TC103RAMP Manual ENG.cdr
Contents
1. cooler is not powerful enough for this object If this parameter is less than 10 then the heater cooler has an exceeding power for the controlled object VI RECOMMENDATIONS VLji Static mode no ramping output no bias A better control of the temperature is achieved by a smaller cycle times However this leads to a more frequent commutation of the relay and to a faster wear out A compromised value in this respect is Tc 10 sec The differential time constant influences the forecasting action of the Controller so to a great extend the initial oscillations of the temperature depend on this constant When no auto tuning is used the recommended value for Td to start with is 40 sec The fast and smooth reaching of the set temperature depends greatly on the integral time constant The temperature controllers TC103RAMP are fuzzy optimized with respect to the PID integral action so that values 7i 200 give a sufficient result for a huge class of objects The gain factor depends entirely on the location of the set temperature on the characteristic of the heater cooler so it is not possible to give any recommended values However if the heater cooler are optimally constructed for the controlled object Xp 25 will suffice All of these recommendations are only given for basic orientation so the best recommendation is to run the auto tuning algorithm and after that dynamically correct the evaluated parameters if need may be The al2. Industrial electronic systems V Bulgaria Pleven 5800 27 Osogovo str EMA tel fax 359 64 870172 tel 359 64 870170 e mail office vema bg com http vema bg com Temperature Controller TC 103 RAMP THERMO CONTROLLER TC1LO3RAMP Thermocontroller with auto tuning of the PID parameters to the controlled object and option for gradually reaching the set value ramp function using dynamical bias feature USER S MANUAL I INTRODUCTION The microprocessor Temperature Controllers TC103RAMP J K R P offer optimal comfort of service and visualization of information The Temperature Controllers TC103RAMP J K R are assigned to work with thermo couples of type J K or R the TC103RAMP P Temperature Controllers with thermistors of type Pt100 The output signal is given either as a relay or a direct current output The Controller can be used as a 2 position on off regulator if the alarm relay is used to control the heater cooler instead of the control output The auto tuning algorithm explores the parameters of the object to be controlled and sets the corresponding PID constants of the Controller The Controller is supplied with an alarm relay output for preventing the temperature from great detours in the technological mode of the controlled object The alarm relay output can work in 16 programmable modes non latch standby sequence included The desired temperature SV Set Value and the current temperature PV Proces
3. SP xxx where xxx is the Set Value of the temperature Now the first parameter Set Value can be changed using the arrow buttons lt lt and gt gt To save the new value and go back to Monitor Mode press 4 To get to any parameter in Program Mode keep pressing or hold pressed the F button until the mnemonics of the parameter shows up on the SV display Simultaneously pressing of both arrow buttons while in Monitor Mode will invoke the Auto tuning Mode s CHARACTERISTICS of the Controller The display reads OPt xxx where xxx is the current temperature and the OPt is blinking In any other mode pressing both arrows will put the Controller back into Monitor Mode In Monitor Mode the display reads the desired temperature Set Value and the current temperature Process Value Blinking of SV indicator means that the standby sequence s CHARACTERISTICS is on i e the Controller has not reached a non alarm zone yet In Monitor Mode are displayed all possible errors EPr Err if the EEPROM chip is damaged or is just replaced xxx oF F ifthe thermocouple is loose V SPECIFIC CHARACTERISTICS 5 1 Deviations from the Set Value The normal deviation of the current temperature from the set temperature is about 1 C or less Greater deviations of 2 3 C are sign of incorrect PID parameters unacceptable outer influences intense electric noises incorrect placement of the temperature sensors or damages 5 2 A
4. arm mode must be selected according to the technological assignment of the controlled object For extruder machines it is very hazardous to run the main motor before the temperatures have not been stabilized and the material along the shaft has not melted In this case alarm modes ALn 9 or 11 must be selected so the alarm standby sequence can be used If it is not acceptable for the temperature to rise above a certain limit then ALU and alarm modes 10 or 11 are used Alarm modes 12 and higher are used when the alarm output must work inversely VLii Ramping mode The time lt r n r S gt for gradually reaching of the set temperature rSP should be a lot greater than the time for which the Controller would reach the set value if no ramp function was used The ramp function can be switched on off by changing the value of parameter r The r ttime specifies the pause after the heater is on to allow for a sensor reaction During this time the Controller output is set to the initial bias ri without any PID feedback The actual ramping starts after this pause and 1s indicated by the ramping output ON When the heater load in ramping mode is a lot greater than the load in static mode then the recommendation is to cancel PID feedback by setting r P 0 and experiment with proper values for r i and r d and then gradually increase the PID feedback gain by ther P parameter 5 r n minutes rt r S seconds A initial startup of t
