9400 OMEGA Cover 1
Contents
1. Function Options Factory settings shown in brackets A on oF 0 1 81sec 20 SP1 proportional cycle time see pages 9 10 Determines the cycle rate of the output device for proportional control Select on oF for ON OFF mode 0 to CF SP1 offset manual reset 50 bAnd Applicable in proportional and ON OFF mode with integral disable Int t oFF oFF on Lock main setpoint Locks the setpoint preventing unauthorised adjustment PROGRAMMER SETTINGS see page 11 0 to 9995 deg hour Sets the ramp rate on oFF hoLd Switches the ramp on or off or hold at last ramp value oFF Oto 1440 min Sets the soak time SP2 OPERATING PARAMETERS see pages 12 13 Function Options Factory settings shown in brackets Oto C F 0 Adjust SP2 setpoint Deviation Alarms DV hi DV Lo bAnd 25 sensor maximum see figure 7 Full scale alarms FS hi FS Lo sensor range f s see figure 8 0 1 C F 2 0 C 3 6 F Adjust SP2 hysteresis or proportional band gain see CyC 2 setting 2596 sensor f s on oFF 0 1 81 seconds Select SP2 ON OFF or proportional cycle time Select on oFF for ON OFF mode or the cycle rate of SP2 output device for proportional mode LEVEL 2 Function Options Factory settings shown in brackets MANUAL CONTROL MODES 0to100 read only Read SP1 output percentage power oFF 1 to 100 not in ON OFF SP1 manual percentage power control For manual control s2. Protectively Earthed cabinet Sensor sheaths should be bonded to protective earth or not be accessible Live parts should not be accessible without the use of a tool When fitted to the final installation an IEC CSA APPRO VED disconnecting device should be used to disconnect both LINE and NEUTRAL conductors simultaneously A clear instruction shall be provided not to position the equipment so that it is difficult to operate the disconnecting device MODEL 9400 TYPICAL CONNECTION DIAGRAM The ssr driver output is allocated to SP1 and wired to switch the load heater using an SSR F1 Fuse time lag type to IEC127 CSA UL rating 250Vac F2 Fuse High Rupture Capacity HRC Suitable for maximum rated load current S1 Switch IEC CSA UL Ap pro ved disconnecting Device Comms option when fitted ra uem mM Suppl Sensor cpr spo i PPY i i 1 alarm 1 state t Load al SSR Line j e Tien Neutral e 1 Option Sensor type Sensor range Thermocouples tc b B 0 to 1800 C 32 to 3272 F tc E E 0 to 600 C 32to 1112F tc J J 0 to 800 C 32 to 1472 F tc K K 50 to 1200 C 58 to 2192 F tc L L 0 to 800 C 32 to 1472 F tcn N 50 to 1200 C 58 to 2192 F tcr R 0 to 1600 C 32 to 2912 F tcs S 0 to 1600 C 32to 2912F tct T 200 250 C 273 482 F Resistance thermo meter rtd 200 400 C 273 752 F Linear process inputs Input mV range 0 to
3. determined by Underwriters Laboratories Inc EN61010 1 CSA 22 2 No 1010 1 92 To offer a minimum of Basic Insulation only Suitable for installation within Catagory Il and Ill and Pollution Degree 2 SEE ELECTRICAL INSTALLATION P29 amp P30 It is the responsibility of the installation engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations CONFIGURATION All functions are front selectable it is the responsibility of the installing engineer to ensure that the configuration is safe Use the program lock to protect critical functions from tampering ULTIMATE SAFETY ALARMS Do not use SP2 as the sole alarm where personal injury or damage may be caused by equipment failure WARRANTY CAL Controls warrant this product free from defect in workmanship and materials for three 3 years from date of purchase 1 Should the unit malfunction return it to the factory If defective it will be repaired or replaced at no charge 2 There are no user servisable parts in this unit This waranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse 3 Components which wear or damage with misuse are excluded e g relays 4 CAL Controls shall not be responsible for any damage or losses however caused which may be experienced as a result of the installation or use of this product CAL Controls
4. error message persists call CAL n NON VO LATILE MEMORY ERROR forage Q Upper display alternates dAtA and FAiL Faa READING AUTOTUNE TUNING CYCLE e Action De power briefly Replace unit if problem RESULTS IN tECh n persists n MANUAL POWER ERROR 1 Index to Upper display alternates hAnd and FAIL Md release A or V lower display will alternate CLA n SP1 set to ON OFF in CYC t and valu 9 Action X Select proportional mode 2 Keep pressed and press A once the lower gt display will alternate Ct b and value eg 19 6 IMMEDIATE FAIL ON AUTOTUNE START Upper display alternates PV tunE and FAiL rrr 3 Repeat step 3 above to view E Lo wer display 0 D Ct 1 Ct 2 Ct 3 Ct 4 oS 1 uS and oS 2 e 1 No setpoint entered L Action Enter setpoint Autotune tuning data and limits 2 SP1 set to O N O FF in Temp pac jeo W Action Select proportional mode Setpoint A Tuning oS1 052 Note To reset and clear error press AW together Y JE briefly to cancel message CA KA Cycle FAIL LATER DURING AUTO TUNE CYCLE er n New PD The thermal characteristics of the load exceed the 6 3 us G l entered by any display 0 0 in 100 output e g Ctb 0 0 see adjacent diagram Autotune algorithm limits The failure point indicated EH Start gt Time IMPROVING CONTROL ACCURACY The following functions are to assist engineers with Using the CheK Control accuracy monitor 3 machine development commissioning and t
5. liability for any breach of this agreement shall not exceed the purchase price paid E amp O E u y 0 rt y Q y y rt FUNCTIONS MENU Range of Adjustment shown in red under description If applicable factory settings shown Setpoint 1 in bold Output Process temperature PV or Function green Note Dual Relay and Dual SSd Output Options inicie Models 9411 and 9422 have their outputs green Setpoint temperature SP or Option orange pre configured see page 22 3 Setpoint 2 Output indicator red le 9 wv wv i 2 DESEE EINE EE NT GR ETSI ELS SET EIE TA TNI EET INSTRUMENT ADJUSTMENTS un W c U To enter or exit program mode Press A W together for 3 seconds To scroll through functions Press Aor V 0 To change levels or options Press A together or V together H CEE EEEE EEEN EMN EREN ELEN EGEN IET MEN MEEN OASIS PEE Quick San En TRY p fal e ea R AOA U To decrease setpoint Press sx W together E 32 To reset an alarm or fault condition Press A W together briefly 0 z g Notes If in difficulty by becoming lost in program mode press A and W ogether for 3 seconds to return to display mode check the LEM lt together for 3 ds to return to display mode check th INSTRUM ENT ADJ USTMENTS above and try again PROGRAMMER SETTINGS SP2 SETTINGS When in program mode after 60 seconds of Sy dd the display will revert to either
