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USER`S MANUAL

1. Measured value Stof vree Measured value Pr Even Measured value peen Measured value en iz 2sec Dis Di Die DiG 25 mn Sie change the program number press one of the push buttons C Qc mie Transition to the next segment Fig 27 Menu of programming control service Status StoP control stop run program in progress ht bv active locking from the deviation control hold stoppage of set point value counting End program end 14 RS 485 INTERFACE WITH MODBUS PROTOCOL 14 1 Introduction The RE72 controller is equipped with a serial interface in RS 485 standard with implemented asynchronous communication protocol MODBUS Combination of serial interface parameters for the RE72 controller device address 1 247 baud rate 4800 9600 19200 38400 57600 bit s operating mode RTU information unit 8N2 8E1 801 8N1 data format integer 16 bit float 32 bit float 2x16 bit maximum response time 500 ms maximum number of registers read out written by a single Modbus frame 116 The RE72 controller realizes following protocol functions Table 8 Code Meaning 03 read out of n registers 06 write of 1 register 16 write of n registers 17 identification of the slave device 59 14 2 Error Codes If the contr
2. 6 E P transducer supply 24V 5 9 tI a 4 e output 2 input signals 3 supply Fig 3 View of controller connecting strips uw 3 Pt10 2 Jumper RTD Pt100 in two wire System 3 2 Thermocouple 3 m supply 4 Fig 4 Supply mu 3 2 1 RTD Pt100 in 3 wire system 4 3 2 Current input 0 4 20 mA 0 4 20 mal Z Jumper Fig 5 Input signals as 3 Pt1000 2 1 RTD Pt1000 0 5 10 2 Voltage input O 5 10 V 6 0 4 20 mO 5 Fig 6 Additional input signal SSR 119 Load 19 Load a 1210 5 12 10 OUT2 OUT i our ouri Output 1 2 relay Output 1 2 voltage 0 5 V a 119 2 98 11 9 208 0 4 20mA 0 10V Sz 12 10 28 12 10 OUT2 OUTI E OUT2 OUTI Output 1 2 continuous Output 1 2 continuous voltage current 0 4 20 mA 0 5 10 V Load Supply Output 3 relay Fig 7 Contr
3. 18 continuous voltage output 0 10V 19 oute Function of output 2 oFF of F without function control signal control signal of stepper control opening control signal of stepper control closing Cool sygna steruj cy ch odzenie AHL control signal cooling AL lower absolute alarm du upper relative alarm dut o lower relative alarm dus inner relative alarm duou outer relative alarm ALE r timer alarm heater damage alarm fiL oS controlling element damage alarm short circuit rEEr retransmission Eu t auxiliary output for the program following control auxiliary output for the program following control Output type 2 4 20 2 relay output 55r voltage output 0 5 V 4 08 continuous current output 4 20 mA 8 28 continuous current output 0 20 mA 0 10 continuous voltage output 0 10V 20 of F without function control signal control signal of stepper control opening control signal of stepper control closing foot control signal cooling RH absolute upper alarm AL o lower absolute alarm du upper relative alarm Function of dut o lower relative alarm out 3 off output 3 du n inner relative alarm duou outer relative alarm timer alarm heater damage alarm ALo5 controlling element damage
4. 1999 9999 linear voltage U 1999 9999 80 15 SOFTWARE UPDATING Function enabling updating of software from the computer of the PC with software LPCon was implemented in controller RE72 from version of software 2 00 Free software LPCon and update files are available at www lumel com pl The connected to the computer convertor RS485 is required on USB to the updating e g the convertor PD10 ae UPDATFR v 07 al Bk Urdzeme Parametry Opcje Aktualizacja j zyk Pomoc Device GA f CE Mee Uwe Doae 2 Polski Enden Port ma 3 COMA Disconnect Backward cnmpakbty made 7 ktos wia Pei DENEN kreca Tobben _ MTUWE gt Paay POT E RETZ 2 00 mo El ZE 4 em Alamy 1 2 Messages Port opened Dever found HE 72 fmre 200 Po amane parameb w w uz dzenu akty uten e ane amer v nen Opi paper Done 000821 M Odczyt danych OK 352193 OK 115307 Fig 28 Program view a LPCon b updating of software Warning Before doing update currently settings of controller should be saved by program LPCon because when software is updated default settings of controller are restored After starting LPCon s software COM port baudrate trans mission mode and adress should be set It can be done in Options Then RE72 controller s
5. tion and valve position read from the additional input To select a step by step control set one of the outputs out out to and one of the outputs out fout to For the algo rithm with no feedback the parameter feb should be set to no for the algorithm with a feedback the parameter Fab should be set to 5 Additionally set the insensitivity range for the set point in which the valve does not change its position the parameter n and select the set of PID parameters Auto tuning algorithm is not available for the step by step control Step by step control with no feedback additionally requires the parame ters settings valve open time amp valve close time true minimum valve work time ant 37 relays state on j nn 3 p oo 100 valve open 9 4 temperature setpoint time Fig 18 Three step step by step control with no feedback The principle of the algorithm shown in Fig 18 is based on conversion of changing the control signal to the relay opening closing time referred to the full opening closing time The differences between the calculated and the actual valve position are unavoidable because of multiple changes in the direction of valve movement due to the inertia of a drive or its wear in the absence of a feedback The controller uses the function of automatic positioning of a drive during operation to eliminate these differences This function does
6. MAX 3 22 Switching level for PID3 0 0 MIN MAX 3 and PID4 sets P d I PID1 set Selection of the constant Big P de PID2 set PID se Pr 23 PID3 set P PIDA set Lower threshold for auto MIN MAX 3 uning 0 0 C Upper threshold for auto 5 MIN MAX 3 uning 800 0 C Stepper control algorithm a id a gonnm without ype YE5 algorithm with feedback D parameters Pb Proportional band 30 0 C 0 1 550 0 C 0 1 990 0 F t Time constant 300 s 0 9999 s calkowania td Integration time 60 0s 0 0 2500 s constant 40 Correction of the 0 0 96 0 100 0 96 control signal for P or PD control type Poe Second set te of PID pa tde rameters RER MIO ue Pb53 Third set of te 3 PID para as PB TI TD YO td3 meters oF Pb Fourth set t4 of PID pa a rameters as PB TI TD YO 23 PbC Proportional band or the cooling channel in relation to PB 100 0 6 0 1 200 P i t Integration time 300s 0 9999 s constan t l Differentiation 60 05 0 0 2500 s ime constant Ai Ar Alarm parameters Set point value for abso 100 0 MIN MAX 3 ute alarm1 Deviation from the set 200 0 200 0 A du point value for relative 0 0 C 360 0 360 0 F alarm 1 7 0 2 100 0 C A 1HY Hysteresis for alarm 1 2 0 C 0 2 180 0 F EE di Arte
7. auto tuning process Rated operating conditions supply voltage frequency ambient temperature storage temperature relative air humidity preheating time operating position resistance of wires connecting the resistance thermometer or the thermocouple with the controller Power input Weight 88 85 253 V a c d c 20 40V 40 440 Hz 0 23 50 C 20 70 C lt 85 condensation inadmissible 30 min any lt 20 O wire 8 VA 02 kg Protection grade ensured by the casing acc to EN 60529 from the frontal plate IP65 from the terminal side IP20 Additional errors in rated operating conditions caused by compensation of thermocouple cold junction temperature changes 290 ambient temperature change lt 100 value of intrinsic error 10 K Safety requirements acc to EN 61010 1 installation category Ill pollution level 2 maximum phase to earth operating voltage for supply circuits output 300 V for input circuits 50V altitude above sea level 2000 m Electromagnetic compatibility noise immunity acc to EN 61000 6 2 standard noise emissions acc to EN 61000 6 4 standard 89 18 CONTROLLER VERSION CODES The way of coding is given in the table 20 Table 20 Output 1 relay voltage 0 5 V continuous current 0 4 20 mA continuous voltage 0 10 V voltage 0 5 V continuous current 0 4 20 mA continuous vo
8. for the upper eH threshold of the 100 0 1999 9999 1 auxiliary linear input off filter disabled 0 0 time constant 0 2 s 0 5 time constant 0 5 s i time constant 1 s Time constant time constant 2 s FILE 2 2 of the filter 5 time constant 5 s 18 time constant 10 s eG time constant 20 s 50 time constant 50 s 188 time constant 100 s 18 Binary input Barn function nont nont none Sto control stop And switching into manual working SP switching SP1 into SP2 r SAt erasing of timer alarm PSEA program start PaSt jump to the next segment PHL d stopping to count the set point in the program out Output parameters Function of Sur output 1 af F without function control dignal control signal for the stepper control opening control signal for the stepper control closing Coot control signal cooling RH upper absolute alarm AL o lower absolute alarm du upper relative alarm dut o lower relative alarm dus inner relative alarm duou outer relative alarm fiut r timer alarm rEtr retransmission i auxiliary output for the program following control auxiliary output for the program following control o LE Output type 1 4 20 2 relay output 55e voltage output 0 5 V 4 28 continuous current output 4 20 mA 8 28 continuous current output 0 20 mA
