Automation System TROVIS 6400 Compact
Contents
1. Gradient AW t cel sec w2 Bigi Xd Desired time ramp for setpoint W Comparator W AW 1 Tw In_ X W In Tw W W1 orW2 WE We or Setpoint ramp ERS eres EE 2E AW t i l l In_ t gt WE 60 SPr Ramp time t sec Boiler temperature T cel t sec Twi 60 Setpoint W l l l l l TOP WM NR Ramp on Fixed value Ramp off l Ramp Fixed value DS l X tracking on Actual value X w x l l I SD re ren st I W j Pip c I Er i t sec Binary input i SP 4 On Off i t sec Start of ramp by setting SPr or NETZ on or binary input OFF Fig 7 Setpoint ramp SPr 23 5 Switching outputs Y1 and Y2 Depending on how configuration block Y was selected the output signal is defined in TROVIS 6494 as either a three step or on off output signal and or limit contacts Continuous action Positioner Switching outputs controller section A YPID m id EM VEI YI ess _ VA PID T 2 1 2 YR D Y 1 Internal feedback Motor operating time t1 X Value for recorder input X Recorder Y 12 O 4 to 20 mA Fig 8 Switching outputs 24 5 1 Three step controller with internal feedback Y2. Fig 6 Front view Controlled variable display top display Controlled variable x sometimes referred to as the Process Variable PV is displayed in the operating level The value of the selected entry option is can be viewed in the parameteriza tion and configuration level Setpoint SP display The current setpoint is displayed in the operating level The display mode can be modified in the following sequence by actuating the operating key 7 setpoint W1 control deviation error XD output variable Y setpoint W2 Configuration blocks and parameters values are presented in both the configuration and parameterization levels resp Control deviation Whenever xd is greater than 0 9 or less than 0 9 the red LED light emitting diode il luminates Display of switching outputs Y1 and Y2 Two red LEDs display indicate the circuit state of the three step on off controller output or the limit alarms Cursor keys Allncrease displayed value 7 Decrease displayed value Function in the operating level standard operation After selecting setpoint W1 or W2 modify setpoint directly acknowledge the value using ENTER key 8 In MANUAL operating mode Direct adjustment of output signal Y Function in the parameterization configuration level Selection of the individual entry options in both directions Adjustment of the related numeric value in the top display 1 MANUAL AUT
3. 1 Inserting on pivot and turning A 3 Screw tight Fig 3 Assembly 3 Electrical connections The easy to install compact controller is equipped with plug type connectors snap in contacts for lead sizes 0 3 to 0 8 mm and an insulating diameter of 1 3 to 2 4 mm or screw terminals for lines 0 5 to 1 5 mm When connecting the electric leads note the pertinent VDE 0100 regu lations and the currently valid regulations mandated by the country where the controller is in tended for use Wiring information The signal and sensor leads are to be isolated from those of the controller and power supply To avoid measuring errors when radio interference is present use shielded lines for signals and sensors The power supply lines of each controller are to be led separately to the corresponding distribut ing bus bar Suppress contactor circuits located in the vicinity against interference using an RC element Terminals X1 Snap in Contacts Power supply Three step switching output 10010253 Va c 2x limit contacts TRIAC fora current 20 5 A requires or 24V a c d c contactors or relays X2 o o An An lt B 2 B 2 C13 3 Ec DA4 ES Eb Note F6 zz Y1 or Y2 can only be operated with G 7 G 7 HE HIB a c voltage Note correct phase o o connection of power supply T
4. 1 The three step controller incorporating internal feedback is selected in the configuration level with configuration switch Y 7 In this configuration scheme switching output YT is then active when the difference between the calculated Ypip signal and the internal feedback is positive Switching output Y2 is always active when this difference is negative With dead band td a range neutral zone can be defined in which the switching signal is still not fo be active Dead band td applies in equal proportions for positive and negative output signals 50 each The hysteresis which can be commonly set for both switching points is set as a percentage using parameter fH Example Ypip 20 YR 16 Y Ypp YR 2 2075 1626 2 A 96 In a situation where the set dead band td 10 Y1 is not active Reason 5 dead band for positive output signals is not exceeded If differential gap tH is set with 1 then YT is only active when Y gt 5 Yl is then disabled whenever Y 4 The internal feedback is to be adapted in seconds to the installed actuator using parameter t1 motor operating time The internal feedback simulates the behaviour of the installed actuator By inserting an internal feedback the discontinuous action controller output takes on a beha viour resembling that of a continuous controller output quasi continuous controller output A Manual PE v VA N Yo 5 N from co
5. a e 0 pem l 2 145 days sauu T se L 4A 5 1 duioJ jurodjeg 7 ISA 1 co p 1 1 a HA njpa Hosa i 1 jndyno Ajejoc d je d _ gt du ICON i A i PHA 34 po d z 1 OA i pa l N l l i Is s S vera 0 X40A O ZM LM Aa Julodyas dS yu oz o Eu y x eee prt ee ojoun pnd nO Er ue E uoypoypow jurodies Jo OH uowqiuid Fig 1 Functional structure of controller 1 2 Technical data Input options Controlled variable x d c current signal A 0 to20mA Ri 500 d c voltage signal 2 0 to 10V Ri 100 ko Resistance thermometer Pt 100 three wire circuit Measuring ranges 100 0 to 400 0 C 30 0 to 150 0 C Resistance thermometer Ni 100 three wire circuit Measuring ranges 60 0 to 180 0 C 20 0t0 90 0 C External changeover of the setpoint Binary input for selection of setpoint W1 W2 with 24 V d c Signal 0 V 2 W1 24 V gt W2 select using SP or external restart of the setpoint ramp Controller outputs Standardized output signals Standardized current signal 4 0 to 20 mA load RB lt 650 Q Switching outputs Y1 and Y2 a c voltage contacts 24 to 250 V a c 0 5 A CAUTION Never apply d c voltage Power supply 100 to 253 V a c or optionally 20 to 30 V AC DC 48
