ZEL-9100 User Manual

User's Manual

DIN EN ISO 9001

Certificate: 01 100 98505

UM91001D

ZEL-4100 / 7100 / 8100 / 9100

Auto-Tune Fuzzy / PID

Process / Temperature Controller

ZESTA ENGINEERING LTD.

Warning Symbol

The Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury or damage to or destruction of part or all of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.

Use the Manual

Installers

System Designer

Expert User

Read Chapter 1, 2

Read All Chapters

Read Page 12

NOTE:

It is strongly recommended that a process should incorporate a LIMIT CONTROL like L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system.

Information in this user's manual is subject to change without notice.

This manual is applicable for the products with software version 23 and later version.

Copyright February 2002, ZESTA ENGINEERING LTD, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of


2 UM91001D

Contents

Page No

Chapter 1 Overview

1-1 General ------------------------- 5

1-2 Ordering Code --------------- 8

1-3 Programming Port ------------ 9

1-4 Keys and Displays --------- 10

1-5 Menu Overview ------------- 12

1-6 Parameter Descriptions ---- 13

Chapter 2 Installation

2-1 Unpaking ------------------------- 20

2-2 Mounting ------------------------- 20

2-3 Wiring precautions --------- 22

2-4 Power Wiring ----------------- 25

2-5 Sensor Installation Guidlines — 25

2-6 Sensor Input Wiring ------- 26

2-7 Control Output Wiring ----- 26

2-8 Alarm Wiring ----------------- 30

2-9 Data Communication ------ 31

Page No

Chapter 4 Applications

4-1 Heat Only Control with Dwell Timer ---- 51

4-2 Cool Only Control ------------------------- 52

4-3 Heat-Cool Control ------------------------- 53

Chapter 5

Calibration -------- 55

Chapter 6

Specifications ---- 60

Chapter 7

Modbus Communications ---- 66

7-1 Functions Supporte --------------------------- 66

7-2 Exception Responses ------------------------- 68

7-3 Parameter Table --------------------------- 69

7-4 Data Conversion --------------------------- 73

7-5 Communication Examples ----------------- 73

Appendix

A-1 Error Codes ------------------ 76

A-2 Warranty ---------------------- 77

Chapter 3 Programming

3-1 Lockout ------------------------ 33

3-2 Signal Input ------------------- 33

3-3 Control Outputs -------------- 34

3-4 Alarm --------------------------- 39

3-5 Configure User Menu ------- 40

3-6 Ramp --------------------------- 41

3-7 Dwell Timer ------------------- 42

3-8 PV Shift ------------------------ 43

3-9 Digital Filter ------------------- 44

3-10 Failure Transfer ------------- 45

3-11 Auto-tuning ------------------ 46

3-12 Manual tuning --------------- 47

3-13 Manual Control ------------- 48

3-14 Data Communication ---- 50

3-15 PV Retransmission ------- 50

UM91001A 3

Figures & Tables

Page No

Figure 1.1 Fuzzy Control Advantage ---------------------------------------------------------------- 6

Figure 1.2 Programming Port Overview ------------------------------------------------------------ 9

Figure 1.3 Front Panel Description ----------------------------------------------------------------- 11

Figure 1.4 Display of Initial Stage ------------------------------------------------------------------- 11

Figure 2.1 Mounting Dimensions ------------------------------------------------------------------- 21

Figure 2.2 Lead Termination for ZEL - 4100, ZEL - 8100 and ZEL - 7100 ------------- 23

Figure 2.3 Lead Termination for ZEL - 9100 ------------------------------------------------------- 23

Figure 2.4 Rear Terminal Connection for ZEL - 4100 and ZEL - 8100 --------------------- 23

Figure 2.5 Rear Terminal Connection for ZEL - 7100 -------------------------------------------- 24

Figure 2.6 Rear Terminal Connection for ZEL - 9100 -------------------------------------------- 24

Figure 2.7 Power Supply Connections ------------------------------------------------------------ 25

Figure 2.8 Sensor Input Wiring ---------------------------------------------------------------------- 26

Figure 2.9 Output 1 Relay or Triac (SSR) to Drive Load --------------------------------------- 26

Figure 2.10 Output 1 Relay or Triac (SSR) to Drive Contactor ------------------------------- 27

Figure 2.11 Output 1 Pulsed Voltage to Drive SSR --------------------------------------------- 27

Figure 2.12 Output 1 Linear Current --------------------------------------------------------------- 28

Figure 2.13 Output 1 Linear Voltage --------------------------------------------------------------- 28

Figure 2.14 Output 2 Relay or Triac (SSR) to Drive Load ------------------------------------- 28

Figure 2.15 Output 2 Relay or Triac (SSR) to Drive Contactor ------------------------------- 29

Figure 2.16 Output 2 Pulsed Voltage to Drive SSR --------------------------------------------- 29

Figure 2.17 Output 2 Linear Current --------------------------------------------------------------- 29

Figure 2.18 Output 2 Linear Voltage -------------------------------------------------------------- 30

Figure 2.19 Alarm Output to Drive Load ---------------------------------------------------------- 30

Figure 2.20 Alarm Output to Drive Contactor ---------------------------------------------------- 30

Figure 2.21 RS-485 Wiring --------------------------------------------------------------------------- 31

Figure 2.22 RS-232 Wiring --------------------------------------------------------------------------- 32

Figure 2.23 Configuration of RS-232 Cable ------------------------------------------------------ 32

Figure 3.1 Conversion Curve for Linear Type Process Value --------------------------------- 34

Figure 3.2 Heat Only ON-OFF Control ------------------------------------------------------------ 35

Figure 3.3 Output 2 Deviation High Alarm -------------------------------------------------------- 38

Figure 3.4 Output 2 Process Low Alarm ---------------------------------------------------------- 38

Figure 3.5 RAMP Function --------------------------------------------------------------------------- 41

Figure 3.6 Dwell Timer Function -------------------------------------------------------------------- 42

Figure 3.7 PV Shift Application ---------------------------------------------------------------------- 43

Figure 3.8 Filter Characteristics --------------------------------------------------------------------- 44

Figure 3.9 Effects of PID Adjustment ------------------------------------------------------------- 49

Figure 4.1 Heat Control Example ------------------------------------------------------------------- 51

Figure 4.2 Cooling Control Example --------------------------------------------------------------- 52

Figure 4.3 Heat-Cool Control Example ------------------------------------------------------------ 53

Figure 5.1 RTD Calibration --------------------------------------------------------------------------- 57

Figure 5.2 Cold Junction Calibration Setup ------------------------------------------------------ 58

Table 1.1 Display Form of Characters ------------------------------------------------------------ 11

Table 3.1 Heat-Cool Control Setup Value --------------------------------------------------------- 34

Table 3.2 PID Adjustment Guide -------------------------------------------------------------------- 48

Table A.1 Error Codes and Corrective Actions -------------------------------------------------- 66

4 UM91001A

Chapter 1 Overview

1 - 1 General

The Fuzzy Logic plus PID microprocessor-based controller series, incorporate two bright, easy to read 4-digit LED displays, indicating process value and set point value. The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time, with the minimum of overshoot during power-up or external load disturbance.

ZEL - 9100 is a 1/16 DIN size panel mount controller. It can also be used for rail mount by adding a rail mount kit . ZEL - 7100 is a

72X72 DIN size panel mount controller. ZEL - 8100 is a 1/8 DIN size panel mount controller and ZEL - 4100 is a 1/4 DIN size panel mount controller. These units are powered by 11-26 or 90-250 VDC

/VAC supply, incorporating a 2 amp. control relay output as standard. The second output can be used as cooling control, or an alarm. Both outputs can select triac, 5V logic output, linear current or linear voltage to drive external device. There are six types of alarm plus a dwell timer can be configured for the third output.The units are fully programmable for PT100 and thermocouple types J,

K, T, E, B, R, S, N, L with no need to modify the unit. The input signal is digitized by using a 18-bit A to D converter. Its fast sampling rate allows the unit to control fast processes.

Digital communications RS-485 or RS-232 ( excluding ZEL - 7100 ) are available as an additional option. These options allow the units to be integrated with supervisory control system and software.

A programming port is available for automatic configuration, calibration and testing without the need to access the keys on front panel.

By using proprietary Fuzzy modified PID technology, the control loop will minimize the overshoot and undershoot in a shortest time. The following diagram is a comparison of results with and without Fuzzy technology.

UM91001B 5

PID control with properly tuned

PID + Fuzzy control

Temperature

Set point

Warm Up Load Disturbance

High Accuracy

The series are manufactured with custom designed ASIC(Application

Specific Integrated Circuit ) technology which contains a 18-bit A to

D converter for high resolution measurement ( true 0.1 BF resolution for thermocouple and PT100 ) and a 15-bit D to A converter for linear current or voltage control output. The ASIC technology provides improved operating performance, low cost, enhanced reliability and higher density.

Time

Fast Sampling Rate

The sampling rate of the input A to D converter reaches 5 times/second.

The fast sampling rate allows this series to control fast processes.

Fuzzy Control

The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes. The results is to enable a process to reach a predetermined set point in the shortest time, with the minimum of overshoot and undershoot during power-up or external load disturbance.

Digital Communication

The units are equipped with RS-485 or RS-232 interface card to provide digital communication. By using the twisted pair wires there are at most 247 units can be connected together via RS-485 interface to a host computer.

Figure 1.1

Fuzzy Control

Advantage

6 UM91001A

Programming Port

A programming port is used to connect the unit to a hand-held programmer or a PC for quick configuration, also can be connected to an ATE system for automatic testing & calibration.

Auto-tune

The auto-tune function allows the user to simplify initial setup for a new system. A clever algorithm is provided to obtain an optimal set of control parameters for the process, and it can be applied either as the process is warming up ( cold start ) or as the process has been in steady state ( warm start ).

Lockout Protection

According to actual security requirement, one of four lockout levels can be selected to prevent the unit from being changed abnormally.

Bumpless Transfer

Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks. Hence, the process can be well controlled temporarily as if the sensor is normal.

Soft-start Ramp

The ramping function is performed during power up as well as any time the set point is changed. It can be ramping up or ramping down. The process value will reach the set point with a predetermined constant rate.

Digital Filter

A first order low pass filter with a programmable time constant is used to improve the stability of process value. This is particularly useful in certain application where the process value is too unstable to be read.

SEL Function

The units have the flexibility for user to select those parameters which are most significant to him and put these parameters in the front of display sequence. There are at most 8 parameters can be selected to allow the user to build his own display sequence.

