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User`s Manual - Future Design Controls

1. 35 Figure 2 6 Power Supply Connections 36 Figure 2 7 Sensor Input Wiring 36 Figure 2 8 Output 1 Relay or Triac SSR to Drive Load 36 Figure 2 9 Output 1 Relay or Triac SSR to Drive Contactor 37 Figure 2 10 Output 1 Pulsed Voltage to Drive SSR 37 Figure 2 11 Output 1 Linear Current 38 Figure 2 12 Output 1 Linear Voltage 38 Figure 2 13 Output 2 Relay or Triac SSR to Drive Load 38 Figure 2 14 Output 2 Relay or Triac SSR to Drive Contactor 39 Figure 2 15 Output 2 Pulsed Voltage to Drive SSR 39 Figure 2 16 Output 2 Linear Current 39 Figure 2 17 Output 2 Linear Voltage 40 Figure 2 18 Alarm Event o
2. 76 Figure 5 1 A Heat Treatment Oven 79 Figure 5 2 Temperature profile of the Heat Treatment Oven 80 Table 3 1 Password operation 44 Table 3 2 Heat Cool control configuration value 47 Table 3 3 Alarm mode description 55 Table 3 4 PID Adjustment Guide 61 Table 4 1 Segment types 66 Table 4 2 Profiler Modes 68 Table 4 3 Parameters that follow segment type e eene emen o 75 Table 7 1 Exception Code Table 89 Table 7 2 Number Conversion Table 90 Table A 1 Error Codes and Corrective Actions 98 4 UM0B421A Chapter 1 Overview 1 1 General The Fuzzy Logic p
3. 9 1 3 Programming Port 11 1 4 Keys and Displays 12 1 5 Key Operation Flowchart 15 1 6 Parameter Descriptions 16 Chapter 2 Installatlon 2 1 Unpacking 3l 2 2 Mounting 21 2 3 Wiring precautions 34 2 4 Power Wiring 36 2 5 Sensor Input Wiring 36 2 6 Control Output Wiring 36 2 7 Alarm Event Output Wiring 40 2 8 Event Input Wiring 41 2 9 Retransmission Output 1 Wiring 41 2 10 Data Communication 42 Chapter 3 Configuration 2 1 POS Word mmm 44 3 2 Signal Input AA 3 3 Event Input 45 3 4 Control Outputs 47 25 ICG a 59 3 6 Configure Home Page 56 3 7 User Calibration esas 56 3 8 Digital Filler 58 3 9 Failure Transfer 59 3 10 Auto tuning 60 3 11 Manual tuning 6 3 12 Manual Mode 63 3 13 Data Communication 63 3 14 Retransmission 64 3 15 Output Scaling 65 Page No Chapter 4 Profiler Operation 4 1 What is set point profiler 66 4 2 Segment connection 67 4 3 Profiler Modes 67 4 4 Running holding an aborting a profile 68 4 5 Viewing and modifyinc profile progress 69 4 6 Start
4. 69 4 7 Holdback 70 4 8 Power failure 72 4 9 Configuring the profiler 74 4 10 Viewing and creating profile 74 4 11 Event Outputs and PIL SEISCTION esai 78 Chapter 5 Applications 79 Chapter 6 Specifications 81 Chapter 7 Modbus Communlcatlons 87 7 1 Functions Supported 8 7 7 2 Exception Responses 89 7 3 Parameter Table 8 9 Chapter 8 Manual Callbratlon 96 Appendlx A 1 98 Appendix A 2 99 UMOB421A Figures amp Tables Page No Figure 1 1 Fuzzy Control Advantage 6 Figure 1 2 Programming Port Overview 11 Figure 1 3 Front Panel Description 13 Figure 1 4 Program code display 2 22 2 ee nnn nen manara oo 14 Figure 2 1 Dimension of Control Board 32 Figure 2 2 Dimension of Display BOOrd 33 Figure 2 3 Lead Termination 34 Figure 2 4 Rear Terminal Connection
5. No Fuse Li Phase Contactor Breaker Heater Load Figure 2 14 Output 2 Relay or Trlac SSR to Drive Contactor 120V 240V Mains Supply E 30mA 5V 5V Pulsed Voltage 33 Kag 33 ov YY I a a Figure 2 15 Output 2 Pulsed Voltage to Drive SSR TE3 O 20mA j Maximum Load 4 20mA 500 ohms Figure 2 16 Output 2 Linear Current UM0B421A 39 TE3 0 1V 0 5V load Minimum Load 1 5V 0 10V 10 K ohms Figure 2 17 Output 2 Linear Voltage 2 7 Alarm Event Output Wiring TES TE4 TES a E EE LOAD 120V 240VAC Mins Supply Figure eH Alarm Event output wiring TES TE4 TES out2 out3 Out4 2 120V 240V o Mains Supply Heater 0 0 Power No Fuse Contactor Breaker ins Relay Output to Drive Contactor Figure 2 19 Alarm Output to Drive Contactor 40 UMOB421A 2 8 Event Input Wiring TE b El switch o Figure 2 20 Event Input wiring 2 9 Retransmission Output Wiring JE Minimum Load 10K ohms for voltage Maximum Load 500 ohm for current Figure 2 21 Retransmit 4 20 0 20 mA Wiring UMOB421A 4 2 10 Data Communication RS 485 to RS 232 TEG network adaptor TX1 SNA10A or SNA10B TX2 RS 232 Twisted Pair Wire TKI 4 1X2 PC Max 247 units can be linked TE6 TX1 3 TX2 2 Terminator 220 ohms 0 5W Figure 2 22 RS 485 Wiring 42 UM0B421A RS 232 CC94 Figure 2 23 RS 232 Wiring If you use a conventional 9 pin RS 2
6. UMOB421A 31 Figure 2 1 Dimension of Control Board 32 UM0B421A Figure 2 2 Dimension of Display Board 0 30 o o e Q eo 8 30 0 00 o o o 8 oo LO N y CO o o N v coco 9 50 0 00 29 30 3 5 40 00 35 00 30 00 30 00 29 75 24 50 24 50 15 50 15 50 10 50 7 50 5 00 0 00 0 00 3 00 5 50 20 00 30 00 30 00 35 00 4 00 4 o o e o oo o o o o so LO e N N N 10 o y gt bx Na UMOB421A 2 3 Wiring Precautions x Before wiring verify the label for correct model number and options Switch off the power while checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded x lt is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible x All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system Beware not to over tighten the terminal screws The torque should not exceed 1 N m 8 9 Lb in or 10 2KgF cm Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in
7. D Penis 1 EE 2 EM TSEHE Process high alarm Deviation high alarm Deviation band End of profile alarm PONE de Static mode alarm EMS 0 2 LF TI Process low alarm Deviation low alarm high low alarm Hold mode alarm Onor n Normal alarm action 1L Ech Latching alarm action Qu d Hold alarm action E Ho Latching amp hold alarm action 23 UMOB421A Parameter Description Register Parameter Address Notation Hysteresis control ES AHY for alarm 3 Range 50 0 LC Low 0 1 High 90 0 LF Default Data Value type 0 11C 0 2 LF oo _ Reserves O mimi No parameter ES selected 1 nl LE INPT selected for home page 2 L UNIT selected for EH m home page DP selected for home page PB1 selected for home page T11 selected for home page TD1 selected for home page PB2 selected for home page TI2 selected for home page TD2 selected for Le Select 1 st home page GEL 1 parameter for OFST selected home page for home page O1HY selected for home page CYC1 selected for home page CYC2 selected for home page CPB selected for home page DB selected for home page 16 H me ATHY selected for home page 17 AP HY A2HY selected for home page 18 A3HY A3HY selected for home page 19 H1 DLAY Selected dL H3 for home page 20 nHEa Manual event output SEL2 Select 2 nd EE parima Same as SEL1 EL d for
8. a PB1 Proportional 500 0 LC 10 0 LC band value 1 Lan High 900 0 LF 18 0 LF Integral time Low 0 High 3600 sec Es value 1 TD1 Derivative time h Ar Proportional 800 0 LE 18 0 LF Integral time lowo High 3000s80 h T Derivative time OFST Offset value for Ta P control TIE 0 Low 0 0 High 100 0 em Ta fw mew Y NAN NA nant No function Lp P coms time proportioning control Cooling linear control MP Output 2 function Al nubc Alarm 1 output l Reverse alarm 1 Output L Event 1 output PG DC power supply output UMOB421A Register Parameter Parameter Description Select BPLS bumpless transfer or 0 0 100 0 to continue output 2 control n Output 2 failure function as the unit fails or cc FE transfer status select OFF 0 or ON 1 for alarm or event output a oh NOR Low 0 1 High 90 0 sec R W LILE 36 CPB L 50 High 300 100 ai roportiona OW igh Pb ae value DB A Heating cooling dead band wo negative value Low 36 0 High 36 0 Yo overlap OP2L Low limit value for nx 38 oPeL output Low 0 High 100 0 Yo OP2H High limit value ah 39 o PH for output 2 Low 0 High 120 0 3 A 118 8 8 2 3 fees fees ooo No function Alarm 2 output Reverse alarm 2 SUIS Output 3 function output Event 2 output DC power supply output Output 3 OFF O3FT Output 3 failure as unit fails BG 3F LE transfe
9. 1 5V 0 10V Resolution 15 bits Accuracy 0 05 96 of span 0 0025 C Load Resistance O 500 ohms for current output 10 K ohms minimum for voltage output Output Regulation 0 01 96 for full load change 84 UMOB421A Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC min Integral Lineartty Error 0 005 96 of span Temperature Effect 0 0025 96 of span C Saturation Low O mA orO V Saturation High 22 2 MA or 5 55V 11 1V min Linear Output Range 0 22 2MA 0 20MA or 4 20MA 0 5 55V 0 5V 1 5V 0 11 1V 0 10V User Interface Dual 4 digit LED Displays Keypad 4 keys Programming Port For automatic setup calibration and testing Communication Port RS 232 and RS 485 Control Mode Output 1 Reverse heating or direct cooling action Output 2 PID cooling control cooling P band 50 30096 of PB dead band 36 0 36 0 Y of PB ON OFF 0 1 90 0 F hysteresis control P band 0 PorPD 0 100 0 96 offset adjustment PID Fuzzy logic modified Proportional band 0 1 900 0 F Integral time O 1000 seconds Derivative time O 360 0 seconds Cycle Time O 1 90 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warm start Fallure Mode Auto transfer to manual mode while sensor break or A D converter damage Ramping Control O 900 0 F minute or O 900 0 F hour ramp rate Digital Filter Function
10. BAUD and Parity Bit PARI such that these values are conform to PC setup conditions If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable should be modified for proper operation of RS 232 communication according to Section 2 10 3 14 Retransmission The profiler can output retransmit process value or set point value via its retransmission terminals RE and RE provided that the retransmission option is ordered To accomplish this you can select rEPY REPV or ESP RESP for OUT4 or OUTS The following parameters should be configured for retransmission OPAL Low limit value for output 4 OPAH High limit value for output 4 RELA Retransmission low scale value for output 4 REH4 Retransmission high scale value for output 4 OPSL Low limit value for output 5 OP5H High limit value for output 5 REL5 Retransmission low scale value for output 5 REHS Retransmission high scale value for output 5 Example If you want to output 4 mA for PV at O C and 20mA for PV at 1000 C via output 5 then you should set the following parameters OUIB er T OP5L 20 0 96 since 20 of a 0 20MA output module equipped will output 4 mA 2096 of 20rmA span OP5H 100 0 96 RES 0C REH5 1000 UMOB421A 64 3 15 Output Scaling The output scaling can be applied to the cases of linear output case 1 in Fig 3 12 and retransmission case 2 in Fig 3 12 The Out L in Fig 3 12 may be O mA OV 1V or 4
