Mounting and Operating Instructions EB 6497 EN
Contents
1. 3 Hysteresis for Y2 Minimum pulse duration in of T 2 p T Switching time For M 3 Period cycle time for pulse modulated control outputs I M 2M 8 or 9 Period cycle time in positive oper direction lor Transit time of associated actuator T 2 Switching time For in Period cycle time in negative oper direction TZ Dead band I 4 Range of values to 19 9 9 relating to the manipulated variable range The dead band note definition is entered for three point stepping control lers with internal or external position feedback the minimum pulse duration for pulse modulated outputs and split point for pulse modulated outputs with split range Refer to section 5 on page 23 for further details The following parameters only apply to versions with additional limit switches GW3 and GWA 1 3A Limit value for GW3 The range of values depends on the configuration block 3 3H Hysteresis for GW3 The range of values depends on the configuration block 3M LH YA Limit value for GW4 The range of values depends on the configuration block 41 LH 4H Hysteresis for GW4 The range of values depends on the configuration block 4 EB 6497EN 15 CONFIGURATION level Operation 4 4 CONFIGURATION level 1 7 Functions linked to the required control task can be determined by the config BIETE uration blocks in the CONFIGURATION level Access is only possib2. 23 Switching outputs Y1 and Y2 aaa aaa a 23 Three point stepping controller with internal position feedback 26 Three point stepping controller with external position feedback 27 Pulse modulated control outputs o a a a 29 Serial 6 3 DeSGriptiOn es eae Bw we 5 ana ne ee SS 3 Technicaldota zu es a 0 eM sc ek oe AO Re 31 Operation 535 555 anne nn 32 Value registers holding registers 2 0 ee ee ee 33 Status registers s a e bbe 9 5 Re nee 34 SIMU u wk eee ee 9 5 6 855 696 9 dn oie ed 35 Tuning control parameters o o a ee 36 6 5 0 4 RA ote et wie ee 38 Checklist ages eo 2 a Ka aan 40 6 8669 44 Changes in Firmware version 1 10 The parameter default settings of TN and operating direction have been changed EB 6497 EN 3 Description Versions 1 Description The TROVIS 6497 Industrial Controller is used to automate industrial and processing plants Through the use of a practical clearly structured functional design various control circuit ar rangements can be configured It may be used as a continuous action controller on off or three point stepping controller with the following control mode options P Pl PD or PID modes A sealed membrane operator panel is used to operate the industrial controller Ope
3. to seconds and increase until oscillation cannot be determined any more Increase the P value until the control loop tends to hunt again Decrease the 7 value until oscillation cannot be determined any more Proceed in the same manner several times until the oscillations cannot be suppressed any more Slightly decrease the K P value and 7 value until the control loop stabilizes itself again Eliminate steady state deviation by adjusting the operating point Y as follows Read the current value of the manipulated variable when the plant is in the steady state and enter as value for parameter Note A setpoint modification also means a change of the operating point 7 PID controller Specify control parameters proportional action coefficient P 0 1 rate time TN 1999 and reset time 7 in the PARAMETER level Set the rate gain H in usual cases between a value of Sand 10 Enter the value of the desired setpoint in the OPERATING level Then modify the manip ulated variable until the control valve slowly opens and the error 3 is eliminated becomes zero Increase the P value until the control loop tends to hunt Set rate time 7 to seconds and increase until oscillation cannot be determined any more Increase the P value until the control loop tends to hunt again Increase the T value until oscillation cannot be determined any more Proceed in the same ma
4. 98 1 1 17 ET Unit of temperature 9 oa 2 0000 3 a 8 00 en 17 x Range of current or voltage signal for X 222 2222 22 17 Range of current or voltage signal for WE 2 222 222 18 Range of current or voltage signal for Y and 18 BT Selecting the input circuitry of the derivative action component 18 WM Selecting the 555 18 YH Blocking the MANUAL AUTOMATIC mode selector key 18 YM Selecting the controller 9 19 YR External position 86056 19 1M and 2M Signaling condition of the limit 65 19 5 and 52 Switching outputs Y1 or Y2 as NO or NC contacts 19 JM and 4 Signaling condition of the limit 5 20 53 and 54 Limit switches GW3 and GW4 as NO or NC contacts 20 TR Update cycle to refresh display of controlled variable 20 FI 89 11 20 K Safety output value 2 ee 20 Ci 0 code numbers 2 Service code 21 0 Auto tuning 56 6 6668 ee ee 68 5 6325 S aea 2 PS Setpointramps ve Be he ee ewe eR 22 SH Station address s s s es 48 Shh aaa Oe WEY 22 BR 80 1 8 22 Standard controller 9 5 23 Continuous action 6 61
5. 0 51 6 17 8 5 9110111112 ka El z Only w reference junction module at terminals 5 6 7 External setpoint WE Setpoint switchover External 4 0 20 mA 0 2 10 V 24 V WE WI position feedback signal 31415 5 12 112 Sy 0 200 1000 Q Controller output control signal Y 2 limit switches Optional 2 limit switches 4 0 20 mA 0 2 10 V Three step output gt mn NN 1 2 112 16115 J14a 14 13 16 15 140 14 13 17 18 19 20 4 op 2 GW3 GW4 N PE 1 Loads gt 50 VA require contactors or relays Ge Power supply Analog output X Optional Serial interface 11 5 PE N L 1 Jaa RA RB TA TB ns V or mA i i 24V DC 120 230 24 V AC Receive Transmit max J0 m over jumpers Fig 4 Terminal assignments 8 EB6497 EN Converting the controller to 1 20 V power supply Electrical connections 001 io r al jti by 4 UMSO 76 9 vuoz 7 0 AOL 2 0 4OyooIpul 48P41039y 2 40419 Bi
6. 150 0 C in 0 1 C steps The valid temperature range is printed on the nameplate next to PT 100 Options Two additional limit switches RS 485 serial interface with Modbus RTU software This manual applies to controllers implementing firmware version 1 10 see page 36 Caution This controller may only be assembled started up and operated by trained personnel familiar with such technical procedures 4 6497 EN Description Technical data 1 2 Technical data Controlled variable X Inputs Direct current signal 4 0 to 20 8 2 5 3 DC voltage signal 0 2 5 10 Ri gt 100 kQ Pt 100 potentiometer self calibrating three wire circuit Version 1 100 to 400 C Resolution 1 C Version 2 30 0 to 150 0 C Resolution 0 1 C Thermocouples requires reference junction module order no 1600 1269 Type K NiCr Ni 50 to 1200 C DIN IEC 584 Type S Pt1ORh Pt 50 to 1700 C DIN IEC 584 Type L Fe CuNi 50 to 800 C DIN 43 710 Type U Cu CuNi 50 to 600 C DIN 43 710 External position feedback YR Potentiometer 0 to 200 to 1000 Q in two wire circuit measuring current with 1000 Q potentiometer approx 2 7 mA with 200 Q potentiometer approx 13 mA or Direct current signal 4 to 20 mA with shunt resistance 549 Q 0 5 W 1 External setpoint WE 4 0 to 20 mA or 0 2 to 10 V selectable over jumpers External setpoint switchover Binary input switchover between WE WI with 24 V DC
7. 549 Q 0 5 W 1 to terminals 1 and 2 see Fig 5 page 9 iM and c t Signaling condition of the limit values for the switching outputs Y1 and Y2 For YM 1 2or 4 set iM and to The values are determined by the parameters A and OR for the correspond ing signaling condition Refer to section 5 page 23 for details o Switching output inactive 1 Xmax X is above the limit Xnin X is below the limit 3 XDnin XD is below the limit XDmox XD is above the limit 5 XDmin and XDinax XD is above or below the limit tracking of con trolled variable monitoring to the set point 5 Vra Y is above the limit On off three point Y 5 below the limit _ control output 8 Pulse modulated control output positive 566 section 5 5 9 Pulse modulated control output negative ___ page 29 5 and 52 Switching outputs Y1 or Y2 as NO or NC contacts 8 NO make contact 1 break contact EB 6497EN 19 CONFIGURATION level Operation MIY 3 and 4 Signaling condition of the limit values Switches wh en 1 a for optional limit switches GW3 and GW4 Y The values are determined by the parameters 3 A and 4A for the correspond 20 EB 6497 EN ing signaling condition o Of Switching output inactive Fo Koax X is above the limit Xin X is below the limit 3 XD is below the limit 4 XD max XD is above the limit 5 XDmin and XD is above or
