CAL Controls CAL3300 Operations Manual
Contents
1. Sequence alarm hoLd When hold is selected in any alarm mode it prevents an alarm signal on power up The alarm is enabled only when the process temperature reaches setpoint A A A A SP SP SP SP setpoint setpoint setpoint setpoint y Z WF Without sequence alarm Alarms on power up With sequence alarm No alarm on Alarm Alarm operates power up enabled normally TO CONFIGURE SP2 AS A PROPORTIONAL CONTROL OUTPUT In level 2 select Sa then select the required option In level 1 select and then set the required proportional band In level 1 select Ee and then set the setpoint SP2 value y SP2 OUTPUT AND LED INDICATION STATES IN ALARM CONDITION ON OFF operating mode Proportional Alarm type operating mode SP2 SP2 Output state LED state Py miata on off mode only SP2 SP2 Output state LED state Temperature above setpoint sty Output ON Output OFF fae Relay or SSd energised Relay or SSd de energised LED ON SP2 ALARM ANNUNCIATOR When an SP2 alarm mode is selected in SP2 A the alarm annunciator AL is displayed alternating with the process temperature during alarm condition Note The annunciator may be disabled by selecting function J option on in level 4 SP2 in cool strategy See heat cool configuration in ADVANCED SETTINGS page 23 ERROR MESSAGES SENSOR FAULT Display flashing o AF and Fail Indic2. NCE New PID values Mm uS Bo entered Start ee Time 100 output Cycle 75 SP QA ab IMPROVING CONTROL ACCURACY The following functions are to assist engineers with machine development commissioning and troubleshooting BREAD sri OUTPUT PERCENTAGE POWER Poor control may be due to incorrectly sized heaters Level 2 constantly displays the output percentage power applied which at normal setpoint should ideally be within 20 80 to achieve stable control f CONTROL ACCURACY MONITOR This measures the control stability to within 0 1 C F The monitor is started using Level 3 and the variance deviation maximum and minimum temperatures are displayed and constantly updated in p Temp Variance Maximum VAre 0 1 W F Lo Minimum gt Time Using the MY Control accuracy monitor To start the monitor select J on Note During monitoring either return to normal operation or remain in program mode To view monitor readings index to The display will alternate between MM and Var Press and hold the display will alternate between Var and the variance displayed in degrees e g 0 6 Press and hold and press A once the display will alternate between VAr and the maximum hi displayed in degrees e g 320 3 Press and hold and press A once the display will alternate between VAr and the minimum Lo displayed in degrees e g 319 7 f oFF
3. Autotune will cause a temporary disturbance Check that the temperature has stabilised in heating mode before running the process in cooling mode If regular temperature oscillations occur change CYC t to optimum value See page 9 To select Autotune Calculated Cycle time Further adjustments Cooling Autotune uses the same calculated value for both SP1 heating and SP2 cooling In some processes regular temperature oscillations occur when cooling Make the following manual adjustment In level 1 double the value of EDEN gt o lt o 5 fa 0 o u 0 et et 3 Q y v to E ad p 0 v v 0 U gt v lt Heat Cool Strategy Configuration continued If no improvement return to the original value and In level 1 halve the value of YC If the process hunts between heating and cooling a deadband setting may be needed Enter a small value eg 1 and observe the process Increase the setting until hunting stops Level 1 adjust value BERE Water cooled applications Water cooled applications operating at temperatures greater than 100 C may suffer from the non linear effect caused by water turning to steam This can be countered by the non linear setting for SP2 In level 2 set EGEE to nL in Multi zone applications When tuning multi zone applications like extruders distortions due to thermal interaction between adjacent zones can be minimised by running autotune on all contro
4. REMINDER OF INSTRUMENT ADJUSTMENTS Press A W together for 3 seconds for program entry or exit Press A or W to scroll through functions Press A together or W together to change levels or alter options Note Ifin difficulty by becoming lost in program mode press A and W together for 3 seconds to return to display mode check the Menu Navigation summary above and try again Select the most appropriate method of Autotune Tune or Tune at Setpoint to suit the application Note The proportional cycle time can be pre selected before starting Autotune see PROPORTIONAL CYCLE TIME The TUNE program should be run with the load cool The output is cycled at 75 of the setpoint value to avoid any overshoot during the tuning cycle The warm up characteristics are monitored and set DAC which minimises overshoot on subsequent warm ups The TUNE AT SETPOINT program is recommended when the setpoint is below 100 C 200 F where TUNE s tuning cycle at 75 setpoint may be too close to ambient to produce good results when the process is already hot and the cooling rate is slow when controlling multi zone or heat cool ap plications to re tune if the setpoint is changed substantially from previous Autotune Note dAC is not re tuned by TUNE AT SETPOINT AUTOTUNE TUNE PROGRAM Temp A Setpoint Tuning DAC PID m um Cycle s F 9 NORSE New PID 114 on off tuning values cycles entered
5. DIN panel cutout and the 9300 Controller in a 1 16 DIN cutout The only differences between the two instruments are their vertical dimensions Both models are sleeve mounted with their front bezel assembly rated NEMA4 IP66 provided that the panel is smooth and the panel cutout is accurate the mounting instructions are carefully followed 51 0 Model 3300 28 5 1 12 includes gasket 116 2 4 57 MECHANICAL INSTALLATION DIN PANEL CUTOUT SIZES 1 32 DIN panel cutout size 45 0mm 0 6mm 0 0mm 1 77in 0 02in 0 0in wide 22 2mm 0 3mm 0 0mm 0 87in 0 01in 0 0in high 9 5mm 0 374in maximum panel thickness 1 16 DIN panel cutout size 45 0mm 0 6mm 0 0mm 1 77in 0 02in 0 0in wide 45 0mm 0 6mm 0 0mm 1 77in 0 02in 0 0in wide 9 5mm 0 374in maximum panel thickness MINIMUM SPACING Cut out Cut out 20 mm 0 79 10 mm 0 39 MOUNTING To mount a Controller proceed as follows 1 Check that the controller is correctly orientated and 4 When refitting the bezel assembly it is important to then slide the unit into the cutout press it firmly into the sleeve until the latch clicks in order to compress the gasket and seal to NEMA4X IP66 2 Slide the panel clamp over the controller sleeve pressing it firmly against the panel until the controller is Cleaning held firmly Wipe down with damp cloth water only 3 The controller front bezel and circuit board assembly can be unplugged from
