VFL Series PID Controllers
Contents
1. Check power lines connection Replace or repair meter Process Value changed abnormally Electromagnetic Interference EMI or Radio Frequency Interference RFI Suppress arcing contacts in system to eliminate high voltage spike sources Separate the sensors and the controller wiring from noisy power lines Ground heaters Entered data lost EEPROM error Replace or repair meter 48VFL amp 96VFL v1 2 07 13 Controller Overview Controller Wiring The controller must be wired before use The controller s input outputs and AC power are connected via its rear terminals Refer to the wiring diagram for details Programming Menus The controller uses a menu based programming format The menu levels are USER PID OPTION and SOFT START Each menu includes a series of parameters that customize the controller The menu structure and parameter descriptions are detailed in the instructions on reverse side of this sheet Inputs The controller accepts an input from a Thermocouple RTD or Analog signal Wire the input as shown in the wiring diagram The measurement PV for Process Variable is displayed on the controller s top LED readout in red Setpoint Value SV The Setpoint Value SV is the process application target value For example in an oven application the desired oven temperature is the SV This SV is changed adjusted as described in the operating instructions The SV2. Relay and Pulse DC Output Specifications Relay outputs SPST dry contact relays can switch up to 5 Amps 110V AC or 24VDC for resistive loads only Pulsed DC outputs 0 to 24 VDC output drives resistive loads to 250 max Control actions Indirect or reverse acting heating and direct acting cooling Control types ON OFF control with Hysteresis dead band Time proportioning control for relay or pulsed DC output Standard proportional output analog output Automatic tuning Push button activation Automatically tunes the proportional band and integral derivative times Manual Tuning Proportional Band Pb 0 0 to 300 0 of Full Scale Integral time or Reset Ti 0 to 3000 seconds includes anti reset wind up Derivative time or Rate Td 0 to 900 seconds Cycle Time 0 to 100 seconds set to 0 for 4 20mA output Hysteresis 0 0 to 25 5 of Full Scale ALARM Output Specifications Alarm relay outputs SPST dry contact relay can switch up to 3 Amps 110VAC for Resistive Loads Alarm modes Deviation Absolute and Band Alarms with dead band Hysteresis adjustment ANALOG Output Specifications Analog output 4 20mA DC Load limits 600 max Programming Set Cycle Time Ct to 0 to enable the analog output 48VFL amp 96VFL v1 2 07 13 Warranty FLIR Systems Inc warrants this Extech Instruments brand device to be free of defects in parts and w
3. Software filter 0 0 99 9 10 0 Time scale for timer alarm Hours Minutes Minutes Seconds 00 00 99 59 00 00 Alarm 1 function Refer to alarm section for details If A1FU None the alarm function is cancelled None Hi Lo dif H dif L bd Hi bd Lo t on t oFF Alarm 1 mode Refer to alarm mode section for detail none Stdy Lath St La Alarm 2 function Refer to alarm function section for detail none Hi Lo dif H 48VFL amp 96VFL v1 2 07 13 If A2FU None it means alarm function is cancelled dif L bd Hi bd Lo t on t oFF Alarm 2 mode Refer to alarm mode section for details none Stdy Lath St La Controller address For use with PC RS 485 interface 0 255 0 Baud rate 2 4k 2400bps 4 8k 4800 bps 9 6k 9600 bps 19 2k 19200 bps 2 4k 4 8k 9 6k 19 2k 9 6k Code Description Range Default Low Scale of Linear Input 1999 9999 199 9 999 9 0 0 High Scale of Linear Input 1999 9999 199 9 999 9 100 0 Scaling for Linear Input 1 Press and hold the UP and DOWN keys simultaneously for 5 seconds to access the LnLo parameter 2 Adjust LnLo setting to correspond to the low scale after adjustment press key once to access LnHi 3 Adjust LnHi setting to correspond to the high scale after adjustment press key once to exit ALARM FUNCTION A1FU A2FU ALARM TYPE ALARM OUTPUT OPERATION Alarm function OFF Output OFF Process high alarm PV SP