11. First order Time Constant O 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UMOB421A 85 Profiler Number of profiles 9 Number of Segment per profile Profile 1 2 3 4 16 Profile 5 6 7 32 Profile 8 9 64 Event Outputs 9 Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity O to 90 96 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 Approval Standards Safety UL61010C 1 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 EMC EN61326 86 UMOB421A Chapter 7 Modbus Communications This chapter specifies the Modbus Communications protocol as RS 232 or RS 485 interface module is installed Only RTU mode is supported Data is transmitted as eight bit binary bytes with start bit 1 stop bit and optional parity checking None Even or Odd Baud rate may be set to 2400 4800 9600 14400 19200 28800 and 38400 7 1 Functions Supported Only function 03 06 and 16 are available for this series of controllers The message formats for each function are described as follows Function 03 Read Holding Registers Query from master Response from slave Slave adaress 1 247 wh Function code 3 Starting address of register Hi
12. 100007 infinite BAGO Password entry Low 0 High 9999 Hi ASP1 10 0 BC AGP Set point for alarm 1 Low 32768 High 32767 18 0 BF iw ASP2 T 10 0 BC AGP Set point for alarm 2 Low 32768 High 32767 18 0 BF RAW Aa L 2768 High 32767 pia H5P3 Set point for alarm 3 ow 32768 High 3276 na 0 BF R W T C thermocouple J_E J type T C P LL Kiype T C EL LL Ttype T C E LL Etype T C b k B type T C r LL Rtype T C 5 LL Stype T C n EL Ntype T C L type T C C type T C 102 L Ptype T C 11 PL gn PT 100 ohms zg INPT Input sensor NPE selection CONDO OF CO N O ce DIN curve i R W 12 PE 5 PT 100 ohms JIS curve 16 UMOB421A Register Parameter Parameter Default maa INPT Input sensor nPE selection HA Input unit uni selection Decimal point selection rt I J E FN a L Operation mode l Pa AA es Input low scale e a LC 4 20 mA linear current input 0 20 mA linear current input 0 60 mV linear millivolt input u 0 1V linear voltage input 0 5V linear voltage input 1 5V linear voltage input 0 10V linear voltage input Degree C unit Degree F unit Process unit No decimal point 1 decimal digit 2 decimal digits 3 decimal digits Profile run mode Profile hold mode Static mode Automatic tuning PID1 mode Automatic tuning PID2 mode Manual mode Off mode Lag Input high scale TN 1 R
13. 40mA oP transducer power supply A Isolated 5V 80MA transducer power supply Output A C Pulsed voltage to drive SSR 14V A0mA 0 None 9 Special order 1 Relay rated 2A 240VAC 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20mA c LP 3 4 Isolated 1 5V 0 5V 0 10V 6 Triac output 1A 240VAC SSR 1 Relay rated 2A 240VAC 7 Isolated 20V 25mA transducer power supply A Apol Saal AER MISURA 8 Isolated 12V 40mA transducer power supply 7 Isolated 20V 25MA transducer power supply A Isolated 5V 80mA transducer power supply 8 Isolated 12V 40mA transducer power supply C Pulsed voltage to drive SSR 14V 40mA A Isolated 5V 80mA transducer power supply 9 Special order C Pulsed voltage to drive SSR 14V 40mA 9 Special order UM0B421A 9 Accessories OM94 6 Isolated 1A 240VAC Triac Output Module SSR OM94 7 14V 40mA SSR Drive Module OM98 3 Isolated 4 20 mA 0 20 mA Analog Output Module OM98 5 Isolated O 10V Analog Output Module CM94 1 Isolated RS 485 Interface Module for Output 5 CM94 2 Isolated RS 232 Interface Module for Output 5 CM94 3 Isolated 4 20mA 0 20m4A Retrans Module for Output 5 CM94 5 Isolated 0 10V Retrans Module for Output 5 DC94 1 Isolated 20V 25mA DC Output Power Supply DC94 2 Isolated 12V 40mA DC Output Power Supply DC94 3 Isolated 5V 80MA DC Output Power Supply CC94 1 RS 232 Interface Cable 2M CC91 2 Programming Port Cable DC21 1 Isolated 20V 25
14. Chapter 6 are not exceeded Except the thermocouple wiring all wiring should use stranded copper conductor with maximum gauge 18 AWG 2 0mm 0 08 max om Figure 2 3 Lead Termination k 4 5 7 0 mm 0 18 0 27 34 UMOB421A IXL cXL WOO FOL 9l O 0 OY vid did gid O PIN 9391 47 lt N st en c 0 en ss ss ses g C NO C NO C NO NC 90 250VAC OP1 OP2 OP3 35 UMOB421A Figure 2 4 Terminal Connection 2 4 Power Wiring 7 Fuse L INA 0 3 90 250 VAC or Figure 2 6 Power Supply Connections 2 5 Sensor Input Wiring IC V mA RID Figure 2 7 Sensor Input Wiring 2 6 Control Output Wiring TE2 pia see Kal ains Supp Figure 2 8 Output 1 Relay or Trlac SSR to Drive Load 30 UM0B421A TE2 120V 240V Mains Supply No Fuse dris iic Contactor Breaker Heater Load Figure 2 9 Output 1 Relay or Trlac SSR to Drive Contactor 120V 240V Mains Supply 30mA 5V 5V Pulsed l Voltage 33 m 33 i MN OV I AE l Figure 2 10 Output 1 Pulsed Voltage to Drive SSR UM0B421A 37 TE2 Maximum Load 4 20mA 500 ohms Figure 2 11 Output 1 Linear Current TE2 0 1V 0 5V la Minimum Load 1 5V 0 10V 10 K ohms Figure 2 12 Output 1 Linear Voltage TE3 0 120 240 AC _ Mains Supply Figure 2 13 Output 2 Relay or Trlac SSR to Drive Load 38 UM0B421A 120V 240V Mains Supply O 0 O
15. HLin HE Pr Hilin yx Required to adjust if ON OFF control is configured O Adjust to meet process requirements x Don t care Table 3 2 Heat Cool control configuration value Heat Only ON OFF Control Select Hanf for OUTI and O1HY is used for adjusting the dead band of ON OFF control The heat only on off control function is shown in the following diagram UMOBA21A 47 PV SP1 Dead band O1HY SP1 O1HY Output 1 Action Time Time Figure 3 2 Heat Only ON OFF Control The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set PB1 TIL TD1 PB2 TI2 TD2 CYC1 CYC2 OFST CPB and 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 HEFL orHL nm for OUTI and set TH and TI2 to ZERO OFST is used to adjust the control offset manual reset O1HY is hidden OFST Function OFST is measured by 96 with range O 100 0 96 In the steady state ie the 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 proportional band that is lower than set point by 25 96 then increase OFST value by 25 96 will compensate the process ofset situation After adjusting OFST to a correct value the process value will move to coincide with set point The auto tu
16. an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of PB A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation process value from the set point It is recommended to use PID control for the Heat Cool control to produce a stable and zero offset process value Other configuration required CYC1 CYC2 O1FT and O2FT CYC is adjusted according to the type of output device Generally select 0 5 2 sec for CYC if solid state relay drive or solid relay is installed for outputl 10 20 sec if relay is installed for outputl and CYC lis ignored if linear output is selected Similar condition is applied for CYC2 selection See section 3 9 for O1FT and O2FT adjustment UMOB421A 5 3 5 Alarms The unit can be configured up to three alarm outputs at OUT2 OUT3 and OUTA There are 9 types of alarm functions can be selected and 4 kinds of alarm modes are available for each alarm function put A process high alarm is independent of set point When the process is higher than the alarm value a process high alarm occurs and the alarm is off as the process value is lower than alarm value minus alarm hysteresis Fig 3 4 shows the
17. cycles are finished 66 Table 4 1 Segment types UMOB421A 4 2 Segment connection Four kinds of combination are allowable for connectiong segments these are Ramp Ramp J NG Ramp Dwell N Dwell Ramp 4 N DwekDwel Lc 4 3 Profiler Modes The profile have eight operating modes In run mode the profiler varies the set point according to the stored profile values RUN light on In hold mode the profile is forzen at its current point In this state you can make temporary changes to any profile parameter for example a target set point a dwell time or the time remaining in the HLD light on current segment Such changes will only remain effective until the profile is reset and run again when they will oe overwritten by the stored profile values UMOB421A 67 Holdback indicates that the process value is lagging the set point by more than a prese HLD liaht Holdback amount holdback band HBBD and that the 9 profile is in HOLD waiting for the process to NGsNes catch up In static mode the profiler is inactive and the th RUN T controller act as a standard controller with P EOT atic the set point determined by the value set in 4 9 the lower display are off In automatic tuning mode the profiler is Both RUN and inactive and the controller executes HLD light are automatic tuning function at its static mode off Upper set point display flashes Both RUN and In manual mode
18. home page SEL3 Select 3 rd CE parameter EL 3 for home page Same as SEL1 24 UM0B421A Register Parameter Parameter Range Default Data Address Notation Description Value type SEL4 Select 4 th GE 4 parameter Same as SELI R W L for home page Select 5 th CELG parameter Same as SEL1 RAW EL for home page Select 6 th 5 loca parameter Same as SEL1 R W for home page SEL7 Select 7 th 76 GE 7 parameter Same as SEL1 R W LL for home page SEL8 Select 8 th 77 GE O parameter Same as SELI R W L for home page Security code for Low 0 High 9999 78 r E ld O unprotected R W mes a 1000 home page unprotected 79 Reserved a NG Current process Set point value at value PV l start of each Controller set point R W profile value SP1 i Start set point value STSP Final set point value for each program Set point value at end of each SP Controller set point R W profile value All outputs go to off execpt end of profile relay Delay time hours minutes between profile initiation and profile start Low 0 00 High 99 59 R W UMOB421A 25 Register Parameter Parameter Address Notation Description HBT Holdback wait HbE time Range F Continue profile from the last set point value Start to run from PV Static mode SP1 OFF mode Low 0 00 High 99 59 hour minute 0 002 nF 1 infinite Resewed of PROF Profile number e Ee selected for view L
19. value to the set point value as soon as possible this is the best choice The two diagrams below illustrate the respective responses Fig 4 3 if power fails during a dwell segment and Fig 4 4 if it fails during a ramp segment Set point Segment dwell time 11 12 power off power on I Ramp Dwell Segment Segment Figure 4 3 Recovery from profile at dwell segment Time Set point Target Set point power off power on Time Ramp segment Dwell Segment Figure 4 4 Recovery from profile at ramp segment 72 UMOB421A If PY is selected then when power is restored the set point starts at the current process value and then runs to the target set point of the active segment This choice provides a smoother recovery The two diagrams below illustrate the respective responses Fig 4 5 if power fails during a dwell segment and Fig 4 6 if it fails during a ramp segment Set point segment dwell time 11 12 power off power on I Ramp segment Figure 4 5 Recovery from PV at dwell segment Dwell Segment Time Set point power off Y Target Set point mm an 4 power on Time Ramp Segment Dwell Segment Figure 4 6 Recovery from PV at ramp segment If SP 1 is selected then when power is restored the profiler is disabled and it enters static mode and SP1 is selected for control set point If oF F is sel