6. Start Silat gt Time 100 output Enter program mode and select iea The controller will alternately display E and oFF Press and hold and press A once The controller will alternately display MM and on Exit program mode The TUNE program will now start The controller will alternately display and the process temperature as it climbs to setpoint Note During tuning the main setpoint SP1 LED will flash When the TUNE program is complete the alternating display stops and the process temperature is displayed The PID values are entered automatically The process temperature will rise to setpoint and control should be stable If not this may be because optimum cycle time is not auto matically implemented To set the cycle time see PROPORTIONAL CYCLE TIME TUNE AT SETPOINT PROGRAM Temp start Se Overshoot RNS during tuning Setpoint Se k NS Prop band New PID ASAA co values Tuning entered 134 on off tuning cycles gt Time 100 output Enter program mode and select The controller will alternately display MM and oFF Select Pees ol At SP The controller will alternately display fF and At SP Exit program mode The TUNE AT SETPOINT program will now start The controller will alternately display NM and the process temperature Note During tuning the main setpoint SP1 LED will flash When the TUNE AT SETPOINT p
7. a followed by the required option below Deviation Deviation Deviation high alarm low alarm band alarm L A Z A Alarm h h state Z Us 5 a gt A teal t ne t Vi tpoint Vi setpoin setpoin setpoin ce Wy we Y p set value A A Full scale Full scale high alarm low alarm AN A 7 fa x gt Pe 1 SP setpoint setpoint Y j A dV hi dV Lo bAnd FS hi FS Lo sets off alarm signal when temperature rises above a pre set temperature above the setpoint sets off alarm signal when temperature falls below a pre set temperature below the setpoint sets off alarm signal when temperature rises above or falls below a pre set temperature above or below the setpoint sets off alarm signal when the temperature rises above setpoint to a pre set temperature above scale minimum sets off alarm signal when the temperature falls below setpoint to a pre set temperature above scale minimum Select level 1 and select Ss and set the required setpoint value y If the factory set hysteresis 2 0 C 3 6 F is unsuitable Index to JM and adjust the setting Check f is set to on oF for alarm Exit program mode SP2 is now operational as an alarm CooL see heat cool configuration page 23 SUBSIDIARY SP2 MODE JM Latch sequence or non linear cool Latch alarm LtCh When activated the alarm latches until manually reset even though the alarm condition may have disappeared
8. making the adjustment the reading will 2 immediately change Allow time for the temperature to stabilise aT before making any further adjustment At this point a ZEro adjustment may be needed refer to step 1 above Check that the temperature correctly stabilises at T and then adjust setpoints to T If an error is present at T repeat from step 2 LINEAR INPUT CALIBRATION In addition to the ten temperature inputs the controller has five linear input ranges which can be calibrated to display a range of engineering units This procedure involves making adjustments to the controller s mo SE and and 3 adjustments found in function menu levels 2 Note The controllers linear inputs are in mV If your transducer provides an output in mA this should be converted to mV by feeding the controller input via a high stability one ohm resistor see figure page 26 Other low Vdc signals can be connected via a suitable voltage divider network to match the controller input requirements gt Q lt 9 5 A M Q n M rF rF 5 e n v to E ad E ad 0 n v 0 U gt v lt Linear Input Calibration continued J i 00000000A 60656066 Outputs lohm Supply 4 20 mA from transducer 1 Power up the controller and in response to the prompt B none select an appropriate Linear Range from the table below Ensure that the Nominal Signal Span chosen is wider than the
9. modes Direct Reverse Caution Settings affect fail safe state SP1 SP2 1r 2d Reverse Direct 1d 2d Direct Direct 1r 2r Reverse Reverse 1d 2r Direct Reverse Select Reverse on SP1 for heating and Direct for cooling applications LEVEL 3 continued fa WN c a cTb Cti ct2 Ct3 Select SP1 2 LED indicator modes Ct4 oS1 uS oS2 Read Autotune tuning cycle data see figure page 14 SP1 SP2 1n 2n Normal Normal ooo 1i 2n Invert Normal Software version number 1n 2i Normal Invert 1i 2i Invert Invert D 0E ALL Resets all functions to factory settings D oo to 25 sensor maximum Sensor span adjust Caution Note current configuration before using this For recalibrating to a remote standard e g External function otherwise initial configuration and O EM Meter data logger See ADVANCED SETTINGS page settings must be re entered D oo to 425 sensor f s Zero sensor error see SPAn MEE o or Select control accuracy monitor MMM 2 i o Read control accuracy monitor Access to level 4 is gained through Rte in level 3 Press and hold amp and W for 10 seconds Enter level 4 at Lock release A and W together Display will alternate noo ly and nonE Program security using Lock Select from three Lock options Press and hold press A to index LEV 3 locks level 3 and 4 only Technical Functions LEV 2 locks levels 2 3 and 4 only Configuration and Technical Functions ALL locks all functions unrestricted LE
10. stops monitor retaining readings f on resets readings On de powering JM resets to oFF and i is zeroed 3 xe ue e lt Ke A e et e Adreundoy FUNCTION LIST The functions and options are available in four levels Note A Functions Menu is shown on the cover fold out Function Options Factory settings shown in brackets SELECT AUTOTUNE PE AE oFF on ParK At Sp Used to switch the Autotune feature on and off to select Park or Autotune at setpoint Park temporarily turns the output s off To use select ParK and exit program mode To disable re enter program at EREI and select oF F SP1 OPERATING PARAMETERS PERE 0 1t0 or SP1 proportional band Gain or Hysteresis 25 sensor maximum Proportional control eliminates the cycling of on off control Heater power is reduced by time proportioning action across the proportional band 102 C 185F Too narrow Too wide oscillates slow warm up and response decrease increase felalaf D AE oFF 0 1to60minutes 5 0 SP1 integral time reset Auto corrects proportional control offset error Too short Too long overshoots and oscillates slow warm up and response PoE oFF 1 200 seconds 25 SP1 derivate time rate Suppresses overshoot and speeds response to disturbances disturbance Too short Too long slow warm up and response oscillates and over corrects under corrects PEG 05 50 x bAnd 1 5 SP1 de