8. Signal 0 V gt internal WI 24 V gt external WE select over WM or external restart of the setpoint ramp Transmitter supply voltage 24 V DC max 30 mA Outputs Control output signal Y selectable over jumpers Current 20 4 0 to 20 mA Load Re lt 500 Q or Voltage 10 0 2 to 10 V Load Rs gt 500 Q Analog output AA 0 4 to 20 0 2 to 10 V Switching outputs Y1 and Y2 Optional 2 limit switches GW3 and GW4 Load rating of switching contacts max 250 V AC 1 A with cos 1 Hysteresis minimum 0 3 Power supply 230 V AC 48 to 62 Hz 120 V AC 48 to 62 Hz Optional 24 V AC 48 to 62 Hz Power failure All parameter values and configuration blocks are internally stored against power failure in a non volatile EEPROM Power consumption 10 VA Permissible temperature Ambient 0 to 50 C Transportation and storage 0 to 70 C Measuring error Linearity Zero point Final value mA V Pt 100 0 2 0 2 0 2 Thermocouple 0 2 0 3 0 3 Degree of protection IP 54 front panel IP 20 case VDE 0110 Part 1 Overvoltage category Degree of contamination 2 Electromagnetic com patibility Requirement stipulated in EN 61000 6 2 EN 61000 6 3 are fulfilled Weight 0 8 kg Opening the controller case Installing the industrial controllers 2 Installing the industrial controllers The industrial controller is designed for panel mounting Its front
9. an external setpoint is con nected y Manipulated variable output variable The range of values is represented as a percentage and depends on the manipulated variable limits determined with Y and Y 7 see page 14 vv Controlled variable actual value 2 This display only appears for approximately 4 seconds Thereafter con trolled variable and manipulated variable are both subsequently dis played again The range of values in the display depends on the measuring range limits to be specified in the CONFIGURATION level with XN and see page 17 12 EB 6497 EN Operation PARAMETER level 4 3 PARAMETER level 819 6 022 rd LILIL Control parameters can be selected in the PARAMETER level Access is only possible after confirming the code number The lower display field 2 indicates the parameter the associated value is indicated in the upper dis play field 1 Accessing the PARAMETER level Press the ENTER key 8 PR appears in the lower display field 2 Press the ENTER key 8 again the display PA flashes Select the code number by pressing the cursor keys A and V see the upper display field 1 Notes on code number see page 21 Re press the ENTER key 8 the PARAMETER level is now opened The first parameter K P proportional action coefficient appears in the lower dis play field 2 The industrial controller returns to the OPERATING level upon entry of a wrong
10. below the limit 6 Y is above the limit Y is below the limit 53 and 54 Limit switches GW3 and GWA as NO or NC contacts 8 NO make contact 1 break contact TA Update cycle to refresh display of controlled variable O Every 50 ms I Every 25 1 Digital filter The digital filter F I is used to delay the analog inputs X and WE Range of values 2 to 9 9 9 s disabled when set to K Safety output value Upon a sensor line break restart value after power failure Selectable between 0 and 109 9 of the manipulated variable output range If the signal range is violated e g sensor line break short circuit manipu lated variable Y is automatically set to the predetermined value of Ki In case of a power failure gt approximately 100 ms manipulated variable Y is used again from the value predetermined in K In the event of a power fail ure lt approximately 100 ms the manipulated variable Y remains at the last value output The controller starts in the last operating mode manual or automatic active before the power failure Operation CONFIGURATION level and 2 code numbers Access to the PARAMETER level 2 Access to the CONFIGURATION level Both code numbers are factory set to Their values can be changed in the range 1999 to 1999 as required In the event that a code number has been forgotten see notes under section Service code number Service co
11. case has the dimensions 96 mm x 96 mm Mount the controller as follows 1 Prepare a panel cut out with the dimensions 92 0 8 x 92 0 8 mm 2 Push the industrial controller into the panel cut out from the front side 3 Insert the two supplied mounting brackets in either the left and right or top and bottom openings provided in the case see Fig 1 4 Turn the threaded rods in the direction of the control panel using a screwdriver clamping the front frame of the case against the control panel o 119 4 68 96 378 oar 112 4 41 I nn 1 ann 2 1 Screw amp lo 13 2 Mounting SS brackets om 4 an 1 gt 3 Nipple 4 Threaded i rods Fig 1 Dimensions of the controller case 5 Front panel 2 1 Opening the controller case To exchange the fuse or for re jumpering see sections 2 2 to 2 4 the case must first be opened as follows 1 Remove terminals unloosen threaded rods and lift off mounting brackets Then pull the industrial controller out of the control panel and force off the front panel 2 Unscrew the two screws at the side and press the two transparent nipples down towards the front using a suitable screwdriver or appropriate tool 3 Remove
12. code number Entering and modifying parameter values To access the PARAMETER level see above Select the parameter using the cursor keys A and V see the lower display field 2 Press the ENTER key 8 the selected parameter flashes Select the parameter value using the cursor keys A and V see the upper display field 1 and accept by pressing the ENTER key 8 Select the next parameter or exit the PARAMETER level see below Exiting the PARAMETER level Press the operating key 7 to return to the OPERATING level If the lower display field 2 flashes first press the ENTER key 8 The following parameters can be selected in the PARAMETER level for the TROVIS 6487 Industrial Controller KP Proportional action coefficient P component of the controller Range of values 0 to 199 9 TN TN Reset time integral action component of the industrial controller Range of values to 9 9 9 s disabled when set to EB 6497EN 13 PARAMETER level Operation 0883 Rate time derivative action component of the industrial controller Ih Range of values to 9 9 9 s disabled when set to 8 Wa 2 Rate gain derivative action gain Range of values to 18 disabled when set to 9 value commonly set between 5 and 18 I iF Operating direction characteristic of the industrial controller ALK 3 0 Direct gt gt Increasing X Increasing Y or decreasingX decreasing Y 1 Reverse lt gt Incre
13. decimal point s depending on configuration block X for XM 1 2 3 Depending on XM YM and assignments 1M to 4M 4 Data are written in EEPROM which is restricted to approx 100 000 write cycles Therefore do not always write in it automatically 6 5 Status register No Access Description 1 R Collective fault internal device fault 2 R Safety output value K1 active 3 R Enable parameterization 4 R Enable configuration 5 R W Limit value switching output Y1 6 R W Limit value switching output Y2 7 R W Limit value of GW3 8 R W Limit value of GW4 9 R W Inhibit parameterization 10 R W Confirm parameterization 11 R W Inhibit configuration 12 R W Confirm configuration 13 R w2 Switchover to MANUAL mode 14 R w2 Switchover to external setpoint WE 15 R Reserved 16 R Reserved 1 The safety output value is set for an input signal fault The alarm is only generated in automatic mode 2 Data are written in EEPROM which is restricted to approx 100 000 write cycles Therefore do not always write in it automatically 34 EB 6497 EN Start up Status register 7 Start up The configuration blocks and parameters must be determined after completing all electrical connections see page 8 deciding what jumpers are needed see page 7 and installing the in dustrial controller see page 6 Always take the characteristics of the control loop into account before putting the industrial con trol
14. normal operation controlled variable X and manipulated variable Y are displayed 2 Switch the MANUAL AUTOMATIC mode selector key to MANUAL mode LED illuminates in the key 3 Open the CONFIGURATION level see page 16 4 Select configuration block 50 using the cursor keys 5 Set the desired tuning mode 50 or 2 and store using the ENTER key 8 6 Press the operating key 7 The industrial controller returns to the OPERATING level 7 Specify the value for the setpoint internal WI or external WE for which a positive error x T of at least 20 of the measuring range is set Check at XD 8 Press the MANUAL AUTOMATIC mode selector key 10 in order to switch to AUTOMATIC mode The control parameters are calculated and stored against power failure as long as the yellow LED flashes in the key After the LED goes out the controller operates in AUTOMATIC mode If the LED does not go out parameters cannot be determined in this manner Abort the process by pressing the MANUAL AUTOMATIC mode selector key Service code number 1732 38 EB 6497 EN 8 Check list Device Plant Process designation Date Default Start up values Select _ Designation Range of values setting modifications OPERATING level Controlled variable Depending on sensor xo Error WI Internal setpoint
