ETR-9000 Digital Temperature Controller User Manual
Contents
1. 9 156 Parameter Descriptions pa bled a aded bebe tex 10 Chapter 2 Installation 13 2 2 13 2 85 EEUU 14 2 4 APOWE WINING 15 2 5 SENSOM 15 2 6 SEMSON Input WIFIFI seres A ner ire ee Ree eon a t ln terea niet e une take 15 2 7 Control Output Wiring eene eene er ener 16 28 rm 18 29 Data COMMUNICATION E 18 Chapter 3 Programming LOCKOUT m 19 3 2 Signal MOU ts 5 EET 19 32 GOMMON OUTST qm PECES 20 tese annealed eet hands cse datis 22 FS Display sso ect mee Rd ied Pep ifia ecd endete tre tcftc prae ect dut dd 23 eoo TEM 23 3 7 Dwell THM EHE 24 9 9 EI eee 24 335 25 3 10 Fall re JrarnSfet dde to ea tero deis saad arme tiem eae apa nama Er eS 25 E PAULO nU aj ajo srein n LIUC 26 3 12 Mari al e dace sese tnn nez gri ena nh nci eb ma Re2. Application 200 200 280 cag 35 C temperature Adjust SHIF Display is stable difference is observed SHIF 35 C SHIF 35 C SHIF 0 Supply more heat PV SV 24 3 9 Digital Filter In certain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from 0 to 60 seconds 0 second represents no filter is applied to the input signal The filter is characterized by the following diagram PV FILT 0 1 sec Figure 3 8 Filter Characteristics FILT 30 ieee Time Note The Filter is available only for PV and is performed for the displayed value only The controller is designed to use unfiltered signal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process 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 A D converter of the controller fails The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode Output 1 Fail
3. Time SP3 power off or touch RESET key ON Figure 3 6 Dwell Timer Function OFF Timer starts If output 2 is configured as dwell timer ALMD will be hidden 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 functiorThe 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 temperature differential is common in any thermal system when heat is transferred from one point to another If the difference between the sensor and the subject is 35 C and the desired temperature at the subject to be heated is 200 C the controlling value or the temperature at the sensor should be 235 C You should input 35 C as to subtract 35 C from the actual process display This in turn will cause the controller to energize the load and bring the process display up to the set point value Subject ue Subject MAN Heater Heat Heat Heat Transfer Transfer Transfer 165 C 165 C 200 C 200 C 200 C 235 C Sensor Sensor Sensor Figure 3 7 PV Shift
4. 2 Release press again for 2 seconds or longer but not longer than 3 seconds then Value release to enter the calibration mode N OY OY CY Y OY OY CY CY Y OY OY OY CY Y OY OY S OY Y OY Y OY OY Y OY OY OY OY OS OY Y OY OO OS OY Y Y OY OO OY 0 0 t9 9 9 9 9J 9 ES 9 9 9 9 9 ES 9 9 9 ES 9 9 9 ES 9 SJ 9 9 ES 9 ES 9 9 ES 9 9 9 ES 9 ES IN Applying these modes will break the control loop and change some of the previous setting data Make sure that the system will tolerate these modes INPT UNIT DP NLO NHI SP1L_ SP1H SHIF FIT DISP PB TD OUT O1TY O1HY OFST RAMP RR OUT2 2 O2FT O2HY CYC2 DB ALMD COMM ADDR BAUD DATA PARI STOP SEL1 SEL2 SELS SEL4 SELS SELG SEL7 SELB 1 6 Parameter Descriptions Table 1 2 Parameter Description one Parameter Description Range SP1 Set point for output 1 Low SP1L High SP1H 259 Set point for output 2 when 18 0 SP2 output 2 performs alarm Low 19999 High 45536 10 0 C function or dwell timer 0 parameters are locked LOCK Select parameters to be locked 1 SEE setup ula Is lockad 0 2 uSEr
5. 29 4 2 Cool Only Control An ETR 9000 is used to control a refrigerator at a temperature below 0 C The temperature is lower than the ambient a cooling action is required For cooling select DIRT for OUT1 Since output 1 is used to drive a magnetic contactor O1TY should be set to RELY A small temperature oscillation is tolerable hence use ON OFF control to reduce the over all cost To achieve ON OFF control the PB is set to zero and O1HY is set at 0 1 C Refrigerator Setup Summary INPT PT DN UNIT C DP 1 DP OUT1 DIRT O1TY RELY Main Supply User Menu PB 0 C OP1 OP2 O1HY 0 1 C o8 Lr J LI PV SP1 SP2 MAN AT v ETR 9000 Figure 4 2 Cooling Control Example 30 4 3 Heat Cool Control An injection mold application requires 120 C control to ensure a consistent quality for parts An oil pipe is buried in the mold Since plastics are injected at higher temperatures e g 250 C the circulation oil needs to be cooled as its temperature rises Here is an example Injection Mold Plastics 120 C Figure 4 3 Heat Cool Control Example OP1 OP2 0 5 I2l1f1 v IL UU PV SP1 SP2 MAN AT c 4 v 8 ETR 9000 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 C DP 1 DP OUT1 REVR O1TY RELY CYC1 18 0 sec O1FT BPLS OUT2 COOL O2TY 4 2
6. 0 20 mA current source with 0 005 96 accuracy 300 ohm resistant source with 0 005 96 accuracy 2 A test chamber providing 25 C 50 C temperature range 3 A switching network SWU16K optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software ETR Net and Smart Network Adaptor SNA10B 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 Manual Calibration Procedures Perform step 1 to enter calibration mode Step 1 Set the Lock parameter to the unlocked condition LOCK NONE Press and hold the scroll key until appears on the display then release the scroll key Press the scroll key for 2 seconds then release the display will show Adi o Jand the unit enters calibration mode Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter Step 2 Short the thermocouple inpt terminals then press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if th
7. 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 AN This instrument is protected throughout by Double Insulation 5 To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture A Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6 A Remove stains from this instrument using a soft dry cloth Do not use harsh chemicals volatile solvents 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 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
