TEMPERATURE CONTROLLER RE81 TYPE USER`S MANUAL
Contents
1. 1600 500 thermocouple of K type 0 1300 thermocouple of S type 0 1600 thermocouple of K type 0 900 C 18 7 CONTROL 7 1 On Off Control When a high accuracy of temperature control is not required especially for objects with a high time constant and not big delay one can apply the On Off control with hysteresis Features of this method are simplicity and reliability Disadvantage of this method is the occurrence of oscillations even at small hysteresis values Output Switched on Switched off Measured Fig 10 Operation way of the heating output type for the On Off control 7 2 Innovative SMART PID Algorythm When we want to obtain a higher accuracy of temperature control one must use the PID algorythm The fine tuning of the controller to the obje ct consists on the manual setting of the proportional element value in tegration element differentiation element or automatically by means of the auto tuning function 19 7 2 1 Auto tuning The controller has the function enabling the selection of PID settings These settings ensure the optimal control in most of cases To begin the auto tuning one must transit to the parameter acc to the fig 7 and hold down the button during at least 2 sec If the control algorithm is set on ON OFF or the auto tuning function is locked then the message is hidden The flickering AT symbol in2. 25 10 ERROR inasi nanasa 25 11 CONTROLLER CONFIGURATION MEANS OF LPCon nnne nnn nnn 26 12 TECHNICAL aaa 31 13 CONTROLLER EXECUTION CODES 34 14 MAINTENANCE AND 35 1 APPLICATION The RE81 controller is destined for the temperature control in plastics food dehydration industries and everywhere when the temperature sta bilizing is necessary The controller co operates directly with resistance thermometers RTD or thermocouple sensors TC The controller has two outputs enabling the two step control step by step three step control and alarm signaling The two step control is acc to the PID or ON OFF algorythm The innovative SMART PID algorithm has been implemented in the con troller 2 CONTROLLER SET The delivered controller is composed of iMac 2 PUG Teils 2 1 pc SNO SCIEW TC ANTS IOC 4 Screw clamp to fix the controller in the 44 4 pcs 1 pc B sere tribes uade iara CA M When unpacking the controller please check whether type and ecutio
3. List of configuration parameters Table 1 Parameter Manufacturer Change range Parameter description setting of the parameter ne Input parameters without decimal Position of the decimal point point 1 decimal ut Output parameters not used control signal upper absolute alarm lower absolute alarm upper relative Configuration of output 1 alarm lower relative alarm internal relative alarm i um ct Citi uc external relative alarm control signal for valve opening not used upper absolute alarm Configuration of output 2 ower absolute alarm upper relative alarm C lower relative alarm internal relative alarm Configuration of output 2 external relative alarm amp control signal for valve closing Control parameters 1 anat On Off control algorythm Control algorythm Kind of control PID control algorythm our direct control cooling reverse control heating Hysteresis 4 HY FABR 9 0 2 99 9 C 2 2 C PID parameters Proportional band PB FABR 6 0 1 999 9 C Differentiation time constant EN Correction of the control 0 999 9 s signal for P or PD type 0 100 0 control Pulse repetition period Dead zone 3 20 0 0 5 99 9 s 10 0 0 0 99 9
4. C Cu od m Alarm parameters Set value for absolute alarm 1 Deviation from the set value for the relative alarm 1 MIN MAX 6 199 0 199 00 17 Hysteresis for the alarm 1 0 2 99 9 Set value for absolute Measuring range of the alarm 2 input Deviation from the set value 499 9 199 9 C for the relative alarm 2 8244 Hysteresis for the alarm 2 0 2 99 9 Parameters of the set value Lower limitation of the set 6 SPL SPH esoo Service parameters OFF lock Auto tuning function locked available 1 Group of parameters visible only when setting the output on the control signal 2 Group of parameters visible only when setting the control algorythm on PID 3 Group of parameters visible only when setting the output on one of the alarm 4 Parameter visible only when setting the control algorithm on On Off 5 Parameter hidden only for readout in the parameter monitoring mode 6 See table 2 Parameters depending on the measuring range table 2 100 RTD 0 250 00 250 0 200 100 RTD 0 600 OO 600 0 300 thermocouple of J type 0 250 00 250 0 20 0 thermocouple of J type 0 600 00 600 0 300 thermocouple of J type 0 900 00 900 0 400 thermocouple of K type 0 600 00 600 0 300 C 1300 450