20. 0 Byte count Starting address of register Lo 0 117 Data Hi 128 143 Data 1 Lo No of words Hi 0 Data 2 Hi No of words Lo 1 118 Data 2 Lo CRC1 6 Hi CRC16 Lo CRC1 6 Hi CRC16 Lo Function 06 Preset single Register Query from master Response from slave Slave address 1 247 sh Function code 6 wh Register address Hi 0 a Register address Lo 0 117 128 143 a Data Hi 4 Data Lo CRC16 Hi _ CRC16 Lo sh UMOB421A 87 Function 16 Preset Multiple Registers Query from master Response from slave slave adaress 1 247 EL Function code 16 4 Starting address of register Hi 0 4 starting address of register Lo 0 117 Jm 128 143 No of words Hi 0 No of words Lo 1 118 MK Byte count 2 236 CRC16 Hi Data 1 Hi CRCTO LO Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo 88 UMOB421A 7 2 Exception Responses If the controller receives a Message which contains a corrupted character parity check error framing error etc or if the CRC16 check fails the controller ignores the message However if the controller receives a syntactically correct message which contains an illegal value if will send an exception response consisting of five bytes as follows slave address offset function code exception code CRC16 Hi CRC16 Lo Where the offset function code is obtained by adding the function code with 128 ie function 3 becomes H
21. 3 Figure 3 7 Deviation low alarm 1 operation 53 Figure 3 8 Deviation band alarm 1 operation 54 Figure 3 9 Two point user calibration 57 Figure 3 10 Filter Characteristics 58 Figure 3 11 Effects of PID Adjustment 62 Figure 3 12 Output scaling function 65 Figure 4 1 Set point profile 66 Figure 4 2 Holdback operation 71 Figure 4 3 Recovery from profile at dwell segment 72 Figure 4 4 Recovery from profile at ramp segment 72 Figure 4 5 Recovery from PV at dwell segment 73 Figure 4 6 Recovery from PV at ramp segment 73 Figure 4 7 Profiling curve example
22. 32 cable instead of CC94 2 the cable must be modified according to the following circuit diagram To DTE PC RS 232 Port 1 DCD 2 RD 3 ID 4 DIR 5 GND 6 DSR 7 RTS 8 CTS Female DB 9 9 RI Figure 2 24 Configuration of RS 232 Cable UM0B421A 43 Chapter 3 Configuration The parameters stored in Home page can be obtained by pressing scroll key The parameters stored in Configuration page are obtained by pressing page key 7 2 times until the display shows Prof then press page key for at least 5 seconds and release to show lonf the Configuration page then press scroll key to get the configuration parameter The upper display indicates the parameter symbol and the lower display indicates the selected value of parameter 3 1 Password There are two parameters which specity the data security function these are PASS password and CODE security code Value of CODE Value of PASS o Anyvalue All parameters are changeable 1000 All parameters are changeable Only Home page parameters are changeable CODE All parameters are changeable Others CODE All parameters are not changeable Table 3 1 Password operation 1000 41000 3 2 Signal Input INPT Selects the sensor type or signal type for signal input Range thermocouple J TC K TC T TC E TC B TC R TC S TICN TC LICC EI RTD PT DN PT JS linear 4 20 0 20 0 60 O 1V 0 5V 1 5V 0 10 UNIT Selects the process unit Rang
23. 83 and the exception code is equal to the value contained in the following table Exception Codd Name Cause Function code is not supported Bad function code by the controller Data value out of range or Illegal data value attempt to write a read only or protected data Illegal data address Register address out of range Table 7 1 Exceptlon Code Table 7 3 Parameter Table You can refer to section 1 6 for the parameter description The register address for each parameter is shown in the first column of the table The register 133 for EROR is the error code The error code description is shown in Table A The register 140 for PROG is the program code of the product The program code is 37 xx for P41 and B42 where xx denotes the software version number For example PROG 37 22 means that the process controller is P41 or B42 with software version 22 UM0B421A 89 7 4 Number System The values stored in registers are based on 2 s complement format The relation between the value of number in register and its actual value is shown as following table Actual value 927 67 10000 Table 7 2 Number Conversion Table 7 5 Communication Example Example 1 Read the real time data register 128 141 Query a 00 os oo ox n wo Example 2 Read segment 2 data of profile 3 Query p o oo o o Ww Starting Addr Data Hi Lo CRCI6 90 UMOB421A Query a os e 2 alo Register Add Data
24. D technology the control loop will minimize the overshoot and undershoot in a shortest time The following diagram is a comparison of results with and without Fuzzy technology UMOB421A 5 PID control with properly tuned PID Fuzzy control Warm Up Load Disturbance Temperature Set point er Figure 1 1 Fuzzy Control Advantage Time The series can be configured as a single set point controller static mode or a ramp and dwell profiling controller profile mode The profile mode feature allows the user to program up to 9 profiles of up to 64 free format ramp dwell jump or end segments each The total segments available for the product is 288 segments The profiling controllers contain the following features Flexible Configuration of Program There are up to 64 segments can be defined for a profile Each segment can be configured as a ramp or a dwell soak segment or defining a repeat number of cycles at arbitray location within the profile and finally terminated by an end segment The user can edit a currently running profile Maximum Capacity of Program There are at most 9 profiles can be defined and 288 segments totally available for all profiles The profiles are divide into three kinds of length The short length profile contains 16 segments the medium length profile contains 32 segments while the long length profile contains 64 segments at most Event Input The event input featur
25. HY A2HY A3HY ADDR When using the up down key to select the parameters you may not obtain all of the above parameters The number of visible parameters is dependent on the configuration codition The hidden parameters for a specific application are also deleted from the values of SEL SEL8 parameters 3 7 User Calibration Each unit is calibrated in the factory before shipment You still can modify the calibration conditions after shipment Purpose of user calibration The basic calibration of the unit is highly stable and set for life User calibration allows you to offset the permanent factory calibration to either 1 Calibrate the unit to meet your reference standard 2 Match the calibration of the unit to that of a particular transducer or sensor input 3 Calibrate the unit to suit the characteristics of a particular installation 4 Remove long term drift in the factory set calibration There are two parameters offset low value OFSTL and offset high value OFSTH which are adjusted to correct the error of process value See section 1 5 for key operation flowchart press 7 key until low calibration page is obtained Send the low signal to the input of unit then press key If the process value the upper display is different from the input signal then you can use a and vw keys to change the OFSTL value the lower display until the process value is equal to the value you want Then press and hold 7 key for 5 sec
26. Hi Lo CRCI6 Query a wo osc oo w w Example 3 Perform reset function Query 00 es oss 025 u to Example 4 Enter auto tuning mode Query wo oo oo o alo Example 5 Enter manual mode Query Te wo oc ow o w w Example 6 Modify the Calibration coefficient Preset the CMND register with 26668 before attempting to change the calibration coefficient Query oo ox oss 029 H to Register Addr Data Hi Lo CRCI6 UM0B421A 9 Example 7 Start from segment 4 to run profile 3 Co o c ow w w Addi Register Add Data Hi Lo CRCI Query Add Register Add Data Hi Lo CRCI6 Example 8 Hold the current profile Query 06 o0 aos co o Hi Add Register Add Data Hi Lo CRCI Example 9 Create the profile which is specified in example of Fig 4 7 D C O lt a Tono o oe o oo wo o Func No of words PROF 1 00 0x32 00 oxa o0 00 oo 00 Hi lo HBBD 5 0 CRI 92 UMOB421A Query _ oxio 00 sB o0 06 ox0c 00 00 00 oo 0x05 OXDC 00 OOF oo oo 00 01 Hi lo Query oxo 00 jos 00 02 04 00 01 00 01 Hi Lo Query loxo 00 oF 00 03 06 00 00 00 03 00 0x14 Hi Lo Query _ oxto 00 oxsB 00 06 awe 00 02 00 oo 009 oxc4 00 oxi4 00 oo 00 01 H lo Query ono co ose oo 02 04 co os oo oW
27. Mode Page Profile Page Home Display m Prof MODE 1 9 run Profile run mode Hold Profile hold mode ma SEAE Static mode TIME A E Automatic tuning PID mode bana Ake Automatic tuning PID2 mode nAn Manual mode eu oFF Off mode fel Using 4 CJ key to select desired mode then 7 V B 5sec ele Enters the selected mode 9 fo 0 o Fo o 9 al 9 o o NANNANANANAN YUUUUUUUUUUU 9 0 e 9 fo 9 o lb o o cocoa aaa aa P2EV Slo Ces 56 EX Se SES 14 UMOB421A Low High Configuration Calibration Calibration Pa Page Page 5 sec D LAH D CALO CAHI al ap OFSTL OFSTH Using 4 or CF key to Using 4 or x key to adjust the offset low value adjust the offset high value lower display until the lower display until the process value higher display process value higher display is equal to the required value is equal to the required value Then Then D5sec f D 5sec Complete calibration Complete calibration procedure for the procedure for the low point calibration high point calibration UMOB421A 1 6 Parameter Descriptions aa Parameter Default pa Controller Static mode 25 0 BC Set point Ma Low SPLO High SPHI 77 0 BF Rw Low 1 00 High 9 63 lala the On number EE Profile number IB Segment number TIME ini Time remaining for T CYCL cycle remaining for Low 1 High 9999 4L the current profile
28. PT K TC OUT4 EVN3 OUTI HTPC OUTS REPV OFT BPLS OP5L 0 0 UNIT LC OP5H 100 0 DP 1 DP RELS 0 0 CYC 18 0 REH5 1000 0 Chapter 6 Specifications Power 90 250 VAC 47 63 Hz 12VA 5W maximum 11 26 VAC VDC 12VA 5W maximum Input Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect A1 5uV C for all inputs except mA input A3 0uV C for mA input Sensor Lead Resistance Effect T C 0 2uV ohrn 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohrn of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 120dB Normal Mode Rejection Ratio NMRR 55cB Sensor Break Detection Sensor open for TC RTD and mv inputs Sensor short for RTD input below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs UMOB421A 81 Characteristics Roa on HER bitak Kidd Uu SETS C coc rawa EE En e 9e 3nsc BIB UE AE Eu ri 82 UM0B421A we E UI O cron en e m C e lt gt lt 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 0 Linear Outpu