4. NIST certification for most products is also provided Call the Customer Service Department for information on calibration services available for this product Annual calibrations should be performed to verify meter performance and accuracy Technical support and general customer service is also provided refer to the contact information provided below Copyright 2013 FLIR Systems Inc All rights reserved including the right of reproduction in whole or in part in any form www extech com Support Lines U S 877 439 8324 International 1 603 324 7800 Technical Support Option 3 E mail support extech com Repair amp Returns Option 4 E mail repair extech com Product specifications are subject to change without notice Please visit our website for the most up to date information www extech com FLIR Commercial Systems Inc 9 Townsend West Nashua NH 03063 USA ISO 9001 Certified
5. Process low alarm PV SP Deviation high alarm PV SP ALSP Deviation low alarm PV SP ALSP Band high alarm OFF PV SP ALSP SP SP ALSP Band low alarm OFF OFF PV SP ALSP SP SP ALSP On timer ALSP PV SP Off timer ALSP PV SP ALARM MODE 48VFL amp 96VFL v1 2 07 13 A1MD A2MD DESCRIPTION Normal alarm mode When timer function is selected with the PV lt SV the timer function is disabled Standby mode When selected in any alarm function an alarm on power up is prevented The alarm is enabled only when the process value reaches the alarm set point Also known as Startup inhibit useful for avoiding alarm trips during startup Latch mode When selected the alarm output and indicator latch when the alarm occurs The alarm output and indicator will remain energized even if the alarm condition has been cleared unless the power to the meter is removed Standby and latch mode AUTOMATIC AND MANUAL OUTPUT CONTROL Automatic control is the normal mode of controller operation In automatic control mode the controller automatically adjusts the control output percentage using PID to bring the PV equal to the SV The PID parameters Pb Ti and Td can be automatically determine using the Auto Tune procedure Manual control allows the user to manually drive the output percentage from 0 0 to 100 0 To access the manual mode
6. 0100 USER PID OPTI levels are adjustable 0101 USER SOFT PID OPTI levels are adjustable 0101 0111 All parameters in all levels are unlocked 1000 1111 1000 0000 1001 0001 1010 0010 1011 0011 1100 0100 The only difference is that Output 2 is unlocked 0100 48VFL amp 96VFL v1 2 07 13 OPTION LEVEL CODE DESCRIPTION RANGE Default Input type selection tYPE RANGE RANGE J 50 1000 58 1832 K 50 1370 58 2498 T 270 400 454 752 E 50 750 58 1382 B 0 1800 32 3272 R 0 1750 32 3182 S 0 1750 32 3182 N 50 1300 58 2372 C 50 1800 58 3272 D PT 200 850 328 1652 J PT 200 650 328 1202 LINE 1999 9999 Refer to figure K Unit of process value Degrees C Degrees F Engineer units for linear input Decimal point selection 0000 No decimal point 000 0 0 1 resolution 00 00 0 01 resolution used for linear input only 0 000 0 001 resolution used for linear input only 0000 000 0 00 00 0 000 0000 Output 1 control action Reverse action for heating Direct action for cooling Low limit of span or range Set the low limit lower than the lowest expected SV and PV display Full range 0 High limit of span or range Set the high limit higher than highest expected SV and PV display Full range 1000
7. wire And note the polarity of input signal 3 To avoid noise induction keep input signal wires away from instrument power lines load lines and power lines of other electrical equipment 48VFL amp 96VFL v1 2 07 13 PROGRAMMING LEVEL PARAMETERS lst Prog Level 2nd Prog Level 3rd Prog Level 4th Prog Level 5th Prog Level 1 When 2nd Output Cooling is not selected CPb Cti Ctd HYS2 and db parameters are not available 2 When Pb 0 0 HYS1 will be skipped 3 When CPb 0 0 HYS2 will be skipped 4 When Pb 0 0 ti td will be skipped 5 When CPb 0 0 Cti Ctd will be skipped 48VFL amp 96VFL v1 2 07 13 PARAMETER DESCRIPTION LEVEL Selection Press keys for at least 5 seconds to access Soft Level Use or key to select programming level Then press key to enter this level LEVEL Description SoFt Level PID Level Option Level USER LEVEL CODE DESCRIPTION RANGE Default Set point value of control LoLt HiLt 500 Alarm 1 set point value Timer set value while A1FU is set to T on or T off the unit can be HH MM or MM SS It depends on the P tnE parameter 1999 9999 00 00 99 59 10 Alarm 2 set point value Timer set value while A2FU is set to T on or T off the unit can be HH MM or MM SS It depends on the P tnE parameter 1999 9999 00 00 99 59 10 Auto tuning is disable Standard t