9. 0 250 monitoring mode Timer function 4103 TIMR RW 1 0 disabled 1 enabled 4104 TIME RW 1 9999 Time counted down by the timer min x 10 Monitoring of the auxiliary input 4105 DI2 RW 0 1 0 disabled 1 enabled Monitoring of heater current 4106 DCT RW 0 24 0 disabled 1 enabled 4107 RW 0 65535 Reserved 4108 RW 0 65535 Reserved 4109 RW 0 65535 Reserved 4110 RW 0 65535 Reserved 4111 TO3 RW 5 999 Pulse period of output 3 s 10 4112 RW 0 65535 Reserved Algorithm for stepper control 4113 FDB RW ora 0 without feedback 1 with feedback Set point for the controlling element 4114 OSSP RW 0 500 Gamage alarm short circuit Ax10 Hysteresis for the controlling element 4115 OSHY RW 0 500 alarm short circuit Ax10 4116 TMVO RW 30 6000 Valve open time s x10 4117 TMVC RW 30 6000 Valve close time s x10 4118 MNTV RW 1 999 Minimum valve work time s x10 4119 YLO RW 0 1000 Minimum control signal x10 4120 YHI RW 0 1000 Maximum control signal x10 1 Value with the decimal point position defined by bits 0 and 1 in the register 4003 2 Parameter to write only in the manual operating mode 71 3 Concerns resistance thermometer inputs 4 Concerns thermocouple inputs 5 Concerns linear inputs 6 Range to write for the continuous current output 7 Concerns output 1 of binary type 8 Concerns o
10. 4163 RW 0 65535 Reserved 4164 RW 0 65535 Reserved 4165 RW 0 65535 Reserved 4166 RW 0 65535 Reserved 4167 RW 0 65535 Reserved 4168 RW 0 65535 Reserved 4169 RW 0 65535 Reserved 4170 STRT RW 0 1 Way to begin the program 0 from value defined by SPO 1 from current measured value 4171 SPO RW acc to Initial set point value table 1759 4172 TMUN RW 0 1 Unit for the segment duration time 2 0 minutes and seconds E 1 hours and minutes 4173 t 2 RRUN RW 0 1 Unit for the accretion rate of the Es set point value 8g 0 minutes a s 1 hours 4174 HOLD RW 0 3 Locking of control deviations e 0 inactive 1 lower 2 upper 3 two sided 4175 CYCN RW 1 999 Number of program repetitions 4176 FAIL RW 0 1 Control after a supply decay 0 program continuation 1 control stoppage 75 4177 4178 4179 4180 4181 4182 4183 4184 4185 Segment 1 END RW Control on the program end 0 control stoppage 1 fixed set point control with the set point value of the last segment PID TYPE RW RW Gain Scheduling function for the program 0 disabled 1 enabled Kind of segment 0 segment defined by the time 1 segment defined by the accretion 2 stoppage of the set point value 3 program end TSP RW acc to table 17 Set point
11. Function eenen 8 5 Control of Heating cooling Type 9 ALARMS m ER 10 11 12 13 14 15 16 17 18 19 TIMER FUNCTION CURRENT TRANSFORMER INPUT ADDITIONAL FUNCTIONS aen 12 1 Control Signal Monitoring neen 12 2 Control sasz crea coner ea enr ensen ned seen 12 3 Signal Retransmission 12 4 Set Point Change Rate Soft Start gra Digital RIMOR soor E 12 6 Manufacturer s Settings unne PROGRAMMING CONTROL aen een 13 1 Description of Programming Control Parameters 51 13 2 Definition of Set Point Value Programs 54 13 3 Control of the Set Point Value Program 57 RS 485 INTERFACE WITH MODBUS PROTOCOL 59 14 1 Introduction rrr rrr erp rere 59 14 2 Error COdOS iioii tee pose rera 60 1453 Register rr 60 SOFTWARE UPDATING aeneo n s 81 ERROR SIGNALING annees en enenenneneneren eren 83 TECHNICAL DATA an ones eere to PiE Go 85 CONTROLLER VERSION 90 MAINTENANCE AND GUARANTEE nee 92 programm version 2 06 1 APPLICATION The RE72 controller is destined for the temperature control in plastics food dehydration industries and everywhere when the temperature change stabilization is nece
12. MIN MAX 3 5Pe Set point value SP2 0 0 C MIN MAX 3 5 3 Set point value SP3 0 0 C MIN MAX 3 5P4 Set point value SP4 0 0 C MIN MAX 3 GPL Lower limitation of the fast 200 C MIN MAX 3 set point value change 25 Upper limitation of the fast p PH set point value change 1767 C MIN RAS S Accretion rate of the set SPee point value SP1 or SP2 0 0 C 9 9989 Mi time unit 4 time unit 4 during the soft start Pr 5 Programming control parameters The description of parameters is in t Serial interface parameters Device address bRud Baud rate 36 he section Programming control table 5 4800 bit s 36 9600 bit s 18e 19200 bit s 384 38400 bit s 5 16 57600 bit s Prot rBn Protocol nont lack rag RTU 8N2 RTU8E1 r 8o t RTU 801 t 8N1 r Etre Parametry retransmisji Pu measured value on the main input PV Pu e measured value on the additional input PV2 P 1 0 measured value Rafa Quantity retransmitted on Pu PV PV2 the continuous output Pe 1 measured value PV2 PV 52 Set point value du control deviation set point value measured value Bal Lower threshold of the 00 MIN MAX 3 signal to retransmit Upper threshold of the 100 0 MIN MAX 3 signal to retransmit
13. emory of alarm 1 off KAR disabled on enabled R2SP Set point value for abso 100 0 MIN MAX 3 ute alarm 2 Deviation from the set 200 0 200 0 C Re o edu poni vaus for relative 0 0 C 360 0 360 0 F 0 2 100 0 a Hysteresis for alarm 2 2 0 C 0 2 180 0 F FE di emory of alarm 2 off ae disabled on enabled n35P Set point value for absolu 100 0 C MIN MAX e alarm 3 Deviation from the set 200 0 200 0 C Adu point value for relative 0 0 C 360 0 360 0 F alarm 3 24 0 2 100 0 C 349 Hysteresis for alarm 3 2 0 C 0 2 180 0 F Memory of alarm 3 off off disabled on enabled hhSP Set point for the heater 00A 0 0 50 0 A damage alarm hbHY Hysteresis for the heater 0 1 50 0A damage alarm Set point for the control 055 ling element damage 0 0A 0 0 50 0 A alarm short circuit Hysteresis for the con oSHY trolling element damage 0 1 50 0 A alarm short circuit SPP Set point value parameters SPnd Kind of set point value 5Pie SP e set point value SP1 or SP2 n set point value with soft start in units per minute set point value with soft start in units per hour set point value from the additional input Pr b set point value from programming control LPru Program No to carry out 1 13 15 SP Set point value SP 0 0 C
14. of stepper control closing 7 4 control signal cooling 5 absolute upper alarm 6 absolute lower alarm 7 relative upper alarm 4032 OUT3 RW 0 15 8 relative lower alarm 9 relative internal alarm 10 relative external alarm 11 timer alarm 12 alarm of heater burnout 13 controlling element damage alarm short circuit 14 auxiliary output EV1 in the programming control 15 auxiliary output EV2 in the programming control 4033 RW 0 65535 Reserved Control algorithm 4034 ALG RW 9 1 0 on off 1 PID Kind of control 4035 TYPE RW 0 1 0 direct control cooling 1 reverse control heating 4036 HY RW 2 999 Hysteresis HY Gain Scheduling function 4037 GTY RW 0 2 1 from set point value 2 constant PID set Number of PID sets for Gain Sche duling from the set point value 4038 GSNB RW 0 2 0 2 PID sets 1 3 PID sets 2 4 PID sets to itchi 4039 GL12 RW a r level for PID1 and PID2 66 acc to table Switching level for PID2 and PID3 4040 GL23 RW 471 sats 4041 GL34 RW a 2 level for PID3 PID4 Choice of a constant PID set 0 PID1 4042 GSET RW 0 53 1 PID2 2 PID3 3 PID4 4043 PB RW 0 99991 Proportional band PB 4044 TI RW 0 9999 Integration time constant TI 5 4045 TD RW 0 23889 Differentiati
15. on 0 or 100 of the power however when the PB parameter is higher than zero one can set the control signal on any value from the range 0 100 12 3 Signal Retransmission The continuous output can be used for the retransmission of selected value e g in order to the temperature recording in the object or the set point value duplication in multi zone furnaces The signal retransmission will be possible if the output 2 is of continuous type We begin the signal retransmission from setting the oute parameter into Additionally one must set the upper and lower limit of the signal to be retransmitted foto and The signal selection for retransmission is carried out through the parameter The recounting method of the retransmitted parameter into a suitable analog signal is shown on the fig 24 A output OUT er out X Out min 7 gt Roto X Fig 24 Recounting of the signal for retransmission 48 The output signal is calculated acc to the following formula Out 7 out Ain out out x Ao Lo Ao Lo Ao Hi The Bate parameter can be set as higher than Fa but the output signal will be then inversed 12 4 Set Point Change Rate Soft Start The limitation of the temperature accretion rate is carried out through the gradually change of the set point value This function is activated after the controller supply connection and duri
16. 1 0 disabled 1 enabled acc to table 4069 A2SP RW 47 Set point value for absolute alarm 2 1 Deviation from the set point value for 4070 A2DV RW 1999 1999 relative alarm 2 4071 2 RW 2 999 1 Hysteresis for alarm 2 Memory of alarm 2 4072 A2LT RW 0 1 0 disabled 1 enabled 4073 A3SP RW 20 101908 set point value for absolute alarm 3 1 Deviation from the set point value for 4074 A3DV RW 1999 1999 relative alarm 3 4075 A3HY RW 2 gg91 Hysteresis for alarm 3 Memory of alarm 3 4076 A3LT RW 0 1 0 disabled 1 enabled 68 4077 RW 0 65535 Reserved 4078 RW 0 65535 Reserved 4079 RW 0 65535 Reserved 4080 RW 0 65535 Reserved Set point value for the heater damage 4081 HBSP RW 0 500 alarm Ax10 Hysteresis for the heater damage 4082 HBHY RW 0 500 alarm Ax10 Kind of set point value 0 set point value SP1 or SP2 1 set point value with soft start in units per minute 2 set point value with soft start in 4083 SPMD RW 0 4 units per hour 3 set point value from the additional input 4 Set point value acc to the programmed control 4084 SP RW E De Set point value SP 4085 SP2 RW ble set point value SP2 4086 SP3 RW ble Set point value SP3 4087 SP4 RW ble set point value SP4 4088 SPLL RW acc to fable Lower limitat