6. seen KEY Y A TO VIEW FUNCTIONS or if the initial configuration has been eama the measured value Any settings already completed will be retained Level C only visable when COMMS Option fitted COMMS SETTINGS E Select unit Press and hold and use the A or W buttons to scroll through the unit selection list until the correct unit is displayed Release the buttons The display will read selected unit e g Press A once E Select SP1 Main setpoint output device Note Dual Relay and Dual SSd Output Options Models 9411 and 9422 have their outputs pre configured see page 22 Press and hold and use the A or W buttons to select SSd or rLY as required The controller will now read selected output device e g The display will now read oo QUICK START To enter initial configuration into controller memory Press and hold both A and W buttons for 3 seconds The upper display will now alternate ParK and measured variable temperature eg 23 ParK is displayed because a setpoint has not yet been entered as shown by the lower display MESRINE To display setpoint Press and hold The displays will now read unit eg and 0 L To enter setpoint Press and hold and use A button to increase or button to decrease the reading and scroll to required setpoint value The digit roll o ver rate increases with time THE CONTROLLER IS NOW OPERATIONAL WITH FAC
7. 385 58 321 v o c E d Ld 0 n T 0 U c gt v lt Linear Input Calibration continued 9 2 5 69 t C N sic d ode Outputs 4 20 mA Suppl from transducer LJ 1 ohm ER 1 Power up the controller and in response to the prompt select an appropriate Linear Range from the table below Ensure that the Nominal Signal Span chosen is wider than the transducer s actual signal span and the Nominal Scale is wider than the full scale of the engineering units to be displayed Linear Range Nom Signal Nom Scale Lin 1 Span Span Lin 2 0 20 mV 0 100 Lin 3 4 20 mV 0 100 Lin 4 0 20 mV 0 1000 Lin 5 4 20 mV 0 1000 0 20 mV 0 2000 Fy Select c M 70 eum then select the process unit F Bar PSI Ph or rh If the required unit is not shown select Set Max Scale Settings 0 400 25 to 400 0 to 3000 250 to 3000 0 to 3000 3 Allocate the output devices at function as described in SET UP enter the configuration into the memory and proceed as follows Calculate the values for the controller settings for and using the example below as a guide 4 to 7mV input from transducer is required to display 0 110 units Chose Linear Range Lin4 4 20mV 0 to 1000 units Nominal Signal Span x required span actual signal span 20 4 x 110 0 587 7 4 hi SC nominal scale span x hi SC Nominal Scale Spa
8. 50mV Displays 0 20mV 4 20mV Lin1 0 100 Lin2 0 100 Lin3 0 1000 Lin4 0 1000 Lin5 0 2000 Notes 1 Linearity 5 95 sensor range Pt 30 Rh Pt 6 Rh Chromel Con lron Constantan Chro mel Alumel Fe Ko nst NiCro sil NiSil Pt 13 Rh Pt Pt 10 Rh Pt Copper Con Pt100 RTD 2 setpoint limits 0 400 25 400 0 3000 250 3000 0 3000 SENSOR SELECTION Linearity 2 0 0 5 0 5 0 25 0 5 0 25 2 0 2 0 0 25 0 25 0 596 0 596 0 596 0 596 0 596 2 Linearity B 5 702 500 C K N 1 gt 350 C exceptions R S 5 lt 300 C T 1 lt 25 gt 150 C RTD Pt100 0 5 lt 100 C aosuas i 0 0 n rt e gt SPECIFICATIO N Thermocouple 9 types Standards CJC rejection External resistance Resistance thermometer RTD 2 Pt100 2 wire Standards Bulb current Linear process inputs mV range IPTS 68 DIN 43710 20 1 0 05 C typical 1000 maximum DIN 43760 1000 0 C 138 5Q 100 C Pt 0 2mA maximum 0 to 50mV Applicable to all inputs SM sensor maximum Calibration accuracy Sampling frequency Common mode rejection 240V 50 60Hz Series mode rejection Temperature co efficient Reference conditions Output devices SSd SSd1 SSd2 0 25 SM 1 C input 10Hz CJC 2 sec Negligible effect up to 140dB 60dB 50 60Hz 150ppm C SM 22 C 2 C rated voltage after 15 minutes settling time solid state relay
9. I d and selected output device e g SSd EX To enter initial configuration into controller memory both A and W buttons for 3 seconds The upper display will now alternate ParK and measured variable temperature eg 23 ParK is displayed because a setpoint has not yet been entered as Press and hold shown by the lower display PAR Im uw TO SET THE MAIN SETPOINT To display the setpoint press and hold the button C and Oor Fand 32will be displayed Press and hold the button Press A to increase or W to decrease the setpoint The main setpoint LED will flash indicating that SP1 output is ON The controller will now be set with the factory PID settings MENU NAVIGATION The facilities of the controller are selected from the multi level menu using the front panel mounted buttons Each level within the multi level menu offers different functions see FUNCTIONS MENU page A3 Each function has a range of user selections or options see In operating mode the upper green display reads process temperature PV and the lower orange display reads setpoint temperature SP When in program mode settings of each function shown in the upper display can be made by selecting an appropriate option from the lower display USING PROGRAM MODE Note The controller will auto exit program mode after 60 seconds of inactivity To enter program mode from normal operating mode Press and hold both A and W buttons for
