Chromalox ETR-3400 Installation & Operation Manual

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Page 1

Installation & Operation Manual

3400 1/32 DIN

Automatic Tuning Smarter

Logic Temperature Controller

PK545

0037-75576

April 2018

Page 2

Safety and Warranty Information

Warning Symbol

This Symbol calls attention to an operating procedure or practice which if not correctly performed or adhered to, could result in severe personal injury or damage to the product or system.

Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.

FM approved high limit controllers should always be used in heated systems.

Manual Use

Installers ................................................... Chapter 1, 2

Basic Function User ............................. Chapter 1, 3, 5

Enhanced Function User .................. Chapter 1, 3, 4, 5

System Designer .......................................All Chapters

Expert User ......................................................Page 11

Warranty and Returns Statement

These products are sold by Chromalox under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to a purchase of these products, as new merchandise, directly from Chromalox or from a Chromalox distributor, representative or reseller and are extended only to the ﬁrst buyer thereof who purchases them other than for the purpose of resale.

Warranty

These products are warranted to be free from functional defects in material and workmanship at the time the products leave Chromalox factory and to conform at that time to the speciﬁcations set forth in the relevant C instruction manuals sheet or sheets, for such products for a period of three years.

THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES, WHICH EXTEND BEYOND THE WARRANTIES HEREIN AND ABOVE SET FORTH. CHROMALOX MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE PRODUCTS.

Limitations

Chromalox shall not be liable for any incidental damages, consequential damages, special damages, or any other damages, costs or expenses excepting only the cost or expense of repair or replacement as described above. Products must be installed and maintained in accordance with Chromalox instructions. There is no warranty against damage to the product resulting from corrosion. Users are responsible for the suitability of the products to their application.

For a valid warranty claim, the product must be returned carriage paid to the supplier within the warranty period. The product must be properly packaged to avoid damage from electrostatic discharge or other forms of harm during transit.

Page 3

Table of Contents

Contents Page Number

Safety & Warranty ................................................................................................................................................... ii

Chapter 1 Overview ................................................................................................................................................ 1

1-1 Features ....................................................................................................................................................... 1

1-2 Ordering Code ............................................................................................................................................. 3

1-3 ProgrammingPort andDIP Switch ............................................................................................................... 4

1-4 Keys and Displays ....................................................................................................................................... 5

1-5 Menu Overview ............................................................................................................................................ 7

1-6 System Modes ............................................................................................................................................. 8

1-7 Parameter Descriptions ............................................................................................................................... 9

Chapter 2 Installation ........................................................................................................................................... 17

2-1 Unpacking ................................................................................................................................................. 17

2-2 Mounting ................................................................................................................................................... 17

2-3 Wiring Precautions .................................................................................................................................... 18

2-4 Power Wiring ............................................................................................................................................. 18

2-5 Sensor Installation Guidelines ................................................................................................................... 19

2-6 Thermocouple Input Wiring ....................................................................................................................... 19

2-7 RTD Input Wiring ....................................................................................................................................... 20

2-8 Linear DC Input Wiring .............................................................................................................................. 20

2-9 CT / Heater Current Input Wiring ............................................................................................................... 21

2-10 Event Input wiring .................................................................................................................................... 22

2-11 Output 1 Wiring ....................................................................................................................................... 22

2-12 Output 2 Wiring ....................................................................................................................................... 24

2-13 Alarm 1 Wiring ......................................................................................................................................... 25

2-14 Alarm 2 Wiring ......................................................................................................................................... 26

2-15 RS-485 .................................................................................................................................................... 27

2-16 RS-232 .................................................................................................................................................... 28

2-17 Analog Retransmission ............................................................................................................................ 29

2-18 Programming Port ................................................................................................................................... 30

Chapter 3 Programming the Basic Function ..................................................................................................... 31

3-1 Input 1 ....................................................................................................................................................... 32

3-2 OUT1 & OUT2 Types ................................................................................................................................. 33