UM91001A 7

1 - 2 Ordering Code

ZEL - 4100 -

ZEL - 7100 -

ZEL - 8100 -

ZEL - 9100 -

Power Input

4: 90 - 250 VAC,

50/60 HZ

5: 11 - 26 VAC or

VDC

9: Special Order

Signal Input

1: Standard Input

Thermocouple:

J, K, T, E, B, R,

S, N, L

RTD: PT100 DIN,

PT100 JIS

2: 0 - 60 mV

3: 0 -1 V

4: 0 - 5 V

5: 1 - 5 V

6: 4 - 20 mA

7: 0 - 20 mA

8: 0 - 10 V

9: Special Order

Output 1

0: None

1: Relay rated 2A/240VAC

2: Pulsed voltage to drive SSR,

5V/30mA

3: Isolated 4 - 20mA / 0 - 20mA

4: Isolated 1 - 5V / 0 - 5V

5: Isolated 0 - 10V

6: Triac output 1A / 240VAC,SSR

C: Pulsed voltage to drive SSR,

14V/40mA

9: Special order

Options

0: Panel mount IP50 standard

1: Panel mount IP65 water

resistant rubber installed

2: DIN Rail mount with IP50

(for ZEL - 9100 only)

3: DIN Rail mount with IP65

(for ZEL - 9100 only)

Communications

0: None

1: RS-485 interface

2: RS-232 interface ( not

available for ZEL - 7100 )

3: Retransmit 4-20mA / 0-20mA

4: Retransmit 1-5 V / 0-5V

5: Retransmit 0-10V

9: Special order

Alarm

0: None

1: Form C relay 2A/240VAC

9: Special order

Output 2

0: None

1: Form A relay 2A/240VAC

2: Pulsed voltage to

drive SSR, 5V / 30mA

3: Isolated 4 - 20mA / 0 - 20mA

4: Isolated 1 - 5V / 0 - 5V

5: Isolated 0 - 10V

6: Triac output, 1A / 240VAC,

SSR

7: Isolated 20V/25mA

transducer power supply

8: Isolated 12V/40mA


9: Isolated 5V/80mA


C: Pulsed voltage to drive SSR,

14V/40mA

A: Special order

8 UM91001C

Accessories

OM94-6 = Isolated 1A / 240VAC Triac Output Module ( SSR )

OM94-7 = 14V / 40mA SSR Drive Module

OM96-3 = Isolated 4 - 20 mA / 0 - 20 mA Analog Output Module

OM96-4 = Isolated 1 - 5V / 0 - 5V Analog Output Module

OM96-5 = Isolated 0 -10V Analog Output Module

CM94-1 = Isolated RS-485 Interface Module for ZEL - 8100/4100/7100

CM94-2 = Isolated RS-232 Interface Module for ZEL - 8100/4100

CM94-3 = Isolated 4 - 20 mA / 0 - 20 mA Retrans Module for

ZEL - 8100/4100/7100

CM94-4 = Isolated 1 - 5V / 0 - 5V Retrans Module for ZEL - 8100,

ZEL - 4100 , ZEL - 7100

CM94-5 = Isolated 0-10V Retrans Module for ZEL - 8100/4100/7100

CM97-1 = Isolated RS-485 Interface Module for ZEL - 9100

CM97-2 = Isolated RS-232 Interface Module for ZEL - 9100

CM97-3 = Isolated 4-20 mA / 0-20mA Retrans Module for ZEL - 9100

CM97-4 = Isolated 1-5V / 0-5V Retrans Module for ZEL - 9100

CM97-5 = Isolated 0-10V Retrans Module for ZEL - 9100

DC94-1 = Isolated 20V/25mA DC Output Power Supply



CC94-1 = RS-232 Interface Cable ( 2M )

CC91-1 = Programming Port Cable

RK91-1 = Rail Mount kit for ZEL - 9100

Related Products

SNA10A = Smart Network Adaptor for third party software, which

converts 255 channels of RS-485 or RS-422 to RS-232

Network.

SNA10B = Smart Network Adaptor for ZE - Net software, which

converts 255 channels of RS-485 or RS-422 to RS-232

network.

SNA12A = Smart Network Adapter for programming port to RS-232

interface

ZE - Set = Configuration Software

UM91001C 8-1

1 - 3 Programming Port

Rear

Terminal

6 4 2

5 3 1

Access Hole

6 4 2

5 3 1

A special connector can be used to touch the programming port which is connected to a PC for automatic configuration, also can be connected to an ATE system for automatic calibration and testing.

The programming port is used for off-line automatic setup and testing procedures only. Don't attempt to make any connection to these pins when the unit is used for a normal control purpose.

Front

Panel

Figure 1.2

Programming Port

Overview

9 UM91001A

1 - 4 Keys and Displays

KEYPAD OPERATION

SCROLL KEY :

This key is used to select a parameter to be viewed or adjusted.

UP KEY :

This key is used to increase the value of selected parameter.

DOWN KEY :

This key is used to decrease the value of selected parameter.

RESET KEY : R

This key is used to:

1. Revert the display to display the process value.

2. Reset the latching alarm, once the alarm condition is

removed.

3. Stop the manual control mode , auto-tuning mode and calibration

mode.

4. Clear the message of communication error and auto-tuning error.

5. Restart the dwell timer when the dwell timer has been time out.

6. Enter the manual control menu during failure mode occurs.

ENTER KEY : Press for 5 seconds or longer .

Press for 5 seconds to:

1. Ener setup menu. The display shows .

2. Enter manual control mode during manual control mode

is selected.

3. Enter auto-tuning mode during auto-tuning mode is

selected.

4. Perform calibration to a selected parameter during the

calibration procedure.

Press for 6.2 seconds to select manual control mode.

Press for 7.4 seconds to select auto-tuning mode.

Press for 8.6 seconds to select calibration mode.

UM91001D 10

Alarm

Indicator

Output 2

Indicator

Output 1

Indicator

OP1 OP2 ALM

Upper Display, to display process value, menu symbol and error code etc.

Process Unit Indicator

C F

Manual

Mode

Indicator

Auto-tuning

Indicator

MAN

AT

Lower Display, to display set point value, parameter value or control output value etc.

ZESTA

R

ZEL - 9100

Figure 1.3 Front Panel Description

4 Buttons for ease of control setup and set point adjustment.

Table 1.1 Display Form of Characters

A

B

C c

D

E

F

G

H h

I

J

K

L

M

N

O

P

Q

R

: Confused Character

S

T

U

V

W

X

Y

Z

?

=

OP1 OP2 ALM

MAN

AT

C F

Display program code of the product for 2.5 seconds.

The left diagram shows program no. 6 for ZEL - 9100 with version 24.

The program no. for ZEL - 7100 is 13, for ZEL - 8100 is 11 and for ZEL - 4100 is 12.

R

ZEL - 9100

Figure 1.4

Display of Initial Stage

11

ZESTA

UM91001D

1 - 5 Menu Overview

User menu

Setup menu

Manual

Mode

Auto-tuning

Mode

Calibration

Mode

PV, SV

5 sec.

*2

SP2

SP3

INPT

UNIT

DP

PB

TI

TD

CYC1

ADDR

*1

BAUD

DATA

PARI

STOP

RELO

REHI

SEL1

SEL2

CPB

DB

ALFN

ALMD

ALHY

ALFT

COMM

ADDR

SEL3

SEL4

SEL5

SEL6

SEL7

SEL8

TD

OUT1

O1TY

O1FT

O1HY

CYC1

OFST

RAMP

RR

OUT2

O2TY

O2FT

O2HY

CYC2

LOCK

INPT

UNIT

DP

INLO

INHI

SP1L

SP1H

SHIF

FILT

PB

TI

6.2 sec.

H_ _ _

C_ _ _

7.4 sec.

Press for 5 seconds to start manual control.

Release then press for 5 seconds to start auto-tuning mode.

8.6 sec.

*3

ADLO

ADHI

RTDL

RTDH

CJLO

CJHI

9.8 sec.

Press for

5 seconds to perform calibration.

Apply these modes will break the control loop and change some of the previous setting data. Make sure that if the system is allowable to apply these modes.

*1: The flow chart shows a complete listing of all parameters. For actual application the number of available parameters depends on setup conditions, and should be less than that shown in the flow chart.

*2:

You can select at most 8 parameters put in the user menu by using SEL1~SEL8 contained at the bottom of setup menu.

*3: Release , press again for 2 seconds or longer (but not longer than 3 seconds), then release to enter the calibration menu.

The user menu shown in the flow chart is corresponding to the default setting for the SEL parameters SEL1 to SEL8. SP3 will be hidden if NONE is selected for

ALFN. SP2 will be hidden if alarm function is not selected for OUT2. The unused parameter will be hidden even if it is selected by SEL parameters.

UM91001D 12

1 - 6 Parameter Descriptions

Parameter

Notation

SP1

SP2

SP3

Parameter Description

Set point for output 1

Set point for output 2 when output 2 performs alarm function

Set point for alarm or dwell timer output

LOCK

INPT

13

Select parameters to be locked

Input sensor selection

Range

Low: SP1L High :SP1H

Low: -19999 High :45536

Low: -19999 High: 45536

4

5

6

2

3

0

1

7

8

9

0 : No parameter

is locked

1 : Setup data are

locked

2 : Setup data and

User data except Set

point are locked

3 : All data are locked

10

11

12

13

14

15

16

17

:

:

:

:

:

:

:

:

J type thermocouple

K type thermocouple

T type thermocouple

E type thermocouple

B type thermocouple

R type thermocouple

S type thermocouple

N type thermocouple

: L type thermocouple

:

:

PT 100 ohms DIN curve

PT 100 ohms JIS curve

:

:

:

:

:

4 - 20 mA linear current input

0 - 20 mA linear current input

:

: 0 - 60 mV linear millivolt input

0 - 1V linear voltage input

0 - 5V linear voltage

input


input


input

UM91001A

Default

Value

25.0 BC

(77.0BF)

10.0 BC

(18.0BF)

10.0 BC

(18.0 BF)

0

1

(0)

Parameter

Notation

UNIT

DP

INLO

INHI

SP1L

SP1H

SHIF

FILT


Input unit selection

Decimal point selection

Input low sale value

Input high scale value

Low limit of set point value

High limit of set point value

PV shift (offset) value

Filter damping time constant of PV

Range

Default

Value

0

1

2

0

:

:

: Degree C unit

Degree F unit

Process unit

:

:

: No decimal point

1 decimal digit

2 decimal digits

0

(1)

1

2

1

3 : 3 decimal digits

Low:

Low:

Low:

-19999

INLO+50

-19999

High:

High:

High:

45486

45536

45536

Low: SP1L High: 45536

Low:

-200.0 LC

(-360.0 LF)

0 :

1

2

3

4

5

6

7

8

9

:

:

:

:

:

:

:

:

:

High:

200.0 LC

( 360.0 LF)

0 second time

constant

0.2 second time

constant

0.5 second time constant

1 second time constant

2 seconds time constant






-17.8 LC

( 0 LF )

93.3 LC

(200.0 LF)

-17.8 LC

(0 LF)

537.8 LC

(1000 LF)

0.0

2

UM91001A 14

Parameter

Notation

TI

TD

CYC1

OFST

15

PB

OUT1

O1TY

O1FT

O1HY

RAMP


Proportional band value

Integral time value

Derivative time value

Low: 0

Low: 0

Low: 0

Range

500.0 LC

(900.0 LF)

High: 1000 sec

High: 360.0 sec

Output 1 function

Output 1 signal type

Output 1 failure transfer mode

0

1

0

1

2

:

: Reverse (heating ) control action

Direct (cooling) control action

: Relay output

: Solid state relay

drive output

: Solid state relay

output

3 : 4-20 mA current

module

4

5

6

7

8

: 0 - 20 mA current

module

:

:

0 - 1V voltage

module

0 - 5V voltage

module

:

:

1 - 5V voltage

module

0 - 10V voltage

module

Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0 % to continue output 1 control function as the unit fails, or select OFF (0) or ON (1) for ON-OFF control.

