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User`s Manual - iProcesSmart.com

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1. 2 12 Output 2 Wiring MM 2 13 Alarm 1 Wiring 2 14 Alarm 2 Wiring MM 2 15 R 485 e eeano 2 16 RS 232 eene nennen nnn nn nnno nne 2 17 Analog Retransmission Chapter 3 Programming Special Functions 3 1 Dwell Timer 3 2 Self Tuning e 3 3 Reload Default Parameters 3 4 Auto Tuning o 3 5 Manual Tuning un 3 6 Signal Conditioner DC Power Supply 3 7 Failure Transfer 3 8 Manual Control eo enn 3 9 Sleep Modi noon 3 10 Pump Control eo eo er rr n 3 11 Remote Lockout eo e n n 3 12 Bumpless Transfer Chapter 4 Callbration
2. Chapter 5 Error Codes and Troubleshooting Chapter 6 Specifications Appendix A 1 Menu Existence Your Settings A 2 Warranty erre ne nnn nnnnnnnnnenn 2 UM25001C Chapter 1 Overview 1 1 Features High accuracy 18 bit input A D High accuracy 15 bit output D A Fast input sample rate 10 times second Two function complexity levels User menu configurable Adaptive heat cool dead band Pump control Fuzzy PID microprocessor based control Automatic programming Differential control Auto tune function Self tune function Sleep mode function Soft start ramp and dwell timer Programmable inputs thermocouple RTD mA VDC Analog input for remote set point and CT Event input for changing function amp set point Programmable digital filter Hardware lockout remote lockout protection Loop break alarm Heater break alarm Sensor break alarm Bumpless transfer RS 485 RS 232 communication Analog retransmission Signal conditioner DC power supply A wide variety of output modules Safety UL CSA IEC1010 1 available Front panel sealed to NEMA 4X amp IP65 EMC CE EN61326 FDC 2500 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit LED display indicating process value The Fuzzy Logic technology enables a process t
3. 7 FUNC COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN1 IN1U DP1 IN1L IN1H IN2 IN2U DP2 IN2L IN2H OUT O1TY CYC O1FT OUT2 O2TY CYC2 co Default O2FT Setting od A1FN FILE AiMD Mode for ATFT 3 seconds A2FN To execute the A2MD default setting A2FT EIFN program PVMD ANNANANANAANANANANAAN U L U U L L U U U U L U U 9 9 19 19 09 9j Ld a LO ld a 9 19 3 9 19 9j a a 9 9 a a 9 e D gt DP LY y LY LY y y y J o Callbration Mode ADO FILT SELF SLEP SPMD SP1L SP1H SP2F ADG DISF V1G SEL1 CJTL SEL2 CJG SEL3 REF1 3 9 t9 3 9 9 t9 ADBA 9 9 9 9 9 9 9 t9 t9 9 9 9 9 9 9 9 9 9 9 9 C9 BA 9 9 9 9 9 9 ES 9 dl 9 9 9 9 9 9 NAN ANANANANDANANAANNANANANNANANANANANANANAANANNANANAAAAN SEL4 SR1 MA1G y D
4. 0 1V 0 5V 1 5V 0 10V 0 20 mA 4 20 mA All parameters are Unlocked Only SP1 SEL1 SEL5 are unlocked Lockout Table 1 1 DIP Switch Only SP1 is unlocked Configuration All Parameters are locked Factory Default Setting 8101010 The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these pins when the unit is used for a normal control purpose When the unit leaves the factory the DIP switch is set so that TC amp RTD are selected for input 1 and all parameters are unlocked Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode However the menu can still be viewed even under lockout SEL1 SEL5 represent those parameters which are selected by using SEL1 SEL2 SEL5 parameters contained in Setup menu Parameters been selected are then allocated at the beginning of the user menu UM25001C 1 4 Keys and Displays The unit is programmed by using three keys on the front panel The available key functions are listed in following table Table 1 2 Keypad Operation FUNCTION DESCRIPTION TOUCHKEYS TAS Up Ke Press and release quickly to increase the value of parameter p Key Press and hold to accelerate increment speed T Down Ke Press and release quickly to decrease the value of parameter w y Press and hold to accelerate decrement speed
5. Retransmit deviation PV SV Value Analog Output Low Scale M uv 0 C Value Low 19999 High 45536 32 0 F 100 0 I Analog Output High Scale Taa 2 QC E n eL High 46536 212 0 F J type thermocouple Ktype thermocouple T type thermocouple E type thermocouple IN1 Sensor Type Selection Btype thermocouple R type thermocouple S type thermocouple UM25001C 9 Table 1 6 Parameter Description continued 3 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value T nmn t t Ntype thermocouple 8 L t t Ltype thermocouple 9 PLE dn PT 100 ohms DIN curve 10 PE IS Pr100ohms JIS curve 1 H eu 4 20 mA linear current input v IN1 1 m i INT Sensor Type Selection 12 1 ALF 0 20 mA linear current input T 13 D iv 0 1V linear Voltage input 14 g 4 H 0 5V linear Voltage input 15 f 1 5V linear Voltage input 16 U z TRE 0 10V linear Voltage input 17 SPEL Special defined sensor curve 0 of Degree C unit vw IN1U n ty IN1 Unit Selection 1 DE Degree F unit m 2 Pu Process unit 0 nodP No decimal point 4 DP1 dP 1 IN1 Decimal Point Selection v dede icis pl 1 2 g P 2decimal digits Setup 3 J F 3 decimal digits EUR v INIL m lL INT Low Scale Value Low 19999 High 45536 0 4 IN1H 1 mn 4H IN1 High Scale Value Low 19999 High 45536 1000 0 nant N2 no function 1 Ck Curre
6. The upper display will show Use up down key to select 0 to 1 If BC unit is required select O for FILE and if BF unit is required select 1 for FILE Then Press for at least 3 seconds The display will flash a moment and the default values are reloaded CAUTION The procedures mentioned above will change the previous setup data Before doing so make sure that if it is really required UM25001C Self tune Menu Selects Disable Self tuning Or Enable Self tuning Default SELF NONE Benefits of Self tune Less disturbance to the process 2 Perform PID control during tuning period 3 Available for ramping set point control and remote set point control FILE O BC Default File FILE 1 BF Default File 25 3 4 Auto Tuning A The auto tuning process is performed at set point 26 The process will oscillate around the set point during tuning process Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of Initial setup for a new process The set point is changed substantially from the previous auto tuning value The control result is unsatisfactory Operation Applicable Conditions 1 The system has been installed normally PB1 0 TI1 0 if PB1 TI1 TD1 2 Use the default values for PID before tuning assigned The default values are PB PB2 18 0 F TI1 Tl2 100 sec TD1 TD2 25 0 sec Of co
7. Coot PID cooling control OUT2 Output 2 Function 2 v P z HL e Perform alarm 2 function 3 dL DG DC power supply module installed 4 O2TY Output 2 Signal Type Same as O1TY 0 X CYC2 4L g Output 2 Cycle Time Low 0 1 High 100 0 sec 180 S Select BPLS bumpless transfer or 0 0 100 0 4 O2FT na ut 2 Failure Transfer 96 to continue output 2 control function as the unit BPLS oae fails power starts or manual mode starts LE Setup 0 nanc No alarm function Menu 1 t 1 rum Dwell timer action 2 dEH Deviation high alarm 3 dEL Deviation low alarm 4 daH Deviation band out of band alarm 5 dhL m Deviation band in band alarm 6 pu H IN1 process value high alarm 7 LU 11 INT process value low alarm vA ATFN Alarm 1 Function PRL p 2 8 PUgH IN2 process value high alarm N2 process value low alarm IN1 or IN2 process value high alarm IN1 or IN2 process value low alarm IN1 IN2 difference process value high alarm IN1 IN2 difference process value low alarm Loop break alarm Sensor break or A D fails Normal alarm action Latching alarm action 4 A1MD Alarm 1 Operation Mode 0 Hold alarm action Latching amp Hold action 11 UM25001C Table 1 6 Parameter Description continued 5 7 Contained Basic Parameter Display Format Description in Function Notation Parameter Default Range 9 Value Z Alarm output OFF as unit fails Setup Menu PVMD DU ad PV Mode Selection Fi
8. Does the process oscillate the process oscillate Yes PB1 PBu Oscillating period gt Tu 2PB1 PB1 0 5PB1 PB1 Load new PID values 1 7 PBu PB1 Tu TI1 0 3 Tu _ TD1 steady state reached NOTE The final PID values can t be zero If PBu 0 then set PB1 1 If Tu lt 1 sec then set TI121 sec the process oscillate 1 6PB1 PB1 0 8PB1 PB1 The above procedure may take a long time before reaching a new steady state since the P band was changed This is particularly true for a slow process So The above manual tuning procedures will take from minutes to hours to obtain optimal PID values 28 UM25001C The PBu is called the Ultimate P Band and the period of oscillation Tu is called the Ultimate Perlod In the flow chart of Figure 3 3 When this occurs The process Is called In a critical steady state Figure 3 4 shows a critical steady state occasion If PB PBu The process sustains to oscillate Figure 3 4 Critical Steady l Set point i State I l Time If the control performance by using above tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB1 or PB2 1 Proportional Band P m E PB1 and or PB2 gh overshoot or Osclllations Increase PB1 or PB2 Slow Response Decrease Tl1 or TI2 2 Integra
9. Indicates output 1 or heating control variable value MV1 ande Means indicates output 2 or cooling control variable value MV2 Now you can use MV2 7 63 up down key to adjust the percentage values for H or C for OUT2 L or Cooling The controller performs open loop control as long as it stays in manual control mode The H value is exported to output 1 OUTI and C value is exported to output 2 provided that OUT2 Is performing cooling function le OUT2 selects COOL Exceptlon If OUTI is configured as ON OFF control le PB1 0 if PB1 Is assigned or PB2 0 if PB2 is assigned by event input the controller will never perform manual control mode Exit Manual Control To press keys the controller will revert to its previous operating mode may be a failure mode or normal control mode 3 9 Sleep Mode To Enter Sleep Mode Sleep Mode Features FUNC selects FULL to provide full function Shut off display SLEP selects YES to enable the sleep mode Shut off outputs Press for 3 seconds the unit will enter its sleep mode Green Power During sleep mode Replace Power Switch 1 Shut off all display except a decimal point which is lit periodically 2 Shut off all outputs and alarms Setup Menu FUNC FULL To Exit Sleep Mode SLEP YES 1 Press to leave the sleep mode 2 Disconnect the power Sleep Function can be used to replace a power switch to reduce the system cost Default SLEP NONE Sleep mode is di