3-3 Rearrange User Menu ............................................................................................................................... 33

3-4 Display SV Instead of PV ........................................................................................................................... 34

3-5 Heat Only Control ...................................................................................................................................... 34

3-6 Cool Only Control ...................................................................................................................................... 35

3-7 Heat - Cool Control ................................................................................................................................... 36

3-8 Dwell Timer ................................................................................................................................................ 37

3-9 Process Alarms .......................................................................................................................................... 38

3-10 Deviation Alarms ...................................................................................................................................... 40

3-11 Deviation Band Alarms ............................................................................................................................ 41

3-12 Heater Break Alarm ................................................................................................................................. 42

3-13 Loop Break Alarm .................................................................................................................................... 43

3-14 Sensor Break Alarm ................................................................................................................................. 44

3-15 SP1 Range ............................................................................................................................................... 44

3-16 PV1 Shift .................................................................................................................................................. 45

3-17 Failure Transfer ........................................................................................................................................ 46

3-18 Bumpless Transfer ................................................................................................................................... 47

3-19 Self-tuning ............................................................................................................................................... 48

3-20 Auto-tuning .............................................................................................................................................. 49

3-21 Manual Tuning ......................................................................................................................................... 51

3-22 Signal Conditioner DC Power Supply ..................................................................................................... 54

3-23 Manual Control ........................................................................................................................................ 55

iii

Page 4

Contents Page Number

3-24 Display Mode ........................................................................................................................................... 55

3-25 Heater Current Monitoring ....................................................................................................................... 56

3-26 Reload Default Values .............................................................................................................................56

Chapter 4 Programming the Full Function ......................................................................................................... 57

4-1 Event Input ................................................................................................................................................ 57

4-2 Second Set Point ....................................................................................................................................... 58

4-3 Second PID Set ......................................................................................................................................... 58

4-4 Ramp & Dwell ............................................................................................................................................ 59

4-5 Remote Set Point ...................................................................................................................................... 60

4-6 Differential Control ..................................................................................................................................... 61

4-7 Output Power Limits .................................................................................................................................. 62

4-8 Data Communication ................................................................................................................................. 63

4-9 Analog Retransmission .............................................................................................................................. 64

4-10 Digital Filter .............................................................................................................................................. 65

4-11 Sleep Mode ............................................................................................................................................. 65

4-12 Pump Control .......................................................................................................................................... 66

4-13 Remote Lockout ...................................................................................................................................... 67

Chapter 5 Applications ........................................................................................................................................ 68

5-1 Pump / Pressure Control ........................................................................................................................... 68

5-2 Variable Period Full Wave SSR ( VPFW SSR ) ........................................................................................... 69

5-3 Heat Only Control ...................................................................................................................................... 71

5-4 Cool Only Control ...................................................................................................................................... 72

5-5 Heat - Cool Control ................................................................................................................................... 73

5-6 Ramp & Dwell ............................................................................................................................................ 74

5-7 Remote Set Point ...................................................................................................................................... 77

5-8 Differential Control ..................................................................................................................................... 78

5-9 Dual Set Point / PID ................................................................................................................................... 79

5-10 RS-485 .................................................................................................................................................... 81

5-11 RS-232 .................................................................................................................................................... 82

5-12 Retransmit ............................................................................................................................................... 82

Chapter 6 Calibration ........................................................................................................................................... 84

Chapter 7 Error Codes & Troubleshooting ......................................................................................................... 87

Chapter 8 Speciﬁcations ..................................................................................................................................... 90

Appendix ............................................................................................................................................................... 94

A-1 Menu Existence Conditions ...................................................................................................................... 94

A-2 Factory Menu Description ......................................................................................................................... 96

A-3 Glossary .................................................................................................................................................... 98

A-4 Memo ...................................................................................................................................................... 104

Page 5

Chapter 1

1-1 Features (**Unique, *Valuable)