10. Operating Manual CAL 9400 Dual Display Autotune Temperature Controller CAL Controls Temperature Controllers SAFETY amp WARRANTY FUNCTIONS MENU QUICK START Quick Start Set up INTRO DUCTION The controllers O VERVIEW Installation Set up Autotune Cycle time SET UP Power up Select input sensor Select display units Allocate output device Enter initial configuration Set main setpoint MENU NAVIGATION Using program mode AUTOTUNE 7 Tune program Tune at setpoint program PRO PORTIO NAL CYCLE TIME Cycle time selection methods Cycle time reco mmendatio ns Autotune calculated cycle time PRO GRAMMER Ramp So ak m CO O Ui Ui Ui Ui Ui Ui Ui UJ CJ CJ CU NON CQ H r2 O O WO WO Oo BH SECO ND SETPOINT SP2 SP2 as an alarm SP2 subsidiary mode SP2 as a proportional output SP2 alarm condition table SP2 alarm annunciator ERROR MESSAGES Recommendations Autotune data in tECH IMPROVING CONTROL ACCURACY Using ChEK accuracy monitor FUNCTION LIST Level 1 Level 2 Level 3 Level 4 OUTPUT OPTIONS ADVANCED SETTINGS Heat Cool strategy Calibration to other instrument Linear input calibration MECHANICAL INSTALLATION DIN panel cut outs Minimum spacing Mounting ELECTRICAL INSTALLATION General requirements Connection diagrams INPUT SENSOR SELECTION SPECIFICATION SAFETY AND WARRANTY INFORMATION INSTALLATION A A Designed for use UL873 only in products where the acceptability is
11. TORY SETTINGS Note For precise control of an application the controller may need to be TUNED Please study section headed FUNCTIO NS and OPTIONS before moving to the section on AUTOTUNE Q c n u et Qy Lj et c le m U 2 Jg le Le m c INTRO DUCTION CAL 9400 The CAL 9400 is a 1 16 DIN dual display dual output miniature controller with PID control strategy Control can be optimised with a single shot autotune either on initial warm up or at setpoint The second setpoint can be configured in a variety of alarm modes or PID Heat Cool strategy A programmer offers a single ramp to setpoint with a choice of timed soak period before switching off the output Control of non temperature processes is achieved by the provision of linear input ranges and scaling in commonly used engineering units Serial communication is available as an option and the easy to use CALCO MMS is a graphic WINDOWS based software package designed for PC supervision of up to 32 instruments for remote adjustment configuration cloning saving and retrieving settings to files and logging and charting in real time CALCO MMS uses the MODBUS protocol via either a fully isolated RS232 or RS485 link depending on the number of instruments and the transmission distances involved in the application A users manual is supplied with the comms option For more information contact CAL For details see rear cover It is suggested
12. appropriate method of Autotune Tune or Tune at Setpoint to suit the application Note The proportional cycle time can be pre selected before starting Autotune see PROPORTIONAL CYCLE TIME The TUNE program should be run with the load cool The output is cycled at 75 ofthe setpoint value to avoid any overshoot during the tuning cycle The warm up characteristics are monitored and set DAC which minimises overshoot on subsequent warm ups The TUNE AT SETPOINT program is recommended when the setpoint is below 100 C 200 F where TUNE s tuning cycle at 75 setpoint may be too close to ambient to produce good results when the process is already hot and the cooling rate is slow when controlling multi zone or heat cool applications to re tune if the setpoint is changed substantially from previous Autotune Note dAC is not re tuned by TUNE AT SETPOINT AUTOTUNE TUNE PROGRAM Temp A Setpoint Tuning DAC PID Cycle 75 SP F E 4 amp 1 s 1 Glues entered start gt Time 100 output Enter program mode and from the display press and hold and press A once the controller will now display oo eee pet Exit program mode ounjoinvy The TUNE program will now start The upper display will alternate between tune and the process temperature as it climbs to setpoint The lower display will read the setpoint value e g Note D
13. at least 3 seconds Release the buttons together and the controller will now display the function and option setting of that TUNCTICNIMERT SR To view function on the same level and display current option Press A or W button once to view the next function Press and hold A or W buttons to scroll through functions The current option or function value is shown in the lower display To change an option value or setting Press and hold the button then press A to increase or W to decrease the value or select the next option Note Checkthe new option value before moving to another function or exiting program mode To change levels Press and hold W to scroll through the functions until LEUL is displayed Release W to display current level Press and hold the button then press A to increase or W to decrease the level Release buttons when required level is obtained To exit program mode Press and hold both A and W buttons for at least 3 seconds Note Control commences with any new instructions now entered in the memory REMINDER OF INSTRUMENT ADJUSTMENTS Press A Y together for 3 seconds for program entry or exit Press A or W to scroll through functions Press A together or W together to change levels or alter options Note Ifin difficulty by becoming lost in program mode press A and W together for 3 seconds to return to display mode check the Menu Navigation summary above and try again Select the most
14. d Release the buttons then press and hold both Press and hold the s button then DIGG DGIO ere A and Y buttons for 3 seconds to enter it into the controllers or V to decrease the displayed cycle time Release U memory buttons when required value is displayed Pre Select Automatic Acceptance of Any Autotune Select d Cycle time or index to another function then exit program mode Before selecting Autotune enter program mode Select until indexing stops and A is displayed in the low er ISO Manual settings Press and hold the button then press and hold Vv Note A indicates that no cycle time exists Seconds Press and hold W to scroll to tunE The controller will now display Press and hold the button and use A to select either on or At SP Release A C le i fe o fe i ON OFF 4 Autotune calculated cycle time RAMP SOAK This feature enables the controller to ramp up or down from current temperature to a target setpoint at a pre determined rate It then controls at the target setpoint for an adjustable soak period before switching off the heat output Set Ramp rate 0 to 9995 deg hour Press A and W buttons for 3 seconds to enter program entry point Press A to scroll to Press and hold then press A or W to scroll to required ramp value in the lower display Set Soak if required 0 to 1440 minutes Press A to scroll to Press and hold then pres