29. User s Manual CERT DIN EN ISO 9001 Certificate 01 100 98505 LJ c 8508421 BA r on WAN fon b TE te pr V s m de gt B42 Board PID Process Temperature Controller UMOB421A Warning Symbol N The Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and rnet Use the Manual e nstallers Read Chapter 1 2 e System Designer Read All Chapters e Expert User Read Page 15 16 NOTE It is strongly recommended that a process should incorporate a LIMIT CONTROL like L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this user s manual is subject to change without This manual is applicable for the products with software version 22 and later version Copyright a July 2012 The Brainchild Corporation all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval systern or translated into any language in any form by any means without the written permission of the Brainchild Corporation 2 UMOB421A Contents Page No Chapter 1 Overview 1 1 General 5 1 2 Ordering Code
30. e C F PU process unit If the unit is neither C nor F then selects PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 DP for linear NO DP 1 DP 2 DP 3 DP INLO Selects the low scale value for the linear type input INHI Selects the high scale value for the linear type input 44 UMOB421A How to use INLO and INHI If 4 20 MA is selected for INPT let SL specifies the input signal low ie 4 MA SH specifies the input signal high ie 20 mA S specifies the current input signal value the conversion curve of the process value is shown as follows process value Figure 3 1 Conversion Curve for Linear Type Process Value input signal Formula PV INLO INHI NLO Example A 4 20 mA current loop pressure transducer with range 0 15 kg crh is connected to input then perform the following setup INPT 4 20 INLO 0 00 INHI 15 00 DP 2 DP Of course you may select other value for DP to alter the resolution 3 3 Event Input The Event input accepts a digital type signal via momentary and close contacts The types of signal 1 relay or switch contacts 2 open collector pull low and 3 TTL logic level can be used to switch the event input one of eight functions can be chosen by using Es Fn ElFN contained in configuration page O NONE Event input no function 1 RUN Applicable when unit is in static mode or Off mode Requires only momentary ty
31. e allows the user to select one of eight functions enter profile run mode enter profile hold mode abort profile mode enter manual mode perform failure transfer enter off mode advance to the next segment and select second set of PID values UMOB421A Programmable Event Outputs Up to three relays are configurable for event outputs and the state of each output can be defined for each segment and end of profile Analog Retransmission The outputs and output 4 of the products can be equipped with analog output module The output can be configured for transmitting the process value as well as set point value High Accuracy The series are manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1 BF resolution for thermocouple and PT100 and a 15 bit D to A converter for linear current or voltage control output The ASIC technology provides improved operating performance low cost enhanced reliability and higher density Fast Sampling Rate The sampling rate of the inout A to D converter reaches 5 times second The fast sampling rate allows this series to control fast processes Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes The results is to enable a process to reach a predeter
32. e for 102 OFSTH high point Low 1999 high 1999 R W calibration mV calibration PL mV calibration Low 1999 high 1999 R W 104 ADHI high coefficient oss io UMOB421A 27 Register Parameter Parameter Range Default Data Address Notation Description Value type RTD calibration RTD calibration RTDH high coefficient Low 1999 high 1999 EX Cold junction 107 CJLO calibration low Low 5 00 high 40 00 RIW coefficient Cold junction 108 CJHI calibration high Low 1999 high 1999 RAW coefficient 1 SRNO Serial number number Low 0 p 9999 Reseved transf BS BPL1 Low 0 High 100 00 Bumpless transfer BPL2 value or MUS kamo High 100000 0 kamo High 100000 100 00 Sense voltage 114 CJCL durig cold junction Low 0 High 7552 calibration low Input signal value 115 CALO during low point Low 32768 High 32767 calibration CAEN Input signal value EH 116 CAHI during high point Low 32768 High 32767 1000 calibration vemm e O Reseved O 22068 1 E a 120 Resewed moo qRseved 2 Reseved 28 UM0B421A Register Parameter Parameter Default Data Address Notation Description Value type m me a fee T E Cus seme T Dus meme LE Dur wen panama IN E Jang a PAAR for cem 1 percentage Low 0 00 High 100 00 value Heating Output 2 percentage Low 0 00 High 100 00 1 value Cooling Ran
33. e minute Profillng curve example you can make a follow Segment Data SGNO 0 SGIY RAMP TGSP 150 0 RTRR 15 P2EV 0000 HBIY segment 0 SGNO SGIY DLL P2EV 0000 HBTY 3 DLLT 20 segment 1 UMOB421A SENO 2 SGTY RAMP TGSP 250 0 RIRR 20 P2EV 0000 HBTY segment 2 SGNO 3 SGTY DLL P2EV 0000 HBTY 3 DLLT 10 segment 3 SGNO 4 SGIY RAMP TGSP 150 0 RIRR 25 segment 4 P2EV 0001 HBIY 2 SGNO 5 SGTY JUMP SEG CYCL 2 segment 5 SGNO 6 SGTY DLL P2EV 0000 HBIY 3 DLLT 24 segment 6 SGNO 7 SGTY RAMP TGSP 650 0 RIRR 30 P2EV 1010 HBTY segment 7 HBIY 3 DLLT 30 SGNO 9 SGTY RAMP TGSP 450 0 SGNO 8 SGTY DLL P2EV 1010 Segment 8 RTRR 30 Segment 9 P2EV 1011 HBTY 2 SGNO 10 SGTY DLL P2EV 1010 Segment 10 HBTY 3 DLLT 20 SGNO 11 SGTY RAMP TGSP 100 0 Segment 11 RTRR 11 P2EV 0001 HBTY 2 CYCL 2 SENO 12 SGTY END Segment 12 FSP 100 0 UMOB421A 77 4 11 Event Outputs and PID Selection The event outputs and PID selection are defined by parameter P2EV in the segment data and parameters OUT2 OUT3 and OUT4 There are up to 3 event outputs can be configured The register 95 shown in section 1 6 describes how to define event status and select PID values There are two sets of PID parameters stored in the memory If the unit is in RUN
34. e process value is too unstable to be read SEL Function The units have the flexibility for user to select those parameters which are most significant to him and put these parameters in the home page There are at most 8 parameters can be selected to allow the user to build his own display sequence 8 UMOB421A 1 2 Ordering Code B22 ODOO00000 Power Inpu Display Board and cable 4 90 250 VAC 47 63 Hz 0 None l 5 11 26 VAC or VDC 3 Display Board with 300mm connection cable 4 Display Board with 1000mm connection cable Signal Inp 1 Standard Input Output 5 Thermocouple 0 None J K T E B R S N L 3 Retransmit 4 20MA O 20MA C P 4 Retransmit 1 5V O 5V 0 10V RTD PT100 DIN PT100 JIS 7 kg kan eid d ub sol ager eo 8 Isolated 12V 40mA 5 0 10V 0 1V 0 5V 1 5V transducer power supply 6 0 20 4 20 mA A Isolated 5V 80MA 9 Special Order transducer power supply D Isolated RS 485 interface E Isolated RS 232 interface Output 0 None Output 4 1 Relay rated 2A 240VAC 0 None 2 Pulsed voltage to drive SSR 1 Relay rated 2A 240VAC 5V 30mA 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA O 20mA 3 Retransmit 4 20mA O 20mA 4 Isolated 1 5V O 5V O 10V 4 Retransmit 1 5V 0 5V O 10V 6 Triac output 1A 240VAC SSR 6 Triac output 1A 240VAC SSR C Pulsed voltage to drive SSR 7 Isolated 20V 25mA 14V 40mA transducer power supply Special order 8 Isolated 12V
35. e refer to section 1 5 for key operation 4 5 Viewing and modifying profile progress Three parameters PFSG TIME CYCL which indicate the status of profile progress The operator can easily view these parameters the current profile and segment number the time remaining for the current segment and the cycle remaining for the current profile on the home page When profile is running if is required to jump to another segment then it requires holding of current profile go to current segment PSEG by pressing Enter button then use Up and Down buttons to modify the segment and then run the profile again When profile is running if it is required to change dwell time or ramp rate of current segment then it requires holding of current profile press Enter button twice to go to TIME and then modify the value and then run the profile again When profile is running if it is required to modify next segment data no need to hold the current profile modifications can be done directly from the configuration 4 6 Start The parameter St Ar in the configuration is used to specify the start point for the profile There are three values for the starting point these are PV Process value default value SP 1 controller set point value STSP start set point value The normal method is to start from the process value because this will produce a smooth and bumpless start to the process However if you want to guarantee the time pe
36. ected then when power is restored the profiler is disabled and it enters OFF mode all the control outputs as well as alarms and events are off 73 UM0B421A 4 9 Configuring the profiler when first installing a profiler you should check that the configuration conforms to your requirement The following parameters are common to all profiles Global Data STAR set point value at start of profile END set point value at end of profile DLAY Delay time before profile start PFR Power fail recovery HBT Holdback wait time The following parameters are used for a specific profile Profile Data PROF Profile number selected for view HBBD Holdback band STSP Start set point value RMPU Unit for ramp segment DLLU Unit for dwell segment The following parameters which apply to each segment in a specific profile segment Data SGNO Segment number SGIY Segment type TGSP Target set point RTRR Ramp time or ramp rate P2EV PID selection and event output states HBTY Holdback type DLLT Dwell time SEG Target segment number for jump segment CYCL Repeat number of cycle FSP Final set point for the end segment 4 10 Viewing and creating a profile Refer to section 1 5 for key operation Press page key to obtain configuration page After completing the configuration of all the parameters including those parameters which are common to all profiles you can proceed to the profile page to create a profile To create a spec