10. LY Lo Pop o ANANANANANAN GE Q M M MU M M 9 9I d d 9 9 V2G 9j 9 gi di a a 9 1 SELS for 3 seconds D v 9 9 9 di a 9 a a a 9 9 di a a a e ANNNNNANANANANANANANANA 3 9 a di 9 9 a 09 19 aa di 9 ld ae D gt LY LY LI LY y p WI LY LI Ly Ly Py D U U U U U U U U U U L U U L L U U Display Go Home The menu will revert to PV SV display after keyboard is kept untouched for 2 minutes except Display Mode Menu and Manual Mode Menu However the menu can revert to PV SV display at any time by pressing and A AAAA AAYA AAYA AA 0 0 DI DI C D Db DI DI DI D D A BI BI C DI AAYA BI DI DI DI DI DI DI DI DI DI BI DI 3 ES o B ES 9 9 9 9 9 9 9 9 9 9 9 EJ 9 9 dl 9
11. Scroll Key Select the parameter in a direct sequence Allow access to more parameters on user menu also used to Enter manual mode auto tune mode default setting mode and to save calibration data during calibration procedure Press ce Enter Key for at least 3 seconds Fress C8 Start Record Key for at least 6 seconds Reset historical values of PVHI and PVLO and start to record the peak process value Press A Reverse Scroll Key Press Mode Key Select the parameter in a reverse sequence during menu scrolling Select the operation Mode in sequence Press A X Reset Key Press for at least 3 seconds Press CO A X Factory Key 4 digit Display to display process value set point value menu symbol parameter value control output value and error code etc Output 1 Indicator Output 2 Indicato Alarm 1 Indicator fd 2o ian C 3 Silicone Rubber Buttons for ease of control setup and set point adjustment Figure 1 4 Front Panel Description Table 1 3 Display Form of Characters Confused Character Reset the front panel display to a normal display mode also used to leave the specific Mode execution to end up the auto tune and manual control execution and to quit the sleep mode Sleep Ke The controller enters the sleep mode if the sleep function SLEP is enabled p sey select YES By ent
12. 1 Vp p 500 VAC and testing 5V AO 15V 80mA 10 05 Vp p 500 VAC Communication Port Connection to PC for supervisory control Alarm 1 Alarm 2 Control Mode Alarm 1 5V DC logic output max source current 100mA Oulput 1 Reverse heating or direct cooling short circuit unprotected action Alarm 2 Relay Form A Max rating 2A 240VAC Output 2 PID cooling control cooling P band 1 life cycles 200 000 for resistive load 255 of PB Alarm Functions Dwell timer ON OFF 0 1 100 0 LF hysteresis control Deviation High Low Alarm P band 0 Deviation Band High Low Alarm P or PD O 100 0 96 offset adjustment PV1 High Low Alarm PID Fuzzy logic modified PV2 High Low Alarm Proportional band 0 1 900 0 LF PV1 or PV2 High Low Alarm Integral time O 1000 seconds PV1 PV2 High Low Alarm Derivative time O 360 0 seconds Loop Break Alarm Cycle Time 0 1 100 0 seconds Sensor Break Alarm Manual Control Heat MV1 and Cool MV2 Alarm Mode Normal Latching Hold Latching Hold Auto tuning Cold start and warm start Dwell Timer 0 6553 5 minutes Self tuning Select None and YES Fallure Mode Auto transfer to manual mode while sensor break or A D converter damage Data Communication Sleep Mode Enable or Disable Interface RS 232 1 unit RS 485 up to 247 units Ramping Control 0 900 0 LF minute or Protocol Modbus Protocol RTU mode O 900 0 LF hour ramp rate Address 1 247 l Powe
13. 10V OV 10 10 5V 10KQ min Linear Output Resolutlon 15 bits Resolution 15 bits Accuracy A0 05 96 of span A0 0025 LC Output Regulation 0 01 96 for full load change Load Resistance Output Settling Time 0 1 sec stable to 99 9 0 500 ohms for current output Isolation Breakdown Voltage 1000 VAC 10 K ohms minimum for voltage output Temperature Effect A0 0025 96 of SPAN LC Output Regulation 0 01 96 for full load change Output Settling Time 0 1 sec stable to 99 9 Trlac SSR Output Isolation Breakdown Voltage 1000 VAC min Rating 1A 240 VAC Integral Linearity Error A0 005 of span Inrush Current 20A for 1 cycle Temperature Effect A0 0025 of span LC Min Load Current 50 mA rms Saturation Low 0 mA or OV Max Off state Leakage 3 mA rms Saturation High 22 2 mA or 5 55V 11 1V min Max On state Voltage 1 5 V rms Linear Output Range 0 22 2mA 0 20mA or 4 20m4A Insulation Resistance 1000 Mohms min at 500 VDC 0 5 59V 0 SV 1 SV Dielectric Strength 2500 VAC for 1 minute pes pas IM DC Voltage Supply Characteristics Installed crt Output 2 DC Voltage Supply Characteristics Installed at Output 2 User Interface l Riople Dual 4 digit LED Displays Upper 0 4 10 mm Type olerance M KLEG Voltage Bamer FEM Lower 0 3 8 mm eypad 3 keys 20V A0 5V 25mA 02Vp p 500 VAC Programming Port For automatic setup calibration 12V A0 3 V 40mA 10
14. 9 OHKAB 9 BBH 9 BBB dl 9 9 9 9 o 9 di CS OCS dl 9 9 9 9 o UUUUUUUUUUUUuUuUuUuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu The flow chart shows a complete listing of all parameters For actual appl depends on se cation the number of available parameters up conditions and should be less than that shown In the flow chart See Appendlx A 1 for the existence condi itions of each parameter 2 You can select at most 5 parameters put In front of the user menu by using SELT to SEL5 contained at the bottom of setup menu Set DISF display format value In the setup menu to determine whether PV or SV Is displayed Apply these modes will break the control loop and change some of the previous setting data Make sure that if the system is allowable to use these modes 13 UM25001C 1 6 Parameter Description Table 1 4 Parameter Description Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value s Set point 1 Low SPIL High SP1H 212 0 F A Dwell Time Low 0 High 6553 5 minutes 0 0 VY A IGP Alarm 1 Set point See Table 1 5 1 6 212 0 F S 200 0 C s 200 0 C 10 0 C m Alarm 1 Deviation Value Low 360 0 F High 360 0 F 18 0 F A A2SP Hg5P Alarm 2 Set point See Table 1 5 1 7 212 0 F T 200 0 C 200 0 C T0 0 C 4 A2DV Add Alarm 2 D
15. A 3 LC The 5520A calibrator is configured as K type thermocouple output with Internal compensation Send a 0 00 LC signal to the unit under calibration UM25001C 37 The unit under calibration is powered in a still alr room with temperature 25 C Stay at least 20 minutes for warming up The DIP Switch Is located at TC Input Perform step 1 stated above then press scroll key until the display shows Apply up down key until value 0 00 is obtained Press scroll key at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 5 00 or 40 00 then the calibration fails x Perform step 10 to calibrate gain of cold Junction compensation if required otherwise perform step 10N to use a nominal value for the cold junction gain if a test chamber for calibration is not avallable Step 10 Setup the equipments same as step 9 The unit under calibration is powered in a still air room with temperature 50A3 BC Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode Perform step 1 stated above then press scroll key until the display shows Apply up down key until value 0 0 Is obtained Press scroll key for at least 3 seconds The display will blink a moment and a new value Is obtained Otherwise If the display didn t blink or If the obtained value Is equal to 199 9 or 199 9 then the c
16. Material BS ASTM DIN NFE Copper Cu white blue red yellow T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe t yellow t white red t yellow J Constantan blue red blue black Cu Ni black black blue black aries brown yellow 4 red yellow K Nickel Aluminum Plue e Hen Purple red yellow green yellow Ni Al frs white black t red yellow Lua blue red white green SOME green green white green i Pt 30 Rh Use va Gs Use Pt 696Rh Copper Wire grey grey Copper Wire 44 Colour of overall sheath UM25001C A 1 Menu Existence Conditions User Settings Menu Existence Conditions Table A2SP Exists If A2FN selects PV1H PV1L PV2H PV2L P12H P12L D12H or D12L so Exists If TI1 Is used for control depends on Event Input and EIEN selection but TI12 0 and OFST PB1 0 or if TI2 is used for control depends on Event input and EIEN selection but TI2 O and PB2 0 REFC Exists If SPMD selects PUMP Exists unconditionally Exists if PB1 0 TD CPB Exists if OUT2 select COOL Exists If EIEN selects SP2 or SPP2 or if SPMD selects PUMP Exists If EIFN selects PID2 or SPP2 Exists if EIFN selects PID2 or SPP2 provided that PB2 0 zi N TD2 If PID2 or SPP2 is selected for EIEN then O1HY exists if PB O or PB2 O If PID2 or SPP2 Is not selected for EIEN then O1HY exists If PB O A1HY Exists if ATFN sele