8. Setup and User data is locked Set point is un locked 3 ALL Al data locked 0 Jtype T C 9 PT 100 ohms DIN 1 Ktype T C 10 PEJS PT 100 ohms JIS 2 Ttype T C 11 4 20 4 20mA i EtypeT C 12 0 00 0 20mA 1 INPT Input sensor selection ABl Bpeue 19 U b0 reponi 0 5 RtypeT C 14 8 10 0 1 6 5 L StypeTIC 15 28 50 0 5V 7 NtypeTIC 16 5U 1 5V 8 L EE LtypeT C 17 QG IB 0 10V 0 9f Degree C unit 0 UNIT Input unit selection 1 Degree unit Pu Process unit 1 DP Decimal point selection 0 No decimal point 2 2 gP 2 decimal digits 1 1 1 1 decimal digit 3 3 gP 3 decimal digits igh 0 F INLO Input low scale value Low 19999 High 45486 17 8 C i PIE 200 0 F INHI Input high scale value Low INLO 50 High 45536 93 3 C O F SP L TM of set point Low 19999 High 45536 178 C SP1H High limit of set point igh 1000 F 360 0 F 360 0 F SHIF PV shift offset value Low 200 0 High 200 0 C 0 0 4 2 D FILT Filter damping time 0 8 0 c 8 d 30 constant of PV 1 0 2 5 5 5 9 6G 60 seconds 2 05 05 6 01 10 3 121 7 20 20 DISP Normal display selection 0 P Display process value 0 1 SP Display set point 1 value 932 0 F 18 0 F PB Proportional band value Low 0 High 500 0 C 10 0 C Tl Integral time value Low 0 High 1000 sec 100 TD Derivative time value Low 0 H
9. TD too high Figure 3 9 gt Time Effects of PID Adjustment 27 3 13 Data Communication The ETR 9000 supports the RTU mode of the Modbus protocol for data communications Other protocols are not available for the series 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 SNA10B has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication 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 up to 988 units ETR communications provide a very powerful and economic solution Setup Enter the setup menu Select RTU for COMM Set individual addresses for each unit which is connected to the same port Set the Baud Rate BAUD Data Bit DATA Parity Bit PARI and Stop Bit STOP such that these values are accordant with PC setup conditions Please see the ETR 9000 communications supplement for mo
10. however all claims for defective Products and parts must be made in writing no later than eighteen 18 months after shipment by Ogden Defective and nonconforming items must be held for Ogden s inspections and returned to the original f o b point upon request THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause it is specifically understood that Products and parts not manufactured and work not performed by Ogden are warranted only to the extent and in the manner that the same are warranted to Ogden by Ogden s vendors and then only to the extent that Ogden is reasonably able to enforce such warranty it being understood Ogden shall have no obligation to initiate litigation unless Buyer undertakes to pay all cost and expenses therefor including but not limited to attorney s fees and indemnifies Ogden against any liability to Ogden s vendors arising out of such litigation Upon Buyer s submission of a claim as provided above and its substantiation Ogden shall at its option either i repair or replace its Products parts or work at the original f o b point of delivery ii refund an equitable portion of the purchase price THE FOREGOING IS OGDEN S ONLY OBLIGATION AND BUYER S EXCLUSIVE REMEDY FOR BREACH OF WARRANTY AND
11. 90 250VAC 47 63Hz 10VA Figure 2 3 Rear Terminal Connection for ETR 9000 E caT 122 F 50 C max air ambient Use copper conductors except on T C input 14 2 4 Power Wiring The ETR 9000 is designed 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 Install a fuse and switch near the controller rated at 2A 250VAC as shown in the following diagram ETR 9000 Fuse 00 07 99 250 VAC or 2AI250VAC s 11 26 Figure 2 4 Power Supply Connections A This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Precautions should be taken to prevent unauthorized 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 close 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
12. K TC K Stay at least 20 minutes in still Figure 5 2 air room Cold Junction Calibration Setup room temperature 25 3 C The 5520A calibrator is configured as K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration The unit under calibration is powered in a still air room with temperature 25 3 C Stay at least 20 minutes for warming up Perform step 1 stated above then press scroll key until the display shows iL a Press up down key to obtain 40 00 Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 5 00 or 40 00 then the calibration fails Perform step 7 to calibrate gain of cold junction compensation if required Step 7 Setup the equipments same as step 6 The unit under calibration is powered in a still air room with temperature 50 3 C Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode 33 Perform step 1 stated above then press scroll key until the display shows Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails This setup is performed in a high temperature chamber hence it is recomm
13. X 48mm H X 94mm D 86 mm depth behind panel Weight ETR 9000 140 grams Approval Standards Safety UL61010C 1 CSA 22 2 No 24 93 EN61010 1 IEC1010 1 Protective Class Ip30 front panel for ETR 9000 Ip20 for terminals and housing with protective cover All indoor use 1326 38 APPENDIX Table A 1 Error Codes and Corrective Actions Displ M eae Error Description Corrective Action Illegal setup values been used Check and correct setup values of OUT2 PB TI and Before COOL is used for OUT2 OUT1 IF OUT2 is required for cooling control the DIRT cooling action has already control should use PID mode PB 7 0 TI 7 0 and been used for OUT1 or PID mode OUT1 should use reverse mode heating action is not used for OUT1 that is PB otherwise don t use OUT2 for cooling control 0 and or TI 0 Communication error bad function Correct the communication software to meet the 7 code protocol requirements l m aal m Communication error register address out of range Communication error attempt to write Don t write a read only data or a protected data to the a read only data or a protected slave Don t issue an over range register address to the slave ne a a Communication error write value which is out of range to a Don t write an over range data to the