17. 150 for currentinput 500 Error detection in the measuring circuit thermocouple Pt100 Pt1000 overrun of measuring range 0 10V over 11 V 0 5 V over 5 5 V 0 20 mA over 22 mA 4 20 mA under 1 mA and over 22 mA Additional input intrinsic error of the real value measurement 0 3 1 digit Measurement time 0 5 s Input resistance 1000 86 Setting range of controller parameters See table 1 Binary input shorting resistance opening out resistance Kinds of outputs 1 and 2 voltageless relay voltage transistor continuous voltage continuous current Kinds of output 3 voltageless relay Way of output operation reverse direct Error of analog outputs Digital interface Modbus protocol baud rate mode voltageless lt 10kQ gt 100 NOC contact load capacity 2A 230 V a c 0 5 V maximum load capacity 40 mA 0 10 Vat Roag 2 1 0 20 mA 4 20 mA at R lt 500 0 NOC contact load capacity 1 A 230 V a c for heating for cooling 0 2 of the range RS 485 4800 9600 19200 38400 57600 bit s RTU 8N2 8E1 801 8N1 87 address maximum response time Supply of object transducers Signaling switching the output 1 on switching the output 2 on 1 247 500 ms 24V d c 5 30 mA switching the output 3 on or switching the binary input on mode of manual control
18. 26 SEc Service parameters SECU Access code to the menu 0 0 9999 FF Sta Auto tuning function on l cked on available E FF di t ae Timer function off deeld on enabled be RE Counting off the time by 30 0 0 1 999 9 min the timer min de Monitoring of the auxiliary BEF off disabled input on enabled ace Monitoring of the heater off of F disabled current on enabled Time of the automatic out tout put from the monitoring 30 s 0 9999 s mode 1 The definition at which the given parameter is shown depends on the parameter 9 position of the decimal point 2 For the output 0 4 20 mA parameter to write for other cases to readout acc to the version code 3 See table 2 4 Time unit defined by the parameter 5259 n He Caution The accessibility of parameters depends on the controller version and its current settings 27 Parameters depended on the measuring range Table 2 Symbol Input sensor MIN MAX P Resistance thermometer 200 9 850 C Pt100 328 OF 1562 F P 10 Resistance thermometer 200 C 850 C Pt1000 328 OF 1562 100 1200 C tru Thermocouple of J type 148 OF 2192 F 100 C 400 C t t Thermocouple of T type 148 OF 752 100 C 1372 C Thermocouple of K type 148 OF 2501 6 OF 4 t 5 Thermocouple of S t
19. After counting down to zero the timer alarm is set which remains active till the moment of the timer erasing To activate the timer function one must set the parameter t on To indicate the alarm state on an output one of the outputs out out 3 should be set to Aler The timer status residual time is RH the mark on the first position To display it one must press the push button till the moment of it appearance on the lower display acc to the fig 13 The return to the set point value display is set by the manufacturer on 30 Sec but can be changed or disabled through the tout parameter Status Description Sygnaling timer stopped Ex temperature over SP Residual time in Starting of the timer Press the Y push button minutes e g 6289 Pause of the timar Press the Y push Flickering residual time button in minutes End count Reaching zero by the timer tind down During the countdown Press amp _ push buttons Timer erasing After the countdown end press the _ J push button through the binary input 44 PV SP time countdown time sec Timer erasing 1 1 d 1 Timer alarm Fig 23 Principle of timer operation 11 CURRENT TRANSFORMER INPUT After connecting the current transformer designation 94 1 the measurement and display of the current flowing through the load steere
20. CONTROLLER 48 x 48 mm RE72 TYPE USER S MANUAL CE Contents T APPLICATION crecer eoe OGG Sowa 5 2 CONTROLLER SET cr oi 5 3 BASIC REQUIREMENTS OPERATIONAL SAFETY 6 4 INSTALLATION aS Sky tad ada dada EPEE ERE 6 4 1 Controller Installation ennen eneen 6 4 2 lactrical Connections 8 4 3 Installation Recommendations 10 5 STARTING TO 11 Ede getkedn 12 6 1 Programming Controller Parameters 13 6 2 Programming Matrix eneen een ennen 6 3 Setting Change 6 4 Parameter Description 7 CONTROLLER INPUTS AND OUTPUTS ae 29 7 1 Main Measuring Inputs nennen een eenen 29 7 2 Additional Measuring Inputs nennen 29 7 3 Binary Inputs TA OUTS o 8 GONTROL 8 1 ON OFF Control owcza eina cn denia 8 2 Innovative SMART PID Algorithm 8 2 1 Auto tuning 8 2 2 Auto tuning and Gain Scheduling 8 2 3 Proceeding Way in Case of a Dissatisfying PID Control 35 8 3 Step by step 1 8 4 Gain Scheduling
21. ST ved signal to higher 5 Transit to higher level oS5P oSHY ee Hyste Set Hyste 5 resis of value of resis of Transit current current current to higher alarm alarm alarm level 13 Transit to higher level 15 6 3 Setting Change The change of the parameter setting begins after pressing the push button during the display of the parameter name The set ting selection is carried out through w and A push buttons and accepted by the push button The change cancellation fol lows after the simultaneous pressing of ww and a push but tons or automatically after 30 sec since the last push button pressure The way to change the setting is shown on the fig 15 4 Beginning gt Cancelation of changes 6 of changes 8 y acceptation of changes Z 2 Value Value decreasing increasing Beginning EMR Cancelation of changes of changes f acceptation of changes C 4 Previous Next parameter parameter AA A A S7 CA Cancelation i 3 4 gt of changes 2 5 Beginning I Acceptation diee ca of changes Cz CJ C Fig 15 Change of number and text parameter settings 16 6 4 Parameter Description The list of parameters in the menu is presented in the table 1 List of configuration parameters Table 1 the linear main input Parameter Parameter M
22. acc totable17 Current set point value SP 4009 RW 0 1000 Control signal of loop 1 96 x10 4010 RW 0 1000 Control signal of loop 2 96 x10 4011 R 0 59994 Timer value s Heater current when the output is 4012 R 0 500 turned on Ax10 Heater current when the output is 4013 R 0 500 turned off A x10 Unit 0 Celsius degrees JA Bie 1 Fahrenheit degrees 2 physical units Kind of main input 0 resistance thermometer Pt100 1 resistance thermometer Pt1000 2 thermocouple of J type 3 thermocouple of T type 4 thermocouple of K type 5 thermocouple of S type 4015 INPT RW 0 14 6 thermocouple of R type 7 thermocouple of B type 8 thermocouple of E type 9 thermocouple on N type 10 thermocouple of L type 11 current input 0 20mA 12 current input 4 20mA 13 voltage input 0 5 V 14 voltage input 0 10 V 62 4016 DP RW 0199 0 29 Position of the decimal point of the main input 0 without decimal place 1 1 decimal place 2 2 decimal places 4017 4018 INLO INHI RW RW 999 9999 9 999 9999 7 Indication for the lower threshold of the analog main input Indication for the upper threshold of the analog main input 4019 SHIF RW SEE EE U Shift of the measured value of the main input 4020 12 RW Kind of the additional input 0 c
23. ae Bide gy AaSP Rate Rasp PbS Alarm Set tion Hyste Memory Parameters foralarm 2 Parameters for alarm 3 Set value parame value resis for of current tore alarm 1 Ei i alam alarm 1 as for alarm 1 as for alarm 1 alarm SPP l Pru sapan SOAP SP SEP mi sey im za of set Re SP value value SP4 limitation limitation rate of param value Ed SP2 SP3 SP SP set value Pri m Progam kan ming control ram chapter Retrans Rot Higher HMM P ower Transit ars mis retransmis Retrans to higher B function threshold hold level att Addr bfud Prot Interface Con Trans Trans Transit parame troller mis mis to higher ters address rate protocol level cu 5 ze dle tout Service Auto tnr Count Monitor Monitor Exit time Transit rame tunin h auxilian heater rom mo to higher PEM code function function of timer output current nitoring o gt Exit from menu 14 Fig 14 Programming matrix FILE bn mn pal Indic of Time Binary gt higher constant input Transit hold of filter function to ister 9 Transit to higher level re re LEY GSab Fa Sat asee ume Ede 5 y BRADEN ching ching Constant nies thres Rever Transit function for GS pings pines setPID hold
24. al type is possible between 0 20 mA and 4 20 mA by the para meter e amp t 9 The position of decimal point which defines the display format of the measured and set point value is set by the parameter de One must also set the indication for the lower and upper analog input threshold Cio and eH The signal from the additional input is displayed with the cha racter d on the first position To display the value one must press the push button till the moment of its appearance on the lower 29 display acc to the fig 13 The return to display the set point value is set by the manufacturer for 30 sec but it can be changed or disabled through the parameter tout 7 3 Binary Inputs The function of the binary input is set by the parameter bru Following binary input functions are available without function the binary input state does not influence the controller operation control stop the control is interrupted and control outputs are behaved as after a sensor damage alarm and retransmission operate independently switching on manual operation transition to the manual control mode switching SP1 on SP2 change ofthe set point value during the control erasing of the timer alarm disabling of the relay responsible for the timer alarm program start the programming control process begins after a prior set of the programming control jump to the next segment the transit
25. alarm short circuit i auxiliary output for the program following control auxiliary output for the program following control Control signal of control output for SFL proportional 0 0 0 0 100 0 control in case of the sensor damage 21 and PID3 sets to Pulse period of output 1 20 06 05 80 98 toe Pulse period of output 2 20 0s 0 5 99 9 s to3 Pulse period of output 3 20 05 0 5 99 9 s Control parameters onaf control algorithm ALE Control algorithm ad on off d control algorithm PID d r direct control cooling Kind of control nu 1 reverse control heating ny Hysteresis 1 196 on LO qp Displacement zone for heating cooling control B 0 0 100 0 C dead zone for stepper 10 0 C 0 0 180 0 F 0 999 1 control truo Valve open time 30 0 s 3 0 600 0 s Valve close time 30 0 s 3 0 600 0 s natu inimum valve work time 0 15 0 1 99 9 s 3 10 inimum control signal 0 0 0 0 100 0 96 J A aximum control signal 100 0 0 0 100 0 Gain Scheduling off of F disabled GEY function 52 from set point value 5 E constant PID set umber of PID sets for gt gt E G5nb Gain Scheduling from e 4 4 PID sets he set point value i r Switching level for PID1 MIN MAX 3 Gi ie and PID sets 0 0 Gt Switching level for PID2 00 MIN