11. transducer s actual signal span and the Nominal Scale is wider than the full scale of the engineering units to be displayed Linear Nom Signal Nom Scale Max Scale Range Span Span Settings Lin 1 0 20 mV 0 100 0 400 Lin 2 4 20 mV 0 100 25 to 400 Lin 3 0 20 mV 0 1000 Oto 3000 Lin 4 4 20 mV 0 1000 250 to 3000 Lin 5 0 20 mV 0 2000 0 to 3000 2 Select then select the process unit C F Bar PSI Ph or rh If the required unit is not shown select Set 3 Allocate the output devices at function as described in SET UP enter the configuration into the memory and proceed as follows Calculate the values for the controller settings for and SPAR using the example below as a guide 4 to 7mV input from transducer is required to display 0 110 units Chose Linear Range Lin4 4 20mV 0 to 1000 units EER Nominal Signal Span x required span actual signal span 20 4 x 110 0 587 7 4 hi SC nominal scale span x_hi SC Nominal Scale Span 587 1000 x 587 242 1000 These settings should provide the correct scaling adjustment but a value for may need to be established by applying the lowest and highest mV input signal and recording the display offset Check that this is the same at each end and enter this plus or minus value as a adjustment Should there be a difference between the two readings a further adjustment of the setting can be made The 3300 Controller is designed to be mounted in a 1 32
12. AL WITH FACTORY SETTINGS Note For precise control of an application the controller may need to be TUNED Please study section headed FUNCTIONS and OPTIONS before moving to the section on AUTOTUNE Q c A A r rt fet e e INTRO DUCTION THE CONTROLLERS fn ee oe The CAL 3300 1 32 DIN and the CAL 9300 1 16 DIN miniature controllers share the same PID control strategy and features while giving the user the flexibility of a choice of panel format Control can be optimised with a single shot autotune either on initial warm up or at setpoint A second setpoint can be configured in a variety of alarm modes or PID Heat Cool strategy A programmer offers a single ramp to setpoint with a choice of timed soak period before switching off the Output Control of non temperature processes is achieved by the provision of linear input ranges and scaling in commonly used engineering units Serial communication is available as an option on both controllers and the easy to use CALCO MMS is a graphic WINDOWS based software package designed for PC supervision of up to 32 instruments for remote adjustment configuration cloning saving and retrieving settings to files and logging and charting in real time CALCO MMS uses the MODBUS protocol via either a fully isolated RS232 or RS485 link depending on the number of instruments and the transmission distances involved in the application A users manual is supplie
13. ATION INTO selected sensor type kasi and eg te S CONTROLLER MEMORY TO SELECT C F Press and hold both A and W buttons for 3 seconds The process temperature e g 23 C and ParK will be Press and release the button the controller will now alternately displayed as no setpoint has yet been selected alternately display and nonE Press and hold the button and using the A button TO SET THE MAIN SETPOINT select C F Bar PSI Ph Rh or SEt as required Release the buttons when the correct unit is displayed To display the setpoint press and hold the button Cand Oor Fand 32will be alternately displayed The controller will now alternately display selected range Press and hold the button Press to increase or Y eg 2C and unit to decrease the setpoint The main setpoint LED will flash indicating that SP1 output is ON The controller will now be set with the factory PID settings MENU NAVIGATION The facilities of the controller are selected from the multi level menu using the front panel mounted buttons Each level within the multi level menu offers different functions see FUNCTIONS MENU for menu of main functions Each function has a range of user select or input options see FUNCTION LIST for functions and options details The controller has two modes program mode and operating mode When in program mode the controller can be programmed with settings and functions to suit the application When in operating mod
14. CAL 3300 and 9300 Autotune Temperature Controllers CAL Controls Temperature Controllers SAFETY amp WARRANTY FUNCTIONS MENU QUICK START Quick Start Set up INTRO DUCTION The controllers OVERVIEW Installation Set up Autotune Cycle time SET UP Power up Select input sensor Select display units Allocate output device Enter initial configuration Set main setpoint MENU NAVIGATION Using program mode AUTO TUNE Tune program Tune at setpoint program PRO PORTIONAL CYCLE TIME Cycle time selection methods Cycle time recommendations Autotune calculated cycle time PROGRAMMER Ramp Soak gt m gt w m m e m e he O LOLCEONNOC OU U UMMM RPW WWUWNNO SECOND SETPOINT SP2 SP2 as an alarm SP2 subsidiary mode SP2 as a proportional output SP2 alarm condition table SP2 alarm annunciator ERROR MESSAGES Recommendations Autotune data in tECH IMPROVING CONTROL ACCURACY Using ChEK accuracy monitor FUNCTION LIST Level 1 Level 2 Level 3 Level 4 OUTPUT OPTIONS ADVANCED SETTINGS Heat Cool strategy Calibration to other instrument Linear input calibration MECHANICAL INSTALLATION DIN panel cut outs Minimum spacing Mounting ELECTRICAL INSTALLATION General requirements Connection diagrams INPUT SENSOR SELECTION SPECIFICATION INDEX 12 12 13 13 13 13 14 14 14 15 15 16 16 18 19 21 22 23 24 25 27 28 Bil 29 29 30 31 32 SAFETY AND WARRANTY INFORMATION INSTALLATION A A Designed fo