37. ed for OUT2 OUT3 or OUTA A direct acting latching alarm output is on as an alarm condition and it will remain unchanged even if the alarm condition is cleared The output state is inverted as a reverse alarm output is selected for OUT2 OUT3 or OUTA A direct acting holding alarm output is off even if an alarm condition may occur on power up This will prevail until the alarm condition returns to the inactive condition thereafter the alarm will operate normally The output state is inverted as a reverse alarm output is selected for OUT2 OUT3 or OUTA A direct acting latching and holding alarm performs both holding and latching alarm functions The output state is inverted as a reverse alarm output is selected for OUT2 OUT3 or OUTA Table 3 3 Alarm mode description The latching alarm output is off when both 4 and LY keys are pressed once the alarm condition is removed UMOB421A 55 3 6 Configure Home Page The conventional controllers are designed with a fixed parameter scrolling This unit has the flexibility for you to select those parameters which are most useful to you and put these parameters in the home page Hence you can have a custom home page There are up to eight parameters can be selected for home page these are SEL SEL8 in the configuration page There are 19 parameters can be selected for SEL SEL8 these are INPT UNIT DE PBT MT TD PB2 TI2 TD2 OFS O IHY CYC 1 CYGC2 CPB DB A1
38. egister Parameter Parameter Default Data Description O second time constant 0 2 second time constant 0 5 second time constant 1 second time constant 2 seconds time constant 5 seconds time constant 10 seconds time constant 20 seconds time constant 30 seconds time constant 60 seconds time constant Filter damping time constant of PV 00 TM Oo al A wo N U a b C C9 C C3 un ru C Ww nant No function run Program run mode Hol d Program hold mode Abot Abort profile mode n Hn Manual mode Failure Transfer Off mode Pass to the next segment oc Select PB2 TI2 amp TD2 for control SPLO Low limit of set a SPHI High limi m Mig imitofset Low SPLO High 32767 OnanE No function 1 HonF Heating on off control 2 HE PL Heating time proportioning control 18 s AU 3H n Heating linear control BAG 4 4 anF Cooling on off control 5LEPL Cooling time proportioning control bElin Cooling linear control sl UMOB421A Register Parameter Parameter Ranae Default Data Address Notation Description g Select BPLS ooo less transfer or 0 0 0 Yo to d Output 1 failure continue output 1 control o IF LE transfer status function as the unit fails or select OFF 0 or ON 1 for ON OFF control O1HY Output 1 ON OFF m 0 1LC 2 Ie de ee Low 0 1 High 90 0 sec 18 0 R W L HL 1 time OP1L Low limit value for T OP1H High limit value
39. ge Bit O Profile run mode Bit 1 Profile hold mode Bit 2 Static mode Bit 3 Automatic tuning mode Bit 4 Manual mode Bit 5 Off mode Bit 6 Failure mode Mode and Bit 7 Profile running up STAT operation status Bit 8 Profile runing down word Bit 9 Profile soaking Bit 10 Alarm 1 active Bit 11 Alarm 2 active Bit 12 Alarm 3 active Bit 13 Event 1 on Bit 14 Event 2 on Bit 15 Event 3 on EE ECC CO E Current profile 134 PFSG and segment Low 1 00 High 9 63 runing Total number of T Total time for T ms mo waa la UMOB421A 29 Register Parameter Parameter Default Data Address Notation Description Value type Set point for ur em ween e Time remaining TIME for the current Low 00 00 High 99 59 segment Cycle remaining High 9999 EE ec en 10000 infinite Program and PROG version code Low 32768 High 32767 of the product Holdback time HBTR remaning for the High 99 59 current segment CMND Low 32768 High 32767 mw rx code Low 32768 High 32767 Jaw Range 1 Read only unless in manual control mode 30 UM0B421A Chapter 2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any cleaning or troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly eq
40. gnal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process 58 UMOB421A 3 9 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 IMA 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 Failure Transfer if activated will perform 1 If output is configured as proportional control je HIPC CTPC HLIN or CLIN selected for OUTI and BPLS is selected for OTFT then output 1 will perform bumpless transfer Thereafter the previous averaging value of MVI will be used for controlling output 1 2 If output 1 is configured as proportional control and a value of O to 100 0 is set for OTFT then output 1 will perform failure transfer Thereafter the value of OTFT will be used for controlling output 1 3 If output 1 is configured as ON OFF control ie HONF or CONF is selected for OUTI then output 1 will transfer to off state if OFF is set for OTFT and transfer to on state if ON is set for OTFT Output 2 Fallure Transfer if activated will perform 1 If OUT2 is configured as CTPC or CLIN and BPLS is selected for O2FT then output 2 will perfo
41. iates above the set point by more than the holdback band HBBD bHnd Deviation Band Holdback is a combination of the two It holds the profile back when the process value deviates either above or below the set point by more than the holdback band HBBD HBT is a global parameter which is common to all profiles HBBD is a parameter which apply to a specific profile HBTY is a parameter which apply to a segment in a specific profile Y LL 70 UMOB421A Holdback on dwell HBBD HBBD Profile held if Profile held if HBTY set to HBTY set to Hi or BAND Lo or BAND HBBD Holdback on positive ramp HBBD Profile held if HBTY set to Hi or BAND Profile held if HBTY set to Lo or BAND Holdback on negative ramp Profile held if HBTY set to Hi or BAND Profile held if HBTY set to Lo or BAND Figure 4 2 Holdback operation UM0B421A 7 4 6 Power fallure If power is lost and then restored while a profile is running the behavior of the profile is determined by the setting of the parameter PFR power fail recovery in profile configuration This can have one of 4 settings cont PY 5P1 and of F If cont is selected then when power is restored the profile continues from where it was interrupted when power was lost The parameters such as set point value SV time remaining TIME and cycle remaining CYCL will be restored to their power down values For application that need to bring the process
42. ific profile you need to set the profile number at first then set HBBD STSP RMPU DLLU and SGNO for this profile 74 UM0B421A The next parameter is segment type SGTY there are four different segment types these are ma Ramp to a new set point at a set rate or in a set time dit Dwell for a set time JunF Jump to a specified segment in the same profile End Make this segment the end of the profile The parameters that follow SGTY segment type depend on the type of segment selected as shown in the table below The function of each parameters follows the table Segment type SGTY selected O RAMP 1 DEL 2 JUMP 3 END res KR M ND RUN Table 4 3 Parameters that follow segment type suppose that you need a profiler to control a process The response of the profiler must be same as the figure shown below UMOB421A 15 Set point PNG 2 y S A OOTP EE UTE Pm ee a 250f A A Camaya ru CEA AG puer JZ N UN MR 150 por de la a a Y Ti 15511 ti 5 6 MO OOF NT es oi EST Tiii DEWMAN QO FT M NINO OT OTOIOT wA Os BR NON DOO oc NO DOO X o 7 Figure 4 In order to meet the response of profiling curve example series of setting of parameters as Global Data STAR STSP END OFF DLAY 0 PFR PV HBT 1 00 Profile Data PROF HBBD 50 STSP 25 0 RMPU HH MM DLLU HH MM 76 Event Event 2 Alarm 3 End of profile AA AA choto PID 2 mi de rm m Tim
43. ill 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 Step 7 Return to the static mode by pressing up and down key at a time then release UMOB421A 97 Appendix A 1 Table A Error Codes and Corrective Actions Displa A Symbol Error Description Corrective Action Check and correct setup values of Illegal setup values been used OUT2 PB TI and OUT IF OUT2 Before COOL is used for OUT2 is required for cooling control the DIRT cooling action has already control should use PID mode PB 4 been used for OUT1 or PID mode 0 TI 0 and OUT should is not used for OUTI that is PB use reverse mode heating action 0 and or TI 0 Otherwise don t use OUT2 for cooling control Correct the communication 10 n error bad function software to meet the protocol requirements ERE Er error register Don t issue an over range ERES out of range register address to the slave Communication error attempt Don t write a read only data or a to write a read only data ora protected data to the slave protected data Communication error write a Don t write an over range data value which is out of range to a to the slave register register Holdback time out Evaluate validity of the PID values The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change
44. io Query o o0 oxsF 00 03 06 00 o0 o0 osfoojooan Lo UMOB421A 93 Query 0x0 o0 oxss 00 06 oxc 00 04 00 o0 o05 ODC 00 x19 00 01 00 O2 Hi lo Query odo oo ose oo 02 04 00 05 co 02 ri lo Query ono co ova ao 02 04 oo or ao oz n io Query oao co osa oo 02 os co os ooo io Query Joad co aee 00 03 08 oo oo co os poca fo Query oo oss 00 06 baa 00 07 00 ao ono 084 oo one oo o 00 o mio Query ETC ACE CC UMOB421A Query oxto 00 ox6F 00 08 o6 00 004 00 o3 o9 oe Hi Lo Query axial 0o ose co 06 oxoc og oos oo oo ox oes oo one 00 c08 oo 02 w to Query 0x0 00 asa 00 02 04 o xos o ov v uo Query oo so ose 00 o 06 foafoa oo os oolong io Query ox1o 00 ox68 00 06 oxoc oo foxos oo 00 0x03 jos 00 oo O1 00 O2 Hi lo Query aro 00 Joss oo oz 04 ooooc oo osa to Query ouo 00 0x63 00 o2 o4 00 02 065 oes Hi Lo UMOB421A 95 Chapter 8 Manual Calibration A Do not proceed through this section unless there is a definite need to re calibrate the controller Otherwise all previous calibration data will be lost Do not attempt recalibration unless you have appropriate calibration equipment If calibra
45. ion fails Step 3 Press the scroll key then release the display will show Step 4 Step 5 Step 6 Send a 60 mV signal to the thermocouple input terminals in correct polarity Press scroll key for at least 5 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 1999 or 1999 then the calibration fails Press the scroll key then release the display will show Send a 100 ohms signal with 3 wire to the RTD input terminals Press scroll key for at least 5 seconds The display will blink a moment Otherwise if the display didn t blink then the calibration fails Press the scroll key then release the display will show Change the ohm s value to 3000hms Press scroll key for at least 5 seconds The display will blink a moment and two values are obtained for and Otherwise if the display didn t blink or if any value obtained for and E 4H is equal to 1999 or 1999 then the calibration fails Connect a K type thermocouple to the thermocouple input terminals Press the scroll key then release the display will show Z IL o Apply up down key until value 0 00 is obtained The unit under calibration is powered in a still air room with temperature 25 C Stay at least 20 minutes for warming up Send a 0 0 C signal to the thermocouple input terminals Apply up down key until 0 00 is obtained Press scroll key for at least 5 seconds The display w