14. are active A positive DB value shows a dead band area over which neither output is active Output 2 ON OFF Control Alarm function The output 2 can also be configured as alarm function There are 6 kinds of alarm functions can be selected for output 2 these are DE HI deviation high alarm DE LO deviation low alarm DB HI deviation band out of band alarm DB LO deviation band band alarm PV HI process high alarm and PV LO process low alarm Refer to Figure 3 3 and Figure 3 4 for the description of deviation alarm and process alarm with normal alarm mode NORM is set for ALMD 21 3 4 Alarm Output 2 can be selected as an alarm output There are 6 types of alarm functions and one dwell timer that can be selected Four seperate alarm modes ALMD can additionally be applied to each alarm function Alarm Failure Transfer is activated as the unit enters failure mode Alarm will go on if ON is set for O2FT and go off if OFF is set for O2FT The unit will enter failure mode when a sensor break occurs or if the A D converter of the unit fails ALARM FUNCTIONS PV A process alarm sets two absolute trigger levels When the process is higher than SP2 a process high alarm PV HI occurs and the alarm is off as the process is lower than SP2 O2HY When the process is lower than SP2 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP2 O2HY A process alarm is independent of set
15. baden Rud dane nd 27 9 19 Data CODbdilo ATOM sees detect Stalls 28 LT 28 Chapter 4 Applications 4 1 Heat Only Control with Dwell Timer eene ene eren enne nnn 29 4 2 COOMONIY 30 4 3 Col COto 31 Chapter 5 Calibration P Chapter 8 35 Appendix ANE Enor Cod pU 39 A 2 Hee ede een acta fed bs p RYE ee ee 39 Chapter 1 Overview 1 1 General Description The ETR 9000 Smarter Logic PID microprocessor based controller incorporates a bright easy to read 4 digit LED display The front LED display can be programmed to indicate either the process or set point value Smarter Logic technology enables a process to reach a predetermined set point in the shortest possible period of time with minimum overshoot during power up or external load disturbance The ETR 9000 is designed to meet industry standard 1 16 DIN size specifications for panel mount controllers The unit is powered by a 90 250 VAC or 11 26 VDC VAC supply incorporating a 2 amp control output relay as standard The second output can be used as a cooling control an alarm or dwell timer Prior to shipment both outputs can be independently configured as triac 5V logic output linear curren
16. type 3 8 ae 0 10V 0 4 0 00 0 20mA Select BPLS bumpless transfer or 0 0 100 0 tout 2 failure t f to continue output 2 control function as the unit O2FT Output 2 falure transfer fails or select ON 0 or OFF 1 for alarm and dwell 0 timer function Output 2 hysteresis value 6 o O2HY when output 2 performs Low 0 1 High 50 0 ae tis alarm function CYC2 Output 2 cycle time Low 0 1 High 90 0 sec 18 0 CPB oong proportional band Low 50 High 300 100 Heating cooling dead DB band negative value Low 36 0 High 36 0 0 overlap 0 ion 2 Hold Hold al ti ALMD Alarm operation mode o Normal alarm action o old alarm action 0 1 LEch Latching alarm action 3 L amp Ho Latching amp Hold action 11 Parameter Description Range SIRE 0 No communication 1 Modbus RTU mode protocol 2 4 gf 4 20mA retransmission output COMM Communication function D EU 020 retransmission output 1 4 5S 0 5V retransmission output 5 1 50 1 5V retransmission output 6 G 10 0 10V retransmission output Address assignment of iah ADOR digital communication Lows Pigh 25 m 0 2 4 Kbits s 4 180 19 2 Kbits s BAUD Baud rate 1 48 48Kbis s 5 288 28 8 Kbits s 2 HM 2 96 96 6 384 38 4 Kbits s 3 14 4 Kbits s Data bit count of digital O 7 data bits 1 DATA icati commu
17. 0 O2FT BPLS Adjust SV to 120 0 C CPB to 125 96 and DB to 4 0 96 Initiate Auto tuning at 120 C 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 If air is used as cooling media instead of oil the CPB is set at 100 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 31 Chapter 5 Calibration Do not proceed through this section unless there is a definite need to re calibrate the controller Otherwise all previous calibration data will be lost Do not attempt recalibration unless you have appropriate calibration equipment If calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to re calibrate the controller AN Entering calibration mode will break the control loop Make sure that if the system is allowable to apply calibration mode Equipment needed before calibration 1 A high accuracy calibrator maintained at NIST standards Fluke 5520A Calibrator recommended with following functions 100 mV millivolt source with 0 005 96 accuracy 0 10 V voltage source with 0 005 96 accuracy
18. IS BUYER S EXCLUSIVE REMEDY AGAINST OGDEN FOR ALL CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT TORT INCLUDING NEGLIGENCE AND STRICT LIABILITY OR OTHER THEORIES BUYER S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND BUYER SHALL HOLD OGDEN HARMLESS THEREFROM ANY ACTION BY BUYER ARISING HEREUNDER OR RELATING HERETO WHETHER BASED ON BREACH OF CONTRACT TORT INCLUDING NEGLIGENCE AND STRICT LIABILITY OR OTHER THEORIES MUST BE COMMENCED WITHIN ONE 1 YEAR AFTER THE DATE OF SHIPMENT OR IT SHALL BE BARRED W2008M RETURNS No product returns can be accepted without a completed Return Material Authorization RMA form 39 Printed in U S A 3 2004 64 West Seegers Road Arlington Heights IL 60005 847 593 8050 Fax 847 593 8062 www ogdenmfg com Ogden Manufacturing Co 2004 OGDEN SMARTER LOGIC ETR and ETR 9000 are Registered Trademarks of Ogden Manufacturing Co MARCA REGISTRADA Specifications subject to change without notice
19. 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 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 For special processes the sensor may need to meet different requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 degrees F 2 degrees C or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement 2 6 Sensor Input Wiring A ME RTD Figure 2 5 Sensor Input Wiring TC V PTB mA 4 POO B TC V PTB 9 TC V mA RID 15 2 7 Control Output Wiring P LOAD gt 120V 240VAC Main Supply Main Supply 0 120V 240V a0 Figure 2 6 Output 1 Relay or Triac SSR to Drive Load Three Figure 2 7 o Output 1 Relay SSR to Drive Contactor Power Load Contactor Breaker SSR 10 420V 240V D C P 9 Oo Main Supply Internal Ci
