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Mounting and Operating Instructions EB 6493 EN

1. IN IN ALRM L MM NR Input LIM1 2 assignment Dig filter Root ext Function gen WE LF Hx P IN1 WE VA LIM1 L1 WE LIM2 L2 WE CLAS WE DI FI WE SQR WE FUNC WE 5 5 8 CLAS X DI FI X SQR X FUNC X Signal mA MM 2 monitoring ICO VA LIM1 L1 X LIM2 L2 X MEAS ayy jo suorpunj Functions of the compact controller PAR KP Proportional action coefficient TN Reset time TV Derivative action time I cco UO oo Y PRE Operating point 10 0 0 0 110 0 Z 6 2 menu Input functions The analog inputs IN1 IN2 are set in the IN menu 6 2 1 This function enables you to define the input signal type and range for the analog input IN1 IN CO INI Input signal IN1 Input signal 1000 1 120 9999 s 9999 s 0 20 mA 4 20 mA 0 10 V 2 10 V 100 PT 1000 PT 100 NI 1000 NI 0 1KOHM PA IN1 O to 20 mA 4 to 20 mA Oto 10V 210 10 V Pt 100 100 500 C Pt 1000 100 500 C Ni 100 60 250 C Ni 1000 60 250 C 0 to 1000 Q Resistance values gt section 11 3 Resistance values gt section 11 3 Resistance values section 11 3 Resistance values
2. Y PA se Eg SA w w g w 297 Y OO PA 10 10 B m CPD KP gt gg WW s 2 120 120 CNTR C PID 8H E CP YP T 2 2 5 Pld TT Mx a 9 E dir d 2 dir I DIRE EI DLAC DIAC gt ind L DI AC Adjust set point Set control behavior Set operating direction 569983 05 m CO E OUT SAFE 4 20 gt 4 20 lal Analog output gm T8 mA mA Set signal range 0 10 gv N 3 7A 10 C OUT al Set three step output CO oFF gt OFF 60 60 MET ET 2 35 T 2 25 TY vom 2d e gt i Fb gj 3 5 LE 5689 83 RE CO k Y FO2 MODE 2 F02 m MODE gt MODE Set restart conditions after power failure Functions of the compact controller 6 Functions of the compact controller In this section all functions of the setup level are described There are nine menus in the setup level which contain the functions and the
3. 37 function 37 root extraction 37 F Fouliolorms 100 Feedforward 52 Functions 32 40 6493 Index 1 Infrared adapter ordernumber 7 Infrared 101 Input sasin 34 CIT TET CET 8 K Key number 18 19 Configuration lisf 106 L aaye 73 Manipulated variable function generotion 61 operating direction 52 Manual 16 operating point setting 52 upon signal failure 36 Manual automatic switchover 55 On off output 62 Operating 12 14 15 Operation di ss 12 26 overview 26 Operator 8 14 Output chonging 16 Output ramp 57 Output rate limitation 57 Output value activate constant output value 55 P 10 Power line frequency 79 132 6493 Process variable increase decrease 54 R Resistance thermometer 9 electrical connection 9 Restart conditions after power fail
4. Binary input 0 1 5 5 TSRA Running time TN s YOUT Analog output BI 1 YPID Internal manipulated variable t YIRA Initial value 5 Fig 13 Output ramp F02 RA YP with ramp increasing descreasing started with YIRA by 58 6493 EN Functions of the compact controller OUT CO RAMP Output ramp output rate limitation oFF RA YP 1 Output ramp started with 10 by binary input F02 RA YP Output ramp started with Y1RA by binary input F03 RA YP Limitation when manipulated variable decreases and increases FO4 RA YP Limitation when manipulated variable increases F05 RA YP Limitation when manipulated variable decreases PA RAMP RA YP TSRA Transit running time 1 9999 5 YIRA Initial value 10 0 0 0 110 0 Z Note Several functions can be assigned to the binary input See page 32 6 5 5 CO BLOC Locking manipulated variable YPID This function locks the control signal when the binary input Bl is activated As a result the current value of the output at the controller output remains unchanged as long as the binary input is ac tive When it is deactivated the locking of the output signal is cancelled and the controller conti nues to work with the last output value OUT CO BLOC Locking manipulated variable YPID oFF BL YP Off on BL YP By binary input BI1 Note Severa
5. Error signal XD higher than the limit Application On off controller for heating CO LIMI Hi L1 XD PA 0 5 L HYS 1 0 Error signal XD lower than the limit CO Lo L1 XD PA LI XD 1 5 26 PA L HYS 0 5 Error signal XD lower than the limit Application On off controller for cooling CO LIM1 Lo L1 XD LI XD 0 5 PA L HYS 1 0 P Absolute volue of XD higher thon the limit CO LIM1 AbS L1 XD PA LI XD 1 5 PA L HYS 0 5 Fig 22 Functioning of limit relays L and L2 example illustrating how L1 functions Part 2 6493 75 Functions of the compact controller 6 6 1 CO 1 Limit relay L1 You can determine the variable to be monitored and the condition for switching the limit relay L1 violation of the upper or lower limit with this function Section 6 6 contains a detailed de scription on how the limit relay works Note The functions of the on off or three step output CO C OUT gt section 6 5 10 and the functions for the binary outputs CO B OUT section 6 5 11 have priority over the settings of the CO LIM1 and CO LIM2 functions ALRM CO Limit relay L1 oFF L1 Lo L1 X When X is not reached Hi L1 X When X is exceeded Lo L1 WE When WE is not reached Hi L1 WE When WE is exceeded Lo L1 YP When YPID is not reached Hi L1 YP When YPID i
6. Error message _ Possible cause Recommended action 1 ERR No access to EEPROM possible 2 ERR EEPROM cannot be programmed Return the controller to SAMSON for repair 3 ERR Factory calibration not available Functions ch ithout any interac 4 ERR hon both Check the functions settings ion by the user P ters changed without any interac 5 2 any interac Check the parameters settings ERR Position of internal and external reference Enter internal external reference vari variable unknown able Data from user calibration changed 1 7 ERR without any interaction by the user Recalibrate the inputs and outputs Adaptati leted after five h t m Adaptation completed oler five hours o No parameters could be determined Change control parameters KP TN TV 31 ERR during the start up adaptation and Y JMP and restart start up adapta tion The signal at the X input is smaller than 32 ERR 0 or greater than 100 during the ad 2 and restart start up adap aptation iiis 33 ERR Too much noise interference during the Increase Y JMP and restart start up adap adaptation tation 100 6493 EN Infrared interface Error message Possible cause Recommended action In CO C PID function select the control 34 ERR Selected PID setting does not allow an algorithm P Pl or PID and restart start up adaptation docta adaptation The Y signal is smaller than O or Change a
7. OC Controlled vorioble X W W2 WE Y or XD Limit reloy L2 active Three step output Limit relay L1 active Three step output 10 11 Fault alarm Hand icon After pressing W2 Y or XD is shown with the value in 2 Bar reading of XD in Enter key 12 Selector key 13 Manual automatic key 14 Cursor key increase scroll forwards 15 decrease scroll backwards 16 Escape key 17 Label exchangeable 18 Infrared interface 6493 13 Operation 5 2 Control keys The keys function varys depending on which level the controller is in Key Operating level Setup level m Access setup level Open menus functions Enter key Activate set point and parameters yellow Only if the set point name W W2 or WE Confirm settings blinks on the display Switch between readings Access parameter level Selector W Internal set point 1 Jump within the value key W2 Internal set point 2 range in the parameter WE External set point level Y Manipulated variable Shift the decimal point one Xd Error place to the right Only when they have been configured see section 6 3 1 Change from manual to automatic mode function Manual and vice versa automatic In manual mode the hand icon appears in the key display aj V Change the value of internal set point Browse within menus Cursor keys Change the control
8. Step change value of manipulated 100 0 20 0 100 0 variable NONI 6 9 2 6 9 3 6 9 4 009 9 Value range is identical to that of the assigned input 2 Decimal position depends on the DP function AUX menu EB 6493 123 Appendix 11 2 Configuration protocol Menu Function CO Parameter PA PAR KP see also CO C PID TN see also CO C PID TV see also CO C PID Y PRE see also CO C PID IN INT INI A INI IN2 2 A IN2 MEAS parameters MAN see also CO SAFE and CO RE CO CLAS X parameters WE parameters X TS X WE TS WE SQR X No porometers WE No porometers FUNC X MIN MAX K1 X K1 Y K2 X K2 Y K3 X K3 Y KA X KA Y K5 X 124 6493 Appendix Menu Function CO Parameter PA IN FUNC X continued K X K Y 7 K7 Y WE MIN MAX K1 X K1 Y K2 X K2 Y K3 X K3 Y KA X KA Y K5 X K5 Y K X K Y 7 KZ Y SETP SP VA W W Y WINT WINT Y WRAN WRAN 2 2 WE parameters SP FU RAMP TSRA
9. Man TSRW Running time of the set point Auto I Temp 1 Actual running time of the set 5 Fig 6 Start set point ramp by binary input SP CO X F02 RAMP Start set point ramp with initial set point This ramp function is started by the binary input An active binary input causes the set point at comparator SP CO to be set to the entered initial set point WIRA A signal change at the binary input from 1 ac tive to 0 inactive starts the ramp and the set point runs until it reaches the target set point internal or external set point After reaching the target set point the ramp stops After this the set point at comparator SP CO follows the target set point e g W without delay If the controller is switched to manual mode while the ramp is running the ramp is stopped and the set point at comparator SP CO adopts again the same value as the con trolled variable X After switching back to automatic mode the ramp continues to run again until reaching the target set point If the binary input is activated again while the ramp is running the set point at comparator SP CO returns to the current value at comparator X retriggering If the controller starts after the power supply has been interrupted for more than one sec ond in automatic mode the set point at comparator SP CO adopts the start set point WIRA when the binary input is active and the target set point when the binary inpu
10. 6493 EN Functions of the compact controller w 1 1 Ce tle 1 r4 SZWINT 1 E TSRW 9 lt s 1 1 I I 1 12224 gt WINT Lower measuring range value 5 WINT Upper measuring range value TSRW Running time of the set point ramp H Actual running time of the set point ramp s Fig 8 Set point continuously active 6 3 2 2 CO SP FU CH SP Set point switchover by binary input This functions enables you to determine the conditions for switching between the internal and external set point oFF CH SP No set point switchover F01 CH SP Switchover between active internal and external set points initiated bi nary input Bl W W2 to WE WE is active when the binary input is active F02 CH SP Switchover between the internal set points initiated by binary input Bl W to W2 W2 is active when the binary input is active W is active when the binary input is not active The CO SP VA function must not be set to WE If the set point W2 is activated over the keypad while the binary input is inactive it is not possible to switchover to the set point W using the binary input EB 6493 EN 45 Functions of the compact controller Note Several functions can be assigned to the binary input See page 32 SETP CO SP FU Set point ramp oFF RAMP Off F01 RAMP Started with actual value proces
11. 100 0 A INT IN2 100 0 A IN2 LL YP Limit for YPID X Y 100 0 Y LI XD Limit for XD 110 0 0 0 110 0 5 Hysteresis 0 10 0 50 100 0 6 7 AUX menu 6 7 1 CO RE CO Additional functions Restart conditions after power failure This function allows you to determine which operating mode and which output value is to be used by the controller after a restart due to a power supply failure F01 MODE Manual mode with constant output value Y1K1 F02 MODE Automatic mode start with output value Y1K1 and the currently valid set point EB 6493 EN 77 Functions of the compact controller AUX CO RE CO Restart conditions after power failure F01 MODE Manual mode with constant output value F02 MODE Auto start with output value PA RE CO MODE Constant output value 710 0 0 0 110 0 25 6 7 2 CO ST IN Reset to default settings This function allows you to reset all parameters functions and calibrated values to their default settings After a reset the message FrEE INIT is generated AUX CO ST IN Reset to default settings FrEE INIT Off All INIT All functions parameters key code FUnC INIT All functions INIT All parameters key code AdJ INIT Calibration values for IN1 IN2 Y 6 7 3 KEYL Lock control keys The keys can be locked bil LOCK All keys locked by binary input on noH W Keys 2 and 8
12. 6 5 8 CO Y SRC Source for analog output Y This functions allows you to determine the source for the analog output Y The manipulated vari able YPID is assigned to the analog output by default Optionally the input variables X WE or the error signal XD can also be assigned as the source The input variables X and WE are issued based on the input measuring range e g for an input measuring range to 200 X 0 C gt Y 0 e g 4 mA and X 200 C gt Y 100 e g 20 mA The error signal is issued on the range 100 to 100 i e XD 100 gt Y 0 e g 4 mA and X 100 Y 100 e g 20 mA EB 6493 EN 61 Functions of the compact controller OUT CO Y SRC Source for analog output Y on Y PID Output YPID on Y X Input X on Y WE Input WE on Y XD Error XD 6 5 9 CO CALC Mathematical adaptation of analog output Y This function causes the continuous action output to be adapted according the following mathe matical formula YOUT Y CA K1 CA K2 CA K3 OUT CO CALC Mathematical adaptation of analog output Y oFF CA Y Off no output signal on CA Y Without condition 5 CA Y With positive sign nE With negative sign PA CALC CA Y 1 Constant 1 0 0 100 0 25 CA K2 Constant 2 CA K3 Constant 3 710 0 0 0 110 0 6 5 10 CO C OUT On off output or three step output The on off output or three step output is configur
13. oz gt 0 4 20 mA WE _ Y SRC CALC Y VA On off or three step output gt On off int 1 ext RF C OUT Configuration of WE 25 2 Automatic B OUT B BO1 In automatc mode Y reading in the operating level In manual mode Y reading in the operating level Assignment to on off output or three step output Assignment to binary output BO2 Assignment to limit relay L1 L2 Configuration of BO2 Y 12 gt gt WE ic Automatic 7 mode B OUT B BO2 Y podwo ayy jo suo puni Functions of the compact controller 6 5 3 CO Y LIM Control signal limitation YPID Control signal limitation is always active The parameters for the minimum and maximum ma nipulated variable can be determined in this function A 4 to 20 mA control signal is assigned as follows 0 4 mA and 100 20 mA OUT CO Y LIM Output signal limitation YPID on LI YP On PA Y LIM Y Minimum manipulated variable 10 0 0 0 110 AY Maximum manipulated variable 10 0 100 0 110 0 6 5 4 CO RAMP Output ramp output rate limitation RA YP and F02 RA YP Output ramp The output ramp is the change of the output at a constant rate The TSRA parameter determ
14. 0 4 20 4 20 mA 0 2 10V 100 Ni 1000 10000 Three wire Two wire Two wire 11 9 I 100 Analog input 12 9 4 E x B 13 T 0 0 Supply output Ls a 20 V max 45 mA 15 4 17 100 7 100 Analog input 191 b IN2 20 0 0 2d ac nalog output g outp 32 Binary input 81 24 KO u BI 4 82 eur EM perpe sz n ME Mc R I a dL MMC Binary x18 e 3 50 V DC NG 84 max 30 mA ume a LC L C C 90 250 24 V AC DC 20 30 V N Three step output On off Binary output Limit relay for electric actuator output 41 Binary output 42 L L BO1 LIM 1 43 v4 51 output 52 BO2 LIM 2 BO2 53 Fig 2 Electrical connection 6493 11 Operation 5 Operation The TROVIS 6493 Compact Controller is a microprocessor controlled compact controller with a flexible software concept for the automation of industrial and processing plants The controller is suitable for use in simple control loops as well as for solving more complex control tasks The flexible software concept allows the user to configure control circuits without modifying the hardware The functions are stored in a read only memory and can be adapted to the specific requirements of the respective control system Configuration parameterization and operation of the TROVIS 6493 Compact Cont
15. 57 reading ay si es eh aed ee tr n 83 set point switchover function 45 Binary input function activate constant output value 55 increase decrease process variable 54 locking control signal 59 manual automatic switchover 55 set point ramp 42 set point switchover 45 status messages 73 Binary outputs reading xu cere eres ets 83 status messages 73 C Configuration how to 17 Index Control oclgorfhm 47 Control 14 78 Control mode selection 50 Control 32 Control signal limitation 57 locking o erre dn 59 35 Controlled variable assignment to analog input 36 37 function generation 37 root extraction 37 Controller firmware version 82 seridlnumber 83 D D component assigned to control output 50 Decimal separator setting 79 Default 78 DIE ae okt Geter hse 12 13 viewing ongle 78 Electrical connection 9 11 Error signal inversion 50 External set point assignment to analog input 36