15. Konst NiCrosil NiSil Pt 13 Rh Pt Pt 10 Rh Pt Copper Con Pt100 RTD 2 setpoint limits 0 400 25 400 0 3000 250 3000 0 3000 SENSOR SELECTION Linearity 2 0 0 5 0 5 0 25 0 5 0 25 2 0 2 0 0 25 0 25 0 5 0 5 0 5 0 5 0 5 2 Linearity B 5 702 500 C K N 1 gt 350 C exceptions R S 5 lt 300 C T 1 lt 25 gt 150 C RTD Pt100 0 5 lt 100 C aosuoas v 0 0 A rt e gt SPECIFICATION Thermocouple 9 types Standards CJC rejection External resistance Resistance thermometer RTD 2 Pt100 2 wire Standards Bulb current Linear process inputs mV range IPTS 68 DIN 43710 20 1 0 05 C typical 1002 maximum DIN 43760 100 0 C 138 5Q 100 C Pt 0 2mA maximum 0 to 50mV Applicable to all inputs SM sensor maximum Calibration accuracy Sampling frequency Common mode rejection Series mode rejection Temperature coefficient Reference conditions Output devices SSd SSd1 SSd2 0 25 SM 1 C input 10Hz CJC 2 sec Negligible effect up to 140dB 240V 50 60Hz 60dB 50 60Hz 150ppm C SM 22 C 2 C rated voltage after 15 minutes settling time solid state relay driver To switch a remote SSR 5Vdc 0 15 15mA non isolated Miniature power relay rLY and rLY1 rLY2 General Displays Keypad Environmental Humidity Altitude Installation Pollution Protection EMC emission EMC
16. VL VEr SP LK Note Locked functions and options may be read Press W to access following functions GAEI Auto stay Program mode auto exit switch Auto exit returns display to normal if 60 seconds of key inactivity select StAY to disable EEEN oF on Disable SP2 alarm annunciator AL Select on to disable AL ENEE oir 1to32 6 Display sensitivity dir direct display of input 1 maximum 32 minimum sensitivity EGEJ 0 1 101 0 0 5 Derivative sensitivity USE THE SOFTWARE SECURITY LOCK THEN REMOVE THIS SECTION y IMPORTANT NOTE FOR OEM s For safety and to protect settings from tampering FACTORY SET OUTPUT OPTIONS DUAL RELAY OR DUAL SSd OUTPUT MODELS Factory Options 3311 9311 and 3322 9322 pre The table below details the factory set output options rLY2 allocate SP1 to terminals 3 and 4 is a 1A electromechanical relay and SSd1 SSd2 is an Note Output device rLY rLY1 is rated 2A identical second SSR drive output Output device rLY2 is rated 1A Factory Option 3311 9311 offers the ability to change the allocation of SP1 to terminals 5 and 6 To make this selection during the initial configuration in either QUICK START page 1b or SET UP page 5 start from step 3 HM TO SELECT SP1 Main setpoint output device From the alternating display Ws and rLY7 press and hold button then press the A once to display rLY2 QUICK START page 1a or SET UP page 5 follow steps 1 and 2 ignore
17. amp rate 0 to 9995 deg hour Press A and W buttons for 3 seconds to enter program entry point zy Press A to scroll to 21 Press and hold then press A or W to scroll to required value Set Soak if required 0 to 1440 minutes Press A to scroll to Press and hold then press A or W to scroll to required soak period Set Ramp On Off On hold Press A to scroll to e Press and hold then press A to select On PRO G RAMMER Deg Deg Target setpoint Ramp hour Ramp hour Target setpoint p Soak gt Time Time Exit program to enter settings into memory and commence ramp to target setpoint Notes In Ramp on configuration if power is removed from the controller the Ramp will re start when power is restored The Ramp hold option suspends the ramp at its last value If no Soak period has been set control at target setpoint continues indefinitely SP2 deviation alarms follow the ramp setpoint and can be used to alarm out of limits ramp rate WARNING The Soak timer is triggered when the ramp setpoint reaches the target setpoint If the ramp rate is set too fast for the process the Soak timer will be triggered before the process temperature reaches the target setpoint SECOND SETPOINT SP2 The second setpoint SP2 can be used to trigger an alarm or as a proportional contro output TO CONFIGURE SP2 AS AN ALARM Enter program mode Select level 2 then
18. ates thermocouple burnout RTD Pt100 open or short circuit or negative over range Action Check sensor wiring NON VOLATILE MEMORY ERROR Display flashing SAE A and Fail Action De power briefly Replace unit if problem persists MANUAL POWER ERROR Display flashing and Fail SP1 set to ON OFF in CYC t Action Select proportional mode IMMEDIATE FAIL ON AUTOTUNE START Display flashing setpoint Eune and FaiL 1 No setpoint entered Action Enter setpoint 2 SP1 setto ON OFF in DEP Action Select proportional mode Note To reset and clear error press AW together briefly to cancel message FAIL LATER DURING AUTOTUNE CYCLE The thermal characteristics of the load exceed the Autotune algorithm limits The failure point indicated by any display 0 0 in ES eg Ctb 0 0 see diagram below Action 1 Change the conditions eg raise setpoint 2 Try Eun At SP 3 Check SP1 P percentage power see IMPROVING CONTROL ACCURACY 4 Ifthe error message persists call CAL for advice READING AUTOTUNE TUNING CYCLE RESULTS IN Index to release A or Y display will alternately display and Ct A Press and hold the display will alternate Ct A and value eg 10 4 N 18 Keep pressed and press A once the display Ct B and value eg 19 6 a Repeat step 3 above to view Ct 1 Ct 2 Ct 3 Ct 4 oS 1 uS and oS 2 Autotune tuning data and limits ep DAC ro Setpoint Tuning oS1 oS 2
19. d with the comms option For more information contact CAL For details see rear cover It is suggested that users read the OVERVIEW section of this manual before any installation or setting up procedures are undertaken Note The controller will not be operational until either the QUICK START or SET UP procedure has been completed NB Please note that in the manual functions are reversed out from a black background and options are shown in bold italic eg I and Park INSTALLATION The Model 3300 controller is designed to be mounted ina 1 32 DIN panel cutout and the Model 9300 in a 1 16 DIN cutout See the INSTALLATION section SET UP After installation the controller requires programming with the following information Type of Input Sensor Operating unit C or F etc Type of Output Device Temperature Setpoint Note The controller will not be operational until this information is entered When the above information has been programmed into the controller it will be operational with the following factory PID proportional band integral time derivative time settings Proportional band Gain 10 C 18 F Integral time Reset 5 mins Proportional cycle time 20 secs Derivative time Rate 25 secs DAC Derivative approach control 1 5 OVERVIEW AUTOTUNE To precisely control an application the controller will need to be tuned using the built in AUTOTUNE feature Autotune teaches the controller t
