Auber Instruments SYL-2381-SSR Instruction Manual

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SYL-2381-SSR PID TEMPERATURE CONTROLLER

INSTRUCTION MANUAL

Version 1.0 (Feb, 2018)

Caution

• This controller is intended to control equipment under normal operating

conditions. If failure or malfunction of it could lead to an abnormal operating condition that could cause personal injury or damage to the equipment or other property, other devices (limit or safety controls) or systems (alarm or supervisory) intended to warn of or protect against failure or malfunction of the controller must be incorporated into and maintained as part of the control system.

• Installing the rubber gasket supplied will protect the controller front panel from

dust and water splash (IP54 rating). Additional protection is needed for higher IP rating.

• This controller carries a 90-day warranty. This warranty is limited to the

controller only.

1. Features

• The PID control with artificial intelligent enhancement for precision temperature

control.

• Auto-tuning function can find the best PID parameter automatically.

• ON/OFF control mode for refrigerator, motor and solenoid valve control

application.

• SSR output control: 6V DC.

• Bumpless transfer between Auto and Manual control mode.

• Optional serial communication port (RS-485/Modbus_RTU).

• The output can be set for SSR output control or relay contactor control by the

user.

• Support 10 different types of commonly used temperature sensor inputs.

2. Specifications

Input type

Thermocouple (TC): K, E, S, R, J, T, B, WRe3/25 RTD (Resistance temperature detector): Pt100, Cu50

Input range

See Table 2

Display

Dual lines, four digits, ° F or °C

Display resolution

1° C, 1°F; or 0.1° C, 0.1° F with Pt100

Accuracy

± 0.2% or ± 1 unit of full input range

Control mode

PID, manual

Output mode

Relay contact: 3 A at 240 VAC. SSR output: 6V DC.

Alarm

Process high/low alarm

Power consumption

< 2 Watt

Power supply

85 ~ 260 VAC / 50 ~ 60 Hz or 85 ~ 260 VDC

Communication (optional)

RS-485 (Modbus_RTU)

Operating condition

0 ~ 50° C, ≤ 85% RH

Mounting cutout

45 x 45 mm

Dimension

48 x 48 x 82 mm (1/16 DIN)

3. Front Panel and Operation

2345

Figure 1. Front panel

① AL1: Relay J1 output indicator.

AT: ON for manual mode. Blinking during auto-tuning process. OUT: main output indicator.

② Up key: value increment / select the next parameter. ③ Down key: value decrement / select previous parameter. ④ Shift key: start auto tuning / shift digit / check output percentage* ⑤ Set key: confirm change / switch between Manual and Auto mode. ⑥ PV window: measured temperature, or, Process Value (PV) ⑦ SV window: set temperature, or, Set Value (SV)

Note *: Press Shift key momentarily to change the SV window from set temperature to real-time output percentage. It will be display as “oXXX”. For example, “o 90” means the current output percentage is 90%. Press Shift key again to switch back to set temperature.

4. Terminal Wiring (back view)

6 7

8 9 10

4 5

SSR

+ -

RTD

Power

AC/DC

85-260V

RRW

(Optional

)

RS485

A+

B-

Figure 2. Terminal assignment of SYL-2381-SSR.

Instruction Manual

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4.1 Sensor connection

4.1.1 Thermocouple

The thermocouple should be connected to terminals 9 and 10. Make sure that polarity is correct. There are two commonly used color codes for the K type thermocouple. US color code uses yellow (positive) and red (negative). Imported DIN color code uses red (positive) and green/blue (negative). The temperature reading will decrease as temperature increases if the connection is reversed.

4.1.2 RTD sensor

For a three-wire RTD with standard DIN color code, the two red wires should be connected to the terminals 9 and 10. The white wire should be connected to terminal 8. For a two-wire RTD, the wires should be connected to terminals 8 and

9. Jump a wire between terminals 9 and 10.

For PT100 sensor, set Input Sensor Type, Inty, to “P100” (1 degree resolution) or “P10.0” (0.1 degree resolution).