6. disabled the setpoint is modified with the set speed until the set value is reached Inhibit HOLD modification of the setpoint SPH 0 W1 W2 can be modified 1 WI can be modified W2 inhibited 2 W2can be modified W1 inhibited 3 W1 W2 inhibited Lock HOLD the MANUAL AUTOMATIC key YH 0 Switchover to MANUAL AUTOMATIC permitted with key 1 Switchover to MANUAL upon sensor breakage safety output value YSt applied 2 Switchover to MANUAL AUTOMATIC locked using key Select controller output Y 0 Continuous controller output with limit contacts Y1 and Y2 1 Three step controller and recorder input for controlled variable x 2 Continuous controller output is available as recorder input for controlled variable x with limit contacts Y1 and Y2 Operating direction Yr Setting O Inverse lt gt Increasing x decreasing Y or decreasing x increasing Y 1 Direct Increasing x increasing Y or decreasing x decreasing Y Select the current range of controller output Y with YO 0 Oto20mA 1 Ato20mA Safety output restart value YSt Should the sensor line break this is used as the restart value following power failure If the senor line breaks the controller output is automatically set to specified value Yst The controller output value can be set from 10 0 to 110 0 of the output variable range ForY 1 YSt 0 095 5 Signal is output YSt gt 100 0 gt Signal is output Y
7. the MANUAL AUTOMATIC key YH 20 Contents Page Select controller output Y 20 Operating direction Yr 20 Select the current range of controller output Y with YO 20 Safety output restart value YSt 21 Limit alarm condition for switching output Y1 21 Switching output Y1 as break or make contact YIC 21 Limit alarm condition for switching output Y2 21 Switching output Y2 as break and make contact Y2C 22 Adaption self tuning AdP 22 Enter code numbers CPA and CCO 22 Code number for servicing 23 Figure setpoint ramp SPr 23 5 Switching outputs Y1 and Y2 24 5 1 Three step controller with internal feedback Y 1 25 5 2 Limit contacts 26 5 2 1 General definition 26 5 2 2 Assignment of the limit alarm conditions for switching outputs Y1 and Y2 27 5 2 3 Monitor output signal Y 27 524 Pulse modulated on off controller output at switching output Y1 and or Y2 28 5 2 5 On off pulse modulated controller output with limit alarm 28 5 2 6 Two pulse modulated on off switching outputs 28 6 Start up procedure 29 EEPROM version 29 6 1 Configure the different controller outputs 29 6 1 1 Continuous action controller Y 0 29 6 1 2 Three step controller with internal feedback Y 1 30 6 1 3 Controlled variable x as recorder input Y 2 30 6 2 Optimize the control parameters 31 6 3 Adaption self tuning 33 6 4 Checklist 34 Figure depicting front view see folding page on back cover 36 1 Description TROVIS 6494 is a digital controller
8. Clocked controller output This corresponds to tmin ono od 5 2 5 On off pulse modulated controller output with limit alarm In this type of output circuit a switching output Y1 or Y2 is pulse modulated in either a positive output signal direction Y1 or Y2 8 or negative output signal direction YI or Y2 9 In this case the period of time t1 and the minimum pulse duration td is set for the pulse modulated controller in the parameterization level The other switching output is activated upon an alarm condition The limit alarm condition is set with configuration switch Y1 1 to 7 controller output Y1 or Y2 1 to 7 controller output Y2 This limit condition refers to the parameter 1A for Y1 or 2A for Y2 set in the parameterization level In addition the differential gap must be set with parameter IH controller output Y1 or 2H controller output Y2 5 2 6 Two pulse modulated on off switching outputs In order to achieve two pulse modulated controller outputs which are effective with positive and or negative output signals Y configuration switch Y1 8 9 and Y2 8 9 must be set In this case the period of time t1 and the minimum pulse duration td are simultaneously set for both pulse modulated controller outputs Example Configuration switch Y1 8 sets the pulse modulated two point switching output which is set by positive output signal Y Configuration switch Y2 9 sets a pulse modulated switching output for neg
9. Controller input options include the following Pt 100 resistance thermometers Ni 100 resist ance thermometers and standardized current voltage signals The controller s command variable to be called the setpoint SP in the remainder of this text for reasons of conformity can be selected between setpoint W1 and setpoint W2 via a key or by means of a binary signal Bumpless transfer in the respective operating mode MANUAL or AUTOMATIC is facilitated by means of the MANUAL AUTOMATIC key 1 1 Version This compact controller is delivered in panel mount design according to DIN 43 700 dimen sions of front frame 48 mm x 96 mm as the following versions Universal input options Ni 100 or Pt 100 resistance thermometer in three wire circuit standardized mA V signals Standard controller output Continuous on off three step limit contact Power supply 100 to 253 V AC TROVIS 6494 0111 20to 30 V AC TROVIS 6494 0121 Connection Crimp contacts or optional screw terminals This manual applies to controllers implementing firmware version 1 00 or later WARNING Assembly commissioning and operation of this controller may only be performed by experienced personnel To X 404 zo SJDDJUOD pwu L A 10 i i 49 9 lbuywoinv rap d reap T sayy jouBiq Bunpiung
10. Y2 0 Only the assignment options for limit alarm contact Y1 are described in the following section Note that limit alarm contact Y2 functions in the same way as that of contact Y 1 Input variable X can be monitored to determine if a limit value is fallen short of Y1 1 or exceeded Y1 2 There is also the possibility of monitoring controlled deviation XD In this case it is possible to monitor the controlled deviation to determine if it is fallen short of configuration switch Y1 3 or exceeded configuration switch Y1 4 When XD is monitored with configuration switch Y1 5 the value can be evaluated to identify whether or not XD has been exceeded Likewise controller output Y can be monitored to determine if it has fallen short of Y1 6 or exceeded Y1 7 The method of monitoring output signal Y is described in the next section 5 2 3 Monitor output signal Y Output signal Y can be monitored to determine if it the limit value is exceeded in either direction Apart from the pure two output used to determine if a limit value is exceeded in either direction a three step action can be implemented when configuration blocks YI and Y2 are appropri ately set With the combination Y1 6 and Y2 7 or Y1 27 and Y2 6 a three step switching output is implemented which uses fixed switching points No internal feedback is applied in this case In this type of configuration either a P or PD algorithm set P d dP is recommended W