15. ref variable XN fo XE 0 WE External setpoint ref variable u Manipulated variable ve tov PARAMETER level KP Proportional action coefficient 0 1 to 199 9 1 0 TN Reset time 1 to 1999 10 Tr Rate time 1 to 1999 0 Off KI Rate gain lto10 0 Off WR Operating direction Oorl 1 lt gt ve Min manipulated variable limit 109 9 to 7 0 vr Max manipulated variable limit Y to 109 9 100 vo Operating point 109 9 to 109 9 0 Limit value of Y1 Depending on M 0 Transfer coefficient 0 0 to 100 0 0 0 Hysteresis of Y1 Depending on M 0 Minimum pulse duration 0 0 to 100 0 0 0 Limit value ofY2 Depending on 2 0 Transfer coefficient 0 0 to 100 0 0 0 2H Hysteresis of Y2 Depending on 2 0 Minimum pulse duration 0 0 to 100 0 0 Ti Period cycle time 0 to 1999 s 10 Te Period cycle time Oto 1999 s 10 TZ Dead band 0 to 109 9 2 0 Options Limit value of GW3 Depending on 3M 0 3H Hysteresis of GW3 Depending on 3M 0 4A Limit value of GW4 Depending on 4 0 4H Hysteresis of GW4 Depending on 4 0 40 EB 6497 EN Default Start up values Select Designation Range of values setting modifications CONFIGURATION level N Min measuring range limit X 1999 to XE 0 KE Max measuring range limit X XN to 1999 100 0 Decimal place 1 000 to 1000 100 0 M Selection of input
16. signal 0 to 6 O Pt 100 Unit of temperature Oorl 0 xx Oorl 0 mA Wir Range of mA or V signal Oorl 0 mA 053 0 Derivative action component Oorl 0 WIM Selection of setpoint 057 0 YH MANUAL AUTOMATIC key 06 0 yM Selection of controller output 0 4 0 YR External position feedback Oor 1 0 iM Oto9 0 Signaling condition of limit value 66 0 5 Oorl 0 52 NO contact or NC contact 06 0 Options for versions with limit switches GW3 and GW4 aM 057 0 uM Signaling condition of limit value 057 0 53 Oorl 0 Gy NO contact or NC contact 061 0 Options for all versions TA Update cycle to refresh display Oorl 0 of controlled variable Fi Digital filter 0 to 1999 5 Ki Safety output value 0 to 109 9 0 Ei PARAMETER level code number 1999 to 1999 0 Ee CONFIGURATION level code 1999 to 1999 0 58 Auto tuning 0t02 0 TS TM Setpoint ramps 1 s to 500 min 0 Options for version with interface SN Station address 0 to 246 0 BR Baud rate 06 0 EB 6497 EN 4 9 Control panel 1 Display of controlled variable 6 Cursor keys 2 Display of manipulated variable 7 Operating key 3 Display of error 8 Enter key 4 Display of switching output 9 WE WI setpoint switchover key 5 Label for engineering unit 10 MANUAL AUTOMATIC mode selector key 44 EB 6497 EN SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69
17. the controller section from the front after lightly tapping the terminal blocks 4 Replace the fuses and or re jumper as required see sections 2 2 to 2 4 5 Subsequently re install the controller section fasten the two screws and assemble the front panel Proceed as instructed in section 2 steps 2 to 4 o o 1 S S as 2 Controller unit 3 1 0 board 2 Display and CPU 2 IED board pea 4 3 Communications board Fig 2 Arrangement of microprocessor boards in the controller unit 4 Power supply board 6 EB6497 EN Installing the industrial controllers Fuses 2 2 Fuses The power supply board see Fig 2 contains an overload protection directly next to the termi nal block For the 230 V version use TR 5 63 mA with the order number 8834 0343 for the 120 V version use TR 5 125 mA order number 8834 0346 To open the case see section 2 1 2 3 Jumpers to switchover between WE Y and AA The external setpoint WE manipulated variable Y and analog recorder connection AA can be wired as either mA or V signals whereby mA is the factory default These signals can be modi fied by jumpering the I O board accordingly see Fig 2 Refer to the jumper locations depicted in Fig 3 To open the case see section 2 1 1 O board components side Jumpers AA For connecting a recorder Y For output control signal Fig 3 Jumper locations WE For external setpoint 2 4 Converting the controller
18. transfer coefficient in negative operating direction e g 15 Dead band in of the manipulated variable range e g 3 1 Mo Pal ap Sn 5 5 Pulse modulated control outputs The pulse modulated control output consists of a switching output its ON time Tein being di rectly proportional to the internal manipulated variable Y in relation to the selected period T1 5 5 1 On off pulse modulated outputs 4 Y2 25 m m tt Time rt ke Y1 Y2 Switching output Pee TI Tein ON time Y Manipulated Fig 12 Pulse modulated control output variable This switching output is configured for Y1 by means of configuration block or 9 where 1 8 iM 8 configures an on off control output with positive operating direction M 9 with a neg ative operating direction Configure Y2 equivalent to 2 The dead band 7 7 indicates at which percentage of the manipulated variable Y the output be gins to switch This corresponds to the minimum pulse duration as a percentage of the period Configuration blocks to be set 0 8 or 3 On off output with positive or negative operating direction u Parameters to be set mi Period cycle time e g 20 s Minimum pulse duration as a percentage of the period T e g 10 EB 6497 EN 29 Pulse modulated control outputs Standard controller outputs 5 5 2 Dual on off pulse modulated outputs This configur
19. tuator An appropriately selected period offers a suitable compromise between the low residual ripple of the controlled variable high switching frequency i e cycle time selected to a low value and a high operating life of the final control element low switching frequency i e pe riod selected to a high value Parameters H and 2H determine the minimum pulse duration as a percentage of the corre sponding period 7 and 72 The value of the minimum pulse duration is to be selected in such a way that the connected actuators or contactors can just begin to switch EB 6497 EN 27 Three point stepping controller with external position feedback Standard controller outputs The transfer coefficients A and 2A specify the inclination of the duty factor Tein TP Tein ON time TP period T1 or T2 This allows the difference to be calculated when the duty factor is one manipulated variable calculated by the industrial controller minus the feedback position of the final control element i e the controller releases a continuous signal The ON time is calcu lated by the following equation Tein Y YR A TP whereby for Tein gt TP applies Tein TP A A or 2A Parameter 72 dead band defines the range extending from the current operating point to the respective switching point and is to be specified as a percentage of the manipulated vari able range To obtain the value for the variable commonly defined for dead band f
20. 2020 13 Exiting the 5 1 13 KP Proportional action coefficient 2 2 ee ee 13 iN Reset imei ao 5 ac eee So ee dae 13 Rotetimess e 3 a cake ar Bae ee od 5 16 eee eo 14 BD Rate gain sse srra padera wea eee a a 14 WR Operating direction wu 8 6 4 8 00 WO 14 yg Y Manipulated variable 5 14 to Operating point lt ss as ehh ada ee nr ae 14 Limit value or transfer coefficient for YI 14 IH Hysteresis or minimum pulse duration for YIl 2222222 14 2A Limit value or transfer 6 86 2 15 2H Hysteresis or minimum pulse duration 2 15 Ti Switching time 2 0 00 44 aaa 15 Te Switching time aaa a 15 T2 Dead bandis a aor ma e aa oa ee ee ww eB 15 JA Limit value for GW3 2 25 oaa 15 JH Hysteresis for GW3 446 eee eb aan 15 4A Limit value for GW4 u HAE OE 15 4H Hysteresis for GWA 0 0 0 15 CONFIGURATION level 22 2 ee a 16 Accessing the 16 Determining and modifying values of the configuration blocks 16 Exiting the CONFIGURATION level 222222222 16 XN and Measuring range limits of the controlled variable X 17 Yr Decimalpoinis sa ae ee eae ee 8 9 17 Contents M Selecting the input
21. 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 6497 EN 5 2 2008 10