4.2 Power to the controller

The power cables should be connected to terminals 1 and 2. Polarity does not matter. It can be powered by 85 - 260 V AC or DC power source. Neither a transformer nor jumper is needed to wire it up. For the sake of consistency with the wiring example described later, we suggest you connect the hot wire to terminal 2 and neutral to 1. Since the controller is in a plastic shell, ground wire is unnecessary.

4.3 Output connection

Three control output options are offered by this controller: (1) The SSR control output provides an 6V DC signal. (2) J1 relay output can be used to turn on a contactor or a solenoid valve. It can also drive a small heater directly if the heater draws less 3 Ampere.

4.3.1 Connecting the load through SSR

Connect terminal 7 to the negative input and terminal 6 to the positive input of the SSR. Set the Control Output Mode (outy) to 1, 2, or 5 depending on the control mode to be used. Then set the Main Output Mode (Coty) to “SSR”. See Figure 11 for an example. Please note that the “0-20” or “4-20” options are not available on this model.

4.3.2 Drive the load through J1 relay

Assuming the controller is powered by a 120 V AC source and the contactor has a 120 V AC coil, jump a wire between terminal 2 and 4. Connect terminal 5 to one lead of the coil and terminal 1 to the other lead of the coil. Set the system Control Output Mode (outy) to 3 or 4 depending on the control mode to be used. Please see Figure 10 for an example.

4.4 Note for first time users

For first time users with no prior experience with PID controllers, the following notes may prevent you from making a few common mistakes.

4.4.1 Power to the heater does not flow through terminal 4 and 5 of the controller.

The controller consumes less than 2 watts of power. It only provides a control signal to the relay. Therefore, 20 gauge wires are sufficient for providing power to terminal 1 and 2. Thicker wires may be more difficult to install.

4.4.2 The J1 relay is “dry single pole switch”. It does not provide power by itself. Figure 10 shows how the J1 relay is wired to pass the 120 V AC power to drive an external contactor which requires 120 V AC for its coil. If the coil of the contactor requires a different voltage than the power supplied to the controller, an additional power source will be needed.

4.4.3 SSR output power does not come from the input of the SSR. The output of the SSR is a single pole switch between terminal 1 and 2 of the SSR. The input of the SSR is for control, or triggering, the SSR. (Please note we are talking about the SSR itself, not the SSR control output of the controller). Figure 11 shows how the SSR output should be wired. When switching a North American 240VAC power, the heater will be live even when the SSR is off. Users should install a double pole mechanical switch to the power input.

5. Parameter Settings

For safety reasons, control parameters are divided into three groups with different pass codes. You should only give the code to those who have the responsibility and knowledge of how to properly change it. Code 0089 contains parameters for system configuration that may need to be changed during the initial set up. Code 0036 contains parameters for tuning the control performance. Code 0001 is for changing set temperature and alarm settings.

5.1 System configuration parameters (accessed by code 0089) The system configuration parameters are listed in Table 1. To change the parameters, press SET key briefly, enter the code “0089” and press SET key again. The procedures to change system parameters are shown in the flow chart in Figure 3.

Operation Mode

0089

Enter Code

Parameter Display

Control output mode

inty

XXXX

outy

psb

Main output mode

Input offset

SET SET

SET

Control function

SET

corf

Display unit(C/F)

end

SET

Input sensor type

XXXX

SET

XXXX

coty

SET

Hysteresis band

SET

Unit ID

SET

XXXX

baud

Baud rate

SET

Figure 3. System parameters setup flow chart.

(1) Press SET key to enter setting mode;

(2) Press >, V, or ∧ key to adjust parameters;

(3) Press SET key to confirm;

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(4) Press V or ∧ key to select the new parameter and repeat step 2 and 3.

(5) Go to “End”, press SET key to exit parameter setting mode.

Table 1. System configuration parameters.

Code

Description

Setting Range

Initial

Note

Inty

Input Sensor Type

See Table 2

outy

Control Output

Mode

1, 2, 3, 4, 5, 6

Coty

coty

Main Output Mode

SSR,

0 - 20 mA (does not

apply),

4 - 20 mA (does not

apply)

SSR

Hysteresis Band

0 ~ 9999

PSb

Input Offset

-100 ~ 100 (deg.)