20. e the controller uses the setting and functions entered in the program mode to control the application USING PROGRAM MODE Note The controller will auto exit program mode after 60 seconds of inactivity To enter program mode from normal operating mode Press and hold both A and W buttons for at least 3 seconds Release the buttons together when the function is displayed this is the program entry point The controller will now alternately display the function and option setting ofthat function e g DERMEE and oFF To view function on the same level Press A Or V button once to view the next function Press and hold A or W buttons to scroll through functions To display the current option or value for a function On release of A or W buttons option alternates with the function To change an option value or setting Press and hold the button then press A to increase or Y to decrease the value or select the next option Note Check the new option value before moving to another function or exiting program mode To change levels Press and hold W to scroll through the functions until LEUL is displayed Release W to display current level Press and hold the button then press A to increase or W to decrease the level Release buttons when required level is obtained To exit program mode Press and hold both A and W buttons for at least 3 seconds Note Control commences with any new instructions now entered in the memory
21. ection method see Pre Select Automatic Acceptance of Any Autotune Cycle time page 10 Pre select before Autotune The controller can be programmed manually with any cycle time between 0 1 and 81 sec This cycle time will not be changed by any Autotune functions For selection method see Pre Select Cycle time Before Autotune page 10 PROPORTIONAL CYCLE TIME Factory set To use the 20 sec factory set cycle time no action is needed whether autotune is used or not CYCLE TIME RECOMMENDATIONS Output Factory Recommended Load max Device Setting Minimum resistive Internal relay rLY rLY1 20 seconds 10 seconds 2A 250 Vac ME 20 seconds 10 seconds 1A 250 Vac Solid state Externally drives 20 seconds 0 1 seconds fitted SSR SSd SSd1 SSd2 n a To Select AUTOTUNE CALCULATED CYCLE TIME On completion of Autotune enter program mode Select The controller will now alternately display a and 20 the factory setting To view the calculated optimum cycle time press and hold the button then press and hold W until indexing stops The controller will display the calculated cycle time and eg A 16 This indicates that the calculated cycle time is 16 seconds cycle time 6 fe e fe o fe e A Proportional Cycle time continued If this cycle time is suitable press and hold both A and W buttons for 3 seconds to enter it into the controllers memory If the calculated cycle time is no
22. fluctuation 12V 24V AC DC 20 4 0 VA Polarity not required WIRING THE CONNECTOR Prepare the cable carefully remove a maximum of 8mm insulation and ideally tin to avoid bridging Prevent excessive cable strain Maximum recommended wire size 32 0 2mm 1 0mm 18AWG INDUCTIVE LOADS To prolong relay contact life and suppress interference it is recommended engineering practice to fit a snubber 0 1uf 100 ohms refer to illustration on page 30 CAUTION Snubber leakage current can cause some electro mechanical devices to be held ON Check with the manufacturers specifications c e 4 c Electrical UJ o ELECTRICAL INSTALLATION continued EN61010 CSA 22 2 No 1010 1 92 Compliance shall not be impaired when fitted to the final installation Designed to offer a minimum of Basic Insulation only The body responsible for the installation is to ensure that supplementary insulation suitable for Installation Category Il or Ill is achieved when fully installed To avoid possible hazards accessible conductive parts of the final installation should be protectively earthed in accordance with EN6010 for Class 1 Equipment Output wiring should be within a Protectively Earthed cabinet Sensor sheaths should be bonded to protective earth or not be accessible Live parts should not be accessible without the use of a tool When fitted to the final installation an IEC CSA APPROVED disconnectin
23. g device should be used to disconnect both LINE and NEUTRAL conductors simultaneo usly A clear instruction shall be provided not to position the equipment so that it is difficult to operate the disconnecting device MODEL 3300 TYPICAL CONNECTION DIAGRAM The SSR driver output is allocated to SP1 and wired to switch the load heater using an SSR F1 Fuse time lag type to IEC127 CSA UL rating 1A 250Vac F2 Fuse High Rupture Capacity HRC Suitable for maximum rated load current S1 Switch IEC CSA UL Approved disconnecting Device Comms option when fitted A upply Output Output Sensor i JSPL SP2 S i a a alarm 1 state Sl Line aan Neutral os Ah Option Sensor type Sensor range Thermocouples tc b B 0 to 1800 C tc E E 0 to 600 C tc J J 0 to 800 C tc K K 50 to 1200 C tc L L 0 to 800 C tc n N 50 to 1200 C tcr R 0 to 1600 C tcs S 0 to 1600 C tct T 200 250 C Resistance thermometer rtd 200 400 C 32 to 3272 F 32 to 1112 F 32 to 1472 F 58 to 2192 F 32 to 1472 F 58 to 2192 F 32 to 2912 F 32 to 2912 F 273 482 F 273 752 F Linear process inputs Input mV range 0 to 50mV Displays 0 20mV Lin1 0 100 Lin2 Lin3 0 1000 Lin4 Lin5 0 2000 Notes 1 Linearity 5 95 sensor range 4 20mV 0 100 0 1000 Pt 30 Rh Pt 6 Rh Chromel Con Iron Constantan Chromel Alumel Fe
24. he main characteristics of the process and learns by cycling the output on and off The results are measured and used to calculate optimum PID values which are automatically entered in the controller memory During AUTOTUNE the optimum cycle time is calculated but is not automatically implemented The cycle time requires manual acceptance unless pre selected To ensure good control over a wide range of applications two versions of the Autotune program are provided TUNE and TUNE AT SETPOINT The TUNE method normally achieves the best results Starting with the load cool tuning occurs during warm up preventing overshoot This method of tuning is recommended The TUNE AT SETPOINT method is used for specialist applications eg Heat cool multizones and processes below 100 C 200 F During the tuning cycle some overshoot occurs because the tuning cycle is at set point The DAC setting is not re calculated CYCLE TIME The choice of cycle time is influenced by the external switching device or load e g contactor SSR Valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Cycle time selection methods The following methods of cycle time selection may be used Autotune calculated After Autotune has been run and completed the calculated cycle time can be manually accepted or adjusted to suit the switch