17. activated will perform 1 If output 1 is configured as proportional control PB1 Z 0 and BPLS is selected for O1FT then output 1 will perform bumpless transfer Thereafter the previous averaging value of MV1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB1 Z 0 and a value of 0 to 100 0 96 is set for O1FT then output 1 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 1 3 If output 1 is configured as ON OFF control PB1 0 then output 1 will be driven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT Output 2 Failure Transfer if activated will perform 1 If OUT2 selects COOL and BPLS is selected for O1FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 selects COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 2 Alarm 1 Failure Transfer is activated as the controller enters failure mode Thereafter the alarm 1 will transfer to the ON or OFF state preset by A1FT Alarm 2 Failure Transfer is activated as the controller enters failure mode Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT UM25001C 30 Figure 3 6 DC Power Supply Applications Don t use the DC power supply beyond Its
18. any damage due to transit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of control 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout MOUNTING CLAMP Figure 2 1 Mounting Dimensions UM25001C 15 2 3 Wiring Precautions Before wiring verify the label for correct model number and options Switch off the power while checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded t isrecommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system The stripped leads as specified in Figure 2 2 below are used for power and sensor connections Beware not to over tigh
19. for both A1FN and A2FN timer can only be properly used for single alarm output E Correct the communication software to meet the protocol Lv E 10 conmnesion err nono Ci e oome er E G ee e cnn wore eta oan tore aoa woe FS ec nn nei oe momcesesne mener 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value during auto tuning 26 Fail to perform auto tuning function procedure 3 Don t change Event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning 29 EEPE EEPROM can t be written correctly Return to factory for repair Input 2 IN2 sensor break or input 2 current below 1 mA if 4 20 mA is selected or input 2 voltage below 0 25V if Replace input 2 sensor 1 5V is selected Input 1 IN1 sensor break or input 1 current below 1 mA if 4 20 mA is selected or input 1 voltage below 0 25V if Replace input 1 sensor 1 5V is selected 40 RdE A to D converter or related component s malfunction Return to factory for repair 40 UM25001C Table 5 2 Common Fallure Causes and Corrective Actions Symptom Probable Causes Corrective Actions Clean contact area on PCB 1 Keypad no function Bad connection between PCB amp keypads Replace keypads TN No power to instrument Check power line connections 2 LED s will not light Power supply defective Replace power supply board 3 Some segments of the display o
20. is not NONE EIFN A2MD PVMD Exists if FUNC selects FULL Setup Menu FILT SELF Exists unconditionally SLEP Exists if FUNC selects FULL SPMD SPIL Exists unconditionally SP1H SP2F Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists unconditionally UM25001C 47 A 2 Warranty WARRANTY Future Design Controls warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or use of Future Design products is the Purchaser s responsibility No claims will be allowed for any damages or losses whether direct indirect incidental special or consequential Specifications are subject to change without notice In addition Future Design reserves the right to make changes without notification to Purchaser to materials or processing that de not affect compliance with any applicable specification Future Design products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use An extended period is available with extra cost upon request Future Design s sole responsibility under this warranty at Future Design s option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse RETURNS No products return ca
21. prevent from being changed by using either Hardware Lockout see Section 1 3 or Remote Lockout or both If you need the parameters to be locked by using an external switch remote lockout function then connect a switch to terminals 10 and 11 see Section 2 10 and choose LOCK for EIFN If remote lockout is configured all parameters will be locked as the external switch is closed When the switch is left open the lockout condition is determined by internal DIP switch hardware lockout see Section 1 3 Hardware Lockout Can be used only during initial setup Remote Lockout Can be used any time UM25001C Remote Lockout 1 Connect external switch to terminal 9 and 2 Set LOCK for EIFN 3 Lock all parameters 33 3 12 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 provided that OUT2 is configured as COOL Bumpless Transfer is enabled by selecting BPLS for O1FT and or O2FT and activated as one of the following cases occurs 1 Power starts within 2 5 seconds 2 The controller enters the failure mode See Section 3 7 for failure mode descriptions 3 The controller enters the manual mode See Section 3 8 for manual mode descriptions 4 The controller enters the calibration mode See Chapter 4 for calibration mode descriptions As the bumpless transfer is activated the controller will transfer to open loop control and uses the previous averaging value of MV1 and M
22. rating current to avoid damage Purchase a correct voltage to suit your external devices Failure Mode Occurs as 1 SB1E 2 SB2E 3 ADER Failure Transfer of alarm 1 and alarm 2 Occurs as 1 Failure mode is activated Failure Transfer Setup 1 O1FT 2 O2FT 3 ATFT 4 A2FT Exception If Loop Break LB alarm or sensor Break SENB alarm is configured for ATFN or A2FN the alarm 1 alarm2 will be switched to ON state independentof the setting of ATFT A2FT If Dwell Timer TIMR is configured for A1FN A2FN the alarm 1 alarm2 will NOT perform failure transfer 3 8 Manual Control The manual control may be used for the following purposes 1 To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller 2 To use manual control Instead of a close loop control as the sensor falls or the controller s A D converter fails NOTE that a bumpless transfer can not be used for a longer time See section 3 12 3 In certain applications it is desirable to supply a process with a constant demand Operation Press until Hand Control appears on the display Means Press ce for 3 seconds then the upper display will begin to flash and the lower MV1 38 4 96 display will show 4 The controller now enters the manual control mode for OUTI or Heating Pressing ce the lower display will show 7 and altemately where T3E3 H _
23. 10V 9 Special order Output 2 Alarm 2 0 None 1 Form A Relay 2A 240VAC 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20mX 4 Isolated 1 5V 0 5V 5 Isolated O 10V 6 Triac Output 1A 240VAC SSR 7 Isolated 20V 25mA DC Output Power Supply 8 Isolated 12V 40 mA DC Output Power Supply 9 Isolated 5V 80mA DC Output Power Supply A Special order Range set by front keyboard Alternative between RS 232 and Input 2 xxx Need to order an accessory CT94 1 if Heater Break detection is required Related Products P1OA Hand held Programmer for FDC Series Controller SNAT10OA Smart Network Adaptor for Third Party Software Converts 255 channels of RS 485 or RS 422 to RS 232 Network SNA10B Smart Network Adaptor for FD Net Software Converts 255 channels of RS 485 or RS 422 to RS 232 Network VPFW20 20 Amp Variable Period Full Wave SSR AC Power Module VPFW50 50 Amp Variable Period Full Wave SSR AC Power Module VPFW100 100 Amp Variable Period Full Wave SSR AC Power Module 1 3 Programming Port and DIP Switch Front Access Hole Rear Panel Terminal Figure 1 3 Access Hole Overview The programming port is used to connect to P10A hand held programmer for automatic programming also can be connected to ATE system for autornatic testing amp calibration DIP Switch Bo lorr TC RTD mV
24. 15 Output 2 Wiring ied Max 1A 240V 120V 240V Mains Supply 120V 240V Mains Supply Trlac SSR Output 0 1V 0 5V 1 5V 0 10V Linear Current Linear Voltage Maximum Load 500 ohms Minimum Load 10 K ohms 30mA 5V Pulsed Voltage Pulsed Voltage to Drive SSR UM25001C 21 2 13 Alarm 1 Wiring Flgure 2 16 Internal Circuit Alarm 1 Wiring j 5V l 7 1K ov 14 LL vu 5VDC Loglc Output 2 14 Alarm 2 Wiring Figure 2 17 Alarm 2 Wiring Max 2A Resistive 120V 240V Mains Supply Relay Output 2 15 RS 485 RS 485 to RS 232 Figure 2 18 network adaptor RS 485 Wiring SNA10A or Last Unit In Network Max 247 units can be linked Terminator 220 ohms 0 5W 22 UM25001C 2 16 RS 232 PC Figure 2 19 cold Sio RS 232 Wiring 9 pin llr RS 232 port al g CC94 1 Note if the FDC 2500 Is configured for RS 232 communication the input 2 and El Event Input are disconnected internally The unit can no longer perform event Input function EIFN and input 2 function When you insert a RS 232 module CM94 2 to the connectors on CPU board C250 the jumper J51 and J52 must be modified as following J52 must be shorted and J51 must be cut and left open Location of jumper is shown in the following diagram Jumper Figure 2 20 Location of Jumper J51 J52 a4 RR dia NO SW51 v o0000 R 00000 CN55 D
25. 6383 EA Table 1 5 Input IN1 or IN2 Range 120 LC 184 LF 1000 LC 1832 LF 250 LC 200 LC C418 LF 328 LF 1300LC 9001C 700LC 6001C 2372 LF 1652 LF 1292 LF 1112 LE 90 Amp 45536 14 200 LC 2500C 100LC olc olc OLC 328 LF 418 LF 148 LE 32 LF 32LF 32 LE 1370LC 400 LC 9001C 1820 LC 1767 8 LC 1767 8 LC 2498 LF 752 LF 1652 LF 3308 LF 3214 LF 3214 LF UM25001C 210 LC 200 LC 346 LF C328 LF 19999 Chapter 2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a Qualified maintenance person only AN To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If
