Controller N480 - NOVUS Automation Inc.

N480
Controller N480
TEMPERATURE CONTROLLER – OPERATION MANUAL – V2.6x
2.5.
1. ASSEMBLY
The controller should be installed in a panel cut out as specified in
item 2.1. First remove the mounting clamp and insert the controller
into the panel cut out. Place the unit into the panel cut-out and slide
the mounting clamp from the rear to a firm grip at the panel.
The internal circuitry can be fully removed from the housing without
disconnecting any wiring. By using the thumb just press the tab in
the lower part of the front panel, grab firmly the front panel and pull
out the circuitry from the housing.
1.1. ELECTRICAL CONNECTIONS
Figure 1 shows the electrical terminals of the controller.
OUT-A
RELAY OUTPUT
4-20mA OUTPUT
PULSE OUTPUT
4-20mA
CONTROL
OUTPUT
OR ALARME 1
2
85-264V
3
4
5
6
16
14
17
15
18
8
9
10 11 12
AL2
SENSOR INPUT
POWER
15-30V
13
7
Pt100: 3-wire connection. Excitation current: 170µA
Thermocouple input impedance: 10MΩ
A/D converter resolution: 15000 steps
Sampling rate: 10 measurements per second
Accuracy: 0.2% of full scale for Pt100 and 0.25% of full
scale ±1°C for T/C
Thermocouples are connected to terminals 8 and 9 with positive in
terminal 8.
Pt100 sensors are connected to terminals 7, 8 and 9, as indicated in
figure 1. For full compensation of cable resistance only cables with
equal wire electrical resistance should be used.
POWER
AC/DC
OUT-B
PULSE
1
TEMPERATURE SENSOR INPUT
•
•
•
•
•
ALARM 2
Figure 1 - Electrical connections
Table 1 shows the sensor types accepted and their respective
codes. via keyboard.
TYPE
CODE
RANGE
J
K
S
Pt100 (Resolution 0,1°C)
Pt100 (Resolution 1°C)
T
0
1
2
3
4
5
-50 to 760°C (-58 to 1400°F)
-90 to 1370°C (-130 to 2498°F)
0 to 1760°C (32 to 3200°F)
-199.9 to 530.0°C (-199.9 to 986.0°F)
-200 to 530°C (-328 to 986°F)
E
6
-30 to 720°C (-22 to 1328°F)
N
7
-90 to 1300°C (-130 to 2372°F)
R
8
0 to 1760°C (32 to 3200°F)
2. SPECIFICATIONS
2.1.
GENERAL
•
•
•
•
•
2.2.
Dimensions: 48x48x106mm (1/16 DIN).
Panel cut-out: 45,5x45,5mm
Weight: 140g (1 relay), 160g (3 relays)
Power: 85 to 264Vdc/ac, 50/60Hz, 3VA max. Optional: 15
to 30Vdc/ac
Operation: 0 to 55°C, humidity 20 to 85%
CONTROL OUTPUT
•
Relay output: SPST (U type) relay. Maximum current
3A/250Vac.
• Voltage pulse output: 5Vdc/20mA
Both outputs are available in the basic model and the desired
main control output is user selected via keyboard (refer to “
Cntr “ prompt). The remaining output can then be used as an
alarm output.
In case of sensor break or failure an error "Erro
Erro" message is
Erro
displayed and the control output is turned off.
2.3.
ALARM OUTPUTS
•
•
2.4.
Alarm Output 1: SPST relay 3A/250Vac or 5Vdc/20mA
pulse
Alarm Output 2: SPST relay 3A/250Vca (optional)
POWER
Mains power is connected to terminals 5 and 6. Check the upper
side of the housing for proper power indication.
Novus Produtos Eletrônicos Ltda. / Tel: +55-51-3323-3600 / www.novus.com.br
-100 to 400 °C (-148 to 752°F)
Table 1 - Sensor types, codes and ranges
3. CONFIGURATION AND OPERATION
Prior to first operation the controller should be fully configured. The
user must set basic parameters as temperature type (“TYPE
TYPE”),
TYPE the
desired control set point (“ SP “), the alarms set points (“SPA1
SPA1”
SPA1 and
“SPA2
SPA2”),
SPA2 etc.