20. Insert the controller into the panel cutout Maximum panel thickness is 1 8 3mm Figure 2 1 Mounting Dimensions 125 32 45 mmj ETR 9000 1 25 32 45 mm 13 2 3 Wiring Precautions x Before wiring verify the correct label to the correct model number and options Switch power off while checking Care must be taken to ensure that maximum voltage rating specifications on the label are not exceeded x It is recommended that power of these units be protected by fuses or circuit breakers rated at the lowest current value possible x All units should be installed inside a suitably grounded metal enclosure to prevent live parts from being accessible to human hands and or metal tools x All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and the 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 2 KgF cm Unused control terminals should 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 for the thermocouple wiring all wiring should use stranded copper conductor with maximum gauge 18 AWG Figure 2 2 D Lead Termination for ETR 9000 TT
21. PK483 OMC58 SOFTWARE VERSION 34 16 and HIGHER Model ETR 9000 AUTOMATIC TUNING 1 16 DIN SMARTER LOGIC Controller INSTRUCTION MANUAL Warning Symbol A This Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury damage or destruction to part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met Using the Manual e Installers Read Chapter 1 2 e System Designer Read All Chapters Expert User Read Page 9 NOTE It is strongly recommended that a process incorporates an FM approved LIMIT CONTROL like the ETR 9040 or ETR 3 which will shut down the equipment at a preset process condition in order to preclude any possible damage to individual components or system Information in this user s manual is subject to change without notice Copyright June 2004 Ogden Manufacturing Co all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system Similarly this manual may not be translated into any language in any form by any means without written permission Ogden Manufacturing Co Contents Page No Chapter 1 Overview 1 1 General Descripli n ee 4 WS Odong COC Em 6 1 8 Programming ase ees 7 14 DISD HURTS 7 IM UU UI M
22. Similar settings are applied for CYC2 selection You can use the auto tuning program for a new process or directly set the appropriate values for PB Tl amp TD according to the historical records for the repeated systems If the control behavior is still inadequate then use manual tuning to improve the control See section 3 12 for manual tuning CPB Programming The cooling proportional band is measured by 96 of PB with range 50 300 Initially set 10096 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of CPB is related to the cooling media used For air used as a cooling media adjust CPB to 100 96 For oil is used as a cooling media adjust CPB to 125 For water used as cooling media adjust CPB to 250 DB Programming Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band between heating and cooling is used an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of PB A negative DB value shows an overlap area over which both outputs
23. 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 a higher density internal storage Fast Sampling Rate The sampling rate of the input A to D converter reaches 5 times second This fast sampling rate allows this series to control fast processes Smarter Logic Control The function of Smarter Logic control is to automatically adjust the PID parameters from time to time These dynamic adjustments are made in order to tune the output value to be more flexible and adaptive to various processes The result is to enable a process to reach a predetermined set point in the shortest possible time with minimum overshoot and or undershoot during power up or external load disturbance Digital Communications The ETR 9000 is equipped with an RS 485 interface option to provide digital communications By using a shielded twisted pair wire up to 247 units can be connected together via an RS 485 interface to a host computer Once the units are all wired together the twisted pair wire will then need to run through an RS 485 to RS 232 converter such as the SNA 10A An industry standard Modbus RTU is used for the communication protocol Programming Port A programming port is used to connect the unit to a hand held programmer or a PC for quick configuration Additionally it can be connected to an Automatic Test Equipment ATE system for automati
24. 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 or inhibits an alarm from kicking on during initial controller power up The alarm is enabled only when the process reaches the set point 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 22 3 5 Display Configuration By using the select parameters feature on the ETR 9000 the user is allowed to customize each individual controller s parameter sequence By setting the SEL parameters 1 through 8 under the setup menu your most commonly used parameters can be made more easily accessible Selecting a specific parameter to one of the 8 SEL options will bring that parameter to the top of the parameter order as shown below Example Set OUT2 PVLO LOCK NONE SEL1 INPT SEL2 UNIT SEL8 DP SEL4 SEL8 NONE then the display scrolling for ETR 9000 becomes sei 5 2 JS ev S 2 3 6 Ramp The ramping function is performed during power up as well as any time the set point is changed Choose MINR units per minute or HRR units per hour for RAMP the unit will perform the ramping function The ramp rate is programmed by adjusting the parameter RR The ramping function is disabled as soon a
25. c testing amp calibration Auto tune The auto tune function allows the user to simplify the initial setup for a new system A clever algorithm is provided to obtain an optimal set of control parameters for the process The Auto tune feature can be applied either as the process is warming up cold start or as the process is in a steady state warm start Lockout Protection In order to meet various security requirements one of four lockout levels can be selected to prevent the unit from being changed without authorization Bumpless Transfer The Bumpless Transfer feature is a unique process protection feature that is employed upon a sensor break condition or input problem Bumpless transfer allows a controller to continue to proportion it s output based on previous process and control characteristics Hence the process can be temporarily controlled just as if running a closed loop control application making the severe problem of a Thermocouple error temporarily invisible Bumpless transfer is not to be used for an extended period time as in open loop control run away may occur Soft start Ramp The ramping function is performed during power up as well as any time the set point is changed It ramp will control both ramp up and or ramp 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