26. F Control Set Point PID Control Warm Start Us If the auto tuning begins near the set point warm start the unit passes the warm up cycle and enters the waiting cycle Afterward the procedures are same as that described for cold start Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of Auto Tuning Error e f PB exceeds 9000 9000 PU 900 0 LF or 500 0 LC or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure e or if event input state is changed so that set point value is changed Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t change event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning See section 3 8 5 Touch any key to reset ALE message UM25001C 27 3 5 Manual Tuning In certain applications very few using both self tuning and auto tuning to Tune a process may be inadequate for the control requirement then you can try manual tuning Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram Use initial PID values to control the process Wait and Examine the Process Is steady state reached Figure 3 3 Manual Tuning Procedure Wait and Examine the Process steady state reached
27. V2 to continue control Without Bumpless Transfer PV K Power interrupted NEL break Set point Large deviation Time Since the hardware and software need time to be initialized the control is abnormal as the power is recovered and results in a large disturbance to the process During the sensor breaks the process loses power With Bumpless Transfer PV za HK Power interrupted Sensor break Set point Load varies Small deviation After bumpless transfer configured the correct control variable is applied immediately as the power is recovered the disturbance is small During the sensor breaks the controller continues to control by using its previous value If the load doesn t change the process will remain stable Thereafter once the load changes the process may run away Therefore you should not rely on a bumpless transfer for a longer time For fail safe reason an additional alarm should be used to announce the operator when the system fails For example a Sensor Break Alarm if configured will switch to failure state and announces the operator to use manual control or take a proper security action when the system enters failure mode 34 UM25001C Bumpless Transfer Setup 1 O1FT BPLS 2 O2FT BPLS Bumpless Transfer Occurs as 1 Power Starts within 2 5 seconds 2 Failure mode is activated 3 Manual mode is activated 4 Calibration mode is a
28. a moment and a new value is obtained Otherwise if the display didn t blink or if tne obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 4 to calibrate voltage function if required for input 1 Step 4 Change the DIP switch for the Voltage Input Press scroll key until DIP Switch Position ON G ne Send a 10 V signal to terminals 10 and E 5 i 0 10V Input polarity Press scroll key for at least 3 seconds The aa display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the callbration falls Perform both steps 5 and 6 to callbrate RID function If required for input 1 Step 5 Change the DIP switch for the RTD input Press scroll key until the DIP Switch Position Isplay sh h Ignal to terminals 8 9 P display shows Send a 100 ohms signal to terminals 8 LII RID Input and 10 according to the connection shown below ici RTD Callbration 8 Pee uu Figure 6 1 Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails 36 UM25001C Step 6 Press scroll key and the display will show Change the ohms value to 300 ohms Press scroll key for at least 3 seconds The display will blink a moment and two values are obtained for SR1 and REF1 last step Otherwise if the display didn t blink or if any value obtained for SRI and REFI is equa
29. alibration fails This setup is performed in a high temperature chamber hence it is recommended to use a computer to perform the procedures Step 10N Perform step 1 stated above then press scroll key until the display shows Apply up down key until value 0 1 Is obtained Press scroll key for at least 3 seconds The display will blink a moment and the new value 0 0 Is obtained Otherwise the calibration fails Caution It is not recommended to use this step 10N since the cold Junction gain Is not able to achieve rated accuracy by this step Final step Step 11 Set the DIP switch to your desired position refer to section 1 3 38 UM25001C Chapter 5 Error Codes amp Troubleshooting A This procedure requires access to the circuitry of a live power unit Dangerous accidental contact with line voltage is possible Only qualified personnel are allowable to perform these procedures Potentially lethal voltages are present Troubleshooting Procedures 1 If an error message Is displayed refer to Table 5 1 to see what cause It Is and apply a corrective action to the failure unit 2 Check each point listed below Experience has proven that many control problems are caused by a defective instrument Line wires are improperly connected No voltage between line terminals Incorrect voltage between line terminals Connections to terminals are open missing or loose Thermocouple is open at tip Thermocouple lead Is bro
30. ansmission 4 eu output Setup r_ BREA m Menu COMM Lonn Communication Interface 4 n L n 0 20 mA analog retransmission 1 Type output 5 U uU 0 1V analog retransmission output m CU 0 5V analog retransmission G u 2 output ds 1 1 5V analog retransmission Td 5 output PH tf1 0 10V analog retransmission Su TU output PROT Prot COMM Protocol Selection O yy Modbus protocol RTU mode 0 8 UM25001C Table 1 6 Parameter Description continued 2 7 Contained Basic Parameter Display Parameter in Function Notation Format Description Address Assignment of Digital AES Addr COMM High 255 0 3 Kbits s baud rate 0 6 Kbits s baud rate 1 2 Kbits s baud rate n c3 C3 2 PU cy LU 2 4 Kbits s baud rate 4 8 Kbits s baud rate Baud Rate of Digital COMM jm 99 Kbits s baud rate 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate Data Bit count of Digital e bs COMM 8 data bits Even parity Parity Bit of Digital COMM Odd parity No parity bit Stop Bit Count of Digital i One stop bit COMM Two stop bits Retransmit IN1 process value Retransmit IN2 process value Retransmit IN1 IN2 difference process value Retransmit IN2 IN1 difference process value Hat n Analog Output Function Retransmit set point value Retransmit output 1 manipulation value Retransmit output 2 manipulation value
31. ctivated Figure 3 21 Benefits of Bumpless Transfer Warning After system fails never depend on bumpless transfer for a long time otherwise it might cause a problem to the system to run away Chapter 4 Calibration Do not proceed through this section unless there is a definite need to re calibrate the controller Otherwise all previous calibration data will be lost Do not attempt recalibration unless you have appropriate calibration equipment If calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to re calibrate the controller IN Entering calibration mode will break the control loop Make sure that if the system is allowable to apply calibration mode Equipments needed before calibration 1 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functions O 100 mV millivolt source with AO 005 96 accuracy 0 10 V voltage source with A0 005 accuracy O 20 mA current source with A0 005 96 accuracy O 300 ohm resistant source with A0 005 96 accuracy 2 A test chamber providing 25 BC 50 BC temperature range 3 A switching network SW6400 optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software FD Net and Smart Network Adaptor SNATOB optional for automatic calibration The calibration procedures described in
32. cts DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A2HY Exists If A2FN selects DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L O1HY If PID2 or SPP2 Is selected for EIEN then PL1 exists If PB1 or PB2 Q If PID2 or SPP2 Is not selected for EIFN then PL1 exists If PB1 0 PL2 Exists If OUT2 selects COOL PLI UM25001C 45 Menu Existence Condltlons User Settings Table continued 2 3 Parameter Your FUNC Exists unconditionally COMM Exists if FUNC selects FULL Exists If COMM selects 485 or 232 AOFN Exists If COMM selects 4 20 0 20 0 1V O 5V 1 5V or 0 10 AOLO bd Exists If COMM selects 4 20 0 20 0 1V O 5V 1 5V or 0 10 and AOFN Is not MV1 and MV2 AOHI Exists unconditionally Setup w Exists If FUNC selects FULL Exists if IN2 selects 4 20 0 20 O 1V 0 5V 1 5V or 0 10 Exists unconditionally Exists If OUT2 selects COOL Menu INIL Exists if INT selects 4 20 0 20 O 1V O 5V 1 5V or 0 10 INTH 46 UM25001C Menu Existence Conditions User Settings Table continued 3 3 Menu Parameter Existence Conditions Notation A1FN Exists unconditionally AIMD Exists if ATFN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB ATFT Exists if ATFN is not NONE A2FN Exists unconditionally Exists if A2FN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB A2FT Exists if A2FN
33. e at lower speed the Pump Control Features pump may not stop running even If the pressure has reached the set point 1 Minimum oscillation of pressure If this happens the pump will be over wom out and waste additional 2 Rapidly stabilized power To avold this the FDC 2500 provides a Reference Constant REFC Ih 3 Guaranteed pump stop the user menu If PUMP is selected for SPMD the controller will periodically 4 Programmable pump stopping test the process by using this reference constant after the pressure has Interval reached its set point If the test shows that the pressure is still consumed by The process the controller will continue to supply appropriate power to the pump If the test shows that the pressure is not consumed by the process the controller will gradually decrease the power to the pump until the pump stops running As this happens the controller enters Idle state The Idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below this set point The Idle state is provided for the purpose of preventing the pump from been restarted too frequently The value of SP2 should be negative to ensure a correct function The pump functions are summarized as follows 1 If the process is demanding material ie lose pressure the controller will precisely control the pressure at set point 2 If the process no longer consumes material the controller will shut off the pump as