8. 48VFL amp 96VFL v1 2 07 13 INSTRUCTION MANUAL VFL Series PID Controllers FRONT PANEL DESCRIPTION PV Process Value SV Setting Value AT Auto tuning LED MA Manual mode LED A1 Alarm 1 LED A2 Alarm 2 LED C1 Control 1 LED C2 Control 2 LED SET KEY Press once to access the next programmable parameter Press and hold this key for 5 seconds to reset alarm timer UP KEY Press to increase the set point or parameter value DOWN KEY Press to decrease the set point or parameter value SHIFT KEY Press the shift key for 5 seconds to execute Auto Tune process Yes 1 mode To abort an Auto Tune process press and hold the shift key for 5 seconds Press the SET and UP keys once to return the normal operation LEVEL KEYS Press and hold the SET amp SHIFT keys simultaneously for 5 seconds to select the programming level and then press the SET key to enter the selected level Press the UP amp DOWN keys simultaneously for 5 seconds to access LnLo amp LnHi parameters PANEL CUTOUT Model A B C D E a b c d 48VFL 48 48 6 100 45 45 0 5 45 0 5 60 48 96VFL 96 96 10 80 91 92 0 5 92 0 5 120 96 Units mm 48VFL amp 96VFL v1 2 07 13 WIRING DIAGRAM Wiring Precautions 1 Before wiring verify the controller label for correct model number and options 2 For thermocouple input use the appropriate compensation
9. Operating conditions 14 to 122oF 10 to 50oC 90 Relative Humidity max Storage temperature 4 to 140oF 20 to 60oC Panel cut out dimensions 1 77 x 1 77 0 02 45 0 x 45 0mm 0 5mm for 48VFL 3 62 x 3 62 0 02 92 0 x 92 0mm 0 5mm for 96VFL Thermocouple Input Specifications Thermocouple TC types J K T E B R S N and C user programmable Temp Indication Accuracy lt 1000 degrees 3 6F 2 0C gt 1000 degrees 7 6F 4 0C TC Break protect Upscale and Downscale Lead wire effect 0 015 ohm Input impedance gt 10M Repeatability 0 83oC Temperature stability 5uV oC typical TC Ranges Type K 58 to 2498oF 50 to 1370oC Type J 58 to 1830oF 50 to 1000oC Type B 32 to 3272oF 0 to 1800oC Type T 454 to 752oF 270 to 400oC Type E 58 to 1382oF 50 to 750oC Type R 32 to 3182oF 0 to 1750oC Type S 32 to 3182oF 0 to 1750oC Type N 58 to 2372oF 50 to 1300oC Type C 58 to 3272oF 50 to 1800oC 48VFL amp 96VFL v1 2 07 13 RTD Input Specifications RTD type Platinum 100 DIN or JIS RTD range 328 to 1202oF 200 to 650oC Break protection Up and down scale Lead wire effect 0 015o Ohm Repeatability 0 2oC Analog Linear Input Specifications Current Input 4 to 20mA DC 2 7 input impedance Voltage Input 1 to 5V DC gt 10M input impedance Display range 1999 to 9999 digits Repeatability Within 1 digit
10. WN arrow keys simultaneously while turning the controller ON Release the keys after the display switches on Security LOCK To lock the controller in order to avoid setpoint and program tampering refer to the information provided in this manual for the LOCK parameter 48VFL amp 96VFL v1 2 07 13 Specifications General Specifications Display Dual 7 segment 4 digit LED Red digits for Process Variable PV and green digits for Setpoint Variable SV Display range 1999 to 9999 Indicating accuracy 0 2 full scale 1 digit Display update rate 4 readings per second Output status indication Front panel Alarm A1 and A2 and Control C1 and C2 status LED s inform the user when an output switches on or off Out of range indication PV display flashes No input indication PV displays OPEN when input terminals are disconnected Auto Tune indication Right most decimal on the PV display flashes while the controller is in the auto tune mode Calibration data Stored in non volatile memory along with user parameter edits Meter construction Case is ABS plastic and the front panel is drip and dust proof Lexan material NEMA and IEC IP55 equivalent Power requirement 90 to 264VAC 50 60Hz automatically accommodates any voltage between 90 to 264VAC Power consumption lt 5VA Insulation Resistance gt 50M Noise rejection Common Mode 120 dB Normal Mode 60 dB typical