26. display in cases of f PB exceeds 9000 9000 PU 900 0 F or 500 0 C e or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don 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 H1 E message 26 12 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning If the control performance by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 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 TI Instability or Oscillations Increase TI Slow Response or Oscillations Decrease TD 3 Derivative Time High Overshoot Increase TD Table 3 2 PID Adjustment Guide Figure 3 9 shows the effects of PID adjustment on process response PV 4 PB too low Perfect P action Set point PB too high Time TI too high PV action Set point TI too low Time PV 4 TD too low Set point D action
27. e if overshooting beyond the normal process value is likely to cause damage 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 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press several times until the AT indicator is lit 5 Press for at least 3 seconds The AT indicator will begin to flash and the auto tuning procedure will begin NOTE The ramping function if used will be disabled once auto tuning is activated The auto tuning mode is disabled as soon as either failure mode or manual control mode occurs 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 will revert to PID control by using its new PID values The PID values obtained are stored in the nonvolatile memory Auto Tuning Error If auto tuning fails an ATER message will appear on the
28. e obtained value is equal to 199 9 or 199 9 then the calibration fails Step 3 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 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform both steps 4 and 5 to calibrate RTD function if required for input 32 Step 4 Press scroll key until the display shows Eat Send a 100 ohms signal to the RTD input terminals according to the connection shown below ETR 9000 100 ohms Figure 5 1 RTD Calibration Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails Step 5 Press scroll key and the display will show Change the ohm s value to 300 ohms Press scroll key for at least 3 seconds The display will blink a moment and two values are obtained for RTDH and RTDL step 4 Otherwise if the display didn t blink or if any value obtained for RTDH and RTDL is equal to 199 9 or 199 9 then the calibration fails Perform step 6 to calibrate offset of cold junction compensation if required Step 6 Setup the equipments according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used 5520A Calibrator ETR 9000
29. ended 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 390 0 5 1 5V 3 92K 0 20mA 4 20mA 3010 2 Perform Step 1 and Step 2 to calibrate the linear input zero 3 Perform Step 3 but send a span signal to the input terminals instead of 60mV The span signal is 1V for 0 1 input 5V for 0 5V 1 5V input 10V for 0 10V input and 20mA for 0 20 or 4 20mA input Final step Step 8 Set the LOCK value to your desired function 34 Chapter 6 Specifications Power 90 250 VAC 47 63 Hz 10VA 5W maximum 11 26 VDC 10VA 5W maximum Input Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 1 5uV C for all inputs except mA input 3 0uV C for mA input Sensor Lead Resistance Effect T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads 200 nA Common Mode Rejection Ratio CMRR 120dB Burn out Current Normal Mode Rejection Ratio NMRR 55dB Sensor Break Detection Sensor open for TC RTD and mV
30. et 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 sophisticated PID and Fuzzy algorithm to achieve a minimal overshoot and a fast response to the process if it is properly tuned 20 Cool only control ON OFF control PD control and PID control can be used for cooling 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 the same as the descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat control NOTE ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation of 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 Cycle Time CYC1 CYC2 O1FT O2FT O1TY amp O2TY parameters are set in accordance with the types of OUT1 amp OUT2 installed CYC1 amp CYC2 are selected according to the output 1 type O1TY amp output 2 type O2TY Generally if SSRD or SSR is used for O1TY select 0 5 2 sec for CYC1 if relay is used for O1TY select 10 20 sec And if linear output is used CYC1 is ignored
31. etup menu The display showd SEE 2 Enter manual control mode where or is displayed 3 Enter auto tuning mode During auto tuning mode AT or is displayed 4 Perform calibration to a selected parameter during the calibration procedure Press for 5 seconds to select calibration mode Deviation Indicator Output 1 Indicator Output 2 Indicator Process Unit Indicator OP1 OP2 L1 LI C F nmnmm VLA LI PV SP1 SP2 MAN AT Auto tuning Indicator Manual Mode Indicator 4 Buttons for ease of control setup and set point adjustment O lAI vIIR ETR 9000 Figure 1 3 Front Panel Description Table 1 1 Character Legend Characters displayed by a Symbol OP1 OP2 0 O F Display program code of the product for 2 5 seconds AJU IL V l LJ The left diagram shows program no 34 with version 16 PV SP1 SP2 MAN AT a Y Figure 1 4 ETR 9000 Display at Power up 1 5 Menu Overview User menu 1 Setup menu 1 Calibration Mode A LOCK Value INPT Value UNIT INLO INHI SP4L Value SP1H SHIF FILT DISP Press for 3 seconds to perform calibration 4 ola 1 The flow chart shows a complete listing of all parameters Not every parameter will be displayed Depending on controller set up some parameters may not be displayed