15. driver To switch a remote SSR 5Vdc 0 15 15mA non iso lated Miniature power relay rly and rLY1 rLY2 General Displays Keypad Enviro nmental Humidity Altitude Installation Pollution Protection EMC emission EMC immunity Ambient Mouldings Weight form A SPST contacts AgCdO 2A 250ac resistive load 1A 250ac resistive load Upper 4 Digits high brightness green LED 10mm 0 4 high Lower 4 Digits Orange LED 9mm 0 35 high Digital range 199 to 9999 Hi res mode 199 9 to 999 9 LED output indicators flashing SP1 square green SP2 round red 3 elastomeric buttons Max 8096 up to 2000M Categories Il and Ill Degree Il NEMA 4X IP66 EN50081 1 FCC Rules 15 subpart J Class A EN50082 2 0 509C 32 130 F flame retardant polycarbonate 130g 4 2 oz Copyright CAL Controls Ltd 1997 Not to be reproduced without prior written permission from CAL Controls Ltd Whilst every effort has been made to ensure the accuracy of the specifications contained in this manual due to our policy of continuous develpment CAL Controls Ltd reserves the right to make changes without prior notice 4 E CAL Controls Temperature Controllers CAL Controls Ltd Bury Mead Road Hitchin Herts SG5 1RT UK Tel 44 0 1462 436161 Fax 44 0 1462 451801 email support cal controls co uk http w w w cal controls com CAL Controls Inc 1580 S Milwaukee Avenue Libertyville IL 60048 USA T
16. e fully detailed onfpage 22 ELECTRICAL INSTALLATION Designed for use with the following supply voltages 100 240V 50 60 Hz 4 0 VA nominal 10 maximum permitted fluctuation 12V 24V AC DC 20 4 5 VA Polarity not required WIRING THE CONNECTOR Prepare the cable carefully remove a maximum of 8mm insulation and ideally tin to avoid bridging Prevent excessive cable strain Maximum recommended wire size 32 0 2mm 1 0mm 18AWG INDUCTIVE LOADS To prolong relay contact life and suppress interference it is recommended engineering practice to fit a snubber 0 1uf 100 ohms refer to illustration on page 30 CAUTION Snubber leakage current can cause some electro mechanical devices to be held ON Check with the manufacturers specifications 1821112913 gt n rt y y rt e gt N O c le m m un c Electrical UJ ELECTRICAL INSTALLATION continued EN61010 CSA 22 2 No 1010 1 92 Compliance shall not be impaired when fitted to the final installation Designed to offer a minimum of Basic Insulation only The body responsible for the installation is to ensure that supplementary insulation suitable for Installation Category Il or Ill is achieved when fully installed To avoid possible hazards accessible conductive parts of the final installation should be protectively earthed in accordance with EN6010 for Class 1 Equipment Output wiring should be within a
17. el 847 680 7080 Fax 847 816 6852 000M06 33014 1 0798
18. en hoLd is selected in any alarm mode it prevents an E P a o alarm signal on power up The alarm is enabled only after me cs e 4 U the process temperature has reached setpoint on off mode only 5 A Full scale Q X t u 5 Temperature above setpoint enh Setpoint one tsink Y wot p U Strategy A 7 Z 7 T Output ON Output OFF e Relay or SSd energised Relay or SSd de energised LED ON Without sequence With sequence alarm Alarms on No alarm on Alarm Alarm operates SP2 ALARM AN N UN CIATO R powerup power up enabled normally When an SP2 alarm mode is selected in SP2 A the alarm rt TO CONFIGURE SP2 AS A PROPORTIONAL annunciator AL is displayed alternating with the process CONTROL OUTPUT temperature during alarm condition and option on in level 4 In level 1 select NEXT and then set the required proportional band Note The annunciator may be disabled by selecting ln dlevel2 Sele GE cote rt E e Pret functi then select the required option NR ain bt CM DD ud SP2 in cool strategy See heat cool configuration in ADVANCED SETTINGS page 23 ERROR MESSAGES SENSOR FAULT Action 1 Change the conditions eg raise setpoint Upper display alternates inPt and FAiL Bl 2 yt ciu e eS ete Le LUE LU Indicates thermocouple burnout RTD Pt100 openor 3 Check SP1 P percentage power short circuit or negative over range see IMPROVING CONTROL ACCURACY Action Check sensor wiring 4 Ifthe
19. eve pressing it firmly against the panel until the controller is Cleaning held firmly Wipe down with damp cloth water only 3 The controller front bezel and circuit board assembly can be unplugged from the sleeve Grasp the bezel firmly by the recesses on each side and pull A screw driver can be used as a lever if required Model 9400 Dimensions in mm inches Note The controller should be isolated before removing or refitting it in the sleeve and electrostatic precautions should be observed when handling the controller outside the sleeve 106 7 4 2 with gasket fitted 51 0 2 0 includes gasket OUTPUT DEVICES Two ofthe following output devices are fitted to the controllers depending on the model 1 Solid state relay drive SSd SSd 1 SSd2 5Vdc 0 15 15mA non isolating To switch a remote SSR or logic 2 Miniature power relay rLY rLY1 2A 250V resistive Form A SPST contacts 3 Sub miniature power relay rLY2 1A 250V resistive Form A SPST contacts OUTPUT DEVICE ALLO CATION Either of the available outputs may be chosen for the main setpoint SP1 the remaining device being automatically allocated to the second setpoint SP2 See example illustrated on page 30 STANDARD MODEL 9400 Output Device 1 Output Device 2 DUAL RELAY MODEL 9411 Output Device 2 Output Device 3 DUAL SSd MODEL 9422 Output Device 1 Output Device 1 Dual relay or dual SSd model options 9411 9422 ar
20. hould a sensor fail Record typical SP1 P values beforehand 100 to 0 duty cycle 100 Set SP1 power limit percentage Limits maximum SP1 heating power during warm up and in proportional band 100 to 0 duty cycle 100 Set SP2 percentage power limit cooling SP2 OPERATING MODES see page 12 13 nonE dV hi dV Lo bAnd FS hi FS Lo Cool Main SP2 operating mode Function Options Factory settings shown in brackets nonE LtCh hoLd nLin Subsidiary SP2 mode latch sequence Non linear cool proportional band INPUT SELECTION AND RANGING 1 0 1 Select display resolution for display of process temperature setpoint OFSt Set 2 hi SC LoSC sensor minimum sensor maximum C F Set full scale sensor minimum sensor maximum C 9F Set scale minimum default 0 C or 32 F Select input sensor nonE See SENSOR SELECTION table page 31 nonE C F bAr Psi Ph rh SEt Select C F or process units OUTPUT CONFIGURATION Note Read only after initial configuration rSET ALL full reset to factory settings required to change E subsequently Function Options Factory settings shown in brackets EIEEEZ nonE rLY SSd rLY1 rLY2 SSd1 Select SP1 output device Eine nonE SSd rLY rLY2 rLY1 SSd2 Read SP2 output device read only Dual Relay and Dual SSd output options Models 9411 and 9422 are factory set See page 22 Note when in initial configuration only Hold and A or W for 10 seconds t