Output 1 ON-OFF control hysteresis

Low: 0.1 High: 50.0 BC(90.0BF)

Output 1 cycle time

Offset value for P control

Ramp function selection

Low: 0.1 High: 90.0 sec.

Low: 0 High: 100.0 %

0 : No Ramp Function

1 : Use unit/minute as

Ramp Rate

2 : Use unit/hour as

Ramp Rate

UM91001A

Default

Value

10.0 LC

(18.0 LF)

100

25.0

0

0

0

0.1LC

(0.2LF)

18.0

25.0

0

Parameter

Notation

RR


Ramp rate

OUT2

O2TY

O2FT

Output 2 function


Output 2 failure transfer mode

Low: 0

Range

High:

500.0 LC

(900.0 LF)

0 : Output 2 No Function

2 : Deviation High Alarm

3 : Deviation Low Alarm

6 : Process High Alarm

7 : Process Low Alarm

8 : Cooling PID Function

0 : Relay output

1

2

3

4

5

6

7

8

:

:

:

:

:

:

:

: Solid state relay drive output

Solid state relay output

4 - 20 mA current module

0 - 20 mA current module

0 - 1V voltage module




Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0 % to continue output 2 control function as the unit fails, or select ON (0) or

OFF (1) for alarm function.

O2HY

CYC2

CPB

Output 2 hysteresis value when output 2 performs alarm function

Output 2 cycle time

Cooling proportional band value

Low: 0.1

Low: 0.1

Low: 50

High: 90.0 sec.

High: 300 %

UM91001A

Default

Value

0.0

2

0

0

0.1 LC

(0.2 LF)

18.0

100

16

Parameter

Notation

DB


Heating-cooling dead band (negative value= overlap)

ALFN

ALMD

ALHY

ALFT

COMM

Alarm function for alarm output

Alarm operation mode

Hysteresis control of alarm

Alarm failure transfer mode

Communication

function

Low: -36.0

Range

High: 36.0 %

Default

Value

0

0 :No alarm function

1 :Dwell timer action

2 :Deviation high alarm

3 :Deviation low alarm

4 :Deviation band out of

band alarm

5 :Deviation band in

band alarm

6 :Process value high

alarm

7 :Process value low

alarm

0

1

2

3

:

:

:

Normal alarm action

Latching alarm action

Hold alarm action

:

Latching & Hold action

Low: 0.1

0

1 :

: Alarm output ON as unit fails

Alarm output OFF as unit fails

0 : No communication

1 : Modbus RTU mode

protocol

2

3

4

5

6

:4-20mA retransmission

output

:0-20mA retransmission

output

:0-5V retransmission

output


output


output

2

0

0.1 LC

(0.2 LF)

0

1

17 UM91001D

Parameter

Notation

ADDR


Address assignment of digital communication

BAUD

DATA

Baud rate of digital communication

Data bit count of digital communication

Range

Low: 1 High: 255

5

6

3

4

0

1

2

:

:

:

:

:

:

:

2.4 Kbits/s baud rate







0 : 7 data bits

1 : 8 data bits

PARI

Parity bit of digital communication

0 : Even parity

1 : Odd parity

2 : No parity bit

Default

Value

2

1

0

STOP

RELO

REHI

Stop bit count of digital communication

Retransmission low scale value

Retransmission high scale value

SEL1

Select 1'st parameter for user menu

0 : One stop bit

1 : Two stop bits

Low: -19999 High: 45536

Low: -19999 High: 45536

3

4

5

6

0

1

2

7

UM91001D

: No parameter selected

:LOCK is put ahead

:INPT is put ahead

:UNIT is put ahead

:DP is put ahead

:SHIF is put ahead

:PB is put ahead

:TI is put ahead

0

0.0 LC

(32.0 LF)

100.0 LC

(212.0 LF)

2

18

Prameter

Notation


SEL1

Select 1'st parameter for user menu

8

9

10

11

17

18

14

15

16

12

13

SEL2

SEL3

SEL4

SEL5

SEL6

SEL7

SEL8

Select 2'nd parameter for user menu

Select 3'rd parameter for user menu

Select 4'th parameter for user menu





Same as SEL1

Same as SEL1

Same as SEL1

Same as SEL1

Same as SEL1

Same as SEL1

Same as SEL1

Range

:TD is put ahead

: O1HY is put ahead

: CYC1 is put ahead

: OFST is put ahead

:RR is put ahead

:O2HY is put ahead

:CYC2 is put ahead

:CPB is put ahead

:DB is put ahead

:ADDR is put ahead

:ALHY is put ahead

Default

Value

2

6

7

8

10

17

3

4

19 UM91001A

Chapter 2 Installation

Dangerous voltages capable of causing death are sometimes present in this instrument.

Before installation or beginning any cleaning or troubleshooting procedures the power to all equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only.

This instrument is protected throughout by Double Insulation . To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture.

Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6.

Remove stains from this instrument using a soft, dry cloth. Don't use harsh chemicals, volatile solvent such as thinner or strong detergents to clean the instrument in order to avoid deformation or discoloration.

2 - 1 Unpacking

Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage.

If any damage due to transit , report and claim with the carrier.

Write down the model number, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) and date code (D/C) are labeled on the box and the housing of control.

2 - 2 Mounting

Make panel cutout to dimension shown in Figure 2.1.

Take both mounting clamps away and insert the controller into panel cutout. Install the mounting clamps back. Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout.

UM91001B 20

Figure 2.1 Mounting Dimensions

Panel Cutout

92 mm

Panel

53 mm

ZEL-4100

Panel

Cutout

45 mm

ZEL-8100

Panel

65 mm

21

Panel Cutout

68 mm

Panel

65 mm

UM91001A

ZEL-7100

Panel

45 mm

Panel

Cutout

ZEL-9100

Panel Mount

11.5mm

104.8mm

7.5mm

48.0mm

11.5mm

104.8mm

2 - 3 Wiring Precautions

* Before wiring, verify the label for correct model number and options. Switch off the power while checking.

* Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded.

* It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible.

* All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools.

* All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring must be suitable for voltage, current, and temperature rating of the system.

* Beware not to over-tighten the terminal screws. The torque should not exceed 1 N-m ( 8.9 Lb-in or 10.2KgF-cm ).

62.0mm

ZEL-9100

Rail Mount

6.5mm

UM91001D 22

*

Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit.

* Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded.

*

Except the thermocouple wiring, all wiring should use stranded copper conductor with maximum gauge 18 AWG.

3.2mm min.

7.0mm max.

Figure 2.2 Lead Termination for

ZEL-4100, ZEL-8100

and ZEL-7100

6.0mm max.

Figure 2.3 Lead Termination

for ZEL-9100

3.0mm min.

90-250VAC

47-63 Hz

12VA

OP1

OP2

ALM

CAT. I I

_

_

5

6

7

8

3

4

1

2

L

C

N

NO

C

NO

C

NO

9 NC

10

11

12

RE+ TX1 TXD 13

RE TX2 RXD 14

COM 15

PTA

TC+, V+

PTB, mA+

TC-, V-

PTB, mA-

16

17

18

19

20

RS-485

RETRANSMISSION

RS-232

50LC max. air ambient

Use copper conductors

(except on T/C input )

A

RTD

B

_ _

V _

TC V mA RTD

B

Figure 2.4 Rear Terminal Connection

for ZEL-4100 and ZEL-8100

23 UM91001D

90-250VAC

47-63 Hz

12VA

1 L 8

_

OP1

CAT. I I

2 N 9

3 RE + 10 TX1

RS-485 or

RETRANSMISSION

ALM

4 RE 11

TX2

PTA

A

OP2

_

5

6

7

TC+, V+

PTB, mA+

TC-, V-

PTB, mA-

12

13

14

_ _

V _

RTD

TC V mA RTD


Use copper conductors (except on T/C input )

B

B

Figure 2.5

Rear Terminal Connection for ZEL-7100

RETRANSMISSION:

RS-232:

RS-485:

RE + RE -

TXD RXD

TX1 TX2

COM

13 14 15

I

ALM

B

V

_

B

A

RTD

_

1

2

3

4

5

6

NO

NC

C

PTA

TC+, V+

PTB, mA+

TC-, V-

PTB, mA-

L

N

7

8

C 9

NO


Use copper conductors (except on T/C input )

Figure 2.6

Rear Terminal Connection for ZEL-9100

10

C 11

NO 12

CAT. I I

_

90-250VAC

47-63 Hz

12VA

_

OP1

OP2

UM91001B 24

2 - 4 Power Wiring

The controller is supplied to operate at 11-26 VAC / VDC or 90-250

VAC. Check that the installation voltage corresponds with the power

rating indicated on the product label before connecting power to

the controller. Near the controller a fuse and a switch rated at

2A/250VAC should be equiped as shown in the following diagram.

ZEL-4100

ZEL-7100

ZEL-8100

L

N

1

2

ZEL-9100

L

N

7

8

Fuse

2A/250VAC

~

~

Figure 2.7 Power Supply Connections

This equipment is designed for installation in an enclosure which provides adequate protection against electric shock. The enclosure must be connected to earth ground.

Local requirements regarding electrical installation should be rigidly observed. Consideration should be given to prevent from unauthorized person access to the power terminals.

2 - 5 Sensor Installation Guidelines

Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater. In a process where the heat demand is variable, the probe should be closed to the work area. Some experiments with probe location are often required to find this optimum position.

In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes.

25 UM91001B

Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes the sensor might need to have different requirements such as leak-proof, antivibration, antiseptic, etc.

Standard sensor limits of error are A4 degrees F (A 2 degrees C ) or 0.75% of sensed temperature (half that for special ) plus drift caused by improper protection or an over-temperature occurrence.

This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement.