16. 6493 EN Functions of the compact controller Confirm the start value I Display 0 0 and ZERO Use the cursor keys to set the end value at the high precision meter Display SPAN and YOUT in alternating sequence Confirm the end value I Display 100 0 and SPAN 6493 EN 85 Typical applications 7 Typical applications 7 1 Temperature control Example 1 Flow temperature control of a heat exchanger fixed set point control with Pt 100 input and mA output The controller receives the flow temperature T in the secondary circuit at input INT from a resis tance thermometer Pt 100 and positions the control valve in the primary circuit by issuing a 4 20 mA signal at the output Y to keep the flow temperature constant at 50 TROVIS 6493 1 I I I I lt Based default settings only the settings marked by need to be made PAR Proportional action coefficient depending on system gt cPA EO Reset time depending on system gt TN 120s IN Input IN2 Input signal Pt 100 1 2 100 Input IN2 Lower measuring range value 0 C 49e NE QU Input 2 Upper measuring range value 100 2 100 0 Input variable X Input 2 CLAS 2 86 6493 EN Typical applications SETP CO SP VA on W Internol set point 50 C gt PA W CNTR Control behovior PI GO ID pi Gp yh Operating direction
17. section 11 3 INI A INI 6 2 2 CO IN2 This function enables you to define the input signal type and range for the analog input IN2 34 6493 EN Lower measuring range value Upper measuring range value Input signal IN2 999 0 0 0 A INT 100 0 9999 6 2 3 5 Functions of the compact controller CO IN2 Input signal 2 0 20 mA 0 to 20 mA 4 20 mA 4 to 20 mA 0 10 V Oto 10V 2 10 V 210 10 V 100 PT 100 100 500 C Resistance values section 11 3 1000 PT Pt 1000 100 500 C Resistance values gt section 11 3 100 NI Ni 100 60 250 C Resistance values gt section 11 3 1000 NI Ni 1000 60 250 C Resistance values section 11 3 0 1 0 to 1000 Q PA IN2 IN2 Lower measuring range value 999 0 0 0 IN2 A IN2 Upper measuring range value IN2 100 0 9999 Signal monitoring This function enables you to define whether the signal ranges of the analog inputs INT and 2 are to be monitored either for a signal exceeding or falling below the signal range When the signal exceeds or falls below the rated signal range the fault alarm output BO3 is activated and the alarm icon lll appears on the display In addition the signal violation is indi cated by one of the following readings blinking on the display Signal exceeds the rated signal range at analog input or at analog inputs
18. Functions of the compact controller 6 4 2 CO SIGN Inversion of error XD This function enables you to reverse the operating direction of the error signal The inversion causes an increasing error signal to be changed into a decreasing error signal or vice versa As a result the control signal s operating direction changes too CNTR CO SIGN Inversion error XD dir d XD Not inverted in d XD Inverted Note The adjusted operating direction can also be changed in CO DIRE see section 6 4 6 6 4 3 CO D PID Assignment of the derivative action component to the control output In PD and PID controllers the error signal or the controlled variable can optionally be assigned as the source for the derivative term DP YP Source for the derivative action component is the error signal XD A change in the controlled variable and set point has an effect on the manipulated variable through the derivative action component F02 DP YP Source for the derivative action component is the controlled variable X A change in the controlled variable has an effect on the manipulated variable through the derivative action component A change in the set point is not taken into account by the derivative action component CNTR CO D PID Assignment of D element to the control output F01 DP YP To error F02 DP YP To controlled variable 6 4 4 CH CA Control mode selection P D PI D For and PID controllers the control
19. Go to the parameter level Display PA Open the parameter level Display code of the first parameter If you want to configure a different parameter Select the required parameter 6493 17 Operation C Activate the parameter s editing mode The code for the function s parameter blinks 2 Change parameter setting Confirm setting After completing all parameter settings Press until the controller is back in the operating level Note The controller automatically returns to the operating level five minutes after the last key has been pressed 5 4 2 Key number The compact controller can be operated with or without a key number Factory default allows the controller to be operated without a key number Operation with a key number is only acti vated after a user defined key number has been assigned The service key number is required to define a user defined key number Note The overriding service key number is specified at the end of the printed Mounting and Operating Instructions This key number allows you to change configuration settings and pa rameter values regardless of the user defined key number We recommend removing the page containing the service key number or making it unreadable prevent misuse 18 6493 EN Operation Prompt for key number Every time you go to the first function or parameter after opening the setup level you are prompted to enter the key numb
20. Percent based on the measuring range of the controlled variable X The FC K3 parameter can be adjusted in the range between 9 99 and 99 99 with two decimal places 6 4 8 CO AC VA Increase decrease actual value process variable This function is used to link add the input signal X to the constant AV K1 when the binary input is active The new process variable is used for closed loop control and shown on the display top row When the binary input is deactivated the input signal X is used again for closed loop con trol CNTR CO Increase decrease actual value oFF IN DE Off bil IN DE By binary input AN K1 Constant in percent vari 7110 0 0 0 110 0 Z able Note Several functions can be assigned to the binary input See page 32 54 6493 EN Functions of the compact controller 6 5 OUT menu Output functions The output functions of the compact controller are determined in this menu 6 5 1 CO SAFE Activate constant output value A defined constant output value Y1K1 can be issued at the control output Y in automatic mode initiated by the binary input The constant output value is activated when the binary input is ac tive When the binary input is deactivated the closed loop control continues starting from this constant output value This function can be used to enable control The constant output value cannot be activated manual mode OUT CO SAFE Act
21. This function allows you to configure the binary outputs BO1 and 2 to report operating states The status of the binary outputs can be read from the I O menu under BIN see section 6 9 4 Note Both binary outputs cannot be used when a three step output is configured section 6 5 10 When an on off output is configured the BO2 can be selected in this function All set tings of B OUT have priority over the settings for the LIM 1 and LIM2 functions see sections 6 6 1 and 6 6 2 OUT CO B OUT Binary output oFF 1 Off Active when binary input is set F02 B BO1 Active when WE is active B BO1 Active in automatic mode Binary output BO2 oFF B BO2 Off B BO2 Active when binary input is set F02 B BO2 Active when WE is active F03 B BO2 Active in automatic mode 6493 EN 73 Functions of the compact controller 6 6 ALRM menu Limit relays The function of the L1 and L2 limit relays is determined in this menu The limit relays monitor a variable for limit violation In the CO LIM1 and CO LIM2 functions the variable to be monitored and the condition for switching the limit relay violation of upper or lower limit is determined The limit is defined in the parameter level in the LI WE LI YPID or LI XD parameter Addi tionally an on off differential hysteresis must be determined in the 1 5 parameter This hysteresis is the distance between the relay switche
22. Y JMP issued Wait for controlled system to settle 50 Returned to output value before starting adaptation Determining parameter 70 71 72 End Adaptation finished Note You can cancel the adaptation by pressing the key 6493 EN 81 Functions of the compact controller If an error occurs during adaptation the error appears on the display and the binary output for fault alarms is activated Error messages 30 ERR 31 ERR 32 ERR 33 ERR 34 ERR 35 ERR 36 ERR Adaptation is completed after five hours at the maximum No parameters could be determined The signal at the X input is smaller than O or greater than 100 95 Recommended action Change Y JMP Too much noise Recommended action Increase Y JMP Selected PID setting does not allow start up adaptation Recommended action In CO C PID function select control algorithm P Pl or PID Control signal Y is smaller than or greater than 100 Recommended action Change Y JMP Malfunction Recommended action Restart adaptation TUNE CO ADAP Start up adaptation oFF ADP S Off run ADP S Start PA ADAP KP Proportional action coefficient 0 1 1 0 100 0 TN Reset time 1 120 9999 s TV Derivative action time cooo s Y JMP Step change value of 100 0 20 0 100 0 manipulated variable 6 9 l O menu Process data This menu enobles you to view different variables and data In addition you can cali
23. 100 0 WINT Internal set point W2 oFF W2 Off on W2 On SP VA W2 2 Internal set point 2 WRAN 0 0 WRAN Input variable WE EB 6493 EN 41 Functions of the compact controller oFF WE Off on WE External set point WE WE Input for external feedback with three step output F02 WE Input for feedforward control 6 3 2 CO SP FU Set point functions 6 3 2 1 CO SP FU RAMP Set point ramp set point ramp is particularly suited for closed loop controlled systems which do not tolerate rapidly changing set points The ramped transition from one set point to another helps to avoid hunting In the set point ramp the set point at the comparator SP CO runs according to the ad justed running time at a constant rate from the initial set point to the target set point Depending on how the CO SP FU function is configured the ramp starts either using the current value of the controlled variable X at the comparotor the initial value WIRA or another set point The running time of the set point ramp is determined for the entire measuring range V WINT to WINT by the TSRW parameter When the set point changes from a value W to a new value W2 the actual running time of the set point ramp is the time t1 as illustrated in Figs 7 and 8 The value for the TSRW parameter can be calculated as follows WINT x WINT TSRW rl 2 WI RAMP Start set point ramp with the controll
24. INT and IN2 Signal falls below the rated signal range at analog input INT or at analog in puts INT and IN2 Signal exceeds the rated signal range at analog input IN2 Signal falls below the rated signal range at analog input IN2 ol ul 02 02 Note The controller can be configured to change to the manual mode when a signal range vio lation occurs Refer to section 6 2 4 IN CO MEAS Signal monitoring oFFME MO INI Analog input INT 2 MEMO Analog input IN2 ALLME MO Analog input INT and 2 6493 EN 35 Functions of the compact controller 6 2 4 CO MAN Switch to manual mode in case of signal failure This function enables you to define whether the controller automatically switches to manual mode after a signal range violation when the signal range monitoring is active CO MEAS oFF FAIL The controller switches to manual mode and the output value Y1K1 is issued The output value Y1K1 only becomes effective when the controller is in automatic mode at the time when the signal range violation occurred 02 FAIL The controller switches to manual mode and the last manipulated variable is issued In manual mode the output value can be changed using the cursor keys and The controller can first change back to automatic mode when the signal range violation no longer exists IN CO MAN Switch to manual mode in case of signal failure oFF FAI
25. WIRA Sp No parameters 6493 EN 125 Appendix Menu Function CO Parameter PA CNTR C PID KP see also PAR TN see also PAR TV see also PAR TVK1 Y PRE see also PAR DZXD Y DZXD DZXD SIGN No parameters D PID No parameters CH CA CLIP CLI M M ADJ parameters DIRE parameters F FOR 1 2 FC K3 AC VA AV K1 OUT SAFE see also CO MAN and RE CO MA AU parameters Y LIM Y Y 5 Y1RA BLOC No parameters FUNC KIX K1 Y K2 X K2 Y 126 EB 6493 EN Appendix Menu Function CO Parameter PA OUT FUNC continued K3 X K3 Y KA X KA Y K5 X K5 Y K X K Y 7 Z Y VA No parameters Y SRC No parameters 2 KPLI KPL2 XSDY ING B OUT B OUTI parameters B OUT2 parameters 6493 EN 127 Appendix Menu Function CO Parameter PA LIMI 5 LIM2 LI WE LI
26. ing point is also necessary if no system deviation is to exist Change to automatic mode 68 In PAR menu step up the KP parameter until the controlled variable shows an harmonic oscillation pattern Every time the KP increases let the controlled system oscillate e g by making small changes in the set point Write down the adjusted KP value as the critical proportional action coefficient Kp crit Multiply KP crit by the factor 0 5 and use the result to set KP at the controller KP 0 5 KP crit KP P controller 0 5 Kp krit Change the set point slightly and check the transient behavior If necessary retune KP slightly until the closed loop shows a satisfactory control behavior 98 6493 EN Start up Proceed as follows for a PID controller Change to manual mode 68 In CNTR menu set the function CO C PID PI CP YP In PAR menu set the parameter KP 0 1 and TN 9999 s In the operating level set the set point W to the required value To do this select W by pressing 5 and adjust the value using the cursor keys In the operating level change the manipulated variable Y so that the controlled variable X has the same value as the set point W error XD 0 To do this select Y by pressing 5 and adjust the value using the cursor keys Change to automatic mode 06 In PAR menu step up the KP parameter until the controlled variable s
27. 0 Z parameters 6 5 7 Value range is identical to that of the assigned input 2 Decimal position depends on the DP function AUX menu EB 6493 EN 115 Appendix Setting Function Parameter Menu Function CO options description level PA OUT Y SRC on Y PID Output YPID no PA Y SRC Y PID Source for analog on Y X Input X no PA Y SRC Y X output Y on Y WE Input WE no PA Y SRC Y WE on Y XD Error XD no PA Y SRC Y XD CALC oFF CA Y Off no output signal Mathematical adap Without condition CALC CA Y tation of analog POSCAY With positive sign CALC CA Y output Y nE CA Y With negative sign CALC CA Y C OUT oFF 2 3 S Off On off or three step 2 STP On off output C OUT 2 3 S output i Fb 3 STP Three step output with internal C OUT 2 STP feedback E Fb 3 STP Three step output with external C OUT 3 STP feedback PP 2 STP On off output with PPM C OUT 2 STP i PP 3 5 Three step output with internal C OUT 3 STP feedback and PPM E PP 3 STP Three step output with external C OUT 2 STP feedback and PPM B OUT oFF B BO1 Off noPA OUT1 B BO1 Binary output BO B BO1 Active when binary input is set F02 B BO1 Active when WE is active B BO1 Active in automatic mode Binary output BO2 oFF B BO2 Off noPA OUT1 B BO2 B BO2 Active when binary input is set F02 B BO2 Active when WE is active F03 B BO2 Active in automatic mode 116 EB 6493 EN The default
28. 25 0 25 0 25 0 25 0 Set point for T2 in 80 0 50 0 20 0 20 0 20 0 20 0 20 0 monss 77777 1 WE C 80 60 cc 40 20 C 20 0 20 40 4 4 Based the default settings only the settings marked gt need to be made PAR Proportional action coefficient depending on system gt PA 10 Reset time depending on system 5 TN 1205 6493 89 Typical applications IN Input INT Input signal Pt 100 gt Ese 100 PT Input INT Lower measuring range value C 0 0 Input INT Upper measuring range value 100 C AINT 100 0 C Input 2 Input signal Pt 100 CO IN2 100 PT Input 2 Lower measuring range value 0 PA 00 Input 2 Upper measuring range value 100 2 100 0 Input variable X Input IN2 CO CLAS 102 Input variable WE Input IN1 1 WE Function generation of input variable WE gt on WE Lower range value of output signal PA MIN Upper range value of output signal MAX 100 0 C Input value 1 7200 Output value 1 gt 900 Cc Input value 2 gt K2X ORE Output value 2 gt Input value 3 250C Output value 3 PA K3Y 20 0 C Input value 4 25056 Output value 4 gt 4 2010 Input volue 5 5 2504 Output value 5 PA K5Y ADO
29. 26 10 K Resolution 0 07 Q 0 007 Binary input Switching contact With external supply 24 V DC 4 31 V DC or Powered by the controller over terminals 81 82 20 V DC Signal state OFF with 0 to 2 V Signal state ON with 4 to 31 V Current consumption 6 mA with 24 V DC 5 5 mA with 20 V DC Outputs Continuous action on off or three step output Analog Rated signal range 0 4 to 20 mA load lt 740 Q output 0 2 to 10 V load gt 3 ka Maximum modulation range 0 to 22 mA 11 V Error 0 2 Temperature influence Zero lt 0 1 26 10 K span lt 0 1 10 K Resolution 0 0015 mA lt 0 0075 with O to 20 mA 0 0094 with 4 to 20 mA 0 75 mV 0 0075 with O to 10 V Binary output Two relays with floating switching contact Binary output BO2 Max 250 V AC max 250 V DC max 1 max 0 1 A DC 5 1 Spark suppression Parallel connection 2 2 nF and varistor 300 V AC in parallel to each relay contact Binary output BO3 for fault alarms Isolated transistor output external supply 3 to 50 V DC max 30 mA Infrared interface Transmission protocol protocol SSP Transmission rate 9600 bit s Angle of reflection 50 Distance infrared adapter and controller Max 0 7 m 104 6493 EN Based on 20 Appendix General specifications Display Backlit LCD Reading