22. Automation System TROVIS 6400 Industrial Controller TROVIS 6497 TROVIS Electronics from SAMSON Mounting and Operating Instructions EB 6497 EN Firmware version 1 1x Edition August 2004 Contents Contents 1 1 1 1 2 2 2 1 2 2 2 3 2 4 3 4 4 1 4 2 4 3 4 4 2 EB 6497 EN Description esras eona 5 598 eee e eS 4 MELSIONSEA oss 100 2 Sie A ied ees eh a dot GE Bi oa er 4 Technical dota ax so sa us ars E 5 Installing the industrial controllers 2 2 2 2 2222 22 6 Opening the controller 56 6 FUSES a a 5 pose Nye oe eee ah ees oe ea ore Seen ty os rae re 7 Jumpers to switchover between WE Y and 7 Converting the controller to 1 20 V power supply 2 222222 7 Electrical connections 2 2 2 ee ee ee 8 Operation or 4 eosa roei aadi a 5 4 iai e a 6 3 ee 10 Process display and control panel 8 8 10 OPERATING levels 24 ses as rn a OA oo Era a s 12 ARETO a dense ser ad de An ne tS des So oe Ge ee 12 WI Internal 585608 12 WE External setpoint 2 cc ee ee eee 12 y Manipulated 65 8 12 x Controlled 6 8 12 PARAMETER 8 13 Accessing the PARAMETER 13 Entering and modifying parameter values 22222222
23. actuating the WE WI setpoint switchover key 9 or by applying an external signal 24 V at termi nals 12 and 5 of the binary input Configuration block WM determines the setpoint and the combination option 0 input disabled Addition of external WE and internal WI Minimum selection between WE and WI Maximum selection between WE and WI Switchover using WE WI key 9 Switchover using WE WI key 9 or by priority of the external signal 24 V Switchover only by the externally issuing signal 24 V wn Cow M a Restart of the setpoint ramp beginning with applied X value YH Blocking the MANUAL AUTOMATIC mode selector key 10 0 Key function enabled Key function disabled 18 EB 6497 EN Operation CONFIGURATION level Iii YM Selecting the controller output G Continuous output see page 23 1 Three point stepping controller w internal position feedback see p 26 2 Three point stepping controller with external position feedback see p 27 3 Continuous controller output functions as recorder connection X 4 Three point stepping controller same as YM 1 and recorder connec tion for controlled variable X at continuous controller output valve posi tion cannot be displayed F External position feedback The position feedback is also possible over a potentiometer 0 to 200 to 1000 Q or over a standardized 4 to 20 mA signal G 0 to 200 to 1000 Q 4 to 20 mA with shunt resistance
24. asing X decreasing Y or decreasing X Increasing Y y 2 y Y Manipulated variable limits These parameters determine the start Y lt and the end value 7 of the WN control output signal The displayed values refer to the percentage of the selected control output range see Y on page 19 Y on page 18 Ye 109 9 to v7 to 109 9 The limits have no effect in MANUAL mode a YE Operating point The operating point Y is specified as a percentage in reference to the manipulated variable PI and PID control modes ignore the operating point Parameters for switching outputs Y1 and Y2 A determine the limit values H 2H determine the hysteresis for switching outputs Y1 and Y2 Configuration blocks M or determine the type of limit value signaling condition and hence the range of values Refer to section 5 on page 23 for more details Limit value or transfer coefficient for Y1 For Gor 3 Limit value or switching point for Y1 e Transfer coefficient H Hysteresis or minimum pulse duration for Y1 For M 0 3 Hysteresis for Y1 e Minimum pulse duration in of 7 Hysteresis 14 EB 6497 EN Operation PARAMETER level 2A Limit value or transfer coefficient for Y2 For Bor 3 Limit value or switching point for Y2 Transfer coefficient 2H Hysteresis or minimum pulse duration for Y2 For M
25. ation is selected with M 8 and 2 9 Both switching outputs Y1 and Y2 are pulse modulated and form two on off control outputs for the positive and negative internal ma nipulated variable Y Parameter T 7 indicates at which percentage of the manipulated variable Y the output begins to switch This corresponds to the minimum pulse duration as a percentage of the period Configuration blocks to be set Pulse modulated positive 9 Pulse modulated negative Parameters to be set Period cycle time e g 20 5 Z Minimum pulse duration as a percentage of the period T e g 3 5 5 3 Dual on off pulse modulated outputs in split range positive or negative This selection is used to operate switching outputs Y1 and Y2 in split range Parameter 77 de termines the split range point in reference to internal manipulated variable Y parameter T no longer specifies the minimum pulse duration Parameters 5 52 determine the operating direction of the split range outputs This is posi tive for 51 52 0 otherwise negative Configuration blocks to be set 8 Split range positive or 9 Split range negative ni lt 8 Split range positive or 9 Split range negative Parameters to be set Period cycle time e g 20 5 Split range point 30 EB 6497 EN Serial interface Description 6 _ Serial interface 6 1 Description The TROVIS 6497 Industrial Controller is able to com
26. be modified using the cursor keys 6 thereby directly influencing the connected control valve EB 6497EN 1 OPERATING level Operation 4 2 OPERATING level LILI l This is the standard operation mode of the industrial controller The upper UNUM display field 1 indicates the actual value of controlled variable X the LWA lower two digit display field 2 indicates the current values 0 to 99 of the manipulated variable Y If the manipulated variable drops below 0 NE will appear in the lower display field If the manipulated variable ex ceeds 99 HO to 9 for 100 to 109 will be displayed Press the operating key 7 to display the following variables in the lower display field 2 The associated values appear in the upper dis play field 1 Select X return to standard operation mode p x Error A xD w x J i WI Internal setpoint internal reference variable 3 ses IL range of values depends on the measuring range limits N and X E predetermined for controlled variable X Switch over to internal setpoint 1 Press the operating key 7 until WI appears in the lower display field 2 Modify the value to the desired value indicated in the upper display field 1 by pressing the cursor keys A and V Press the operating key 7 the value is stored insusceptible to power fail ure L WE External setpoint external reference variable A value is displayed under the condition that
27. de number higher level code number for servicing is specified on page 38 of this man ual permitting the CONFIGURATION level to be opened despite the entered code numbers and To avoid unauthorized use separate this number from page 38 or scratch over to make fully illegible The code numbers se lected can then be read when configuration blocks or 2 are called up Entry Open CONFIGURATION level see page 16 use the Service code number as the code 50 Auto tuning 8 Disabled no auto tuning Only selectable when MANUAL AUTOMATIC mode selector key 10 is set to MANUAL mode 1 Ready for auto tuning tuned according to setpoint for loops with a delay gt 10 s 2 Ready for auto tuning tuned according to disturbance variable for loops with a delay gt 10 s Auto tuning enables the industrial controller to automatically tune itself to the characteristics of the control loop in the start up phase and to calculate the ideal control parameters The appropriate tuning is to be determined by se lecting 1 or 2 For control loops which are critical and extremely fast and for which the control valve must not be abruptly adjusted select in order to dis able the tuning facility see also section 7 2 page 38 EB 6497 EN 21 CONFIGURATION level Operation TS Setpoint ramp wa A setpoint ramp alters the setpoint at a constant speed Configuration block 8 7S determines the time for completing the ent
28. defined in the industrial controller to identify a subscriber user in the communication network Configuration block 5N configures a station address in the CONFIGURATION level The factory default is set to 2 off After a station address has been configured configuration block SN cannot be reset to 3 any more 6 3 2 Allocating the value register Value registers contain values of analog variables e g controlled variable setpoint etc Value registers 1 2 3 4 6 7 8 11 55 56 57 can only be read by the control station if they are denoted by an R Read The remaining value registers can be both read and written by the control station R W Read Write 6 3 3 Allocating the status register Status registers contain binary information such as fault alarms relay states or operating mes sages Status registers 1 to 4and 15 16 can only be read by the control station read only Status reg isters 5 to 14 can be both read and written R W 6 3 4 Modbus protocol The Modbus communications protocol defines the communication standard implemented be tween the industrial controller and the control station In this communication scheme the control station acts as the master the industrial controller as the slave Therefore the industrial con troller may only respond to control station requests 6 3 5 Function code 01 Read Coil Status This function code reads status registers see table on page 34 in the industrial contr