2 - 6 Sensor Input Wiring

PTA

TC+, V+

PTB, mA+

TC-, V-

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

PTB, mA-

18

19

20

12

13

14

4

5

6

A

RTD

B

_ _

V _

TC V MA RTD

B

Figure 2.8 Sensor Input Wiring

2 - 7 Control Output Wiring

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

LOAD

_

3

4

8

9

9

10

120V/240VAC

Mains Supply

Figure 2.9

Output 1 Relay or Triac (SSR) to Drive Load

UM91001A 26

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

_

3

4

8

9

9

10

120V /240V

Mains Supply

Three

Phase

Heater

Power

Three Phase

Delta

Heater

Load

Contactor

No Fuse

Breaker

Figure 2.10

Output 1 Relay or Triac (SSR) to Drive Contactor

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

3

4

8

9

9

10 _

SSR

_

Load

120V /240V

Mains Supply

30mA / 5V

Pulsed

Voltage

Internal Circuit

5V

33

33

0V

+

Figure 2.11 Output 1 Pulsed Voltage to Drive SSR

27 UM91001A

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

3

4

8

9

9

10

0 - 20mA,

4 - 20mA

Load

_

Maximum Load

500 ohms

Figure 2.12 Output 1 Linear Current

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

3

4

8

9

9

10

0 - 1V, 0 - 5V

1 - 5V, 0 - 10V

Load

_

Minimum Load

10 K ohms

Figure 2.13 Output 1 Linear Voltage

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

_

5

6

6

7

11

12

Load

120V/240VAC

Mains Supply

Figure 2.14

Output 2 Relay or Triac (SSR) to Drive Load

UM91001A 28

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

_

5

6

6

7

11

12

120V /240V

Mains Supply

Three Phase

Delta

Heater

Load

Contactor

No Fuse

Breaker

Figure 2.15

Output 2 Relay or Triac (SSR) to Drive Contactor

Three

Phase

Heater

Power

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

5

6

6

7

11

12 _

SSR

_

Load

120V /240V

Mains Supply

30mA / 5V

Pulsed

Voltage

Internal Circuit

5V

33

33

0V

+

Figure 2.16 Output 2 Pulsed Voltage to Drive SSR

29

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

5

6

6

7

11

12

0 - 20mA,

4 - 20mA

Load

_

Figure 2.17 Output 2 Linear Current

Maximum Load

500 ohms

UM91001A

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

5

6

6

7

11

12

0 - 1V, 0 - 5V

1 - 5V, 0 - 10V

Load

_

Minimum Load

10 K ohms

Figure 2.18 Output 2 Linear Voltage

2 - 8 Alarm Wiring

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

7

8

9

3

4

5

3

1

2

Load

120V/240VAC

Mains Supply

Figure 2.19 Alarm Output to Drive Load

ZEL-4100

ZEL-8100 ZEL-7100 ZEL-9100

7

8

9

3

4

5

3

1

2

120V /240V

Mains Supply

Three Phase

Delta

Heater

Load

Contactor

No Fuse

Breaker

Relay Output to

Drive Contactor

Figure 2.20 Alarm Output to Drive Contactor

Three

Phase

Heater

Power

UM91001A 30

2 - 9 Data Communication

ZEL-4100

ZEL-8100

ZEL-9100

TX1

TX2

13

14

ZEL-7100

10

11

TX1

TX2

Twisted-Pair Wire

ZEL-4100

ZEL-8100

ZEL-9100 ZEL-7100

TX1

TX1 13 10

TX2 14 11

TX2

RS-485 to RS-232 network adaptor

SNA10A or

SNA10B

TX1

TX2

RS-232

PC

31

Max. 247 units can be linked

ZEL-4100

ZEL-8100

ZEL-9100

TX1

TX2

13

14

ZEL-7100

10

11

TX1

TX2

Terminator

220 ohms / 0.5W

Figure 2.21 RS-485 Wiring

UM91001A

RS-232

ZEL-4100

ZEL-8100

ZEL-9100

TXD

RXD

COM

13

14

15

PC

9-pin

RS-232 port

CC94-1

Figure 2.22

RS-232 Wiring

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable must be modified according to the following circuit diagram.

To DTE ( PC ) RS-232 Port

ZEL-4100

ZEL-8100

ZEL-9100

TXD

RXD

13

14

COM 15

TX1

TX2

COM

RD

TD

GND

3

4

5

1

2

6

7

8

9

Female DB-9

Figure 2.23

Configuration of RS-232 Cable

1 DCD

2 RD

3 TD

4 DTR

5 GND

6 DSR

7 RTS

8 CTS

9 RI

UM91001A 32

Chapter 3 Programming

Press for 5 seconds and release to enter setup menu. Press to select the desired parameter. The upper display indicates the parameter symbol, and the lower display indicates the selected value of parameter.

3 - 1 Lockout

There are four security levels can be selected by using LOCK parameter.

If NONE is selected for LOCK, then no parameter is locked.

If SET is selected for LOCK, then all setup data are locked.

If USER is selected for LOCK, then all setup data as well as user data

(refer to section 1-5) except set point are locked to prevent from being changed.

If ALL is selected for LOCK, then all parameters are locked to prevent from being changed.

3 - 2 Signal Input

INPT: Selects the sensor type or signal type for signal input.

Range: ( thermocouple ) J_TC, K_TC, T_TC, E_TC, B_TC, R_TC

S_TC, N_TC, L_TC

( RTD ) PT.DN, PT.JS

(linear ) 4-20, 0-20, 0-60, 0-1V, 0-5V, 1-5V, 0-10

UNIT: Selects the process unit

Range: LC, LF, PU( process unit ). If the unit is neither LC nor LF,

then selects PU.

DP: Selects the resolution of process value.

Range: ( for T/C and RTD ) NO.DP, 1-DP

(for linear ) NO.DP, 1-DP, 2-DP, 3-DP

INLO: Selects the low scale value for the linear type input.

INHI : Selects the high scale value for the linear type input.

How to use INLO and INHI :

If 4 - 20 mA is selected for INPT,let SL specifies the input signal low

( ie. 4 mA ), SH specifies the input signal high ( ie. 20 mA ), S specifies the current input signal value, the conversion curve of the process value is shown as follows :

33 UM91001D

process value

INHI

PV

Figure 3.1

Conversion Curve for

Linear Type Process Value

INLO input signal

SL S SH

Formula : PV = INLO + ( INHI - INLO )

S - SL

SH - SL

Example : A 4-20 mA current loop pressure transducer with range

0 - 15 kg/cm is connected to input, then perform the

INPT = 4 - 20 INLO = 0.00

INHI = 15.00 DP = 2-DP

Of course, you may select other value for DP to alter the resolution.

3 - 3 Control Outputs

There are 4 kinds of control modes can be configured as shown in Table 3.1

Table 3.1 Heat-Cool Control Setup Value

Control

Modes

Heat only

Cool only

Heat: PID

Cool: ON-OFF

Heat: PID

Cool: PID

OUT1

REVR

DIRT

REVR

REVR

: Don't care

: Adjust to met process

requirements

OUT2

DE.HI

COOL

O1HY O2HY CPB

: Required if ON-OFF control

is configured

DB

UM91001A 34

Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0,

O1HY is used to adjust dead band for ON-OFF control, The output 1 hysteresis ( O1HY ) is enabled in case of PB = 0 . The heat only on-off control function is shown in the following diagram :

PV

SP1

Dead band = O1HY

SP1 - O1HY

OUT1 Action

Time

ON

OFF

Time

Figure 3.2 Heat Only

ON-OFF Control

The ON-OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest. If ON-OFF control is set ( ie.

PB = 0 ), TI, TD, CYC1, OFST, CYC2, CPB, DB will be hidden and have no function to the system. The auto-tuning mode and bumpless transfer will be disabled too.

Heat only P ( or PD ) control : Select REVR for OUT1, set TI to 0,

OFST is used to adjust the control offset ( manual reset ). O1HY is hidden if PB is not equal to 0. OFST Function : OFST is measured by

% with range 0 - 100.0 %. In the steady state ( ie. process has been stabilized ) if the process value is lower than the set point a definite value, say 5 LC, while 20 LC is used for PB, that is lower 25 %, then increase OFST 25 %, and vice versa.

35 UM91001A

After adjusting OFST value, the process value will be varied and eventually, coincide with set point. Using the P control ( TI set to 0 ), the auto-tuning is disabled. Refer to section 3-12 " manual tuning " for the adjustment of PB and TD. Manual reset ( adjust OFST ) is not practical because the load may change from time to time and often need to adjust

OFST repeatedly. The PID control can avoid this situation.

Heat only PID control : Selecting REVR for OUT1, PB and TI should not be zero. Operate auto-tuning for the new process, or set PB, TI and TD with historical values. See section 3-11 for auto-tuning operation. If the control result is still unsatisfactory, then use manual tuning to improve the control . See section 3-12 for manual tuning. The unit contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned.

Cool only control:ON-OFF control, P ( PD ) control and PID control can be used for cool control. Set OUT1 to DIRT ( direct action ). The other functions for cool only ON-OFF control, cool only P ( PD ) control and cool only PID control are same as descriptions for heat only control except that the output variable

( and action ) for the cool control is inverse to the heat control.

NOTE :

The ON-OFF control may result excessive overshoot and undershoot problems in the process. The P ( or PD ) control will result in a deviation process value from the set point. It is recommended to use PID control for the Heat-Cool control to produce a stable and zero offset process value.

Other Setup Required : O1TY, CYC1, O2TY, CYC2, O1FT, O2FT

O1TY & O2TY are set in accordance with the types of OUT1 & OUT2 installed. CYC1 & CYC2 are selected according to the output 1 type

( O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for

CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used for O1TY, and CYC1 is ignored if linear output is used. Similar condition is applied for CYC2 selection.

UM91001A 36

You can use the auto-tuning program for the new process or directly set the appropriate values for PB, TI & TD according to the historical records for the repeated systems. If the control behavior is still inadequate, then use manual tuning to improve the control. See section 3-12 for manual tuning.

CPB Programming : The cooling proportional band is measured by % of PB with range

50~300. Initially set 100% for CPB and examine the cooling effect. If cooling action should be enhanced then decrease CPB, if cooling action is too strong then increase CPB. The value of

CPB is related to PB and its value remains unchanged throughout the auto-tuning procedures.

Adjustment of CPB is related to the cooling media used. For air is used as cooling media, adjust

CPB at 100(%).For oil is used as cooling media, adjust CPB at 125(%). For water is used as cooling media, adjust CPB at 250(%).

DB Programming: Adjustment of DB is dependent on the system requirements. If more positive value of DB ( greater dead band ) is used, an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur. If more negative value of DB ( greater overlap ) is used, an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur. It is adjustable in the range -36.0% to 36.0 % of PB. A negative DB value shows an overlap area over which both outputs are active. A positive DB value shows a dead band area over which neither output is active.

Output 2 ON-OFF Control ( Alarm function ): The output 2 can also be configured as alarm function. There are 4 kinds of alarm functions can be selected for output 2, these are: DE.HI (deviation high alarm ),

DE.LO (deviation low alarm ), PV.HI (process high alarm ) and PV.LO

( process low alarm ). Refer to Figure 3.3 and Figure 3.4 for the description of deviation alarm and process alarm.

37 UM91001A

SV+SP2

SV+SP2-O2HY

OUT2 Action

ON

OFF

PV OUT2=DE.HI

SP2+O2HY

SP2

OUT2 Action

ON

OFF

PV

Figure 3.3 Output 2 Deviation

High Alarm

Figure 3.4 Output 2 Process

Low Alarm

UM91001A

Time

Time

Time

Time

38

3 - 4 Alarm

The controller has one alarm output. There are 6 types of alarm functions and one dwell timer can be selected, and four kinds of alarm modes ( ALMD ) are available for each alarm function

( ALFN ). Besides the alarm output, the output 2 can also be configured as another alarm. But output 2 only provides 4 kinds of alarm functions and only normal alarm mode is avaiable for this alarm.

A process alarm sets two absolute trigger levels. When the process is higher than SP3, a process high alarm ( PV.HI ) occurs, and the alarm is off as the process is lower than SP3-ALHY. When the process is lower than SP3, a process low alarm ( PV.LO ) occurs and the alarm is off as the process is higher than SP3+ALHY. A process alarm is independent of set point.

A deviation alarm alerts the user when the process deviates too far from set point. When the process is higher than SV+SP3, a deviation high alarm (DE.HI) occurs and the alarm is off as the process is lower than SV+SP3-ALHY. When the process is lower than SV+SP3, a deviation low alarm (DE.LO) occurs and the alarm is off as the process is higher than SV+SP3+ALHY. Trigger level of deviation alarm is moving with set point.

A deviation band alarm presets two trigger levels relative to set point.