30. 43760 1987 09 e 9 550 40 30 20 10 0 10 20 30 40 Q 69 5 74 3 79 1 84 1 89 3 94 6 100 0 105 6 111 2 117 1 123 0 50 60 70 80 90 100 110 120 130 140 150 Q 129 1 135 3 141 7 148 3 154 9 161 8 168 8 176 0 183 3 190 9 198 6 eo 170 180 190 200 210 220 230 240 250 O 2066 214 8 223 2 231 8 2407 249 8 259 2 2689 278 9 289 2 Ni 1000 measuring elements Refer to the resistance values for Ni 100 measuring elements and mulitply them by 10 6493 129 Appendix 11 4 Used abbreviations W2 WE XD Controlled variable Manipulated variable Internal set point reference variable Internal set point reference variable External set point reference variable disturbance variable external position feed back Error Minimum value of a variable Maximum value of a variable 130 6493 Index A Abbreviations 130 AGCESSONIOS ses re ses Duos dar Spies 7 Analog inputs calibration 83 reading 83 Analog output calibration 83 mathematical adaptation 62 reading delu 83 signal range 1 SOUFCG ulis rx n Maa eins 61 Application examples pressure control 91 temperature control 86 Article 7 Binary input output ramp function
31. 6 7 4 parameters 6 7 5 parameters 6 7 6 Value range is identical to that of the assigned input 2 Decimal position depends on the DP function AUX menu EB 6493 EN 121 Appendix Bo Setting Function Parameter Menu Function CO options description level PA Start up adaptation TUNE ADAP oFF ADP S Off Start up adaptation run ADP S Start 5 Process data ro CIN Display Firmware version S No Display Serial number ANA INT Analog input IN1 Display analog inputs IN2 Analog input IN2 outputs CO VA Controlled variable before function generation WE VA WE before function generation FE CO WE after function generation SERCO Set point at comparator YPID YPID after limitation YOUT Analog output BIN Binary input Display binary inputs and Binary output outputs BO2 Binary output BO2 ADJ INT Analog input IN1 Calibration AdJ 2 Analog input 2 AdJ YOUT Analog output The default setting is written in bold 122 EB 6493 EN Appendix T m e y sapi m and a followed by B Parameter Refer to selection Parameter description Value range section KP Proportional action coefficient 10010 6 8 Reset time a TV Derivative action time U sos PY e
32. 6 7 6 6 8 6 9 6 9 1 6 9 2 6 9 3 6 9 4 6 9 5 7 1 4 58 6493 EN CO D PID Assignment of the derivative action component to the control output CO CH CA Control mode selection M ADJ Operating point preset by manual operation for NPD 552502 bie TOR Shek S S CO DIRE Operating direction of manipulated variable CO F FOR Feedforward control AC VA Increase decrease actual value process variable OUT menu CO SAFE Activate constant output value MA AU Manual automatic switchover Control signal limitation CO RAMP Output ramp output rate limitation CO BLOC Locking manipulated variable YPID CO FUNC Function generation of manipulated variable CO Y VA Signal range for analog outputY CO Y SRC Source for analog output Y CO CALC Mathematical adaptation of analog output Y CO C OUT On off output or three step output CO B OUT Binary outputs and BO2 for status messages ALRM menu CO LIMI 11 CO LIM2 12 AUX menu Additional functions CO RE CO Restart conditions after power failure CO ST IN Reset
33. 6493 101 Infrared interface Bracket Order no 1400 9769 Infrared adapter Order no 8864 0900 Connector to RS 232 port of a computer Fig 23 Connecting an infrared adapter The infrared interface can be accessed from the front of the controller It is located above the SAMSON logo Fig 23 An infrared adapter order no 8864 0900 is required for data transmission between the se rial RS 232 port of the computer and the infrared interface on the controller A bracket order no 1400 9769 ensures that the adapter is properly aligned in front of the controller The infra red adapter can be connected to the USB port of the computer using the USB to RS 232 adapter order no 8812 2001 For this purpose a driver must be installed on the computer This driver can be downloaded from the Internet at www samson de in Services gt Software gt TROVIS VIEW gt USB RS 232 adapter 8812 2001 Note To ensure data transmission functions properly place the infrared adapter so that the dis tance to the infrared interface does not exceed 0 7 m and that the max angle 25 is kept 102 6493 EN 11 Appendix 11 1 Technical data Appendix Inputs Analog input IN1 Analog input IN2 Two analog inputs optionally for controlled variable X or external set point WE 0 4 to 20 mA or 0 2 to 10 V temperature sensor 100 Pr 1000 Ni 100 Ni 1000 potentiometer 1 ko Input for
34. CNTR Controller 22 6493 EN Operation Enter menu Display CO and C PID first function in CNTR menu Open function Display current setting of C PID function Activate the function s editing mode Display prompt for key number Only for operation with key number Enter the valid key number 27 in the example Exit prompt for key number The CP YP function can be edited PI blinks 6493 23 Operation 24 EB 6493 EN 2x Change the PI control algorithm to PID algorithm Confirm setting The editing mode is exited Change to the parameter level Display PA and C PID CP YP blink in alternating se quence Open the parameter level Display KP the first parameter of the C PID function C3 Activate the parameter s editing mode KP blinks Operation Change the proportional action coefficient KP to 1 5 3 Confirm setting The editing mode is exited Note If you want to change other parameters in the function set ting select these parameters and repeat the steps in the gray shaded backgroand E 4x Return to the operating level 6493 25 Operation 5 5 Overview of operating steps In following the operation of the controller is shown in schematic form Open setup level 2 Enter menu 3 Select function parameter 4 Display setting 5 Activate the editing mode to change setting Change setting Confirm
35. LIM1 L1 XD Hi L1 XD When XD is exceeded LIM1 L1 XD AbS L1 XD When absolute value of XD is LIM1 L1 XD exceeded LIM2 oFF L2 Off Limit relay L2 Lo L2 X When X is not reached LIM2 L2 X Hi L2 X When X is exceeded LIM2 L2 X Lo L2 WE When WE is not reached LIM2 L2 WE Hi L2 WE When WE is exceeded LIM2 L2 WE Lo L2 YP When YPID is not reached LIM2 L2 YP Hi L2 YP When YPIDis exceeded LIM2 L2 YP Lo L2 XD When XD is not reached LIM2 L2 XD Hi L2 XD When XD is exceeded LIM2 L2 XD AbS L2 XD When absolute value of XD is 2 12 ceeded 118 6493 EN The default setting is written in bold Appendix T lor m TENE SENNIE dede aa B and m followed by B Parameter Refer to selection Parameter description Value range section U X Limit for X X INT 100 0 A INI 6 6 1 IN2 100 0 IN2 LI WE Limit for WE X INI 100 0 A IN1 2 IN2 100 0 IN2 LI YP Limit for YPID Y 100 0 Y Limit for XD 110 0 0 0 110 0 5 Hysteresis 0 10 0 50 100 0 25 L X Limit for X V IN1 100 0 A INI 662 IN2 100 0 A IN2 2 LI WE Limit for WE X INT 100 0 A INI 12 IN2 100 0 A IN2 12 LI YP Limit for YPID Y 100 0 Y Limit for XD 110 0 0 0 110 0 LI HYS Hysteresis 0 10 0 50 100 0 1 1 2 Value range is identical to that of the assigned
36. Menu Function CO options description level PA Controller CNTR P action C PID CP YP Control algorithm action C PID CP YP Pd CP YP PD action C PID CP YP Pld CP YP PID action C PID CP YP PPI CP YP P action C PID CP YP SIGN dir d XD Not inverted noPA SIGN XD Inversion of error in d XD Inverted XD D PID F01 DP YP To error noPA D PID DP YP Assign D element fo 2 DP YP To controlled variable control output CH CA oFF CC P Off Control mode FO1 CC P By error selection P D PI D 2 By set point M ADJ oFF MA YP Off noPA M ADJ MA YP Operating point on On preset by manual mode for YPID DIRE dir d DI AC Direct noPA DIRE DI AC Operating direction DI AC Inverted of man variable F FOR oFF FECO Off Feedforward control 5 FECO With positive sign F FOR FECO 6 FECO With negative sign F FOR FECO AC VA oFF IN DE Off Increase decrease IN DE By binary input AC VA IN DE actual value The default setting is written in bold 112 EB 6493 EN Appendix lor m estes e y SEINIO I E n qus and 8 4 followed by Refer to selection Parameter description Value range section KP Proportional action coefficient 0 1 1 0 100 0 6 4 1 TN Reset time 2 Derivative action time 95505 TVK1 Deriv
37. SIGN M ADJ CNTR ALRM xe Limit relays LIM LIM2 w Dead band Limiter 7 idm L1 XD L2 XD C PID Feedforward control O ANE WE x FCK2 s PV 20 he P AVKI Op direction reversal T X Y PRE o D X O i DPID DIRE Functions of the compact controller Assignment between control parameters and control behavior P PI PD PID 2 TN 23 1 Y PRE DZXD Y DZXD DZXD CNTR CO C PID Control algorithm P CP YP P PI CP YP PI Pd PD Pld PID PPI CP YP PA C PID KP Proportional action coefficient 0 1 1 0 100 0 TN Reset time sas 1230 PERO SI Derivative action time sss TVK1 Derivative action gain 0 10 1 00 10 00 Y PRE Operating point 10 0 0 0 110 DZXD Dead band error XD 0 0 110 0 Y DZXD Minimum effective error XD 7110 0 96 DZXD DZXD Maximum effective error XD DZXD 110 0 Note The control parameters KP TN TV and Y PRE can also be set in the PAR menv 6493 EN 49
38. Signal range 0 4 to 20 mA or 0 2 to 10 V current and Maximum permissible values Current 50 mA voltage 25 V voltage Internal resistance Current Ri 50 Q voltage Ri 20 Perm common mode voltage Oto 5V Error Zero 0 2 span lt 0 2 linearity 0 2 P ty Temperature influence lt 0 1 10 K for zero and span Resolution 0 0024 mA lt 0 012 with O to 20 mA 0 015 with 4 to 20 mA lt 1 2 mV 0 012 with O to 10 V Transmitter supply Acc to IEC 381 NAMUR NE 06 20 V DC max 45 mA resistant to short circuit Temperature For sensor sensor Pt 100 Pt 1000 according to DIN EN 60751 Ni 100 Ni 1000 according to DIN 43760 Measuring range Pt 100 Pr 1000 100 to 500 C Ni 100 Ni 1000 60 to 250 C Wire resistance Three wire Ri2 lt 15 Q Error Pt 100 Pt 1000 in the range between 40 and 150 C Zero lt 0 2 span lt 0 2 linearity lt 0 2 Zero lt 0 1 span lt 0 1 linearity lt 0 1 Temperature influence lt 0 2 10 K for zero and span Resolution lt 0 04 C lt 0 007 with 100 to 500 C Based on 20 C 6493 103 Appendix Inputs Potentiometer Nominal value 1 three wire Wire resistance lt 15 Q per wire Error Zero 0 2 span 0 2 Temperature influence Zero lt 0 1 10 span lt 0 2
39. The software together with a device specific module allow the con figuration and parameterization of the de vice The _ device specific module TROVIS 6493 can be downloaded free of charge from the SAMSON website Ser vices gt Software gt TROVIS VIEW Additional information on TROVIS VIEW e g system requirements can found on the SAMSON website and in the Data Sheet T 6661 EN Device version Installation 3 Installation The TROVIS 6493 Compact Controller is designed for panel mounting Its front case has the di mensions 48 x 96 mm 1 Prepare a panel cut out with the dimensions 45 0 6 x 9240 8 mm Push the compact controller into the panel cut out from the front Insert supplied mounting clips 2 in the notches on the top and bottom Fig 1 Turn the threaded rods in the direction of the control panel using a screwdriver clamp ing the case against the control panel Installation depth including terminals 158 6 18 TES L 3 2 2 Sm 8 s 5 OQ 9 59 1 Compact controller 2 Mounting clip 3 Control panel Fig 1 Installation Dimension in mm inch 8 186493 EN Electrical connection 4 Electrical connection N Risk of electric shock When installing electric cables you are required to observe the regulations governing electrica
40. be adapted to various transit times e g to extend or retract the actuator stem by the gain factors and the cycle durations A comparator calculates the difference from the manipulated variable YPID target posi tion and the feedback signal Y calculated actual position Depending on the differ ence YPID Y the position pulses are generated as follows The greater the positive difference is the longer the positioning pulses Y will be The greater the negative difference is the longer the positioning pulses will be If the difference is within the range of TZ 2 no positioning pulse is issued If the positive difference is smaller than TZ 2 X TYL1 a positioning pulse Y is not issued If the negative difference is smaller than TZ 2 MTYL2 a positioning pulse Y is not issued If the manipulated variable is smaller or equal to 0 the pulse Y causes the re lay BO2 to be activated constantly If the manipulated variable YPID is smaller or equal to 100 the pulse Y causes the relay to be activated constantly In manual mode the relays are not controlled over the three step output The relay Y can be actuated by pressing the and the relay BO2 Y by the key in manual mode 6493 69 Functions of the compact controller 1 Manipulated variable reading in operating level as Y in automatic mode menu as YPID 2 Read
41. controller 6 3 1 CO SP VA Set point setting This function enables you to define which set point W2 or WE is activated The internal set point W is always active The set point and its measuring range can be determined in the parameter level The measuring range X WINT AWINT must be identical to the measuring range of the controlled variable X INT AINT or MIN2 2 or it must be identical to the output range MIN MAX when function generation is active The internal set points W and W2 can only be adjusted within the upper and lower adjustment limits MWRAN AWRAN Function of input variable WE on WE WE is used as the external set point WE WE is used for external position feedback with three step output see section 6 5 10 In this setting WE is not displayed in the operating level The reading is shown only in the 1 menu see section 6 9 3 F02 WE WE is used for feedforward control see section 6 4 7 In this setting WE is not displayed in the operating level The reading is only shown in the 1 menu see section 6 9 3 SETP SP VA Internal set point W onW On SP VA W w Internal set point WRAN 0 0 WRAN WINT Lower measuring range value 999 0 0 A WINT W W2 WINT Upper measuring range value WINT 100 0 9999 W W2 WRAN Lower adjustment limit W W2 WINT 0 0 WRAN WRAN Upper adjustment limit W W2 WRAN
42. on relay BO2 In manual mode the on off output is actuated by the manual output value and the relay is clocked according the adjusted pulse pause ratio The on off output with adjustable hysteresis is described on page 62 6493 67 Functions of the compact controller 1 Manipulated variable reading in operating level as Y in menu as YPID Fig 18 output with PPM Note Two different configurations of the on off output are possible 1 on off output to monitor the limit of error signal XD or controlled variable X using limit relays L1 and L2 see section 6 6 2 on off output to monitor the limit of the manipulated variable Y See 2 STP setting in section 4 5 10 Ifthe on off output is configured the relay cannot be used for limit monitoring If a limit monitoring CO LIM2 is configured for the relay 2 the relay no longer works as an on off output with PPM The minimum duty cycle is additionally configured in the CO Y LIM function by setting the Y parameter in percent based on the cycle duration TYL1 The maximum duty cycle is configured in the CO Y LIM function by setting the parameter in percent based on the cycle duration TYL1 OUT CO C OUT On off output or three step output SIP On off output with PPM PA C OUT 2 STP KPLI Gain Y BO1 cas Ua OOO Cycle duration 1 0 10 0 9999 s
43. range 999 to 9999 start value end value and decimal separator can be selected Configuration Functions saved in read only memory for fixed set point and follow up control one control circuit Power supply 90 to 250 V AC 47 to 63 Hz 24 V AC DC 20 to 30 V AC DC 47 to 63 Hz Power consumption 13 90 to 250 V external fuse gt 630 mA slow 7 VA 24 V external fuse gt 1 25 A slow Temperature Ambient O to 50 C Shipping and storage 20 to 70 C Mechanical environmental testing for storage transportation and operation Sinusoidal vibrations acc to IEC 60068 2 6 2 Hz amplitude 3 5 mm 9 to 200 Hz acceleration 10 m s 200 to 500 Hz acceleration 15 m s Random vibrations acc to IEC 60068 2 64 1 0 m2 s3 10 to 200 Hz 0 3 m2 s3 200 to 2000 Hz Shocks acc to IEC 60068 2 27 Acceleration 100 m s duration 11 ms Degree of protection IP 65 front IP 30 housing IP OO terminals according to EN 60529 Device safety Protection class 11 Overvoltage category II Degree of contamination 2 Acc to EN 61010 1 Design and testing according to EN 61010 Electromagnetic compatability Requirements according to EN 61000 6 2 EN 61000 6 3 EN 61326 1 Electrical connection 1 5 mm screw terminals Scanning time lt 80 ms Weight Approx 0 5 kg Compliance Ce Efl 6493 105 Appendix 11 1 Co