5. JO uonoeuoo euoniodoJug did un 4 194614 sisauaisk y 041009 JO y oi puly OUOD 10009 UORISUPA me oa 222 H 3o eui oi c indino Li1ndino weet gt ea C i JOUBIU oui Jo JO uonisog 23 t 8 14 6 3 Setting Change The change of the parameter setting begins after pressing the button during the display of the parameter name The setting selection is carried out through and 4 buttons and accepted by the button The change cancellation follows after pressing the button or automatically after 30 sec since the last button pressure The way to change the setting is shown on the fig 9 Cancelation of changes Beginning of changes acceptation of changes v Value Value decreasing increasing Beginning Cancelation of changes of changes acceptation of changes Previous parameter parameter Fig 9 Change of number and text parameter settings 15 6 4 Parameter Description The list of parameters in the menu is presented in the table 1
6. 8N2 9600 1000 5 a 1 Data reading OK 2 Apply Fig 14 View of Windows for the RE81 controller configuration 30 12 TECHNICAL DATA Input signals to the table 5 Input signals and measuring ranges for inputs Tablica 5 Sensor type Resistance thermometer acc to EN 60751 measuring current 0 25 Thermocouple of J type acc to EN 60584 1 0 250 Fe CuNi 0 600 0 900 Thermocouple of acc to EN 60584 1 0 600 NiCr NiAl 0 900 0 1300 Thermocouple of S acc to 60584 1 PtRhTO PI 0 1600 Resistance of the sensor line lt 10 one must connect with wires of the same section and length Measurement time 0 338 Detection of error the measurement circuit termocouple Pt100 overflow of measuring range 31 Kinds of outputs for output 1 voltageless relay binary voltage for output 2 voltageless relay Way of output operation reverse direct Signalling of active output display of set point value Rated operating conditions supply voltage supply voltage frequency ambient temperature storage temperature relative air humidity external magnetic field warm up time operating position Power consumption Weight Protection grade ensured by the casing from frontal side from terminal side 32 switching contact overload 5 A 230 V 6 V for Imax 50 mA 11 V without load N
7. appears and press the button In order to exit from the programming matrix to the normal working mode one must transit between levels until the symbol appears and press the button Some controller parameters can be invisible it depends on the current configuration The table 1 includes the description of parameters The return to the normal working mode follows automatically after 30 seconds since the last button pressure 13 6 2 Programming Matrix y 4X3 G uoinounj sJejeuJeJed 1euBiu do 9poo u c naac 372 2323 323 1euBiu eui oi 195 eui 195 eui C eddy uone 18S ns C C 2 100 2 Cul z wieje JeuDiu z uue e Jo y JO 195 ejniosqe eui eui ol SISOJO1SAH uonei ea y Jo 18S SsiseJo s H y JO 19S G my aes Chee wf GHEY uedi nni do 202 eo m adi X eL Cd 10 d eui yoly poued JO 1 1uejsuoo jueisuoo pueq peeg
8. the button Change acceptacion Fig 6 Change of the set point value 11 6 SERVICE The controller service is presented on the fig 7 SOIAIOS 19 OJ1uOO JO Z SAY Jo apoy 12805 0852 5 eu jo JO julod jas 195 ou Bulseaioaq 6 1 Programming Controller Parameters The pressure and holding down the button during ca 2 sec cau ses the entry in the programming matrix The programming matrix can be protected by an access code In case when giving a wrong value of the code it is only possible to see settings through without the possibility of changes The fig 8 presents the transition matrix in the programming mode The transition between levels is carrying out by means of w Jand 44 buttons and the level selection by means of the button After selecting the level the transition between parameters is carried out by means of w Jand A buttons In order to change the parameter setting one must proceed acc to the section 6 3 setting change In order to exit from the selected level one must transit between parame ters until the symbol