46. ished Since the condition is changing when an additional heater is tumed on the PID control parameter should be different from the case of single heater A B42 process controller is perfectly to meet the above requirements The system diagram is shown below Recorder 19120 9 7 2 1 AC MAN Figure 5 1 A Heat Treatment Oven 79 UMOB421A The output 1 is used to drive the main heater The output 2 is used to drive the cooling fan the output 3 is used for end of profile relay and the output 4 is used to drive the auxiliary heater Temperature Time Figure 5 2 Temperature proflle of the Heat Treatment Oven The temperature profile is shown as Fig 5 2 To achieve this profile the profiler is configured by the following setting Global Data STAR PV END OFF DLAY 0 PFR CONT HBT 0 05 Profile Data PROF HBBD 50 RMPU HH MM DLLU HH MM segment Data SGNO SGTY RAMP TGSP 400 0 RIRR 25 P2EV 0000 HBTY 1 Auto tuning is performed at 400 LC for SGNO 2 SGTY DLL P2EV 0000 HBTY 3 DLLT 21 SGNO 3 SGTY RAMP TGSP 1000 0 RIRR 9 P2EV 1100 HBTY SGNO 4 SGTY DLL P2EV 1100 HBTY 3 DLLT 18 PID1 and 1000LC for PID2 80 UMOB421A SGNO 5 SGTY RAMP IGSP 25 0 RTRR 15 P2EV 0001 HBTY 2 SGNO 6 SGIY END CYCL 1 FSP 25 0 Controller Configuration Data ALF2 ENDP OUT2 EVNI A2MD 0000 OUT3 ALM2 IN
47. lus PID microprocessor based profiling controller series incorporate two bright easy to read 4 digit LED displays indicating process value and set point value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The unit is powered by 11 26 or 90 250 VDC VAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control an event output or an alarm Both outputs can select triac logic output linear current or linear voltage to drive external device The units are fully programmable for PT100 and thermocouple types J K LE B R S N L C P with no need to modify the unit The input signal is digitized by using a 18 bit A to D converter Its fast sampling rate allows the unit to control fast processes There are more functions than the heating and cooling control could be configured for the controller outputs these include up to three alarm outputs up to three event outputs and up to two analog retransmission outputs Digital communications RS 485 or RS 232 are available as an additional option These options allow the units to be integrated with supervisory control system and software A programming port is available for automatic configuration calibration and testing without the need to access the keys on front panel By using proprietary Fuzzy modified PI
48. mA and out H may be 20mA SV or 10V according the output module installed MV1 or 100 0 Electrical Out L Out H Output Retransmission High Low Electrical Out L Out H Output Figure 3 12 Output scaling function UM0B421A 65 Chapter 4 Profiler Operation 4 1 What is set point profiler Many applications need to vary temperature or process value with time such applications need a controller which varies a set point as a function of time The process controller B42 can do this The set point is varied by using a set point profiler The profile is stored as a series of ramp and dwell segments as shown below Set point Time Figure 4 1 Set polnt profile In each segment you can define the state of up to 3 event outputs which can drive either relay logic or triac outputs depending on the modules installed A profile is executed either once repeated a set number of times or repeated continuously If repeated a set number of times then the number of cycles must be specified as part of the profile There are four types of segment The set point ramp linearly from its current value to a new value either at a rate ramp rate or in a set timg ramp time you must specify the ramp rate or the ramp time and the target set point when creating or modifying a profile The profile either ends in this segment or repeats a set number of cycles The profile stops after the repeated
49. mA DC Output Power Supply for Output 5 DC21 2 Isolated 12V 40mA DC Output Power Supply for Output 5 DC21 3 Isolated 5V 80MA DC Output Power Supply for Output 5 10 UMOB421A 1 3 Programming Port BS0B421A CN52 AO AOt IVA0SZ 06 N 1 OO A zzz SSE A COM TX2 TX1 pin1 1dO ON 9 ON 9 ON 9 QO Programming Port CAL caL s 2 s a s cws ZdO TC 7dO ON 9 SSE PTB PTB PTA TC O O Figure 1 2 Programming Port Overview A special connector can be used to touch the programming port which is connected to a PC for automatic configuration also can be connected to an ATE system for automatic calibration and testing The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these pins when the unit is used for a normal control purpose UMOB421A 11 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY a This key is used to increase the value of selected parameter DOWN KEY v This key is used to decrease the value of selected parameter PAGE KEY This key is used to select desired page of parameters REVERSE SCROLL 4 Press both and a keys to jump to the previous parameter RESET KEY 4 Lv Press both a and v keys to 1 Revert the display to display the process value 2 Reset the latchi
50. mined set point in the shortest time with the minimum of overshoot and undershoot during power up or external load disturbance Digital Communication The units are equipped with RS 485 or RS 232 interface card to provide digital communication By using the twisted pair wires there are at most 247 units can be connected together via RS 485 interface to a host computer UMOB421A 7 Programming Port A programming port is used to connect the unit to a hand held programmer or a PC for quick configuration also can be connected to an ATE system for automatic testing amp calibration Auto tune The auto tune function allows the user to simplify initial setup for a new system A clever algorithm is provided to obtain an optimal set of control parameters for the process and it can be applied either as the process is warming up cold start or as the process has been in steady state warm start Lockout Protection According to actual security requirement a password is provided to prevent the unit from being changed abnormally Burnpless Transfer Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks Hence the process can be well controlled temporarily as if the sensor is normal Digital Filter A first order low pass filter with a programmable time constant is used to improve the stability of process value This is particularly useful in certain application where th
51. ng alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and off mode then enters the static mode 4 Clear the message of communication error holdback time out error and auto tuning error 5 To reset new profile start segment to 1 00 after earlier profile is completed when RUN and HLD LED s are blinking together ENTER KEY Press for 5 seconds to 1 Enter the selected mode to run 2 Execute calibration procedure for the low point and high point calibration 12 UMOB421A Upper Display to display process value Output Status menu symbol and error code etc indicators for Lower Display to display set point value output output 4 parameter value or control output value etc O e dame ame um Out2 o A0 D RUN On profile held E Ye ma NE Flashing profile in holdback ki sv state A Running ramp up segment v Running ramp down segment AY Running dwell segment Both off profile held or in static mode 4 Buttons for ease of control setup and set point adjustment Figure 1 3 Front Panel Description E P 2 m mm bos On profile running aa H H H H o Flashing profile in delayed state The unit will disolay the program code for 2 5 seconds during power up The display shows program number 37 with program version 22 The program no 37 Figure 1 4 Program code display UM0B421A 13 1 5 Key Operation Flowchart Home Page
52. ning mode is disabled for P or PD control Refer to section 3 11 for manual tuning P or PD control is not prefect because the load may change from time to time and you need to adjust OFST often The PID control can avoid this defect 48 UM0B421A Heat only PID control Set HE PL or Hi n for OUTI and non zero value of proportional band and integral time Perform auto tuning to the new process or set correct values for PB1 TI1 and TDI If the control result is still unsatisfactory then perform manual tuning to improve the control See section 3 11 for manual tuning The unit contains a very clever PID and fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is tuned properly Cool only control ON OFF control P or PD control and PID control can be selected for cool only control through Output 1 Set OUTI to Conf EEPE or LL n the other functions for cool only ON OFF control cool only P PD control and cool only PID control are same as descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat control Heat Cool control Three types of combination for heat cool control are available as shown in table 3 1 The casel case3 in Fig 3 3 show the heat PID and cool PID operation The case 4 show the heat PID and cool ON OFF operation Output Power 96 PB1 or PB2 100 Output 1 Out
53. oller performs open loop control as long as it stays in manual mode ExIt Manaul Made To press both 4 and v keys the controller will revert to static mode and show home display 3 13 Data Communication The controllers support RTU mode of Modbus protocol for the data communication Other protocols are not available for the series Two types of interface are available for Data Communication These are RS 485 and RS 232 interface Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS 232 RS 485 is less sensitive to the noise and suitable for a longer distance communication RS 485 can communicate without error over 1 km distance while RS 232 is not 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 SNATOA SNATOB has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication But there is no need to be sad Many RS 485 units up to 247 units can be connected to one RS 232 port therefore a PC with 4 comm ports can communicate with 988 units It is quite economic 53 UMOB421A Setup Enters the configuration page Select COMM for OUTA or OUTS Set Unequal addresses for those units which are connected to the same port Set the Baud Rate