**High accuracy 18-bit input A D **High accuracy 15-bit output D A **Fast input sample rate (5 times / second) **Two function complexity levels **User menu conﬁgurable **Adaptive heat-cool dead band **Pump control *Fuzzy + PID microprocessor-based control *Automatic programming *Differential control *Auto-tune function *Self-tune function *Sleep mode function *“Soft-start” ramp and dwell timer *Programmable inputs (thermocouple, RTD, mA, VDC)

ETR-3400 Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright, easy to read 4-digit LED display, indicating the process or set value. 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. The units are housed in a 1/32 DIN case, measuring 24 mm x 48 mm with 98 mm behind panel depth. The units feature three touch keys to select the various control and input parameters. Using a unique function, you can put at most 5 parameters in front of the user menu by using SEL1 to SEL5 contained in the setup menu. This is particularly useful for quick access to commonly used settings.

ETR-3400 is powered by 11-26 V DC / AC or 90 - 264 V AC supply, incorporating a 3 amp. control relay output, 5V logic alarm output and a 3 amp. alarm relay output. The second alarm can be conﬁgured into second output for cooling purposes or a dwell timer. Alternative output options include SSR drive, triac, 4 - 20 mA and 0 - 10 volts. ETR- 3400 is fully programmable for PT100, thermocouple types J, K, T, E, B, R, S, N, L, 0 - 20 mA, 4 -20 mA and voltage signal input, with no need to modify the unit. The input signals are digitized by using a 18-bit A to D converter. Its fast sampling rate allows the ETR-3400 to control fast processes such as pressure and ﬂow. The selftune feature can be used to optimize the control parameters as soon as undesired control result is observed. Unlike auto-tuning, Self-tune will produce less disturbance to the process Digital communications, RS-485, RS-232 or 4 - 20 mA retransmission are available as an additional option. These options allow ETR-3400 to be integrated with supervisory Three different methods can be used to program the ETR-3400. 1) Use the keys on the front panel to program the unit manually, 2) Use a PC and setup software to program the unit via RS-485 or RS-232 COMM port. 3) Use P10A, a hand-held programmer speciﬁcally designed for the ETR series controllers.

Although PID control has been used and proved to be an efﬁcient controlling method by many industries, PID tuning is difﬁcult to deal wit, some sophisticated systems such as second and higher order systems, long time-lag systems, during set point change and/or load disturbance. The PID principle is based on a mathematic modeling which is obtained by tuning the process. Unfortunately, many systems are too complex to describe in numerical terms precisely. In addition, these systems may vary from time to time. In order to overcome the imperfections of PID control, Smarter Logic Technology is introduced. Smarter Logic is a linguistic control which controls the system by experience and does not need to simulate the system precisely as PID. Smarter Logic is the OGDEN trade mark for Fuzzy Logic . An ETR with Smarter Logic continues decision making and will prevent initial overshoot and set point differentials due to process disturbances. Control results are virtually perfect. Not only is control performance improved, software and design innovations have made available other improvements over conventional controllers.

*Analog input for remote set point and CT *Event input for changing function & set point *Programmable digital ﬁlter *Hardware lockout + remote lockout protection *Loop break alarm *Heater break alarm *Sensor break alarm + Bumpless transfer *RS-485, RS-232 communication *Analog retransmission *Signal conditioner DC power supply *A wide variety of output modules available *Safety UL / CSA / IEC1010 1 *EMC / CE EN61326 *Front panel sealed to NEMA 4X & IP65

Page 6

information

Figure 1.1 Fuzzy PID System Block

PID + FUZZY CONTROL

Set

MV PV

PROCESS

PID

Digital information

FUZZY

Fuzzy Rule

Language information

Fuzzy Inference Engine

The function of Fuzzy Logic is to adjust PID parameters internally in order to make

PID + FUZZY CONTROL

Smarter Logic causes the following:

If temperature difference is large and temperature rate is large, then delta MV is large.