34. ering correct security code to allow execution of engineering programs This function is used only at the factory to manage the diagnostic reports The user should never attempt to operate this function How to display a 5 digit number For a number with decimal point the display will be shifted one digit right 199 99 will be displayed by 199 9 4553 6 will be displayed by 4553 Power On Sequence 1 Display segments off for 0 5 secs 2 Display segments on for 2 0 secs 3 Display program code for 2 5 secs 4 Display date code for 1 25 secs 5 Display s n code for 1 25 secs For a number without decimal point the display will be divided into two alternating phases 19999 will be displayed by n n l l 45536 will be displayed by d d s 9999 will be displayed by Program Version Program No P 2 1 JL 1 D zz 0333 NS Year 1999 UM25001C 1 5 Menu Overview PV Value SV Value I C C L moor LC User Menu Hand Manual Control A Mode Mode A Press for 3 seconds to enter the auto tuning mode for 3 seconds Auto tuning Display _ Mode
35. eviation Value Low 360 0 F High 360 0 F 18 0 F f 500 0 C RAMP c Hab Ramp Rate Low 0 High 900 0 F 0 0 4 OFST mE 5L Offset Value for P control Low 0 High 100 0 96 250 r Reference Constant for igh REFC CEP L Specific Function Low 0 High 60 2 200 0 C igh 200 09C A SHIF GH F PV1 Shift offset Value Low 360 0 F High 360 0 F 0 0 4 PB1 Ph Proportional Band 1 Value Low 0 High 900 0 F 189 F User A TM E Integral Time 1 Value Low 0 High 1000 sec 100 Menu 4 TD1 Ed Derivative Time 1 Value Low 0 High 360 0 sec 250 v CPB EB Ea Proportional Band T 1 High 255 100 37 8 C SP2 GAP Set point 2 See Table 1 5 1 8 100 0 F PB2 Pbg Proportional Band 2 Value Low 0 High 900 0 F d End F TI2 E g Integral Time 2 Value Low 0 High 1000 sec 100 TD2 Ladd Derivative Time 2 Value Low 0 High 360 0 sec 25 0 Output 1 ON OFF Control Sa 99 6 C Y O1HY n IHH Hysteresis ono Low 0 1 High 100 0 F 0 1 4 A1HY A 10 U Hysteresis Control of Alarm 1 Low 0 1 High d E F 0 1 4 A2HY ACHY Hysteresis Control of Alarm 2 Low 0 1 High d aa F 0 1 PL1 PL Output 1 Power Limit Low 0 High 100 96 100 PL2 PL 2 Output 2 Power Limit Low 0 High 100 96 100 o SASL Basic Function Mode A FUNC Fis Af Function Complexity Level bASL 1 1 Fol L Full Function Mode 0 nant No communication function 1 YAS RS 485 interface 2 PAC RS 232 interface m 4 20 mA analog retr
36. f error are A4degrees F A2degrees C or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement UM25001C 17 2 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2 5 The correct type of thermocouple extension lead wire or compensating cable must be used for the entire distance between the controller and the thermocouple ensuring that the t polarity is correctly observed throughout Joints in the cable should be avoided if possible If the length of thermocouple plus the extension wire is too long it may affect the temperature measurement A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce 1 degree C temperature error approximately Figure 2 5 Thermocouple Input Wiring 2 7 RTD Input Wiring RTD connection are shown in Figure 2 6 with the compensating lead connected to terminal 9 For two wire RTD inputs terminals 9 and 10 should be linked The three wire RTD offers the capability of lead resistance compensation provided that the Two wire RTD should be avoided if possible for the purpose of accuracy A 0 4 ohm lead resistance of a two wire RTD will produce 1 degree C temperature error NE rnm Flgure 2 6 RTD Input Wiring on gt DIP Switch Three
37. function with an ON OFF control Learning cycle is used to test the characteristics of the process The data are measured and used to determine the optimal PID values At the end of the two successive ON OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory After the auto tuning procedures are completed the process display will cease to flash and the unit revert to PID control by using its new PID values During pre tune stage the PID values will be modified if any unstable phenomenon which is caused by incorrect PID values is detected Without pre tune stage like other conventional controller the tuning result will be strongly related to the time when the auto tuning is applied Hence different values will be obtained every time as auto tuning is completed without pre tune It is particularly true when the auto tuning are applied by using cold start and warrn start UM25001C Auto tuning Auto tuning Begins Complete Cycle Cycle Learning Cycle New PID Cycle all Fe 2 Integral Time Pre tune Stage PV Figure 3 2 Auto tuning Procedure Set Point Post tune Stage ON OFF Control I PID Control PID Control Time Cold Start Auto tuning Auto tuning Begins Complete T stage PV Waiting Cycle Learning Cycle New PID Cycle 2 Integral Time Pre tune Stage Post tune Stage pw 1 PID Control ON OF
38. ge spike sources Radio Frequency interference RFI Separate sensor and controller wiring from EEPROM defective dirty power lines ground heaters Replace EEPROM 10 Display blinks entered values change by themselves UM25001C 41 Chapter 6 Specifications Power 90 264 VAC 47 63 Hz 15VA 7W maximum 11 26 VAC VDC 15VA 7W maximum Input 1 Resolution 18 bits Sampling Rate 10 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect A0 005 96 of reading LC Sensor Lead Reslstance Effect T C 0 2uV ohm 3 wire RTD 2 6 LC ohrn of resistance difference of two leads 2 wire RTD 2 6 LC ohrn of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 1 20dB Sensor Break Detection Sensor open for TC RTD and mV inputs below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mv inputs 0 1 second for 4 20 mA and 1 5 V inputs Input Impedance Accuracy Input 25 C Impedance Characteristics Range 120 C 1000 C 184 F 1832 F 200 C 1370 C 328 F 2498 F 250 C 400 C 418 F 752 F 100 C 900 C 148 F 1652 F 0 C 1820 C 32 F 3308 F 0 C 1767 8 C 32 F 3214 F 0 C 1767 8 C Input 2 Resolution 18 bits Sampling Rate 2
39. idden md Same case is for alarm 2 A1 or A2 l TIME l Example ON ip ag Set ATFN TIMR or A2FN TIMR but not both o3 Em Adjust TIME in minutes d AT1MD if ATFN TIMR or A2MD if A2FN TIMR is ignored in this case Time If alarm 1 is selected for dwell timer an external 5V DC relay is required to drive Timer starts AC load Figure 3 1 Dwell Timer Function 24 UM25001C 3 2 Self Tuning The Self tuning which is designed by using an Innovative algortthm provides an alternative option for tuning the controller It is activated as soon as SELF is selected with YES When Self tuning is working the controller will change its working PID values and compares the process behavior with previous cycle If the new PID values achieve a better control then changing the next PID values in the same direction otherwise changing the next PID values in reverse direction When an optimal condition is obtained the optimal PID values will be stored in PB1 TI1 TD1 or PB2 TI2 TD2 which is determined by Event Input conditions When Self tuning is completed the value of SELF will be changed from YES to NONE to disable self tuning function When the Self tuning is enabled the control variables are tuned slowly so that the disturbance to the process is less than auto tuning Usually the Self tuning will perform successfully with no need to apply additional autottuning Exceptions The Self tuning will be disabled as soon as one of the follo
40. isplay If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable must be modified according to the following circuit diagram To DTE PC RS 232 Port 1 DCD FDC 2500 2RD 31D Figure 2 21 TQ e gure 2 Q 4 DIR Configuration of RS 232 TX2 10 5 GND Cable 6 DSR 7 RTS com 14 8 CIS 9 RI Female DB 9 UM25001C 23 2 17 Analog Retransmission The total effective resistance of serial The total effective resistance of parallel loads can t exceed 500 ohms loads should be greater than 10K Ohms Load Indicators Indicators PLC s PLC s 1 5V 0 5V S Recorders Recorders 0 10V 4 Load Data loggers Data loggers Inverters etc Inverters etc aaa Retransmlt Current Retransmlt Voltage Figure 2 22 Analog Retransmission Wiring Chapter 2 Programming Special Functions 3 1 Dwell Timer Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for ATFN or A2FN but not both otherwise Er07 will appear As the dwell timer is configured the parameter TIME is used for dwell time adjustment The dwell time is measured in minute ranging from 0 to 6553 5 minutes Once the process reaches the set point the dwell timer starts to count from zero until thel time out The timer relay will remain unchanged until time out The dwell timr operation is shown as following diagram T E cU T Error Code LCT L I 7 If alarm 1 is configured as dwell timer ATSE ATDV ATHY and ATMD are h