11. is shown on the controller s lower LED display digits in green Control Outputs The control outputs C1 amp C2 are to be wired to an external control device such as a heater valve switch etc The controller automatically adjusts external devices to bring the Process Variable PV in line with the Setpoint Variable SV Available outputs are Relay Pulsed DC and 4 20mA Analog Output Tuning The controller must be tuned for every new application It is strongly recommended that user run the Auto Tune function AT Note that the controller must be wired and ready to go before Auto Tune is started Auto Tune optimizes the controller s response to exactly match the characteristics and dynamics of the process at hand Although auto tuning will be sufficient in most cases there may be times when manual adjustments are required Qualified personnel can Manually Tune the controller using the PID parameters in the PID Menu Level Note that improper tuning can cause sever process disturbances Use Auto Tuning when possible Again use Auto Tune whenever possible Alarm Outputs The controller has alarm output relays A1 amp A2 that can be used to switch on off a lamp sound a buzzer shut down a heater etc at a programmed alarm setpoint Refer to the discussion of Alarms on the main instruction page System Reset To revert all of the parameters to their original factory default settings press and hold the UP and DO
12. ntroller can also be set to ON OFF PI PD and P control mode Set Pb 0 for ON OFF control mode Set ti 0 for PD control mode Set td 0 fro PI control mode and ti td 0 fro P control mode The Hysteresis dead band for ON OFF control operates as follows ON OFF SP HYST SP HYST SP When the second control output output 2 is used the proportional band of output 2 and the dead band interact as detailed below Output Heating Cooling PV Overlap Dead Band Band ERROR MESSAGE AND TROUBLESHOOTING 48VFL amp 96VFL v1 2 07 13 Symptom Probable Solution Sensor break error Sensor not connected Replace sensor Check that the sensor is connected correctly A D converter damage Unit must be repaired or replaced Check for outside source of damage such as transient voltage spikes Auto tune time out error Set Pb ti td manually Keypad not functioning Keypad is locked Keypad is defective Set to an appropriate value Have unit repaired Process value unstable Improper setting of Pb Ti Td and CT Start AT process to set Pb Ti Td automatically Set Pb Ti Td manually No heat or output No heater power or fuse open Output device defective or incorrect output used Check output wiring and fuse Replace output device LEDs and display not lighting up No power to controller SMPS failure
13. orkmanship for one year from date of shipment a six month limited warranty applies to sensors and cables If it should become necessary to return the instrument for service during or beyond the warranty period contact the Customer Service Department for authorization Visit the website www extech com for contact information A Return Authorization RA number must be issued before any product is returned The sender is responsible for shipping charges freight insurance and proper packaging to prevent damage in transit This warranty does not apply to defects resulting from action of the user such as misuse improper wiring operation outside of specification improper maintenance or repair or unauthorized modification FLIR Systems Inc specifically disclaims any implied warranties or merchantability or fitness for a specific purpose and will not be liable for any direct indirect incidental or consequential damages FLIR s total liability is limited to repair or replacement of the product The warranty set forth above is inclusive and no other warranty whether written or oral is expressed or implied Calibration Repair and Customer Care Services FLIR Systems Inc offers repair and calibration services for the Extech Instruments products we sell