If temperature difference is large and temperature rate is small, then delta MV is small.

DefuzzifierFuzzifier

Digital

Figure 1.2 Fuzzy PID Enhances Control Stability

Temperature

point

Warm Up

PID tuned controller PID+Fuzzy control

Load Disturbance

Time

Page 7

1-2 Ordering Code

CT94-1 = 0 - 50 Amp. AC Current T OM95-3 = Isolated 4 - 20 mA / 0 - 20 mA Analog Output Module OM95-4 = Isolated 1 - 5V / 0 - 5V Analog Output Module OM95-5 = Isolated 0 - 10V Analog Output Module OM94-6 = Isolated 1A / 240V DC94-1 = Isolated 20V / 25mA DC Output P DC94-2 = Isolated 12V / 40mA DC Output P DC94-3 = Isolated 5V / 80mA DC Output P CM94-1 = Isolated RS CM94-2 = Isolated RS CM94-3 = Isolated 4 - 20 mA / 0 - 20 mA R CM94-4 = Isolated 1 - 5V / 0 - 5V R CM94-5 = Isolated 0 - 10V R CC94-1 = RS UM34001A = ETR-3400 User's Manual

Standard Model: ETR

-Net

ETR-3400

1 2

4: 90 - 264 VAC, 50/60 HZ

4: 90 - 264 VAC, 50/60 HZ 5: 11 - 26 VAC or VDC

5: 11 - 26 VAC or VDC

1: Standard Input

Input 1 - Universal Input

Thermocouple: J, K, T, E, B,

R, S, N, L

RTD: PT100 DIN, PT100 JIS

RTD: PT100 DIN, PT100 JIS Current: 4 - 20mA, 0 - 20 mA.

Current: 4 - 20mA, 0 - 20 mA. Voltage: 0 - 1V, 0 - 5V, 1 - 5V,

Voltage: 0 - 1V, 0 - 5V, 1 - 5V,

0 - 10V

Input 2 -

Example

90 - 264 operating voltage

90 - 264 operating voltage Input: Standard Input

Input: Standard Input Output 1: Relay

Output 1: Relay Output 2: Relay

Output 2: Relay Alarm 1: 5V Logic Output

Alarm 1: 5V Logic Output RS- 485 Communication Interface

RS- 485 Communication Interface

ccessories

Input 2 -

-3400-411111

****

CT: 0 - 50 Amp. AC Current

Transformer

Voltage Input: 0 - 1V, 0 - 5V,

1 - 5V, 0 - 10V.

Event Input ( EI )

******

ransformer

AC Triac Output Module ( SSR )

-485 Interface Module

-232 Interface Cable (2M)

-485 Interface Module

-232 Interface Module

etransmission Module

3 4

1: Relay rated 2A/240VAC

1: Relay rated 2A/240VAC 2: Pulsed voltage to

2: Pulsed voltage to

drive SSR, 5V/30mA

3: Isolated

4 - 20mA / 0 - 20mA

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

4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V

5: Isolated 0 - 10V 6: Triac Output

6: Triac Output

1A / 240VAC,SSR

C: SSR Drive 14V/30mA

ower Supply

ower Supply ower Supply

ower Supply

etransmission Module

1: 5V Logic

Output

0: None

0: None 1: Form A Relay 2A/240VAC

1: Form A Relay 2A/240VAC 2: Pulsed voltage to

2: Pulsed voltage to

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

3: Isolated 4 - 20mA / 0 - 20mA 4: Isolated 1 - 5V / 0 - 5V

4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V

5: Isolated 0 - 10V 6: Triac Output, 1A / 240VAC, SSR

6: Triac Output, 1A / 240VAC, SSR 7: Isolated 20V / 25mA DC

7: Isolated 20V / 25mA DC

8: Isolated 12V / 40 mA DC

9: Isolated 5V / 80mA DC

C: SSR Drive 14V/30mA

Range set by front keyboard

Alternative between RS-232 and Input 2

****

Need to order an accessory CT94-1 if

******

Heater Break detection is required.