29. direct adjustment of manipulated variable signal Y PARAMETER and CONFIGURATION level Selection of a single parameter or configura tion block lower display in 2 selection of the associated values upper display in 1 Operating key OPERATING level Selection of certain controller variables see page 12 PARAMETER level Return to the OPERATING level and AUTOMATIC mode CONFIGURATION level Return to the OPERATING level and MANUAL mode When manipulated variable display 2 flashes first press the yellow ENTER key 8 ENTER key OPERATING level Call up the PARAMETER level PR and CONFIGURATION level 5 confirm the entered code number and enter the selected level PARAMETER CONFIGURATION level Call up the displayed parameter or configura tion block flashing in the lower display field 2 indicates that values can be modified enter and confirm the value displayed in the upper field 1 WE WI external internal setpoint switchover key Selection of the external and internal setpoint When the external setpoint WE is selected the yellow LED in the key illuminates Switching to an external setpoint can also be made by applying an external 24 V DC sig IIM nal note configuration block WM see page 18 MANUAL AUTOMATIC mode selector key Bumpless transfer from MANUAL to AUTOMATIC mode or vice versa MANUAL mode is indicated by a flashing yellow LED in the key In MANUAL mode the manipulated variable can
30. ee step output Configuration blocks to be set men f w 4 14 Parameters to be set T Operating time of the actuator e g 120 5 IH Hysteresis in e g 2 8 TZ Dead band of the manipulated variable range e g 3 Ln H E Ays y PE Y continuous t Y2 From contin Y1 2 vous controller 11 1 LI part i 2 lt Fig 10 Three point stepping controller with internal position feedback 26 EB 6497 EN Standard controller outputs Three point stepping controller with external position feedback 5 3 1 Calibrating the potentiometer After connecting a potentiometer for the position feedback it must be calibrated The potentiometer must be calibrated prior to start up Please note that the industrial control auto matically calibrates the span zero however is already fixed Calibrate the potentiometer as follows Set the jumper Y to the mA position see Fig 3 page 73 Set the potentiometer to the maximum value 200 to 1000 Q Open the CONFIGURATION level see page 16 Select the configuration block M using the cursor keys Press the ENTER key Depending on the output select YM or 2 using the cursor keys Press the ENTER key Press the MANUAL AUTOMATIC mode selector key AL appears in the upper display field while the calibration is being
31. for W 38 Y R W 0t0 3 0 Range selection for Y 39 DI R W Oorl 0 Assignment of derivative action component 40 WM R W4 057 0 Selection of setpoint 4 YH R wA Oorl 0 Blocking the MANUAL AUTOMATIC key 42 R W 04 0 Selection of controller output EB 6497 EN 33 Status register Serial interface No Name Access Register range Div Description 43 YR R W4 Oorl 0 External position feedback Q mA 44 1M R W4 0t09 0 Signaling condition of GW1 45 2M R W4 0t09 0 Signaling condition of GW2 46 5 R W4 06 1 0 NC contact NO contact of Y1 GW1 47 52 R W4 06 1 0 NC contact NO contact of Y2 GW2 48 3M R W4 057 0 Signaling condition of GW3 49 4M R W4 057 0 Signaling condition of GW4 50 53 R W4 06 1 0 NC contact NO contact of GW3 51 54 R W4 06 1 0 NC contact NO contact of GW4 52 TA R W4 06 1 0 Update cycle to refresh display 1 53 R W4 010199 0 Digital filter for X and WE 54 KI R W4 010109 1 Safety output value 5 Cl R 1999 to 1999 0 PARAMETER level code number 56 C2 R 1999 to 1999 0 CONFIGURATION level code number 57 SO R 0t02 0 Auto tuning 58 TS R W4 Oto 30000 Setpoint ramp 1 Consisting of software version e g 1 00 and Pt 100 version 1 or 2 100 1 or 100 2 respectively 23 Varies depending on how input signal XM is configured No decimal point for XM 3 4 5 6 and XM 0 version 1 One decimal point for XM 0 version 2 Decimal point for 0 to 3
32. g 2 wire transmitter 4 wire transmitter LL 6 oe ajdnosouney 00144 EB 6497 EN 9 Process display and control panel elements Operation 4 Operation Unfold the last page of this manual showing the control panel to obtain a better understanding of this description when reading the following sections The industrial controller is designed with a three level operating structure OPERATING level PARAMETER level and CONFIGURATION level Depending on the selected level mode the keys and visual displays assume various functions The controller should always be configured CO level first then the parameters selected PA level and finally tuned Section 5 on page 23 clearly describes how the industrial controller is to be tuned to both the control application and the directly controlled system 4 1 Process display and control panel elements 1 Controlled variable actual value display OPERATING level Display of controlled variable SESH Display upon breakage of sensor line If a sensor break is determined at the input of the industrial controller or if the input range is exceeded in either direc tion an over or under appear on the display In this case the manipulated vari able is automatically adjusted to the value predetermined in configuration block F safety output value T
33. he industrial controller operates in standard mode once the sensor break has been corrected PARAMETER and CONFIGURATION level Display of the numerical value relating to the selected parameter or configuration block 2 Manipulated variable output value display OPERATING level Display of manipulated variable in For values gt 100 an H appears on the display for values lt O NE appears or display of the external position feedback PARAMETER and CONFIGURATION level Display of the designation associated with the selected parameter or configuration block Note If GC is displayed here the default calibration of the controller has been lost If this error occurs please return the device to SAMSON 3 Error w x display The yellow LED indicates the controlled range with zero offset the two red LEDs indicate the error designated as XD instead of e on the controller for a deviation of at least 1 A Switching output display Two LEDs indicate the output state of the on off three step control output or limit alarms 5 Label for physical unit of temperature Specification of the engineering unit applicable for the controlled variable display 1 10 EB 6497 EN Operation Process display and control panel elements 6 Cursor keys A Increase displayed value V Decrease displayed value OPERATING level After selecting W T direct change of the setpoint In MANUAL mode see MANUAL AUTOMATIC mode selector key
34. in K see also section 7 1 and 7 2 EB 6497 EN 35 Tuning control parameters Start up 7 1 Tuning control parameters The industrial controller must be tuned to the dynamic behavior of the loop using the parame ters Proportional action coefficient K P reset time TN and rate time This permits the con troller to compensate for control deviations caused by disturbances by reducing these to zero or maintain them in very confined limits If you do not have previous experience in selecting values for the control loop proceed as follows 56 the MANUAL AUTOMATIC mode selector key 10 to MANUAL mode ag the attached control valve is the CLOSED position if applicable via the cursor eys After deciding which control mode is necessary proceed further as instructed below P controller Th _ 14 Specify control parameters proportional action coefficient K P 0 1 reset time Gand rate time 1 in the PARAMETER level Enter the desired value of the setpoint in the OPERATING level Then modify the manip ulated variable until the control valve slowly opens and the error 3 is eliminated becomes zero Switch over to AUTOMATIC mode Increase K P value until the control loop tends to hunt Reduce the K P value until oscillation cannot be determined any more Correct steady state deviation by selecting the operating point as follows Read the current value