41. ken Shorted thermocouple leads Short across terminals Open or shorted heater circuit Open coll in extemal contactor Burned out line fuses Bumed out relay inside control Defective solid state relays Defective line switches Burned out contactor Defective circuit breakers 3 If the points listed on the above chart have been checked and the controller does not function properly It Is suggested that the Instrument be retumed to the factory for Inspection Do not attempt to make repairs without qualified engineer and proper technical information It may create costly damage Also it is advisable to use adequate packing materials to prevent damage in transportation 4 Dismantle the controller according to Figure 5 1 Refer to Table 5 2 for some probable causes and actions D Press both sides of the latch located on rear terminal block Hold tightly and remove the terminal block from the housing 2 Expand the rear edge of the housing by using a tool Pull out the PCB from the housing LL ZZ Figure 5 1 Dismantiing the Controller e Cc C 2500 fd gt UM25001C 39 Table 5 1 Error Codes and Corrective Actions S Error Description Corrective Action Illegal setup values been used PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD PV and SPMD It is meaningless for control and SV can t use the same value for normal control Illegal setup values been used PV2 is
42. l User s Manual FDC 2500 Self Tune Fuzzy PID Process Temperature Controller C O N TR OL S UM25001C CONTENTS Chapter 1 Overview 1 1 Features oomen nnn enn 1 2 Ordering Code e n rr nnn 1 3 Programming Port and DIP Switch 1 4 Keys and Displays 1 5 Menu Overview 1 6 Parameters Description Chapter 2 Installation 2 1 Unpacking 2 2 Mounting eo en er o 2 3 Wiring Precautions 2 4 Power Wiring nnnm 2 5 Sensor Installation Guidelines 2 6 Thermocouple Input Wiring 2 7 RTD Input Wiring 2 8 Linear DC Input Wiring 2 9 CT Heater Current Input Wiring 2 10 Event Input Wiring 2 11 Output 1 Wiring
43. l Time I instabolty TI1 and or TI2 nstabliily OF Osclllations Increase TI1 or TI2 Table 3 2 PID Adjustment Gulde Slow Response or 3 pae ive l D Oscillations Decrease TD1 or TD2 and or High Overshoot Increase TD1 or TD2 Figure 3 5 Effects of PID Adjustment P action L action Tl too high PV 4 PB too low Perfect Tl too low PB too high Time Time D action PV 4 TD too low Perfect Set point TD too high Time UM25001C 29 3 6 Signal Conditioner DC Power Supply Three types of Isolated DC power supply are available to supply an external transmitter or sensor These are 20V rated at 25mA 12V rated at 40 mA and 5V rated at 80 mA The DC voltage is delivered to the output 2 terminals Two lIne Transmitter Set oum d PS DC Power Supply Caution 3 7 Failure Transfer The controller will enter failure mode as one of the following conditions occurs 1 SB1E occurs due to the input 1 sensor break or input 1 current below 1mA if 4 20 mA is selected or input 1 voltage below 0 25V if 1 5 V is selected if PV1 P1 2 or P2 1 is selected for PVMD or PV1 is selected for SPMD 2 SB2E occurs due to the input 2 sensor break or input 2 current below 1mA if 4 20 mA is selected or input 2 voltage below 0 25V if 1 5 V is selected if PV2 P1 2 or P2 1 is selected for PVMD or PV2 is selected for SPMD 3 ADER occurs due to the A D converter of the controller fails Output 1 Failure Transfer if
44. long as possible 3 The controller will restart tne pump to control the pressure at set point as soon as the material is demanded again while the pressure falls below a predetermined value ie SP1 SP2 32 UM25001C Programming Gulde 1 Perform auto tuning to the system under such condition that the material ie pressure is exhausted at typical rate A typical value for PB1 is about 10 Kg cme TI is about 1 second TDI is about 0 2 second 2 If the process oscillates around set point after auto tuning then increase PB1 until the process can be stabilized at set point The typical value of PB1 is about half to two times of the range of pressure sensor 3 Increase FILT Filter can further reduce oscillation amplitude But a value of FILT higher than 5 seconds is not recommended A typical value for FILT is0 5o0r1 4 Close the valves and examine that if tne controller can shut off the pump each time The value of REFC is adjusted as small as possible so that the controller can shut off the pump each time when all the valves are closed A typical value for REFC is between 3 and 5 5 An ordinary pump may slowly lose the pressure even if the valves are completely closed Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time as the valves are closed A typical value for SP2 is about 0 50 Kg cr 3 11 Remote Lockout The parameters can be locked to
45. lter Damping Time I FILT Fi LE Constant of PV AET A IFE un 1 Failure Transfer Alarm output ON as unit fails A2FN AEF a Alarm 2 Function Same as A1FN A2MD Hod Alarm 2 Operation Mode Same as ATMD A2FT ACFE uo 2 Failure Transfer Same as A1FT Event input no function SP2 activated to replace SP1 S Tt Ip activated to replace A o Reset alarm 1 output EIFN Reset alarm 2 output n Event Input Function E E en Self Tuning Function Selection 0 second time constant 0 2 second time constant Ca C3 3 C C3 C3 u PU Ln Pu 03 0 5 second time constant 1second time constant 2 seconds time constant 5 seconds time constant n 20 seconds time constant 30 seconds time constant Cw Gu Mu e 60 seconds time constant L Reset alarm 1 amp alarm 2 Disable Output 1 Disable Output 2 Disable Output 1 amp Output 2 Lock All Parameters Use PV1 as process value Use PV2 as process value Use PV1 PV2 difference as process value Use PV2 PV1 difference as process value 10 seconds time constant Self tune function disabled Self tune function enabled 12 Sleep mode Function Selection UM25001C Sleep mode function disabled Sleep mode function enabled Table 1 6 Parameter Description continued 6 7 Contained Basic Calibration Mode Menu Functio Parameter Display Parameter Notation Format Description Use SP1 or SP2 depends
46. lto 199 9 or 199 9 Then the calibration fails Perform step 7 to calibrate mA function if required for input 1 Step 7 Change the DIP switch for mA Input Press scroll key until the display DIP Switch Position shows Send a 20 mA signal to terminals 9 and 10 in ON correct polarity Press scroll key for at least 3 seconds The display B R A mA Input will blink a moment and a new value Is obtained Otherwise If the display didn t blink or If the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 8 to callbrate voltage as well as CT function If required Step 8 for input 2 Press scroll key until the display shows Z4 Send a 10 V signal to terminals 10 and 11 in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value Is obtalned Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 9 to calibrate offset of cold Junction compensation If Step 9 required The DIP switch is set for T C input Setup the equipments according to the following diagram for DIP Switch Position calibrating the cold junction compensation Note that a K type ON IC t thermocouple must be used i A A npu 5520A K 9 Calibrator FDC 2500 KTC K 10 Flgure 6 2 a Cold Junction Stay at least 20 minutes in still Callbration Setup air room room temperature 25
47. me Digital communications RS 485 RS 232 or 4 20 mA retransmission are available as an additional option These options allow FDC 2500 to be integrated with supervisory control system and software or alternatively drive remote display chart recorders or data loggers Three kinds of method can be used To program FDC 2500 1 Use keys onfront panel to program the unit manually 2 Use a PC and setup software to program the unit via RS 485 or RS 232 COMM port 3 Palm Pilot handheld device Avallable first quarter of 2001 The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation output value MV more flexible and adaptive to various processes PID Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison curves below PID control when properly tuned PID Fuzzy control Temperature Set point f Figure 1 2 Fuzzy PID Warm Up Load Disturbance Stability UM25001C 3 1 2 Ordering Code FDC 2500 4 Power Input 1 2 3 4 90 264 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input 1 Standard Input Input 1 Universal Input Thermocouple J K T E B R S N L RTD PT100 DIN PT100 JIS Current 4 20mA 0 20 mA Voltage 0 1V 0 5V 1 5V 0 10V Output 1 Input 2 x 0 None CT 0 50 Amp AC Curent 1 Relay rated 2A 240VAC Tra
48. n be accepted without a completed Return Material Authorization RMA form fd FuTUREDESIGN UM25001C NOIS3O03un AnJ S 10 N LN O 2
49. nsformer x x 2 Pulsed voltage to Voltage Input O 1V O 5V drive SSR 5V 30mA 1 5V 0 10V 3 Isolated Event Input El Isolated O 10V Triac Output 1A 240VAC SSR 9 Special order 9 Special Order G Gn Example Standard Model FDC 2500 411111 s 90 264 operating voltage e Inout Standard Input e Output 1 Relay Output 2 Relay Alarm 1 5V Logic Output e RS 485 Communication Interface Accessorles CT94 0 50 Amp AC Current Transformer OM95 3 Isolated 4 20 mA 0 20 mA Analog Output Module OM95 4 Isolated 1 5V 0 5V Analog Output Module OM95 5 Isolated 0 10V Analog Output Module OM94 6 Isolated 1A 240VAC Triac Output Module SSR DC94 1 Isolated 20V 25mA DC Output Power Supply DC94 2 Isolated 12V 40mA DC Output Power Supply DC94 3 Isolated 5V 80mA DC Output Power Supply CM94 1 Isolated RS 485 Interface Module CM94 2 Isolated RS 232 Interface Module CM94 3 Isolated 4 20 mA 0 20 mA Retransmission Module CM94 4 Isolated 1 5V 0 5V Retransmission Module CM94 5 Isolated 0 10V Retransmission Module CC94 1 RS 232 Interface Cable 2M UM25001C FDC 2500 User s Manual 4 UM25001C Alarm 1 1 5V Logic Output 9 Special order 4 20mA 0 20m Isolated 1 5V O 5v 5 6 Communications 0 None 1 RS 485 2 RS 232 3 Retransmit 4 20mA 0 20mA A Retransmit 1 5V O 5V B Retransmit O