44. set point 9 PAR menu reduce the KP parameter again until the controlled system stops oscillat ing 8 1 Tuning according to the Ziegler and Nichols method Various tuning methods such as the Ziegler and Nichols method are described in control engi neering literature The Ziegler and Nichols tuning method can only be applied to controlled sys tems that allow the controlled variable to start to oscillate itself For the frequency responese test the controller must run with P action in closed loop operation 96 6493 EN Start up Proceed as follows for a controller ONS Change to manual mode 8 In CNTR menu set the function CO C PID PI CP YP In PAR menu set the parameters KP 0 1 and TN 9999 s In the operating level set the set point W to the required value To do this select W by pressing 5 and adjust the value using the cursor keys In the operating level change the manipulated variable Y so that the controlled variable X has the same value as the set point W error XD 0 To do this select Y by pressing and adjust the value using the cursor keys Change to automatic mode B In PAR menu step up the KP parameter until the controlled variable shows an harmonic oscillation pattern Every time the KP increases let the controlled system oscillate e g by making small changes in the set point Write down the adjusted KP value as the critical proportional action co
45. setting is written in bold Appendix T l or m EID S T m and a followed by B Parameter Refer to selection Parameter description Value range section No parameters 6 5 8 1 Constant 1 0 0 100 0 25 6 5 9 2 Constant 2 0 0 1 0 10 0 CA K3 Constant 3 710 0 0 00 110 0 25 0 1 1 0 100 0 6 5 10 2 2 0 1 1 0 100 0 TYLI Cycle duration BO1 1 0 10 0 9999 s TYL2 Cycle duration Y BO2 1 0 10 0 9999 s MTYL1 Min duty cycle Y 0 1 1 05 TYLI TYL2 duty cycle Y BO2 0 1 1 05 TYL2 XSDY Hysteresis 0 10 0 50 25 TZ TZ Dead band XSDY 2 00 100 0 TY Transit time 1 60 9999 s parameters Groni No parameters 1 2 Value range is identical to that of the assigned input Decimal position depends on the DP function AUX menu 6493 117 Appendix E Setting Function Parameter Menu Function CO options description level PA Limit relays LUMI oFF L1 Off Limit relay L1 lo L1 X When X is not reached LIM1 L1 X Hi L1 X When X is exceeded LIM1 L1 X Lo When WE is not reached LIMT LT WE Hi LI WE When WE is exceeded LIMT LT WE lo L1 YP When YPID is not reached LIM1 L1 YP Hi L1 YP When YPID is exceeded LIM1 L1 YP Lo L1 XD When XD is not reached
46. signal 4 to 20 mA CO INI 4 20 mA Input INT Lower measuring range value bar YINI O bar Input INT Upper measuring range value 10 bar 10 bar Input IN2 Input signal 4 20 mA CO IN2 4 20 mA Input 2 Lower measuring range value bar 2 Obar Input 2 Upper measuring range value 10 bar gt 2 10bar Input variable X Input IN1 CO CLAS ln1 X Input variable WE Input IN2 2 WE 6493 93 Typical applications SETP CO SP VA W Internal set point 6 bar A W 6 bar Enable external set point WE SP VA on WE CNTR Control behavior GO lp Operating direction Increasing CO DIRE dir d DIAC OUT Output signal 4 to 20 mA 4 20 mA AUX Restart conditions after power failure Automatic mode CO RECO 2 MODE Initial value of manipulated variable Y VIKI 0 0 Activate the external set point WE in the operating level 1 Press until WE appears on the display WE blinks 2 Press to activate WE WE stops blinking 94 6493 EN 8 Start up Start up The controller must be installed section 3 wired section 4 and adapted to the control task by performing the configuration and parameterization You can write down the settings you have made in the configuration protocol on page 124 Optimizing the control parameters The controller must be adapted to the dynamic behavior of the controlle
47. signal cannot be clearly assigned to a value IN CO FUNC Function generation of X oFF X on X PA FUNC X Off On MIN MAX KAX K7 Y oFF WE on WE PA FUNC WE Lower range value of output signal Upper range value of output signal Input value 1 Output value 1 Input value 7 Output value 7 Function generation of WE 999 0 0 0 MAX MIN 100 0 9999 A INI Y IN2 A IN2 MIN MAX V INT A INT Y IN2 A IN2 MIN MAX Off On MIN MAX K1 Y K7 X KAM 6 3 SETP menu Lower range value of output signal Upper range value of output signal Input value 1 Output value 2 Input value 7 Output value 7 Set point 999 0 0 MAX MIN 100 9999 X INT A INI IN2 A IN2 MIN MAX X INT A INI IN2 A IN2 MIN MAX This menu enables enables you to determine the functions of a set point The compact controller has two internal set points W and W2 as well as an external set point WE 6493 EN 39 667984 OP 4135 FE CO Set point setting Set point ramp WE sal WE w w O 5 w2 w2 O BI CH SP W W2 WE SPFU 5 SP FU SPCO ayy jo suo puni Functions of the compact
48. started with YIRA by binary input RA YP Limitation when manipulated variable decreases and increases RA YP Limitation when manipulated variable F05 RA YP increases Limitation when manipulated variable decreases BLOC oFF BL YP Off noPA BLOC BL YP Locking manipulated BL YP By binary input variable YPID FUNC oFF FU YP Off Function generation FU YP On FUNC FU YP of manipulated vari able Y VA oFF Y Off no PA Y VA Y Signal range for an 0 20 mA 0 to 20 mA no PA Y VA mA alog output Y 4 20mA 4 20 no 0 10 V 10 V no PA Y VA V 2 10 V 2 to 10V no PA Y VA V The default setting is written in bold 114 EB 6493 EN Appendix Lor ad Land B followed by Parameter Refer to selection Parameter description Value range section Constant output value 710 0 0 0 110 0 6 5 1 No parameters 6 5 2 Minimum manipulated variable 710 0 0 0 110 0 25 6 5 3 XY Maximum manipulated variable 710 0 100 0 110 0 25 TSRA Transit running time 99995 6 5 4 YIRA Initial value 10 0 0 0 110 0 No parameters 699 K1 X Input value 1 10 0 0 0 110 0 6 5 6 K1 Y Output value 1 10 0 0 0 110 0 K7 X Input value 7 10 0 0 0 110 0 K7 Y Output value 7 10 0 0 0 110
49. 1000 in a three wire circuit The resistance of each connection lead must be the same and not exceed 15 Lead calibration is not necessary Resistance thermometers can also be connected in two wire circuits In this case connect a jumper between the controller terminals Take into account that the lead resistance may reach several ohms over long distances causing the measured value to be considerably distorted This measured value can be compensated for by a correction value Refer to section 6 4 7 CO F FOR Feedforward control on page 52 6493 EN 9 Electrical connection Potentiometers The analog inputs IN1 and IN2 are designed for the connection of a potentiometer with two wire or three wire connection A potentiometer is used for example for position feedback of an electrical actuator or for input of an external set point Generally for potentiometers we recommend performing a zero and span calibration Refer to section 6 9 5 CO ADJ Calibration of analog inputs and analog output on page 83 10 6493 EN Electrical connection Current Current Voltage Resistance Potentiometer Two wire thermometer transmitter I Pt 100 Pt 1000
50. Fb 3 STP Hysteresis PA XSDY 0 5 Dead band TZ 2 0 Transit time actuator gt IN 120s AUX Restart conditions after power failure Automatic mode RECO 02 MODE Initial value of manipulated variable Y 0 0 Variation on example 2 the measured temperature is to be issued at the analog output as a 4 20 mA signal perform the following settings Output signal Y 4 20 mA Assign output to input variable X OUT Y VA Y SRC 4 20 mA on Y X 88 6493 EN Typical applications Example 3 Outdoor temperature based control of the flow temperature of a heat exchanger follow up control with Pt 100 input and three step output The controller receives the flow temperature T2 in the secondary circuit at input AI2 from a resis tance thermometer Pt 100 and positions the control valve in the primary circuit over the three step output to keep the flow temperature constant In the outdoor temperature based control the set point is determined by the outdoor tempera ture For this purpose the outdoor temperature 1 is measured by a resistance thermometer Pt 100 at input AIT This input is assigned to the input variable WE The set point for the flow temperature is calculated from the outdoor temperature by performing a function generation of the input variable WE 1 2 3 4 5 6 7 Outdoor temperature 1 in C 20 0 5 0 25 0
51. Functions of the compact controller Note The target position of the actuator can be limited by the CO Y LIM function using the X Y and parameters travel limitation OUT CO On off output or three step output E Fb 3 STP Three step output with external feedback PA C OUT 3 STP XSDY Hysteresis 0 10 0 50 75 TZ TZ Dead band XSDY 2 00 100 0 25 PP 2 STP On off output with pulse pause modulation PPM The on off output with pulse pause modulation PPM changes the continuous action YPID signal into a pulse sequence whose pulse pause ratio varies depending on the value of YPID Fig 18 The on off output can be used to control electric heating ovens for example The duty cycle TE of the on off signal Y is calculated as follows _ Y TZ KPLI i 100 1961 TYL1 s The TYLI parameter is the cycle duration and the maximum duty cycle at the same time KPL1 is a gain factor The TYL1 parameter specifies the minimum duty cycle of the on off signal Y Due to the hardware the minimum duty cycle is at least 0 3 seconds When the and parameters are suitably chosen the on off output with PPM provides a good compromise between small fluctuations in the controlled vari able high switching frequency and high service life of the final control element low switching frequency The on off output has a direct effect on the relay BO1 and a re verse effect
52. Increasing CO DIRE dir d DIAC OUT Output signal Y 4 20 mA Y VA 4 20 mA AUX Restart conditions after power failure Automatic mode CO RECO F02MODE Initial value of manipulated variable Y 0 0 2 Flow temperature control of a heat exchanger fixed set point control with Pt 100 input and three step output The controller receives the flow temperature T in the secondary circuit at input IN2 from a resis tance thermometer Pt 100 and positions the control valve in the primary circuit over the three step output to keep the flow temperature constant at 50 The transit time of the electric actuator is 120 s 6493 EN 87 Typical applications Based on the default settings only the settings marked by need to be made PAR Proportional action coefficient depending on system gt PA 10 Reset time depending on system 1205 Input 2 Input signal Pt 100 Meo MI 100 PT Input IN2 Lower measuring range value 0 C Jue m ONC Input 2 Upper measuring range value 100 2 100 0 Input variable X Input 2 CLAS 102 X SP VA W Internal set point 50 gt PA 50 0 CNTR Control behavior GO PI Gp YP Operating direction Increasing 695 dir d DIAC OUT Three step output with internal feedback gt i
53. L Off FAIL With output value Y1K1 2 FAIL With last manipulated variable value PA MAN Constant output 710 0 110 0 25 Note The Y1K1 parameter can also be defined in CO SAFE and CO RE CO functions Refer fo sections 6 5 1 and 6 7 1 6 2 5 CO CLAS Assignment of X and WE to analog inputs Internally the compact controller operates with the analog input signals X and WE The CLAS function is used to assign these signals to the analog inputs INT or IN2 By default X is assigned to analog input 2 and WE to analog input INT IN CO CLAS Assignment of X to analog inputs In2 X X zIN2 In X Assignment of WE to analog inputs In WE WE INT In2 WE WE 2 36 6493 EN Functions of the compact controller 6 2 6 CO DIFI Filtering of X and WE This function enables you to determine whether X and or WE are to be filtered The first order filter low pass filter or Pt behavior smooths the selected signals and suppresses input signal interferences of higher frequency The time constant of the element is defined the TS X parameter for the input signal X and by TS WE for the input signal WE IN CO DI FI Filtering of input variable X oFF X Off on X On TS X Time constant of X filter 0 1 1 0 100 0 5 Filtering of input variable WE oFF WE Off on WE On TS WE Time constant of WE filter 0 1 1 0 100 0 s 6 2 7 SQR Root extrac
54. PAR Proportional action coefficient depending on system gt PA 110 Reset time depending on system 105 Input INT Input signal 4 to 20 mA CO INI 4 20 mA Input INT Lower measuring range value bar PA YINI O0 bar Input INT Upper measuring range value 10 bar gt AINI 210 bar Input variable X Input INT CO CLAS In1 X SETP SP VA on W Internal set point 6 bar gt PA 6 bar CNTR Control behavior GO CJA PI Gp YP Operating direction Increasing CO dir d DLAC OUT Output signal 4 to 20 mA 4 20 mA AUX Restart conditions after power failure Automatic mode RECO 2 MODE Initial value of manipulated variable Y 0 0 92 6493 EN 5 Pressure control fixed set point control with mA input and mA output Typical applications The controller receives the pressure downstream of the control valve as a 4 to 20 mA signal from a transmitter at input INT and issues a 4 to 20 mA signal at output Y to position the valve to keep the pressure constant at bar A 4 to 20 mA signal is used to issue the external set point The measuring range of the transmitter is O to 10 bar Based on the default settings only the settings marked by gt need to be made PAR Proportional action coefficient depending on system gt o Reset time depending on system gt TN 10s IN Input INT Input
55. SZ Min duty cycle 2 0 10 2 00 100 0 68 6493 EN Functions of the compact controller i PP 3 STP Three step output with internal position feedback and PPM The three step output with internal position feedback and pulse pause modulation PPM issues the positioning pulses with pulse pause modulation The position of the actuator is calculated from the entered transit time TY transit time of the actuator and the internal feedback of the positioning pulses Note that the actual po sition of the actuator may differ from the calculated position A characteristic can be adjusted to generate the positioning pulses Y and Y The dead band TZ is used to adjust the distance of the zero points of both characteris tics The greater TZ is defined the longer it takes to switch between Y and Y The parameter is used to adjust the gain of the characteristic for the signal Y KPL2 parameter is used to adjust the gain of the characteristic for the signal Y The parameter is used to adjust the cycle duration for the signal Y The TYL2 parameter is used to adjust the cycle duration for the signal Y The YTYL1 parameter is used to adjust the minimum duty cycle for the signal Y The MTYL2 parameter is used to adjust the minimum duty cycle for the signal Y Due to the hardware the minimum duty cycle is at least 0 3 seconds The three step output can
56. T Input value 6 250 Output value 6 PA 6 20 0 C Input value 7 PA K7X 1250 Output value 7 gt OT SETP SP VA W Internal set point 25 gt PA 25 0 Enable external set point WE gt SP VA on WE CNTR Control behavior PGP YP Operating direction Increasing GO DIRE dir d DI AC 90 6493 EN Typical applications OUT Three step output with internal feedback COUT i Fb 3 STP Hysteresis 5 0 5 Dead band TZ 2 0 Transit time actuator 1205 AUX Restart conditions after power failure Automatic mode CO RECO 2 Initial value of manipulated variable Y 0 0 Activate the external set point WE the operating level 1 Press until WE appears on the display WE blinks 2 Press to activate WE WE stops blinking 7 2 Pressure control Example 4 Pressure control fixed set point control with mA input and mA output The controller receives the pressure downstream of the control valve as a 4 to 20 mA signal from a transmitter at input INT and issues a 4 to 20 mA signal at output Y to position the valve to keep the pressure constant at 6 bar The measuring range of the transmitter is to 10 bar 6493 EN 91 Typical applications Based on the default settings only the settings marked by need to be made
57. TROVIS 6400 Automation System TROVIS 6493 Compact Controller As nd RER TR SA Mounting and Operating Instructions EB 6493 EN TROVIS Firmware version 4 03 Z Esrari fom SAMSON Edition April 2012 Definitions of the signal words used these instructions DANGER NOTICE indicates a hazardous situation which if not indicates a property damage message avoided will result in death or serious injury Note Supplementary explanations informati WARNING on and tips indicates a hazardous situation which if not avoided could result in death or serious injury 2 EB6493 EN Contents 1 2 2 1 2 2 3 4 5 5 1 5 2 5 3 5 3 1 5 3 2 5 3 3 5 4 5 4 1 5 4 2 5 4 3 5 5 6 1 6 2 6 2 1 6 2 2 6 2 4 6 2 5 6 2 6 6 2 7 6 2 8 6 3 6 3 1 6 3 2 6 4 6 4 1 6 4 2 Contents Page Important safety instructions 6 Device version 0 7 Article Soda s gt ek Sa SO a b ds 7 ACCESSORIES icr opes p perse ertet 7 Installation 8 Electrical connection 9 sw E aa a 12 12 Control 14 Operating 15 Changing the internal 2 2 15 Switching betw