Control Direction

0: heating; 1: cooling

0 CorF

CorF

Display Unit

C, F

Unit ID

1 ~ 64

baud

bAud

Baud Rate

1200, 2400, 4800,

9600

End

Exit

Note 1. The controller is preset for K type thermocouple input. If any other type of sensor is used, the Inty value needs to be changed to the corresponding symbol as shown in Table 2.

Table 2. Temperature sensor code.

Symbol

Description

Working Temperature Range

t T TC, Type T

-200 ~ 400° C; -320 ~ 752° F

TC, Type R

-50 ~ 1600° C; -58 ~ 2900° F

TC, Type J

-200 ~ 1200° C; -320 ~ 2200°F

WRE

WRe

TC, WRe 3/25

0 ~ 2300° C; 32 ~ 4200° F

b B TC, Type B

350 ~ 1800° C; 660 ~ 3300° F

s S TC, Type S

-50 ~ 1600° C; -58 ~ 2900° F

k K TC, Type K

-200 ~ 1300° C; -320 ~ 2400°F

TC, Type E

-200 ~ 900° C; -320 ~ 1650° F

P100

RTD, Pt100

-200 ~ 600° C; -320 ~ 1100° F

P10.0

RTD, Pt100

-99.9 ~ 600.0° C; -99.9 ~ 999.9° F

Cu50

RTD, Cu50

-50.0 ~ 150.0° C; -60 ~ 300°F

Note 2. The setting of outy determines the control output mode. When it is set to: 1 - J1 relay works as absolute alarm output; SSR port as PID control output; 2 - J1 relay works as derivation alarm output; SSR port as PID control output; 3 - J1 relay works as PID control output; SSR port disabled; 4 - J1 relay works as on/off control output; SSR port disabled; 5 - J1 relay works as absolute alarm output; SSR port disabled.

Note 3. The setting of Coty determines the main output modes on the SSR port (terminal 7 & 8). When it is set to:

“SSR” - Main output is set to SSR output mode (default). “0-20” - Not available on SYL-2381-mA. “4-20” - Not available on SYL-2381-mA.

Note 4. Hysteresis Band Hy (also called dead band, or differential) is used in on/off control mode. Its unit is in degrees (° C or ° F). When the controller works in on/off control mode for heating, the output will be off when PV > SV and on again when

PV < (SV - Hy). When the controller works in on/off control model for cooling, the output will be off when PV < SV and on again when PV > (SV + Hy).

Note 5. Input offset PSb is used to set an input offset to compensate the error produced by the sensor. For example, if the meter displays 3ºC when probe is in ice/water mixture, setting PSb = -3, will make the controller display 0º C. To set a negative value, use Shift (>) key to go to the very left digit, then press Down key (V) until the first digit change to “-”.

Note 6. Parameter ID and bAud are used for RS485 communication. For details, please check the supplementary manual.

5.2 PID parameters (accessed by code 0036)

The PID control parameters are listed in Table 3. To change the parameters, press SET key, enter code “0036”, and press SET key again. The operation to change these parameters is similar to what is shown in the flow chart in Figure 3.

The values of the P, I, and D parameters are critical for good response time, accuracy, and stability of the system. Using the Auto-tune function to automatically determine these parameters is recommended for the first-time users. If the autotuning result is not satisfactory, you can manually fine-tune the PID constants for improved performance.

Table 3. PID parameters.

Symbol

Description

Setting Range

Initial

Note

Proportional

Constant

0.1 ~ 9999.9

5.0

I I Integral Time

2 ~ 1999 (sec)

100 8 d d Derivative Time

0 ~ 399 (sec)

End

Exit

Note 7. Proportional Constant (P): Also called Proportional Band. Its unit is degree. If CorF is set to ° F, the unit of P is 1° F. If CorF is set to ° C, the unit of P is 1° C. Assuming the set temperature SV is set to 200° F, Proportional Constant P is set to 5.0. When integral (I) and derivative (d) actions are both removed, i.e., I = 0 and d = 0, the controller’s output should change from 100% to 0% as the temperature increases from 195° F to 200° F. The smaller the P value, the stronger the action will be for the same amount of temperature difference between SV and PV.