The two trigger levels are SV+SP3 and SV - SP3 for alarm. When the process is higher than ( SV+SP3 ) or lower than ( SV - SP3 ), a deviation band high alarm ( DB.HI ) occurs. When the process is within the trigger levels, a deviation band low alarm (DB.LO) occurs.

In the above descriptions SV denotes the current set point value for control which is different from SP1 as the ramp function is performed.

There are four types of alarm modes available for each alarm function, these are: Normal alarm, Latching alarm, Holding alarm and Latching/

Holding alarm. They are described as follows:

39 UM91001A

Normal Alarm : ALMD = NORM

When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm condition.

Latching Alarm : ALMD = LTCH

If a latching alarm is selected, once the alarm output is energized, it will remain unchanged even if the alarm condition is cleared. The latching alarm is reset when the RESET key is pressed, once the alarm condition is removed.

Holding Alarm : ALMD = HOLD

A holding alarm prevents an alarm from power up. The alarm is enabled only when the process reaches the set point value.

Afterwards, the alarm performs same function as normal alarm.

Latching / Holding Alarm : ALMD = LT.HO

A latching / holding alarm performs both holding and latching function.

The latching alarm is reset when the RESET key is pressed, once the alarm condition is removed.

Alarm Failure Transfer is activated as the unit enters failure mode.

Alarm will go on if ON is set for ALFT and go off if OFF is set for ALFT. The unit will enter failure mode when sensor break occurs or if the A-D converter of the unit fails.

3 - 5 Configure User Menu

The conventional controllers are designed with a fixed parameters' scrolling.

If you need a more friendly operation to suit your application, the vender will say " sorry " to you. The series have the flexibility for you to select those parameters which are most significant to you and put these parameters in the

front of display sequence.

SEL1~SEL8 : Selects the parameter for view and change in the user menu.

Range : LOCK, INPT, UNIT, DP, SHIF, PB, TI, TD, O1HY, CYC1, OFST,

RR, O2HY, CYC2, CPB, DB, ADDR, ALHY

When using the up-down key to select the parameters, you may not obtain all of the above parameters. The number of visible parameters is dependent on the setup condition. The hidden parameters for the specific application are also deleted from the SEL selection.

UM91001A 40

Example :

OUT2 selects DE.LO PB= 100.0 SEL1 selects INPT

SEL2 selects UNIT SEL3 selects PB SEL4 selects TI

SEL5~SEL8 selects NONE Now, the upper display scrolling becomes :

PV

3 - 6 Ramp

The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for RAMP, the unit will perform the ramping function. The ramp rate is programmed by adjusting RR. The ramping function is disabled as soon as the failure mode, the manual control mode, the auto-tuning mode or the calibration

Mode occurs.

Example without Dwell Timer

Select MINR for RAMP, selects LC for UNIT, selects 1-DP for DP,

Set RR= 10.0. SV is set to 200 LC initially, and changed to 100 LC after

30 minutes since power up. The starting temperature is 30 LC. After power

Up the process is running like the curve shown below:

PV

200

C

100

C

30

C

0 17 30 40

Time

(minutes)

Figure 3.5 RAMP Function

Note:

When the ramp function is used, the lower display will show the current ramping value. However it will revert to show the set point value as soon as the up or down key is touched for adjustment. The ramping value is initiated to process value either as power up or RR and /or set point are changed.

Setting RR to zero means no ramp function at all.

41 UM91001A

3 - 7 Dwell Timer

Alarm output can be configured as dwell timer by selecting TIMR for

ALFN . As the dwell timer is configured, the parameter SP3 is used for dwell time adjustment. The dwell time is measured in minute ranging from 0.1 to 4553.6 minutes. Once the process reaches the set point the dwell timer starts to count down until zero ( time out ). The timer relay will remain unchanged until time out. The dwell timer operation is shown as following diagram.

After time out the dwell timer will be restarted by pressing the RESET key.

The timer stops to count during the manual control mode, failure mode,

Calibration period and auto-tuning period.

PV

SP power off or touch RESET key

Time

ON

OFF

ALM

SP3

Timer starts

Figure 3.6 Dwell Timer Function

If alarm is configured as dwell timer, ALHY and ALMD are hidden.

Time

UM91001A 42

3 - 8 PV Shift

In certain applications it is desirable to shift the controller display value from its actual value.

This can be easily accomplished by using the PV shift function.

The SHIF function will alter PV only.

Here is an example. A process is equipped with a heater, a sensor and a subject to be warmed up. Due to the design and position of the components in the system, the sensor could not be placed any closer to the part. Thermal gradient ( different temperature ) is common and necessary to an extent in any thermal system for heat to be transferred from one point to another. If the difference between the sensor and the subject is 35 LC, and the desired temperature at the subject to be heated is 200 LC, the controlling value or the temperature at the sensor should be 235 LC. You should input -35 LC as to subtract 35 LC from the actual process display. This in turn will cause the controller to energize the load and bring the process display up to the set point value.

Subject

165 C

Heat

Transfer

200 C

Sensor

C

Heater

Subject

165 C

Heat

Transfer

200 C

Sensor

C

Heater

Subject

200 C

Heat

Transfer

235 C

Sensor

C

Heater

35 C temperature difference is observed

SHIF= 0

Adjust SHIF

SHIF= -35 C

Supply more heat

Figure 3.7

PV Shift Application

Display is stable

SHIF= -35 C

PV=SV

43 UM91001A

3 - 9 Digital Filter

In certain application the process value is too unstable to be read. To improve this a programmable low pass filter incorporated in the controller can be used. This is a first order filter with time constant specified by FILT parameter . The default value of FILT is 0.5 sec. before shipping. Adjust FILT to change the time constant from 0 to 60 seconds. 0 second represents no filter is applied to the input signal. The filter is characterized by the following diagram.

PV

1 sec

FILT=0

FILT=1

FILT=30

1 sec

Time

Figure 3.8

Filter Characteristics

NOTE :

The Filter is available only for PV, and is performed for the displayed value only. The controller is designed to use unfiltered signal for control even if Filter is applied. A lagged ( filtered ) signal, if used for control, may produce an unstable process.

UM91001A 44

3 - 10 Failure Transfer

The controller will enter occurs:

as one of the following conditions

1. occurs due to the input sensor break or input current below

1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is

selected .

2. occurs due to the A-D converter of the controller fails.

The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode.

Output 1 Failure Transfer, if activated, will perform :

1. If output 1 is configured as proportional control ( PB=0 ), and BPLS

is selected for O1FT, then output 1 will perform bumpless transfer.

Thereafter the previous averaging value of MV1 will be used for

controlling output 1.

2. If output 1 is configured as proportional control ( PB=0 ), and a

value of 0 to 100.0 % is set for O1FT, then output 1 will perform

failure transfer. Thereafter the value of O1FT will be used for

controlling output 1.

3. If output 1 is configured as ON-OFF control ( PB=0 ), then output 1

will transfer to off state if OFF is set for O1FT and transfer to on

state if ON is set for O1FT.

Output 2 Failure Transfer, if activated, will perform :

1. If OUT2 is configured as COOL, and BPLS is selected for O2FT,

then output 2 will perform bumpless transfer. Thereafter the previous

averaging value of MV2 will be used for controlling output 2.

2. If OUT2 is configured as COOL, and a value of 0 to 100.0 % is set

for O2FT, then output 2 will perform failure transfer. Thereafter the

value of O2FT will be used for controlling output 2.

3. If OUT2 is configured as alarm function, and OFF is set for O2FT,

then output 2 will transfer to off state, otherwise, output 2 will transfer

to on state if ON is set for O2FT.

Alarm Failure Transfer is activated as the controller enters failure mode.

Thereafter the alarm will transfer to the ON or OFF state which is determined by the set value of ALFT.

45 UM91001A

3 - 11 Auto-tuning

The auto-tuning process is performed at set point.

The process will oscillate around the set point during tuning process.

Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage.

*

*

*

The auto-tuning is applied in cases of :

Initial setup for a new process

The set point is changed substantially from the previous auto- tuning value

The control result is unsatisfactory

Operation :

1. The system has been installed normally.

2. Set the correct values for the setup menu of the unit.

But don't use a zero value for PB and TI , otherwise, the

auto-tuning program will be disabled. The LOCK parameter

should be set at NONE.

3. Set the set point to a normal operating value or a lower value if

overshooting beyond the normal process value is likely to

cause damage.

4. Press and hold until appears on the display.

5. Press for at least 5 seconds. The AT indicator will begin to

flash and the auto-tuning procedure is beginning.

NOTE :

The ramping function, if used, will be disabled once auto-tuning is proceeding.

The auto-tuning mode is disabled as soon as either failure mode

or manual control mode occurs.

UM91001D 46

Procedures:

The auto-tuning can be applied either as the process is warming

up ( Cold Start ) or as the process has been in steady state ( Warm Start ).

After the auto-tuning procedures are completed, the AT indicator will cease to flash and the unit revert to PID control by using its new PID values. The

PID values obtained are stored in the nonvolatile memory.

Auto-Tuning Error

If auto-tuning fails an ATER message will appear on the upper display in cases of :

If PB exceeds 9000 ( 9000 PU, 900.0 LF or 500.0 LC ).

or if TI exceeds 1000 seconds.

or if set point is changed during auto-tuning procedure.

Solutions to

1. Try auto-tuning once again.

2. Don't change set point value during auto-tuning procedure.

3. Don't set zero value for PB and TI.

4. Use manual tuning instead of auto-tuning. ( See section 3-12 ).

5. Touch RESET key to reset message.

3 - 12 Manual Tuning

In certain applications ( very few ) using auto-tuning to tune a process may be inadequate for the control requirement, then you can try manual tuning.

If the control performance by using auto- tuning is still unsatisfactory, the following rules can be applied for further adjustment of PID values :

47 UM91001A

ADJUSTMENT SEQUENCE

(1) Proportional Band ( PB )

(2) Integral Time ( TI )

(3) Derivative Time ( TD )

SYMPTOM

Slow Response

High overshoot or

Oscillations

Slow Response

Instability or

Oscillations

Slow Response or

Oscillations

High Overshoot

SOLUTION

Decrease PB

Increase PB

Decrease TI

Increase TI

Decrease TD

Increase TD

Table 3.2 PID Adjustment Guide

Figure 3.9 shows the effects of PID adjustment on process response.

3 - 13 Manual Control

Operation:

To enable manual control the LOCK parameter should be set with

NONE, then press for 6.2 seconds ( Hand

Control ) will appear on the display. Press for 5 seconds then the

MAN indicator will begin to flash and the lower display will show

. The controller now enters the manual control mode

. indicates output control variable for output 1, and indicates control variable for output 2. Now you can use up-down key to adjust the percentage values for the heating or cooling output.

The controller performs open loop control as long as it stays in manual control mode.

Exit Manual Control

UM91001D 48

49

PV

Set point

PV

Set point

PV

Set point

Perfect

PB too low

P action

PB too high

Time

TI too high

TI too low

Perfect

Time

TD too low

Perfect

I action

TD too high

Time

Figure 3.9 Effects of PID Adjustment

D action

UM91001A

3 - 14 Data Communication

The controllers support RTU mode of Modbus protocol for the data communication. Other protocols are not available for the series.

Two types of interface are available for Data Communication. These are RS-485 and RS-232 interface. Since RS-485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS-232, RS-485 is less sensitive to the noise and suitable for a longer distance communication. RS-485 can communicate without error over 1 km distance while RS-232 is not recommended for a distance over 20 meters.