54. onds The low point calibration is finished The similar procedure is applied to high point calibration 56 UMOB421A Displayed value User Calibration Offset Desired high introduced point value l Factory Hi oo a ey A O on ce Calibration calibra on Offset Low point introduced Caliblavlon A ii Desired low point value Input signal Figure 3 9 Two point user calibration The two points construct a straight line For the reason of accuracy it is best to calibrate with the two points as far as possible After user calibration is complete the input type will be stored in the memory If the input type is changed a calibration error will occur and an eror code HEr is displayed UM0B421A 57 3 8 Digital Filfer In certain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from O to 60 seconds O second represents no filter is applied to the input signal The filter is characterized by PV FILT 0 l sec Pisika pa FILT 30 NAN Time Figure 3 10 Filter Characteristics Note The Filter is available only for PV and is performed for the displayed value only The controller is designed to use unfiltered si
55. or HOLD mode the PID sets are selected by the most significant bit of parameter P2EV If the unit is in STAT mode static or controller mode the PID sets are selected by event input function EIFN If the unit is in A T mode then PB1 TI1 IDI are selected If the unit is in AT2 mode then PB2 TI2 and TD2 are selected There is a parameter MAEO which allows you to manually turn the output on and off when parameter OUTI OUT2 or OUT3 is configured as event output It is a four bit binary number O inactive active the USB is to turn on off the Event 1 the second bit is to turn on off the Event 2 and the 3rd bit is to turn on off the Event 3 This parameter MAEO can be accessed either via communication port or via front key switch and MAEO can be viewed in home page by selecting it in one of SELI through SEL8 The parameter MAEO will be not active in the profile mode or off mode and will be active in static manual and auto turn modes 78 UM0B421A Chapter 5 Applications A heat treatment oven need to vary temperature as a function of time Because the process requires a rapid increase of temperature as it is heated and a rapid decrease of temperature as it is cooled In order to achieve a rapid increase of temperature an additional heater is turned on at higher range of temperature A cooling fan is turned on to accelerate the cooling rate as the temperature falls fast An alarm is required to announce the operator as the procedure is fin
56. ow 1 High 9 Power fail DE recovery UBER Kat Holdback band Low 1 High 555 LC 999LF STSP Start set point RMPU Unit for ramp rA segment DLLU Unit for dwell dl L u segment EM Segment number Segment type for the selected segment number HHan Hours Minutes n1155 Minutes Seconds Ini n units per minute IHr units per hour HHnn Hours Minutes 1155 Minutes Seconds Low 0 High 15 PROF 1 4 31 PROF 5 7 63 PROF 8 9 0r AnP T ALL 2 SN 3 End TGSP Target set point E for ramp segment LOW SPLO High SPHI 26 UMOB421A Default Data Value type Register Parameter Parameter Address Notation Description Range Time duration or Ramp rate for High 5999 ramp segment R W Four bit binary number States assignment O inactive 1 active of PID selection ririrari LI LILILI and event outputs for ramp and Ll Event 1 dwell segment Event 2 Event 3 PID 2 Holdback disabled f Deviation low holdback Holdback type Deviation high RAW RAW holdback Deviation band holdback DLLT Duration time for v RE dwell segment Low 0 High 99 59 Target segment a Low 0 High 15 PROF 1 4 PROF 5 7 jump segment 63 PROF 8 9 Repeat number of aw cycles for the High 9999 1 jump and end _ p C RAW segment SIN FSP Final set point for T Offset value for 101 OFSTL low point Low 1999 high 1999 R W calibration Offset valu
57. pe input Event input close unit will enter run mode UMOB421A 45 2 HOLD Applicable when unit is running Event input close Hold the profile Event input open Run profile again Resume from the segment where it hold earlier 3 ABOT Applies when unit is in run mode Requires only momentary type input Event input close Unit will abort the current running profile and enter static mode 4 MAN Applies when unit is in static mode or run mode Event input close Outputs performs bumpless transfer Event input open Unit will perform normal PID operation 5 FTRA Applies when unit is in static mode or run mode Event input close Performs failure transfer function Event input open Unit will perform normal PID operation 6 OFF Applies when unit is in static mode or run mode Event input close All outputs alarm turn off profile stops running Event input open If running profile resumes where it was put into off condition outputs alarms active again as per configuration 7 PASS Applies when unit is run mode Requires only momentary type input to pass to next segment Event input close Profile will move ahead by 1 segment 8 PID2 Applies when unit is in static mode or run mode If chosen close the event input pins the PB2 TI2 and TD2 will replace PB1 TI and TDI for control 46 UMOB421A 3 4 Control Outputs There are five types of control modes can be configured as shown in Table 3 2 Control Heat only Cool only HEP P
58. process high alarm operation Process value Al arm value ASP ASP1 A1HY Output 2 on aT r OUT2 ALM1 Output 2 om 1 OUT2 rAL1 Figure 3 4 Process high alarm 1 operation PULE A Process low alarm is independent of set point When the process is lower than the alarm value a process low alarm occurs and the alarm is off as the process value is higher than alarm value alarm hysteresis Fig 3 5 shows the process low alarm operation Process value no A Alarm value IN Output 29 on Cf OUT2 ALM1 Output 2 OB l OUT2 rAL1 Figure 3 5 Process low alarm 1 operation ASP1 A1HY ASP1 52 UMOB421A dEH Adeviation high alarm alerts the operator when the process deviates too high from set point value When the process is higher than SV ASP1 a deviation high alarm occurs and the alarm is off as the process is lower than SV ASP1 AT HY Figure 3 6 shows the deviation high alarm operation Y Process value SV ASP1 SV ASP1 A1HY JAlarm value SV set point value Output228 TI JT oUr2 AlM1 on Output 25ff 1 f7 L OQUT2 rAll Figure 3 6 Deviation high alarm 1 operation dEl a A deviation low alarm alerts the operator when the process deviates too low from set point value When the process is lower than SV ASP1 ASPI is negative value a deviation low alarm occurs and the alarm is off as the process is higher than SV ASP 1 ATHY Figure 3 7 sho
59. put2 Output 1 0 Process value negative overlap UMOB421A 49 Output Power PB1 or PB2 CPB Output 1 Output2 100 Output 1 0 Process value DB positive Output Power 96 100 PB1orPB2 CPB gt AA Output 1 Output2 0 Output 1 DB 0 Process value Output OUT2 ALM1 0 Power 96 ALF1 JEH PB1 or PB2 A1HY ASP1 A1HY tout 2 100 Output2 Output 2 OFF Output 2 ON Output 1 0 Process value SV Figure 3 3 Heat cool Control 50 UMOB421A CPB Configuration The cooling proportional band is measured by Of PB with range 50 300 Initially set 100 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of CPB is related to the cooling media used For air is used as cooling media adjust CPB at 100 For oil is used as cooling media adjust CPB at 125 96 For water is used as cooling media adjust CPB at 250 DB Configuration Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used
60. r status o Output 3 ON as unit fails 0 non No function 1 HL Ag Alarm 3 output 2 HL 3 Reverse alarm 3 output cout 3 idi 3 Ea Output 4 function 3 E n7 Event 3 output 4 EPY Retransmit process value 5 ESF Retransmit set point value 6 UPS DC power supply output E pa 20 UM0B421A Default Data Value type Register Parameter Parameter Address Notation Description Output 4 failure Output 4 OFF 45 transfer status as unit fails Output 4 ON as unit fails Low limit value for High 100 0 output 4 High limit value OP4H for output 4 High 120 0 Yo oPYH 2 Retransmission RELA low scale value for EL Y output Low 32768 High 32767 r L a REHA Retransmission Z 111 high scale value Low 32768 High 32767 rEHH for output4 No function Communication port Retransmit process 51 UE Output 5 function value Out Retransmit set point value DC power supply output OP5L Low limit value for cA output 5 Low 0 High 100 0 Yo OP5H High limit value Na o for output 5 Low 0 High 120 0 REL5 Retransmission El low scale value for Low 32768 High 32767 FF 2 output 5 REH5 Retransmission high scale value a T EHS for output 5 Low 32768 High 32767 ADDR Address assignment of T Addr digital High 247 communication UMOB421A 2 Register Parameter Parameter Ranae Default Data Address Notation Desc
61. riod of the first segment you should set SP1 or SISP for the start point UM0B421A 69 4 7 Holdback As the set point ramps up or down or dwells the measured value may lag behind or deviate from the set point by an undesirable amont Holdback is available to freeze the profile at its current state should this occur The action of Holdback is the same as a deviation alarm It can be enabled or disabled Holdback has three parameters HBT holdback wait time HBBD holdback band and HBTY holdback type If the error from the set point exceeds the set holdback band HBBD then the holdback feature if enabled will automatically freeze the profile at its current point and flash the HLD light At the same time the holaback timer begins to count When the value of holdback timer exceeds the value of holdback wait time HBT the profiler will no longer be freezed and jump to its next segment at the same time an eror code HhEr will be displayed When the error comes within the holdback band HBBD the program will resume normal running There are four different Holdback types The choice of type is made by setting HBTY parameter when creating a profile and may be one of the following aFF Disables Holdback no action is taken Deviation Low Holdback holds the profile back when the process value deviates below the set point by more then the holdback band HBBD H Deviation high holaback holds the profile back when the process value dev