58. YP LI HYS AUX see also CO MAN and CO SAFE ST IN parameters AUX KEYL parameters VIEW parameters FREQ parameters DP parameters TUNE KP TN TV 128 6493 EN 11 3 Values for resistance thermometers Pt 100 measuring elements values according to DIN EN 60751 2009 05 Appendix ec 100 20 80 O 60 50 40 90 20 10 0 Q 60 26 64 30 68 33 72 33 76 33 80 31 84 27 88 22 92 16 95 09 100 00 wo 20 30 40 50 60 70 80 90 100 110 103 90 107 79 111 67 115 54 119 40 123 24 127 08 130 90 13471 138 51 142 29 cq 130 140 150 160 170 180 190 200 210 220 Q 146 07 149 83 153 58 157 33 161 05 164 77 168 48 172 17 175 86 179 53 183 19 ec 230 240 250 260 270 280 290 300 310 320 330 Q 156 84 190 47 194 10 197 71 201 31 204 90 208 48 212 05 215 61 219 15 222 68 340 350 360 370 380 390 400 410 420 430 440 Q 226 21 229 72 233 21 236 70 240 18 243 64 247 09 250 53 253 96 257 38 260 78 ec 450 460 470 480 490 500 Q 264 18 267 56 270 93 274 29 277 64 280 98 Pt 1000 measuring elements Refer to the resistance values for Pt 100 measuring elements and mulitply them by 10 Ni 100 measuring elements values according to DIN
59. al modifications 4 02 old 4 03 new Internal modifications 6493 5 Important safety instructions Important safety instructions For your own safety follow these instructions concerning the mounting start up and operation of the compact controller The compact controller may only be mounted started up or operated by trained and ex perienced personnel familiar with the product According to these Mounting and Operating Instructions trained personnel refers to in dividuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the relevant standards The controller is intended for use in low voltage installations For wiring and maintenance you are required to observe the relevant safety regula tions To avoid damage to any equipment the following also applies Proper shipping and appropriate storage are assumed 6 6493 EN 2 Device version 2 1 Article code TROVIS 6493 032 x Compact Controller Power supply 90 to 250 V AC 4 24 V AC DC 5 2 2 Accessories Accessories Order no TROVIS VIEW Configuration and Operator Interface 6661 Infrared adapter RS 232 8864 0900 Bracket for infrared adapter 1400 9769 USB to RS 232 adapter 8812 2001 The TROVIS VIEW software is a common operator interface for various smart SAMSON devices
60. ant output value 10 0 110 0 6 2 4 parameters 6 2 5 parameters TS X Time constant of X filter ss roma Qs 6 2 6 TS WE Time constant of WE filter 0 1 1 0 100 0 5 parameters 6 2 7 parameters MIN Lower range value of output signal 999 0 0 MAX 628 Upper range value of output signal MIN 100 0 9999 K1 X Input value 1 V IN2 AIN2 K1 Y Output value 1 MIN MAX K7 X Input value 7 MIN2 AIN2 K7 Y Output value 7 MIN MAX MIN Lower range value of output signal 999 0 0 MAX Upper range value of output signal MIN 100 0 9999 K1 X Input value 1 AINT V IN2 AIN2 K1 Y Output value 1 MIN MAX K7 X Input value 7 V IN2 AIN2 K7 Y Output value 7 MIN MAX Value range is identical to that of the assigned input 2 Decimal position depends on the DP function AUX menu EB 6493 109 Appendix Bo Setting Function Parameter Menu Function CO options description level PA Set point SETP SP VA onW On SP VA W Internal set point w Internal set point oFF W2 Off w2 on W2 On P VA W2 Input variable oFF WE Off noPA SP VA WE WE on WE External set point WE WE Input for external feedback with
61. are locked The controller remains in the operating mode active before the keys were locked AUX CO KEYL Lock control keys oFF LOCK Off bil LOCK Switched on off by binary input on noH W Selector manual automatic and cursor keys off Note Several functions can be assigned to the binary input See page 32 6 7 4 CO VIEW Top bottom viewing angle of display The contrast for the top and bottom viewing angle of the display can be changed from Level 1 to Level 10 The default setting Level 6 only needs to be changed in extreme installation situations 78 6493 EN Functions of the compact controller AUX CO VIEW Top bottom viewing angle of display 01 VIEW Level 1 06 VIEW Level 6 10 VIEW Level 10 6 7 5 CO FREQ Power line frequency ripple filter This function is used to filter out 50 Hz or 60 Hz ripple signals from the input signal at the analog input Select the power frequency 50 Hz or 60 Hz of the low voltage installation The power frequency must be set even when the controller is operated by DC voltage AUX CO FREQ Power line frequency on 50Hz 50 Hz on 60Hz 60 Hz 6 7 6 CO DP Decimal separator setting This function is used to select the number of digits after the decimal point for the controlled varia ble and set point reading In addition you can select the number of digits after the decimal point for parameters directly related to the analog inputs These parameters include Me
62. asuring range value 999 0 0 0 A INT 6 2 1 INI Upper measuring range value Y IN1 100 0 9999 132 Lower measuring range value 999 0 0 0 IN2 6 2 2 IN2 Upper measuring range value IN2 100 0 9999 2 No parameter 6 2 3 1 2 Value range is identical to that of the assigned input Decimal position depends on the DP function AUX menu 6493 EN 107 Appendix Bo Setting Function Parameter Men Function CO options description level PA IN MAN off FAIL Off Switch to manual FAIL With output value Y1K1 MAN FAIL mode in case of FO2 FAIL With last manipulated variable signal failure value CLAS In2 X X IN2 noPA CLAS X Assignment of X In X X2 INI to analog inputs Assignment of WE In WE WE INT noPA CLAS WE to analog inputs 2 WE WE IN2 DI FI oFF X Off Filtering input on X On DI FI X variable X Filtering input oFF WE Off variable WE on WE On DI FI WE SQR oFF X Off noPA SQR X Root extraction of X X On Root extraction of oFF WE Off noPA SQR WE WE on WE On FUNC oFF X Off Function generation X On FUNC X of X Function generation oFF WE Off of WE on WE On FUNC WE The default setting is written in bold 108 6493 EN Appendix E EE I E Y B 4 and followed by Parameter Refer to selection Parameter description Value range section Const
63. asuring ranges of the analog inputs Function generation of the input variables X and WE Limit values and LI WE for the limit monitoring of the input variables X and WE If the measured value parameter value is too large meaning the decimal point cannot be dis played in the reading the number of digits after the decimal point is automatically reduced After the measured value parameter value becomes smaller again its reading automatically returns to the configured number of digits after the decimal point AUX CO DP Decimal separator setting on DP1 No digit on DP2 One digit on DP3 Two digits 6493 79 Functions of the compact controller 6 8 TUNE Start up adaptation The purpose of the adaptation is to quickly determine the best settings for the control parameters KP TN and TV with minimum knowledge of the process to be controlled The TN and Tv parameters are calculated according to the rules introduced by Chien Hrones and Reswick for the aperiodic control operation and a good timing behavior The following points must be observed The adaptation can only be used for controlled systems with self regulation The controlled variable must be as constant as possible at the beginning of the adapta tion The disturbance variables must not be changed during the adaptation First set the manipulated variable Y to a start value The start up adaption is started when you select run ADP S The analo
64. ative action gain 0 10 1 00 10 00 Y PRE Operating point 710 0 0 0 110 0 DZXD Dead band error XD 0 0 110 0 25 Y DZXD Minimum effective error XD 7110 0 96 DZXD DZXD Maximum effective error XD DZXD 110 0 parameters 6 4 2 parameters 6 4 3 Max limit for PI D control 7110 0 10 0 110 0 25 6 4 4 CLI M Min limit for PI D control 7110 0 10 0 110 0 parameters 6 4 5 parameters 6 4 6 ESRI Constant 1 0 0 110 0 6 4 7 FC K2 Constant 2 0 0 1 0 100 0 Constant 3 7110 0 0 00 110 0 AV KI Constant in percent actual value 7110 0 0 0 110 0 Z 6 4 8 1 2 Value range is identical to that of the assigned input Decimal position depends on the DP function AUX menu 6493 EN 113 Appendix Bo Setting Function Parameter Menu Function CO options description level PA Output functions OUT SAFE oFF SA VA Activate constant bil SA VA By binary input SAFE SA VA output value MA AU oFFCH MA noPA MA AU CH MA Manual automatic bil CH MA binary input BIT switchover Y LIM on LI YP On Y LIM LI YP Control signal limitation YPID RAMP oFF RA YP Off Output ramp output RA YP Output ramp started with RAMP RA YP rate limitation 10 by binary input FO2 RA YP Output ramp
65. brate zero and span for the analog inputs INT and IN2 as well as the analog output Y 6 9 1 CO CIN Firmware version Firmware version reading Firmware version 82 6493 EN Functions of the compact controller 6 9 2 CO S No Serial number Serial number reading 5 Serial number 6 9 3 CO Read analog inputs and outputs The analog values are shown in this function ro CO ANA Analog values INT Analog input INT IN2 Analog input 2 CO VA Controlled variable before function generation WE VA WE before function generation LENS WE after function generation SRECO Set point at comparator YPID YPID after limitation YOUT Analog output 6 9 4 CO BIN Read binary inputs and outputs You can read the states of the binary input and those of the binary outputs in this function CO BIN Binary values Binary input Binary output BO2 Binary output BO2 6 9 5 CO ADJ Calibration of analog inputs and analog output This function allows you to perform a calibration of the zero and span for the analog inputs and the analog output The analog inputs and the analog output are calibrated by default factory calibration By performing a user calibration based on the system long cables small cable cross sections or tolerances of the sensors and final control elements can be compensated for The user calibra tion can be reset to the factory calibrati
66. ction can be used for a measured value correction For example if a Pt 100 sensor is connected in a two wire circuit and has a higher temperature 52 EB 6493 EN Functions of the compact controller reading due to the lead resistance the reading error can be compensated by a negative correc tion value Example The temperature reading is 2 higher than the actual temperature measuring ran ge to 100 The reading error is corrected by the following setting Function CO F FOR setting POS FECO Parameter PA FC K1 0 0 FC K2 0 0 FC K3 2 0 Note A measured value can also be corrected by performing a function generation on the input variable CO FUNC section 6 2 8 or by calibrating the input CO ADJ section 6 9 5 WE WE FC K1 FC K2 FC K3 WE FC K3 WE FC K3 1 WE WE WE FC K1 FC K2 FC K3 WE WE FC KT FC K2 FC K3 Fig 11 Feedforward control with positive a and negative b sign Input variable Valuated input variable Constant 1 Constant 2 Constant 3 6493 53 Functions of the compact controller CNTR CO F FOR Feedforward control oFF FECO Off POS FECO With positive sign nE FECO With negative sign FC K1 Constant 1 0 0 110 0 FC K2 Constant 2 0 0 1 0 100 0 FC K3 Constant 3 110 0 0 00 110 0
67. d band XSDY 2 00 100 0 i Fb 3 STP Three step output with internal position feedback The three step output is used to drive an electric actuator or any other equipment with in tegral control action using two relays The relay BO1 moves the actuator in the direction e g the actuator stem retracts the valve opens and the relay BO2 moves the actuator in the direction e g the actuator stem extends the valve closes If both relays are inactive the actuator stops moving For the three step output with internal feedback the position of the actuator is calculated from the entered transit time TY transit time of the actuator and the internal feedback of the positioning pulses Please note that the actual position of the actuator may differ from the calculated position 6493 63 Functions of the compact controller The three step output has two pairs of switching points Y and Each pair consists of a switch on point and a switch off point The hysteresis XSDY determines the distance between the switch on point and switch off point The smaller XSDY is defined the shorter the positioning pulses and the more switching there is Note that the hysteresis must always be smaller than TZ 2 The dead band TZ determines the distance between the positioning pulses and The larger TZ is defined the longer the switchover between and Y takes comparator calculates the difference from the manipulated
68. d system over the pa rameters KP TN and TV to ensure that system deviations caused by disturbances can be elimi nated or largely suppressed There are two ways to tune these parameters either by performing the start up adaption section 6 8 or by manual optimization The latter is described in the fol lowing sections We can only give general instructions Proceed as follows for a controller 10 Change the set point slightly and check the transient behavior If necessary retune Change to manual mode 2 In CNTR menu select the function CO C PID PI CP YP In PAR menu set the parameters KP 0 1 and TN 9999 s In the operating level set the set point W to the required value To do this select W by pressing B and adjust the value using the cursor keys In the operating level change the manipulated variable Y so that the controlled variable X has the same value as the set point W error XD 0 To do this select Y by pressing and adjust the value using the cursor keys Change to automatic mode In PAR menu step up the KP parameter until the controlled system shows a tendency to oscillate Every time the KP increases let the controlled system oscillate e g by making small changes in the set point In PAR menu reduce the KP parameter again until the controlled system stops oscillating In PAR menu step down the TN parameter until the controlled system starts to osci
69. e end positions using the constant signals Y and Y CO C OUT On off output or three step output i Fb 3 STP Three step output with internal feedback PA C OUT 3 STP XSDY Hysteresis 0 10 0 50 25 TZ TZ Dead band XSDY 2 00 100 0 JY Transit time 6077 ooo s E Fb 3 STP Three step output with external position feedbock The three step output is used to drive an electric actuator or any other equipment with in tegral control action using two relays The relay moves the actuator in the direction e g the actuator stem retracts the valve opens and the relay BO2 moves the actuator in the direction e g the actuator stem extends the valve closes If both relays are inactive the actuator stops moving For the three step output with external position feedback the position of the actuator is fed back over the input variable WE for example with a potentiometer The hysteresis XSDY determines the distance between the switch on point and switch off point The smaller XSDY is defined the shorter the positioning pulses and the more switching there is Note that the hysteresis must always be smaller than TZ 2 The dead band TZ determines the distance between the positioning pulses Y and Y The larger TZ is defined the longer the switchover between Y and Y takes A comparator calculates the difference from the manipulated variable YPID target posi tion and the feedback signal WE actual pos
70. ed by this function on 2 STP On off output to monitor limits of the manipulated variable The on off output Y has an effect on the relay This output can assume the ON and OFF states and can be used to control electric heating ovens for example This version of the on off output monitors the manipulated variable YPID for a violation of the lower limit TZ The activating point is determined by the limit TZ and the deactivating point is determineed by the hysteresis XSDY If the relay is activated appears on the display In manual mode the on off output is inactive and the relay BO1 can be actuated by pressing the key Refer to section 4 for the electrical wiring 62 6493 EN Functions of the compact controller Fig 15 On off output XSDY Y 1 Ypp Y 0 TZ Yop OUT Note Two different configurations of the on off output are possible 1 on off output with pulse pause modulation see page 67 2 on off output to monitor the limit of error signal XD or controlled variable X using limit relays L1 and L2 see page 74 If the relay is configured with the 2 STP setting to be used as an on off out put the relay BO2 is available to issue limit alarms or status messages CO On off output or three step output on 2 STP On off output PA C OUT 2 STP XSDY Hysteresis 0 10 0 50 TZ We Dea