11. cursor keys 5 and V such that the control valve slowly opens and xd becomes zero Increase P value until the controlled system inclines to oscillate Setd value to 1s and increase until oscillations cease Slowly increase P value until oscillations resume Increase d value until no more oscillations can be determined Proceed a few times in the same manner until oscillations cannot be suppressed any more Slightly decrease P and d value so that the controlled system comes to abatement again Decrease value until the plant inclines to oscillate again and increase again until oscilla tions cease 6 3 Adaption self tuning For optimum configuration of control loops the characteristic values of the controlled system must be known Self tuning is an automized function used to record and optimize the dynamic system characteristics Self tuning of TROVIS 6494 involves evaluation of the measured transfer function from which the ideal control parameters are calculated Before conducting the adaption the control loop should assume a calm state for five minutes with an controller output value under 80 The desired control mode PI or PID response must be selected prior to conducting the adap tion PI control mode is selected with the control parameters P 0 for integral action com ponent and dP 0 PID control mode implies use of control parameters P O and dP 0 for I integral action component and
12. for display purposes Example x input 01 20 mA In 2100 0 In 300 0 x 50 10 mA display 200 0 Decimal point Ind for In 2or 3 The decimal point and the controlled variable can be selected by the user in the bottom display and top displays resp 0 No decimal point e g W12 132 1 Onedecimalpoint e g W1 13 2 2 Twodecimal points e g W1 1 32 3 Three decimal points e g W1 0 132 When input signal of resistance thermometers Pt 100 or Ni 100 is selected Ind 1 15 set i e a decimal point is shown Select the current or voltage ranges of controlled variable x with InO 0 Oto20mA or OtolOV Depending on the selection 1 4t020mA or 21 010V Depending on the selection inapplicable for Pt 100 or Ni 100 Unit of temperature Int Temperatures can be displayed in either Celsius or Fahrenheit 0 C 1 Any change of this configuration block causes the new measuring range limits to be stored Example In 0 Measuring range In 30 0 and In 150 0 in C with Int 0 Change the unit oftemperature to Fahrenheit with Int 1 The new measuring range is now modified according to the limits below In_ 22 0 and In 302 0 in F Digital filter InF Digital filter InF has the function of filtering analog input x Range of values 0 0 to 120 0 sec with 0 0 disabled e g for fast controlled systems Select the input circuitry of the D derivative action component with dl The di
13. integrating many sophisticated functions into a single com pact module used to automate plants used in industrial applications and process engineering Its well thought functional design which takes user needs into mind allows diverse control cir cuit arrangements to be configured TROVIS 6494 can be effectively used in a wide range of applications as a either a continuous action controller on off two step controller or three step controller with the option of P proportional proportional plus integral PD proportional plus derivative or PID proportional plus integral plus derivative action Self tuning a standard option uses the built in intelligence capabilities to automatically deter mine and set the appropriate control parameters Operation of this advanced controller is designed according to the concept of user friendliness and uses the following three level operating structure 1 operating level standard operation 2 parameterization level and 3 configuration level The first level the operating level contains visual displays for standard control operation and can be accessed at any time whereas the parameter and configuration levels are protected by user definable code numbers Functions in the second level the parameterization level include modification of control parameters and optimum adaption to the controlled system Selection of controller functions is facilitated in the third level the configuration level
14. to 62 Hz 7 V 7VA Permissible temperature Ambient 0 to 50 C Shipping and storage Oto 70 C Measuring accuracy Linearity error Zero error Span error mA V Pt 100 Ni 100 0 2 0 2 0 2 Temperature effect Zero error Span error Pt 100 Ni 100 0 3 10 K 0 3 10 K mA V 0 2 10 K 0 2 10 K Utilization category Humidity rating F according to DIN 40 040 Degree ofprotection IP 54 front side IP 20 encapsulation Power failure All control parameters and configuration blocks are stored in a non volatile EEPROM protected against power down i e no battery design Weight 0 3kg 2 Installation TROVIS 6494 is smartly engineered as a panel mount unit the front dimensions of which com pactly measure 48 x 96 mm A panel cut out of 45504 x 92 08 mm is to be fabricated for as sembly of the plastic enclosure After sliding the controller in the panel cut out the supplied clamps depicted in Fig 3 are to be locked in place at the top and bottom in the accommodating pins of the enclosure A screw driver can consequently be used to turn the threaded rods clamp ing the controller s front frame against the panel j 123 4 84 111 4 37 48 1 89 N 2 9 o Fig 2 Dimensions in mm inch Front Front 2 Pivot Lock in d 8 place we ES E m im
15. 0 0 0 0 1A Limit value Y1 Acc to alarm cond 0 0 IH Differential gap Y1 0 1 to 100 0 1 0 2A Limit value Y2 Acc to alarm cond 0 0 2H Differential gap Y2 0 1 to 100 0 1 0 fl Period 11099995 120 Motor operating time 11 9999 s 120 td Dead band Y 1 0 1 to 100 0 1 0 Min pulse duration 0 1 to 100 0 2 0 fH Hysteresis 0 1 to 100 0 1 0 34 Checklist Device Plant Process designation Date Selection Designation Rangeofvalues Factory Start up option default values block modifications Configuration level In Type of input signal 0105 1 In Min measuring range limit X Depending on In 100 0 In Max measuring range limit X Depending on In 400 0 Ind Decimal point 0103 1 Ind Range selection current voltage Oor 1 Int Unit of temperature C F Oor 1 0 InF Digital filter 0 0 to 120 0 s 0 5 di D action component Oor 0 SP Selection of setpoint SP Oto 4 0 SPr Setpoint ramp Oto 9999 s 0 SPH Inhibition of setpoint modification Oto 3 0 YH Lock MANUAL AUTOMATIC key 0102 0 Y Select controller output 0102 0 Yr Operating direction Oor 1 1 Yo Select the current range output Oor 1 1 YSt Safety output restart value 110 0t0110 0 10 0 Yl Limit alarm condition 0109 0 YIC Make or break contact Y1 Oorl 0 Y2 Limit alarm condition 0109 0 Y2C Make or break contact Y2 Oorl 0 AdP Adaption O