Note 8. Integral Time (I): Brings the system up to the set value (SV) by adding to the output that is proportional to how far the process value (PV) is from the set value (SV) and how long it has been there. When I is set to a smaller value, the response speed is faster but the system is less stable. When I is set to a larger value, the respond speed is slower, but the system is more stable.

Note 9. Derivative Time (d): Responds to the rate of process temperature (PV) change, so that the controller can compensate in advance before the difference between SV and PV (|SV - PV|) gets too big. A larger d value increases its action. Setting d value too small or too large would decrease the stability of the system, cause oscillation, or even make the system non-convergent.

5.3 Control parameters

The control parameters are listed in Table 4. To change the parameters, press they SET key, enter code “0038”, then press the SET key again. The procedures to change control parameters are similar to what is shown in Figure 3.

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Table 4. Control parameters.

Symbol

Description

Setting Range

Initial

Note

Proportional Band

Range Limit

1 ~ 1999

300

SouF

Damp Constant

0.1 ~ 1.0

0.2

Control Cycle

1 ~ 500 (sec)

FILt

Digital Filter Strength

0 ~ 3

End

Exit

Note 10. Proportional Band Range Limit (bb): This parameter sets a temperature range in which the Proportional Constant (P) functions. If the absolute value of the difference between PV and SV is greater than bb, the proportional output will always be 100%. If a user wish to use parameter bb to fine tune the performance of the controller, the value of bb should be smaller than the value of P. By default,

bb is set to 300 degrees.

Note 11. Damp Constant (SouF): This constant can help the PID controller further

improve its control quality. It uses the artificial intelligence to dampen the temperature overshot. When SouF is set to a small value, the system may overshoot; when SouF is set to a high value, the system will be over-damped.

SouF too low

SouF acceptable

SouF too high

Figure 4. Using damp constant to adjust the control results.

Note 12. Control Cycle (ot): It is a time period setting (unit in seconds) that decide how often does the controller calculates and changes its output. A smaller ot can result in a better control precision. However, when using the relay output or control an external relay/contactor, set ot to a small value will operate the relay frequently and shorten the its life. When Outy is set to 1 or 2, set ot to 1 ~ 3 seconds; when Outy is set to 3, set ot to 20 ~ 40 seconds; when Outy is set to 4 or 5, ot setting is ignored. Generally speaking, set ot to small value for a fast response system, set ot to larger value for a slow response system.

Note 13. Digital Filter (Filt): Filt = 0 (default), filter disabled; Filt = 1, weak filtering effect; Filt = 3, strongest filtering effect. Stronger filtering increases the stability of the readout display, but causes more delay in the response to changes in temperature.

5.3 Set value setting and alarm setting (accessed by code 0001)

The set value and alarm parameters are listed in Table 5. To change the parameters, press SET key, enter code “0001”, and press SET key again. The procedures to change control parameters are similar to what is shown in Figure

Table 5. Set temperature and alarm parameters.

Symbol

Description

Initial

Setting

Note

Target temperature

(Set Value)

800

AH1

J1 pull-in temperature

900

AL1

J1 drop-out temperature

800

END

Exit

Note 12. There are two ways to set the target temperature:

a. In the normal operation mode, press ∧or V key to directly increase or

decrease the SV. Then wait about 4 seconds to allow the controller save the new SV.

b. Press SET key once, enter code 0001, the press SET key again to confirm. Then the display will flash SV (Su) in the top display. Press the SET key again

to show the current SV setting in the bottom display. Now use >, ∧,and V key to

enter the new SV and press the SET key to save the value. Press V key to put END on the top display, then press SET key to exit; or you can wait about 30 seconds then the controller will return to normal operation mode.

Note 13. Alarm setting (AH1 and AL1). The J1 relay can be set to works as absolute temperature alarm (when outy = 1 or 5), or as temperature deviation alarm (when outy = 2).

1) Absolute alarm (outy = 1 or 5)

When J1 works as an absolute temperature alarm, the AH1 is the alarm-on temperature, AL1 is the alarm-off temperature. When AH1 > AL1, J1 works as an absolute high temperature alarm: when PV is higher than AH1, J1 relay pulls in; when PV is lower than AL1, J1 relay drops out. The diagram is shown in Figure 5 to illustrate how it works. When AH1 < AL1, J1 works as an absolute low temperature alarm. A diagram is shown in Figure 6 to illustrate how it works. When AH1 = AL1, the alarm is disabled.