9. LATION 4 1 Controller Installation Fix the controller in the panel which the thickness should not exceed 15 mm by means of four screw clamps acc the fig 1 The panel cut out should have 45799 x 45796 mm dimensions The controller must be introduced from the panel front with disconnec ted supply voltage Before the insertion into the panel one must check the correct placement of the seal Fig 1 Controller fixing in the panel Controller overall dimensions presented on the fig 2 Fig 2 Controller overall dimensions 4 2 Electrical Connections The controller has two separable terminal strips with screw terminals which enable the wire connection of 2 5 mm cross section Output 2 Output 1 Configuration through PD14 Input HTD Pt100 HTD Pt100 Thermocouple in two wire system in three wire system Fig 4 Connection of input signals gt A Supply Output 1 binary voltage to SSR control Ag Output 2 relay Supply Fig 5 Supply and load circuit connection 4 3 Installation Recommendations In order to obtain a full fastness against electromagnetic noise it is recommended to observe following principles do not supply the controller from the network in the proximity of devices generating high pulse noise and do not apply common earthing circuits apply network filters apply metallic shields in the shape of tubes or braids
10. NiAl 0 600 07 thermocouple NiCr NiAl 0 900 08 thermocouple NiCr NiAl 0 1300 C 09 thermocouple PtRh10 Pt 0 1600 C 10 Output 1 qc m E 1 binary 0 6 V Tor SSR control ek Ya Y Cherie 2 Version standard EEE E EE TAE EE E EE S 00 custom made TP XX Language T X Acceptance tests without additional requirements et 0 with an extra quality inspection certificate 1 acc to the customer s request X Output 2 relay After agreement with the manufacturer 34 Example of Order The code RE81 06 2 00 E 0 means RE81 temperature controller of RE81 type 06 input TC J 0 900 2 output binary 0 6 V SSR control 00 standard version E English language without extra quality requirements 14 MAINTENANCE AND GUARANTEE The RE81 controller does not require any periodical maintenance In case of some incorrect operations 1 From the Shipping During the Period Given in the Annexed Guarantee Card One should take the controller down from the installation and return it to the Manufacturer s Quality Control Dept If the unit has been used in compliance with the instructi
11. OC contakt overload capacity 1 A 230 V for heating for cooling 230 V a c 10 50 60 Hz 0 23 50 20 TC 85 without water vapour condensation 400 A m 30 min any lt 5 lt 0 25 acc to EN 60529 IP 65 IP 20 Additional errors rated operating conditions caused by compensation of reference junction temperature changes 2 line resistance change of the thermocouple sensor lt 50 of the basic error value change of the ambient temperature lt 100 of the basic error 10 Safety requirements acc to EN 61010 1 1 isolation between circuits basic installation category pollution level 2 maximal phase to earth operating voltage for supply circuit outputs 300 V for input circuits 50 V altitude above sea level 2000 m Electromagnetic compatibility noise immunity acc to EN 61000 6 2 noise emissions acc to EN 61000 6 41 1 Current standard editions are in Conformity Declaration 33 13 ORDER CODES The coding way is given in the table 6 Ordering codes Table 6 Input RTD Pt100 50 100 01 RTD Pt100 250 02 Pt100 600 03 thermocouple J Fe CuNi 250 04 thermocouple J Fe CuNi 0 600 05 thermocouple J Fe CuNi 900 06 thermocouple NiCr
12. TEMPERATURE CONTROLLER RE81 TYPE USER S MANUAL Contents 1 5 2 CONTROLLER SE 5 3 BASIC REQUIREMENTS OPERATIONAL SAFETY 6 4 7 4 1 Controller Installation 4 2 Electrical 9 4 3 Installation 5 10 5 STARTING TO 11 0 12 6 1 Programming Controller Parameters 13 6 2 Programming wantin hia a aN E 14 Seting Cange 15 6 4 Parameter 16 7 GONTROL E 19 CVs NOE FIG VIDET uude enu n rp lad ond pred en dep duin a 19 7 2 Innovative SMART PID Algorythm 19 7 3 Three step Control e Ea hn ne 22 ALABMS 23 9 ADDITIONAL FUNCTIONS 24 9 1 Display of the Control 24 9 2 Manual sad sa adu 24 9 3 Manufacturer s settings
13. asuring range has admit that the overflow been exceeded resulted exceeding of the input measuring range Very non linear object Carry out the auto tuning preventing to obtain correct again If that does not help values of PID parameters or choose PID parameters an interference has occurred manually 7 2 2 Proceeding Way in Case of an Unsatisfactory PID Control It is recommended to select PID parameters changing the value in a twice higher or twice less During the change one must respect follo wing principles a Slow response of the jump decrease the proportional band decrease the integration and differentiation time b Over regulations increase the proportional band increase the differentiation time 21 C Oscillations increase the proportional band increase the integration time decrease the differentiation time d Instability Increase the integration time 7 3 Step by step Three state Control The step by step 3 state control is applied to the valve control One must set the out 408 oute and set the dead zone around the set value The first line valve opening operates for a set value equal SP 4 2 as a reverse controller the second line valve closure operates for a set value equal SP n 2 as a non reverse controller Parameters for the second line are identical as for the first line For the step by step contr