16. Automation System TROVIS 6400 Compact Controller TROVIS 6494 DSC Edition June 1994 Mounting and operating instructions EB 6494 E Contents Page 1 Description 4 1 1 Version 4 1 2 Technical data 6 2 Installation 7 3 Electrical connections 8 4 Operation 10 4 1 Control panel displays and operating elements 10 4 2 Operation of the three levels 12 4 2 1 Operating level 12 Modify setpoint W1 12 Display sensor line breakage 13 4 2 2 Parameterization level 14 Determine and modify the control parameters 14 Open the parameterization level 14 Proportional action coefficient P Kp 15 Integral action reset time I Tn 15 Derivative action rate time d Tv 15 Derivative action rate gain dP 15 Output variable limits Y and Y 15 Working point YP 15 Limitvalues TA and 2A 15 Differential gap 1H and 2H 15 Duration of switching period and motor operating time t1 16 Dead band neutral zone td 16 Hysteresis th 16 4 2 3 Configuration level 17 Determine and modify controller functions 17 Open the configuration level 17 Select input signal In 18 Measuring range limits In and In 18 Decimal point Ind 18 Selectthe current or voltage ranges of controlled variable x with InO 18 Unit of temperature Int 19 Digital filter InF 19 Select the input circuitry of the D derivative action component with dl 19 Select setpoint SP 19 Setpoint ramp SPr 20 Inhibit HOLD modification of setpoint SPH 20 Lock HOLD
17. D derivative action component Select the operating direc tion and the controller output prior to proceeding with the adaption The adaption option is selected in the configuration level with configuration block AdP Con figuration switch AdP 1 is used to set an adaption for optimum behaviour when the disturb ance z is instabile After exiting the configuration level the controller assumes MANUAL oper ation Controlled variable x can be viewed in the top display output variable y can be viewed in the bottom display Now the adaption is ready to be started by means of the MANUAL AUTO MATIC key 6 If not desired de select in the configuration level with configuration switch AdP Ousing the yellow ENTER key 8 Running the adaption procedure is accomplished by actuating the MANUAL AUTOMATIC key If the current controller output value is less than 80 no adoption is initiated As soon as the adaption has been started all keys except the MANUAL AUTOMATIC key are locked until the adaption has completed By starting the adaption routine a 20 step change of output variable y is controller output in a positive direction which informs the controller of a step response which it uses to calculate the ideal control parameters The LED in the MANUAL AUTOMATIC key continues to flash until the control parameters are calculated and stored If necessary the adaption procedure can be aborted at any time using the MANUAL AUTO MATIC key Afte
18. OMATIC changeover When selecting manual adjustment to either controller output Y or switching outputs Y1 and Y2 the yellow LED located in the key illuminates Using the MANUAL AUTOMATIC key the controller can be bumplessly switched over from MANUAL to AUTOMATIC operation or vice versa The MANUAL setting allows the user to directly operate the connected control valve Con troller output value Y can be modified using cursor keys 5 j and V In MANUAL opera ting mode the controller output value can be viewed in the bottom display panel Operating key Function in the operating level standard operation Switch over to select the controller variables in one direction following sequence setpoint W1 XD output variable Y setpoint W2 see section 4 2 1 Function in the parameterization configuration level Return to the operating level standard operation from the current levels ENTER key Function in the operating level standard operation Accept and store the numeric value specified for setpoint W1 or W2 Access the code num bers for parameterization level PA and configuration level CO To acknowledge the code number entered and simultaneously enter the selected level Function in the parameterization configuration level Selection of the entry options flashes when selected Accept and store the numeric value entered Changeover between setpoints W1 and W2 Choice between setpoint W1 and W2 When set
19. Stin the range from 0 0 to 100 0 no signal is output Limit alarm condition for switching output Y 1 For Y 1 Y1 is inactive and cannot be modified The alarm condition refers to the numeric value of the value entered under parameterization op tion 1A 0 Switching output Y1 is not set 1 Contact Y switches when x falls below the limit value 2 Contact Yl switches when x exceeds the limit value 3 Contact Yl switches when xd falls below the limit value 4 Contact Y switches when xd exceeds the limit value 5 Contact Yl switches when Ixdl exceeds the limit value 6 Contact Y1 switches when y falls below the limit value 7 Contact Yl switches when y exceeds the limit value 8 Clocked controller output positive 9 Clocked controller output negative Switching output Y1 as break or make contact YIC 0 Make NC contact 1 Break NO contact Limit alarm condition for switching output Y2 For Y 1 Y2 is inactive and cannot be modified The alarm condition refers to the numeric value of the value entered under parameterization op tion 2A 0 Switching output Y2 is not set 1 Contact Y2 switches when x falls below the limit value 2 Contact Y2 switches when y exceeds the limit value 3 Contact Y2 switches when xd falls below the limit value 4 Contact Y2 switches when xd exceeds the limit value 5 Contact Y2 switches when xd exceeds the limit value 6 Contact Y2 switches when y falls b
20. ative output signals Y Pulse modulated on off controller outputs are suitable to control heating cooling applica tions 28 6 Start up procedure EPROM version After switching on the power supply the controller displays the current EPROM version installed for a few seconds in the bottom display panel e g 1 00 Device type 6494 is displayed in the top display panel note important information to be specified when servicing or placing customer inquiries IMPORTANT Always proceed in the following order 1 configuration 2 parameterization 3 optimiza tion same order as described in this manual 1 Configuration After power is supplied to the controller and all inputs outputs have been connected the controller must be adapted tuned to the control task to be solved by determining functions in the configuration level For this purpose individual configuration blocks are to be configured and set as detailed in section 4 2 3 2 Parameterization Whether the controller shall operate as a P Pl PD or PID controller must be determined in the parameterization level Even in this case all parameterization options must be set section 4 2 2 3 Optimization Control parameters P and d for adaption to the controlled system must be set and modified in the optimization procedure section 6 2 P I and d represent Kp Tn and Tv proportional reset and rate resp 6 1 Configure the different controller outputs The differen