50. nt transformer input 4 D TY 0 1V linear voltage input IN2 1 ng IN2 Signal Type Selection 5 1 5H 0 5V linear voltage input e U 1 5V linear voltage input i T D ii if 0 10V linear voltage input 20 E E m Perform Event input function IN2U 1 ngu IN2 Unit Selection Same as IN1U 2 DP2 dP 2 IN2 Decimal Point Selection Same as DP1 1 IN2L 1 nel IN2 Low Scale Value Low 19999 High 45536 0 IN2H AH IN2 High Scale Value Low 19999 High 45536 1000 or E Ue Reverse heating control action 4 OUT1 out Output 1 Function 0 1 gi rm E Direct cooling control action 0 Et Lj Relay output 1 5 5 r gd Solid state relay drive output 2 5 br Solid state relay output Y O1TY o E S Output 1 Signal Type 3 Q4 B 4 20 mA current module 0 10 UM25001C Table 1 6 Parameter Description continued 4 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value 4 B eti O 20 mA current module 5 IH 0 1V voltage module A O1TY o EY Output 1 Signal Type 6 GU 0 5V voltage module 7 l b 1 1 5V voltage module amp m ID 0 10V voltage module vA CYC1 C uL Output 1 Cycle Time Low 0 1 High 100 0 sec 1 80 y Select BPLS bumpless transfer or 0 0 100 0 4 O1FT Vn 1 Failure Transfer 96 to continue output 1 control function as the unit BPLS ode fails power starts or manual mode starts nian E Output 2 no function
51. o reach a predetermined set point in the shortesttime with tne minimum of overshoot during power up or external load disturbance The units are housed in a 1 32 DIN case measuring 24 mm x 48 mm with 98 mm behind panel depth The units feature three touch keys to select the various control and input parameters Using a unique function you can put at most 5 parameters in front of user menu by using SELT to SEL5 contained in the setup menu This is particularly useful to OEM s as it is easy to configure menu to suit the specific application FDC 2500 is powered by 11 26 or 90 264 VDC AC supply incorporating a 3 amp control relay output 5V logic alarm output and a 3 amp alarm relay output as standard whereby second alarm can be exceptionally configured into second output for cooling purpose or dwell timer Alternative output options include SSR drive triac 4 20 mA and O 10 volts FDC 2500 is fully programmable for PT100 thermocouple types J K T E B R S N L O 20mA 4 20mA and voltage signal input with no need to modify the unit The input signals are digitized by using a 18 blt A to D converter Its fast sampling rate allows the FDC 2500 to control fast processes such as pressure and flow Self tune is incorporated The self tune can be used to optimize the control parameters as soon as undesired control result is observed Unlike auto tuning Self tune will produce less disturbance to the process during tuning and can be used any ti
52. on EIFN LC as set point cr Use minute ramp rate as set point Z Use hour ramp rate as set point SP Ad Set point Mode Selection d Use IN1 process value as set point Use IN2 process value as set point Selected for pump control 1 L SP1 Low Scale Value Low 19999 High 45536 OLC 32 0 LF SP1 High Scale Value Low 19999 High 45536 set point 2 SP2 is an actual value Fermabofest point 2 Value gt al point 2 SP2 is a deviation value l Display PV value Display Format Display SV value No parameter put ahead Parameter TIME put ahead Parameter A1SP put ahead Parameter A1DV put ahead Parameter A2SP put ahead Parameter A2DV put ahead Parameter RAMP put ahead Parameter OFST put ahead Select 1 st Parameter I Parameter REFC put ahead Parameter SHIF put ahead Parameter PB1 put ahead Parameter TI1 put ahead Parameter TD1 put ahead Parameter CPB put ahead 14 Reserved not used 15 5Pe2 Parameter SP2 put ahead 16 Phe Parameter PB2 put ahead 17 fy e Parameter TI2 put ahead 18 t de Parameter TD2 put ahead Select 2 nd Parameter Same as SEL1 Select 3 rd Parameter Same as SEL1 Select 4 th Parameter Same as SEL1 Select 5 th Parameter Same as SEL1 Ato D Zero Calibration l Coefficient Low 360 Ato D Gain Calibration l aha Coefficient Low 199 9 High 199 9 Voltage Input 1 Gain ah Calibration Coefficient 7199 9 High 199 9 NS SISINISISI amp IS Cold J
53. r LED display or LED lamp defective Replace LED display or LED lamp LED lamps not lit or lit erroneously Related LED driver defective Replace the related transistor or IC chip Analog portion or A D converter defective Replace related components or board 4 Display Unstable Thermocouple RTD or sensor defective Check thermocouple RTD or sensor Intermittent connection of sensor wiring Check sensor wiring connections Wrong sensor or thermocouple type wrong Check sensor or thermocouple type and if 9 Considerable error in temperature input mode selected proper input mode was selected indication Analog portion of A D converter defective Replace related components or board Coounts down scale as process warms _ 7 Reversed input wiring of sensor Check and correct No heater power output incorrect output Check output wiring and output device device used Replace output device Output device defective Replace output fuse Open fuse outside of the instrument 8 Heat or output stays on but indicator Output device shorted or power service Check and replace reads normal Shorted 7 No heat or output CPU or EEPROM non volatile memory Check and replace 9 Control abnormal or operation incorrect defective Key switch defective Read the setup procedure carefully Incorrect setup values Suppress arcing contacts in system to Electromagnetic interference EMI or eliminate high volta
54. r Limit O 100 96 output 1 and output 2 Baud Rate 0 3 38 4 Kbits sec Pump Pressure Control Sophisticated functions Data Bits 7 or 8 bits provided Panty Bit None Even or Odd Adaptive Heat Cool Dead Band Self adjustment Stop Bit 1 or 2 bits Remote Set Point Programmable range for voltage Communication Buffer 50 bytes or current input Differential Control Control PV1 PV2 at set point Analog Retransmission Functions PV1 PV2 PV1 PV2 PV2 PV1 Set Point Digital Filter MV1 MV2 PV SV deviation value Function First order Output Signal 4 20 mA 0 20 mA 0 1V 0 5V Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 1 SV 0 10V seconds programmable UM25001C 43 Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature AO C to 60 C Humidity 0 to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strength 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m for 2 hours Shock Resistance 200 m s 20 g Moldings Flame retardant polycarbonate Dimensions 50mm W X 26 5mm H X 110 5mm D 98 0 mm depth behind panel Welght 120 grams Approval Standards Safety UL Pending CSA CE The color codes used on the thermocouple extension leads are shown in Table 6 1 Table 6 1 Thermocouple Cable Color Codes Thermocouple Cable British American German French Type
55. sabled Note If the Sleep mode is not required by your system the SLEP should select NONE to disable sleep mode against undesirable occurrence UM25001C 31 3 10 Pump Control Pump Control function is one of the unique features of FDC 2500 Using this PUMP A Cost Effective function the pressure In a process can be controlled excellently The pressure yet Perfect Solution in a process is commonly generated by a pump driven by a variable speed motor The complete system has the following characteristics which affects the control behavior 1 The system Is very nolsy 2 The pressure Is changed very rapidly 3 The pump characteristics is uira nonlinear with respect to its speed 4 The pump can t generate any more pressure as its speed is lower than half of Its rating speed 5 An ordinary pump may slowly lose the pressure even If The valves are completely closed Obviously a conventional controller can fulfill tne conditions mentioned above Only the superior noise rejection capability in addition to the fast sampling rate owned by FDC 2500 can realize such application To achieve this set the following parameters In the setup menu FUNC FULL Key menu EIFN NONE SPMD PVMD PV1 SP2F FILT 0 5 SELF NONE is SPMD PUMP SP2F DEVI and program the following parameters in the user menu REFC Reference constant SP2 A negative value is added to SP1 to obtain the set point for idle state Since the pump can t produce any more pressur
56. ten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 8 are not exceeded Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electrical noise can enter and adversely affect the operation of microprocessor based controls For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to ground at one end only 2 0mm 0 08 max m mmm Figure 2 2 Lead Termination E m 4 5 7 0 mm 0 18 0 27 OUT2 ALM2 OUT1 FST L N Leo Lo 90 264 VAC 2A 240 VAC 2A 240 VAC 41 63 Hz 15VA V CT TC EL TC V CT AO AO PTA PIB PTB RCOM TX TX2 Figure 2 3 Rear Terminal T t E Q 9 Connectlon Diagram ALM1 ALAR cR Lod Lais La Lel Bl ori ALM1 LOGIC OUTPUT 16 UM25001C 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDC or 90 264VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller 9 gt 90 264 VAC or o 11 26 VAC VDC Figure 2 4 Power Suppl