35. ire setpoint range X N to E The actual time TS to modify the setpoint is calculated by the industrial con troller from this see Fig 6 This setpoint ramp is effective for every modifica tion of the setpoint In this respect note configuration block WM 7 see page 18 This setting causes the setpoint to perform an X tracking W X by adding the binary in put After switching back the input the setpoint changes by the speed selected with T S until the desired value is obtained Range of values 75 is first indicated in the lower display field 2 and the value in the upper display field 1 is specified in seconds U to 1800 s AF terwards the lower display in 2 switches to 7T 1 and the time is displayed in minutes 30 to 500 min To disable set the parameter to 9 N SN Station address MIR 5 Of disabled I to 246 BF Baud rate selecting data transmission speed O 4800 bits s 1 9 bits s wi XE XN Lower measuring range value w2 XE Upper measuring range value Ww Setpoint wi wi Old setpoint value XN W2 New setpoint value TS TS Time set for setpoint ramp 7 5 TS TS Calculated actual time for changing the set points Wland W2 Fig 6 Setpoint ramp 22 EB 6497 EN Standard controller outputs Continuous action controller 5 Standard controller outputs The standard version of the TROVIS 6497 Industrial Controller has one continuous
36. le after vhf The lower display field 2 indicates the configuration block the upper dis confirming the code number play field 1 indicates the associated value Configuration blocks can be se lected and modified in the specified range ETETE Accessing the CONFIGURATION level WILL 16 EB 6497 EN Press ENTER key 8 PR appears in the lower display field 2 Press cursor key A O appears in the lower display field 2 Press the ENTER key 8 2 flashes Enter the code number using the cursor keys A and V see upper display field 1 Notes on the code number see page 21 Re press the ENTER key 8 the CONFIGURATION level is opened The first configuration block N appears in the lower display field 2 Upon entry of a wrong code number the industrial controller returns to the OPERATING level Determining and modifying values of the configuration blocks Open the CONFIGURATION level see above Select the configuration block using the cursor keys A and V Press the ENTER key 8 the selected configuration block flashes Select the desired value in the upper display field 1 using the cursor keys A and V and store by pressing the ENTER key 8 MANUAL mode is enabled the first time a value is modified Advance to the next configuration block using the cursor keys or exit the CONFIGURATION level see below Exiting the CONFIGURATION level Pressing the operating key 7 returns to the OPERATING le
37. ler into operation Avoid potential risks by means of appropriate parameters Make note of the configured values after putting the controller into operation Note The industrial controller should first be configured then enter the parameters and finally tune them Firmware version EPROM version After switching on the mains power supply the implemented firmware version of the industrial controller is shown in the upper display field This version number is important when making in quiries Configure the industrial controller as following Open the CONFIGURATION level see page 16 ba ali Select the input signal Determine the measuring range of the input signal by means of N start value and E end value Select the control outputs with YM 1M 2M Y page 23 Select the desired special functions such as digital filter F I unit of temperature T sig naling conditions of the limit value 8 3 4M or safety output value K R see also section 5 beginning with Open the PARAMETER level see page 13 Determine the operating direction by means of WR Limit the output signal by means of Y and 7 Enter the parameters for the desired output see also section 5 beginning with page 23 Determine the desired limit values with 8 3 4A Tune the plant by entering the parameters Proportional action coefficient K P reset time TN rate time and rate ga
38. municate with a control station via the se rial interface A complete automation system for process control can be constructed by means of software capable of process visualization and communication Here the commonly used Modbus communications protocol is implemented as the communication standard The hard ware relating to the serial interface satisfies the requirement of the RS 485 interface RS Rec ommended Standard according to EIA If the controller is intended to terminate the bus five soldering jumpers LB1 to LB5 must be connected on the components soldering side of the interface board see Fig 2 page 6 RS 232 RS 485 443 gt BB Gi EM moa BO SON e BUM s BOM s BUM Fig 13 Process control system with TROVIS 6497 Industrial Controllers 6 2 Technical data Physical interface RS 485 Communications protocol Modbus RTU 584 Data transmission Asynchronous half duplex four wire Character format RTU 8 bits 1 start bit 8 data bits 1 stop bit Baud rate A800 or 9600 bits second Number of addressable stations 246 Transmittable data Configuration parameters operating state process variables EB 6497 EN 31 Operation Serial interface 6 3 Operation 6 3 1 Setting the station addresses An unassigned station address is
39. ng outputs Y1 and Y2 Standard controller outputs This hysteresis is the differential gap between the on off state of the limit switch When exceeded in either direction the hysteresis acts in the opposite direction of the monitored variables see Fig 8 X XD Y Monitored variable XXD Y TAL AH T XXDY 1A 2A Limit value for X XD Y 1A 4A 1A 4A Value exceeds the limit Value falls below the limit 11 on off differential Fig 8 Limit switches GW State of limit switch Switching outputs Y1 and Y2 can be used as limit switches when configuration block M 8 The signaling conditions of the limit values are assigned as follows 3 Disabled limit switch Maximum minimum absolute value of the controlled variable 3 4 Minimum maximum absolute value of the error percentage Minimum and maximum absolute value of the error percent age with XDmin limit values set under A ER 3A 4A are negative 6 1 Absolute value of the manipulated variable Configuration blocks to be set m en M 4M lto 1 Y1 Y2 as limit switch only when YM otherwise 0 lto 7 Optional limit switch GW3 GW4 Parameters to be entered Limit value For Y1 Y2 only when Y 8 otherwise 0 Hysteresis For Y1 Y2 only when M 8 otherwise 0 3A 4R Limit value For GW3 GWA 3H 4H Hysteresis For GW3 GW4 24 EB 6497 EN Standard contr
40. nner several times until the oscillations cannot be suppressed any more Slightly decrease the K P value and 7 value until the control loop stabilizes itself again Reduce the value slightly until the control loop tends to hunt again and increase it again until no oscillations cannot be determined any more EB 6497 EN 37 Auto tuning Start up 7 2 Auto tuning Auto tuning is a special feature of the industrial controller which in the start up phase effec tively determines the characteristics of the control loop and calculates the optimum control pa rameters This function should only be used on control loops which are not critically fast and have short dead bands If auto tuning is used the tuning procedures described in section 7 1 can be omit ted The automatically determined control parameters should be checked for applicability before switching to AUTOMATIC mode If the industrial controller indicates an unsatisfactory behavior when being operated the calcu lated control parameters must be manually modified Proceed as follows to automatically determine the control parameters 1 Prerequisites The control loop must be stable and in the steady state for at least 5 minutes i e the er ror 3 must not have changed A Pl algorithm is to be specified for the industrial controller rate gain K 3 0 If a PID algorithm is desired set the parameter to K 3 1 The controller runs in the OPERATING level