71. ed proportional ac tion coefficient KP is to be set to 1 5 Refer to the overview in section 11 1 This overview shows that time behavior is determined by the C PID function in the CNTR menu 2 8 m Setting Function Parameter level Menu Function options description PA Control structure and functions CNTR PCP NAP IP C PID CP YP Control algorithm C PID CP YP Pd CP YP PD C PID CP YP Pld PID C PID CP YP The default setting is written in bold 6493 21 Operation The proportional action coefficient is set using the KP parameter followed by E Parameter Parameter Refer to selection description Value range section KP Proportional action coefficient 0 1 1 0 100 0 6 4 1 Reset time 55996 TV Derivative action time 1 10 9999 s TVK1 Derivative action gain 0 10 1 00 10 00 Y PRE Operating point 10 0 0 0 110 0 DZXD Dead zone error XD 0 0 110 0 Y DZXD Minimum effective error XD 110 0 DZXD DZXD Maximum effective error XD DZXD 110 0 The controller is in the operating level The reading the display looks like this Xd W X C3 Open the setup level Display PAR Control parameters menu M 3x Select
72. ed variable at the comparator This ramp function is started by a binary input An active binary input causes the set point at comparator SP CO to adopt the same value as the current value of the controlled variable at comparator X A signal change at the binary input from 1 active to O in active starts the ramp and the set point runs until it reaches the target set point internal or external set point After reaching the target set point the ramp stops After this the set point at comparator SP CO follows the target set point e g W without delay If the controller is switched to manual mode while the ramp is running the ramp is stopped and the set point adopts the same value as the controlled variable X After switching back to automatic mode the ramp continues to run again until reaching the target set point If the binary input is activated again while the ramp is running the set point at comparator SP CO returns to the current value at comparator X retriggering If the controller starts after the power supply has been interrupted for more than sec ond in automatic mode the set point at comparator SP CO adopts the same value as at the comparator when the binary input is active and the target set point when the binary input in not active 42 6493 EN Functions of the compact controller SZWINT eee er E WINT Lower measuring range value WINT Upper measuring range value
73. een set points 2 15 Switching over to manual mode and changing the control output 16 Setupilevel 225255525 Poe ee eb dune 16 Configuring the 17 Kev n mber Gee bate 18 Example showing configuration and parameterization 21 Overview of operating 26 Functions of the compact controller 32 PAR menu Control 32 IN menu Input functions 5 34 Input signal INT 34 CO IN2 Input signal 22 34 CO MEAS Signal monitoring 2 2 35 CO MAN Switch to manual mode in case of signal failure 36 CO CLAS Assignment of X and WE to analog inputs 36 CO DI FI Filtering f Xand WE 37 CO SQR Root extraction of Xand WE 37 CO FUNC Function generation of Xand 37 SETP menu Set point 39 SP VA Set point setting 41 SP FU Set point functions ooa 42 CNTR menu Controller functions oaa a 47 CO C PID Control algorithm lt s aw e ea 47 SIGN Inversion 50 6493 3 Contents 6 4 3 6 4 4 6 4 5 6 4 6 6 4 7 6 4 8 6 5 6 5 1 6 5 2 6 5 3 6 5 4 6 5 5 6 5 6 6 5 7 6 5 8 6 5 9 6 5 10 6 5 11 6 6 6 6 1 6 6 2 6 7 6 7 1 6 7 2 6 7 3 6 7 4 6 7 5
74. efficient Kp crit Use a stopwatch to time the oscillation time for one entire oscillation to find Terit To achieve a more precise result time several oscillations and calculate the average time from the results Controlled variable t s Multiply KP crit and Terit by the factors listed in the table below Use the results for KP and TN accordingly KP TN TV controller 0 45 Kp crit 0 85 Tai Change the set point slightly and check transient behavior If necessary retune and TN until the closed loop shows a satisfactory control behavior 6493 97 Start up Proceed as follows for a P controller Change to manual mode 6 In CNTR menu set the function CO C PID P CP YP In PAR menu set the parameter KP 0 1 In the operating level set the set point W to the required value To do this select W by pressing 5 and adjust the value using the cursor keys In the operating level change the manipulated variable Y so that the controlled variable X has the same value as the set point W error XD 0 To do this select Y by pressing 5 and adjust the value using the cursor keys f m The output Y reading is the operating point of the manipulated variable In PAR menu set the Y PRE parameter to the previously determined operating point of the manipulated variable Y NOTE For a P controller every time the set point is changed the change of the operat
75. er KEY blinks Note When this reading appears you can change the user de fined key number See Activate deactivate operation with key number Operation without key number Exit prompt for key number Operation with key number Enter the valid key number In this example it is 12 3 Exit prompt for key number Note If you enter an incorrect key number you are prompted again to enter the key number In this case a 1 appears on the display instead of Activate deactivate operation with key number The controller is in the operating level The reading on the display looks like this 6493 19 Operation Open the setup level Open the parameter level Activate prompt for key number KEY blinks Enter the service key number Confirm the service key number Display and KEYP Note A number instead of means that a key number is al ready active The reading shown is the valid key number 20 6493 EN Operation Enter your own key number 12 in this example Note To deactivate operation with key number select in the display Exit prompt for key number The controller returns to the setup level Press until the controller is back in the operating level 5 4 3 Example showing configuration and parameterization The compact controller is to configured to be a PID controller The associat
76. f PI D action is determined there If the error signal moves outside the range again the integral term is saved and the last output value is set as the operating point If the controller changes from automatic to manual mode the operating point required for the plant must be re set again before returning to the automatic mode The operating point is only saved temporarily Y PRE parameter does not have any effect After power failure the operating point must be re set in manual mode CNTR CO CH CA Control mode selection P D PI D oFF Off F01 CC P By error F02 CC P By set point PA CH CA CLIP Maximum limit for PI D control 7110 0 10 0 110 0 25 CLI M Minimum limit for PI D control 7110 0 10 0 110 0 25 w xp4 PI D w Set point Error signal CLM CUP Maximum limit for range of PI D control P D gt CLI M Minimum limit for range of PI D t control Fig 10 Control mode changeover 6493 51 Functions of the compact controller 6 4 5 CO M ADJ Operating point preset by manual operation for YPID This function enables you to define an operating point in manual mode In automatic mode the defined operating point is added to the calculated manipulated variable The defined operating point remains effective until either the operating point setting in manual mode is deactivated by selecting oFF MA YP or until a new operating point is set
77. follows The compact controller is in the operating level 1 In manual mode the manipulated variable Y to the operating point so that the con trolled variable X has the same value as the set point W Increase the manipulated variable Y for example by 10 with step change value of the manipulated variable Y JMP 20 and wait until the controlled variable X does not change anymore Check whether the controlled variable is within the permissible range Reduce the manipulated variable Y for example by 20 with step change value of the manipulated variable Y JMP 20 and wait until the controlled variable X does not change anymore Check whether the controlled variable is within the permissible range In TUNE menu select CO ADAP function and set the step change value Y JMP In TUNE menu select CO ADAP function Select run ADP S to start the adaptation How long the adaptation takes is determined by the time behavior of the controlled sys tem If the controlled variable does not reach an end value within five hours the adaptation is automatically cancelled After starting the adaptation status messages on the start up adaptation are displayed in the top row Status messages 10 Adaptation started 20 Noise measurement approx 10 seconds 40 Step value of manipulated variable Y Ypip Y JMP issued Wait for controlled system to react step response 41 Step value of manipulated variable Y
78. g output is stepped up or down by the step change value of the ma nipulated variable Y JMP parameter The controller waits for the response from the controlled system until a new stable state of the controlled variable is reached The controller then deter mines the control parameters from the course of the controlled variable After the adaptation is completed the controller issues the output value again which was active in manual mode before the adaptation Before the adaptation the operating point of the manipulated variable must be known You can find it in the manual mode by adjusting the manipulated variable Y in manual mode so that the controlled variable X has the same value as the set point W The step change of the manipulated variable must be large as possible and be located around the operating point e g start value above the operating point and end value below it On de termining the step change value and the start value make sure that the manipulated vari able is within the range of the manipulated variable and that the controlled variable is within the measuring range Furthermore make sure the controlled variable for the process does not as sume any impermissible values Check this point before the adaptation To do this set the ma nipulated variable in manual mode after the step change and then before the step change 80 6493 EN Functions of the compact controller To run start up adaption proceed as
79. hows an harmonic oscillation pattern Every time the KP increases let the controlled system oscillate e g by making small changes in the set point Write down the adjusted KP value as the critical proportional action coefficient KP crit Use a stopwatch to time the oscillation time for one entire oscillation to find Tcrit To achieve a more precise result time several oscillations and calculate the average time from the results In CNTR menu set the function CO C PID PID CP YP and change again to automatic mode Multiply and Terit by the factors listed in the table below Use these results for KP TN and TV accordingly KP TN TV PID controller 0 59 Kp crit 0 50 Tai 0 12 Tai Change the set point slightly and check the transient behavior If necessary retune KP TN and TV slightly until the closed loop shows a satisfactory control behovior 6493 99 Fault alarms 9 Fault alarms When an error occurs it is indicated on the display and causes the binary output for fault alarms to be activated An error no longer appears on the display after it has been remedied Error messages their possible cause and recommended action to be taken can be found in the table below Note When an error is not described in detail in this section we recommend to switch off the power supply and wait five seconds before switching it back on again
80. imits are constantly set to K1 Y or K7 Y The compact controller completes the polygonal curve by generating straight lines Fig 4 If you have entered an output value greater than MAX or smaller than MIN it will be set to the value of MAX or MIN Section 7 shows an example of function generation MIN Lower range value of output signal E Upper range value of output signal K1 Y Output value 1 K5 Y Output value 5 K7 Y Output value 7 E K1 X Input value 1 gt ks x Input volue 5 K6 X Input value 6 K7 X Input value 7 E Signal before function generation input signal t K1 X K5 X K6 X K7 X E Signal after function generation output signal Fig 4 Function generation Note We recommend creating a table or to plot the curve in a Cartesian coordinate system The seven points for function generation must be selected to be able to plot the curve properly The controller calculates a straight line between points Seven points must be defined even if the signal course can be plotted sufficiently with less than seven points If necessary enter the lirst points or the last points to be the same 38 6493 EN Functions of the compact controller The polygonal chain of the curve is not restricted Polygonal curves with more than one max imum or minimum are possible However make sure that only one output value is assigned fo an input value Otherwise the input
81. in manual mode If the operating point setting in manual mode is deactivated the manipulated variable determined in manual mode assumes the calculated value within approx two seconds After a power supply failure the operating point in manual mode must be reset CNTR CO Operating point preset by manual operation for YPID oFF MA YP 6 4 6 DIRE Operating direction of manipulated variable The operating direction of the manipulated variable can be adapted to the operating direction of the controlled system or control valve The manipulated variable can either act directly or in versely to the error signal signal error set point process variable Note The operating direction can also be inverted in CO SIGN Refer to section 6 4 2 CNTR CO DIRE Operating direction manipulated variable dir d DI AC Direct in d DI AC Inverted 6 4 7 CO F FOR Feedforward control The input variable WE can be used for feedforward control see section 6 3 1 The disturbance signal can be valuated by parameters according to the following formula and linked addition This disturbance signal is added to the controlled variable WE FC K1 FC K2 FC K3 with WE FC K1 gt 0 FC K1 FC K2 and FC K3 are constants that can be defined in the parameter level The plus or minus sign of the formula is determined in the CO F FOR function Refer to section 6 4 7 The D CO F FOR fun
82. ines the running time for the output ramp and the rate as a result This parameter is based on a change of the output by 100 Fig 13 When the binary input is activated the control output is set to the initial value When the binary input is deactivated the output ramp starts In the RA YP setting the initial value is fixed at 10 0 Select the F02 RA YP setting to enter the initial value as required using the YIRA parameter The output ramp is stopped in manual mode and upon restart after a power failure RA YP 4 RA YP and 5 RA YP Output rate limitation The rate of output change can be limited for a decreasing and or an increasing output In the limited direction s the manipulated variable changes only as fast as TSRA parameter al lows it to This parameter is based on a change of the output by 100 If the rate of output change is slower than the defined rate of changes limitation will not be effective Fig 14 illustrates the effect of the described function The rate of change for the output vy is cal culated as follows 100 Y TSRA 6493 EN 57 Functions of the compact controller Ramp increasing Ramp increasing Initial value YIRA 0 0 Initial value YIRA lt 100 YOUT YOUT wp Pd ve 100 RE 100 Ramp decreasing Initial value YIRA 100 YPID YOUT YIRA 100 p 1 1 ror
83. ing of internal position feedback in operat ing level as Y in manual mode Fig 19 Three step output with internal position feedback and PPM OUT CO C OUT On off output or three step output IPP SIP Three step output with internal feedback and PPM PA C OUT 3 STP KPLI KPL2 TYL2 NALI Y TYL2 TZ TY 70 6493 EN Gain Y Gain Y BO2 Cycle duration BO1 Cycle duration Y BO2 Min duty cycle BO1 Min duty cycle Y BO1 Dead band Transit time Mon ose ONE 0 10 1 0 100 0 1 0 100 0 10 0 9999 s 10 0 9999 s 1 05 ae UOS ea MALAI 2 00 100 0 Z 60 9999 s Functions of the compact controller E PP 3 STP Three step output with external position feedback and PPM The three step output with external position feedback and pulse pause modulation PPM is sues the positioning pulses with pulse pause modulation The position of the actuator is fed back for example by a potentiometer over the input vari able WE A characteristic can be adjusted to generate the positioning pulses Y and Y The dead band TZ is used to adjust the distance of the zero points of both characteris tics The greater TZ is defined the longer it takes to switch between Y and Y The parameter is used to adjust the gain of the characteristic for the signal Y The KPL2 parameter