14. r secondary control output cooling Set 0 0 for ON OFF 0 0 300 0 10 0 Integral time for secondary control output When PB 0 0 this parameter will be not available When set to zero Pb amp td 0 for PD control 0 3600sec 240 Derivative time for secondary control output When Pb 0 0 this parameter will be not available When set to zero Pb amp ti 0 for PI control 0 900sec 60 Proportional cycle time of output 2 0 100sec 15 Hysteresis for ON OFF control on output 1 0 2000 0 0 200 0 1 Hysteresis for ON OFF control on output 2 0 2000 0 0 200 0 1 Hysteresis of alarm 1 0 2000 1 Hysteresis of alarm 2 0 2000 1 Dead band value This defines the area in which output 1 and output 2 are both active negative value or the area in which output 1 and output 2 are both inactive positive value 1000 1000 100 0 100 0 0 Set point offset This value will be added to SV to perform control It mainly used to eliminate offset error during Pb control 1000 1000 100 0 100 0 0 Process value offset Permits the user to offset the PV indication from the actual PV 1000 2000 100 0 200 0 0 Parameter lock This security feature locks out selected levels or single parameters prohibiting tampering and inadvertent programming changes 0000 All parameters are locked out 0001 Only SP is adjustable 0010 Only USER level is adjustable 0011 USER and PID levels are adjustable
15. set the parameter to the right most decimal MA on the SV display will flash The parameter will then alternately display and the process value The output percentage can then be adjusted using the UP or DOWN keys To abort the manual control simply set to AUTO TUNE In order to automatically set the PID parameters in the PID level Pb proportional band ti integral time also known as reset and td derivative time also known as rate first adjust the controller s set point to a value that closely approximates the application at hand Set the parameter to for standard applications or for minimizing SV overshoot see diagram below The right most decimal point AT on the PV display will flash in Auto Tune mode This procedure will run two cycle oscillations After that the controller performs PID control with the learned PID value to verify the results Finally the PID values will be entered into the nonvolatile memory and then starts the Fuzzy enhanced PID control The auto tune process can last from several minutes up to two hours depending on the process in question A time out error will occur if the auto tune process can not be completed within two hours in this case try to set the PID parameters manually To abort an auto tune process simply set the parameter to 48VFL amp 96VFL v1 2 07 13 The co
16. ype auto tuning Autotune PV is compared wit SV during auto tuning Low PV type auto tuning PV is compared with SV 10 FS during Auto tuning no Disable the manual mode Manual control Enable the manual mode no Output percentage Adjustable when Hand is set to Yes 100 0 100 0 0 0 SOFT LEVEL Code Description Range Default Ramp rate for the process value to limit an abrupt Change of process min 0 9999 0 0 999 9 0 0 Set point value of soft start LoLt HiLt Output percentage of soft start 0 0 100 0 100 0 PID LEVEL CODE DESCRIPTION RANGE Default Proportional band variable Set to 0 0 for ON OFF control mode 0 0 300 0 10 0 Integral time Reset This value is automatically calculated by activating the Autotune function If desired the user can later 0 3600sec 240 48VFL amp 96VFL v1 2 07 13 adjust this parameter to better suit the application When PB 0 0 this parameter will be not available When set to zero Pb amp td 0 for PD control Derivative Rate This value is automatically calculated by activating the Auto tune function If desired the user can later adjust this parameter to better suit the application When PB 0 0 this parameter will be not available When set to zero Pb amp td 0 for PI control 0 900sec 60 Proportional cycle time of output 1 0 100sec 15 Proportional band variable fo
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