25. immunity Ambient Mouldings Weight form A SPST contacts AgCdO 2A 250ac resistive load 1A 250ac resistive load Main 4 Digits high brightness green LED 10mm 0 4 high Digital range 199 to 9999 Hi res mode 199 9 to 999 9 LED output indicators flashing SP1 square green SP2 round red 3 elastomeric buttons Max 80 up to 2000M Categories Il and Ill Degree Il NEMA 4X IP66 EN50081 1 FCC Rules 15 subpart J Class A EN50082 2 0 50 C 32 130 F flame retardant polycarbonate 3300 110g 3 9 oz 9300 120g 4 2 oz Copyright CAL Controls Ltd 1997 Not to be reproduced without prior written permission from CAL Controls Ltd Whilst every effort has been made to ensure the accuracy of the specifications contained in this manual due to our policy of continuous develpment CAL Controls Ltd reserves the right to make changes without prior notice CAE CAL Controls Temperature Controllers CAL Controls Ltd Bury Mead Road Hitchin Herts SG5 1RT UK Tel 44 0 1462 436161 Fax 44 0 1462 451801 email sup port cal controls co uk http w ww cal controls com CAL Controls Inc 1580 S Milwaukee Avenue Libertyville IL 60048 USA Tel 847 680 7080 Fax 847 816 6852 000M01 33007 3 0898
26. ing device For selection method see Select Autotune Calculated Cycle time Pre select autotune cycle time The controller can be programmed to automatically accept the calculated Autotune cycle time For selection method see Pre Select Automatic Acceptance of Any Autotune Cycle time Pre select before autotune The controller can be programmed manually with any cycle time between 0 1 and 81 sec This cycle time will not be changed by any Autotune functions For selection method see Pre Select Cycle time Before Autotune Factory set To use the 20 sec factory set cycle time no action is needed whether Autotune is used or not Further information can be programmed into the controller see SECOND SETPOINT RANGING AND SETPOINT LOCK IMPROVING CONTROL ACCURACY Functions and options The facilities of the controller are selected from the multi level menu using the front panel mounted buttons Note Itis advisable to study this section before any programming is undertaken Each level within the multi level menu offers different functions see FUNCTIONS MENU for menu of main functions Each function has a range of user selections or options see FUNCTION LIST for functions and options details Note Please note that in the manual functions are reversed out froma black background and options are shown in bold italic eg HE and Park The controller has two modes program mode and operating mode When in program mode the control
27. ler can be programmed with settings and functions to suit the application When in operating mode the controller uses the setting and functions entered in the program mode to control the application and also displays the process variable temperature For full details on how to program the controller see VIEWING AND SELECTING FUNCTIONS Note In this manual the letter k is represented by the character B SET UP This section details the four step initial configuration MJ TO SELECT SP1 Main setpoint output device that enables control with factory PID settings to start once the setpoint has been entered Note Dual Relay and Dual SSd Output Options POWER UP Models acai and 3322 9322 have their outputs pre configured see page 22 On power up the controller will display the self test sequence and brief display blanking and then alternately Press and release the A button the controller will now display Cee and nonE alternately display er dl and nonE Press and hold the button and using the A button SELECT INPUT SENSOR select SSd or rLY as required Release the buttons when the correct device is displayed Press and hold and use either the A or W buttons to The controller will now alternately display n and scroll through the sensor selection see table p 31 selected output device eg SSd When the correct sensor is displayed release the buttons The controller will now alternately display BTO ENTER INITIAL CONFIGUR
28. llers at the same time CALIBRATION TO ANOTHER INSTRUMENT If the controller and instrument readings are different the EEA and or EEE function in Function Menu Level 3 will require adjustment Adjust Erol to make an equal adjustment across the full scale of the controller and EEE to make a correction when the error increases decreases across the scale 1 To adjust using the EZ function 1 1 Substitute measured values in the expression Instrument reading controller reading Example Instrument reading 396 Controller reading 400 396 400 4 1 2 Adjust BEJE to 4 to correct error To make a correction when there are different errors across the scale Calibration to Another Instrument continued Adjust using the EEE function 2 2 1 2 2 2 3 2 4 2 5 Chose a temperature near the bottom and another near the top of the scale Run the process at the lower temperature T4 Note the error E between the controller and the instrument readings Repeat at the upper temperature T and note error E gt Substitute the values for T T E and E in the expression below to calculate E E X hi SC SPAn ToT For hi SC settings see level 2 Example Ty Ty Instrument reading 58 385 Controller reading 60 400 Error E 2 E 15 15 2 x 450 13 x 450 17 9 385 58 327 Therefore adjust SPAn to 18 to correct error Notes 1 After