84. input Decimal position depends on the DP function AUX menu 6493 119 Appendix Setting Function Parameter Menu Function CO options description level PA Additional functions AUX RE CO MODE Manual with constant output RE CO MODE Restart conditions after F02 MODE Auto start with output value RE CO MODE power failure ST IN FrEE INIT Off completed noPA ST IN INIT Reset to default settings All INIT All functions parameters and code number FUnC INIT All functions PArA INIT All parameters and code number Ad INIT Calibration values for INI IN2 Y KEYL oFF LOCK Off noPA KEYL LOCK Lock control keys bil LOCK Switched on off by binary input Selector manual automatic and on noH W cursors keys off VIEW 01 VIEW Level 1 noPA Top bottom viewing angle of display 06 VIEW Level 6 10 VIEW Level 10 FREQ on 50Hz 50 Hz noPA FREQ Power line frequency on 60Hz 60 Hz DP on DPO No digit noPA DPI Decimal seperator setting DP1 One digit on DP2 Two digits The default setting is written in bold 120 6493 EN Appendix T lor m e y sapi m and a followed by B Parameter Refer to selection Parameter description Value range section Constant output value 10 0 0 0 110 0 6 7 1 parameters 6 7 2 parameters OUS parameters
85. ir parameters Each menu is dedicated to the functions of a certain topic PAR Control parameters IN Input SETP Set points CNTR Controller OUT Output ALRM Limit relays AUX Additional functions TUNE Start up adaptation Process data Section 11 1 contains an overview of all the menus functions and parameters Functions are identified in the display by CO whereas the parameter level is identified by PA Functions of the binary input SETP menu CO SP FU RAMP Start set point ramp section 6 3 2 SETP menu CO SP FU CH SP Switch over set points section 6 3 2 CNTR menu CO AC VA Increase decrease actual value process variable section 6 4 8 OUT menu CO SAFE Activate constant output value section 6 5 1 OUT menu CO MA AU Manual automatic switchover section 6 5 2 OUT menu CO RAMP Start output ramp section 6 5 4 OUT menu CO BLOC Locking manipulated variable gt section 6 5 5 OUT menu CO B OUT Activate binary outputs gt section 6 5 11 6 1 PAR menu Control parameters This menu does not contain any functions When you open this menu the controller immediately jumps to the parameter level PA It allows you to quickly set the control parameters Note The control parameters can also be set in the CNTR menu C PID function Refer to sec tion 6 4 1 32 6493 EN 5680 8 NI
86. is used to adjust the gain of the characteristic for the signal Y The parameter is used to adjust the cycle duration for the signal Y The TYL2 parameter is used to adjust the cycle duration for the signal Y The YTYL1 parameter is used to adjust the minimum duty cycle for the signal Y The YTYL2 parameter is used to adjust the minimum duty cycle for the signal Y Due to the hardware the minimum duty cycle is at least 0 3 seconds A comparator calculates the difference from the manipulated variable YPID target posi tion and the input variable WE actual position Depending on the difference YPID WE the position pulses are generated as follows The greater the positive difference is the longer the positioning pulses Y will be The greater the negative difference is the longer the positioning pulses will be If the difference is within the range of TZ 2 no positioning pulse is issued If the positive difference is smaller than TZ 2 X TYL1 a positioning pulse Y is not issued If the negative difference is smaller than TZ 2 MTYL2 a positioning pulse Y is not issued The input variable WE must be configured for position feedback Example position feedback with a potentiometer at input IN2 Configure input signal for analog input IN2 IN menu IN2 function setting O 1 gt section 6 2 2 Assign the input variable WE to the analog input IN2 IN menu CO CLAS func
87. it relays AUX Additional functions TUNE Start up adaptation O Process data Section 11 1 describes all the menus functions and parameters 16 6493 EN Operation 5 4 1 Configuring the controller To set a function or parameter you need to know the abbreviated code used for the func tion parameter and the menu where it can be found Refer to section 11 1 for an overview of these codes Section 5 4 3 describes an example on how to configure the controller To proceed The controller is in the operating level Open the setup level Display PAR Control parameters menu If the function you want to configure is located in a different menu Select the required menu IN SETP CNTR OUT ALRM AUX TUNE or Open menu Display CO and abbreviated code of the first function in the current menu If you want to configure a different function Select the required function Open the function Display Current function setting Activate the function s editing mode Current function setting blinks Note Every time you go to the first function after opening the setup level you are prompted to enter the key number display and KEY You only need to enter the key number if a key number has already been assigned to the controller gt section 5 4 2 If this is not the case entry of the key number can be skipped by pressing the enter key D Change function setting Confirm setting
88. ition Depending on the difference YPID WE the position pulses are generated as follows If the difference is greater than TZ 2 the pulse Y activates the relay If the difference is greater than TZ 2 the pulse Y activates the relay BO2 6493 EN 65 Functions of the compact controller Ifthe difference is smaller than the amount TZ 2 XSDY both relays are deactivated In manual mode the relays are not controlled over the three step output The relay BO Y can be actuated by pressing the key and the relay BO2 Y by the key in manual mode The input variable WE must be configured for position feedback Example position feedback with a potentiometer at input IN2 Configure input signal for analog input IN2 IN menu IN2 function setting 0 1 gt section 6 2 2 Assign the input variable WE to the analog input IN2 IN menu CO CLAS function setting In2 WE gt section 6 2 5 Assign the input variable WE to the external position feedback SETP menu CO SP VA function setting WE gt section 6 3 1 Manipulated variable reading in operating level as Y in automatic mode menu as YPID Reading of external position feedback in operating level as Y in manual mode menu FE CO 2 Fig 17 Three step output with external feedback 66 6493 EN
89. ivate constant output value oFF SA VA Off bil SA VA By binary input BI1 PA SAFE Constant output value 710 0 0 0 110 0 Note Several functions can be assigned to the binary input See page 32 6 5 2 CO MA AU Manual automatic switchover This function causes the controller to switch to manual mode when the binary input is acti vated During which the key is locked The controller returns to automatic mode when the bi nary input is deactivated The controller can be changed to the manual mode and back into automatic mode using the B key when the binary input is deactivated OUT MA AU Manual automatic switchover oFF CH MA Off bil CH MA By binary input Note Several functions can be assigned to the binary input See page 32 6493 55 660983 96 JNO Z 1 2 3 OUT OUT TUNE OUT ALRM YPID Constant LIMTI 2 output value Manual Limitation Ramp Locking Adaptation Function generation a lo L Em D IH LIMI LIM2 SAFE MAAU YUM RAMP BLOC ADAP FUNC FU YP LI YP L2 YP OUT OUT Qv Your Output Y Mathematical adaptation of control output Control signal range YPID gt x Sp Y CAK1 x CAK2 CAK3 OU mA 1 XD
90. l power plant installation in the country where the controller is to be installed Installation notes Install the power supply lines and the signal lines separately Do not install them parallel to each other To improve noise immunity observe a minimum distance of 10 cm between the power cable and the measuring input lines To avoid measurement errors or other disturbances use shielded cables for the analog and binary signal lines Ground the shield at one end either at the controller inlet or at the con trol cabinet outlet using the largest possible cross section Connect the central grounding point and the PE grounding conductor with a cable gt 10 using the shortest route Inductances in the control cabinet e g contactor coils are to be equipped with suitable in terference suppressors RC elements Control cabinet elements with high field strength e g transformers or frequency converters are to be shielded with separators providing a good ground connection The controller has screw terminals for 1 5 mm wires 0 5 to 1 5 mm wire cross section The lines are connected to the terminal strips 1 and 2 as shown in the following wiring diagram Fig 2 Transmitter supply The controller has a supply output to power a maximum of two two wire transmitters 20 V DC 45 mA and the binary input Resistance thermometers The analog inputs IN1 and IN2 are designed for the connection of resistance thermometers Pt 100 and Pt
91. l functions can be assigned to the binary input See page 32 6493 59 Functions of the compact controller F03 RA YP setting Limitation when manipulated variable decreases and increases 04 RA YP setting Limitation when manipulated variable increases F05 RA YP setting Limitation when manipulated variable decreases Fig 14 Output rate limitation fa TSRA 5 5 YPID YOUT TSRA Internal manipulated variable Analog output Running time 60 EB 6493 EN Functions of the compact controller 6 5 6 CO FUNC Function generation of manipulated variable A function generation can be performed on the manipulated variable Y in the same way as for the input variables X and WE Function generation is described in detail in section 6 2 8 The in put and output values are entered in percent OUT CO FUNC Function generation of manipulated variable oFF FU YP Off on FU YP On PA FUNC FU YP K1 X Input value 1 10 0 0 0 110 0 K1 Y Output value 1 10 0 0 0 110 0 K7 X Input value 7 10 0 0 0 110 0 K7 Y Output value 7 10 0 0 0 110 0 6 5 7 CO Y VA Signal range for analog output Y This function allows the signal range for the analog output to be determined OUT CO Y VA Signal range for analog output Y oFF Y Off 0 20 mA 0 to 20 mA 4 20 mA 4 to 20 mA 0 10 V Oto 10V 2 10 210 10V
92. llate Every time the TN is reduced let the controlled system to oscillate e g by making small changes in the set point In PAR menu raise the TN parameter slightly until the controlled system stops oscillating and TN until the closed loop has a satisfactory control behavior 6493 95 Start up Proceed as follows for a P controller 1 Change to manual mode 84 2 In CNTR menu set the function CO C PID P 3 In PAR menu set the parameter KP 0 1 4 In the operating level the set point W to the required value To do this select W by pressing and adjust the value using the cursor keys 82 5 n the operating level change the manipulated variable Y so that the controlled variable X has the same value as the set point W error XD 0 To do this select Y by pressing f and adjust the value using the cursor keys 82 The output Y reading is the operating point of the manipulated variable 6 n PAR menu set the Y PRE parameter to the previously determined operating point of the manipulated variable Y NOTE For a P controller every time the set point is changed the change of the operat ing point is also necessary if no system deviation is to exist Change to automatic mode 68 8 In PAR menu step up the KP parameter until the controlled system shows a tendency to oscillate Every time the KP increases let the controlled system oscillate e g by making small changes in the
93. mode selection enables the controller to be operated various operating states with or without the integral term This function allows the integral term to be automatically activated by the error signal or by the set point It can only be selected when a Pl or PID behavior has been configured Refer to section 6 4 1 The P D PI D control mode selection is preferably to be used when the set point is to start up as quickly as possible and without overshooting while no offset is to exist This is required espe 50 6493 EN Functions of the compact controller cially for control of discontinuous processes such as during batch operation of an autoclave an open steam vulcanizer or a furnace With control mode selection the controller works as a P or PD or the or PID controller de pending on the error signal or the set point Outside a definable range of the error signal or set point the controller works as a P or PD controller While within this range the integral term is activated and the controller works as a or PID controller The range is defined by the CLI P and CLI M parameters Fig 10 illustrates this behavior Note for 01 CC P setting If the controller changes from manual to automatic mode while the error signal is outside the defined range the operating point is determined by the last manual output value The operating point is effective until the error signal returns to the range The oper ating point o
94. nd restart start up adap 35 ERR greater than 100 during the adapta tation tion 36 ERR Error during adaptation Restart start up adaptation Return the controller to SAMSON for re 255 ERR Calibration missing SAMSON Upper limit violation of rated signal ol mn range at analog input INT or at analog inputs INT and IN2 The error message depends on how BEEN MEAS is configured see section Lower limit violation of rated signal range 6 2 3 vul mn at analog input INT or at analog inputs IN1 and IN2 Upper limit violation of rated signal 2 range at analog input 2 The error message depends on how EMEN CO MEAS is configured see section 2 mn Lower limit violation of rated signal range 6 2 3 u 2 3 at analog input 2 10 Infrared interface The TROVIS 6493 Controller is fitted with an infrared interface which allows the controller to communicate with the TROVIS VIEW interface Note The TROVIS VIEW software is a common operator interface for various smart SAMSON devices The software together with a device specific module allow the configuration and parameterization of the device The device specific module for TROVIS 6493 can be downloaded free of charge from the SAMSON website Services gt Software gt TROVIS VIEW Additional information on TROVIS VIEW e g system requirements can foand on the SAMSON website and in the Data Sheet T 6661 EN
95. nfiguration list Setting Function Parameter Menu Function CO options description level PA Control parameters PAR Input IN 0 20 20 mA INT mA Input signal 4 20 mA 4 to 20 mA IN1 mA INI 0 10 0 10 IN1 V 2 10 210 10V INT V 100 PT Pt 100 100 500 C IN1 PT 1000 PT Pt 1000 100 500 C IN1 PT 100 NI Ni 100 60 250 C IN1 NI 1000 NI Ni 1000 60 250 C IN1 PT O IKOHM 1000 Q IN1 KOHM IN2 0 20 mA 0 to 20 mA IN2 mA Input signal 4 20 mA 4 to 20 mA IN2 mA IN2 0 10 V Oto 10V IN2 V 2 10 V 2 to 10V IN2 V 100 PT Pt 100 100 500 C IN2 PT 1000 PT Pt 1000 100 500 C IN2 PT 100 NI Ni 100 60 250 C 2 1000 NI Ni 1000 60 250 C IN2 PT O IKOHM 01010000 IN2 KOHM MEAS oFFME MO Off noPA MEAS ME MO Signal monitoring INI Analog input INT IN2 ME MO Analog input IN2 ALL Analog input INT and 2 106 6493 EN The default setting is written bold Appendix or m xl E and m followed by 4 Parameter Refer to selection Parameter description Value range section KP Proportional action coefficient Reset time TV Derivative action time Y PRE Operating point 0 1 1 0 100 0 6 1 1 120 9999 s 1 10 9999 s 10 0 0 0 110 0 INI Lower me
96. on AUX menu CO ST IN function AdJ INIT setting Refer to section 6 7 2 6493 EN 83 Functions of the compact controller CO ADJ Calibration IN1 Analog input IN1 2 Analog input 2 YOUT Analog output Calibrating the analog input 1 2 3 4 n Connect a high precision meter at the input INT 2 In 1 menu select the function ADJ Select the input you want to calibrate AdJ IN2 using the cursor keys m Confirm the input you have selected You are prompted to enter the key number Enter the key number or continue by pressing 7 Use the high precision meter to set the input signal to the required start value Display ZERO and INT IN2 in alternating sequence Confirm the start value D Display 0 0 and ZERO Use the high precision meter to set the input signal to the required end value Display SPAN and INT 2 in alternating sequence Confirm the end value D Display 100 0 and SPAN Calibrating the analog output 1 n Connect a high precision meter at the analog output Y In 1 menu select Select the output YOUT using the cursor keys Confirm the output D You are prompted to enter the key number Enter the key number or continue by pressing P Use the cursor keys to set the start value at the high precision meter Display ZERO and YOUT in alternating sequence 84