21. hunting stops Level 1 adjust value ED Water cooled applications Water cooled applications operating at temperatures greater than 100 C may suffer from the non linear effect caused by water turning to steam This can be countered by the non linear setting for SP2 In level 2 set PH to nL in Multi zone applications When tuning multi zone applications like extruders distortions due to thermal interaction between adjacent zones can be minimised by running autotune onpall controllers at the same time CALIBRATION TO ANOTHER INSTRUMENT If the controller and instrument readings are different the u Level 3 and or function in Function Men will require adjustment Adjust to make an equal adjustment across the full scale of the controller and to make a correction when the error increases decreases across the scale 1 To adjust using the 11 1 2 function Substitute measured values in the expression Instrument reading controller reading Example Instrument reading 396 Controllerreading 400 396 400 4 Adjust eno 4 to correct error Calibration to Another Instrument continued 2 5 Therefore adjust SPAn to 18 to correct error To make a correction when there are different errors across the scale Notes 1 After making the adjustment the reading will immediately change Allow time for the temperature 2 Adjust using the function to stabilise at T before making any f
22. is needed whether autotune is used or not CYCLE TIME RECO MMENDATIONS Output Factory Recommended Load max Device Setting Minimum resistive Internal relay 20 seconds 10 seconds 2A 250 Vac rLY rLY1 Internal relay 20 seconds 10 seconds 1A 250 Vac rLY2 Solid state Externally drives 20 seconds 0 1 seconds fitted SSR SSd SSd 1 SSd2 n a To Select AUTOTUNE CALCULATED CYCLE TIME On completion of Autotune enter program mode Select The controller will display CYC t and 20 the factory setting IItee cOfld S ertet en To view the calculated optimum cycle time press and hold the button then press and hold W until indexing stops The controller will display the calculated cycle time in the lower display e g A 16 This indicates that the calculated cycle time is 16 seconds i v T Q rt y OU e EE E e Wy We Proportional Cycle time continued The controller will now run Autotune and will accept the calculated cycle time E If this cycle time is suitable press and hold both A and V buttons for 3 seconds to enter it into the controllers To Pre Select Cycle time Before Autotune DER memory Before selecting Autotune enter program mode If the calculated cycle time is not compatible with the switching device press and ho e Uttonthenpress eleet ient 9 itching devi d hold the button th Select zm and hold A or W until a more suitable cycle time is U displaye
23. n 587 1000 x 587 242 1000 These settings should provide the correct scaling adjustment but a value for ZEro may need to be established by applying the lowest and highest mV input signal and recording the display offset Check that this is the same at each end and enter this plus or minus value as a ZEro adjustment Should there be a difference between the two readings a further adjustment of the SPAn setting can be made MECHANICAL INSTALLATION The 9400 Controller is designed to be mounted in a 1 16 DIN panel MINIMUM SPACING 4 cutout 0 The unit is sleeve mounted with the front bezel assembly rated n NEMA4 IP66 provided that 5 the panel is smooth and the panel cutout is accurate the mounting instructions are carefully followed 5 20 mm A DIN PANEL CUTOUT 0 79 y 1 16 DIN panel cutout size 45 0mm 0 6mm 0 0mm 1 77in 0 02in 0 0in wide 45 0mm 0 6mm 0 0mm 1 77in 0 02in 0 0in wide 9 5mm 0 374in maximum panel thickness 10 mm 0 39 gt un rt y y rt 0 gt N m c le m m u c Mechanical N MOUNTING To mount a Controller proceed as follows 1 Check that the controller is correctly orientated and 4 When refitting the bezel assembly it is important to then slide the unit into the cutout press it firmly into the sleeve until the latch clicks in order to compress the gasket and seal to NEMA4X IP66 2 Slide the panel clamp over the controller sle
24. n temperature rises above or falls z Select level 2 ze below a pre set temperature above or below the setpoint e then followed by the required option below arit Q aon poon evar on FS hi sets off alarm signal when the temperature rises above P Z setpoint to a pre set temperature above scale minimum 7 7 Alarm 7 A o sate A FS Lo sets off alarm signal when the temperature falls below m aid setpoint to a pre set temperature above scale minimum d pe A Sa Des setpoin setpoin v setpoin Select level 1 CU w x 7 7 and set the required setpoint value y c set value 7 7 If the f ips o Z 7 e factory set hysteresis 2 0 C 3 6 F is unsuitable U Index to T ll cd righ alarm lo Sn and adjust the setting V PY A u Check n i Z is set to on oF for alarm Poux spo i setpoint setpoint Exit program mode SP2 is now operational as an alarm 7 ll CooL see heat cool configuration page 23 4 SUBSIDIARY SP2 MODE ud In level 1 select NEEPTEEEOO iR En Latch sequence or non linear cool and then set the setpoint SP2 value y Latch alarm LtCh SP2 OUTPUT AND LED INDICATION STATES IN When activated the alarm latches until manually reset even ALARM CONDITION v though the alarm condition may have disappeared E Alarm type ON OFF Proportional D operating mode operating mode Sequence alarm hoLd Ss Out eee LED state Out ves LED date n f nm u Wh