Relay on Relay on

Figure 5. Absolute high alarm Figure 6. Absolute low alarm

AL1

AH1

AL1

2) Deviation alarm (outy = 2)

When J1 is set as a deviation alarm, it will be activated if PV deviates too far away from the set value (SV). AH1 defines the deviation high alarm, AL1 defines the deviation low alarm. For the deviation high alarm, when PV is higher than (SV + AH1) relay J1 will pull in, when PV drops below (SV + AH1 -Hy) relay J1 will drop out; for the deviation low alarm, when PV is lower than (SV - AL1) relay J1 will pull in, when PV is higher than (SV - AL1 + Hy) relay J1 will drop out. To deactivated the deviation high alarm, set AH1 = 0; to deactivated the deviation low alarm, set AL1 = 0.

Figure.7 J1 relay works as derivation alarms

(SV = 100, AH1 = 20, AL1 = 30, Hy = 10).

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6. Auto-tuning

The Auto-tuning function (also called self-tuning) can automatically optimize the PID parameters for the system. The auto-tuning function will use the on/off mode to heat up the system until it passes the set point, then let it cool down. It will repeat this about three times. Based on the response time of the system, the built-in artificial intelligence program will calculate and set the PID parameters for the controller. If your system has a very slow response, the auto-tuning could take a long time.

AT start

AT calculation

AT end

OFF

ON/OFF PID

Figure 8. Auto-tuning.

6.1 To start auto-tuning, press and hold > key about 3 seconds until the “AT” indicator starts to blink, which indicates auto-tuning is in progress. When “AT” stops blinking, the auto-tuning is finished. Now, the newly calculated PID parameters are set to be used for the system. Please note that auto-tuning is only for PID control mode (when “outy” is set at 1, 2 or 3).

6.2 To stop the Auto-tuning, press and hold > key about 3 seconds until “AT” indicator stops blinking. In this case, no new PID parameters are calculated. The control will resume PID control with previous PID parameters.

7. On/off control mode

In on/off control mode, the controller works like a mechanical thermostat. It simply turns on or off the output when PV is below or above the SV. On/off control is not as precise as PID control mode. However, this control mode is suitable for inductive loads such as motors, compressors, or solenoid valves that do not like pulsed power.

When the temperature passes the set point, the heater (or cooler) will be turned off. When the temperature drops back to below the hysteresis band (Hy) the heater will be turned on again. Please see the Note 4 in 5.1 for details.

On this controller, only J1 relay can be used for on/off control. To use the on/off mode, set outy = 4. Then set Hy to a desired value based on the requirements of the control precision. Smaller Hy values result in tighter temperature control, but also cause the on/off action to occur more frequently. In the PID parameters menu (code 0036), only ot and FILt settings will apply to on/off control mode. Settings for other parameters P, I, D, and SouF have no effect on/off control.

Figure 9. On/off control mode for heating (left) and cooling (right), in both

situations SV = 100 and Hy = 20.

8. Manual mode

Manual mode allows the user to manually adjust the output as a percentage of the total output power. It is like a stove dial. The output is independent of the temperature sensor reading. The manual control mode can only be switched from PID control mode, not from on/off control mode. To switch from the PID mode to manual mode, press and hold the SET key 4 seconds till the “AT” indicator turns on. In manual mode, the SV window will show the percentage of the power output. The very left digit in the SV window should show letter M (M). To switch from manual mode to PID mode, press and hold SET key 4 seconds till the “AT” indicator turns off. This controller offers “bumpless” switch from PID mode to manual mode. For example, if the controller is sending 75% of power in PID mode,

when user switch to manual mode the controller will show “m 75” in the bottom

display, the output will stay at 75% till the user changes the output percentage.

9. Serial communication

RS485 serial communication is an optional feature available on RS485. It complies with the widely-accepted MODBUS_RTU protocol. Please refer to the supplementary manual for details.