21. een entered and stored first Use cursor keys 5 A and V to select the desired configuration block If the yellow ENTER key 8 is subsequently pressed the block chosen flashes in the bottom display panel Now use cursor keys 5 and V to set the desired value or selection block in the top display panel Accept and store this entry by pressing the ENTER key 8 After modifying a value and actuating the ENTER key 8 the controller operates in MANUAL mode Use cursor keys 5 A and V to advance to the next configuration block or press the operating key 7 to return to the operating level The MANUAL function is activated and switch was made to output variable Y in the bottom dis play Switch can be made to AUTOMATIC operation by actuating the MANUAL AUTOMATIC key 6 Open the configuration level Press the yellow ENTER key 8 PA appears in the bottom display panel Press cursor key A CO appears in the bottom display panel Code number Bu O appears in thetop display panel Press ENTER key 8 CO flashes in the bottom display panel Use cursor keys 5 V and A to set the specified code number in configu ration block CCO if no number was entered in CCO the factory default 0 remains in force Press the ENTER key 8 to confirm the code number and open the configu ration level The first configuration block In appears If the wrong code number is entered the co
22. elow the limit value 7 Contact Y2 switches when y exceeds the limit value 8 Clocked controller output positive 9 Clocked controller output negative 21 22 Switching output Y2 as break and make contact Y2C 0 Break NO contact 1 Make NC contact Adaption self tuning AdP 0 Off no adaption 1 Ready for adaption optimize following disturbance z Adaption is an auto tuning function implemented in the start up phase which allows the controller to independently adapt tune itself to the condi tions of the controlled system and calculate the optimum control par ameters For those controlled systems which are critical and extremely fast those in which the control valve is not adjusted abruptively configuration block is to be set to AP 0 and hence disabled see also section 6 3 Enter code numbers CPA and CCO Code numbers CPA and CCO CPA Code number of the parameterization level CCO Code number of the configuration level Range of values 0 to 9999 Procedure for entering modifying the code number Press yellow ENTER key 8 PA appears in the bottom display Press cursor key 5 j CO appears in the bottom display Press ENTER key 8 CO display flashes Default code number 0 is dis played in the top display panel If a code number has already been defined enter this number using cursor keys 5 Aland V subsequent modification is then possible Press ENTER key 8 The config
23. erminals X2 Controller input controlled variable x Pt 100 Ni 100 A 0 to 20 mA 2 0 to 10V lc Screw terminals m Pi i i par Back DE mA V j o o XI Binary input BE Controller output output signal y 0 24V continuous 4 0 to 20 mA S E 218 on A OT N ie Toc T mA Oo O Note When using a three step switching output or limit contacts the continuous controller output is available as analog output for controlled variable x Fig 4 Terminal assignment Pt 100 SN y x Recorder Ni 100 i 1 4 0 to 20 mA 1 Al PE l 1 een of E A PE CDM pm DE PET Dg a L NPE i Lee I 1 Y1 and Y2 can defined by the user for use as limit values or motor drive Fig 5 Diagram of connections WARNING Always disconnect the power supply lines prior to plugging removing the plug connectors If this is ignored the glass fuse Type T63 mA 250 V order no 8834 0298 con tained on the power board in the device may be required to be exchanged 4 Operation 4 1 Control panel displays and operating elements 3 Oxp A J 5 Ovi ny Biv Oy2 as Ey 8 9w2 PU 6 E
24. f control parameters are to be set the parameterization level is opened after the code number has been entered and accepted Select the desired parameterization option using cursor keys 5 Aland V If the yellow ENTER key 8 is consequently pressed the selected option flashes in the bottom display panel Use cursor keys 5 Aland V to set the desired value in the top display press the ENTER key 8 to accept and store this value Advance to the next parameterization option using cursor keys 5 A and V or return to the operating level standard operation by pressing the operating key 7 Open the parameterization level EBEN Press yellow ENTER key 8 PA appears in the bottom display panel code number 0 appears in the top display panel Press ENTER key 8 PA flashes in the bottom display panel Enter the specified code number if no number was entered the factory de fault value 0 is assumed in configuration block CPA using cursor keys 5 VlandIX Press ENTER key 8 again to open the parameterization level P appears as the first control parameter in the display If the wrong code number is entered the controller returns to the operating level The following parameterization options listed can be selected and modi fied using cursor keys 5 Aland V Proportional action coefficient P Kp P action component of the co
25. fferential action component ofthe controller can be either directly ap plied to controlled variable x or behind the setpoint actual reference junc tion of xd Fig 1 0 Tox input 1 Tocontrol deviation xd Select setpoint SP Switching between setpoints W1 and W2 is accomplished either by actua ting the W1 W2 key 9 or applying an external signal 24 V via termi nal connections 2 and B of the binary input Selection and combination op tions of the setpoints are determined via configuration block SP 0 WI active W2 disabled 1 W1 W2 Switchover only permitted via key 2 W1 W2 Switchover permitted by either key or binary input binary input has priority i e BE 0 Switchover permitted via key BE 1 Switchover not permitted via key W2 is active 3 Switchover permitted only via binary input 4 Restart the setpoint ramp via binary input BE beginning from existing x value W2 is disabled 20 Setpoint ramp SPr explanatory Fig 7 see page 23 The setpoint ramp causes a modification of the setpoint over a defined time Range of values O to 9999 sec The time in which a modification of the setpoint by 100 should be set This time ramp is effective for every modification of setpoint To disable this op tion set the parameter to 0 In this context note configuration block SP 4 which performs an x track ing w x by enabling the binary input of the setpoint After the input is switched back
26. mi nates setpoint WT is selected in the display The range of values depends on the measuring range limit and In specified for controlled vari able x Any decimal points are displayed analogous to the controlled vari able display Modify setpoint W1 The displayed value can be modified to the desired value using cursor keys 5 land VI After a single press of a cursor key 5 the display of the setpoint flashes in dicating that a new value may now be set Afterwards actuate the ENTER key 8 to accept and store the value which is then retained in non volatile memory even in event of power loss If the new setpoint is not to be stored or activated return can be made to the operating level standard operation by means of the operating key 7 If other controller variables are to be displayed in the bottom display panel the operating key 7 must be actuated each time In the sequence of the defined display the following control parameters are displayed in the bottom display in conjunction with a yellow LED 10 Control deviation error xd xd w x The numeric value of the control deviation is displayed in the bottom display panel In connection with this yellow LED XD illuminates for the display mode control deviation 10 The displayed value is specified as a percent Output variable y The numeric value of the output variable is displayed as a percent in the bot tom display panel The range of