25. o move to or from output devices in shaded portion Sensor burn out break protection Caution Settings affect fail safe state SP1 SP2 uP SC Upscale Upscale dn SC Downscale Downscale lu 2d Upscale Downscale 1d 2u Downscale Upscale Select output modes Direct Reverse Caution Settings affect fail safe state SP1 SP2 1r 2d Reverse Direct 1d 2d Direct Direct 1r2r Reverse Reverse 1d 2r Direct Reverse Select Reverse on SP1 for heating and Direct for cooling applications LEVEL 3 continued Function Options Factory settings shown in brackets Select SP1 2 LED indicator modes SP1 SP2 1n 2n Normal Normal 1i 2n Invert Normal 1n 2i Normal Invert 1i 2i Invert Invert 0 0 to 25 sensor maximum Sensor span adjust For recalibrating to a remote standard e g External Meter data logger See ADVANCED SETTINGS page 0 0 to 25 sensor f s Zero sensor error see SPAn oFF on Select control accuracy monitor Var hi Lo Read control accuracy monitor Function Options Factory settings shown in brackets CtA CTb Ct1 Ct2 Ct3 Ct4 oS1 uS oS2 Read Autotune tuning cycle data see figure page 14 Software version number nonE ALL Resets all functions to factory settings Note current configuration before using this function otherwise initial configuration and OEM settings must be re entered Caution LEVEL 4 Function Options Factory settings shown in brackets Access to level 4 i
26. ol of the process during transition from heating to cooling This is achieved by using PID control for heating and cooling with the proportioning bands linked by an adjustable deadband ADVANCED SETTINGS From cold normal procedure on a new installation Enter setpoint and allow the process to reach the setpoint using factory settings for heating only Autotune at setpoint ake the following pre settings Level 1 A to RE 10 and EH 10 Level 2 set ER to Cool Level 1 set zd to At SP Autotune will cause a temporary disturbance Check that the temperature has stabilised in heating mode before running the process in cooling mode If regular temperature oscillations occur change CYC t to optimum value See page 9 To select Autotune Calculated Cycle time Further adjustments Cooling Autotune uses the same calculated bAnd value for both SP1 heating and SP2 cooling In some processes regular temperature oscillations occur when cooling Make the following manual adjustment In level 1 double the value of gt o lt U n 0 o u 0 rt rt 5 a u un o c E d Ld 0 n T 0 U c gt v lt Heat Cool Strategy Configuration continued If no improvement return to the original value and In level 1 halve the value of ES If the process hunts between heating and cooling a deadband setting may be needed Enter a small value eg 1 and observe the process Increase the setting until
27. on how to program the controller see VIEWING AND SELECTING FUNCTIONS Note In this manual the letter k is represented by the character E This section details the four step initial configuration that enables control with factory PID settings to start once the setpoint has been entered PO WER UP On power up the controller will display the self test sequence and brief display blanking MEM rn rr El SELECT INPUT SENSOR Press and hold and use either the A or W buttons to scroll through the sensor selection see table p 31 When the correct sensor is displayed release the buttons The controller will now display selected sensor type e g sss eee eene NM FA TO SELECT C F Press and release the A button the controller will now CSD cence eee ae ae Press and hold the button and using the A button select C F Bar PSI Ph Rh or SEt as required Release the buttons when the correct unit is displayed The controller will now display unit and e g C Mal SET UP EJ TO SELECT SP1 Main setpoint output device Note Dual Relay and Dual SSd Output Options Models 9411 and 9422 have their outputs pre configured see page 22 Press and release the A button the controller will now display 22 Press and hold the button and using the A button select SSd or rLY as required Release the buttons when the correct device is displayed The controller will now display SP
28. out A3 Function Options Factory settings shown in brackets SELECT AUTO TUNE oFF on ParK At Sp Used to switch the Autotune feature on and off to select ParK or Autotune at setpoint ParK temporarily turns the output s off To use select ParK and exit program mode To disable re enter program at tunE and select oFF SP1 OPERATING PARAMETERS 0 110 C F 109C 189F SP1 proportional band Gain or Hysteresis 2596 sensor maximum Proportional control eliminates the cycling of on off control Heater power is reduced by time proportioning action across the proportional band Too narrow Too wide oscillates slow warm up and response increase EERE decrease Function Options Factory settings shown in brackets m oFF 0 1 to 60 minutes 5 0 SP1 integral time reset Auto corrects proportional control offset error Too short Too long overshoots and oscillates slow warm up and response oFF 1 200seconds 25 SP1 derivate time rate Suppresses overshoot and speeds response to disturbances disturbance Too short Too long slow warm up and response oscillates and over corrects under corrects 0 5 5 0 x bAnd 1 5 SP1 derivative approach control dAC Tunes warm up characteristics independent of normal operating conditions by controlling when derivative action starts during warm up smaller dAC value nearer setpoint Too small Too large overshoots slow stepped warm up LEVEL 1 continued
29. re automatically entered in the controller memory During AUTOTUNE the optimum cycle time is calculated but is not automatically implemented The cycle time requires manual acceptance unless pre selected To ensure good control over a wide range of applications two versions of the Autotune program are provided TUNE and TUNE AT SETPOINT The TUNE method normally achieves the best results Starting with the load cool tuning occurs during warm up preventing overshoot This method of tuning is recommended The TUNE AT SETPOINT method is used for specialist applications eg Heat cool multizones and processes below 100 C 200 F During the tuning cycle some overshoot occurs because the tuning cycle is at set point The DAC setting is not re calculated 3 0 gt i 0 gt le CYCLE TIME The choice of cycle time is influenced by the external switching device or load e g contactor SSR Valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Cycle time selection methods The following methods of cycle time selection may be used Autotune calculated After Autotune has been run and completed the calculated cycle time can be manually accepted or adjusted to suit the switching device For selection method see Select Autotune Calculated Cycle time Pre select autotune cycle time The controller can be p