62. ription g 24 2 4 Kbits s baud rate 46 4 8 Kbits s baud rate Baud rate of digital 95 9 6 Kbits s baud rate communication kalika 144 14 4 Kbits s baud rate 4 190 19 2 Kbits s baud rate 5 C BB 28 8 Kbits s baud rate 6 JAY 38 4 Kbits s baud rate TIT Parity bit of digital Even parity communication Odd parity No parity bit 0 PYH Process high alarm 1 PU y Process low alarm 2 gd EH Deviation high alarm 3 dEL p Deviation low alarm Alarm 1 function 4dbHL Deviation band high low alarm 5 EndP End of profile alarm 6 Hol d Hold mode alarm 7 5E HL Static mode alarm Onor n Normal alarm action 1L E c h Latching alarm action 2HaL d Hold alarm action 3L E Ha Latching amp hold alarm action A1HY Hysteresis control o 50 0LC 22 UMOB421A Parameter Description Register Parameter Address Notation ALF2 BLEg Alarm 2 function A2MD Alarm 2 operation Aond mode A2HY Hysteresis control Ac EE for alarm 2 Range 0 PUH 1 pul Process high alarm L p Process low alarm 2 deh 3 dELa 4 dbHL Deviation high alarm Deviation low alarm Deviation band high low alarm 5EndP 6 HaL d TSEAE End of profile alarm Hold mode alarm Static mode alarm Onor Normal alarm action 1L Ech Latching alarm action 2HaL d Hold alarm action 3L E Ha Latching amp hold alarm action 50 0 LC EON 90 0 LF High Reserved
63. rm bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 is configured as CTPC or CLIN and a value of O to 100 0 76 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 OUT3 and OUTA Failure Transfer is activated as the controller enters failure mode Thereafter the alarm will transfer to the ON or OFF state which is determined by the set value of O3FT or O4FT UM0B421A 59 3 10 Auto tuning The auto tuning process is performed at set point The process will oscillate around the set point during tuning process Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of x Initial setup for a new process The set point is changed substantially from the previous auto tuning value The control result is unsatisfactory Operation 1 Set the correct values for the configuration page Nonzero value for PB and TI should be set Set a correct password for the unit 2 Set EIFN PID2 if a second set of PID is required to be tuned 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal p
64. rocess value is likely to cause damage Then enters the A T mode The upper display will begin to flash and the auto tuning procedure for PIDT is beginning 4 If the system needs to use a second set of PID values then after the first auto tuning is complete close the event input of the unit and repeat the step 3 to the second set of PID values NOTE 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 upper display will cease to flash and the unit revert to PID control by using its new PID values The PID values obtained are stored in the nonvolatile memory 60 UM0B421A Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of e f PB exceeds 9000 9000 PU 900 0 F or 500 0 C e or if Tl exceeds 3600 seconds e Or if set point is changed during auto tuning procedure Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t set zero value for PB and Tl 4 Use manual tuning instead of auto tuning See section 3 12 5 Touch A and v key to reset message 3 11 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequa
65. set point value during auto tuning procedure Fail to perform auto tuning function 3 Use manual tuning instead of auto tuning 4 Don t set a zero value for PB 5 Don t set a zero value for TI 6 Touch RESET key Calibrate the new input type or change input type to the calibrated one 29 EEPE EEPROM can t be written correctly Return to factory for repair Cold junction compensation for 30 30 EJE thermocouple malfunction Retum to factory for repair Input sensor break or input current below 1 mA if 4 20 mA is 39 selected or input voltage below REPIGCE IPUIsEnsor 0 25V if 1 5V is selected A to D converter or related f 40 Ader component s malfunction Return to factory for repair 08 UMOB421A You have selected an input type which was not calibrated UMOB421A 99
66. t Characteristics Type Zero Span Load Tolerance Tolerance Capacity 4 20 mA 3 6 4 MA 20 21 MA 50092 max 0 20 MA 20 21 mA 5009 max 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 3 MA rms Max On state Voltage 1 5 V rms Insulation Resistance 1000 Mohms min at 500 VDC Dlelectric Strength 2500 VAC for 1 minute UMOB421A 83 DC Voltage Supply Characteristics Installed at Output 2 Type Tolerance Max Output Current Ripple Voltage Isolation Barrier 02Vep soo VAC TEN 1iVpp S00 Vac A0 25 V 0 05 Vp p 500VAC Alarm Alarm Relay Form C Rating 2A 240VAC life cycles 200 000 for resistive load Alarm Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV High Low Alarm Alarm Mode Normal 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 Parity Bit None Even or Odd Communication Buffer 256 bytes Analog Retransmission Output Signal 4 20 mA 0 20 mA O 5V
67. te 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 SEQUENCE SYMPTOM SOLUTION High overshoot or Oscillations Slow Response Decrease Tl 1 Proportional Band PB Increase PB 2 Integral Time TI Instability or Increase TI Oscillations Slow Response or 3 Derivative Time TD Oscillations Decrease TD Table 3 4 PID Adjustment Gulde Figure 3 11 shows the effects of PID adjustment on process response UMOB421A 61 PV PB too low Perfect Set point P action PB too high Time Tl too high PV Set point action Perfect TI too low Time PV TD too low Perfect Set point D actlon ID too high Time Figure 3 11 Effects of PID Adjustment 62 UMOB421A 3 12 Manual Mode Operatlon To enable manual control the password PASS should be set with a value equal to CODE except CODE 0 Press 5 keyto get Gad mode select then use 4 and v keys to obtain 5384 Man Then press key for 5 seconds the unit now enters the manual mode The upper display will begin to flash and the lower display will show or indicates control percentage value for heating output and indicates control percentage value for cooling output Now you can use up and down key to adjust the percentage values for the heating or cooling output The contr
68. the profiler is inactive and d UE s man the heating and cooling output values can Ol SPPE be adjusted at the lower display by up dow Ka showes H___ orf cc Both RUN and In off mode the profiler is inactive and all 1H ED light are off Upper display shows OFF and flashes Both RUN and The profile is complete HLD lights flash outputs are disabled That is all the control outputs alarms and event outputs are off Table 4 2 Profller Modes 4 4 Running holding and aborting a profile Press page key until mode page is obtained The upper display will show nodi and the lower display is the values for mode selection By using up down key until run is obtained Press page key for 5 seconds then the profiler enters RUN mode If HaL d is obtained pressing the page key for 5 seconds will enter HOLD mode 68 UM0B421A The operator may abort i e terminate the current profile by holding page key for more than 5 seconds during the lower display shows SEAL When the program is aborted the profiler is inactive and enters static mode At the same time both the RUN light and HLD light are off If RUN and HLD LED s are blinking simultaneously it indicates the end of previous running profile it requires to Reset profile controller by pressing UP and DOWN keys together to take Profile start segment PFSG 1 00 Select the profile and segment by pressing Enter Key P 1 00 indicates profile and segment 00 is selected Pleas
69. tion 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 Equipments needed before calibration 1 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functions O 100 MV millivolt source with 0 005 96 accuracy O 10 V voltage source with 0 005 accuracy O 20 mA current source with 0 005 accuracy O 300 ohm resistant source with 0 005 accuracy 2 A test chamber providing 25 C 50 C temperature range The calibration procedures described in the following section are a step by step manual procedures 96 UMOB421A Step 1 Manual Calibration Procedures Press the page key then release for 2 times until the F oF appears on the display Press the page key for least 5 seconds then release the display will show Press the page key for at least 5 seconds then release the display will show Step 2 Press the scroll key for at least 5 seconds then release the display will show and the unit enters calibration mode Send a 0 0 mV signal to the thermocouple input terminals Press scroll key for at least 5 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 1999 or 1999 then the calibrat
70. uipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only A This instrument is protected throughout by Double Insulatior Er 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 Don t use harsh chemicals volatile solvent such as thinner or strong detergents to clean the instrument in order to avoid deformation or discoloration 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due to transit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of control 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout
71. utput wiring 40 Figure 2 19 Alarm Output to Drive Contactor 40 Figure 2 20 Event Input wiring 41 Figure 2 21 Retransmit 4 20 0 20 mA Wiring 41 Figure 2 22 RS 485 Wiring 42 Figure 2 23 RS 232 Wiring 43 Figure 2 24 Configuration of RS 232 Cable 43 Figure 3 1 Conversion Curve for Linear Type Process Value 45 Figure 3 2 Heat Only ON OFF Control 48 Figure 3 3 Heat cool Control 50 Figure 3 4 Process high alarm 1 operation 52 Figure 3 5 Process low alarm 1 operation 52 Figure 3 6 Deviation high alarm 1 operation 5
72. ws the deviation low alarm operation SV set point value Process value SV ASP1 A1HY SV ASP1 Output 294 L UT OuT2 ALM1 20N Output 25 L L ourm rA Figure 3 7 Deviation low alarm 1 operation UMOBA21A 53 dbHL A deviation band high low alarm presets two trigger levels relative to set point value The two trigger levels are SV ASP1 and SV ASP 1 for alarm When the process is higer than SV ASP1 or lower than SV ASP1 a deviation band alarm occurs When the process is within the trigger levels SV ASP1 A1HY and SV ASP1 A1HY where ASP1 must be positive value Figuree 3 8 shows the deviation band alarm 1 opertion Process value SV ASP1 SV ASP1 A1HY SV set point value SV ASP1 A1HY SV ASP1 I Output 206 f1 L U12 AlM1 Output 2081 1 FU OUT2 rAL1 Figure 3 8 Deviation band alarm 1 operation The above description is based on alarm 1 which is selected for output 2 the operations of alarm 2 and alarm 3 are same as alarm In the above description SV denotes the current set point value for control which is different from SP1 as the profile mode is performed 54 UMOB421A The alarm modes A1MD A2MD and A3MD are set by using a three bit of binary number alarm mode Description value A direct acting normal alarm output is off as the non alarm Ne condition and on as an alarm condition The output state is J J inverted as a reverse alarm output is select

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