 Perform Reset Funct
56. s out of range register address to the slave Communication error attempt Don t write a read only 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 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 p _ Fail to perform auto tuning during auto tuning procedure a a 8 26 7 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 TI 6 Touch RESET key 29 EE EEPROM can t be written correctly Return to factory for repair 30 IC Cold junction compensation for R fac es thermocouple malfunction GEES Input sensor break or input current below 1 mA if 4 20 mA is A Replace input sensor 39 Sher selected or input voltage below P P 0 25V if 1 5V is selected A to D converter or related 40 AdeEr Return to factory for repair component s malfunction UM 91001A 76 WARRANTY ZESTA ENGINEERING LTD is pleased to offer suggestions on the use of its various products However ZESTA makes no warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or u
57. se of ZESTA 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 ZESTA reserves the right to make changes without notification to Purchaser to materials or processing that do not affect compliance with any applicable specification ZESTA 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 ZESTA S sole responsibility under this warranty at ZESTA 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 RETURNS No products return can be accepted without a completed Return Material Authorization RMA form 77 UM91001A ZESTA ENGINEERING 212 Watline Avenue Mississauga Ontario Canada L4Z 1P4 Voice 905 568 3100 Fax 905 568 3131 Website www zesta com Email info zesta com sos IPU mpd 1144 2204 sun oiny 0016 0018 OOI 001 TAZ GIT 20133119 3 VISHZ
58. t true 0 1 BF 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 6 UM 91001A 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 t
59. transmission high scale value 4 4 35 Alarm opertion mode 0 65535 36 Alarm hysteresis 5 Sr 37 Alarm failure transfer 0 65535 38 Communication function 0 65535 39 Address 0 65535 N 40 Baud rate 0 65535 N 4 Data bit count 0 65535 2 Parity bit o 65535 W 43 Stop bit count 0 65535 JW 44 Selection 1 0 65535 JW 45 Selection 2 0 65535 46 Selection 3 0 65535 47 Selection 4 0 65535 N 48 Selection 5 0 65535 N 49 Selection 6 0 65535 50 Selection 7 0 65535 51 Selection 8 0 65535 N 52 mV calibration low coefficient 1999 9 4553 6 N 53 mV calibration high coefficient 1999 9 4553 6 54 RTD calibration low coefficient 1999 9 4553 6 N 55 RTDH RTD calibration high coefficient 1999 9 4553 6 N 56 Cold junction calibration low coefficient 199 99 455 36 N 51 CJHI Cold junction calibration high coefficient 1999 9 4553 6 N 58 Date Code 0 65535 59 SRNO Serial Number 0 65535 N 60 Working hours of the controller 0 65535 N UM91001D Parameter rw Notes 61 Bumpless transfer of OPI 0 00 655 35 62 Bumpless transfer of OP2 0 00 655 35 63 Cold junction signal low 0 000 65 535 64 128 Process value 4 4 65 129 Current set point value 4 4 Read only control output value 0 00 655 35 r control Read only 0 control output value 0 00 655 35 iem control 68 emaining time of dwell timer 1999 9 4553 6 69 Error code 71 0 655
60. ts UNIT SEL selects SEL4 selects SEL5 SELB selects Now the upper display scrolling becomes S Caps ren t 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 PV 200 i5 Figure 3 5 RAMP Function KS 30 gt Time 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 41 UM 91001A 3 7 Dwell Timer Alarm output can be configured as dwell timer by selecting TIMR for ALEN As the dwell timer is configured the parameter SP3 is used for dwell time adjustment
61. urs 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 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 39 UM91001A Normal Alarm ALMD NORM When a normal alarm is selected the alarm output is de energized in the nor alarm condition and energized 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
62. w 0 ZE The temperature is lower than the ambient a cooling action is required Hence select DIRT for Since output is used to drive a magnetic contactor OITY selects RELY A small temperature oscillation is tolerable hence use ON OFF control to reduce the over all cost To achieve ON OFF control PB is set with zero and O1HY is set at 0 1 ZE Setup Summary INPT PT DN UNIT LC DP 1 DP OUTI DIRT Refrigerator OITY RELY RTD Mains Supply User Menu 19 20 5 PB 0 LC 18 4 011 01 ZESTA _ZEL 8100 Figure 4 2 Cooling Control Example UM 91001A 52 4 3 Heat Cool Control An injection mold required to be controlled at 120 LC to ensure a consistent quality for the parts An oil pipe is buried in the mold Since plastics is injected at higher temperature e g 250 LC the circulation oil needs to be cooled as its temperature rises Here is an example Injection Mold Plastics DOC Oil Pump Freezer RTD Heater Suppl 420 mA PES OUT2 4 louti se 4 gan 1200 zf Ian CIS 5 o Figure 4 3 Heat Cool Control Example ZESTA _ZEL 8100 53 UM 91001A The PID Heat Cool is used for the above example To achieve this set the following parameters in the Setup Menu INPT PT DN UNIT LC DP 1 DP Adjust SV at 120 0 LC CPB at 125
63. 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 occurs or if the A D converter of the unit fails 3 5 Configure User Menu The conventional controllers are designed with a fixed parameters scrolling If you need a more friendly operation to suit your application the vender will say sorry to you The series have the flexibility for you to select those parameters which are most significant to you and put these parameters in the front of display sequence SEL1 SELS Selects the parameter for view and change in the user menu Range LOCK INPT UNIT DP SHIF PB TI TD 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 UM 91001A 40 Example OUT selects DE LO 100 0 SEL selects INPT SEL2 selec

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