30. rogrammed to automatically accept the calculated Autotune cycle time For selection method see Pre Select Automatic Acceptance of Any Autotune Cycle time Pre select before autotune The controller can be programmed manually with any cycle time between 0 1 and 81 sec This cycle time will not be changed by any Autotune functions For selection method see Pre Select Cycle time Before Autotune Factory set To use the 20 sec factory set cycle time no action is needed whether Autotune is used or not Further information can be programmed into the controller see SECOND SETPOINT RANGING AND SETPOINT LOCK IMPROVING CONTROL ACCURACY Functions and options The facilities of the controller are selected from the multi level menu using the front panel mounted buttons Note Itis advisable to study this section before any programming is undertaken Each level within the multi level menu offers different functions see FUNCTIONS MENU for menu of main functions Each function has a range of user selections or options see FUNCTION LIST for functions and options details The controller has two modes program mode and operating mode When in program mode the controller can be programmed with settings and functions to suit the application When in operating mode the controller uses the setting and functions entered in the program mode to control the application and also displays both the process variable and setpoint temperatures For full details
31. roubleshooting eru 5 To start the monitor select aa UD c a i Bree READ SP1 OUTPUT PERCENTAGE POWER ubi on Note During monitoring either return to normal operation 0 Poor control may be due to incorrectly sized heaters or remain in program mode lt SP1 P Level 2 constantly displays the output percentage power applied which at normal setpoint To view monitor readings index to MMM mu 3 should ideally be within 20 8096 to achieve stable e control The lower display will alternate between Var and the variance displayed in degrees e g 0 6 CONTROL ACCURACY MONITOR EEE n Press and hold and press A once the lower display will e This measures the control stability to within 0 1 C F alternate between VAr and the maximum hi displayed 5 in degrees e g 320 3 m The monitor is started using CheK Level 3 and the variance deviation maximum and minimum temperature Press and hold and press A once the lower display will o are displayed and constantly updated ino pag alternate between VAr and the minimum Lo displayed in degrees e g 319 7 CheK oFF stops monitor retaining readings Temp Variance Maximum VAr 0 19 5 hr ru y rem rimi CheK on resets readings sss Ree an Lo Minimum On de powering CheK resets to oFFand rEAd is zeroed Time n n e ini Qj n lt 15 FUNCTIO N LIST Levels 1 to 4 Note A Functions Menu is shown on the cover fold
32. s A or W to scroll to required soak period in the lower display Set Ramp On Off On hold Press A to scroll to sss Press and hold then press A to select On PROGRAMMER Deg Deg Target Soak setpoint 7 Ramp hour Ramp hour Target setpoint Soak gt gt Time Time Exit program to enter settings into memory and commence ramp to target setpoint Notes In Ramp on configuration if power is removed from the controller the Ramp will re start when power is restored The Ramp hold option suspends the ramp at its last value If no Soak period has been set control at target setpoint continues indefinitely SP2 deviation alarms follow the ramp setpoint and can be used to alarm out of limits ramp rate WARNING The Soak timer is triggered when the ramp setpoint reaches the target setpoint If the ramp rate is set too fast for the process the Soak timer will be triggered before the process temperature reaches the target setpoint AQDMUWeIB Old 11 SECOND SETPOINT SP2 The second setpoint SP2 can be used to trigger an alarm dV hi sets off alarm signal when temperature rises above a or as a proportional control output pre set temperature above the setpoint TO CONFIGURE SP2 AS AN ALARM dV Lo sets off alarm signal when temperature falls below a pre set m temperature below the setpoint Enter program mode c bAnd sets off alarm signal whe
33. s gained through in level 3 Press WP access TOU Wing functio ti Press and hold A and W for 10 seconds Auto STAY Program mode auto exit switch Auto exit returns display to normal if 60 seconds of Enter level 4 at Lock release A and W together f An h 9 key inactivity select StAY to disable Display reads ER oFF on Program security using Lock Disable SP2 alarm annunciator AL Select on to disable AL Select from three Lock options dir 1to32 6 Display sensitivity dir direct display of input 1 maximum 32 minimum sensitivity Press and hold k press A to index LEV 3 locks level 3 and 4 only Technical Functions 0 1to 1 0 0 5 Derivative sensitivity LEV 2 locks levels 2 3 and 4 only Configuration and Technical Functions ALL locks all functions MTM ER Note Locked functions and options may be read M IMPORTANT NOTE FOR OEM s For safety and to protect settings from tampering USE THE SOFTWARE SECURITY LOCK THEN REMOVE THIS SECTION FACTORY SET OUTPUT OPTIONS DUAL RELAY OR DUAL SSd OUTPUT MODELS The table below details the factory set output options rLY2 is a 1A electromechanical relay and SSd1 SSd2 is an identical second SSR drive output Terminals Product Code 3 4 5 6 rLY1 2A rLY2 1A 9411 SSd1 SSd2 9422 QUICK START page 1a jor SET UP page 5 follow steps 1 and 2 ignore step 3 and proceed