32. 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 specify 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 process value INHI PV Figure 3 1 INLO Conversion Curve for Linear Type Process Value input signal Example A 4 20 mA current loop pressure transducer with range 0 15 kg cm is is being used for measurement and wired to the input perform the following setup Formula PV INLO INH 2286 INLO 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 19 3 3 Control Outputs There are 4 kinds of control modes that can be configured as shown in Table 3 1 Table 3 1 Heat Cool Control Setup Value ee OUTI OUT O1HY O2HY CPB DB Heat only REVR x x X x Cool only DIRT x K x x x Cool ON OFF DEM 2 2 Bu E REVR COOL x x O O N A Adjust to meet process requirements yx Required if ON OFF control is configured Heat Only ON OFF Control Select REVR for OUT1 Set PB to 0 O1HY is used to adjust dead band for ON OFF control The output 1 hysteresis O1HY is enabled in case of PB 0 The heat only on off control function is shown in the following diagra
33. igh 360 0 sec 25 0 10 Parameter Default Notation Parameter Description Range Value 0 E Reverse heating control OUT1 Output 1 function 1 di Direct cooling control 0 0 ELY Relay 5 g 18 0 1V 1 55rg Solid state relay drive 6 0 69 0 5V O1TY Output 1 signal type 2 55 Solid state relay 7 1 50 1 5 0 3 4 20 4 20 8 2 10 0 10V 4 0 00 0 20 Select BPLS bumpless transfer or 0 0 Output 1 failure transfer 100 0 to continue output 1 control function O1FT mode as the unit fails or select OFF 0 or ON 1 for 0 ON OFF control Output 1 ON OFF control 0 2 F O1HY Low 0 1 High 50 0 C 90 0 F 0 1 C CYC1 Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST Offset value for P control Low 0 High 100 0 96 25 0 RAMP Ramp function selection 0 uneven 2 Hrer Use unit hour 0 1 5A nr Use unit minute 900 0 F RR Ramp rate Low 0 High 500 0 C 0 0 0 nanE Output 2 No Function 5 dito Deviation in band Alarm 1 E Ar Dwell timer action 6 PYH Process High Alarm 2 Deviation High Alarm 7 Process Low Alarm OUT2 Output 2 function 3 Deviation Low Alarm 8 CooL Cooling PID Function 4 dbH Deviation out of band Alarm 0 r amp LY Relay output 5 8 10 0 1V 1 55rd Solid state relay dive 6 0 50 0 5V 2 r Solid state rel 7 1 59 1 5V O2TY Output 2 signal
34. 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 35 Characteristics Table 6 1 Characteristics Type Range Accuracy 25 C Input Impedance J 120 C 1000 C 184 F 1832 F 2 C 2 2 K 200 C 1370 328 F 2498 F 2 C 22 T 250 C 400 418 F 752 F 2 2 2 100 C 900 148 F 1652 F 2 2 2MQ B 0 C 1800 32 F 3272 F 200 C 1800 2 2MQ R 0 C 1767 8 32 F 3214 F 2 C 22 MQ 5 0 C 1767 8 32 F 3214 F 2 C 2 2MQ N 250 C 1300 418 F 2372 F 2 C 22 L 200 C 900 328 F 1652 F 2 C 22 PT100 DIN 210 C 700 C 346 F 1292 F 0 4 C 1 3KQ PT100 JIS 200 C 600 C 328 F 1112 F 0 4 C 1 mV 8mV 70mV 0 05 1 3K mA 3mA 27mA 0 05 96 7050 V 1 3V 11 5V 0 05 96 650K Q Output 1 Output 2 Relay Rating 24 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Table 6 2 Linear Output Characteristics Type Zero Tolerance Span Tolerance Load Capacity 4 20 mA 3 6 4 mA 20 21 mA 500 2 max 0 20 mA 0 mA 20 21 mA 5000
35. m PV A 5 1 4 Dead band 5 1 O1HY gt Time OUT1 Action Figure 3 2 Heat Only ON OFF Control OFF gt Time The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized 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 transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI to 0 OFST is used to adjust the control offset manual reset O1HY is hidden if PB is not equal to 0 OFST Function OFST is measured by 96 with range 0 100 0 In the steady state ie process has been stabilized if the process value is lower than the set point by a definite value say 5 C while 20 C is used for PB that is lower 25 96 then increase OFST 25 96 and vice versa After adjusting the OFST value the process value will be varied and eventually coincide with the 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 PID control setup can avoid this situation Heat only PID control Selecting REVR for OUT1 PB and TI should not be zero Operate auto tuning for the new process or s
36. max 0 5V OV 5 5 25 10 KQ min 1 5V 09 1V 5 5 25 10 0 10V OV 10 10 5V 10 KQ min 36 Linear Output Resolution 15 bits Output Regulation 0 02 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC Temperature Effect 0 01 of SPAN C Triac SSR Output Rating 1A 240 VAC Inrush Current 20A for 1 cycle Min Load Current 50 mA rms Max Off state Leakage mA rms Max On state Voltage 1 5 V rms Insulation Resistance 1000 Mohms min at 500 VDC Dielectric Strength 2500 VAC for 1 minute DC Voltage Supply Characteristics Installed at Output 2 Table 6 3 DC Voltage Supply Characteristics Type Tolerance Max Output Current Ripple Voltage Isolation Barrier 20V 0 5 V 25 0 2 Vp p 500 VAC 12V 3V 40 mA 0 1 Vp p 500 VAC 5V 0 15V 80 mA 0 05 Vp p 500 VAC Output 2 Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV High Low Alarm PID cooling control Alarm Mode Normal Latching 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 37 Use
37. nication 1 Gb EL 8 data bits PARI Parity bit of digital 0 EYEn Evenpariy 2 parity bit 0 communication 1 odd Odd parity stop Stop bit count of digital O One stop bit 0 communication 1 gb Two stop bits RELO Retransmission low scale Low 19999 High 45536 32 0 F value 0 0 C Retransmission high scale High 45536 212 0 F REHI valle Low 19999 g 100 0 C 0 No parameter selected 9 o IHY O1HY is put ahead 1 LOCK is put ahead 10 CYC 1 is put ahead 2 nPE is put ahead 11 oF SE OFST is put ahead SEL1 parameter for 12 RRis put ahead 2 4 dP DP is put ahead 13 O2HY is put ahead 5 SH F SHIF is put ahead 14 CYC2 is put ahead 6 PB is put ahead 15 LPb CPB is put ahead 7 E Tl is put ahead 16 db DB is put ahead 8 Ed put ahead 17 Hddr ADDR is put ahead Select 2 nd parameter for SEL2 user menu Same as SEL1 3 Select 3 rd parameter for SEL3 user menu Same as SEL1 4 Select 4 th parameter for SEL4 user menu Same as SEL1 6 Select 5 th parameter for SEL5 user menu Same as SEL1 7 Select 6 th parameter for SEL6 user menu Same as SEL1 8 Select 7 th parameter for SEL7 user menu Same as SEL1 10 Select 8 th parameter for SEL8 user menu Same as SEL1 17 12 Chapter 2 Installation Dangerous voltages capable of causing death are sometimes present in this instrument