3.1. PARAMETERS FLOW CHART
The programming parameters are organized in 4 different sets or
levels:
•
•
•
•
Operation level
Alarms and tuning level
Configuration level
Calibration level
At power up the controller displays a prompt at the Operation Level
and remains in this level while under normal operation.
The other levels are only accessed when a change of parameters is
necessary (except for Set Point change). To reach these other
parameters the user must keep the INDEX Key (
) pressed for
about three seconds. After this time the controller will show the first
parameter of the next level. By keeping the INDEX key pressed for
another 3 seconds the next level will be accessed.
key when the desired level is reached. Press once
Release the
to go to the next prompt in the same level.
the
When a parameter is shown the display will alternate its name and
value. The value can then be changed by pressing the
or
key.
1/3
Controller N480
After the last parameter in one level is reached the controller returns
to operation level and the display will indicate the measured
temperature.
3.4.
CONFIGURATION LEVEL
Type
tYPE
The display will also go back to the measured temperature whenever
the display is inactive for 20 seconds or more.
When a parameter value is changed via keyboard the controller will
only accept the new value after the user presses the INDEX key to
go to next prompt or if the keyboard is left inactive for 20 seconds.
For disabling the keyboard, move the internal strap to the position
KEY DISABLE. All parameters will be protected, accept the SP
parameter.
KEY
DISABLE
Figure 2 – Strap in normal operating
position (enabled)
3.2.
KEY
DISABLE
Figura 3 – Strap position for inhibiting the
keyboard
unit
OPERATION LEVEL
TEMPERATURE
INDICATION
END
SP
Set Point
rAte
rAtE
TEMPERATURE measured by the sensor.
At power up, the upper display shows the process
temperature value. It also shows the messages
described in chapter 5 of this manual.
The lower displays shows the set point value which
is the temperature value desired for the process.
TIME FOR SOAK: Time in minutes which the
temperature will remain at the selected “ SP “.
time for soak
Refer to item 4.
Rvn
run
RUN: At this prompt the user sets the control output
and alarms to active or to inactive.
0 - inactive outputs; 1 - active outputs;
TUNING AND ALARMS LEVEL
Atvn
Auto tune
A(t
ACtion
(ntr
Control
TEMPERATURE RATE OF RISE: The user defines
the rate of temperature rise from the starting
temperature to the value set in “ SP ”.
Rate is defined in °C / minute.
T Sp
3.3.
Vnit
AUTO-TUNE: Activates the auto-tuning of PID
parameters.
0 - Auto-tune is off;
1 - Auto-tune is on;
PROPORTIONAL BAND: percentage of maximum
Proportional input span.
band
When set ot zero (0), control action is ON/OFF.
spll
SP Low Limit
spKl
Dt
derivative
time
(t
Cycle time
KySt
HYSterisis
A1SP
DERIVATIVE TIME: Derivative time constant in
seconds. This constant is not used when controller
is set to ON/OFF action (Pb=0).
CYCLE TIME: Pulse Width Modulation (PWM)
period in seconds. This term is not used when
controller is set to ON/OFF action (Pb=0).
CONTROL HYSTERESIS: Is the hysteresis for
ON/OFF control (set in temperature units).
This parameter is only used when the controller is
in ON/OFF mode (Pb=0).
SETPOINT for Alarm 1: Triping point for alarm 1
SP Alarm 1
A2SP
SETPOINT for Alarm 2: Triping point for alarm 2
SP Alarm 2
Novus Produtos Eletrônicos Ltda. Tel.:+55-51-3323-3600
TEMPERATURE UNIT: Selects display indication
for degrees Celsius or Farenheit.
0 - degrees Celsius ( °C );
1 - degrees Farenheit ( °F );
CONTROL ACTION:
0 - reverse action. Generally used for heating.
1 - direct action. Generally used for cooling.