34. straight to step 4 Factory O ptions 9411 and 9422 pre allocate SP1 to terminals 3 and 4 Note Output device rLY rLY1 is rated 2A Output device rLY2 is rated 1A Factory Option 9411 offers the ability to change the allocation of SP1 to terminals 5 and 6 To make this selection during the initial configuration in either QUICK START page 1b jor SET UP page 5 start from step 3 EJ TO SELECT SP1 main setpoint output device From the GiSplay intersections obere nee 5 press and hold button then press the A once ra to display rLY2 in the lower display Before embarking on the Advanced Settings please familiarise yourself with the basic operation of the controller as described in this manual The following instructions assume that the user understands how to make the initial configuration can navigate through the Function Menu and successfully Autotune the controller in heating mode HEAT COOL STRATEGY CONFIGURATION Using Ka Cool option Heat Cool strategy is a feature that improves control of processes that need heating and cooling depending on the conditions for example Enviro nmental test chambers used in rooms where the ambient temperature swings above and below the test temperature Plastics extruders where the material initially needs heating then cooling when it begins to heat itself exothermically due to pressure and friction applied by the pro cess The purpose of cool strategy is to maintain smooth contr
35. that users read the O VERVIEW section of this manual before any installation or setting up procedures are undertaken Note The controller will not be operational until either the QUICK START or SET UP procedure has been completed NB Please note that in program mode functions are shown in the upper display green and options in the lower display orange c INSTALLATION The Model 9400 controller is designed to be mounted in a 1 16 DIN panel cut out See the INSTALLATION section SET UP After installation the controller requires programming with the following information Type of Input Sensor Operating unit C or F etc Type of Output Device Temperature Setpoint Note The controller will not be operational until this information is entered When the above information has been programmed into the controller it will be operational with the following factory PID proportional band integral time derivative time settings Proportional band Gain 10 C 18 F Integral time Reset 5 mins Proportional cycle time 20 secs Derivative time Rate 25 secs DAC Derivative approach control 15 OVERVIEW AUTOTUNE To precisely control an application the controller will need to be tuned using the built in AUTO TUNE feature Autotune teaches the controller the main characteristics of the process and learns by cycling the output on and off The results are measured and used to calculate optimum PID values which a
36. tions Press A together or W together to change levels or alter And from the display Selled ee options Note Ifin difficulty by becoming lost in program mode press A and W together for 3 seconds to return Exit program mode to display mode check the Menu Navigation summary above and try again The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device CYCLE TIME SELECTION METHODS The following methods of cycle time selection may be used Autotune calculated After Autotune has been run and completed the calculated Cycle time can be manually accepted or adjusted to suit the switching device For selection method see Select Autotune Calculated Cycle time Pre select Autotune cycle time The controller can be programmed to automatically accept any calculated Autotune cycle time For selection method see Pre Select Automatic Acceptance of Any Autotune Cycle time page 10 Pre select before Autotune The controller can be programmed manually with any Cycle time between 0 1 and 81 sec This cycle time will not be changed by any Autotune functions For selection method see Pre Select Cycle time Before Autotune PROPORTIONAL CYCLE TIME Factory set To use the 20 sec factory set cycle time no action
37. uring tuning the main setpoint SP1 LED will flash When the TUNE program is complete the upper alternating The TUNE AT SETPOINT program will now start The upper display display stops and only the process temperature is displayed The PID will alternate tune and the process temperature values are entered automatically The process temperature will rise The lower display will read the setpoint value to setpoint and control should be stable If not this may be because optimum cycle time is not automatically implemented To Note During tuning the main setpoint SP1 LED will flash set the cycle time see PROPORTIONAL CYCLE TIME When the TUNE AT SETPOINT program is complete the upper TUNE AT SETPOINT PRO GRAM alternating display stops and only the process temperature is displayed The PID values are entered automatically The Q Temp Start ERES process temperature will rise to setpoint and control should c A be stable If not this may be because optimum cycle time E Overshoot a 5 NN during tuning is not auto matically implemented To set the cycle time see one 4 1 PRO PORTIO NAL CYCLE TIME Lud pon Prop band New PID a N IN values 0 Tuning entered 13h on off tuning b hd cycles gt Time 3 100 output EE REMINDER OF INSTRUMENT ADJUSTMENTS Enter program mode and select s Press A W together for 3 seconds for program entry or exit Press A or W to scroll through func
38. urther adjustment EE Atthis point a ZEro adjustment may be needed refer Q 2 1 Chose a temperature near the bottom and to step 1 above lt another near the top of the scale y 2 Check that the temperature correctly stabilises at T5 2 2 Run the process at the lower temperature T1 and then adjust setpoints to T If an error is present e Note the error Ey between the controller and the at T repeat from step 2 A instrument readings 0 LINEAR INPUT CALIBRATION 2 3 Repeat at the upper temperature T2 and note o error Ey In addition to the ten temperature inputs the controller has five linear input ranges which can be calibrated to display a range of 2 4 Substitute the values for Ty T5 E1 and E in the engineering units This procedure involves making adjustments to v expression below to calculate the controller s hi SC ZEro and SPAn adjustments found in 0 function menu levels 2 and 3 rr E E X hi SC SPAn rt T2 T4 Note The controllers linear inputs are in mV If your transducer provides an output in mA this should be converted to mV For hi SC settings see level 2 by feeding the controller input via a high stability one ohm 3 resistor see figure page 26 Other low Vdc signals can be Q Example T 1 connected via a suitable voltage divider network to match v Instrument reading 58 385 the controller input requirements Controller reading 60 400 Error E 2 E 15 15 2 x 450 13 x 450 17 9
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