14. ektrycznych S A ul Sulechowska 1 65 022 Zielona G ra Poland Tel 48 68 329 51 00 exchange Export Department Fax 48 68 329 51 01 Tel 48 68 329 53 02 or 53 04 e mail lumel glumel com pl Fax 48 68 325 40 91 http www lumel com pl e mail export lumel com pl RE81 07A 13 10 2010
15. en the inscription appears the upper display 10 ERROR SIGNALING Character messages signaling the incorrect controller operation Table 4 Error code Reason Procedure upper display Check if the type of chosen sensor is in compliance with the connected one Check if input signal values are situated in the appropriate range If yes check if there is not a short circuit in the HTD or the thermocouple is con nected inversely Check if the type of chosen sen Upper overflow of the sor is in compliance with the con Down overflow of the measuring range or lack of RTD measuring range or nected one Check if input signal break in the sensor values are situated in the appropri circuit ate range If yes check if there is no break in the sensor circuit Connect the controller supply Input discalibrated again and if that is not effective contact the nearest service shop Check sum error Connect the controller supply of configuration again and if that is not effective parameters contact the nearest service shop When selecting the step by step Incorrect controller control both outputs must be set configuration as follows 48P and 25 11 CONTROLLER CONFIGURATION BY MEANS OF THE LPCon PROGRAM The LPCon program is destined for the controller configuration One must connect the PC computer through the PD14 programmer and af ter selecting the Option gt Connection co
16. forms about the activity of the auto tuning function The auto tuning duration time depends on dynamic properties of the object and can last maximally 10 hours During the auto tuning or directly after it over regulations can occur and for these reasons one must set a less set point value if it possible The auto tuning is composed of following stages Carrying out the experiment Experiment finished with success calculation of PID settings and stored the error code is on the display them in the non volatile memory one must confirm it beginning of PID control with new transition to the manual work mode settings The auto tuning process will be broken without PID settings calculation if a controller supply decay occurs or the button is pressed In such a case the control with current PID settings will begin If the auto tuning experiment does not end with success then an error code will be displayed acc to the table 3 20 Error codes for auto tuning Table 3 P or PD control has been One select PI PID control i e the Tl unit must be selected higher than zero The button has been pressed The maximal auto tuning dura Check if the temperature sen tion time has been exceeded sor is correctly situated if the B ae set point value is not set too The waiting time of switching higher for the given object has been exceeded Take note of the way to append the sensor Do not The input me
17. lue 0 0 Set point SP amp PID parameters Special functions Decani cen Restoration of factory settings canes pee Monitoring Data About RE81 controller SP Low Limit 0 0 SP High Limit 250 0 Refresh Apply 1 COM6 RTU 8N2 9600 1000ms a 1 Data reading OK 2 Configurator RE81DIg iol File Device Parameters Options Language Help Load Groups of parameters Configuration of input OUTPUT 1 Output function tput x Set point SP amp PID parameters power Special functions 00 Restoration of factory settings Alarm setpoint Monitoring Data Deviation forthe gt gt About RE81 controller e ET fo 0 Alarm hysteresis 2 0 English OUTPUT Dutput function without function Alarm setpoint o 0 Deviation for the o 1 relative alarm 0 0 Alarm hysteresis 2 0 Apply RTU 8N2 9600 1000ms 1 Data reading OK Z Configurator RE81DIg iol x File Device Parameters Options Language Help 4 ptions Configuration of input Outputs alarms Set point SP amp PID parameters Special functions Control algorithm Restoration of factory settings Monitoring Data onoff PID About RE81 controller Proportional band Pb poo Integral time ti s 00 Polski Set Point Derivative time td s 0 0 Manual Reset Y Ti P PD only i Hysteresis 8 Cycle