29. mpleted will be retained COMMS SETTINGS i W X U P O QUICK START After power up the controller requires programming with the following information Type of Sensor See list of temperature sensors p 31 Operating unit See list of units p 18 Allocation of Output Device to SP1 SP2 Relay or SSd Temperature Setpoint eg Degrees When the above information has been programmed into the controller it will be operational with the following factory settings Proportional band Gain 102C 18 F Integral time Reset 5 mins Derivative time Rate 25 secs Proportional cycle time 20 secs Typical setting for relay output DAC Derivative approach control 15 Average setting for minimum overshoot NB Please note that in the manual functions are reversed out from a black background and options are shown in bold italic eg ERE and Park Note In this manual the letter k is represented by the character Note During the following procedure the display will revert to alternating and nonE after 60 seconds of key inactivity but will retain any settings already completed Should this occur or in the event of becoming lost in the program please start again from the alternating h APE and nonE display QUICK START SET UP On power up the controller will display the self test sequence followed by alternating D APE and nonE FFM Select input sensor Press and hold and use the Aor W buttons to sc
30. r use UL873 only in products where the acceptability is determined by Underwriters Laboratories Inc EN61010 1 CSA 22 2 No 1010 1 92 To offer a minimum of Basic Insulation only Suitable for installation within Catagory Il and III and Pollution Degree 2 SEE ELECTRICAL INSTALLATION P29 amp P30 It is the responsibility of the installation engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations CONFIGURATION All functions are front selectable it is the responsibility of the installing engineer to ensure that the configuration is safe Use the program lock to protect critical functions from tampering ULTIMATE SAFETY ALARMS Do not use SP2 as the sole alarm where personal injury or damage may be caused by equipment failure WARRANTY CAL Controls warrant this product free from defect in workmanship and materials for three 3 years from date of purchase 1 Should the unit malfunction return it to the factory If defective it will be repaired or replaced at no charge There are no user servisable parts in this unit This waranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse Components which wear or damage with misuse are excluded e g relays CAL Controls shall not be responsible for any damage or losses however caused which may be experienced asa result of
31. rivative approach control dAC Tunes warm up characteristics independent of normal operating conditions by controlling when derivative action starts during warm up smaller dAC value nearer setpoint Too small Too large oversho ots slow stepped warm up LEVEL 1 continued A on oF 0 1 81sec 20 SP1 proportional cycle time see pages 9 L0 Determines the cycle rate of the output device for proportional control Select on oF for ON OFF mode D oio or SP1 offset manual reset 50 bAnd Applicable in proportional and ON OFF mode with integral disable Int t oFF EEEN oA on Lock main setpoint Locks the setpoint preventing unauthorised adjustment PROGRAMMER SETTINGS see page 11 0 to 9995 deg hour Sets the ramp rate on oFF hold Switches the ramp on or off or hold at last ramp value oFF Oto 1440 min Sets the soak time SP2 OPERATING PARAMETERS see pages ERS 0 to cr 0 Adjust SP2 setpoint Deviation Alarms DV hi DV Lo bAnd 25 sensor maximum see figure 7 Full scale alarms FS hi FS Lo sensor range f s see figure 8 0 1 C F 2 0 C 3 6 F Adjust SP2 hysteresis or proportional band gain see CyC 2 setting 25 sensor f s rar on oFF 0 1 81 seconds Select SP2 ON OFF or proportional cycle time Select on oFF for ON OFF mode or the cycle rate of SP2 output device for proportional mode MANUAL CONTROL MODES M9 t0 100 read only Read SP1 output percen
32. rogram is complete the alternating display stops and the process temperature is displayed The PID values are entered automatically The process temperature will rise to setpoint and control should be stable If not this may be because optimum cycle time is not automatically implemented To set the cycle time see PROPORTIONAL CYCLE TIME REMINDER OF INSTRUMENT ADJ USTMENTS Press amp W together for 3 seconds for program entry or exit Press A or W to scroll through functions Press A together or W together to change levels or alter options Note Ifin difficulty by becoming lost in program mode press A and W together for 3 seconds to return to display mode check the Menu Navigation summary above and try again The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device CYCLE TIME SELECTION METHODS The following methods of cycle time selection may be used Autotune calculated After Autotune has been run and completed the calculated cycle time can be manually accepted or adjusted to suit the switching device For selection method see Select Autotune Calculated Cycle time Pre select Autotune cycle time The controller can be programmed to automatically accept any calculated Autotune cycle time For sel
33. roll through the sensor selection list until the correct sensor is displayed Release the buttons The display now alternates selected sensor type co BEHA and Te S The display will now alternate Pum E and nonE Press A once EJ Select unit Press and hold and use the A or W buttons to scroll through the unit selection list until the correct unit is displayed Release the buttons The display will now alternate selected unit eg Loam amp i The display will now alternate and nonE Press A once EJ Select SP1 Main setpoint output device Note Dual Relay and Dual SSd Output Options Models 3311 9311 and 3322 9322 have their outputs pre configured see page 22 Press and hold and use the A or W buttons to select SSd or rLY as required The controller will now alternate selected output device e g ERE and sso QUICK START EJ To enter initial configuration into controller memory both A and W buttons for 3 seconds The display will now alternate Park and measured variable temperature eg 23 ParK is displayed because a setpoint has not yet been entered Press and hold To display setpoint Press and hold The display will now alternate Oand unit eg To enter setpoint Press and hold and use A button to increase or W button to decrease the reading and scroll to required setpoint value The digit roll over rate increases with time THE CONTROLLER IS NOW OPERATION