26. anufac Range of parameter changes symbol description 3 sensors Linear input setting nP Input parameters unm t Unit ec 9C Celsius degrees F Fahrenheit degrees Pu physical units raed Kind of main Pt t input Pt 10 Pt1000 t d thermocouple of J type t t thermocouple of T type t thermocouple of K type t 5 thermocouple of S type t r thermocouple of R type t 6 thermocouple of B type t amp thermocouple of E type t n thermocouple of N type t L thermocouple of L type 2 20 linear current 0 20mA 4 080 linear curren 4 20mA 8 5 linear voltage 0 5 V G 18 linear voltage 0 10 V ae Position of the i dP O dP without 2 dP without main input decimal point decimal point decimal point 1 dP 1 deci dP 1 deci mal place mal place e dP 2 deci mal place Indication for the lower threshold of 0 0 1999 9999 1 17 ndication or the upper hreshold of 100 0 1999 9999 1 he linear main input measured va T ue shift of the 100 0 100 0 C SH main input 0 080 180 0 180 0 F 999 999 1 ind of the 4 29 2 20 linear current 0 20 mA auxiliary input 4 28 linear current 4 20 mA 8_dP without decimal place Position of the ja 1 dP 1 deci dPe decimal point mee 7 mal place dP 2 decimal place Indication for the lower o threshold of the 0 0 1999 9999 1 auxiliary linear input Indication
27. arantee period One should turn over the instrument to repair it in a certified service workshop Our policy is one of continuous improvement and we reserve the right to make changes in design and speci fications of any products as engineering advances or necessity requires and revise the above specifications without notice 92 93 LUMEL LUMEL S A ul S ubicka 1 65 127 Zielona G ra Poland Tel 48 68 45 75 100 Fax 48 68 45 75 508 e mail lumel lumel com pl http www lumel com pl Export Department Tel 48 68 45 75 302 Fax 48 68 32 54 091 e mail export lumel com pl RE72 09C
28. cially for objects with a great time constant and small delay one can apply the on off control with hysteresis Advantages of this way of control are simplicity and liability but disad vantage are the occurring oscillations even at small hysteresis values Output HS Switched on Switched off gt sp Measured value Fig 16 Operation way of the heating output type 8 2 Innovative SMART PID Algorithm When a high accuracy of the temperature control is required one must use the PID algorithm The applied innovative SMART PID algorithm is characterized by an increased accuracy for a widen class range of controlled objects The controller tuning of the object consists on the manual setting of the proportional element value integration element differentiation element or automatically by means of the auto tuning function 32 8 2 1 Auto tuning The controller has the function to select PID settings These settings ensure in most of case an optimal control To begin the auto tuning one musttransittothe tun message acc to the fig 13 and hold down the 3 push button during at least 2 seconds If the control algorithm is set on on off or the auto tuning function is locked then the tung message will be hidden For a correct realization of the auto tuning function it is required to set Sttoand 5 The 5 Lo parameter must be set on the value cor responding to the measured value at disabled contro
29. cking when the deviation exceeds hb do 50 0 5 50 0 C Bon f oFF Output 2 as the auxiliary output Ev1 disabled EYPE of segment stoppage of set point value St e te RE 02 00 Segment time 2h00 120 minutes u Output 2 as the auxiliary output Ev1 disabled ERE trnE Kind of segment accretion time ESA 50 0 Target set point value 50 0 C n FEBE CUBE 01 40 Segment time 1h40 100 minutes ht du 0 0 Inactive locking u GA Output 2 as the auxiliary output Ev1 enabled End Kind of segment program end 5609 u Output 2 as the auxiliary output Ev1 disabled 56 13 3 Control of the Set Point Value Program When the 55d parameter is set on r 5 the controller controls the object in compliance with the set point value changing in time acc to the given program Before starting the control with the changeable set point value one must select the required program parameter Pr To start the program one must press w and a push buttons when the inscription Sto appears on the lower display fig 27 s The lighted dot in the right corner of the lower display means that the programming control is lasting During the program duration one can display parameters of the realized program i e program status pro gram number number of the operating segment the number of cycles which still remains to carry out time which goes by in the segment time which r
30. 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 device 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 create the risk of injury to personnel or meter damage For more detailed information please study the User s Manual 4 INSTALLATION 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 to the fig 1 The panel cut out should have 45 0 x 45 0 mm 6 Fig 1 Controller fixing in the panel Controller overall dimensions are presented on the fig 2 max 93 8 Fig 2 Controller dimensions 4 2 Electrical Connections The controller has two separable terminal strips with screw termi nals One strip enables to connect the supply and outputs by a wire of 2 5 mm cross section The second strip enables to connect input signals by a wire of 1 5 mm cross section 9 9 p 8 interface RS 485 7 output 1 input 3 binary input C
31. controller behaviour 5 a after a supply decay 5773 9 END RW 0 1 Way of the controller behaviour a on the program end 5774 PID RW 0 1 Gain Scheduling function for the program 5775 TYPE RW 0 3 of segment 5776 L TSP RW acc to Set point value on the segment table 171 end 5777 gt TIME RW 0 5999 Segment duration 0 5778 RR RW 4 55001 Accretion rate of the set point value 77 5779 HLDV RW 0 2000 9 Control deviation value over which the counting of the set point value is interrupted 5780 RW ed State of auxiliary outputs 5781 PID RW TE PID set for the segment 5873 TYPE RW 0 3 Kind of segment 5874 TSP RW acc to Set point value on the segment table end 17 5875 TIME RW 0 5999 Segment duration 5876 amp RR RW 4 5500 1 Accretion rate of the set point BY value 5877 HLDV RW 0 2000 9 Control deviation value over which the counting of the set point value is interrupted 5878 RW 0 3 State of auxiliary outputs 5879 PID RW PID set for the segment 1 Value with the decimal point position defined by bits 0 and 1 in the register 4002 Map of registers from address 7000 and 7500 Table 16 88 3 25 Description 5 lt s amp cc O 7000 7500 R Measured value PV 7002 7501 R a
32. d by the output 1 is possible The first output must be of relay or voltage 0 5 V type For the current coun ting the minimal time of the output switching on must be at least 200 ms The transformer work range is equal from 0 to 50 A The heater current is displayed with the mark 8 in the first position In order to display the heater current one must press the push button till the moment 45 of it appearance on the lower display acc to the fig 13 The return to the set point value display is set by the manufacturer on 30 sec but can be changed or disabled through the tout parameter Two types of alarms concerning the heating element are ava ilable The alarm of damage the control element and alarm of the heater burnout The alarm of the control element damage is realized by the current measurement when the control element is disabled however the burnout alarm is realized when the control element is enabled The alarm configuration includes setting the alarm type For the heater damage alarm out or out 3 855 and for the con trolling element damage alarm out 2 or out 3 At o5 Remaining para meters to set are the alarm set point value 54 57 0557 and the 59 oSHS hysteresis N For a correct detection of the heater alarm burnout the heating element can not be connected later than the controller 46 12 ADDITIONAL FUNCTIONS 12 1 Control Signal Monitoring The control signal of heating type is di
33. d press the push button Some controller parameters can be invisible it depends on the current configuration The table 1 includes the description of para meters The return to the normal working mode follows automatically after 30 seconds since the last push button pressure 13 6 2 Programming Matrix m de SHE sty Input unt Kindof Pos of Que of Shitof kindof Pos of Indic parame Unit main decimal thres rod auxiliary decimal of lower ters input point hold hold value input point threshold outP out oute ary outj HEL ta toe to3 Output Function Type of Function Type of Function Damage Impulse Impulse Impulse parame of output aut of output 2 of signal ters put output 2 output 3 ut 1 ut2 ut 3 ctel ALG tavo taue pato Control Control EIRE na Valve Valve i Min Max parame algorit control Ei zone opening closing ofthe steering steering ters m time time valve signal signal Submenu P de T e Submenu i P d3 Submenu P dt n EE Pb t td qe Pol EC tat ters Propor Integra Different tion of Parameters as for Propor Integra Different tional tion Time time control PID1 tion tion time time ban constant constant signal band constant constant m