CONTROL OUTPUT:
0 - Sets control output to terminals OUT A.
1 - Sets control output to terminals OUT B.
As control output is defined to terminals OUT A,
alarm output is automatically set to OUT B.
If control output is defined to OUT B alarm 1 will
then be automatically set to OUT A.
SET POINT LOW LIMIT: sets the lower range for
SV
SET POINT HIGH LIMIT: Sets the upper range for SV.
SP High Limit
A1fv
Alarm 1 Function
A2fv
Alarm 2 Function
Aiky
A2ky
Alarm HYsteresis
Pb
INTEGRAL RATE: Integral time constant in
Ir
integral rate repetitions per minute (Reset). This constant is not
used when controller is set to ON/OFF action
(Pb=0).
INPUT TYPE: Selects the input sensor type to be
connected to the controller. This is the first
parameter to be set.
0 - Thermocouple type J;
1 - Thermocouple type K;
2 - Thermocouple type S;
3 - Pt100 with 0,1° resolution;
4 - Pt100 with 1° resolution;
5 - Thermocouple type T;
6 - Thermocouple type E;
7 - Termopar tipo N;
8 - Termopar tipo R;
3.5.
FUNCTION OF ALARM 1: Refer to table 2 for
function description and respective codes to set at
this prompt.
FUNCTION OF ALARM 2: Refer to table 2 for
function description and respective codes to set at
this prompt.
ALARM 1 AND ALARM 2 HYSTERESIS: Defines
the differential range between the PV value at
which the alarm is turned on and the value at which
it is turned off (in engineering units).
CALIBRATION LEVEL
ATENTION
These parameters are used to calibrate the temperature
measurement and should only be dealt with by experienced and well
equipped personnel.
Inl(
Input Low
Calibration
InK(
Input High
Calibration
(j L
Cold Junction Low
Calibration
SENSOR OFFSET CALIBRATION. Sets the
temperature sensor low calibration (offset). The
display shows only the corrected temperature and
not the offset added. A signal simulator should be
used to inject a low value signal to properly adjust
the offset.
INPUT HIGH CALIBRATION. Sets the sensor input
circuit gain or high calibration.
A signal simulator should be used to inject a high
value signal to properly adjust the offset.
COLD JUNCTION OFFSET CALIBRATION: Sets
the cold junction offset calibration. A good
thermometer or a temperature simulator should be
used to properly adjust this parameter.
2/3
Controller N480
4. RAMP TO SOAK FUNCTION CHARACTERISTICS
This function makes the process temperature rise gradually from the
starting point (present PV) to the temperature value set in “ SP “
(Ramp). The user defines the rate of rise in degrees per minute at
the “rAtE
rAtE”
rAtE prompt.
When SP is reached the temperature is leveled at this point for 1 to
9999 minutes as programmed at the “ t SP ” prompt. Setting 0
(zero) at “ t SP ” defines an infinite length soak profile.
To disable the ramp function Set 0.0 at the “rAtE
rAtE”
rAtE prompt. To
disable the soak function set 1 at the “ t SP ” prompt (thus making
a 1 minute soak) and the control output will go off in 1 minute. To
restart control set 1 at the “ rvn ” prompt.
After a power failure the controller will resume ramp to soak
execution at the equivalent previous ramp point. If the proces
temperature is the same as the SP (no temperature drop) the
controller will repeat the soak segment.
Temperature
The alarm will actuate only after the occurrence of a non alarm
condition followed by a new occurrence for the alarm.
Table 2 shows each alarm function operation with their respective
code. Alarm 1 is used as an example.
TYPE
CODE
LOW
0
ACTION
TEMPERATURE
Alarm ON
SPA1
HIGH
1
Alarm ON
TEMPERATURE
SPA1
LOW
differential
SPA1
2
Alarm ON
Negative
SPA1
Positive
HIGH
differential
SP + SPA1
TEMPERATURE
SP + SPA1
SP
Alarm ON
TEMPERATURE
Negative
Soak
SP
Alarm
ON
SPA1
3
TEMPERATURE
SP + SPA1
SP
Alarm
ON
SPA1
SP
Positive
SP
Ramp
PV
Time
Figure 2 - Ramp to Soak Function
differential
or
deviation
SPA1
4
SPA1
Connection and configuration errors state for most of the problems in
using the controller. A final revision of parameters will save time and
further losses.