18. n code on the data plate correspond to the order 3 BASIC REQUIREMENTS OPERATIONAL SAFETY In the safety service scope the controller meets to requirements of the EN 61010 1 standard Observations Concerning Operational Safety e All operations concerning transport installation and commissioning as well as maintenance must be carried out by qualified skilled personnel and national regulations for the prevention of accidents must be observed e Before switching the controller on one must check the correctness of connections to the network e Do not connect the controller to the network through an autotrans former e Before removing the controller casing one must switch the supply off and disconnect measuring circuits e he removal of the controller casing during the guarantee contract period may cause its cancellation e he controller fulfills requirements related to electromagnetic compatibility in the industrial environment e When connecting the supply one must remember that a switch or a circuit breaker should be installed in the room This switch should be located near the controller easy accessible by the operator and suitably marked as an element switching the controller off e Non authorized removal of the casing inappropriate use incorrect installation or operation creates the risk of injury to personnel or meter damage For more detailed information please study the User s Manual 4 INSTAL
19. nfiguration menu configure the connection for the RE81 controller we choose the address 1 baud rate 9600 RTU mode 1000 ms timeout and the suitable COM port un der which the controller of the PD14 programmer has been installed Caution The programming of RE81 controller parameters must be carried out at disconnected measured circuits Configurator a _ File Device Parameters Options Language Help di pt Option Connection settings Baud rate Timeout ms 9600 Y 000 Transmission mode Address Cancel DK RTU 8N2 9600 1000ms 1 Fig 13 Connection configuration to the RE81 controller 26 After the connection configuration one must choose Device trollers gt RE81 from the menu and next click the Readout icon in order to read out all parameters One can also read out parameters in each group by clicking the Refresh button To change the setting one must write the new value in the parameter window and click the Apply button Windows with controller configuration parameters are shown on the fig 14 Some edition fields may be locked This means that they are not used in the current controller configuration Configurator 8 81019 File Device Parameters Options Language Help 2 j Open Save Load Send Polski Exit parameters Configuration of input Outputs alarms Offset of measured va
20. ol the PD algorithm is recommended The operation of the step by step three state controller with the PD al gorithm is unattainable for the step by step control Output 100 Line 1 opening Line 2 closure 0 i Input signal Fig 11 Step by step three state control 22 8 ALARMS One can configure controller outputs as alarm outputs For this aim one must set the out and or eut e parameter as one of the alarms Available types of alarms are given on the fig 12 Absolute upper Absolute lower Helative upper Helative upper out AH out out out Relative lower Relative lower Relative internal Relative external out dot o out out du 1n out duon Fig 12 Kind of alarms The set point value for absolute alarms is the value defined by the ALSP 1252 parameter and for relative alarms it is the deviation from the set point value 82 du parameter Alarm hysteresis i e the zone around the set point value in which the input state is not changed is defined by the 55 4 parameter 23 9 ADDITIONAL FUNCTIONS 9 1 Display of the Control Signal After pressing the button the value 0 100 of the control sig nal is displayed on the display The index is displayed on the first digit for the step by step control index o for opening and c for closure The control signal will be displayed
21. ons the Manufacturer warrants to repair it free of charge 2 After the Guarantee Period One should turn over the controller to repair it in a certified service workshop The disassembling of the casing causes the cancellation of the granted guarantee opare parts are available for the period of five years from the date of purchase Our policy is one of continuous improvement and we reserve the right to make changes in design and specifications of any products as engineering advances or necessity requires and revise the above specifications without notice 35 SALES PROGRAM MEASUREMENT DIGITAL and BARGRAPH PANEL METERS CONTROL MEASURING TRANSDUCERS RECORDING ANALOG PANEL METERS DIN INSTRUMENTS DIGITAL CLAMP ON METERS INDUSTRIAL PROCESS and POWER CONTROLLERS CHART and PAPERLESS RECORDERS 1 PHASE and 3 PHASE WATT HOUR METERS LARGE SIZE DISPLAY PANELS ELEMENTS OF INTEGRATION SYSTEMS ACCESSORIES for MEASURING INSTRUMENTS SHUNTS CUSTOM MADE PRODUCTS ACCORDING CUSTOMER S REQUIREMENTS WE ALSO OFFER OUR SERVICES IN THE PRODUCTION OF ALUMINIUM ALLOY PRESSURE CASTINGS PRECISION ENGINEERING and THERMOPLASTICS PARTS SUBCONTRACTING of ELECTRONIC DEVICES SMT PRESSURE CASTINGS and OTHER TOOLS QUALITY PROCEDURES According to ISO 9001 and ISO 14001 international requirements All our instruments have CE mark For more information please write to or phone our Export Department LUMEL Lubuskie Zak ady Aparat w El