Using a PC for data communication is the most economic way. The signal is transmitted and received through the PC communication Port ( generally RS-232 ). Since a standard PC can't support RS-485 port, a network adaptor ( such as SNA10A, SNA10B ) has to be used to convert

RS-485 to RS-232 for a PC if RS-485 is required for the data communication. But there is no need to be sad. Many RS-485 units ( up to 247 units ) can be connected to one RS-232 port, therefore a PC with 4 comm ports can communicate with 988 units. It is quite economic.

Setup

Enters the setup menu.

Select RTU for COMM . Set individual address as for those units which are connected to the same port.

Set the Baud Rate ( BAUD ), Data Bit ( DATA ), Parity Bit ( PARI ) and Stop Bit ( STOP ) such that these values are accordant with PC setup conditions.

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable should be modified for proper operation of RS-232 communication according to Section 2-9.

3 - 15 PV Retransmission

The controller can output (retransmit) process value via its retransmission terminals RE+ and RE- provided that the retransmission option is ordered. A correct signal type should be selected for COMM parameter to meet the retransmission option installed. RELO and REHI are adjusted to specify the low scale and high scale values of retransmission.

UM91001A 50

Chapter 4 Applications

4 - 1 Heat Only Control with Dwell Timer

An oven is designed to dry the products at 150 ZEL for 30 minutes and then stay unpowered for another batch. A ZEL-8100 equipped with dwell timer is used for this purpose. The system diagram is shown as follows :

Set

SP1=150.0

SP3 =30.0

19 20

C

Oven

T/C

Heater

Figure 4.1

Heat Control

Example

R

9

ZESTA

7

ZEL - 8100

4 3

OUT1

ON

Mains

Supply

Timer ( ALM ) OFF

To achieve this function set the following parameters in the setup menu.

INPT=K_TC UNIT= LC DP=1_DP

OUT1=REVR O1TY=RELY CYC1=18.0

O1FT=BPLS ALFN=TIMR ALFT=ON

Auto-Tuning is performed at 150 LC for a new oven.

51 UM91001A

4 - 2 Cool Only Control

A ZEL-8100 is used to control a refrigerator at temperature below 0 ZE. The temperature is lower than the ambient, a cooling action is required. Hence select DIRT for OUT1. Since output 1 is used to drive a magnetic contactor, O1TY selects RELY. A small temperature oscillation is tolerable, hence use ON-OFF control to reduce the over-all cost. To achieve ON-

OFF control, PB is set with zero and O1HY is set at 0.1 ZE.

Setup Summary:

INPT=PT.DN

UNIT= LC

DP=1-DP

OUT1=DIRT

O1TY=RELY

Refrigerator

RTD

Mains

Supply

User Menu:

PB = 0 ( LC )

O1HY=0.1 ( LC )

18

19 20 3

4

R

ZESTA ZEL - 8100

Figure 4.2

Cooling Control Example

UM91001A 52

4 - 3 Heat-Cool Control

An injection mold required to be controlled at 120 LC to ensure a consistent quality for the parts. An oil pipe is buried in the mold. Since plastics is injected at higher temperature ( e.g.

250 LC ), the circulation oil needs to be cooled as its temperature rises. Here is an example:

Plastics

Injection Mold

120 C

Freezer

Oil Tank

Oil

Pump

RTD

4-20 mA

OUT2

5,6

OUT1

3 4

20

19

18

INPT

Heater

Supply

R

ZESTA ZEL - 8100

Figure 4.3

Heat-Cool Control Example

53 UM91001A

The PID Heat-Cool is used for the above example. To achieve this set the following parameters in the Setup Menu:

INPT=PT.DN

UNIT= LC

DP= 1-DP

OUT1=REVR

O1TY=RELY

CYC1=18.0 (sec.)

O1FT=BPLS

OUT2=COOL

O2TY=4-20

O2FT=BPLS

Adjust SV at 120.0 LC , CPB at 125 ( % ) and DB at -4.0 (%).

Apply Auto-tuning at 120 LC for a new system to get an optimal PID values. See Section 3-11.

Adjustment of CPB is related to the cooling media used. If water is used as cooling media instead of oil, the CPB is set at 250 (%). If air is used as cooling media instead of oil, the CPB is set at 100 (%). Adjustment of DB is dependent on the system requirements. More positive value of DB will prevent unwanted cooling action, but will increase the temperature overshoot, while more negative value of DB will achieve less temperature overshoot, but will increase unwanted cooling action.

UM91001A 54

Chapter 5 Calibration

Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be lost. Do not attempt recalibration unless you have appropriate calibration equipment. If calibration data is lost, you will need to return the controller to your supplier who may charge you a service fee to re-calibrate the controller.

Entering calibration mode will break the control loop. Make sure

that if the system is allowable to apply calibration mode.

Equipments needed before calibration:

(1) A high accuracy calibrator ( Fluke 5520A Calibrator

recommended ) with following functions:

0 - 100 mV millivolt source with A0.005 % accuracy

0 - 10 V voltage source with A0.005 % accuracy

0 - 20 mA current source with A0.005 % accuracy

0 - 300 ohm resistant source with A0.005 % accuracy

(2) A test chamber providing 25 ZE - 50 ZE temperature range

(3) A switching network ( SWU16K, optional for automatic

calibration )

(4) A calibration fixture equipped with programming units ( optional

for automatic calibration )

(5) A PC installed with calibration software ZE-Net and Smart

Network Adaptor SNA10B ( optional for automatic calibration )

The calibration procedures described in the following section are a step by step manual procedures.

Since it needs 30 minutes to warm up an unit before calibration, calibrating the unit one by one is quite inefficient. An automatic calibration system for small quantity as well as for unlimited quantity is available upon request.

55 UM91001A

Manual Calibration Procedures

Step 1.

* Perform step 1 to enter calibration mode.

Set the Lock parameter to the unlocked condition

( LOCK=NONE).

Press and hold the scroll key until appears on the display, then release the scroll key.

Press the scroll key for 2 seconds then release,the display will show and the unit enters calibration mode .

* Perform step 2 to calibrate Zero of A to D converter and step 3 to calibrate gain of A to D converter.

Step 2.

Short the thermocouple inpt terminals , then press scroll key for at least 5 seconds. The display will blink a moment and a new value is obtained. Otherwise, if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.

Step 3.

Press scroll key until the display shows . Send a 60mV signal to the thermocouple input terminals in correct polarity.

Press scroll key for at least 5 seconds. The display will blink a moment and a new value is obtained. Otherwise, if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.

* Perform both steps 4 and 5 to calibrate RTD function ( if required ) for input .

UM91001D 56

Step 4.

Press scroll key until the display shows . Send a 100 ohms signal to the RTD input terminals according to the connection shown below:

100 ohms

ZEL-4100

ZEL-8100

18

19

20

ZEL-7100

12

13

14

ZEL-9100

4

5

6

Figure 5.1 RTD Calibration

Press scroll key for at least 5 seconds . The display will blink a moment, otherwise the calibration fails.

Step 5.

Press scroll key and the display will show . Change the ohm's value to 300 ohms. Press scroll key for at least 5 seconds. The display will blink a moment and two values are obtained for RTDH and RTDL ( step 4 ). Otherwise, if the display didn't blink or if any value obtained for RTDH and

RTDL is equal to -199.9 or 199.9 , then the calibration fails.

* Perform step 6 to calibrate offset of cold junction compensation, if required.

Step 6.

Setup the equipments according to the following diagram for calibrating the cold junction compensation. Note that a

K type thermocouple must be used.

57 UM91001D

5520A

Calibrator

K-TC

ZEL-4100

ZEL-8100

ZEL-7100

K+

19

20

13

14

K -

Stay at least 20 minutes in still-air room room temperature 25 A 3 LC

ZEL-9100

5

6

Figure 5.2

Cold Junction Calibration Setup

The 5520A calibrator is configured as K type thermocouple output with internal compensation.

Send a 0.00 LC signal to the unit under calibration.

The unit under calibration is powered in a still-air room with temperature 25A3 ZE. Stay at least 20 minutes for warming up. Perform step 1 stated above, then press scroll key until the display shows . Press up/down key to obtain40.00.

Press scroll key for at least 5 seconds. The display will blink a moment and a new value is obtained. Otherwise, if the display didn't blink or if the obtained value is equal to -5.00 or

40.00, then the calibration fails.

Step 7.

* Perform step 7 to calibrate gain of cold junction compensation if required.

Setup the equipments same as step 6. The unit under calibration is powered in a still-air room with temperature 50A3 ZE. Stay at least 20 minutes for warming up. The calibrator source is set at

0.00 ZE with internal compensation mode.

UM91001D 58

Perform step 1 stated above, then press scroll key until the display shows . Press scroll key for at least 5 seconds.

The display will blink a moment and a new value is obtained.

Otherwise, if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.

This setup is performed in a high temperature chamber, hence

it is recommended to use a computer to perform the procedures.

* Input modification and recalibration procedures for a linear voltage or a linear current input:

1. Remove R60(3.3K) and install two 1/4 W resistors RA and RB

on the control board with the recommended values specified

in the following table.

The low temperature coefficient resistors should be used for

RA and RB.

Input Function

T/C, RTD, 0~60mV

0 ~ 1 V

0 ~ 5V, 1 ~ 5V

0 ~ 10 V

0~20mA, 4~20mA

RA

X

61.9K

324K

649K

39W

RB

X

3.92K

3.92K

3.92K

3.01W

R60

3.3K

X

X

X

X

2. Perform Step 1 and Step 2 to calibrate the linear input zero.

3. Perform Step 3 but send a span signal to the input terminals

instead of 60mV. The span signal is 1V for 0~1V input, 5V for

0~5V or 1~5V input, 10V for 0~10V input and 20mA for

0~20mA or 4~20mA input.

* Final step

Step 8.

Set the LOCK value to your desired function.

59 UM91001D

Chapter 6 Specifications

Power

90 - 250 VAC, 47 - 63 Hz, 12VA, 5W maximum

11 - 26 VAC / VDC, 12VA, 5W maximum

Input

Resolution : 18 bits

Sampling Rate : 5 times / second

Maximum Rating : -2 VDC minimum, 12 VDC maximum

( 1 minute for mA input )

Temperature Effect : A1.5uV/ ZE for all inputs except

mA input

A3.0uV/ ZE for mA input

Sensor Lead Resistance Effect :

T/C: 0.2uV/ohm

3-wire RTD: 2.6 LC/ohm of resistance difference of two

leads

2-wire RTD: 2.6 LC/ohm of resistance sum of two leads

Burn-out Current :

200 nA

Common Mode Rejection Ratio ( CMRR ): 120dB

Normal Mode Rejection Ratio ( NMRR ): 55dB

Sensor Break Detection :

Sensor open for TC, RTD and mV inputs,

Sensor short for RTD input below 1 mA for 4-20 mA input, below 0.25V for 1 - 5 V input, unavailable for other inputs.

Sensor Break Responding Time :

Within 4 seconds for TC, RTD and mV inputs,

0.1 second for 4-20 mA and 1 - 5 V inputs.