Related Products

SNA10A = Smart Network Adaptor for Third

SNA10B = Smart Network Adaptor for ETR

0: None

0: None 1: RS-485

1: RS-485 2: RS-232

2: RS-232 3: Retransmit 4-20mA/0-20mA

3: Retransmit 4-20mA/0-20mA 4: Retransmit 1 - 5V / 0 - 5V

4: Retransmit 1 - 5V / 0 - 5V 5: Retransmit 0 - 10V

5: Retransmit 0 - 10V

drive SSR, 5V / 30mA

****

Output Power Supply

P10A = Hand-held Programmer for ETR

Series Controller

Party Software, Converts 247

Party Software, Converts 247 channels of RS-485 or RS-422 to

channels of RS-485 or RS-422 to RS-232 Network

RS-232 Network

Software, Converts 247 channels

Software, Converts 247 channels of RS-485 or RS-422 to RS-232

of RS-485 or RS-422 to RS-232 Network

Network

Page 8

1-3 Programming Port and DIP Switch

Front Panel

erminal

Table 1.1 DIP Switch Configuration

Figure 1.3 Access Hole Overview

Access Hole

432

PIDNO

The programming port connects to the

P11A hand-held programmer for automatic programming, this also connects to an ATE system for automatic calibration and testing.

Rear T

DIP Switch

:ON :OFF

TC, RTD, mV

Input 1

Select

0-1V, 0-5V, 1-5V, 0-10V

0-20 mA, 4-20 mA

All parameters are Unlocked

Only SP1, SEL1 SEL5 are unlocked

Lockout

Only SP1is unlocked

Factory Default Setting

The mini jumper ( programming port ) is used for off-line automatic setup and testing procedures only. Don’t attempt to make any connection to these jumpers when the unit is powered on.

When the unit leaves the factory, the DIP switch is set so that TC & RTD are selected. Lockout function is used to disable the adjustment of parameters as well as operation of the unit prior to setup being performe

*SEL1- SEL5 represent those parameters which are selected by using SEL1, SEL2,...SEL5 parameters contained in Setup menu. Parameters that were selected are then allocated to the chosen SEL position.

All Parameters are locked

Page 9

1-4 Keys and Displays

Pressand releasequickly to increase thevalue of parameter. Pressand holdtoaccelerateincrementspeed.

Pressand releasequickly to decreasethe value of parameter. Pressand holdtoaccelerate decrement speed.

Select the parameter in adirect sequence.

Allow access to more parametersonuser menu, also used to Enter manual mode, auto-tune mode,defaultsetting modeand to save calibrationdata duringcalibrationprocedure.

Select the parameter in a reverse sequenceduring menu scrolling.

Select the operation Mode in sequence.

Reset the frontdisplay to anormal display mode from anywhere within the parameterbank. This also exits theauto-tuneand manual control operation while quitting thesleep mode.

The controllerentersthe sleep modeifthe sleep function ( SLEP)is enabled ( selectYES ).

By entering correct security codeto allow execution of engineering programs. This function is used onlyatthe factory to manage thediagnostic reports. The user should never attempt to operate this function.

Press for at least3seconds

Press for at least6seconds

Press

Press for at least3seconds

Up Key

Down Key

Scroll Key

EnterKey

Start Record Key

Reverse Scroll Key

ModeKey

Reset Key

Sleep Key

Factory Key

NOITPIRCSEDNOITCNUFSYEKHCUOT

Reset historicalvaluesofPVHI and PVLO andstart to recordthe peak process value.

Table 1.2 Keypad Operation

Output Indicator

3 Silicone Rubber Buttons

4-digit Display

How to display a 5-digit number?

The unit is programmed by using three keys on the front panel. The available key functions are listed in following table.