27. nd stored by pressing the yellow ENTER key 8 P controller Inthe parameterization level specify control parameters with P 0 1 1 0 offand d 0 off n the operating level set the setpoint to the desired value and then modify the output vari able using cursor keys 5 A and V such that the control valve slowly opens and xd becomes zero Switch to AUTOMATIC Increase P value until the controlled system inclines to oscillate Slightly decrease P value until no more oscillation can be determined Correct offset steady state deviation by setting working point YO as indicated below In the steady state of the plant read the current value of output variable y and enter as value for working point YP in parameterization option YP IMPORTANT Every change of setpoint also causes a change of working point YP Pl controller In the paratmerization level specify control parameters with P 0 1 I 2000 maximum and d 0 off n the operating level set the setpoint to the desired value and then modify the output vari able using cursor keys 5 A and V such that the control valve slowly opens and xd becomes zero Switch to AUTOMATIC Increase P value until the controlled system inclines to oscillate Slightly decrease the P value until no more oscillation can be determined Decrease value until the system inclines to oscillate Slightly increase value u
28. ntil no more oscillation can be determined 31 PD controller In the parameterization level specify control parameters with P 0 1 0 offand d 0 off and set derivative action rate gain dP normally to a value between 5 and 10 In the operating level set the setpoint to the desired value and then modify the output vari able with using cursor keys 5 and V such that the control valve slowly opens and xd becomes zero Increase P value until control system inclines to oscillate Setd value to 1s and then increase until oscillations cease Increase P value until oscillations resume Increase d value until no more oscillations can be determined Proceed a few times in the same manner until oscillations cannot be suppressed any more Slightly decrease P value and d value so that the controlled system comes to abatement again Correct offset by setting working point YP as indicated below In the steady state of the plant read the current value of output variable y and enter as value for working point YP IMPORTANT Every change of setpoint also causes a change of working point YP PID controller 32 In the parameterization level specify control parameters with P 0 1 I 2000 and d 0 off and set derivative action rate gain dP to a value normally between 5 and 10 In the operating level set the setpoint to the desired value and then modify the controller out put value with the
29. ntinuous action T controller section Y2 i p VA LI Comparator Yr YR MANUAL Y2 AUTOMATIC J key Internal feedback Motor operating time t1 X Value for recorder input X Recorder 0 4 to 20 mA Fig 9 Three step switching t1 Operating time of the implemented actuator in seconds td Dead band as a percentage tH Hysteresis as a percentage For the selection of three step controller providing internal feedback Y 1 configuration blocks Y1 and Y2are insignificant and cannot be altered 25 5 2 Limit contacts Y Oor 2 5 2 1 General definition Each limit contact Y1 and Y2 can independent of one another be assigned a value This value can be monitored to determine whether it is exceeded in either direction Limit contacts are as signed using configuration block Y1 switching output YT and configuration block Y2 switch ing output Y2 The limit value is set in the paramterization level as a percentage using parameter IA or 2A This is set absolutely assignment to input signal X or as a percent assignment to an internal signal Y or XD using parameter TA or 2A resp A limit contact similar to an on off controller output contains a differential gap which is set as a percentage with parameter or 2H referring to the range of the monitored variable The limit alarm contact basically contain
30. ntroller Range of values 0 1 to 100 0 Integral action reset time I Tn l action component of the controller Range of values O to 2000 s disabled when set to O Derivative action rate time D Tv D action component of the controller Range of values 0 to 2000 s disabled when set to 0 Derivative action rate gain dP gain of the D action component Range of values 0 0 to 10 0 D action component only enabled when a value gt 0 is specified for dP Output variable limits Y 110 025 0Y Y Y_to 110 0 This limit is ineffective for MANUAL function Selection of the output variable range determines the lower limit start and upper limit end value of the output signal range The numeric values are displayed as percents of the selected controller output range Example YO 0 current range 0 to 20 mA Y_ 20 Y 80 controller output Y 4 to 16 mA Working point YP only active if action component 0 The setting range of working point YP corresponds to the setting range for output variable Y To set working point YP the current value of the output variable display must be read when the plant is in the steady state and set as value for the working point Thus the offset steady state deviation of a P or PD controller is elimi nated when the setpoint is fixed set The limit value and the differential gap for switching outputs Y1 and Y2 are defined with the dis plays shown below Selection of the limit value and the ala
31. ntroller returns to the operating level standard operation All the configuration blocks listed below can be selected and modified via cursor keys 5 Aland V Select input signal In Configuration block In determines the controller input signal The following input options can be defined using selection options O to 5 0 Pt100 30 0 to 150 0 C 1 100 100 0 to 400 0 C 2 Current O 4 to 20 mA 3 Voltage 0 2 to 10V 4 Ni 100 20 0to 90 0 C 5 Ni 100 60 0 to 180 0 C Measuring range limits In and In Starting value minimum value In End value maximum value The measuring range of controlled variable x is determined in configuration block In Using In and In the measuring range can be determined by the user in the range of In Both the lower limit and upper limit range value mu tually limit each other If for example the configuration is assigned In 0 for Pt 100 with 30 0 to 150 0 C measuring range the measuring range of controlled variable x is defined at In 2 30 0 and In 150 0 This measuring range can be modified within limits In and In For the input signals involving current or voltage the measuring range is determined at In_ 0 0 and In 100 0 in the configuration process If the measuring range limits are modified in the range from 1999 to 9999 with variable decimal point the input signals are only converted