UM91001B 60

Characteristics:

Type

J

K

T

E

Range

-120 C - 1000 C

( -184 F - 1832 F )

-200 C 1370 C

( -328 F - 2498 F )

-250 C - 400 C

( -418 F - 752 F )

-100 C - 900 C

( -148 F - 1652 F )

B

0 C - 1800 C

( 32 BF - 3272 BF )

R

S

N

L

PT100

( DIN )

PT100

( JIS ) mV mA

V

0 C - 1767.8 C

( 32 BF - 3214 BF )

0 C - 1767.8 C

( 32 BF - 3214 BF )

-250 C - 1300 C

( -418 F - 2372 F )

-200 C - 900 C

( -328 F - 1652 F )

-210 C - 700 C

( -346 F - 1292 F )

-200 C - 600 C

( -328 F - 1112 F )

-8mV - 70mV

-3mA - 27mA

-1.3V - 11.5V

A2 LC

A2 LC

A2 LC

A2 LC

A0.4 LC

A0.4 LC

A0.05 %

A0.05 %

A0.05 %

Accuracy

@ 25 C

A2 LC

A2 LC

A2 LC

A2 LC

A2 LC

( 200 C -

1800 C )

Input

Impedance

2.2 M

2.2 M

2.2 M

2.2 M

2.2 M

2.2 M

2.2 M

2.2 M

2.2 M

1.3 K

1.3 K

2.2 M

70.5

650 K

61 UM91001A

Output 1 / Output 2

Relay Rating : 2A/240 VAC, life cycles 200,000 for

resistive load

Pulsed Voltage : Source Voltage 5V,

current limiting resistance 66 .

Linear Output Characteristics

Type

4~20 mA

Zero

Tolerance

3.6~4 mA

0~20 mA

0 ~ 5 V

1 ~ 5 V

0 ~ 10 V

0 mA

0 V

0.9 ~ 1 V

0 V

Span

Tolerance

20~21 mA

20~21 mA

5 ~ 5.25 V

5 ~ 5.25 V

10 ~10.5 V

Linear Output


Output Regulation : 0.02 % for full load change

Output Settling Time : 0.1 sec. ( stable to 99.9 % )

Isolation Breakdown Voltage : 1000 VAC

Temperature Effect : A0.01 % of SPAN / LC

Triac ( SSR ) Output

Rating : 1A / 240 VAC

Inrush Current : 20A for 1 cycle

Min. Load Current : 50 mA rms

Max. Off-state Leakage : 3 mA rms

Max. On-state Voltage : 1.5 V rms

Insulation Resistance : 1000 Mohms min. at 500 VDC

Dielectric Strength : 2500 VAC for 1 minute

Load

Capacity

500W max.

500W max.

10 K

W

min.

10 KW min.

10 KW min.

UM91001B 62

DC Voltage Supply Characteristics ( Installed at Output 2 )

Type Tolerance Max. Output Current Ripple Voltage Isolation Barrier

20 V A1 V 25 mA 0.2 Vp-p 500 VAC

12 V A0.6 V 40 mA 0.1 Vp-p 500 VAC

5 V A0.25 V 80 mA 0.05 Vp-p 500 VAC

Alarm

Alarm Relay : Form C Rating

2A/240VAC, life cycles 200,000 for resistive load.

Alarm Functions : Dwell timer, Deviation High / Low Alarm,

Deviation Band High / Low Alarm,

PV High / Low Alarm,

Alarm Mode : Normal, Latching, Hold, Latching / Hold.

Dwell Timer : 0.1 - 4553.6 minutes

Data Communication

Interface : RS-232 ( 1 unit ), RS-485 ( up to 247 units )

Protocol : Modbus Protocol RTU mode

Address : 1 - 247

Baud Rate : 2.4 ~ 38.4 Kbits/sec

Data Bits : 7 or 8 bits

Parity Bit : None, Even or Odd

Stop Bit : 1 or 2 bits

Communication Buffer : 160 bytes

Analog Retransmission

Output Signal : 4-20 mA, 0-20 mA, 0 - 5V,

1 - 5V, 0 - 10V


Accuracy : A0.05 % of span A0.0025 %/ LC

Load Resistance :

0 - 500 ohms ( for current output )

10 K ohms minimum ( for voltage output )

Output Regulation : 0.01 % for full load change

63 UM91001D

Output Settling Time : 0.1 sec. (stable to 99.9 % )

Isolation Breakdown Voltage : 1000 VAC min.

Integral Linearity Error : A0.005 % of span

Temperature Effect : A0.0025 % of span/ LC

Saturation Low : 0 mA ( or 0V )

Saturation High : 22.2 mA ( or 5.55V, 11.1V min. )

Linear Output Range :0-22.2mA(0-20mA or 4-20mA)

0-5.55V ( 0 - 5V, 1 - 5V )

0 - 11.1 V ( 0 - 10V )

User Interface

Dual 4-digit LED Displays

Keypad : 4 keys

Programming Port : For automatic setup, calibration and testing

Communication Port : Connection to PC for supervisory control

Control Mode

Output 1 : Reverse ( heating ) or direct ( cooling ) action

Output 2 : PID cooling control, cooling P band 50~300%

of PB, dead band -36.0 ~ 36.0 % of PB

ON-OFF : 0.1 - 90.0 ( LF ) hysteresis control ( P band = 0 )

P or PD : 0 - 100.0 % offset adjustment

PID : Fuzzy logic modified

Proportional band 0.1 ~ 900.0 LF.

Integral time 0 - 1000 seconds

Derivative time 0 - 360.0 seconds

Cycle Time : 0.1 - 90.0 seconds

Manual Control : Heat (MV1) and Cool (MV2)

Auto-tuning : Cold start and warm start

Failure Mode : Auto-transfer to manual mode while

sensor break or A-D converter damage

Ramping Control : 0 - 900.0 LF/minute or

0 - 900.0 LF/hour ramp rate

Digital Filter

Function : First order

Time Constant : 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60

seconds programmable

UM91001A 64

Environmental & Physical

Operating Temperature : -10 ZE to 50 ZE

Storage Temperature : -40 ZE to 60 ZE

Humidity : 0 to 90 % RH ( non-condensing )

Altitude: 2000m maximum

Pollution: Degree 2

Insulation Resistance : 20 Mohms min. ( at 500 VDC )

Dielectric Strength : 2000 VAC, 50/60 Hz for 1 minute

Vibration Resistance : 10 - 55 Hz, 10 m/s for 2 hours

2

2

Shock Resistance : 200 m/s ( 20 g )

Moldings : Flame retardant polycarbonate

Dimensions :

ZEL-4100 ----- 96mm(W) X 96mm(H) X 65mm(D),

53 mm depth behind panel

ZEL-7100 ----- 72mm(W) X 72mm(H) X 78.2mm(D),


ZEL-8100 ----- 48mm(W) X 96mm(H) X 80mm(D),


ZEL-9100 ----- 48mm(W) X 48mm(H) X 116mm(D),


Weight : ZEL-4100 ----- 250 grams

ZEL-7100 ----- 200 grams

ZEL-8100 ----- 210 grams

ZEL-9100 ----- 150 grams

Approval Standards

Safety : UL61010C-1

CSA C22.2 No.24-93

EN61010-1 ( IEC1010-1 )

Protective Class :

IP65 for panel with additional option

IP50 for panel without additional option

IP20 for terminals and housing with protective cover.

All indoor use.

EMC: EN61326

65 UM91001D

Chapter 7 Modbus Communications

This chapter specifies the Modbus Communications protocol as

RS-232 or RS-485 interface module is installed. Only RTU mode is supported. Data is transmitted as eight-bit binary bytes with 1 start bit,

1 stop bit and optional parity checking (None, Even or Odd). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800 and 38400.

7 - 1 Functions Supported

Only function 03, 06 and 16 are available for this series of controllers.

The message formats for each function are described as follows:

Function 03: Read Holding Registers

Query ( from master )

Slave address (0-255)

Function code (3)

Starting address of register Hi (0)

Starting address of register Lo (0-79,

128-131)

No. of words Hi (0)

No. of words Lo (1-79)

CRC16 Hi

CRC16 Lo

Response ( from slave )

Byte count

Data 1 Hi

Data 1 Lo

Data 2 Hi

Data 2 Lo

CRC16 Hi

CRC16 Lo

Function 06: Preset single Register



Function code (6)

Register address Hi (0)

Register address Lo (0-79, 128-131)

Data Hi

Data Lo

CRC16 Hi

CRC16 Lo


UM91001B 66

Function 16: Preset Multiple Registers



Function code (16)

Starting address of register Hi (0)

Starting address of register Lo (0-79,

128-131)

No. of words Hi (0)

No. of words Lo (1-79)

Byte count (2-158)

Data 1 Hi

Data 1 Lo

Data 2 Hi

Data 2 Lo

CRC16 Hi

CRC16 Lo


CRC16 Hi

CRC16 Lo

67 UM91001B

7 - 2 Exception Responses

If the controller receives a message which contains a corrupted character (parity check error, framing error etc.), or if the CRC16 check fails, the controller ignores the message.

However, if the controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows: slave address +offset function code + exception code + CRC16 Hi + CRC16 Lo

Where the offset function code is obtained by adding the function code with 128 (ie. function 3 becomes H'83), and the exception code is equal to the value contained in the following table:

Exception Code

1

2

3

Name

Bad function code

Illegal data address

Illegal data value

Cause

Function code is not supported by the controller

Register address out of range

Data value out of range or attempt to write a read-only or protected data

UM91001A 68

7 - 3 Parameter Table

17

18

19

20

21

13

14

15

16

22

23

24

25

26

27

28

29

9

10

11

12

7

8

5

6

Register

Address

0

1

2

3

4

Parameter

Notation

Parameter

SP1

SP2

Set point 1

Set point 2

SP3

LOCK

INPT

Set point 3

Lock code

Input sensor selection

UNIT

DP

Measuring unit

Decimal point position

INLO

INHI

Low scale value for linear input

High scale value for linear input

SP1L

SP1H

Low limit of SP1

High limit of SP1

SHIF

FILT

PV shift value

Filter time constant

DISP

PB

Display form ( for C21 )