57. the following section are a step by step manual procedures Since it needs 30 minutes to warm up an unit before calibration calibrating the unit one by one is quite inefficient An automatic calibration system for small quantity as well as for unlimited quantity Is available upon request UM25001C 35 Manual Calibration Procedures Perform step 1 to enter calibration mode Step 1 Set the lockout DIP switch to the unlocked condition both switches 3 and 4 are off Press both scroll and down keys and release them quickly The operation mode menu will appear on the display Repeat the operation several times until appear on the display Press scroll key for at least 3 seconds the display will show 52 and the unit enters calibration mode The output 1 and output 2 use their failure transfer values to control Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter The DIP switch is set for T C Input Step 2 Short terminals10 and 11 then press scroll key for at least 3 seconds DIP Switch Position The display will blink a moment and a new value Is obtained er sd E EE T C Input Otherwise If the display didn t blink or if the obtained value is equal to EPI En 360 or 360 then the calibration fails Step 3 Press scroll key until the display shows Send a 60mV signal to terminals 10 and 11 in correct polarity Press scroll key for at least 3 seconds The display will blink
58. times second Maximum Rating 2 VDC minimum 12 VDC maximum Temperature Effect A0 005 96 of reading BC Common Mode Rejection Ratio CMRR 120dB Sensor Break Detectlon below 0 25V for 1 5V input unavailable for other inputs Sensor Break Responding Time 0 5 second Characteristics Type Range q Accuracy Input at pu Q 25 C Impedance A0 4 A2 96 CT94 1 0 50 0A of Reading 265 KO A0 2A 1 3V 11 5V Input 3 Event Input Logic Low 10V minimum 0 28V maximum Logic High Open or 0 32V minimum 10V maximum External pull down Resistance 200 KR maximum Extemal pull up Reslstance not necessary Functions Select second set point and or PID reset alarm 1 and or alarm 2 disable output 1 and or output 2 remote lockout Output 1 Output 2 Relay Rating 24 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 42 32 F 3214 F 250 C 1800 C 418 F 2372 F 200 C 900 C 328 F 1652 F 210 C 700 C 346 F 1292 F 200 C 600 C 328 F 1112 F 8mv 70mV A0 05 3mA 27mA V 1 3V 11 5V AQ 05 96 AQ 05 96 302 KQ UM25001C Linear Output Characteristics Type E ak s 0 G 4 20 mA 3 8 AmA 20 21 mA 5000 max 0 20 mA 0 MA 20 21 mA 5000 max 0 5V OV 5 5 25V 10KQ min 1 5V 0 95 1V 5 525V 10KQ min 0
59. unction Low Temperature Calibration 5 00 BC High 40 00 LC Coefficient UM25001C 13 Table 1 6 Parameter Description continued 7 7 Contained Basic Parameter Display in Function Notation Format Parameter Description Default Value Cr L Au Cold Junction Gain Calibration Coefficient Calibration Mode Menu SR1 Srl MAIG Reference Voltage 1 Calibration Coefficient for Serial Resistance 1 Calibration Coefficient for mA Input 1 Gain Calibration Coefficient Voltage Input 2 Gain Calibration Coefficient High 199 9 v v v vA PUH Historical Maximum Value of Low 19999 High 45536 VA Pulp Historical Minimum Value of Low 19999 High 45536 m 4 H___ Current Output 1 Value Low 0 High 100 00 96 4 L Current Output 2 Value Low 0 High 100 00 96 v DV g Gurrent Deviation PV SV Low 12600 High 12600 Display vA PV1 PY 1 IN1 Process Value Low 19999 High 45536 Mode A PY IN2 Process Value Low 19999 High 45536 Menu 4 PL eae Proportional Band Low 0 High z D E 4 TI LE Current Integral Time Value Low 0 High 4000 sec V Ed Comet Derivative Time m 0 High 1440 sec NH v dew UE emu howe 39400016 High 90 001C 4 PVR PY Current Process Rate Value Low 16383 High 16383 4 P r H Maximum Process Rate Value Low 16383 High 16383 4 PY L Minimum Process Rate Value Low 16383 High 1
60. urse you can use other PB2 70 TI2 70 if PB2 TI2 TD2 reasonable values for PID before tuning according to your previous assigned experiences But don t use a zero value for PB1 and TI1 or PB2 and TI2 otherwise the auto tuning program will be disabled 3 Set The set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press until appears on the display 5 Press for at least 3 seconds The upper display will begin to flash and the auto tuning procedure is beginning NOTE Any of the ramping function remote set point or pump function if used will be disabled once auto tuning is proceeding Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warm Start See Figure 3 2 If the auto tuning begins apart from the set point Cold Start the unit Pre tune Function Advantage enters Warm up cycle As the process reaches the set point value the Consistent tuning results can be unit enters watting cycle The waiting cycle elapses a double integral obtained time Tl or TI2 dependent on the selection see Section 4 1 then it enters a leaming cycle The double integral time is introduced to allow The process to reach a stable state Before learning cycle the unit performs pre tune function with a PID control While in learning cycle the unit performs post tune
61. used for both PVMD Illegal setup values been used P1 2 or P2 1 is used for Check and correct setup values of PVMD and SPMD 3 PVMD while PV1 or PV2 is used for SPMD Dependent Difference of PV1 and PV2 can t be used for PV while PV1 values used for PV and SV will create incorrect result or PV2 is used for SV of control Illegal setup values been used Before COOL is used for Check and correct setup values of OUT2 PB1 PB2 T OUT2 DIRT cooling action has already been used for TI2 and OQUT1 IF OUT2 is required for cooling control the OUT or PID mode is not used for OUT1 that is PB1 or control should use PID mode PB D TI 2 Q and OUT1 PB2 0 and TI1 or TI2 2 O should use reverse mode heating action otherwise don t use OUT2 for cooling control Illegal setup values been used unequal INTU and IN2U or Check and correct setup values of INTU IN2U DP1 DP2 unequal DP1 and DP2 while P1 2 or P2 1 is used for PVMD PVMD SPMD A1FN or A2FN Same unit and decimal point or PV1 or PV2 is used for SPMD or P1 2 H P1 2 L D1 2 H should be used if both PV1 and PV2 are used for PV SV or D1 2 L are used for ATFN or A2FN alarm 1 or alarm 2 Illegal setup values been used OUT 2 select AL2 but Check and correct setup values of OUT2 and A2FN OUT2 A2FN select NONE will not perform alarm function if A2FN select NONE 7 Illegal setup values been used Dwell timer TIMR is Check and correct setup values of ATFN and A2FN Dwell selected
62. wing conditions occurs SELF is selected with NONE The controller is used for on off control that is PB 0 Ihe controller is used for manual reset that is TI O The controller is under loop break condition The controller is under failure mode e g sensor break Ihe controller is under manual control mode The controller is under sleep mode The controller is being calibrated Co 4 Gx On E 0C n K If the self tuning is enabled the auto tuning can still be used any time The self tuning will use the auto tuning results for its initial values Benefits of Self tuning 1 Unlike auto tuning Self tuning will produce less disturbance to the 2 process Unlike auto tuning Self tuning doesn t change control mode during tuning 3 period It always performs PID control Changing set point during Self tuning is allowable Hence Self tuning can be used for ramping set point control as well as remote set point control where the set point is changed from time to time The parameter SELF is contained in setup menu Refer to Section 1 5 to obtain SELF for initiating a self tuning 3 93 Reload Default Values The default values listed in Table 1 4 are stored in the memory as the product leaves the factory In certain occasions it is desirable to retain these values after the parameter values have been changed Here is a convenient tool to reload the default values Operatlon Press several times until Then press
63. wire RTD Two wire RTD 18 UM25001C 2 8 Linear DC Input Wiring DC linear voltage and linear current connections for input 1 are shown in Figure 2 7 and Figure 2 8 DC linear voltage and linear current connections for input 2 are shown in Figure 2 9 and Figure 2 10 Figure 2 7 Input 1 Linear Voltage Wiring zi fe N 5 o DIP Switch l l 0 1V 0 5V 1 5V 0 10V Figure 2 9 Input 2 Linear Voltage Wiring 0 1V 0 5v Lp T 1 5V 0 10V Figure 2 8 Input 1 Linear Current Wiring x ul W s o 7 i DIP Switch 0 20mA or 4 20mA QM Figure 2 10 Input 2 Linear Current Wiring 0 20mA or 4 20mA s O IN2 DBY or F BV 2 9 CT Heater Current Input Wiring CT Signal Input Figure 2 11 CT Input Wiring for SIngle Phase Heater Make sure that the total current through CT94 1 not exceed 50A rms 2 10 Event Input wiring Figure 2 13 Event Input Wiring Switch Input Open Collector Input The event input can accept a switch signal as well as an open collector signal The event Input function EIFN Is activated as the switch Is closed or an open collector L or a logic signal Is pulled down 2 11 Output 1 Wiring Max 2A Max 1A 240V 120V 240V 20V 240V Mains Supply Mains Supply Figure 2 14 Output 1 Wiring Relay Output 30mA 5V Pulsed Voltage 0 1V 0 5V 1 5V 0 10V Linear Voltage 20 UM25001C 2 12 Output 2 Wiring Figure 2
64. y Connectlons A This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Consideration should be given to prevent from unauthorized person access to the power terminals 2 5 Sensor installation Guidelines Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed closed to the heater In a process where the heat demand is variable the probe should be closed to the work area Some experiments with probe location are often required to find this optimum position In a liquid process addition of a stirrer will help to eliminate thermal lag Since the thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better resultsin most air heated processes Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process requirements In special processes the sensor might need to have different requirements such as leak proof anti vibration antiseptic etc Standard sensor limits o

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