22. time 20 0 Control type heating bd Refresh Apply cone RTU 8N2 9600 1000ms a 1 Data reading OK Z Configurator RE81DIg loj xl File Device Parameters Options Language Help gt Save Options Load Configuration of input Outputs alarms Set point SP amp PID parameters Special functions Restoration of factory settings Monitoring Data About RE81 controller Polski English C locking unlocking Access code to the s menu of controller Refresh Apply RTU 8N2 9600 1000ms 1 Data reading y Configurator RE81DIg File Device Parameters Options Language Help s Options Load parameters Polski English Configuration of input Dutputs alarms Set point SP amp PID parameters Special functions Restoration of factory settings Monitoring Data About RE81 controller Restoration of factory settings Refresh COMB RTU 8N2 9600 1000ms a 1 Data reading OK 215 xl 29 Configurator RE81DIg File Device Parameters Options Language Help E Options Groups of parameters Configuration of input Outputs alarms Set point SP amp PID parameters Special functions Restoration of factory settings About RE81 controller 15 x Exit 0100000000000000 0000000000000000 Refresh cons RTU
23. to conduct supplying wires wires leading measuring signals should be twisted in pairs and for resistance sensors in 3 wire connection twisted of wires of the same length cross section and resistance and led in a shield as above all shields should be one side earthed or connected to the protection wire the nearest possible to the controller apply the general principle that wires leading different signals should be led at the maximal distance between them no less than 30 cm and the crossing of these groups of wires made at right angle 90 10 5 STARTING TO WORK After turning the supply on the controller carries out the display test displays the e 8 inscription the program version and next displays the measured value A character message informing about abnormali ties may appear on the display table 4 The On Off control algorythm is set by the manufacturer with hysteresis given in the table 2 Changing the Set Value One can change the set point value by pressing the wr or the 44 button fig 6 The beginning of change is signaled by the fli ckering point of the lower display One must accept the new set point value by pressing the button during 30 seconds since the last pressure of the wr button In the contrary the old value will be restored Measured value Set point value Signaling the change Cancelling To change the the change set point value press one of
24. when out or out 92 and out e 5CL For the step by step control switching between opening and closure is carried out after pressing the w Jor 4 button 9 2 Manual Control The manual control gives the possibility of the object identification test ing or control it after the sensor damage The entry to the manual control follows after holding down the button during the control signal display The manual control is signaled by the diode pulsation with the symbol The controller interrupts the automatic control and begins the manual control of the output For the On Off control one can set the control signal on 0 or 100 by w buttons The control signal value is on the lower display preceded by the h symbol For the PID control one can set the control signal w Jand 4 buttons on any value from the 0 0 100 range The control signal va lue is on the lower display preceded by the h symbol For the step by step control the valve opening is carried out during holding the a button down the closure during holding the w button down The valve state is displayed on the lower display SC GP stopped opening 24 05 closure The exit to the normal working mode follows after pressing the button 24 9 3 Manufacturer s Settings One can restore manufacturer s settings by holding down w and 44 buttons during the supply turning on till the moment wh
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