38. point Figure 3 3 Output 2 Process Low Alarm A deviation alarm alerts the user when the PV process deviates too far from set point When the process is higher than SV SP2 a SV SP2 1 deviation high alarm DE HI occurs and the alarm is off as the process is lower than SV SP2 O2HY SV SP2 O2HY When the process is lower than SV SP2 a deviation low alarm DE LO 72 Action occurs and the alarm is off as the process is higher than SV SP24 O2HY Trigger level p NN Figure 3 4 Output 2 Deviation High Alarm 1 1 1 1 I t Time 1 1 1 of deviation alarm is moving with set point Time A deviation band alarm presets two trigger levels relative to the set point The two trigger levels are SV SP2 and SV SP2 for alarm When the process is higher than SV SP2 or lower than SV SP2 deviation band high alarm DB HI occurs When the process is within the trigger levels a deviation band low alarm DB LO occurs Note In the above descriptions SV denotes the current set point value for control which is different from SP1 as the ramp function is performed ALARM MODES Normal Alarm ALMD NORM When a normal alarm is selected the alarm output is de energized in the non alarm condition and energized in an alarm condition Latching Alarm ALMD LTCH If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the
39. process value This is particularly useful in certain applications where the process value is too unstable to be read 1 2 Ordering Code ETR 9000 Power Input 4 90 250 VAC 50 60 HZ 5 11 26 VAC or VDC Signal Input 1 Standard Input Thermocouple J TE RTD PT100 DIN Pt100 JIS Current 4 20 0 20mA Voltage 0 1V 0 5V 1 5V 0 10V Output 1 Display Color 0 None 1 Red 1 Relay rated Standard 2A 240VAC 2 Green 2 SSR Drive 5 Special Order 3 Isolated 4 20mA 0 20mA 4 Isolated 1 5V 0 5V 5 Isolated 10V 6 Triac output 1A 240VAC SSR C SSR Drive 14V 30mA Output 2 None Form A relay 2A 240VAC SSR Drive 5V 30mA Isolated 4 20mA 0 20mA Isolated 1 5V 0 5V Isolated 10V Triac output 1 240VAC SSR Isolated transducer ower sup solated transducer ower SU solated 5 transducer power suppl A RS 485 interface SSR Drive 14V 30mA z Related Products SNA10A Smart Network Adaptor for third party software which converts 255 channels of RS 485 or RS 422 to RS 232 Network SNA10B Smart Network Adaptor for ETR Net software which converts 255 channels of RS 485 or RS 422 to RS 232 network SNA12A Smart Network Adaptor for programming port to RS 232 interface ETR Set Configuration Software CC94 1 RS 232 Interface Cable 2M CETR 9000 2 Prog
40. r Interface Single 4 digit LED Display Keypad 4 keys for ETR 9000 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 F hysteresis control band 0 PorPD 0 100 0 offset adjustment PID Fuzzy logic modified Proportional band 0 1 900 0 F 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 F minute or 0 900 0 F hour ramp rate Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity 0 to 90 RH non condensing Altitude 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 s for 2 hours Shock Resistance 200 m s 20 g Moldings Flame retardant polycarbonate Dimensions ETR 9000 48mm W
41. ramming port cable 1 3 Programming Port control board pin 1 Programming Port Open housing Top view of ETR 9000 pem Power board Figure 1 2 Programming Port Overview The programming port which is connected to a PC through an adapter cable SNA12A 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 while the unit is being used for normal control purposes or is powered up 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY This key is used to increase the value of the selected parameter DOWN KEY v This key is used to decrease the value of the selected parameter RESET KEY This key is used to 1 Revert the display back to the process value or set point value from anywhere in the program 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 or auto tuning error Restart the dwell timer when the dwell timer has timed out Enter the manual control menu during failure mode conditions Ook WP Pil Press for 3 seconds or longer Press for 3 seconds to 1 Enter s
42. rcuit 30 mA 1 4 5V Or 30mA 5Vdc 33 E Pulsed 38 n Voltage Dm I Figure 2 8 Output 1 Pulsed Voltage to Drive SSR 10175 20mA Maxi aximum Load 4 20mA ad 500 ohms 0 1V 0 5V Load Minimum Load 9 1 5V 0 10V 10 K ohms 16 Figure 2 9 Output 1 Linear Current Figure 2 10 Output 1 Linear Voltage Main Supply 120V 240VAC E P e 420V 24V 1 Main Supply o Three Three Phase Phase Delta Heater Heater Power Load Contactor Breaker SSR Loadi 120V pay D C acu Main Supply Internal Circuit Figure 2 11 Output 2 Relay or Triac SSR to Drive Load Figure 2 12 Output 2 Relay or Triac SSR to Drive Contactor Figure 2 13 Output 2 Pulsed Voltage to Drive SSR a2 74 5L v q 1 5V i 14Vdc or 33 P 30mA 5V I Pulsed qe NES Voltage A MM a 2 9 Figure 2 14 NUT Output 2 Linear Current _ 1 4 20mA T 500 ohms 2 ERA Minimum Load Figure 2 15 1 1 5V0 10V 10 K ohms Output 2 Linear Voltage 17 2 8 Alarm Wiring J LOAD 7 120V 240VAC Figure 2 16 BT Main Supply Alarm Output to Drive Load P 2 120V 240V 14 Main Supply o Three Figure 2 17 o o Phase Alarm Output to Drive Contactor Three Phase Delta Contactor Breaker Heater Load Relay Output to Drive Con
43. re detailed information 3 14 Manual Control Operation To enable manual control operation the LOCK parameter should be set to NONE then press several times and H _ _ _ Heating output or _ _ _ Cooling output will appear on the display Press co for3 seconds then the MAN indicator will begin to flash The controller now enters the manual control mode indicates the output control variable for output 1 and indicates control variable for output 2 Now you can use the up down keys to adjust the percentage values for the heating or cooling outputs The controller performs open loop control as long as it stays in manual control mode Exit Manual Control To press key the controller will revert to its normal display mode 28 Chapter 4 Applications 4 1 Heat Only Control with Dwell Timer An oven is designed to dry products at 150 for 30 minutes and then stay unpowered for another batch An ETR 9000 set up for a dwell timer is used for this purpose A single phase system diagram is shown as follows Set SP1 150 0 SP2 30 0 OP1 OP2 C F 5 C7 yd SP1 8 2 MAN AT Figure 4 1 Heat Control Timer Example To achieve this function set the following parameters in the setup menu INPT K_TC UNIT C DP 1_DP OUT1 REVR O1TY RELY CYC1 18 0 O1FT BPLS OUT2 TIMR O2FT ON Auto Tuning is performed at 150 C for a new oven