32. or1 0 CPA Code no of parameterization level Oto 9999 0 cco Code no of configuration level O to 9999 0 35 Control deviation display 10 Controller output display 10 Setpoint SP display 10 display 3 Switching output display 4 ENTER key 8 HW Control deviation _ i Front view DC Unit of temperature label Controlled variable display or value specification is Setpoint SP display 1 or entry option w2 Operating key 7 Cursor keys 5 MANUAL AUTOMATIC key 6 Setpoint SP key 9 Due to technical reasons the term control deviation XD has been used to represent the setpoint error e w x The correct abbreviation reads correctly as e 36 37 SAMSON MESS UND REGELTECHNIK Weism llerstra e 3 D 60314 Frankfurt am Main Postfach 10 19 01 D 60019 Frankfurt am Main Telefon 0 69 4 00 90 Telefax 0 69 400 95 07 EB 6494 E S C 03 95
33. orking point YP should be set and the output variable limit Y should be set to 100 0 A Y 1H lt _ On gt Y A 2A Off lt gt gt 9 1A Y Y A lt gt On 2 2H Y Fig 11 Switching 2 on off output with Y1 7 and Y2 6 27 5 2 4 Pulse modulated on off controller output at switching output Y1 and or Y2 The pulse modulated controller output is a switching output in which the output signal is a pulse frequency In this case the pulse pause ratio is varied for a specified period of time tT Here the period is entered in seconds with parameter t1 The minimum on time is set as a percentage using parameter fd Selection of the pulse modulated switching output is made in configuration block YI 8 9 and or Y2 8 9 Y1 8 selects a clocked controller output in a positive direction of output sig nal Y When configuration switch Y1 9 a clocked control controller output Y1 is selected in a negative direction of output signal Y Switching output Y2 operates similarly with Y2 8 or 9 The switching action operates the same as an on off controller output with internal feedback YI Y2 On On Y 75 HE Y 25 ES ber gt Of gt itmin gt tmin t Example m ne Period t1 100s Min pulstimetd 5 mnt 5 100 i mie E MAUS T Fig 12
34. point W2 is active the yellow LED located in the key illuminates In addition selection can be made between setpoint W1 to W2 by applying 24 V d c to an external signal note configuration block SP page 19 10 Display variables XD Y and W2 The three yellow LEDs indicate which variable control deviation XD controller output Y set point W2 is displayed in the bottom display panel that was selected using the operating key 7 Setpoint W1 is usually displayed here 11 Label for physical unit of temperature Physical unit specification of the top and bottom display It is attached above the top display panel using the supplied adhesive label For this purpose first remove the clamped on frame 4 2 Operation of the three levels Operation of the controller is divided into the following three levels of operation also referred to as operating modes 1 operating level standard operation 2 parameterization level and 3 configuration level 4 2 1 Operating level This is the standard operating level of the controller Controlled variable x is displayed in the top display panel setpoint W1 is displayed in the bottom display panel Controlled variable x The range of values in the display depends on the minimum and maximum measuring range limits which are to be specified in the configuration level see page 18 with In and In Setpoint W1 Setpoint W2 is displayed in the bottom display panel If no LED 10 illu
35. r dead band via parameter td Optimize the plant by entering control parameters P I d and dP 6 1 3 Controlled variable x as recorder input Y 2 Controlled variable x can be used as a recorder input Switching outputs Y1 and Y2 are avail able as limit contacts Open the configuration level see page 17 Select the input signal via In Determine the input range via In and In Determine the output signal via Y 2 Determine the operating direction via Yr Select the desired extended function such as digital filter InF and temperature display in Fahrenheit Int Alarm conditions can be selected for limit contacts YI and Y2 by means of configuration blocks Y1 and Y2 resp Open the parameterization level see page 14 Limit the output signal Y via Y and Y Enter the desired limit values for 1A and 2A Enterthe desired differential gap of the limit values via 1H and 2H rep Optimize the plant by entering control parameters P I d and dP 30 6 2 Optimize the control parameters tune the controller to the controlled system In order for the controller to keep the control deviations caused by disturbances in certain limits or eliminate for all setpoints control parameters P I d and dP are used to adopt tune the controller to the dynamic performance of the controlled system Note that control parameters and setpoints entered are only effective after they have been ac cepted a
36. r the adaption is finished the controller assumes MANUAL operation All control par ameters determined by the adaption are stored and in non volatile and memory protected against power loss Their values can be changed as desired in the parameterization level Restraint The controller output option of the self tuning function is to be selected so small that the system excitation does not assume a critical value for the process The adaption procedure implemented in TROVIS 6494 is intended for controlled systems where recovery action and dead time are crucial factors which must be dealt with gt s Code number for servicing 1732 33 Checklist Device Plant Process designation Date Selection Designation Rangeofvalues Factory Start up option default values block modifications Operating level X Controlled variable Dep on input Internal setpoint 1 In_toln 0 XD Control deviation error 100 0 to 100 0 Y Output variable Y w2 Internal setpoint 2 In toin 0 Parameterization level P Proportional action coefficient Kp 0 1 to 100 0 1 0 I Integral reset time Tn O2 Off Oto 2000 s 0 d Derivative rate time Tv 0 2 Off Oto 2000s 0 dP Derivative rate gain O Off 0 010 10 0 0 0 Y_ Min output variable limit 110 0t0Y 0 0 Max output variable limit Y_t0 110 0 100 0 YP Working point 110 0 to 11