34. e Manual Occ working mode opening 8 and Monitering Measured closing the of control value e valve 7 L Ees 2 sd o 5 Measured 8 value Auto tuning NZ En t mode 9 aes un R i Monitoring of additional Messed e value v dicc 2 Monitoring f Measured of heater current value j aw 8 ew Caution The Screen accessibility depends on the controller version and its current setting 12 6 1 Programming of controller parameters The pressure and holding down the push button during ca 2 sec causes the entry in the programming matrix The pro gramming 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 14 presents the transition matrix in the programming mode The transition between levels is carrying out by means of w or _ a push buttons and the level selection by means of the push button After selecting the level the transition between parameters is carried out by means of Cw Jor Ca push buttons In order to change the parameter setting one must proceed acc to the section 6 3 In order to exit from the selected level one must transit between para meters until the symbol appears and press the push button In order to exit from the programming matrix to the normal working mode one must transit between levels until the symbol appears an
35. emained to the end of the segment time which remained to the program end After finishing the program the dot is gone out or the program is rene wed if the number of the program repetition is higher than 1 After finishing the control auxiliary outputs are in the state defined by parameters output state for the segment set as the program end When the parameter hat locking in the program is set onto or bfad and the locking value t du in the operating segment is higher than zero then the size of the control deviation is controlled set point value minus measured value For ot d t o the locking is active when the measured value is below the set point value diminished by the lo cking value For hetd the locking is active when the measured value exceeds the set point value by the locking value For Hot d bAnd the locking is active as for the upper and lower locking If the locking is active then the counting of the set point value is interrupted and the dot in the right corner is flickering The controller controls acc to the last calculated set point value 57 Normal operating mode Status monitoring ea Monitoring of the operating programm Monitoring of the operating segment Monitoring of the number of cycles to carry out Time which goes by in the remains to the program end 58 Measured value Set point value
36. gment 00 01 00 01 99 59 2 duration rr Accretion 0 1 0 1 1 5500 rate of the set 550 0 C time unit point time unit 1 9900 0 1 990 0 F 3 F f unit time unit 4 HL do Value of the 0 0 0 0 0 2000 control devia 200 0 C c tion for which 0 0 oc 3 the counting 360 0 F 0 3600 F of set point is interrupted State of the off off disabled auxiliary on enabled output no 1 Eve State of the off off disabled auxiliary on enabled Output no 2 Aad PID set for Pd Prg PID1 the segment de PID2 P d3 PID3 d PID4 1 See table 2 2 The time unit is defined by the parameter trun 3 The resolution to show the given parameter depends on the parameter dP Position of the decimal point 4 The time unit is defined by the parameter c cu 53 13 2 Definition of Set Point Value Programs One can define 15 programs The maximum number of seg ments in the program is equal to 15 To render visible parameters related to the programming control in the menu the parameter 5 5d must be set on Prd For each program one must set parameters given in the submenu of program parameters For each segment one must select the kind of segment and next parameters depending on the kind of segment acc to the table 6 One must also set the output state only when out I out 3 are seton Eu Eug parameter o tand Eue List of segment configuration
37. he PID control algorithm with the proportional range 30 C inte gration time constant of 300 seconds differentiation time constant of 60 seconds and pulse period of 20 seconds is set by the manufacturer Changing the Set Point Value One can change the set point value by pressing the w or 4 push button fig 12 The beginning of change is signaled by the flickering dot of the lower display One must accept the new set point value by pressing the push button during 30 seconds since the last pressure of the w jor a push button In the contrary the old value will be restored The change limitation is set by parameters 57 L L and SPLH measured value i signaling set point the change value change acceptation Fig 12 Fast change to change the set point value press one of of set point value the push button 11 6 SERVICE The controller service is presented on the fig 13 Mode of normal work Measured Increasing the value set point value n Monitoring zZ of remaining Measured Start pause Decreasing the timer value set point value time S t mM Erasing 2 sec Monitoring Ty ea of control Measured signal value heating h Ew Manual working mode heating Measured cooling signal value cooling T c De Mode of parameter SS rogrammin Monitoring Measured eee 2 of control valu
38. hest 8 2 3 Proceeding Way in Case of a Dissatisfying PID Control The best way to select PID parameters is to change the value into a twice higher or into a twice lower During changes one must respect following principles a Oscillations increase the proportional band increase the integration time decrease the differentiation time b Over regulations increase the proportional band 35 increase the integration time increase the differentiation time c Instability decrease the proportional band decrease the differentiation tim a Slow jump response decrease the proportional band decrease the integration time 36 Run of the controlled Algorithms of contro ller operations quantity P PD PI PID Pbl Pb tdi Pbl ppf cif tal Pb Pb tdf pb tifl Ph cif df Pb tdi Pb Pbl til Pb til Fig 17 Way to correct PID parameters 8 3 Step by step control The controller s step by step control algorithm without feedback was changed The description is provided below The controller offers two algorithms of the step by step control for cylinder control with no feedback signal from the valve opening and closing of the valve is based on PID parameters and control deviation with a feedback signal from the valve positioning device opening and closing of the valve is based on PID parameters control devia
39. hould be selected from Device Push icon Load to read and save current settings Open window Lumel Updater LU figure 28b from Updating gt Updating of devices firmware Push Con nect Update progress is shown in Messages section Text Port opened 81 appear after correctly opened port Putting controller in update s mode can be done in two ways remote from LU with settings from LPCon port baudrate transmission mode and adress or by turning power on while button pressed Message boot in the upper display signal the availability to update LU will show message Device found with name and current version of firmware Using button a valid file should be selected If the file is correct message File opened will show Send button should be pressed During firmware update the leds on the upper bargraph indicate process progress If firmware update is successful de vice starts normal operation and message Done and update duration will show Close LU and next press Send button to restore previously read parameters Current firmware version can be checked when controller is power on Warning Power loss during firmware update could result permanent controller damage 82 16 ERROR SIGNALING Character messages Table 18 Error code upper display Reason Procedure Down overflow of the measuring range or shorting in the sen sor circuit Upper overflow of the measuring range or break in the
40. ion of the fast set point 17 value change acc to fable Upper limitation of the fast set point AU SPL SEE 17 value change 1 Accretion rate of the set point value 4090 SPRR R 0 9999 SP or SP2 during the soft start 4091 ADDR RW 1 247 Device address 69 4092 BAUD RW Baud rate 0 4800 1 9600 2 19200 3 38400 4 57600 4093 PROT RW Protocol 0 lack 1 RTU 8N2 2 8T1 3 801 4 RTU 8N1 4094 RW 0 65535 Reserved 4095 AOFN RW Quantity retransmitted on the main input 0 measured value on the main input PV 1 measured value on the additional input PV2 2 measured value PV PV2 3 measured value PV2 PV 4 set point value 5 deviation set point value measured value PV 4096 AOLO RW acc to fable 17 Lower signal limit for retransmission 4097 AOHI RW acc to fable lis Upper signal limit for retransmission 4098 SECU RW 0 9999 Access code to the menu 4099 STFN RW Auto tuning function 0 locked 1 unlocked 4100 STLO RW acc to fable 17 Lower threshold for auto tuning 4101 STHI RW acc to jable 17 Upper threshold for auto tuning 70 Time of automatic output from the 4102 TOUT RW
41. ion to the next segment follows during the duration of programming control stoppage to count the set point value in the program the stoppage of set point value counting follows during the duration of the programming control 30 7 4 Outputs The controller has maximal three outputs Each of them can be configured as a control or an alarm output For the proportional control with the exception of analog outputs the pulse period is additionally set The pulse period is the time which goes by between succes sive switches of the output during the proportional control The length of the pulse period must be chosen depending on dynamic object pro perties and suitably for the output device For fast processes it is recom mended to use SSR relays The relay output is used to steer contac tors in slow changing processes The application of a high pulse period to steer slow changing processes can give unwanted effects in the sha pe of oscillations In theory lower the pulse period better the control but for a relay output it can be as large as possible in order to prolong the relay life Recommendations concerning the pulse period Table 3 Output Pulse period to Load Recommended 205 Electromagnetic min 10 s 2A 230V a c relay min 5 s 1A 230V a c Transistor output 1 9 SSR relay 31 8 CONTROL 8 1 ON OFF Control When a high accuracy of temperature control is not required espe