44. s the failure mode the manual control mode the auto tuning mode or the calibration mode occurs Example without Dwell Timer Select MINR for RAMP select C for UNIT select 1 DP for Set RR 10 0 SV is set to 200 C initially and manually changed to 100 C after 30 minutes from power up The starting temperature is 30 C After power up the process is running like the curve shown below Figure 3 5 RAMP Function Time minutes Note When the ramp function is used the display will show the current ramping value However it will revert to showing 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 the set point is changed Setting RR to zero disables the ramp function 23 3 7 Dwell Timer Output 2 can be configured as a dwell timer by selecting TIMR for OUT2 As the dwell timer is configured the parameter SP2 is used for dwell time adjustment The dwell time is measured in minutes 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 in the following diagram After time out the dwell timer will be restarted by pressing the RESET key The timer stops counting during the manual control mode failure mode calibration period and auto tuning period PV 4
45. 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 during auto tuning procedure 3 Use manual tuning instead of auto tuning 4 Dont set a zero value for PB 5 Don t set a zero value for 6 Touch RESET key Fail to perform auto tuning function N EEPROM can t be written correctly Return to factory for repair Cold junction compensation for thermocouple malfunction 99 Return to factory for repair Input sensor break or input current below 1 mA if 4 20 mA is selected or input voltage below 0 25V if 1 5V is selected muc A to D converter or related component s malfunction 39 Replace input sensor Return to factory for repair ms A oa A 2 WARRANTY AND LIMITATION OF REMEDY AND LIABILITY Ogden warrants only that the Products and parts manufactured by Ogden when shipped and the work performed by Ogden when performed will meet all applicable specification and other specific product and work requirements including those of performance if any and will be free from defects in material and workmanship under normal conditions of use All claims for defective or nonconforming both hereinafter called defective Products parts or work under this warranty must be made in writing immediately upon discovery and in any event within one 1 year from delivery provided
46. t or linear voltage to drive an external device There are six independent programmable alarms plus a dwell timer that can be configured for the second output The units are fully programmable for RTD PT100 and thermocouple types J K T R S N L without need to physically modify the unit The input signal is digitized by using an 18 bit A to D converter A fast sampling rate of 5 times per second allows the unit to provide closed loop control for fast processes Digital communications RS 485 or RS 232 are available as an additional option This option allows the units to be integrated with a supervisory control system and or software A programming port is available for automatic configuration calibration and testing without the need to access the keys on the front panel By using proprietary Fuzzy modified PID technology Smarter Logic the control loop will minimize the overshoot and undershoot in the shortest time possible The following diagram is a comparison of the results with and without Fuzzy technology PID control with properly tuned PID Fuzzy control Set point Figure 1 1 Fuzzy Control Advantage Warm Up Load Disturbance Time High Accuracy The ETR 9000 is manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1 F resolution for thermocouple and PT100 and
47. tactor 2 9 Data Communication RS 485 ETR 9000 Shielded Twisted Pair Wire ETR 9000 B 1 RS 485 to RS 232 network adaptor SNA10A or SNA10B RS 232 w C Tx2 Max 247 units can be linked ETR 9000 Figure 2 18 RS 485 Wiring Terminating Resistor 220 ohms 0 5W 18 Chapter 3 Programming Press for 3 seconds and release to enter setup menu Press to select the desired parameter The display indicates the parameter of choice Press 4 or v to view or adjust the value of the selected parameter 3 1 Lockout There are four security levels that can be selected by using the LOCK parameter If NONE is selected for LOCK then all parameters are unlocked If SET is selected for LOCK then all setup menu parameters are locked If USER is selected for LOCK then all setup and user parameters refer to section 1 5 except set point are locked If ALL is selected for LOCK then all parameters are locked to prevent any changes 3 2 Signal Input INPT Selects the sensor or signal type for signal input Range thermocouple J K T E 5 RTD PT DN PT JS linear 4 20mA 0 20mA 0 60mvV 0 1V 0 5 1 5V 0 10V UNIT Selects the process unit Range C F PU process unit If the unit is neither C nor F then select PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 DP for linear NO DP 1 DP 2 DP 3 DP INLO Selects the low scale value
48. ure Transfer if activated will perform 1 If output 1 is configured as proportional control PB 0 and BPLS is selected for O1FT then output 1 will perform bumpless transfer Thereafter the previous control output value MV1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB 0 and a value of 0 to 100 0 96 is set for then output 1 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 1 3 If output 1 is configured as ON OFF control PB 0 then output 1 will transfer to off state if OFF is set for OTFT and transfer to on state if ON is set for O1FT Output 2 Failure Transfer if activated will perform 1 If OUT2 is configured as COOL and BPLS is selected for O2FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 is configured as COOL 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 3 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 25 3 11 Auto tuning The auto tuning process is performed at set point The process will oscillate around the set point during the tuning process Set a set point to a lower valu
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