37. rm condition is set in the configuration level via configura tion block Y1 or Y2 Further explanations on the switching outputs can be found in chapter 5 fA For Y Oor 2 Limit value YI For Y Oor 2 Differential gap for YI ELE For Y 0or2 Limit value for Y2 For Y Oor 2 Differential gap for Y2 N SSH For Y2 00r 2 Duration of period for pulse pause Switching output Y1 Y2 8 or 9 Setting range 1 to 9999 sec For Y 1 Motor operating time of the final control element connected Setting range 1 to 9999 sec Dead band neutral zone td Range of values 0 1 to 100 0 in reference to the output signal The dead band for Y 1 is entered for the three step controller and the minimum pulse duration is entered for the switching outputs see chapter 5 page 9 for further details ENIM For Y 1 Differential gap Range 0 1 to 100 0 After actuating the operating key 7 the controller returns to the operating level standard operation 4 2 3 Configuration level In the configuration level the controller function is determined for the required control task to be solved Access can be made to the configuration level by entering the code number The code number is preset factory preconfiguration to 0 and can be modified in configuration block CCO see page 22 Determine and modify the controller functions If controller functions are to be set the configuration level is opened considering the code num ber has b
38. s two circuit states closed opened triggered by means of a snap action element If the switching condition of the limit value is satisfied the switching output is closed otherwise it is open Fig 10 clarifies the behaviour of the activated limit alarm contact Y1 or Y2 when it is exceeded in either direction The controller output is disabled up to a set limit value After limit value 1A is exceeded minus the differential gap the limit contact is open Underrange of a limit value is monitored analogous to that of an exceeded limit value The con troller output remains disabled until the limit contact is reached After the limit value has been fallen short of the contact is closed As soon as the limit value plus differential gap has been ex ceeded the contact is opened When limit value exceeded When limit value fallen short of Y1 2 Y1 2 Onf gt On lt gt Y A A Y OFF us 4 Off 4 FR 1A or 2A 1A or 2A Monitored variable Limit value Limitvalue X XD Y 1 2H 1 or 2H Differential gap Differential gap Fig 10 Limit contacts with snap action element 26 5 2 2 Assignment of the limit alarm conditions for switching outputs Y1 and Y2 Limit alarm contact Y1 is assigned in configuration block YT Y2 is assigned with configuration block Y2 The default configuration does not assign an alarm condition to the limit alarm con tacts configuration switches Y1 O and
39. t controller output signals also require a different procedure in the commissioning phase Proceed in the order presented below 6 1 1 Continuous action controller Y 0 Open the configuration level page 17 Select the input signal via In Determine the input range via In and In Determine the output signal via Y 0 continuous Determine the operating direction via Yr Select the desired extended function such as digital filter InF temperature display in Fahrenheit Int or alarm conditions for limit contacts Y1 and Y2 Open the parameterization level page 14 Limit output signal Y via Y and Y Enter desired limit values for 1A 2A Optimize the plant by entering control parameters P I d and dP 29 6 1 2 Three step controller with internal feedback Y 1 Controlled variable x can also be used as a recorder input Open the configuration level see page 17 Select the input signal via In Determine the input range via In and In Determine the output signal via Y Y 1 three step controller Determine the operating direction via Yr Select the desired extended functions such as digital filter InF and temperature display in Fahrenheit Int YI and Y2 cannot be used as limit contacts here any more Therefore set both of these to 0 Open the parameterization level see page 1 4 Motor operating time via parameter Differential gap via parameter tH Ente
40. uration level is opened and the first con figuration block In is displayed Actuate cursor keys 5 Aland V until either configuration block CPA ap pears for the parameterization level or configuration block CCO appears for the configuration level Press ENTER key 8 CPA or CCO resp flash O or the previously entered code number appear in the top display Use the cursor keys 5 Aland V to enter or modify the desired code num ber Press ENTER key 8 in order to accept and store the personal code number Actuate operating key 7 in order to return the controller to the operating level standard operation Code number for servicing Page 33 of this operating manual contains the subordinate code number for servicing which should be memorized This special code allows despite the entered code number CPA and CCO values to be modified in the configuration level In order to prevent this code number from access by unauthorized persons either cut out or scribble over this number on page 33 making it unrecognizable Access can be made to configuration level CO by entering the special code number described above The code numbers for the parameterization level can be interrogated and modified in configu ration block CPA The configuration level can be manipulated similarly in configuration block CCO W1 Setpoint ramp
41. values in the display depends on the measuring range limit which is to be specified with Y and Y in the par ameterization level The yellow LED 10 of output variable Y illuminates Modify setpoint W2 Setpoint W2 is presented for viewing purposes in the bottom display panel A change of setpoint W2 is performed analogous to that of setpoint W1 The yellow LED 10 of setpoint W2 illuminates If no LED 10 illuminates WT is selected as active setpoint in the display Display sensor line breakage If a sensor wire break or short circuit is detected at the controller input or an input range is exceeded in either direction three bars appear in the top dis play panel designated o over or u under In this case the output signal is automatically set to the value specified in configuration block YSt safety output value to restart when AUTOMATIC mode is enabled After correcting the defect the controller operates in standard operation 4 2 2 Parameterization level Control parameters can be set in the parameterization level Values set in this level are protected against unauthorized access by means of a code number personal security code lock Access to the parameterization level must be first obtained by entering the code number before set values can be modified The code number is pre set factory configuration to O and can be modified in configuration block CPA see page 22 Determine and modify the control parameters I
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