41. o 110 0 Position feedback 7 R 1999 101999 2 Error 8 Y R 1099 to 1099 1 Manipulated variable PID 9 YHAND 1999 to 1999 1 Manipulated variable output 10 WI R W4 1999 101999 2 Internal setpoint int reference variable 11 SN R 1 to 246 0 Station address 12 KP R wA 010199 1 Proportional action coefficient 13 TN R W 0101999 0 Reset time 14 TV R W 010199 0 0 time 15 KD R W4 0 to 10 0 Rate gain 16 WR R wA Oorl 0 Reverse error 17 YMIN R W 1099 to 1099 1 Minimum manipulated variable limit 18 YMAX R W 1099 to 1099 1 Maximum manipulated variable limit 19 YO R W4 1099 to 1099 Operating point 20 1A R W4 1999 to 1999 2 Limit value switching output Y1 21 1H R W4 0101999 3 Hysteresis Y1 22 2A R W4 1999 10199 3 Limit value switching output Y2 23 2H R W4 0 to 1999 3 Hysteresis Y2 24 TI R W4 0101999 0 Switching time period cycle time 25 72 R W4 010199 0 Switching time period cycle time 26 TZ R W4 010109 1 Dead zone 27 3A R W4 1999 to 1999 3 Limit value of GW3 28 3H R W4 0101099 3 Hysteresis of GW3 29 4A R W 1999 101999 3 Limit value of GW4 30 AH R W4 0 to 1099 3 Hysteresis of GW4 31 XN R W 1999 to 1999 2 Minimum controlled variable limit 32 XE R W 1999 to 1999 2 Maximum controlled variable limit 33 X R W4 0t0 3 0 Decimal point 34 R W4 0 to 6 0 Input signal 35 R W Oorl 0 Unit of temperature 36 R wA Oorl 0 Range selection for X 37 W R wA Oorl 0 Range selection
42. of manipulated variable when the plant is in the steady state and enter as value under parameter Note A setpoint modification also means a change of the operating point 7 PI controller Specify control parameters proportional action coefficient KP 0 1 reset time TN 9 9 9 maximum and rate time 7 in the PARAMETER level Enter the value of the desired setpoint in the OPERATING level Then modify the manip ulated variable until the control valve slowly opens and the error 3 is eliminated becomes zero Switchover to AUTOMATIC mode Increase K P value until the control loop tends to hunt Slightly decrease the P value until oscillation cannot be determined any more Reduce the TN value until the control loop tends to hunt Slightly increase the value until oscillation cannot be determined any more 36 886497 EN Start up Tuning control parameters PD controller Specify control parameters proportional action coefficient KP 0 1 rate time Ti and reset time TN in the PARAMETER level Set the rate gain K T in usual cases between a value of Sand 10 Enter the value of the desired setpoint in the OPERATING level Then modify the manip ulated variable until the control valve slowly opens and the error 3 is eliminated becomes zero Increase the P value until the control loop tends to hunt Set rate time 7
43. oller and transmits these to the control station 6 3 6 Function code 05 Force Single Coil A certain status register is modified in the industrial controller by the control station with this function code see table on page 34 6 3 7 Function code 03 Read Holding Register This function code allows status registers see table on page 33 to be read from the industrial controller and after conversion in the numeric format displayed on the PC 6 3 8 Function code 06 Preset Single Register With this function code the control station reads and modifies a certain value register in the in dustrial controller see table on page 33 6 3 9 Error messages according to Modbus The communication interface responds with an error message upon illegal operations These types of illegal actions include for example attempt to read more than 58 value registers or at tempt to write read only registers containing status information or values 32 EB 6497 EN Serial interface Value registers holding registers 6 4 Value registers holding registers No Name Access Register range Div Description ID R 6497 0 Controller ID 2 VN R 1001 to 1002 1 Version Software Pt 100 3 X R 1999 to 1999 2 Controlled variable 4 WE R 1999 to 1999 2 External setpoint ext reference variable 5 0 Reserved 6 YSTELL R 10 t
44. oller outputs Switching outputs Y1 and Y2 5 2 2 On off three step control output wM 1M Configuration blocks YM and 5 or configure the on off control output which cor responds to monitoring a limit value for overcrossing by manipulated variable Parameter A determines the limit value for the switching point H determines the hysteresis as an abso lute value of the manipulated variable Configuration blocks YM iM and 2M 7 configure the three step control output Pa g g p p rameters A and 2A determine limit value for the switching point H and 2H determine the hysteresis as an absolute value of the manipulated variable Ensure that the difference be tween the upper and lower switching point is larger than the sum of the respective differential values 2A 2 2H When selecting the on off or three step control output it is recommended to choose a P or PD algorithm for the process control application set KP Tr K I The operating point and the minimum maximum control manipulated variable limits lt and Y are to be selected in such a way that the outputs are always able to be switched on or off Limit switches GW3 and GW4 also Y2 with on off control output can be further assigned to any signaling condition of the limit value Configuration blocks 5 2 3 1 are used to configure switching outputs Y1 and Y2 and limit switches GW3 and GW4 as 1 NO make con
45. output Two switching outputs Y1 and Y2 are additionally available These outputs can be configured as limit switches or on off three step control outputs 5 1 Continuous action controller Configuration block configures TROVIS 6497 as a continuous action controller De pending how the jumper Y is selected see Fig 3 on page 7 either a continuous mA or V signal is applied at terminals 1 and 2 5 2 Switching outputs Y1 and Y2 Configuration blocks M and M 2M determine the functions of switching outputs Y1 and Y2 v y continuous 1 x 52 YM 1 aa 2 TI _YR 0 1200 1000 Q YR YR 4 20 mA Fig 7 Switching outputs Y1 and Y2 5 2 1 Limit switches TROVIS 6497 provides four limit switches switching outputs Y1 and Y2 and two optional limit switches GW3 and GW4 A limit switch monitors a variable to ensure that a minimum or maximum value limit value is maintained Configuration blocks M 2M 3M signaling condition of limit value de termine which variable is to be monitored for exceeding in either direction Parameters A 2A 3A and YA determine the limit value for the corresponding variable Moreover a hyster esis value on off differential must be specified for each limit switch by means of parameters 1H CH 3H and 4H EB 6497 EN 23 Switchi
46. performed The calibration is finished when CAL dis appears The position feedback message is indicated in the lower display field Note If position feedback is not wanted for YM the lower display field can be set to 24 To achieve this perform the calibration described above using open terminals Subsequently lay the jumper between terminal 1 and 2 OS Optionally select YM After calibration with open terminals and laying the jumper see above 2 appears on the display instead of In this configuration a recorder can be con nected to log the controlled variable X 5 4 Three point stepping controller with external position feedback Select this output using configuration block M 2 The position of the final control element op erated is transmitted as a feedback signal by means of a potentiometer 0 to 200 to 1000 Q or a direct current signal 4 to 20 mA with shunt over the input of the external feedback YR ter minals 1 and 2 The maximum permissible current consumption of the potentiometer must be observed The measuring current on connecting a 1 83 potentiometer is approx 2 7 mA approx 13 mA with a 200 Q potentiometer The manipulated variable can be limited as required Actuators with different transit times to open and close the valve are supported Parameters T and 2 specify the period not the transit time in the positive and negative direction of the ac
47. r 2 0 2 to10V decimal point see 3 NiCr Ni K 50 to 1200 C te PHORh Pt S 50 to 1700 C wiin rer m o 5 junction module Fe CuNi L 50 to 800 C 6 Cu CuNi U 50 to 600 C VINE 7 Unit of temperature G C Celsius 1 Fahrenheit Range of current or voltage signal for X 0 010 20 6 0 to 10 V depending on selection of 1 Ato 20 mA or 2 to 10 V depending on selection of ignored for Pt 100 or thermocouple Tor Tor 2 gt gt gt gt EB 6497 EN 17 CONFIGURATION level Operation A I Range of current or voltage signal for WE AL 0 Oto20mAor0to10V Depending on jumper WE Ato 20 mA or2to10V Depending on jumper WE mA is factory default Range of current or voltage signal for Y and AA Y depending on jumper Y AA depending on jumper AA mA is factory default mA is factory default 20 to 20 mA or 10 to 10 V 0 to 20 mA or 0 to 10 V Ato20mAor 2tol0V 0 to 20 mA or 0 to 10 V 20 to 20 mA or 10 to 10 V 4 to 20 mA or 2 to 10 V 4 9 20 mAor 2t0 10V 4 to 20 mA or 2 to 10 V w 877 TI Selecting the input circuitry of the derivative action component The input variable for the derivative action component of the industrial con troller can optionally be the controlled variable X or error XD 8 input Error XD UI 1s Selecting the setpoint ZUM An external setpoint WE can be applied either by