10. Application Examples

10.1 A furnace needs to be controlled at 1200° F. The power source is 120 V AC.

The heating element is 1800 W at 120 V. It is switched on/off by a contactor. The coil voltage of the contactor is 120 V AC. The temperature sensor is a type K thermocouple.

a. Wiring diagram.

9 10

4 5

K type TC

Fuse

Contactor

Heater

120VAC

Figure 10. A typical wiring set up for powder coating oven and kiln. This diagram also applies to 240 V AC power system if both the heater and the coil voltage of the contactor are 240 V AC.

b. Parameter settings. These are the parameters that need to be changed from the initial value: outy = 3 for PID mode with J1 relay output; ot = 20 to avoid switching the contactor too often; for target temperature set SV = 1200° F.

10.2 A water tank needs to be controlled at 150.0° F. Alarm 1 will go off if temperature is over 155.0° F. The power source is 240V AC. The heating element is switched by a SSR. A Pt100 RTD sensor with 0.1° resolution input is used as the temperature sensor.

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a. Wiring diagram

SSR

9 10

4 5

RTD

Heater

240VAC

Alarm1

240V buzzer

Figure 11. Typical wiring set up for beer brewing and bird incubator. For smoker control, the RTD sensor should be replaced by K type thermocouple

b. Parameter setting. These are the parameters that need to be changed from the initial value:

Inty = P10.0, SV = 150.0° F, AH1 = 155.0°F, AL1 = 154.0° F outy = 1, coty = SSR for PID mode with SSR output.

If the default PID settings are not good for you, please try to use Auto-tune to optimize the PID settings: power up the controller. Press and hold the “>” key until “AT” starts to blink. The controller starts the Auto-tuning. When the “AT” stops blinking, the new PID parameters are generated for the system. The controller is in normal operation mode. The tank will be maintained at 150.0 ° F.

Please note that you don’t not have to wire or set the alarm to control the temperature.

11. Error Message and Trouble Shooting

11.1 Display EEEE

This is an input error message. The possible reasons are, the sensor is not connected correctly; the input setting is wrong type; or the sensor is defective. If this happens when using thermocouple sensor, you can short terminal 9 and 10 with a copper wire or paper clip. If then the display shows ambient temperature, the thermocouple is probably defective. If this happens when using the RTD sensor, check the input sensor type (Inty) setting first because most controllers are shipped with input sensor type set for type K thermocouple. Then check the wiring. The two red wires should be on terminal 9 and 10. The clear wire should be on terminal 8.

11.2 No output

When outy is set to 1 or 2, the control output is sent to the SSR port (pin 6 and 7). The control output is synchronized with the OUT indicator. The flashing frequency of the OUT light is an indication of the SSR triggering status. When OUT light is ON, SSR should be triggered; when OUT light is OFF, SSR should be off. When outy is set to 3 or 4, the control output is sent through J1 relay. The J1 relay action is synchronized with the AL1 indicator. When AL1 is on, J1 relay should pull in; when AL1 is off, J1 relay should drop out. If the control signal and the indicator are

synchronized, please check whether the external device is working properly. Please also confirm coty is set to SSR.

11.3 Poor accuracy Please make sure calibration is done by immersing the probe in liquid. Comparing the probe reading with a reference probe in air is not recommended because the response time of probes can vary a lot. Different probes are designed for different applications, and they can be quite different in their thermal mass, which will affect their response time a lot. Some of our sensors have response time more than 10 minutes in the air. When the calibration is done correctly in liquid and the error is 5° F or larger, the most common problem for a thermocouple probe is improper connection between the thermocouple and the controller. A thermocouple needs to be connected directly to the controller unless thermocouple connector and thermocouple extension wire are used. A copper connector, copper wire, or thermocouple extension wire with wrong polarity connected on the thermocouple will cause the reading drift more than 5° F.

Auber Instruments Inc.

5755 North Point Parkway, Suite 99,

Alpharetta, GA 30022

www.auberins.com

Email: info@auberins.com

Tel: 770-569-8420

No part of this manual shall be copied, reproduced, or transmitted in any way without the

prior, written consent of Auber Instruments. Auber Instruments retains the exclusive rights

to all information included in this document.

Auber Instruments SYL-2381-SSR Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual