Home

Heat Manager Pro Connect - CasCade Automation Systems BV

1. You can now reboot the system After rebooting the system will try to communicate with the TIO modules and check their configuration When that was successful the Heat Manager will try to communicate with all the other connected devices When a communication error occurs an error screen will appear if not the system will show various startup screens incl your logo when selected and continue to the main menu Heat Manager Connect Engineering Manual V1 3 Page 30 6 ENGINEERING SETTINGS AND PREFERENCES This screen shows an overview of the settings menu screen To enter this menu press SETTINGS in the main menu screen The RECORDER CFG LIMIT SET and MODEM menu items are covered in the User Manual please consult that manual for those settings Note that the LIMIT SET button is only visible when you have DIO external signaling modules connected the MODEM button is visible when the external GPRS modem is connected The CURRENT SET button is visible when during the setup the THVA1 thyristor modules or the Z CT current sense module have been selected SETTINGS RECORDR CF6 CONTROL CFG LIMIT SET CURRENT SET MODEN SYSTEM OPERATION MAIN MENU Heat Manager Connect Engineering Manual V1 3 Page 31 6 1 Controller configuration This screen is for tuning the PID settings Only change this when you have experience with adjusting these settings otherwise an unstable temperature control can occur SETTINGS SETTINGS MAIN MENU
2. First select the controller channel you want to change since they are all the same we will select channel 1 as an example SETTINGS LJ DEFAULT H J COPY TO ALL J AUTOTUNE Le Le LEL SETTINGS CONTROL CFG Here you can tune the PID settings For most situations the default settings are ok these are Prop Band 11 0 C Int action 180sec Der Action 20sec Cycle time 10 0sec Dig Filter 15 0sec When the programmer is in a soak segment you can push the AUTOTUNE button the system will try to determine the PID settings by executing an automated calibration procedure Only perform this operation when you have experience with setting these values The COPY TO ALL button copies the PID settings for this channel to all other channels The DEFAULT button sets the PID settings back to the settings above Heat Manager Connect Engineering Manual V1 3 Page 32 6 2 Current Set Press SETTINGS Current Set to the correct settings for the current limits and heater break alarms You must also select which channel you wish to set After selecting the right channel the following screen will appear when a CT module has been selected CURRENT MAXIMUN CURRENT NOW SET TO COPY TO ALL CURRENT SET MAIN MENU With this screen you can set the desired nominal current for the heating element that is connected to this channel The current setting is displayed above the buttons Keep the desired current button press
3. Meet the new heat Engineering manual Heat Manager Pro Connect Heat Manager Connect Engineering Manual V1 3 Page 1 Thank you for choosing Heat Manager Pro Connect Series This manual should enable you to use your machine to full satisfaction Every effort has been made to provide you with maximum performance ergonomics and benefits from this premium quality product Version History 1 7 9 2010 Initial version V1 0 06 2 2014 Version 1 1 Updated for Heat Manager Connect software version 4401T V103 133 2 1 2 2014 Version 1 2 Pin levels added and cosmetic changes chapter on PID control FAQ updated 30 12 2014 Version 1 3 Updated for Heat Manager Connect software version V105 146 CT module functionality for guarding element currents added New menu structure documented small changes Heat Manager Connect Engineering Manual V1 3 Page 2 TABLE OF CONTENTS TABLE OF CONTENTS READ THIS FIRST Explanation of symbols Welding Thermocouples Touchscreen introduction Touchscreen maintenance Touchscreen cleaning 7 CONNECT TIO DIO CT MODULES 1 1 Power and communication signals 1 2 RS 485 communication termination resistor 1 3 Temperature sensors and control relays TIO module 1 4 Digital outputs DIO module 1 5 Current measurement inputs CT module 2 SET HARDWARE CONFIGURATION OF TIO DIO CT MODULES 3 CONNECT TOUCHSCREEN 3 1 Power supply connector 3 2 RS 485 communication connector 4 STARTING FO
4. O WEP Key3 Hexadecimal x 64bits O WEP Key4 Hexadecimal v 64bits Apply as Temp amp Connect Save Settings amp Connect Configure the Wireless connection by using the following settings Roaming Threshold Normal SSID HMPConnect1 Topology Ad Hoc Mode Wireless Band Mode G Only TxRate Auto Channel 1 Authentication Open Encryption WEP WEP Key ASCII 128bits heatmanager01 Press Save Settings amp Connect to finish setting up the Wireless Connection on the PC W module Heat Manager Connect Engineering Manual V1 3 Page 52 7 2 Setup your PC for connection with the PC W when present Open up the start menu and click Configuration screen gt Network Connections Here you will see Wireless Network Connection Right click on this Icon and select Properties to open up the TCP IP settings screen The TCP IP screen will look as follows Eigenschappen voor Internet protocol TCP IP AR Configure the Wireless connection on your pc by using the following settings a Algemeen P instellingen kunnen automatisch worden toegewezen als het netwerk i deze mogelijkheid ondersteunt Als dit niet het geval is dient u de Use the followin IP Address netwerkbeheerder naar de geschikte P nstellingen te vragen IP address 7O 0 502 subnet mask 255 255 255 0 Default gateway 700 50 7 Automatisch een P adres laten toewijzen Het volgende P adres geb
5. The TIO DIO modules only accept the new setting after a power cycle Heat Manager Connect Engineering Manual V1 3 Page 16 3 CONNECT TOUCHSCREEN 3 1 Power supply connector The touchscreen must be supplied with 24VDC This must be connected to the power supply connector of the touchscreen Please regard the polarity of the 24VDC signals Opening Button The FG functional ground must also be connected to the central PE protective earth connection of the unit This can prevent damage to the touchscreen in case of an electrostatic discharge Heat Manager Connect Engineering Manual V1 3 Page 17 3 2 RS 485 communication connector Connect the RS 485 communication port COM2 on the touchscreen with the 9 pole sub D plug female with the first TIO module T R b white T R a brown SG green Connector side 2 T R a brown 120E 1 4W 1 T R b white ee 5 SG green _ Fs n to connector housing OR aaa Solder side Cable type LICY 2x2x0 25mm7 To the left you see the 9 pole connector on the side of the touchscreen To the right you see the part of the cable that must be connected to the first TIO Note that on the TIO module you connect T R A White wire to T R B The 1200hm bus termination resistor must be connected between the T R A and T R B communication lines on the last module in the communication line between T R A 3 and T R B 4 When using a 6 channel
6. Afer System saving configuration you have to restart the device tr 9 LAN Settings rotten tender lt IP Address 70 0 50 100 one Piezak dnsszaned Subnet Mask 255 255 255 0 7 Default Gateway 70 0507 nat eae Wel ore save the settings after having filled in all ONS Settings the values SNMP By enabling SNMP you alow De maragersent utr to collect the informa on of Seria Server You can change the Gevice network identity ss wef by Changing the eyelem name locator and contact SNMP Setti ngs Warning note that after you saved your settings with another IP address the module can no longer be approached at the default IP addresses 10 0 50 100 Heat Manager Connect Engineering Manual V1 3 Page 51 Configure the Wireless settings of your PC W module Open up the Wireless Settings by clicking on Wireless in the main menu on the left The screen will look as follows Wireless Wireless Setting O O O O Roaming Threshold dBm Low 25 80 Normal 50 70 High 75 60 SSID HMPConnect1 BSSID AP MAC il C1 Enable Topology Ad Hoc Mode x Ad Hoc Mode doesn t support DHCP Static IP only Wireless Band Mode G Ony TaRate Ato Channel im Authentication Open IS i Encryption WEP WPA PSK 8 63 ASCII or 64 HEX WEP Keyt ASCII 128bits v heatmanager0 O WEP Key2 Hexadecimal v 6abits_
7. Heat Manager Connect Engineering Manual V1 3 Page 62 9 2 3 Integral action stands for integral action It takes a summation of the deviations between set value and process value from the past into account This action is necessary for removing the small offset error that remains between set value and process value when only a P action would be used The integral control action is also referred to as reset The degree of integral action is expressed as an integral time in seconds The purpose of the integral action is to automatically compensate for any steady state offset that is inherent with a controller that only works with a proportional action The integral action moves or resets the proportional band up or down depending on the offset The integral time of the controller is adjustable and determines how fast the proportional band is moved TEMP SV A too high setting of the integral action will result in a very slowly reacting process with big over and undershoots A too low setting of the integral action will result in a control system that can never reach the set value exactly There will remain a small offset error and the desired set value is not reached The trick here is also to reach the setting that more or less corresponds to the actual inertia of the system under control Now we go back to the speed control of our car with the gas pedal When you push in the gas pedal fully it takes some time to rev up the engine an
8. Manager Heat Manager Connect Engineering Manual V1 3 Page 59 9 PID CONTROL A The default settings for the PID controllers in the Heat Manager have been determined by performing a lot of tests in actual real life process situations When you keep the ratio between heating power and work piece mass the same you can use the same settings for most process conditions PID control can be considered as the intelligence or brain of the controller The same is when you are driving a car on the highway and wish to control the speed at 100 km hr Because of varying road conditions different tarmac driving up or downhill it is necessary to increase and decrease throttle to hold the desired speed You will also notice that your foot automatically does this Try to concentrate more on what you are actually doing and you will notice that it is actually quite impressive on how the brain executes this apparently easy task Your brain is now acting as some kind of very high level adaptive PID controller 9 1 A bit of history In the past century when automation became more and more important in industry mathematicians and engineers tried to find a way to integrate this knowledge into an automated system PID controllers date back to the 1890s governor design PID controllers were subsequently developed in automatic ship steering One of the earliest examples of a PID type controller was developed by Elmer Sperry in 1911 while the first publi
9. and CT modules 1 1 Power and communication signals Please remove the left most TIO from the backplane You can also remove the cabling protection cover from the connection screws On the first most left TIO module channel 1 4 you must connect the 24VDC power supply and the RS 465 communication line connected to COM 2 on the touchscreen to the backplane behind the TIO We strongly advise a 2x2x0 25mme or thicker LICY cable for the communications A Please regard the polarity of the 24VDC signals Number on the backplane 24VDC OVDC OVDE S E RS 485 T R A brown wire S RS 485 T R B white wire RS 485 SG green wire A You don t have to connect 24VDC power and communication signals to the next TIO and DIO modules The power supply and communication signals are internally transferred via the backplane A We strongly advise that you don t use the backplane for bridging the 24VDC lines to other modules in the system This can cause irreparable damage to the backplane and or modules Heat Manager Connect Engineering Manual V1 3 Page 8 1 2 RS 485 communication termination resistor To enable a reliable communication between the touchscreen and the modules you need to add a 120 ohm termination resistor between the T R A and T R B line brown and white wire This must be done on the last communication module that is connected to the communication line Host computer Master Touchscreen side COM 2
10. electronic analog PID controllers were made with tube amplifiers After the invention of the solid state transistor things were progressing into analog solid state PID controllers and later with digital IC technology the first truly digital controllers were invented that make very advanced adaptable PID controllers possible under quickly varying process conditions Heat Manager Connect Engineering Manual V1 3 Page 60 9 2 From theory to practice In order to fully understand a PID controller an extensive and thorough mathematical knowledge of Laplace and Z domain transformations is necessary That goes too far for this manual We therefore take a more practical approach and try to describe a PID controller in common language that almost everybody can understand To make things easier we will start out with a very simple on off controller think of the old thermostat that was used in the past to control the temperature in a room the modern types used nowadays are almost all PID controlled 9 2 1 ON OFF control action ON OFF temperature control is the simplest and least expensive form of control available The output signal from a controller is either FULLY ON or FULLY OFF depending on the direction of the deviation between the set value and process value The figure below shows the characteristics of an ON OFF control action PV PY Process Value j SV Set Value The ON OFF control action takes place if any deviation from the
11. is displayed according to the 24hr time notation Year Sec Month Min Day Hour Press the corresponding digit to show the keyboard The keyboard allows you to edit its value only when the filled in value fits within the allowed range The allowed range will be shown on the keyboard Note that this date and time can always be changed later Choose setup type Press the USE WIZARD button in the Choose setup type screen The button will start flashing as soon as it has been selected Now press next to start configuring your system the other option load FR USB is not implemented yet in the software USE WIZARD Select user language Start by selecting the language which you want your operators to use This works in the same way as selecting the setup language Your selected language will start flashing Press NEXT to continue your configuration The user language can always be changed later Please note that the French translation is not implemented yet Heat Manager Connect Engineering Manual V1 3 Page 23 Select number of channels You will be asked to select the number of channels that your Heat Managers has Note that you cannot choose a 12 channel setup when you do not have a 12 channel configuration using 3 Z TIO A modules Currently you have a 6 channel version consisting of 1 TIO A and 1 TIO B module or 12 channel version consisting of 3 TIO A modules Press the desired configuration Your selection will start to f
12. is performed in the easy mode Heat Manager Connect Engineering Manual V1 3 Page 36 6 3 3 Change date and time Enter the date amp time menu by pressing SETTINGS gt SYSTEM Here you can change the system date and time settings by pressing the DATE amp TIME tab 3rd from the left You can change the values by pressing on them and entering the new desired setting A Note that the date format is Year Month Day Note that the time format is Hour Minutes Seconds Change Time hour Change date yy mm dd min sec Heat Manager Connect Engineering Manual V1 3 Page 37 6 3 4 Change security settings You can change the systems security settings in in the security menu This menu can be accessed by pressing SETTINGS gt SYSTEM Press the SECURITY tab 4th from the left to show the security menu A The PIN code system is only active in the advanced mode In the easy mode you are always automatically logged on SETTINGS SETTINGS MAIN MENU There are 4 levels of access within the Heat Manager These access levels are described below Level PIN Description Limits 1 1111 Used for operators that are only allowed to Cannot change control type heating start and stop channels profile and system configurations 2 2222 Used for operators that are also allowed to Cannot change control configuration change heating profiles and system settings 3 3333 For experienced operators Cannot change system security settin
13. present between the A and B communication line on the LAST module in the communication line Otherwise communication errors are possible Check the green led indicators on the TIO modules Rx Tx they must flash green The FAIL RUN light on the TIO modules must be continuously on Check that the internal wire bridges inside the 9 pole sub D plug female that will be connected to the COM port on the touchscreen are present This is necessary for 44011T 4301TW 4201 TW touchscreens You need to power cycle the Heat Manager to recover from this error Heat Manager Connect Engineering Manual V1 3 Page 20 0 INITIAL SETUP Language setup After the system detects your initial startup you will be asked to choose the setup language Note that this is the language used for setting up the Heat Manager This is not the language that the user will see we will set that up later on during the setup process Dutch English German French not implemented yet a Confirm selection You can select the desired language by pressing on the corresponding flag Your selection will be highlighted after doing so Press EXECUTE to continue the initial setup and confirm your selection End user license agreement After setting up the language the End user license agreement will be displayed Press the up and down buttons to scroll through the license scroll up n Scroll down Agree button Return to language Confirm agreeme
14. set value occurs This action responds quickly but is sensitive to input noise which causes chattering ON OFF switching at short intervals Therefore in actual use the ON OFF temperature control action has some hysteresis which is named dead band or control sensitivity This prevents the quick chattering around the set value when the process value is very near Heat Manager Connect Engineering Manual V1 3 Page 61 9 2 2 Proportional action P stands for proportional action and is a multiplication factor of the deviation between actual set value and process value Proportional action control is also referred to as P or gain in some control systems With the proportional action the controlled process no longer switches as a direct result of the deviation between set value and process value but controls this proportiona to this deviation The proportional action control is active within a user definable zone around the set value called the proportional band Pb When the process value PV enters the proportional band the output becomes gradually smaller and the process value stabilizes somewhere within the proportional band In the Heat Manager you set the proportional band in degrees but beware that there are other brands of systems that set this value in a percentage of the measurement span Proper adjustment of the proportional band will result in smooth control However it is very seldom that the actual process value stabilizes e
15. situation the programmer will remain at the same temperature set value and step time until all thermocouples of the programmer group are not in burnout state Polarity error when sensor below The Heat Manager will detect a polarity error warning when a process value drops below this temperature The default setting is 50 degrees Heat Manager Connect Engineering Manual V1 3 Page 34 6 3 2 Change general settings Enter the system settings menu by pressing SETTINGS gt SYSTEM You can change the general settings on the GENERAL tab Restart type With restart type you can select whether the Heat Manager can automatically re start all channels when the power on the Heat Manager returns after a power failure When you select hot the Heat Managers automatically restarts the running channels and continues with the set values where the power failed When the power was off for a long time you need to restart the Heat Manager because the temperatures have dropped way below this set value When you select cold the Heat Manager will automatically stop when the power returns an operator intervention is now necessary to restart the channels they will then start at the actual process value of the programmer Operation language only visible here when external signaling modules are selected With operation language you can switch the language of the Heat Manger between English German and Dutch French language is not implemented yet Y
16. CT SET when present This screen can be used to set the various nominal heating element current settings and select alarming options SETTINGS CT SET RE INIT SET MAX CURRENT FOR 1 2 AND 3 HEATER MATS SETTINGS MAIN MENU In box 1 2 and 3 you can set the nominal current settings that are used in the CURRENT SET menu option of the SETTINGS Off by current alarm Put a mark here when you want to switch the channel with a current alarm off Note this only works with a channel in Fixed SV mode in Programmer mode the channel keeps on running but an visible and audible alarm is given Block HBA and MELT alarm Put a mark here if you only want the CT module to react to maximum current alarms ADV SIM Toggle between the advanced settings overview and the simplified overview When you switch to the advanced view the following screen will appear SETTINGS SETTINGS MAIN MENU These settings are for experienced users Consult the supplier if you want to make changes here Heat Manager Connect Engineering Manual V1 3 Page 47 6 4 10 RE INIT SETTINGS RE INTT RUN SETUP TIO INIT SETTINGS MAIN MENU Only execute this procedure when you are familiar with the setup procedure of the Heat Manager Otherwise possible damage to the system and or a dangerous situation can occur Be sure to store the actual heating profiles on the USB stick before executing this function During the setup the Heat Manager needs to rea
17. D loop where the slave loop controls the heating to the process with its separate sensor near the heater as process value input The set value for the slave comes from output of the master PID controller that measures the actual desired process value of the product When you change a P action you also influence the and D action responses in some kind of way The same goes when you change the or D action everything is connected together more or less Don t start to move down in spiraling circles and change only 1 parameter at a time and verify very well if this improves the situation or not A good idea is to always write down carefully what you are doing so you begin to see a pattern in your workflow and take a few steps back if desired Dont set the D action too high since this very easily results in an unstable process control Use this only for fine tuning after you set the P and factors correctly When you change an action you need to wait for the process to respond to the new situation This can take many minutes and depends on the inertia of the process Watch the recorder output of the process value to determine if it stabilizes or not Generally speaking it is important to keep the ratio between heating power versus mass of the system the same after determining the correct PID settings for your system You can then use the same settings for different situations 9 7 More information Consult the internet on more in
18. DIO CT modules you will find a small dipswitch with 8 switches this must be set to the same setting for each module 38400 bps amp bit no parity 1 stop bit and Modbus protocol A Use a very small watch makers screw driver to change these settings since these very small switches are easily damaged Below you see the factory default setting DIP switch Module z mainframe Right side view Factory set value 19200 bps u or oF marapay Sep te ON OFF OFF Dontsetthisone S OFF ON OFF DataT bit Even parity Stop tt ON ON OFF Data7 bit Odd parity Stop tbt OFF OFF ON Data 8bit without parity Stop t ON OFF ON Dontsetthisone OFF ON ON Data amp bit Even parity Stop bit ON ON ON Data amp bit Odd parity Stop tbt When the Modbus communication protocol is selected this seting becomes nvaid Factory set value Data amp bit without panty Stop 1 bit a Protocol OFF PRK CE communication O PON Ms Factory set value RKC communication ci e Switch No 7 and 8 must be always OFF Do not set to ON When two or more modules are connected on the same communication line the DIP switch settings of all modules must be the same In the table below you see the needed settings for the Heat Manager You must adjust these settings for all TIO DIO and CT modules These settings are all the same for all these modules _ Bipswiteh Number 1 8 3 458 75 A
19. Heat Manager configuration with 1 4 channel TIO and 1 2 channel TIO you need to connect the communication cable to the first leftmost TIO with rotating switch set to 0 and the bus termination resistor to the rightmost TIO with rotating switch set to 1 When using 3 TIO modules and 1 DIO module you must connect the communication cable to the first leftmost TIO with rotating switch set to O and the bus ttermination resistor to the rightmost DIO module last module on the communication line Connect the screen of the cable to the housing of the 9 pole Sub D plug For a GP4201TW 4301TW and 4401T touchscreen you need to make the following internal connections inside the 9 pole sub D plug female that will be connected to the COM 2 port on the touchscreen Connect point 1 to 3 Connect point 2 to 7 Connect point 4 to 8 Connect point 6 to 9 A Watch very carefully when making these interconnections on the 9 pole sub D plug Heat Manager Connect Engineering Manual V1 3 Page 18 4 STARTING FOR THE FIRST TIME When the Heat Manager starts it will first try to communicate with the first and second TIO modules so they must be connected properly When this test fails an error screen will appear with advice on how to check the problem Here is some advice on what to check when this screen appears Check the rotating switch with the TIO address The left is for the first TIO channels 1 4 and must be O internally converted to Mod
20. Module type controller SRZ TO modue Pair wire i Sise RS 485 ae g E TRIAS 2 TIR A 5 oe tp Si SG v P ielded twisted aap iihi Bus termination resistor 1200hm 0 25W on 4g Bil i y 1 s the last TIO DIO module between 3 and 4 op SHI mica backplane TR BH 4 R Termination resistor Example 122092 12 W SG A Watch out with the 24VDC signals never connect them to the RS 485 communication signals Heat Manager Connect Engineering Manual V1 3 Page 9 1 3 Temperature sensors and control relays TIO module Check the diagram below here you can see where the temperature sensors and relay contacts must be connected on the TIO module Right top of the TIO module is channel 1 right bottom channel 2 left top channel 3 and left bottom channel 4 lt Connecter type module gt lt Common to both 2 Ch 4 Ch tupes Voltage pulse Current Vottage Shown here is a TIO A module 4 channels so 4 green connectors When you have a 6 channel Heat Manager the second module consists of a so called TIO B only 2 connectors on the right side Open collector sput OUT4 5 Isolated between each input channel Voltage pulse output Current output and Voltage output Not isolated between output and power supply A The connection numbers of channel 1 and 2 right side of the TIO module are increasing from bottom to the top For the channels 3 and 4 the numbers of the connectors are decreasing when looking
21. Now press the SETUP button and all modules will be re configured by the system This will take a few minutes to finish A DIO digital output external signaling modules must be manually re initialized after replacement There is no configuration detection Do this with the SETTINGS SYSTEM RE INIT procedure and perform the TIO INIT see the corresponding chapter in this manual on how to get to that screen In case of emergency you can configure the DIO modules later Heat Manager Connect Engineering Manual V1 3 Page 69 10 4 don t know what went wrong with the setup configuration and wish to reset the touchscreen back to its factory defaults A Only proceed with this procedure if you are 100 sure about this all stored settings heating profiles and data logging inside the touchscreen except the stored CSV files on the SD CF card will be erased from the backup memory When this procedure is executed in the wrong order a re load of the touchscreen at the supplier may be necessary A Before executing this action be sure to store the actual 100 heating profile database on the USB stick in the PROFILE SET menu First we need to get the touchscreen in the offline mode this is not easy For this you need to be in the main menu and push the corners of the screen but just inside the black square intermittently If you see a gray bar appear STOP don t push anywhere anymore You need to push the screen intermittently first p
22. R THE FIRST TIME 5 INITIAL SETUP 6 ENGINEERING SETTINGS AND PREFERENCES 6 1 Controller configuration 6 2 Current Set 6 3 Change system settings 6 4 Advanced system settings 7 NETWORK SETTINGS 7 1 Setup PC W in Ad Hoc Wi Fi configuration when present 7 2 Setup your PC for connection with the PC W when present 17 17 18 19 21 31 32 33 34 40 50 90 03 Heat Manager Connect Engineering Manual V1 3 Page 3 7 3 Assigning an IP address to the touchscreen 04 7 A Setting up the ProMux ethernet to RS232 485 convertor for communication with RKC THV A1 thyristor modules when present Od 8 COMMON FUNCTIONS 57 8 1 Built in QWERTY keyboard ari 6 2 Numeric keyboard 58 Login keyboard 58 6 4 Using the built in file manager og g PID CONTROL 60 9 1 A bit of history 60 9 2 From theory to practice 61 9 3 Work step by step and by one 65 9 4 Auto tuning 66 9 5 Write down the newly determined PID values 66 9 6 Common pitfalls 67 9 7 More information 67 10 FREQUENTLY ASKED QUESTIONS 68 10 1 selected by mistake an extra TIO DIO module in the setup and now the system continuously gives a communication error how to get out of this hang up 68 10 2 started a new setup procedure but forgot to store the actual profiles file to the USB stick 68 10 3 One of my TIO or DIO modules broke down and need to replace them what should do and in what order 69 10 4 don t know what went wrong with the setu
23. THV SETTINGS when present This screen shows the actual status of communication with the RKC THV A1 thyristor modules used for controlling the heating elements These modules are controlled via a Modbus TCP to RS465 convertor The units itself work with a Modbus RTU serial protocol Heat Manager Connect Engineering Manual V1 3 Page 44 6 4 6 RECORDER when present This screen shows the actual status of the Chino AL AH 4000 recorder communication and its settings This recorder communicates with the Heat Manager via a Modbus TCP connection Heat Manager Connect Engineering Manual V1 3 Page 45 6 4 7 DIO 1 when present This screen shows the actual status of the DIO digital outputs for channels 1 6 A total of 8 digital Outputs are used For each digital output you can select if it is active high or low output relay activated or not when temperature inside band If you push the output type text behind the corresponding channel the output action will be inverted from the current situation 6 4 8 DIO 2 when present This screen shows the actual status of the DIO digital outputs for channels 7 12 A For each digital output you can select if it is active high or low output relay activated or not when temperature inside band If you push the output type text behind the corresponding channel the output action will be inverted from the current situation Heat Manager Connect Engineering Manual V1 3 Page 46 6 4 9 Z
24. ager Return to previous folder Previous page Next page DEL Deletes the selected file or folder COPY Selects al the files in the displayed folder DISP Displays the files in the selected folder PASTE Pastes the file that was cut or copied ALL Copies the selected file or folder DEL Cuts the selected file or folder Transferring data from the internal SD CF card to USB stick Use the following steps to copy files from the CF Card to the USB stick or vice versa using the file manager First make sure that your USB stick is connected to the Heat Manager and push on the SD lt gt USB button select the files you wish to transfer from the left column of the file manager The files you have selected will be highlighted in white Entire directories can also be selected Directories are shown with lt DIR gt next to the folder name You can either choose to copy the files or cut the files Press CUT or COPY The USB section will now be highlighted in yellow Select the directory in which you want the files to be stored Now press PASTE to copy the files Close the file manager by pressing the X button on the top right The files are now copied and the USB stick and it can be removed Do not disconnect the USB device until you have closed down the file manager A Always check if your CSV files can correctly be opened on the PC before removing these files from the internal SD CF card of the Heat
25. an try to load it by pushing the continue button You can skip this step at this stage but need to perform it before actually starting a profile in the Heat Manager in both the advanced and easy mode CONTINUE Select options first screen select the options that are available for your Heat Manager Modem connected GPRS modem for LogOnline present THV Thyristor units 6 RKC thyristor units used for driving the heating outputs Recorder comms Communication with a Chino AL H4000 recorder start stop etc Advanced made Work with 100 recipes and the 16 step profile editor When not selected the Heat Manager works in so called easy mode only 1 profile in channel with ramp up soak and ramp down step Heat Manager Connect Engineering Manual V1 3 Page 26 Select options second screen Customer specific screens External Signal Module when selected a customer logo is shown at startup for a short time before the Heat Manager continues The logo is also shown in the info menu These logos are present on the SD CF card Logo_start jopg 620x372 pixels for startup and Logo_info jog 835x283 for the info screen You can change the logos yourself and put them on the internal SD CF card you can remove it from the underside of the touchscreen When you dont select this option the normal startup with CasCade logo is shown Make sure the new file sizes don t exceed the original size so first size down the pictures you want to
26. bus address 1 The right one is for the second TIO channel 5 6 or 5 8 respectively depending on Heat Manager type and must be 1 internally converted to Modbus address 2 The third TIO channel 9 12 must be 2 internally converted to Modbus address 3 Watch out when using external signaling modules DIO modules the first DIO module must ALSO have the rotating switch set to address O internally converted to Modbus address 17 The second DIO module must have address 1 internally converted to Modbus address 18 The current measurement modules CT modules must have its rotary switch set to O internally converted to Modbus address 33 Also check the small dip switches on the side of the TIO DIO and CT modules you have to remove them from the DIN rail to check otherwise you cannot see them Put them in the configuration shown above this is for setting the communication speed to 38400bps no parity 8 data bits 1 stop bit and Modbus communication protocol Heat Manager Connect Engineering Manual V1 3 Page 19 When all these settings are correct you need to check the wiring from the COM2 communication port of the touchscreen to the TIO module It sometimes helps to swap the A and B line see bottom of TIO module backplane Make sure there is 24VDC present on the TIO modules You can check this by looking at the green FAIL RUN light on the TIO DIO CT module this should be continuously on Also check if a 120 ohm resistor is
27. ction numbers of digital output channels 1 to 8 right side of the TIO module are increasing from bottom to the top CN1 amp CNe2 For the digital input channels 1 to 8 the numbers of the connectors are decreasing when looking from bottom to the top Watch very carefully before connecting and check this with the side connection diagram on the side of the DIO Heat Manager Connect Engineering Manual V1 3 Page 11 Heat Manager Function ae number DO Temperature inside band channel 14 si DO Temperature inside band channel 14 si inside band channel 1 DO2 Temperature inside band channel 2 DOS Temperature inside band channel 3 po 04 Temperature inside band channel 4 po 05 Temperature inside band channel 5 pC DOB Temperature inside band channel6 Please note that for each digital output signal you can select whether the signal is active high or low This can be set in the advanced system settings of the Heat Manager Heat Manager Connect Engineering Manual V1 3 Page 12 1 5 Current measurement inputs CT module This part of the manual describes the signals on the CT current measurement module This module can monitor the actual current that is flowing through the heating element and can detect the following situations e Short circuit in heating element e Heater break in heating element current below nominal value e Maximum current in heating element for overcurrent protection The actual current measuremen
28. d images on a touch screen can be interactive too meaning they will react on a touch by your finger The interface on the touch screen is optimized for ergonomic operation In practice this means that all objects are positioned and sized such that they can be touched easily with your finger without the need for a stylus or precise positioning A soft tipped stylus can be used if preferred but is normally not required for proper operation Touching objects on a touch screen can be compared with a mouse click on a computer screen Based on the shown graphical user interface and your finger s position on the screen the system can determine what action it should take when an object is touched A To prevent accidental unwanted actions some objects may require a prolonged touch meaning you should keep your fingers pressed longer on a certain object like a button or display to invoke the required action Example The RUN PROG button to start the programmer on the operation screen requires a prolonged touch for about 7 sec Touchscreen maintenance A IMPORTANT READ THIS FIRST Never operate a machine until you have fully understood it s safe working conditions and operating principles Never operate the machine unless you are authorized to do so Heat Manager Connect Engineering Manual V1 3 Page 6 NORMAL EVERY DAY USAGE Your touch screen utilizes a sensitive touch mechanism The technique used provides reliable Operation even w
29. d speed up Also when you let go of the pedal it takes some time to let the engine rev down This is mainly because of mechanical inertia inside the engine The weight of the car itself is also very important a big heavy truck takes much more time to speed up then a small compact car In a laboratory on rollers we determine the speed of the car as a function of the gas pedal position this can now be considered as the P action This situation does not correspond to a real road situation where you have wind and different kinds of tarmac To compensate for this the gas pedal needs to be pushed in a bit more or less depending on the situation This last action can be considered as the integral action it fine tunes the actual gas pedal setting but in a very slow way otherwise we overshoot the desired speed Heat Manager Connect Engineering Manual V1 3 Page 63 9 2 4 Differential action The D stands for differential or sometimes called derivative action This takes the rate of change per time unit of a deviation between set value and process value into account Differential action temperature control is also referred to as rate The degree of differential action is expressed by the differential time in seconds The controller measures the rate of the temperature increase per time unit and moves the proportional band to minimize overshoot The output change is directly proportional to the rate of change in the process value PV per ti
30. d this file from the USB stick Go to the PROFILE SET menu to store this file to the USB stick RUN SETUP ONLY PROCEED WHEN YOU HAVE AN USB STICK WITH THE FILE FOO001 BIN DEFAULT PROFILES FILE STORED TO IT RUN SETUP Use this option to select a new configuration without initializing the control system module TI0s DIOs Press the button for more than one second to invoke the initial setup process this is to prevent accidental pushing on this button Read the Initial Setup chapter to help you guide through the initial setup process Heat Manager Connect Engineering Manual V1 3 Page 48 TIO INIT select the TIO INIT option to only initialize the control system modules TlOs DIOs and select a new configuration A new setup will not be performed Only the settings in the modules will be set correctly Remarks You an only execute these functions when all the channels in the Heat Manager are in the stopped state You can use this setting if you replaced a TIO DIO or CT module and want to write the correct settings to it In case of emergency the default heating profile FOQ0001 BIN file resides on the SD CF Card It can be copied manually from the SD CF Card location FILEN FOO001 BIN to the USB Device also in the same directory with the File Manager from the HISTORY menu After that you can load the default profile file in the PROFILE SET menu Select LOAD FR USB for this and follow the instructions on the screen Push EDIT
31. ding the customer specific logo when selected and continue to the main menu If the Heat Manager detects TIO modules that are not configured the following screen will appear Heat Manager Connect Engineering Manual V1 3 Page 28 Now press the SETUP button and all modules will be re configured by the Heat Manager The screen below will appear when this procedure starts DIO digital output external signaling modules and CT current sensor modules must be manually re initialized after replacement There is no configuration detection Do this with the SETTINGS SYSTEM RE INIT procedure and perform the TIO INIT see the corresponding chapter in this manual on how to get to that screen This can be done later if desired Checking syste Comgunication and wiring Please wait The touchscreen tries to communicate with the first TIO module when this is successful the following screen will appear when not successful an error message will be displayed Heat Manager Connect Engineering Manual V1 3 Page 29 Configuring Control Systeg Please wait INIT The Heat Manager will now configure the temperature controllers TIO modules and all other optional IO selected in the setup This takes a few minutes to complete since hundreds and hundreds of parameters need to be set in the temperature control modules After all has been finished correctly the following screen will appear The systema ill be ready for use after reboot
32. e consider this manual adjustment procedure more like an art than a science It is very important that you have a graphic overview of the process values so you can see if your modifications give improvements or not then you need to move in the other direction It is always best to first start by setting the and D factors to O and only use the P action When you roughly feel how the process reacts to a step like change of the set value you can try the addition of the action to get the process value exactly on the set value Later on you add the D action to improve responsiveness After that you start changing the P or D values one by one Try doubling them or halving them and see how the process reacts to It This procedure must be re done until you are satisfied with the new settings When you see a process value that is slowly oscillating with a small amplitude and long period towards the desired set value you are on the right track with these settings We know from practice that the D action should be roughly 25 of the action Certainly not more Heat Manager Connect Engineering Manual V1 3 Page 65 9 4 Auto tuning It is also possible to make use of the auto tuning feature in the Heat Manager This is only possible when the controller is in a soak dwell segment and the set value does not change over time After enabling this feature the controller will perform a few test cycles where it automatically tries to det
33. e end Action at profile end sets the action that needs to be performed when the profile is finished You can either choose to stop control all channels will be switched off and the process cools down in a natural way You can also select cont control in this case the temperature set value of the programmed profile will remain on the last value and the channels will not be switched off Heat Manager Connect Engineering Manual V1 3 Page 41 6 4 2 TIO INFO SETTINGS mes Ji ccc Ji ICICI a SETTINGS MAIN MENU This screen shows the actual temperatures that are currently on the 6 channels or 12 when selected channels This can be used for calibration purposes CAL When you press this button the current time and date will be stored inside the Heat Manager as a reference to when it was last calibrated Keep this button pressed for 3 seconds to activate MAX TEMP Toggle between actual temperature and maximum temperature overview The maximum temperature screen shows the highest temperatures ever measured inside the TIO module These values cannot be reset Heat Manager Connect Engineering Manual V1 3 Page 42 6 4 3 AGP INFO SETTINGS OFFLINE SETTINGS MAIN MENU Batt condition This screen shows the actual condition of the internal non volatile memory backup battery that is used for storing the parameters recipe setup and recording buffer of the Heat Manager A green light means that the batte
34. ed for 1 second and the HeatManager will write the desired current to the module COPY TO ALL Write the selected settings to all 6 current monitoring channels CURRENT SET select another channel for current setting 1 6 MAIN MENU Return to the main menu Heat Manager Connect Engineering Manual V1 3 Page 33 6 3 Change system settings 6 3 1 Changing input type Enter the system settings input type menu by pressing SETTINGS gt SYSTEM Here you can change the settings on the INPUT TYPE tab The temperature unit selection can only be changed when all channels in the Heat Manager are in stopped state SETTINGS INPUT TYPE GENERAL CELSIUS Continue SETTINGS MAIN MENU Unit selection You can change the temperature unit by pressing the down arrow next to the label the temperature unit can be set in Celsius or Fahrenheit Select the preferred temperature unit by pressing the desired setting Your selection will be highlighted in white Press the OK button for a few seconds to confirm your choice this is to prevent accidental changes The Heat Manager will now start re configuring the temperature control modules please be patient and follow the instructions on the screen Action at TC break or polarity error You can select whether the programmer needs to continue with the profile when an open thermocouple is detected By default this setting is set to continue You can also change this into hold In this
35. ermine the PID settings based on so called step wise changes of the set value After changing the controller output to maximum or minimum monitors the physical behavior of the process value and determines the settings based on oscillation amplitude and period After performing many tests with various control systems Ziegler and Nichols derived formulas on how to convert the results of these tests into PID settings as a starting point before actual fine tuning can take place It sometimes takes a while before the system actually determines the new values during this auto tuning cycle Please be patient and wait until you see the newly determined values appear This can take some minutes and depends on how quickly the process reacts to the controller If the controller was not able to determine the new values it will leave the PID settings on the values before the start of the auto tuning procedure Watch out these calculated PID values are only a rough indication of the actual perfect PID settings and can result in an unstable process so keep in mind that manual fine tuning is often necessary Important only perform auto tuning when the process reached a stable state controller output and process value more or less stable The set value must also be stable so this is only possible in a soak segment and not in a ramp up down segment Warning Never execute an auto tuning procedure when the process conditions are not stable The softwa
36. formation about this there is an excellent Wikipedia page with much more information on this subject See http en wikipedia org wiki PID_ controller Parts of this description comes from the website of RKC instruments see http www rkcinst co jp english control_O1 htm Heat Manager Connect Engineering Manual V1 3 Page 67 10 FREQUENTLY ASKED QUESTIONS 10 1 selected by mistake an extra TIO DIO module in the setup and now the system continuously gives a communication error how to get out of this hang up When the communication error screen shows up push for 1 second on the round indicator middle below in the screen with this you will force a new re init procedure You can now de select the extra IO modules 10 2 started a new setup procedure but forgot to store the actual profiles file to the USB stick The default empty binary file with 100 empty profiles is also stored to the SD CF card inside the touchscreen On the setup screen that asks for the USB stick with profiles you just push SKIP and finish the setup After that go to the file manager in the history menu and there you can copy the SD CF CARD FILE FO0001 BIN file to the USB stick On the USB stick this file must also be in the FILEN FOQ001 BIN directory otherwise the Heat Manager cannot find it After storing this file correctly to the USB Stick you can perform a re load of the profiles file in the PROFILE SET menu select LOAD FR USB for this a
37. from bottom to the top Watch very carefully before connecting and check this with the side connection diagram on the side of the TIO Heat Manager Connect Engineering Manual V1 3 Page 10 1 4 Digital outputs DIO module This part of the manual describes the signals on the DIO digital output module The digital outputs on the DIO modules are fitted with potential free dry contacts These contacts are divided in two groups group 1 DO1 4 and group 2 DOS 8 Each group has 1 central common line Relay contact output Here you see the principle schematic diagram You need to connect the common COM line for each group Example when you want to switch 230VAC AC signals with output DO1 8 you need to connect both COM lines and connect them to 1 side of the AC power supply The output signals of the DIO module go to the A1 control point of the 230Vac power relay you want to switch The A2 side of the control point of the relay goes to the other side of the 23Q0VAC Other example when you want to switch DO1 4 with 24VDC and 230VAC with DOS 8 you need to connect the COM line of DO1 4 to 24VDC and the COM line of DO5 8 to 2EGOVAC The outputs of the DIO modules are coded as follows Relay contact output Open collector output CN1 A The digital outputs are on the right hand side of the DIO module Right top you find DO1 4 and right bottom DO5 8 To the left side of the module are the digital inputs A The conne
38. gs 4 4444 Administrator None The PIN code of the 4 access levels can be changed by pressing the corresponding PIN The PIN always has to be 4 digits O000 to 9999 Note that the PIN of one access level cannot be the same as any of the other 3 Heat Manager Connect Engineering Manual V1 3 Page 38 PIN code lock When having filled in an incorrect PIN X amount of times the system will be blocked for a X amount of time The time the system is disabled can be set using the PIN disable timer The PIN disable timer is the amount of seconds that the system will be blocked The maximum amount of PIN attempts can be set by pressing Max PIN attempts The maximum amount of PIN entries can be set from 1 to 9 A login session will expire after an X amount of time when the system is not in use The time before expiring can be set using the Expire Timer option The entered value is measured in seconds 10 to 9999 rN Always write down the changed PIN codes otherwise you cannot access the Heat Manager anymore In case of emergency you can perform a new setup from the advanced system settings The PIN codes will then be reset to their original values A When you log on many times with the wrong PIN code the screen appears locked In case of emergency you can enter unlock code 3712 The PIN code will now reset to OOOO Log in with the reset PIN code of OOOO and enter the new desired PIN codes in the SYSTEM SETTING PIN code setup scree
39. hen the screen is modestly covered with moist and dirt It also allows the wear of rubber gloves And even under these conditions it should normally react already on a gentle touch A Some buttons may require a prolonged touch to prevent unwanted actions If the touch screen fails to respond ask yourself first whether you have applied a valid command If in doubt you could check the responsiveness of the touch screen by using other commands Each valid command will invoke a short beep confirming the reception of the touch However whether or not the actual action is performed depends also on other conditions Avoid applying excessive force on the touch screen and never use sharp or hard objects e g nails tools kitchenware or a pencil to operate it In either case you might damage the screen and void your warranty Touchscreen cleaning Your touch screen is provided with a durable front sheet which is water oil and fat resistant The best way to clean the front sheet is with a soft Iukewarm and mildly moist cloth special disposable front cover protection sheets that will reinforce and protect your touch screen are available through your dealer Never use solvents e g thinner tri turpentine hot water soda abrasives or other aggressive matter for cleaning Heat Manager Connect Engineering Manual V1 3 Page 7 1 CONNECT TIO DIO CT MODULES This part describes how to connect all signals to the TIO and if present DIO
40. in the PROFILE SET menu to verify if the loading procedure went correctly If the list contains TEST or another name TEST or another name Program 3 EMPTY or another name etc The loading procedure went correctly If the screen appears empty try again Heat Manager Connect Engineering Manual V1 3 Page 49 7 NETWORK SETTINGS 7 1 Setup PC W in Ad Hoc Wi Fi configuration when present Use the following steps to configure a so called Ad Hoc configuration with your PC W Wireless module Configure the network settings of your PC W module In order to connect to the PC Ws built in web interface you must make sure that your computers IP is in the same range as the module The modules default IP address is 10 0 50 1 00 If you Cannot connect to the PC W using this address press the reset button to restore its default settings The RESET button is located on the front of the module next to the Ethernet port The button needs to be pressed using a paperclip RESET button To start configuring the module type its IP address into your PC s web browser to open the web interface Click on Network in the main menu on the left to open up the network settings This screen will look as follows Heat Manager Connect Engineering Manual V1 3 Page 50 Wireless Client Adaptor Overview Network monr Networking Configure the PC W using the following Serial TOPP settings To Configure network settings of Berie Server
41. is by modulating the controller output back to a lower value e g 50 When the output is 50 and the cycle time is 15 seconds the relay will be on for 7 5 seconds then switch off for 7 5 seconds switch back on for 7 5 seconds etc etc etc When the controller output is only 10 the relay will be switched on for 0 1 x 15 1 5 seconds and then remain off for 15 1 5 13 5 seconds The problem is that we introduce some kind of ag time into the system Of course it would be a good idea to set this cycle time as low as possible because then the controller can react more quickly to varying process conditions The major disadvantage is then that the mechanica relay has to switch very quickly on and off This will damage the contacts of the mechanical relay too quickly and wear them out too fast As a compromise the cycle time has been set to 15 seconds for this purpose When you make use of thyristor modules or solid state relays the cycle time can be set at the lowest possible value O 1s since these modules don t have mechanical contacts The controller output can directly drive the modules proportionally which will result in a quick response to varying process conditions and a more stable and accurate process control Heat Manager Connect Engineering Manual V1 3 Page 64 9 3 Work step by step and by one When you adjust a PID controller by hand a lot of experience and as the Germans say fingerspitzen gefuehl is necessary W
42. isetond X naliercomds X nihecond or T Satt Module IP 70050707 Gateway 700 50 7 subnet Mask 255 255 255 0 server IP 70 0 50 702 Server IP has the same IP address as the touch screen Heat Manager Connect Engineering Manual V1 3 Page 56 8 COMMON FUNCTIONS 8 1 Built in QWERTY keyboard While using the Heat Manager Connect you will be asked to fill in all sorts of information This can be done by making use of the built in touch keyboard The keyboard is as displayed below You will notice that the keyboard makes use of the standard QWERTY layout The things you must know to make correct use of the keyboard are Your written text will be displayed in the input field at the top of the screen You can change the layout from QWERTY to numeric and vice versa by pressing the 123 ABC button at the left bottom of the keyboard Use the BS and CLR buttons to clear parts of the inserted text Close the keyboard by pressing ESC at the left bottom of the screen Move the cursor by pressing the Left and Right arrow buttons at the right bottom of the keyboard Confirm your entry by pressing ENTER Input field Backspace Switch to numbers and symbols Clear entire row Close keyboard Confirm Move cursor Heat Manager Connect Engineering Manual V1 3 Page 57 8 2 Numeric keyboard You make use of the numeric keyboard when edi
43. lash Press NEXT to confirm your selection 6 CHANWEL Temperature unit selection You can select the preferred temperature unit Note that the unit selection can always be changed later on Press NEXT after you have made a selection When using Celsius the Heat Manager works with 1 decimal behind the comma In Fahrenheit mode the Heat Manager works in whole degrees without a number behind the comma FAHRENHEIJ Heat Manager Connect Engineering Manual V1 3 Page 24 Select input type select thermocouple type K or S select TC K 1200 C when using RKC TIO modules default setting select TC K 800 C when using a single board RKC B400 module special version with limited functionality Select restart type Select HOT if you want the system to resume where it left off when a power failure occurs Select COLD if you want all channels to stop when a power failure occurs This setting can always be changed later in the system settings Heat Manager Connect Engineering Manual V1 3 Page 25 Preload profiles Insert the USB stick with the default profile database file on it This file FOQQ001 BIN is a binary file supplied by CasCade and for backup reasons present in de FILE directory on the SD CF card Put this FO0001 BIN file on an empty USB stick in the directory FILE make the directory if it does not exist The Heat Manager expects that the file is in this directory After the USB stick has been inserted you c
44. me unit Theoretically speaking a heating process is a pure integrator and can be controlled by using only a P and action most slow processes are Practice however shows that a small amount of D action can improve accuracy and especially responsiveness to changing external circumstances just a bit further A D action is often used in positioning systems Servo applications where quick movements are performed A D action is also important in a tunnel furnace where the product load differs from time to time Sometimes no product feed here the D action is used to prevent over or undershoot under various process load conditions that change more quickly than the integral time of the process Itself A too high D action will result in a very unstable process with large over and undershoots A too low D action will result in a system that does not respond quick enough too late to varying process conditions This will also result in an unstable system with over and undershoots 9 2 5 Cycle time Another important setting in a PID controller is its cycle time This time is the time span used by the controller to calculate how long a relay should be on or off Here is an example we have a mechanical relay that is driving a heating element and the cycle time Is set to 15 seconds When the controller output is 100 the relay will be continuously activated When the process value goes a bit over the set value the controller starts to react to th
45. much larger you can download the free program IRFANVIEW google to convert it to the correct size When you open your edited file in Irfanview and store it again you can set the desired file size Normally speaking the default options in Irfanview are correct for this Store the file again in Irfanview with the correct file size and compression setting can solve the problem Heat Manager Connect Engineering Manual V1 3 Page 71 11 NOTES Heat Manager Connect Engineering Manual V1 3 Page 72
46. n Heat Manager Connect Engineering Manual V1 3 Page 39 6 4 Advanced system settings Hardware configuration settings can be re configured in the Advanced Settings menu This menu is accessed from the SYSTEM SETTINGS menu in the following way Enter the SYSTEM SETTINGS menu by pressing SETTINGS gt SYSTEM Now go to the Security tab lt from the left Note that an arrow gt has appeared on the right top of the screen N Advanced System Settings arrow appears only with PIN level 4 access Press the arrow to enter the next screen with the advanced system settings Here you will see the following tabs PROFILE CFG TIO INFO AGP INFO and REMOTE CTRL FROR ILE GEU TIO TNFO ROP INFO REMOTE CTRE Heat Manager Connect Engineering Manual V1 3 Page 40 6 4 1 PROFILE CFG On this screen you can set different settings with regard to the programmers SETTINGS Ramp Ambient STOP CONTROL SETTINGS MAIN MENU Pref prog method When creating a heating profile the step configuration screen will always start with a ramp display degrees per hour You can switch this function to time by selecting time as the Preferred Program Method Press OK to confirm the preferred method Start profile from When creating a profile you can choose to either start from the ambient temperature or from zero degrees Use the Start Profile From to select your desired method Press OK to confirm Action profil
47. nd follow the instructions on the screen Push EDIT in the PROFILE SET menu to verify if the loading procedure went OK If the list contains TEST or another name TEST or another name Program 3 EMPTY or another name etc The loading procedure went correctly If the list appears complete empty try again Heat Manager Connect Engineering Manual V1 3 Page 68 10 3 One of my TIO or DIO modules broke down and need to replace them what should I do and in what order Power down the Heat Manager touchscreen and its TI0 DIO modules completely Make sure you write down the exact serial numbers on the side of the module you wish to replace E g Put them on a copier so you can use it for reference Make sure you get a replacement type with exactly the same letter and number combination Make sure that you set the round address switch and the small dipswitches on the side of the module exactly the same as the settings on the broken module Click the new module in the system and start the Heat Manager At startup the Heat Manager will see if the TIO module needs configuration Please note that this is only done for TIO modules but not for DIO modules you need to re init them manually from the setup screen When the Heat Manager detects a TIO module that is not configured it will show the following screen This means that the Heat Manager can communicate with the TIO modules but needs to re configure them to the correct settings
48. nt selection After reading the agreement you can press the Yes agree button to agree with the content of the license You cannot continue the initial setup without agreeing to the end user license agreement Contact CasCade if you have any questions about the license agreement The NEXT button will be highlighted as soon as you have agreed with the license Press the NEXT button to continue the initial setup Heat Manager Connect Engineering Manual V1 3 Page 21 Edit system information After agreeing to the End user license agreement you can enter the system information You can fill in the identification serial and order numbers Identification number Edit ID no Serial number Edit serial no Order number Edit order no Return to License Confirm editing agreement system info Press lt lt EDIT HERE gt gt next to the corresponding field to edit its value The keyboard will now appear allowing you to enter the desired data Repeat this action for all 3 fields A If this is your first time using the built in keyboard read the keyboard information in the Common section of this manual to understand its functions Heat Manager Connect Engineering Manual V1 3 Page 22 Adjust date and time You can set the correct date and time by pressing the corresponding button Keep in mind that the date is arranged according to the international standard which is year month day The time
49. onding fields to bring up the keyboard and fill in the desired values Configure your touchscreen by using the settings Settings Settings Error Settings Settings following settings Piire lt Q P at em an S P Address 70 0 50 102 beet 3 S Subnet Mask 255 255 255 0 ook oe Fe a a lt Port 8000 TIA N i lt Gateway 10 0 50 1 Seed ferrin 5 Your new settings will automatically be Duplex Settings saved when you press enter Back Pik Now press Exit to terminate the offline mode and restart the touchscreen the touchscreen can now be accessed at the IP address that Is entered Please make sure that you don t set the same IP addresses inside a network this will cause IP conflicts and the communication will not work Heat Manager Connect Engineering Manual V1 3 Page 54 7 4 Setting up the ProMux ethernet to RS232 485 convertor for communication with RKC THV A1 thyristor modules when present Enter the Promus web interface by typing the following URL into your browser htto 10 050 707 ip htm If you Cannot approach the module with this URL it is recommended that you reset it to its default settings You can do this by opening the module push in the two clips on the side and removing the default IP jumper Turn the module on and off again and place the jumper back The module now has its default settings back including its default IP address DEFAULT IP J
50. ou don t need to restart the system Batch info at start When batch info at start is enabled the Heat Manager demands that you enter the batch information when you start the first channel so this occurs only when all channels had been previously off starting other channels after this will not ask the batch info again Heat Manager Connect Engineering Manual V1 3 Page 35 Operation Mode The operation mode selects the way the heating profile is edited on the Heat Manager There are two modes the advanced mode and the easy mode In the advanced mode you can use a profile database of 100 profiles each consisting of 16 steps in the Heat Manager The profile editor assists you while editing each step in the profile In the easy mode there can be only 1 profile running in channel 1 that consists only of a ramp up soak segment and a cool down segment A Please note that the operation mode can only be changed when all channels are in stopped state A Be sure to set a correct new channel configuration and when necessary profile setting after changing from easy mode to advanced mode and vice versa A When you switch from advanced to easy mode the default profile is loaded This profile is ramp up to 600 C at 150 C per hour soak for 1 hour and 5 minutes ramp down to 300 C at 150 C hour after set value reach 300 C all channels off Cooling down in a natural way A This default profile is also loaded when a channel set
51. p configuration and wish to reset the touchscreen back to Its factory defaults 70 10 5 changed the logo files on the SD CF card but the Heat Manager does not show them at startup 71 11 NOTES 72 Heat Manager Connect Engineering Manual V1 3 Page 4 READ THIS FIRST Explanation of symbols The following signs have been used throughout this manual to draw your attention Hint Useful hints for ease of operation Printed in Blue A Info Information you should know to fully understand your system and benefit from its properties Printed in green A Warning Read these important messages before executing the desired operation Printed in red A Warning Read these important messages before executing the desired operation Printed in red Welding Thermocouples Do not weld thermocouples while connected to the system This may damage the system Heat Manager Connect Engineering Manual V1 3 Page 5 Touchscreen introduction Your machine has been equipped with a Human Machine Interface or HMI or more popular called A touch screen If you are familiar with touch screen operation found nowadays on modern cell phones navigation systems informational displays etc you may want to skip this section If however this is the first time you are using a touch screen please keep in mind that in contradiction with older fashioned operating panels utilizing mechanical buttons lamps and displays both the displays an
52. re algorithm assumes that all external factors with regard to the process are not changing while performing this operation Please remember that a manually tuned controller almost always outperforms a controller that was set with auto tuning Auto tuning is more or less a rough indication if you need some direction on where to start 9 5 Write down the newly determined PID values It is very important that you write down the newly determined PID values so you dont lose these painstakingly difficult to determine values A software upgrade re init procedure or controller module re init necessary after a replacement will restore the PID values back to their default values as programmed in the software of the Heat Manager Heat Manager Connect Engineering Manual V1 3 Page 66 9 6 Common pitfalls A system that is oscillating around its set value or reacting too slow to process variations is almost always caused by a PID controller that needs fine tuning Beware when it takes many minutes of time for a process value to change after step wise change of the set value This is caused by a so called dead time in the process and Is very difficult to overcome with PID settings in 1 PID loop alone The most common solutions for these kind of process issues are Measure more directly the actual product process value bring sensor nearer to product Make use of a so called cascaded control system where we make use of a master slave PI
53. ruiken P adres Click on OK to confirm the new configuration Subnetmasker Standaard gateway G De volgende DNS serveradressen gebruiken Voorkeurs DNS server Attematieve DNS server Test your wireless connection to the PC W module You can connect to the PC W by using WEP password you entered in the PC W module The password is heatmanagerO 1 A With some PCs it is necessary to fully restart it with a power down up to make use of the new IP settings Heat Manager Connect Engineering Manual V1 3 Page 53 7 3 Assigning an IP address to the touchscreen The touchscreen settings can be changed during operation by entering the touchscreen offline mode This can be done by either pressing the upper right then the bottom left corner or the upper left and then bottom right corner Note that you need to push inside the black rectangle but just on the edges of the corners You need to push in a rapid click click way with finger 2 just after the finger that pushes 1 You must not push both fingers together but just after another The menu bar will now appear on the bottom or top of the screen now immediately stop pushing or it disappears again Press the Offline button to enter the System menu Go to the Touchscreen mode and touch Main Unit Settings Now press Ethernet Local Settings this will show the IP configuration screen Press on the corresp
54. ry is ok red means that there is a fault with this battery Contact your supplier when this happens TIO x comms ok When the light is green the communication between the touchscreen and the TIO module is ok Number of samples left to trigger buffer almost full warning When the buffer that is used for sampling is below this amount you will get a pre warning the sampling however keeps on running until not sampling positions in the buffer is left You then get an alarm that prompts you to store the measurements and clear the buffer Editor Firmware Here you can see the software versions used in the Heat Manager SYSTEM platform This shows the hardware version of the touchscreen A If you set the touchscreen to offline all control and communications between the touchscreen and the TIO DIO control modules will be stopped and will remain on the last received set values The TIO modules however keep on controlling the temperatures on the last received set value Proceed with care OFFLINE Push this button to enter the offline mode keep it pressed for a few seconds Heat Manager Connect Engineering Manual V1 3 Page 43 6 4 4 REMOTE CTRL SETTINGS SETTINGS MAIN MENU This screen is used when an external heater control is used It shows the Modbus TCP status addresses for external control These values can be accessed via the Modbus TCP interface protocol that is mapped on the ethernet interface of the HeatManager 6 4 5
55. shed theoretical analysis of a PID controller was by Russian American engineer Nicolas Minorsky in 1922 Minorsky was designing automatic steering systems for the US Naw and based his analysis on observations of a helmsman Observing that the helmsman controlled the ship not only based on the current error but also on past error and current rate of change This was then made mathematical by Minorsky His goal was stability not general control which significantly simplified the problem While proportional control provides stability against small disturbances it was insufficient for dealing with a steady disturbance notably a stiff gale due to droop which required adding the integral term Finally the derivative term was added to improve control Trials were carried out on the USS New Mexico with the controller controlling the angular velocity not angle of the rudder PI control yielded sustained yaw angular error of 2 while adding D yielded yaw of 1 6 better than most helmsmen could achieve The Navy ultimately did not adopt the system due to resistance by personnel Similar work was carried out and published by several others in the 1930s In the early history of automatic process control the PID controller was implemented as a mechanical device These mechanical controllers used a lever spring and a mass and were often energized by compressed air These pneumatic controllers were once the industry standard Later on the first
56. t is done with so called current transformers that are also available from CasCade In this example you see that every current is looped through a CT but in a normal situation you don t need to loop it Only feed 1 cable through the hole of the CT In this example a terminal type Z CT is shown but most customers use the connector type see below Warning make sure that the connections of the CTs are very tight Otherwise high voltages across the Z CT module can occur that can damage this module Heat Manager Connect Engineering Manual V1 3 Page 13 The input connections are configured on the modules in the following way currently only channel s CT1 6 are used Current transfommer CT Current transformer CT input CTF to CT 12 l input CT1 to CTE CH3 l 7 cr For channel 2 amp 3 and 5 amp 6 only 1 common is used There 2 wires of 2 separate CTs are connected together to the same terminal This is normal and not a problem The address switch should be set to O actual Modbus address is 33 Heat Manager Connect Engineering Manual V1 3 Page 14 2 SET HARDWARE CONFIGURATION OF TIO DIO CT MODULES Address setting switch Setting range 0 to F 0 to 15 Decimal Factory set value 0 Module that must be set on the rotating Modbus commun ication address The TIO DIO CT modules only accept the new setting after a power cycle Heat Manager Connect Engineering Manual V1 3 Page 15 On the side of the TIO
57. ting heating profiles The functions of this keyboard are be explained below Minimal value Maximal value Input field ILI II Clear input completely Backspace delete last input Confirm input Close Keyboard CER ENFER The minimal and maximal values that can be entered will be displayed at the top of the keyboard Values that do not fall in this range will not be accepted by the system you hear a few beeps Use the number buttons to fill in the Input field Use the BS and CLR buttons to clear areas of the input field You can close the Keyboard by pressing the ESC button Confirm your entered data by pressing the ENTER button 8 3 Login keyboard After pressing the LOGIN button the login keyboard will appear The login keyboard works in the same way as the numeric keyboard The only difference is that the input field will cover up your input with for safety reasons Your login code Is a 4 digit number Input field Backspace Clear input Close Keyboard Confirm input ENTER Heat Manager Connect Engineering Manual V1 3 Page 58 8 4 Using the built in file manager You use the built in file manager to transfer files from the SD CF card to the USB device and vice versa The left part of the file manager will show you the files that are on the SD CF card where the right part of the browser will show you the files from the USB device Close the File Man
58. umper ProMux module Heat Manager Connect Engineering Manual V1 3 Page 55 Now you can approach the module with the following URL Atto 4 169 254 771 717 7 ip htm After doing so the Serial Ethernet converter amp Modbus Gateway screen will open up A Make sure that you set our pc in the same IP range 169 254 11 xx otherwise you cannot reach the module with your pc You must write down the original IP address of your PC before changing it because you need to set IT back to the original values after setting Mohair IP 19 Dein Garvu IP Salmet Mesk P 3 10 Sodea Teer Oe w Converter Mode 2 Che Tzoroi p Pon Number 432 Sere P 14 Modbus Comem 5 Wacidog PROCON ELECTRONICS Serial Ethernet Converter amp Modbus Gateway Fiberuct Configuration Parameters 191 m is f if if 10 X second Communication Modes up the module Sont isp u Server Standard Mode Mud Socket a Server Socket Lester Mode Sangi socket 2 Cimi Remote Socket Open Mode Single socat Tame to wait befar sending Ra Chars when tii Poot 20004 im Mode 0 a ata Mode 1 2 X 10 misccotsh Modbus TCP 802 Mode LAJ ont Mode onb X Inma f RS237 R5455 Commenirations Port Parameter load Pate Data Bits j Peara g Stine Bas RSISIRSHE g Serial Zeyh y Tenecer RSIS On Deier l0 RS455 OF Deisy 0 Module Name T00 MMT CPBOONY Or Nene Izreen Jd DRIL JRS X 10 wll
59. use This option is for selecting if the extra output relay unit for controlling the welding light is present in the system select 01 06 if the channel 1 6 DIO output module is present select 07 12 if the channel 7 12 DIO output module is present Current sensor module channel 01 06 This option must be selected when an extra Z CT module for monitoring the heating element currents is connected USE CUSTOMER SPECIFIC SCREENS EXT SIGNAL MODULE CHANNEL 01 06 EXT SIGNAL MODULE CHANNEL 07 12 CURRENT SENSE MODULE CHANNEL 01 06 PREVIOUS A When selecting the external signal module for channel 07 12 both DIO modules must be present in the system When you only use 1 DIO module for channel 01 06 only select external signal module channel 01 06 It is not possible to only use a DIO module for channel 07 12 channel 01 06 has to be present in this case Heat Manager Connect Engineering Manual V1 3 Page 27 When al data is correctly filled in you can confirm this by pressing the YES STORE button Your configuration will now be saved After this you can reboot the system If you still have doubts you can push re init to perform the whole setup from the start The system vill be ready for use after reboot After rebooting the first time the Heat Manager will check if the TIO temperature controller modules are configured correctly If they are configured correctly the system will show various startup screens inclu
60. ush 1 and quickly after that 2 so don t push both fingers at the same time Now follow these steps after the gray bar appears exactly in this order 1 Push Offline 2 Enter system password 15 enter 3 Go to the right top button Initialization Menu 4 Push only Initialize Backup SRAM and nothing else otherwise a re load at the supplier is necessary Oo Enter system password 19 enter 6 Push Start 7 Push Yes if you are sure about this Push Close 9 Push Exit 10 Push Yes The touchscreen will now restart in the factory default state You can now perform a clean setup To be 100 sure you can perform a TIO INIT from the system settings menu the TIO DIO modules will now be re initialized completely to the default settings for the Heat Manager Heat Manager Connect Engineering Manual V1 3 Page 70 10 5 I changed the logo files on the SD CF card but the Heat Manager does not show them at startup It sometimes happens that after editing the Logo_start jog 620x372 pixels or the Logo_info jpg 635x283 pixels it is not displayed at startup but the files are there and the pixel sizes of these files are correct It is very important that you used the same JPEG compression when saving the edited file Saving a JPEG file is just a container but does not specify the compression ratio Make sure that the saved file has about the same size as the previous one SOkKB When your new file is
61. xactly on the set value and it usually becomes stable with some deviation from the set value called offset A high P value gives the control system a large band of modulation the major disadvantage is that the reaction to the deviation can be quite slow A too low P value however gives an oscillating system where the process value continuously over and undershoots the set value We call that hunting the controller hunts to reach the set value Visualize this by thinking of the gas pedal in a car with automatic transmission a high P value is a gas pedal where you can push it very far in so you can control in an accurate way but need to push it far in and out to reach the speed that you want A low P value however is a gas pedal that has a very small travel but controls the speed of the motor from idle to maximum rev with only a small push on the pedal It is clear that this situation makes it also difficult to reach the speed you want you over and undershoot the speed all the time more like a classic on off control The trick is to reach the correct value where the oscillation is very low but with a quick enough responsiveness to deviations Large slow systems that react slowly to deviations generally need a higher P action than small quick systems TEMP oV Pb Proportional band Note Setting the P action to O will result in on off control action This will result in relatively large over and undershoots

Heat Manager Pro Connect - CasCade Automation Systems BV

Contents

Download Pdf Manuals

Related Search

Related Contents