5. he Controller The set temperature SSP is gradually reached by the PID feedback unit in static mode B the set temperature SSP is reached and maintained in static mode C the user starts ramping by changing the value of r parameter Next r t seconds the Controller outputs the initial bias value r i without any acceleration in it No PID feedback D the actual ramping begins the ramping output is set to ON The set temperature is linearly changed from SSP to rSP for r n minutes and r S seconds The value of the bias is also accelerated from its initial value ri by rd percents for 1000 seconds E ramping endpoint is reached ramping output is OFF The Controller is back to static mode while cooling off F end of cooling Anew cycle of the Controller can be initiated as in A Note The ramping mode C D E can be interrupted by the user by changing the value of r parameter The Controller will continue in static mode with SSP set temperature VII MECHANICAL CONNECTION AND MOUNTING The Controller is assigned for mounting on facet panels of electrical units The slot for mounting should have a square shape of 92x92 mm To secure the Controller on the panel use the attaching screws The connector pin attachment of the Controller is pictured on its rear panel The connecting wires must be isolated and of minimal diameter of 0 5 mm Direct control of powerful heating cooling elements should be avoided Use thyristor elements as s
6. hown on the figure below is recommended since they are not exposed to frequent commutations and fast wear out TC1O3RAMP __ 6 7 8 9 10 11 1 2 3 4 5 a3 Thermocouple 220 VAC Thermi stor 560 1w 100 0 25w 100 0 25w
7. larm Standby Sequence The alarm standby sequence is initiated on startup of the Controller or on going back to the Monitor Mode after a parameter change only when the alarm mode is greater than 7 Aln gt 7 During the alarm standby sequence the SV display is blinking and the alarm output is working as if in a non alarm zone i e OFF for alarm modes 8 to 11 and ON for alarm modes 12 to 15 On the first occurrence of a non alarm zone the alarm standby sequence finishes up Use this feature when alarm situations before the Controller has stabilized the temperature must be ignored e g when wanting to prevent the extruder from running cold 5 3 Auto tuning The auto tuning algorithm enables the Controller to adjust its PID parameters to the characteristics of the controlled object for a more precise temperature regulation The only parameter needed is SSP The auto tuning can be started in Monitor Mode by pressing both arrow buttons lt lt and gt gt The SV display reads a blinking OPrt indicating that the self optimization routine is still going on Pressing the both arrow buttons once more will cancel the auto tuning It is recommended to give a tolerance of at least 25 degrees Celsius between the starting and the set temperature before starting the auto tuning algorithm since the self optimization uses the step response method 4 If the gain factor after auto tuning is greater than 80 it will mean that the heater
8. rSP 5 rt pause time before ramp start 6 ri start value of the bias in percent 7 1 d acceleration rate of the bias in percent for thousand seconds 8 r ramp toggle Changing the value of this parameter will start stop ramping 9 rP Xp factor for PID in ramp 10 S P Xp factor for PID in static mode 11 rtd the differential constant for PID in ramp 12 Std the differential constant for PID in static mode 13 rti the integral constant for PID in ramp 14 Sti the integral constant for PID in static mode 15 rtc the length of cycle in ramp 16 Stc the length of cycle in static time 17 ALL lower alarm limit of temperature 18 ALU upper alarm limit of temperature 19 ALn number type ofan alarm mode 0 to 15 ALL ALU 0 no alarm output 1 the alarm zone is under ALL 2 the alarm zone is above ALU 3 under ALL and above ALU 4 to 7 same as types 0 to 3 however the alarm output is inverted 8 to 15 same as types 0 to 7 but with a non latch standby sequence The standby sequence is initiated upon startup of the Controller or end of Program Mode and finished at the first occurrence of a non alarm zone During the standby sequence the SV display is blinking and the alarm output works as if in a non alarm zone i e the alarm output is off for types 8 11 and on for types 12 15 IV PROGRAM MONITORANDAUTO TUNING MODES Program Mode is switched on by pressing the F button The display reads S
9. s Value are constantly displayed The processes of heating ramping and alarm are indicated by separate light diodes All parameters of the Controller can be set changed in Program Mode In this case the mnemonics of the parameters are shown on the SV display and the current values of the parameters are shown on the PV display Using the arrow buttons lt lt and gt gt the parameters values can be changed by one unit or at a faster rate when the button is held pressed for a longer time The values of the parameters are automatically restricted within their possible limits Il TECHNICAL FEATURES 1 Range of regulation of temperature 99 C to 450 C 2 Accuracy 0 2to1 3 Ranges of parameters gain factor Xp 0to100 differential constant time Td 0 to 250 sec integral constant time Ti 0 to 999 sec length of cycle Tc 0 to 200 sec alarm limits tAL 99 C to 450 C 4 Indication seven segment height 14 2 mm om 5 Control output relay type max 250 V 2A cos 1 open collector type 0 18V up to30mA direct current up to20 mA 6 Supply voltage 187 to 242 V at 48 62 Hz 7 Size 96x96x85 mm 8 Ambient temperature 0to50 C HI MNEMONICS OF THE PARAMETERS 1 SSP set temperature SV in static no ramp mode 2 rSP ramp endpoint 3 rn ramp time in minutes for the SV to gradually change from SSP to rSP 4 r S ramp time in seconds for the SV to gradually change from SSP to
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