42. iscalibrated additional input 2 Discalibrated analog output 1 3 Discalibrated analog output 2 4 14 Reserved 15 Checksum error of controller memory 73 Register map from address 4150 Table 15 74 z 5a o g no 5 R 25 Description BE 5 Ss ro O E 4150 RW 0 14 Program number for realization 0 means first program 4151 RW 0 1 Program start stop 0 program stop 1 program start the write causes the program start from the beginning 4152 RW 0 1 Stoppage of set point value coun ting in the program 0 disabled 1 enabled 4153 RW 0 14 Realized segment 0 means the first program The write causes the jump to the given segment 4154 R Control status 0 control stop 1 program in progress 2 active locking from the control deviation 3 Stoppage of set point value counting by the push button binary input or interface 4 program end 4155 R Number of cycles which remains to the end 4156 R Time which goes out in the segment LSB s 4157 R Time which goes out in the seg ment MSB s 4158 R Time to the segment end LSB s 4159 R Time to the segment end MSB s 4160 R Time to the program end LSB s 4161 R Time to the program end MSB s 4162 RW 0 65535 Reserved
43. l For temperature control objects one can set 0 C One must set the 5 H parameter on the value corresponding to the maximum measured value at switched on control on full power The flickering ST symbol informs about the activity of the auto tuning function The duration of auto tuning depends on dynamic object properties and can last maximally 10 hours In the middle of the auto tuning or directly after it over regulations can occur and for this reason one must set a smaller set point if it possible The auto tuning is composed of following stages Autotuning process Autotuning finished with success calculation of PID settings and stored them in the non volatile memory beginning of PID control with new settings the error code is on the display one must confirm it transition to the manual work mode 33 The auto tuning process will be stopped without counting PID settings if a supply decay occurs or the push button is pressed In this case the control with current PID settings begins If the auto tuning is not achieved with success the error code will be displayed acc to the table 4 Error codes for auto tuning Table 4 The set point value is incor rect Error code Reason How to proceed One must select PI PID ESG A PD lt control control i e the TI element must be higher than zero One must change one or more set point value or Stio SEH The push button wa
44. loop cooling 0 gt Set point value Temperature C Fig 21 Control with two loops heating cooling type 9 ALARMS Four alarms are available in the controller which can be assigned to each output The alarm configuration requires the selection of the alarm kind through setting out out out 3 and out para meters on the suitable type of alarm Available types of alarms are given on the fig 22 ALSP 50 Ride lt 0 Absolute upper Absolute lower Relative upper AL o duh 42 Agu 50 Alde Rt du A Aidu lt 0 Bin tates Relative lower Relative internal Relative external duta du duou Fig 22 Kinds of alarms The set point value for absolute alarms is the value defined by the Ax 5P parameter and for relative alarms it is the deviation from the set point value in the main channel x u parameter The alarm hysteresis i e the zone around the set point value in which the output state is not changed is defined by 4x 44 parameter One can set the alarm latch i e the memorizing of the alarm state after stopping alarm conditions parameter Axtt on The erasing of alarm memory can be made by the simultaneous pressure of and push buttons in the normal working mode or interface 43 10 TIMER FUNCTION When reaching the set point temperature SP the timer begins the countdown of the time defined by the amp 5 parameter
45. ltage 0 10 V Option none output 3 relay binary input current transformer input 1 additional current input 0 4 20 mA supply of transducers 24 V d c 30mA Supply 85r 253VaiGidiG 20 40V a c d c Version standard custom made Language polish english other2 Acceptance tests without extra quality requirements with an extra quality inspection certificate acc to customer s request 2 90 1 Only when a relay or voltage 0 5 V is also selected on the output 1 2 Only after agreeing with the manufacturer Ordering Example The code RE72 1 2 2 1 00 E 7 means RE72 temperature controller of RE72 type 1 output 1 relay 2 output 2 voltage 0 5 V 2 option with binary output 1 supply 85 253 V a c d c 00 standard version E documentation and descriptions in English version 1 with an extra quality inspection certificate 91 19 Maintenance and Guarantee The RE72 controller does not require any periodical maintenance In case of some incorrect operations After the dispatch date and in the period stated in the guarantee card One should return the instrument to the Manufacturer s Quality In spection Dept If the instrument has been used in compliance with the instructions we guarantee to repair it free of charge The disassembling of the housing causes the cancellation of the granted guarantee After the gu
46. n cause its unforeseen behaviour 84 17 TECHNICAL DATA Main input Input signals and measuring ranges Table 19 Sensor type Standard Range aes Pt100 EN 200 850 C 328 1562 F Pe Pt1000 60751 A2 1997 200 850 328 1562 F Pe id Fe CuNi J 100 1200 148 2192 F Td Cu CuNi T 100 400 C 148 752 F t t NiCr NiAl K 100 1372 148 2501 6 F e e PtRh10 Pt S EN 60584 0 1767 C 32 3212 6 F 5 PtRh13 Pt R 1 1997 0 1767 C 32 3212 6 F ter PtRh30 PtRh6 B 0 1767 C 32 3212 6 F 65 NiCr CuNi E 100 1000 C 148 1832 F NiCrSi NiSi 100 1300 148 2372 F Ete Chromel Kopel L 100 800 C 148 1472 F t i linear current 1 0 20 mA 0 20 mA 2 00 linear current I POSTRA 4 20 mA 4 20 mA 4 00 linear voltage U 0 5 V 0 5 V 0 5 linear voltage U 0 10V 0 10V 2 10 1 The intrinsic error is related to measuring range 200 1767 392 3212 6 F 85 Intrinsic error of the real value measurement 0 2 for resistance thermometer inputs 0 3 for inputs for thermocouple sensors 0 5 for B R S 0 2 1 digit for linear inputs Current flowing through the resistance thermometer sensor 0 22 mA Measurement time 0 2 s Input resistance for voltage input
47. ng the change of the set point value This function allows to reach softly from the actual temperature to the set point value One must write the accretion value in the 5 r parameter and the time unit in the rAnP parameter The accretion rate equals zero means that the soft start is disabled 12 5 Digital Filter In case when the measured value is instable one can switch a programmed low pass filter on One must set the lowest possible time constant at which the measured value is stable A high time constant can cause the control instability A high time constant can cause a control instability The time constant of the filter t can be set from 0 2 sec up to 100 seconds 49 a digital filter d witht a digital filter 0 63A time constant FILE Fig 25 Time characteristic of the filter 12 6 Manufacturer s Settings Manufacturer s settings can be restored during the supply connection by holding down w push buttons till the moment when the Ffbr inscription appears on the higher display 50 13 PROGRAMMING CONTROL 13 1 Description of Programming Control Parameters List of configuration parameters Table 5 Pe 6G Programming control Pra Sub menu of the program no 1 Pr 15 Sub menu of the program no 15 PCFG Sub menu of program parameters 5 _ Range of parameter E Parameter 5 5 E gt descri
48. not require user intervention and its function is to extend switching on time of the relay when the control signal reaches 0 or 100 The relay for opening closing will remain on for a time equal to the time of a valve full open close from a moment of a signal reaching 100 0 The positioning of the valve will be stopped once the signal is equal to the maximum value 38 In the specific case the positioning is performed by completely closing the valve it is carried out each time after turning the controller supply on changing full open close time The time of full opening of the valve can have a different value than the time of closing Both parameters should be set to the same value when using a drive with identical times 39 8 4 Gain Scheduling function For control systems Where the object behaves decidedly differen tly in various temperatures it is recommended to use the Gain Schedu ling function The controller allows to remember up to four sets of PID parameters and switch them over automatically The switching between PID sets runs percussiveless and with hysteresis in order to eliminate oscillations on switching limits The Gt parameter settles the way of the function operation off The function is disabled a switching depending on the set point value For the fixed set point control one must also choose the num ber of PID sets the amp 5n parameter and set switching levels G
49. ol outputs alarming 6 5 Fig 8 Binary input current 5 transformer Fig 9 Current transformer input 6 RS 485 A 7 5 Fig 10 RS 485 Interface Fig 11 Supply of 24V transducers 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 earth circuits apply network filters 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 909 10 5 STARTING TO WORK After turning the supply on the controller carries out the display test displays the e inscription the program version and next displays measured and set point values A character message informing about abnormalities may appear on the display table 18 T