Error messages are displayed to help the user to identify possible
problems.
: Process temperature is below the selected sensor
range.
: Process temperature is above the selected sensor
range
: Controller or sensor error. Example:
• Broken thermocouple or Pt100.
• Pt100 badly connected, short-circuited or high cable
resistance.
5.1. ELECTRONIC SERIAL NUMBER VISUALIZATION
To read the 8-digit serial number go to the Operation Level and
press the
key for 3 seconds. The display will show the first 4
digits. Keep the
key pressed for 3 seconds and the display will
show the last 4 digits.
SERIAL NUMBER
LAST 4 DIGITS
Positive
Input
sensor
error or
heater
break
detection
5
End of
Program
6
Alarm
Functions
7
8
9
10
11
SP - SPA1
SP
Alarm
ON
SP - SPA1
SP + SPA1
Alarm
ON
SP
TEMPERATURE
SP + SPA1
Alarm is ON whenever:
•
•
•
•
Temperature is below/above selected range;
Termocouple or Pt100 is broken;
Pt100 is shorted;
Pt100 is badly connected or wire impedance is
too high;
• The heater resistence is broken
With alarm
inhibition at
power-up
Activated when the programmed soak time is run
out. Refer to item 4 of this manual.
Low limit alarm disabled at power-up
High limit alarm disabled at power-up
Differential low limit alarm disabled at power-up
Differential high limit alarm disabled at power-up
Differential alarm disabled at power-up
Table 2 - Alarm functions and their identification codes
7. PID AUTO TUNE
During auto tune the temperature is controlled in ON/OFF mode at
the programmed Set Point (SV). Depending on the process
characteristics large oscillations above and below SV may occur and
auto tuning may take several minutes to be concluded.
The recommended procedure is as follows:
•
•
Program a new SP close to the desired final temperature
other than the present measured temperature.
Enable the auto tune at the “Atvn
Atvn”
Atvn prompt by selecting 1.
•
Set 1 at the “rvn
rvn”
rvn prompt.
FIRST 4 DIGITS
When powering the unit the display will show the software version
for a few seconds.
Alarm ON
TEMPERATURE
Negative
5. PROBLEMS WITH THE CONTROLLER
TEMPERATURE
SP + SPA1
6. ALARM FUNCTIONS
During auto tune large oscillations will be induced around the
setpoint. Make sure the process can accept these oscillations.
Low and high alarms are used to signal minimum and maximum
temperature values as programmed in the “SPA1
SPA1”
SPA2”
SPA1 ande “SPA2
SPA2
prompts.
If auto tuning results are not satisfactory refer to table 3 for manual
fine tuning procedure.
Differential alarms are used to indicate deviations from the desired
setpoint (SP) temperature. These deviations are programmed at the
“SPA1
SPA1”
SPA2”
SPA1 and “SPA2
SPA2 prompts.
Error alarm shows sensor defects or not properly connected.
Alarm hysteresis is fixed and factory set as described below:
•
•
Pt100: 1.1ºC
Thermocouples: type J: 1.3ºC; types K and S: 2.3ºC
6.1. ALARM INITIAL BLOCKING
The initial blocking option inhibits the alarm from being recognized if
an alarm condition is present when the controller is first energized.
Novus Produtos Eletrônicos Ltda. Tel.:+55-51-3323-3600
PARAMETER
RESPONSE
SOLUTION
Proportional
Slow Response
Decrease
Band
Large Oscillation
Increase
Integral
Slow Response
Increase
Rate
Large Oscillation
Decrease
Derivative
Slow Response or
Instability
Decrease
Time
Large Oscillation
Increase
Table 3 - Suggestions for manual tuning of PID parameters
3/3