P ( proportional ) band

Integral time TI

TD

OUT1

O1TY

O1FT

O1HY

CYC1

OFST

RAMP

RR

OUT2

Derivative time

Output 1 function


Output 1 failure transfer

Output 1 ON-OFF hysteresis

Output 1 cycle time

Offset value for P control

Ramp function

Ramp rate

Output 2 function

RELO Retransmission low scale value

O2TY

O2FT


Output 2 failure transfer

O2HY Output 2 ON-OFF hysteresis

69 UM91001D

65535

65535

*4

*4

*4

*4

*4

65535

65535

*5

Scale

High

*4

*7

*6

65535

65535

65535

6553.5

65535

65535

4553.6

*5

6553.5

6553.5

65535

*5

65535

*4

65535

4553.6

*5

0

0.0

0

0

*4

*4

*4

0

0

*5

*4

*4

0

0

Scale

Low

*4

*7

*6

0

0

-1999.9

*5

0.0

0.0

*4

0

0

*5

0

-1999.9

*5

Notes

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

51

52

53

54

46

47

48

49

50

43

44

45

39

40

41

42

55

56

57

58

59

60

Register

Address

30

31

32

33

34

35

36

37

38

Parameter

Notation

CYC2

CPB

DB

ALFN

REHI

ALMD

STOP

SEL1

SEL2

SEL3

SEL4

SEL5

SEL6

SEL7

ALHY

ALFT

COMM

ADDR

BAUD

DATA

PARI

SEL8

ADLO

ADHI

RTDL

RTDH

CJLO

CJHI

DATE

SRNO

HOUR

Output 2 cycle time

Cooling P band

Heating-cooling dead band

Alarm function

Retransmission high scale value

Alarm opertion mode

Alarm hysteresis

Alarm failure transfer

Communication function

Address

Baud rate

Data bit count

Parity bit

Stop bit count

Selection 1

Selection 2

Selection 3

Selection 4

Selection 5

Selection 6

Selection 7

Selection 8

Parameter mV calibration low coefficient mV calibration high coefficient

RTD calibration low coefficient

RTD calibration high coefficient

Cold junction calibration low coefficient

Cold junction calibration high coefficient

Date Code

Serial Number

Working hours of the controller

65535

65535

65535

65535

65535

65535

65535

4553.6

65535

65535

65535

65535

65535

65535

65535

Scale

High

6553.5

65535

4553.6

65535

*4

65535

*5

65535

4553.6

4553.6

4553.6

455.36

4553.6

65535

65535

65535

0

0

0

0

0

0

0

-1999.9

0

0

0

0

0

0

0

0

*4

0

*5

0

Scale

Low

0.0

0

-1999.9

-1999.9

-1999.9

-1999.9

-199.99

-1999.9

0

0

0

Notes

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

UM91001D 70

Register

Address

61

62

63

64, 128

65, 129

Parameter

Notation

BPL1

BPL2

CJCL

PV

SV

Parameter

Bumpless transfer of OP1

Bumpless transfer of OP2

Cold junction signal low

Process value

Current set point value

66

130

67

131

MV1

MV2

OP1 control output value

OP2 control output value

77

78

79

73

74

75

76

68

69

70

71, 140

72

TIMER

EROR

MODE

PROG

CMND

JOB1

JOB2

JOB3

CJCT

Remaining time of dwell timer

Error code *1

Operation mode & alarm status *2

Program code *3

Command code

Job code

Job code

Job code

Cold Junction Temperature

Reserved

Reserved

Reserved

*1: The error code is show in the first column of Table A.1.

*2: Definition for the value of MODE register

H'000X = Normal mode

H'010X = Calibration mode

H'020X = Auto-tuning mode

H'030X = Manual control mode

H'040X = Failure mode

H'0X00 = Alarm status is off

H'0x01 = Alarm status is on

The alarm status is shown in

MV2 instead of MODE for models C21 and C91.

Scale

Low

0.00

0.00

0.000

*4

*4

0.00

0.00

-1999.9

0

0

0.00

0

0

0

0

-199.99

0

0

0

4553.6

65535

65535

655.35

65535

65535

65535

65535

455.36

65535

65535

65535

Scale

High

655.35

655.35

65.535

*4

*4

Notes

655.35

R

R

R

R

R

Read only, unless in manual control

655.35

Read only, unless in manual control

R/W

R/W

R/W

R/W

R

R

R

R

R

R

R

R

71 UM91001D

*3: The PROG Code is defined in the following table:

Model No.

Conditions

ZEL-9100 ZEL-8100 ZEL-4100 ZEL-7100 C21 C91

PROG Code 6.XX

11.XX

12.XX

13.XX

33.XX

34.XX

Where XX denotes the software version number. For example:

PROG=34.18 means that the controller is C91 with software version 18.

*4: The scale high/low values are defined in the following table for SP1,

INLO, INHI, SP1L, SP1H, SHIF, PV, SV, RELO and REHI:

Non-linear

input

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

Scale low

Scale high

-1999.9

4553.6

-19999

45536

-1999.9

4553.6

-199.99

455.36

-19.999

45.536

*5: The scale high/low values are defined in the following table for PB,

O1HY, RR, O2HY and ALHY:

Conditions

Non-linear

input

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

Scale low

Scale high

0.0

6553.5

0

65535

0.0

6553.5

0.00

655.35

0.000

65.535

*6: The scale high/low values are defined in the following table for SP3:

Conditions

ALFN=1

(TIMR)

Non-linear

input

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

Scale low

Scale high

-1999.9

4553.6

-1999.9

4553.6

-19999

45536

-1999.9

4553.6

-199.99

455.36

-19.999

45.536

*7: The scale high/low values are defined in the following table for Sp2:

For C21 and C91.

Conditions

OUT2=1

(TIMR)

Non-linear

input

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

Scale low

Scale high

-1999.9

4553.6

-1999.9

4553.6

-19999

45536

-1999.9

4553.6

-199.99

455.36

-19.999

45.536

UM91001D 72

For ZEL-9100, ZEL-8100, ZEL-7100 and ZEL-4100

Conditions

Non-linear

input

Linear input

DP = 0

Linear input

DP = 1

Scale low

Scale high

-1999.9

4553.6

-19999

45536

-1999.9

4553.6

Linear input

DP = 2

-199.99

455.36

Linear input

DP = 3

-19.999

45.536

7 - 4 Data Conversion

The word data are regarded as unsigned ( positive ) data in the

Modbus message. However, the actual value of the parameter may be negative value with decimal point. The high/low scale values for each parameter are used for the purpose of such conversion.

Let M = Value of Modbus message

A = Actual value of the parameter

SL = Scale low value of the parameter

SH = Scale high value of the parameter

The conversion formulas are as follows:

M =

65535

SH-SL

( A - SL )

A =

SH-SL

65535

M + SL

7 - 5 Communication Examples :

Example 1: Down load the default values via the programming port

The programming port can perform Modbus communications regardless of the incorrect setup values of address, baud, parity, stop bit etc. It is especially useful during the first time configuration for the controller. The host must be set with 9600 baud rate, 8 data bits, even parity and 1 stop bit.

The Modbus message frame with hexadecimal values is shown as follows:

73 UM91001A

01 10 00 00

Addr. Func. Starting Addr.

00 34

No. of words

68 4F

Bytes SP1=25.0

19 4E

SP2=10.0

83 4E

SP3=10.0

83

00

LOCK=0

00 00

INPT=1

01 00

UNIT=0

00 00

DP=1

01 4D

INLO=-17.8

6D 51 C4

INHI=93.3

4D

SP1L=-17.8

6D 63

SP1H=537.8

21 4E

SHIF=0.0

1F 00 02 00

FILT=2 DISP=0

00 00

PB=10.0

64

00

TI=100

64 00 FA

TD=25.0

00

OUT1=0

00 00

O1TY=0

00 4E

O1FT=0

1F 00 01

O1HY=0.1

00 B4

CYC1=18.0

00 FA

OFST=25.0

00

RAMP=0

00 00

RR=0.0

00 00 02

OUT2=2

4E 1F

RELO=0.0

00

O2TY=0

00 4E 1F

O2FT=0

00 01

O2HY=0.1

00 B4

CYC2=18.0

00 64

CPB=100

4E

DB=0

1F

00

ALFN=2

02 52 07

REHI=100.0

00

ALMD=0

00 00 01

ALHY=0.1

00

ADDR=1

01 00 02

BAUD=2

00

DATA=1

01 00

PARI=0

00

00

ALFT=0

00 00 01

COMM=1

00

STOP=0

00 00

SEL1=2

02

00

SEL2=3

03 00 04

SEL3=4

00

SEL4=6

06 00

SEL5=7

07 00

SEL6=8

08 00

SEL7=10

0A

00

SEL8=17

11 Hi Lo

CRC16

UM91001D 74

Example 2: Read PV, SV, MV1 and MV2.

Send the following message to the controller via the COMM port or programming port:

03 00

H'40

H'80

00 04 Hi Lo

Addr.

Func.

Starting Addr.

No. of words CRC16

Query

06 00 H'48 H'68 H'25

Addr.

Func.

Register Addr.

Example 4: Enter Auto-tuning Mode

Query

06 00 H'48

Data Hi/Lo

H'68 H'28

Addr.

Func.

Register Addr.

Example 5: Enter Manual Control Mode

Query

06 00 H'48

Data Hi/Lo

H'68 H'27

Hi

CRC16

Lo

Hi

CRC16

Lo

Hi Lo

Addr.

Func.

Register Addr.

Example 6: Read All Parameters

Query

03 00 00

Data Hi/Lo

00 H'50 Hi

CRC16

Lo

Addr.

Func.

Starting Addr.

No. of words CRC16

Example 7: Modify the Calibration Coefficient

Preset the CMND register with 26669 before attempting to change the calibration coefficient.

06 00 H'48 H'68 H'2D Hi Lo

Addr.

Func.

Register Addr.

Data Hi / Lo CRC16

75 UM91001D

Table A.1 Error Codes and Corrective Actions

Error

Code

Display

Symbol

Error Description

4

Illegal setup values been used:

Before COOL is used for OUT2,

DIRT ( cooling action ) has already been used for OUT1, or PID mode is not used for OUT1 ( that is PB

= 0, and / or TI = 0 )

10

11

14

15

Communication error: bad function code

Communication error: register address out of range

Communication error: attempt to write a read-only data or a protected data

Communication error: write a value which is out of range to a register

Corrective Action

Check and correct setup values of

OUT2, PB, TI and OUT1. IF OUT2 is required for cooling control, the control should use PID mode ( PB

= 0, TI = 0 ) and OUT1 should use reverse mode (heating action)

, otherwise, don't use OUT2 for cooling control.

Correct the communication software to meet the protocol requirements.

Don't issue an over-range register address to the slave.

Don't write a read-only data or a protected data to the slave.

Don't write an over-range data to the slave register.

26

Fail to perform auto-tuning function

1.The PID values obtained after

auto-tuning procedure are out

of range. Retry auto-tuning.

2.Don't change set point value

during auto-tuning procedure.

3.Use manual tuning instead of

auto-tuning.

4. Don't set a zero value for PB.

5. Don't set a zero value for TI.

6. Touch RESET key

Return to factory for repair.

29

30

39

40

EEPROM can't be written correctly

Cold junction compensation for thermocouple malfunction

Input sensor break, or input current below 1 mA if 4-20 mA is selected, or input voltage below

0.25V if 1 - 5V is selected

A to D converter or related component(s) malfunction


Replace input sensor.


UM91001A 76

WARRANTY

ZESTA ENGINEERING LTD, is pleased to offer suggestions on the use of its various products.

However, ZESTA makes no warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The selection, application or use of

ZESTA products is the Purchaser's responsibility. No claims will be allowed for any damages or losses, whether direct, indirect, incidental, special or consequential. Specifications are subject to change without notice. In addition, ZESTA reserves the right to make changes-without notification to Purchaser-to materials or processing that do not affect compliance with any applicable specification. ZESTA products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use. An extended period is available with extra cost upon request. ZESTA’S sole responsibility under this warranty, at

ZESTA’S option, is limited to replacement or repair, free of charge, or refund of purchase price within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuse or abuse.

RETURNS

No products return can be accepted without a completed Return Material Authorization

( RMA ) form.

77 UM91001A


212 Watline Avenue

Mississauga, Ontario, Canada

L4Z 1P4

Voice: (905) 568 - 3100

Fax: (905) 568 - 3131

Website: www.zesta.com

Email: [email protected]

No results