97. output functions and parameters Only when selected using the selector key Change function settings Only when Y has been selected using the and parameter values selector key or when manual mode W has been selected Display currently valid set point Return to the operating Escape key level stepwise No keys After approx 5 minutes the reading on the Changes back to operating pressed display changes back to the currently valid level after approx 5 minutes set point Exception in manual mode and when the manipulated variable is displayed 14 EB 6493 EN Operation 5 3 Operating level The controller is in this level when control operation is active Key information on the control process are displayed in this level The default display shows the controlled variable X error signal Xd the currently valid set point W W2 or WE the active limit relay as well as informa tion on the three step output if applicable Note Other variables such as the error in can be displayed instead of the currently valid set point To do this press the selector key until the required variable is displayed The following variables can be selected internal set point W manipulated variable Y error and de pending on the configuration in the SETP menu the internal set point W W2 and the external set point WE The following actions can be performed in the operating level Changing the internal set poin
98. roller can be performed either directly using the keys on the front panel refer to section 5 2 or using the TROVIS VIEW Configuration and Operator Interface see section 10 Principally there are two levels which provide different key functions and different displays the operating level and the setup level The readings in the display see section 5 1 and the func tions of the keys see section 5 2 differ depending on which level the controller is in 5 1 Display No Operating level Setup level Depending on the level selected the following vari ables and operating states are shown on the display 1 Controlled variable X Designations settings and values 2 Value assumed W W2 WE Y or Xd of the functions and parameters 2 section 11 1 3 limit relay L2 active Not displayed 4 Three step output Not displayed 5 Limit relay 11 active Not displayed 6 Three step output or on off output Not displayed 7 Fault alarms see section 6 2 3 Not displayed 8 Hand icon displayed in manual mode Not displayed no icon in automatic mode 9 Press key to display W W2 WE Y or Xd Fast access to parameters in sequence The associated value appears in 2 Every time you press l deci W2 and WE only when they have been mal point of a parameter is shifted activated see section 6 3 1 one place to the right 10 Bar display of Xd in percent Not displayed 12 EB 6493 EN Operation
99. s exceeded Lo L1 XD When XD is not reached Hi L1 XD When XD is exceeded AbS L1 XD When absolute value of XD is exceeded PA LIM1 L1 Limit for X X 100 0 A INT IN2 100 0 A IN2 LI WE Limit for WE X 100 0 A INI IN2 100 0 A IN2 LI YP Limit for YPID X Y 100 0 LI XD Limit for XD 7110 0 0 0 110 0 5 Hysteresis 0 10 0 50 100 0 9 6 6 2 CO LIM2 Limit relay L2 You can determine the variable to be monitored and the condition for switching the limit relay L2 violation of the upper or lower limit with this function Section 6 6 contains a detailed de scription on how the limit relay works 76 6493 EN Functions of the compact controller Note The functions of the on off or three step output CO C OUT gt gt section 6 5 10 and the functions for the binary outputs CO B OUT section 6 5 11 have priority over the settings of the CO LIM1 and CO LIM2 functions ALRM CO LIM2 Limit relay L2 oFF L2 Off Lo L2 X When X is not reached Hi L2 X When X is exceeded Lo L2 WE When WE is not reached Hi L2 WE When WE is exceeded Lo L2 YP When YPID is not reached Hi L2 YP When YPID is exceeded Lo L2 XD When XD is not reached Hi L2 XD When XD is exceeded AbS L2 XD When absolute value of XD is exceeded PA LIM2 L2 L X X INT 100 0 A INT IN2 100 0 A IN2 LI WE Limit for WE
100. s on and off It is specified in percent based on the measuring range Figs 21 and 22 show how the limit relays function based on an example in which the controlled variable X is monitored with a list of the parameter settings The diagrams show that when a variable is monitored for violation of the upper limit the limit relay is activated when the ad justed limit LI WE LI YPID or LI XD is exceeded In the other direction the limit relay is de activated when the variable falls below the limit minus the hysteresis L HYS If a variable is moni tored for violation of the lower limit by the limit relay the limit relay is activated when the vari able falls below LI WE LI YPID or In the other direction the limit relay is deactivated when the limit is exceeded minus the hysteresis L HY An active limit relay is indicated on the display by the B icon for limit relay 1 limit re lay 2 L HYS Controlled variable X lower than the limit CO LIMIT Lo L1 X PA 10 0 C PA L HYS 0 5 L X L HYS Controlled variable X higher than the limit CO LIM1 Hi L1 X PA 90 0 C PA L HYS 0 5 LI X Fig 21 Functioning of limit relays L1 and L2 example illustrating how L1 functions Port 1 74 6493 EN Functions of the compact controller Error signal XD higher than the limit CO LIMT PA LLXD 1 5 LHYS 0 5
101. s variable by binary input FO2 RAMP Started with WIRA by binary input FO3 RAMP Without start condition PA SP FU RAMP TSRW Transit running time I ace UO 29995 WIRA Initial value XWINT 0 0 AWINT Set point W W2 WE switchover oFF CH SP CH SP W W2 WE by binary input F02 CH SP W W2 by binary input 46 6493 EN Functions of the compact controller 6 4 CNTR menu Controller functions This menu enables enables you to determine the control behavior In particular you can deter mine whether the controller is to function with P PD PID or 2 action Furthermore you can configure the feedforward control and additional control functions in this menu 6 4 1 CO C PID Control algorithm In this function the control algorithm and control parameters are configured The controller is set to action by default The proportional action coefficient KP acts as gain on the P and D terms Increasing the proportional action coefficient makes the output amplitude increase in a P controller The reset integral time TN is the parameter of the term TN is the time it takes for the in tegral term during a step response a controller to produce the same change in out put as the P term Increasing the reset time TN causes a reduction in the rate of change in the output when the error is constant The derivative action time TV is the parameter of the D term The derivati
102. setting Open parameter level 1 Every time you open the setup level and before you activate the editing mode for the first time you are prompted to enter the key number If settings are to be made without entering the key number press the enter key again to activate the editing mode Configuration is en abled until you exit the setup level 26 6493 EN LG 6 9 91 level 0 0 INT 100 0 z INI Set control parameters Input INT Set input signal and measuring range 5699 93 92 ij E Y PA 00 0 0 w m 8 Input IN2 100 gt 100 100 0 a 100 0 Set input signal PT kr 71 2 g 21000 Y 2 2 12 m Assign input variable X 1 m X pl i Y In m gt nl lg WE WE 1 2 In2 WE 60 3569
103. t section 5 3 1 Switching between set points section 5 3 2 Switching to the manual mode and changing the control output gt section 5 3 3 5 3 1 Changing the internal set point 3 Select internal set point W or W2 Increase the set point EJ Decrease the set point 5 3 2 Switching between set points 8 Select set point W W2 WE If a set point is not active the set point name W2 or WE blinks on the display C3 Activate the set point The set point name W W2 WE stops blinking The previously active set point is deactivated 6493 15 Operation 5 3 3 Switching over to manual mode and changing the control output B Switch to manual mode The hand icon 3 and the control output Y manipulated variable appear the display Increase the manipulated variable Reduce the manipulated variable Return to automatic mode Return to automatic mode The hand icon is no longer displayed The currently valid set point is shown on the dis play Note If required you can display the control output manipulated variable Y by pressing the key 5 4 Setup level This level enables you to adapt the compact controller to the control task You can adapt preset functions to your specific needs and change parameters The functions are arranged in nine main menus PAR Control parameters IN Input SETP Set point CNTR Controller OUT Output ALRM Lim
104. t in not active 6493 EN 43 Functions of the compact controller 5 X 1 1 WRA 4 14 T l SZWINT 1 TSRW pag i i 5 1 Fog 1 1 1 1 l TE ME r T 1 1 i i m Y WINT Lower measuring range value s X WINT Upper measuring range value TSRW Running time of the set point WIRA Initial value p H Actual running time of the set s point ramp Fig 7 Start set point ramp by binary input SP CO WIRA F03 RAMP Set point continuously active without start condition The ramp function in this setting is continuously active Every change of the set point causes a ramped change of the set point at comparator SP CO even after switchover between set points The diagram shows the set point ramp SP CO during a switchover between set points W W2 additional settings CO SP VA W2 and CO SP FU CH SP initiated by the binary input If the controller is switched to manual mode while the ramp is running the ramp is stopped and the set point at comparator SP CO adopts the current value at comparator X After switching back to automatic mode the ramp continues to run again until reach ing the target set point If the controller starts after the power supply has been interrupted for more than one second in automatic mode the set point at comparator SP CO adopts the target set point
105. three step output F02 WE Input for feedforward control SP FU oFF RAMP Off Set point ramp 1 RAMP Started with actual value by binary SP FU RAMP input FO2 RAMP Started with WIRA by binary SP FU RAMP input RAMP Without start conditions Set point switchover CH SP Off noPA SP VA CH SP 5 W W2 WE by binary input W W2 by binary input F02 CH SP 110 EB 6493 EN The default setting is written in bold Appendix IE ad Land B followed by Parameter Refer to selection Parameter description Value range section W Internal set point Y WINT Lower measuring range value W W2 WRAN Upper measuring range value W W2 Lower adjustment limit W W2 Upper adjustment limit W W2 X WRAN 0 0 AWRAN X 63 1 999 0 0 AWINT WINT 100 0 9999 WINT 0 0 AWRAN WRAN 100 0 W2 Internal set point WRAN 0 0 AWRAN No parameters TSRW Transit time WIRA Initial value 1 10 9999 s 6 3 2 0 0 A WINT parameters 1 2 Value range is identical to that of the assigned input Decimal position depends on the DP function AUX menu 6493 EN 111 Appendix Bo Setting Function Parameter
106. tion setting In2 WE gt section 6 2 5 Assign the input variable WE to the external position feedback SETP menu CO SP VA function setting WE gt section 6 3 1 In manual mode the relays are controlled over the three step output The manual output value Y is used to issue the target position for the three step output 6493 71 Functions of the compact controller Note The target position of the actuator can be limited by the CO Y LIM function using the X Y and parameters travel limitation 1 Manipulated variable reading 1 in operating level as Y in automatic and manual mode 1 in O ANA menu as YPID 1 2 Reading of external position feedback menu as FE CO Fig 20 Three step output with external position feedback and PPM 72 6493 EN Functions of the compact controller OUT CO C OUT On off output or three step output E PP 3 STP Three step output with external feedback and PPM PA C OUT 3 STP KPLI Gain 1 0 1 1 0 100 0 KPL2 Gain Y BO2 KOW ooa IO 00 0 Cycle duration 1 0 10 0 9999 s TYL2 Cycle duration Y BO2 1 0 10 0 9999 s Min duty cycle sos oon IAL Y TYL2 Min duty cycle BO1 rO sit MAA TZ Dead band 0 10 2 00 100 0 6 5 11 CO B OUT Binary outputs BO1 and BO2 for status messages
107. tion of X and WE This function performs a root extraction of the input variables and internally standardizes them between O 100 X 2 10 X and WE 10 WE The root extraction function is used for flow rate measurement by an orifice plate assembly to calculate the flow rate from a measured differential pressure IN CO SQR Root extraction of X oFF X Off on X On Root extraction of WE oFF WE Off on WE On 6 2 8 CO FUNC Function generation of X and WE The function generation is used to revaluate an input signal to allow further processing This function makes it possible to adapt auxiliary reference or equivalence variables inherent in measurement or industrial processes for the control circuit or to perform a linearization This can be performed when the correlation between the input signal and the required new output 6493 EN 37 Functions of the compact controller signal is known i e due to scientific laws empirical data or measured data Examples include the correlation between steam pressure and temperature Seven coordinates exist for function generation Each coordinate is defined by an input value and an output value Numerical values e g in or bar are entered The parameters MIN and MAX are used to determine the measuring range of the output sig nal If K1 Y or K7 Y do not agree with MIN and MAX the output values for the func tion generated signal which are below or above these l
108. to default settings CO KEYL Lock control CO VIEW Top bottom viewing angle of display CO FREQ Power line frequency ripple CO DP Decimal separator CO TUNE Start up l O menu Process data 2 CO CIN Firmware Serial number CO ANA Read analog inputs and outputs CO BIN Read binary inputs and outputs ADJ Calibration of analog inputs and analog output Typical Temperature esa 7 2 8 1 10 11 11 1 11 1 11 2 11 3 11 4 Contents Pressure control ERETYAO M ee ea dees 91 Star Up vow oa euh RP gd s X e Re Ros cR Y SEU 95 Tuning according to the Ziegler and Nichols method 96 Fault alarms 100 Infrared interface 101 Appendix us bP G gg 103 Technical 103 Configuration list 106 Configuration 2 124 Values for resistance thermometers 2 129 Used abbreviations sar e serras reseput oE 130 ee RERUM S A 131 Firmware revisions 4 01 old 4 02 new Intern
109. ure 77 S Safety instruclions 6 Set point adjusting 15 switching internal internal internal ex ternal 42 Set point 41 Set point switchover 45 Setuplevel 12 14 16 Signal failure changeover to manual mode 36 c sue 95 99 oi eee 80 tuning Ziegler and 5 96 Status 5 73 T Technical data 103 105 Three step output 62 Transmitter supply 9 electrical connection 9 TROVIS VIEW order 7 6493 EN 133 134 6493 6493 135 SAMSON MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 6493 EN 2015 04
110. variable YPID target position and the feedback signal Y calculated actual position Depending on the dif ference YPID Y the position pulses are generated as follows If the difference is greater than TZ 2 the pulse Y activates the relay If the difference is greater than TZ 2 the pulse Y activates the relay BO2 Ifthe difference is smaller than the amount TZ 2 XSDY both relays are deactivated Fig 16 Three step output with internal feedback manual mode Manipulated variable reading in operating level as Y in automatic mode in O ANA menu as YPID 2 Reading of internal position feed back in operating level as Y in 64 6493 EN OUT Functions of the compact controller If the manipulated variable is equal or greater than 100 the pulse Y causes the relay BOT to be activated constantly If the manipulated variable YPID is equal or smaller than 0 the pulse Y causes the relay BO1 to be activated constantly In manual mode the relays are not controlled over the three step output The relay BOI Y can be actuated by pressing the Il key and the relay BO2 Y by the key in manual mode Note on control signal limitation O Y LIM see section 6 5 3 The X Y parameter must nof be set to be greater than 0 0 and the parameter must not be set to be smaller than 100 0 5 This ensures that the three step output can bring the actuator into th
111. ve action time TV is the time it takes the rise response of a PD controller to reach a certain output earlier than it would with just its P term Increasing the derivative action time TV causes an increase in output amplitude when the error rate of change is constant After ramped error changes a larger derivative ac tion time TV causes the D term to continue to have a longer effect The derivative action gain TVK1 is a gain factor for the derivative term The operating point Y PRE of the P or PD controller determines the output value which is fed to the controlled system when the process value is the same as the set point The dead band error DZXD allows you to define the range of the signal error Within this range the effective error signal is zero and the control signal does not change The dead band can be used to calm the control loop by suppressing a frequently change of the control valve at the operating point Limiting the error signal Using the X DZXD and ADZXD parameters the effective error signal can be limited for calculating the control signal The X DZXD parameter is used to define the lower limit of the negative error signal while the ADZXD parameter is used to define the top limit of the positive error signal 6493 EN 47 Ni 6679843 4IND 6 ayy jo suo puni

Mounting and Operating Instructions EB 6493 EN

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