34. step 3 and proceed straight to step 4 Before embarking on the Advanced Settings please familiarise yourself with the basic operation of the controller as described in this manual The following instructions assume that the user understands how to make the initial configuration can navigate through the Function Menu and successfully Autotune the controller in heating mode HEAT COOL STRATEGY CONFIGURATION Using BEEE Cool option Heat Cool strategy is a feature that improves control of processes that need heating and cooling depending on the conditions for example Environmental test chambers used in rooms where the ambient temperature swings above and below the test temperature Plastics extruders where the material initially needs heating then cooling when it begins to heat itself exothermically due to pressure and friction applied by the process The purpose of cool strategy is to maintain smooth control of the process during transition from heating to cooling This is achieved by using PID control for heating and cooling with the proportioning bands linked by an adjustable deadband ADVANCED SETTINGS From cold normal procedure on a new installation Enter setpoint and allow the process to reach the setpoint using factory settings for heating only Autotune at setpoint Make the following pre settings Level 1 set AC to 1 0 EYE to 10 and PERE to 10 Level 2 set E to Cool Level 1 set Eune to At SP
35. t compatible with the switching device press and hold the button then press and hold A or W until a more suitable cycle time is displayed Release the buttons then press and hold both A and W buttons for 3 seconds to enter it into the controllers memory Pre Select Automatic Acceptance of Any Autotune Cycle time Before selecting Autotune enter program mode Select TJCE Press and hold the button then press and hold W until indexing stops and A is displayed Note A indicates that no cycle time exists Press and hold W to scroll to The controller will now alternately display PE RE and oFF Press and hold the button and use A to select either on or At SP Release A The controller will now run Autotune and will accept the calculated cycle time To Pre Select Cycle time Before Autotune Before selecting Autotune enter program mode Select iy Press and hold the button then press A to increase or W to decrease the displayed cycle time Release buttons when required value is displayed Select HE RE or index to another function then exit program mode Factory setting Manual settings v Seconds ON OFF Autotune calculated cycle time RAMP SOAK This feature enables the controller to ramp up or down from current temperature to a target setpoint at a pre determined rate It then controls at the target setpoint for an adjustable soak period before switching off the heat output Set R
36. tage power WE oFF 1 to 100 not in ON OFF SP1 manual percentage power control For manual control should a sensor fail Record typical SP1 P values beforehand B00 too duty cycle 100 Set SP1 power limit percentage Limits maximum SP1 heating power during warm up and in proportional band BS 100to0 dutycycle 100 Set SP2 percentage power limit cooling SP2 OPERATING MODES see page BS fnonE dvhi dv Lo bAnd FS hi FS Lo Cool Main SP2 operating mode D 0E Lich hold nLin Subsidiary SP2 mode latch sequence Non linear cool proportional band INPUT SELECTION AND RANGING E o o Select display resolution for display of process temperature setpoint OFSt Set 2 hi SC LoSC a sensor minimum sensor maximum C F Set full scale sensor minimum sensor maximum C 9F Set scale minimum default 0 C or 32 F Select input sensor nonE See SENSOR SELECTION table nonE F bAr Psi Ph rh SEt Select C F or process units OUTPUT CONFIGURATION Note Read only after initial configuration rSET ALL full reset to factory settings required to change subsequently ERM none rly ssa Select SP1 output device EEE none SSd rly Read SP2 output device read only Sensor burn out break protection Caution Settings affect fail safe state SP1 SP2 uP SC Upscale Upscale dn SC Downscale Downscale 1u 2d Upscale Downscale 1d 2u Downscale Upscale Select output
37. the installation or use of this product CAL Controls liability for any breach of this agreement shall not exceed the purchase price paid E amp O E N Ww ES FUNCTIONS MENU process temperature PV or setpoint SP Range of Adjustment shown in red under description If applicable factory settings shown in bold Note Dual Relay and Dual SSd Output Options Models 3311 9311 and 3322 9322 have their outputs pre configured see page 22 Main setpoint SP1 P Second setpoint e i SP2 REME EE E e E a E G GE ES FE INSTRUMENT ADJUSTMENTS c yo To enter or exit program mode Press A W together for 3 seconds To scroll through functions Press Aor Y 0 To change levels or options Press A together or W together _ To view setpoint Press ad To increase setpoint Press A together U To decrease setpoint Press W together c To reset an alarm or fault condition Press A W together briefly z Notes Ifin difficulty by becoming lost in program mode press A and W together for 3 seconds to return to display mode check the PROGRAMMER SETTINGS SP2 SETTINGS INSTRUMENT ADJ USTMENTS above and try again Level enm When in program mode after 60 seconds of key inactivity the eve only visable when COMMS KEY V A TO VIEW FUNCTIONS display will revert to either MES nonE or if the Option fitted initial configuration has been completed the measured value Any settings already co
38. the sleeve Grasp the bezel firmly by the recesses on each side and pull A screwdriver can be used as a lever if required Model 9300 a Dimensions in mm inches Note The controller should be isolated before removing or refitting it in the sleeve and electrostatic precautions should be observed when handling the controller outside the sleeve 51 0 2 0 includes gasket 106 7 4 2 with gasket fitted OUTPUT DEVICES Two of the following output devices are fitted to the controllers depending on the model 1 Solid state relay drive SSd SSd1 SSd2 5Vdc 0 15 15mA non isolating To switch a remote SSR or logic 2 Miniature power relay rLY rLY1 2A 250V resistive Form A SPST contacts 3 Sub miniature power relay rLY2 1A 250V resistive Form A SPST contacts OUTPUT DEVICE ALLO CATION Either of the available outputs may be chosen for the main setpoint SP1 the remaining device being auto matically allocated to the second setpoint SP2 See example illustrated on page 30 STANDARD MODELS 3300 9300 Output Device 1 Output Device 2 DUAL RELAY MODELS 3311 9311 Output Device 2 Output Device 3 DUAL SSd MODELS 3322 9322 Output Device 1 Output Device 1 Dual relay or dual SSd model options 3311 3322 and 3322 9322 are fully detailed on page 22 ELECTRICAL INSTALLATION Designed for use with the following supply voltages 100 240V 50 60 Hz 4 0 VA nominal 10 maximum permitted
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