50. oller receives a request with a transmission or checksum error the request will be ignored For a request syntheti cally correct but with incorrect values the controller will send an answer including the error code Possible error codes and their meanings are presented in the table 9 Error codes Table 9 Code Meaning reason 01 forbidden function The function is not serviced by the controller 02 forbidden data address 03 forbidden data value The register address is beyond the range The register value is beyond the range or the register is only to readout 14 3 Register Map Map of register groups Table 10 Range of a gt ence Type of values Description 4000 4149 Integer The value is situated in a 16 Bits 16 bit register 4150 5899 Integer The value is situated in a 16 Bits 16 bit register 7000 7099 float The value is situated in two successi 2x16 Bits ve 16 bit registers Registers only for readout 7500 7599 float 32 Bits The value is situated in two successi ve 32 bit registers Registers only for readout 60 In the controller data are situated in 16 bit registers The list of registers for write and readout is presented in the table 11 Operation means the possibility of readout and the operation RW means the possibility for readout and write Map of registers from address 4000 Table 11 sel sg
51. on time constant TD s x10 4046 YO RW 0 1000 Pama d Gl TORRE 4047 PB2 RW 99991 Proportional band PB2 4048 TI2 RW 0 9999 Integration time constant TI2 s x 10 4049 TD2 RW 0 9999 Differentiation time constant TD2 s x10 4050 YO2 RW 0 1000 SPD ary d TEE OEP 4051 PB3 RW 0 99991 Proportional band PB3 4052 RW 0 9999 Integration time constant TI3 s 4053 TD3 RW 0 9999 Differentiation time constant TD3 s x10 4054 RW 0 1000 Po 61 A ARE 4055 PB4 RW 0 9999 Proportional band PB4 4056 TI4 RW 0 9999 Integration time constant TI4 s 4057 TD4 RW 059998 Differentiation time constant TD4 s x10 4058 Y04 RW 0 1000 A nd 4059 TO1 RW 5 2999 Pulse period of output 1 s x10 67 Displacement zone for heating coo 4060 HN RW 0 999 1 ling control or dead zone for stepper control Proportional band PBC x10 in 4061 PBC RW 1 2000 relation to PB 4062 TIC RW 0 9999 Integration time constant TIC s x10 4063 TDC RW 0 2999 Differentiation time constant TDC s 4064 TO2 RW 5 999 Pulse period of output 2 s x10 4065 15 RW 20101800 Set point value for absolute alarm 1 Deviation from the set point value for 1 4066 A1DV RW 1999 1999 relative alarm 1 4067 RW 2 999 Hysteresis for alarm 1 Memory of alarm 1 4068 A1LT RW 0
52. oo 5 5 Parameter Descripti Oc os ption 9 range Register of commands 1 input in the automatic control mode 2 input in the manual control mode 3 beginning of the auto tuning 4000 W 16 4 erasing of alarm memory 5 restoration of manufacturer s settings apart interface settings and defined programs 6 restoration of manufacturer s settings of defined programs 4001 R 1100 298 Number of program version x100 Version code of the controller bit 2 1 0 OUTPUT 1 0 0 1 output 1 relay 010 output 1 0 5 V 0 1 1 output 1 continuous current 0 4 20 mA 100 output 1 continuous voltage 0 10 V bit 5 4 3 OUTPUT 2 00 1 output 2 relay 0 1 0 output 2 0 5 V 4002 R 0 11 output 2 continuous current 0 4 20 mA 100 output 2 continuous voltage 0 10 V bit 8 7 6 OPTIONS 00 1 output 3 relay 0 1 0 binary input 0 1 1 current transformer input 100 additional current input 0 4 20 mA 1 0 1 supply of transducers 24V d c 30 mA 61 Controller status description in 4003 R 0 0xFFFF table 12 4004 R 0 0xFFFF Alarm state description in table 13 4005 R 0 0xFFFF Error status Description in table 14 4006 R acc totable17 Measured value PV 4007 R 1999 9999 Measured value on additional input 4008 R
53. p in dependence from the number of PID sets Gi ie GLe3 Gt 34 b For the programmed control one can set the PID set indivi dually for each segment Then one must set the 2 d parame ter on on for the given Pr program in the FEFE group Permanently setting of one PID set the PID set is put through SEE p the amp 5 amp parameter a w lt a m fu w a m fu Fig 19 Gain Scheduling switched over from SP 40 time Fig 20 Gain Scheduling switched over for each segment in the programmed control 8 5 Control of Heating cooling Type For the heating cooling control one of the outputs out fout 3 should be set to one of the outputs out out 3 should be set to Coot and the displacement zone H for cooling should be configured For the heating loop the PID parameters should be configured Pb t Ed for the cooling loop the PID parameters Pal t C tat The parameter P amp C is defined as the ratio of the pb parameter from the range 0 1 200 0 96 The pulse period for logic outputs relay SSR is set independently for the heating and cooling loops depending on the output these are to toi If there is the need to use the PID control in one loop and the ON OFF control in the other loop one output should be set to PID control and the other one upper relative alarm 41 control output 100 Main loop heating Auxiliary
54. parameters Table 6 ESP ESP te nt te nE er hLdu hidu The fig 26 and the table 7 represent an example of set point value program It is assumed in the program that the temperature in the object has to increase from the initial temperature in the object up to 800 C with the rate of 20 C per minute at the active locking from the deviation Next during 120 minutes the temperature is maintained locking disab led after that the temperature has to decrease to 50 C during 100 minutes locking disabled During the object cooling one must turn on the fan connected to the auxiliary output no 2 parameter owt set on 7 54 PV A 50 C OUT A time ON OFF 40 min 120 min 100 min time Fig 26 Example of program Parameter values for the example as above Table 7 Parameter Value Meaning Stet Pu Start to count the set point value from the current temperature HALA Time unit hour minute rrun mn Unit for the accretion rate minute PERG Locking for th acti tw hold bAnd ocking for the program active two sided Cyl 1 Number of program repetitions FAL conl Program continuation after a supply decay End Stof Control stoppage after the program end 55 EIRE rAtE Kind of segment accretion rate ESP 800 0 Target set point value 800 0 C er 20 0 Accretion rate 20 0 C minute mn GO T Active lo
55. ption 5 5 Rae Linear a input Strt Way to begin 520 from the way the program defined by SPO Pu from the currently measured value 520 Initial set 0 0 MIN MAX 9 point value tiun Unit for the AnSS 5255 minutes and segment du seconds ration time 44 44 hours and minutes rrun Unit for the n minutes accretion rate Hour hours of the set point value hold Locking of as di 5 inactive the control Lo lower deviation Hi upper bfad reversible 51 CSC Number of 1 1 999 program repetition FALL Control after font Cont program the supply continuation decay St oP control stoppage End Control on StoP StoP Control stoppage the program LSP fixed set point end control with set point from the last segment Pra Gain off off disabled Scheduling on enabled function for the program 0 Submenu of program parameters Submenu of program parameters St 5 Submenu of program parameters Parameter symbol e m Parameter description Kind of seg ment Manufac turer s setting t AE Range of parameter change sensors linear input t segment defined by the time segment defined by the accretion duEL set point stoppage End program end 52 ESP Set point on 0 0 C MIN MAX the segment end t AE Se
56. ry output EV2 in the programming control 64 Output 1 type R 1 6 1 relay output 2 voltage output 0 5 V 4028 O1TY 3 current output 4 20 mA 4 current output 0 20 mA RW 3 4 5 voltage output 0 5 V 6 voltage output 0 10 V Control signal of control output for 4029 YFL RW 0 1000 proportional control in case of sensor damage x10 Function of output 2 0 without function 1 control signal 2 control signal of stepper control opening 7 3 control signal of stepper control closing 7 4 control signal cooling 5 absolute upper alarm 6 absolute lower alarm 7 relative upper alarm 4030 OUT2 RW 16 8 relative lower alarm 9 relative internal alarm 10 relative external alarm 11 timer alarm 12 alarm of heater burnout 13 controlling element damage alarm short circuit 14 retransmission8 15 auxiliary output EV1 in the programming control 16 auxiliary output EV2 in the programming control Output 2 type R 0 6 0 without relay 1 relay output 2 voltage output 0 5 V So KO 3 current output 4 20 mA RW 3 49 4 current output 0 20 mA 5 voltage output 0 5 V 6 voltage output 0 10 V 65 Function of output 3 0 without function 1 control signal 2 control signal of stepper control opening 7 3 control signal
57. s pressed The maximal duration KOM time of auto tuning was Check if the temperature exceeded sensor is correctly placed and if the set point value CEN The waiting time for swit is not set too higher for the ching was exceeded given object Pay attention for the sen sor connection way Do E The measuring input range not allow that an over re mete was exceeded gulation could cause the exceeding of the input me asuring range Very non linear object making impossible obtain correct PID parame ter values or noises have occurred Carry out the auto tuning again If that does not help select manually PID para meters 8 2 2 Auto tuning and Gain Scheduling In case when Gain Scheduling is used one can carry out the auto tuning in two ways The first way consist on choosing a suitable set of PID para meters in which calculated PID parameters will be stored and realizing the auto tuning on the level of the currently chosen set point value for the fixed set point control One must set the Gt parameter on 5 and choose G5Et between P d and P The second way enables the automatic realization of the auto tuning for all PID sets One must set the Gt 9 parameter on 57 and choose the number of PID sets for setting parameter Set point values for individual PID sets must be give in 57 520 523 5 parameters from the lowest to the hig