48. ration is di vided into three simple logical levels OPERATING level PARAMETER level and CONFIGURATION level Accessing the OPERATING level via displays for standard control operation is possible at any time User selectable code numbers must be entered in order to access the PARAMETER and CONFIGURATION levels In the PARAMETER level control parameters can be modified and optimally tuned specifically to the process In the CONFIGURATION level various controller functions can be selected The controller accepts the following universal inputs Pt 100 resistance thermometers thermocouples standardized current and voltage signals as well as two wire transmitters The controller s setpoint can switched between the internal ii I setpoint and external WE setpoint reference variable by means of the WE WI setpoint switchover key or over a binary signal Moreover the setpoints can be selected and interconnected Bumpless transfer in the respective operating mode is made using the MANUAL AUTOMATIC mode selector key Essential control parameters can be automatically determined and selected by the program us ing special auto tuning software feature 1 1 Versions TROVIS 6497 03 Output Continuous action on off three step analog output limit switches Input Two temperature ranges are available for measuring temperature with three wire Pt 100 resis tance thermometers Version 1 100 C to 400 C in 1 C steps Version 2 30 0 C to
49. rom nega tive switching point to positive switching point double TZ In MANUAL mode a modification of does not directly affect the three step output rather the input of the positioner integrated in the industrial controller The duty cycle is shifted by chang ing the positioner s error deviation The industrial controller is pulsed according to the new duty cycle Configuration blocks to be set vM m YR Gor Selection of external feedback signal IYS 4 8 Tlmin 100 Ex 5 zZ N Y2 YR T2 T2min _T2 H2 T2min 700 YR 0 200 1000 2 YR YR 4 20 TEin ON time TP Duty cycle TP Period TP 1 for Y YR gt 0 Tl min T2min Minimum ON time TP 0 for Y YR lt 0 1H 2H Minimum pulse duration in Fig 11 Three point stepping controller with external position feedback 28 EB 6497 EN Standard controller outputs Pulse modulated control outputs Parameters to be set E Period in positive operating direction e g 20 s Te Period in negative operating direction e g 20 s Minimum pulse duration in positive operating direction in of T e g 10 eH Minimum pulse duration in negative operating direction in of TO e g 10 Gain transfer coefficient in positive operating direction e g 15 Gain
50. tact 5 52 53 54 0 i e the relay closes when the signaling condition is satisfied or 2 NC break contact 5 52 53 54 1 i e the relay opens when the signaling condition is satisfied Configuration blocks to be set iM On off controller 2 3 4M Utol iM 6orl Three point controller eM lor sat Utol Parameters to be set Switching point IH EH Hysteresis 1 On 1 2 2 2 ae Y Y1 Y2 Switching output Y Manipulated variable On 4 MEN F 1A 2A Switching point y2 1H 2H Hysteresis Fig 9 Three point control output Yo Operating point EB 6497EN 25 Three point stepping controller with internal position feedback Standard controller outputs 5 3 Three point stepping controller with internal position feedback The three point stepping controller with internal position feedback is selected with configuration block M Switching outputs Y1 and Y2 form the three step output and are no longer avail Mm able as limit switches M and 2 are to be set to zero The operating time and effective ON time of the actuator are used to calculate the position of the final control element The operating time of the actuator is specified by means of parameter 7 This value can be found in the actuator s technical description In this output circuitry it must have the same val
51. to 120 V power supply The controller can be converted from the power supply 230 V to 120 V To proceed make the following changes on the soldering side of the power supply board see Fig 2 1 Open soldering jumper 230 V 2 Close soldering jumpers 120 V 1 and 120 V 2 3 Replace fuse TR 5 63 mA with fuse TR 5 125 mA see also section 2 2 EB 6497 EN 7 Converting the controller to 1 20 V power supply Electrical connections 3 Electrical connections Plug in modular terminals are provided for the wires with cross sections from 0 5 to 1 5 mm2 Always observe the pertinent VDE 0100 regulations and those regulations and guidelines valid in the country where the controller is intended to be installed Installation notes The signal and sensor lines are to be wired separately from the leads of the controller and power supply Use shielded signal and sensor lines to avoid measuring errors associated with radio interfer ence Always ground the shielded electrical lines on the side of the industrial controller Separately install the power supply lines and protective conductors of each industrial controller at the corresponding distributing bar Protective circuits located in the vicinity must be sup pressed against interference by means of a resistor capacitor RC combination Controller input controlled variable X 2 wire tr nsmilter 4 0 20 mA 0 2 10 V Pt 100 Thermocouple X input 4 20 mA 819110 8 9
52. ue to enable opening and closing of the final control element The range of values for the manipulated variable cannot be limited The parameters of the manipulated vari D able limits and Y are to be set to the minimum and maximum value External position feedback is not required for the control algorithm However the position ofthe final control element can be indicated in the lower display field to monitor the control valve For this purpose the position feedback signal must be determined using configuration block R When a potentiometer is connected it must be calibrated see section 5 3 1 If the position of the final control element is not to be displayed see notes in section 5 3 1 Parameter H specifies the hysteresis as a percentage of the manipulated variable Y and must not be larger than the product of 2 T 2 Parameter T 7 dead band defines the range from the current operating point to the respective switching point and is to be specified as a percentage of manipulated variable range To obtain the value for the variable commonly defined as dead time from negative switching point to positive switching point 2 must be doubled The industrial controller must be configured as a PI controller in order for it to perform the re quired three point stepping characteristic When this requirement is met it operates as a quasi continuous controller In MANUAL mode a modification of directly affects the thr
53. vel whereby MANUAL mode is still activated The manipulated variable 15 switched to in the lower display field 2 Press the MANUAL AUTOMATIC mode selector key the controller switches to AUTOMATIC mode Operation CONFIGURATION level The following configuration blocks determine the controller functions YAT and E Measuring range limits of the controlled variable X z IN These configuration blocks determine the initial value and end value YAE E of controlled variable X They limit each other Ai M 8 3 Measuring range see temperature range under also 4 5 6 can ke limited in respective range xM 2 Measuring range selectable between 1999 and 1999 with consideration of the decimal point The selected measuring range refers to an internal signal range from 4 to 20 mA 0 to 100 e g for a pressure transducer having a measuring range from 1 to 3 bar se lect XN 1 0 i e 4 mA or 0 xE 3 0 i e 20 mA or 100 Decimal points only for mA or V inputs i e Tor 2 ARA decimal point for the upper display field 1 can be defined between 0 and 3 e g 10 0 0 no decimal 1 900 three decimal places H M xM Selecting the input signal Configuration block M determines the input circuitry input signal The fol lowing inputs can be determined Pr100 Version 1 100 to 400 Version 2 30 0 to 150 0 C 1 4 0 t020mA Range selection unde
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