58. sen sor circuit 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 no break in the sensor circuit 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 no break in the sensor circuit Incorrect controller After selecting the valve opening configuration on one output the valve closing should be set on another out put Incorrect controller After selecting the cooling type configuration control on one output the rever se control heating and the PID enn OWA algorithm ALG PID should be set on another output 5 Auto tuning is ended Check the reason of the auto tu ES with failure ning process interruption in the auto tuning point 83 Input discalibrated Turn off and turn on again the controller supply when this not help contact the nearest service shop Continuous output discalibrated Turn off and turn on again the controller supply when this not help contact the nearest service shop Error of readout veri fication from the non volatile memory Turn off and turn on again the controller supply when this not help contact the nearest service shop The controller exploitation in his state ca
59. splayed with the mark a on the first position of cooling type is displayed with the mark of valve opening is displayed with the mark o and valve closing is displayed with the mark The accessibility of the control signal de pends on the suitable controller configuration To display the control signal one must press the push button till the moment of its appearance on the lower display acc to the fig 13 The return to the set point value display is set by the manufacturer on 30 sec but it can be changed or disabled through the tout parameter 12 2 Manual Control The input to the manual control mode follows after holding down the lt push button during the control signal display The manual control is signaled by the pulsation of the LED diode The controller interrupts the automatic control and begins the manual control of the output The control signal value is on the lower display preceded by the symbol h for the main channel and for the auxiliary channel cooling The lt push button serves to transit between chan nels if the heating cooling control mode has been selected The w push buttons serve to change the control signal The exit to the normal working mode follows after the simulta neous pressure of w and push buttons 47 At set on off control on the output 1 parameter PB 0 one can set the control signal
60. ssary The measuring input is universal for resistance thermometers RTD ther mocouple sensors TC or for linear standard signals The controller has three outputs enabling the two step control step by step three step control three step control of heating cooling type and alarm signaling The two step control is acc to the PID or ON OFF algorithm The innovative SMART PID algorithm has been implemented in the con troller 2 CONTROLLER SET The delivered controller set is composed of 1 RE72 controller nr 2 Plug with 6 screw terminals 3 Plug with 8 screw terminals 4 Screw clamp to fix the controller 4 3 BASIC REQUIREMENTS OPERATIONAL SAFETY In the safety service scope the controller meets to requirements of the EN 61010 1 standard Observations Concerning the 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 Donotconnectthe controller to the network through an autotransformer e The removal of the controller casing during the guarantee contract period may cause its cancellation e The controller fulfills requirements related to electromagnetic compa tibility in the industrial environment e When
61. urrent inpur 0 20mA 1 current input 4 20mA 4021 DP2 RW Position of the decimal point of the additional input 0 without a decimal place 1 1 decimal place 2 2 decimal places 4022 I2LO RW 999 9999 7 Indication for the lower threshold of the analog main input 4023 I2HI RW SEE 999 Indication for the upper threshold of the analog main input 4024 FILT RW Time constant of the filter 0 OFF 1 0 2 sec 2 0 5 sec 3 1 sec 4 2 sec 5 5 sec 6 10 sec 7 20 sec 8 50 sec 9 100 sec Binary input function 0 none 1 control stop 2 switching on manual control 3 switching SP1into SP2 4025 BNIN RW DESA 4 erasing of the timer alarm 5 program start 6 jump to the next segment 7 stoppage of set point value coun ting in the program 4026 RW 0 65535 reserved Function of output 1 0 without function 1 control signal 2 control signal of stepper control opening 7 3 control signal of stepper control closing 7 4 control signal cooling 5 absolute upper alarm 4027 OUT4 RW 0 14 6 absolute lower alarm 7 relative upper alarm 8 relative lower alarm 9 relative internal alarm 10 relative external alarm 11 timer alarm 12 retransmission 8 13 auxiliary output EV1 in the programming control 14 auxilia
62. utput 1 of continuous type Register 4003 controller status Table 12 bit Description Decimal point position for MODBUS registers from address 0 1 4000 depending on the input 0 2 9 2 3 pp point position for MODBUS registers from address depending on the additional input 0 2 4 Auto tuning finished with failure 5 Soft start 1 active 0 inactive 6 Timer status 1 countdown finished 0 remaining states 7 Automatic control manual 0 auto 1 manual 8 Auto tuning 1 active 0 inactive 9 10 Current set of PID parameters 0 PID1 1 PID2 2 PID3 3 PID4 11 12 Reserved 13 Measured value beyond the measuring range 14 Measured value on the additional input beyond the measu ring input 15 Controller error check the error register 1 For sensor inputs value is equal 1 for linear inputs the value is depended on the parameter dp register 4023 72 Register 4004 alarm state Table 13 Bit Description 0 State of alarm 1 1 active 0 inactive 1 State of alarm 2 1 active 0 inactive 2 State of alarm 3 1 active 0 inactive 3 Reserved 4 Alarm state of heater burning 5 Alarm state of permanent output 1 shorting 1 active 0 inactive 6 15 Reserved Register 4005 error register Table 14 Bit Description 0 Discalibrated input 1 D
63. value on the additional N 7003 7502 R Current set point value SP 7006 7503 R Control signal of output 1 7008 7504 R Control signal of output 2 7010 7505 SP R Set point value SP 7012 7506 SP2 R Set point value SP2 7014 7507 A1SP R Set point value for the absolute alarm 1 7016 7508 A1DV R Deviation from the set point value for the relative alarm 1 7018 7509 A2sP R Set point value for the absolute alarm 2 7020 7510 A2DV R Deviation from the set point value for the relative alarm 2 7022 7511 A3SP R Set point value for the absolute alarm 3 7024 7512 A3DV Deviation from the set point value for the relative alarm 3 Input ranges Table 17 Range Kind of sensors UNIT C UNIT F a x10 x10 UNIT PU Pt100 2000 8500 3280 15620 Pt1000 2000 8500 3280 15620 Fe CuNi J 1000 12000 1480 21920 Cu CuNi T 1000 4000 1480 7520 79 NiCr NiAI 1000 13720 1480 25016 PtRh10 Pt S 0 17670 320 32126 PtRh13 Pt R 0 17670 320 32126 PtRh30 PtRh6 B 0 17670 320 32126 NiCr CuNi E 1000 10000 1480 18320 NiCrSi NiSi N 1000 13000 1480 23720 chromel kopel L 1000 8000 1480 14720 linear current 1 1999 9999 linear current 1 1999 9999 linear voltage U
64. value on the segment end TIME RW 1 5999 Segment duration RR RW 1 5500 1 Accretion rate of the set point HLDV RW 0 2000 9 Value of the control deviation over which the set point value counting is interrupted RW State of auxiliary outputs sum of bits bit 0 is set auxiliary output EV1 is turned on bit 1 is set auxiliary output EV2 is turned on PID RW PID set for the segment 0 PID1 1 PID2 2 PID3 3 PID4 76 4277 TYPE RW 0 3 Kind of segment 4278 TSP RW acc to Set point value on the segment table 171 end 4279 w TIME RW 0 5999 Segment duration 4280 RR RW 4 5500 Accretion rate of the set point E value 4281 8 HLDV RW 2000 Control deviation value over which the set point value counting is interrupted 4282 RW bad State of auxiliary outputs 4283 PID RW aes PID set for the segment 5766 STRT RW 0 1 Way of program beginning 5767 SPO RW acc to Initial set point value table 171 5768 TMUN RW 0 1 Unit for the segment duration time o 5769 RRUN RW 0 1 Unit for the accretion rate of the 2 set point value U 5770 S HOLD RW 022 3 Blockings of the control deviation 5771 CYCN RW 1 999 Number of program repetitions sE 5772 8 FAIL RW 0 1 Way of the
65. ype A i Gie ed 9 1 Esc Thermocouple of R type ian A e C 4 OI t b Thermocouple of B type G e G 100 C 1000 C t t Thermocouple of E type 148 OF 1832 100 C 1300 C t n Thermocouple of N type 148 OF 2372 OF E Est Thermocouple of L type Z d 2 20 Linear current 0 20mA 1999 1 9999 1 4 25 Linear current 4 20 mA 1999 1 9999 1 2 10 Linear voltage 0 10 V 1999 1 9999 1 1 The definition at which the given parameter is shown depends on the parameter d position of the decimal 28 7 CONTROLLER INPUTS AND OUTPUTS 7 1 Main Measuring Inputs The main input is the source of measured value taking part in control and alarms The main input is an universal input to which one can connect different types of sensors or standard signals The selection of the input signal type is made by the parameter nt 5 The position of the decimal point which defines the display for mat of the measured and the set point value is set by the parameter d For linear inputs one must set the indication for the lower and upper analog input threshold ate nt The correction of the mea sured value indication is carried out by the parameter 5 F 7 2 Additional Measuring Inputs The additional input can be the source of remote set point value 5259 set n2 or the signal for retransmission o set on Pug The additional input is a linear input The selection of the input sign

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