Alarm 1 Indicator

Output 1 Indicator

ETR-3400

Figure 1.4 Front Panel Layout

Table 1.3 Character Legend

A B C

: These characters are displayed with symbols

E F

J K L M

For a number with decimal point the

to display process value, set point value, menu symbol, parameter value, control output value and error code etc.

N O P

Q R

for ease of control setup

and set point adjustment.

S T

X Y Z ?

display will be shifted one digit right:

-199.99 will be displayed by -199.9

4553.6 will be displayed by 4553

For a number without decimal point the display will be divided into two

alternating phases:

-19999 will be displa ye d by:

45536 will be displayed by:

-9999 will be displaye d by:

Page 10

Power On

ETR-3400

All segments of display and indicators are left off for 0.5 second.

Figure 1.5 Display Sequence o

Initial Power-up

All segments of display and indicators are lit for 2 seconds.

Display program code of the product for 2.5 seconds.

Each display stays for 1.25 seconds

The left diagram shows program no. 0 ( for ETR-3400 ) with version

35.

Program Code

Program version

Program No.

ETR-3400

Display Date Code and Serial number for 2.5 seconds. Each display stays for 1.25 seconds

Date Code

The left diagram shows Year 1998,

Month July ( 7 ), Date 31'st and Serial number 192. This means that the product is the 192'nd unit produced on July 31'st, 1998. Note that the month code stands for October, BNovember C stands for.

stands for and

December

Date (31st)

Month (December)

Year (1999)

Display used hours for 2.5 seconds. The 6-digit number of hour is indicated

by two successive displays and each one stays on for 1.25 seconds.

The left diagram shows that the unit has been used for 23456.2 hours since production.

Page 11

1-5 Menu Overview

User Menu

PV Value

SV Value

Setup Menu

Hand (Manual) Control Mode

Auto-tuning Mode

Pressfor 3 secondsto enter the auto-tuning mode

Display Mode

Default Setting Mode

3 seconds

FILE

for

To execute the default setting program

Calibration Mode

Entering these modes will break the control loop and change some of the previous setting data. Make sure that settings are properly backed up prior to initiating if they are to be used again.

for3seconds

H C

PVHI

PVLO H C

DV PV1 PV2

CJCT

PVR

PVRH PVRL

AD0

ADG

V1G

CJTL

CJG

REF1

SR1

MA1G

V2G

SEL1 SEL2 SEL3

SEL4

FUNC

COMM

PROT ADDR BAUD DATA

PARI STOP AOFN AOLO

AOHI

IN1

IN1U

DP1

IN1L

IN1H

IN2

IN2U

DP2

IN2L

IN2H OUT1

O1TY

CYC1

O1FT OUT2 O2TY CYC2

O2FT

A1FN A1MD

A1FT

A2FN A2MD

A2FT

EIFN

PVMD

FILT SELF SLEP

SPMD

SP1L SP1H SP2F

DISF SEL1 SEL2 SEL3 SEL4 SEL5

*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. See Appendix A for the existence conditions of each parameter.

You can select at most 5 parameters to put in front of the

*2:

user menu by using SEL1 to SEL5 located at the end of the setup process

*3:

Set DISF (display format) value in the setup menu to chan

e between PV (Process Value) and SV (Setpoint Value)

Display Return

The menu will return to displaying the selected PV or SV after 2 min. if no entry is made except, when in the

Display Mode or in the Manual Mode.

However, the menu can return to the selected PV or SV display at any time by pressing and .

SEL5

TIME A1SP A1DV A2SP A2DV

RAMP

OFST

REFC

SHIF

PB1

TI1

TD1

CPB

SP2 PB2

TI2

TD2

O1HY

A1HY A2HY

PL1 PL2

for 3 seconds

Page 12

1-6 System Modes

Priority

The controller performs a closed loop control mode under its normal control mode operation. The controller will maintain its normal control mode when you are operating the user menu, setup menu or display mode, reloading default values or applying an event input signal. Under certain conditions the normal control mode will transfer to an Exception Mode. The exception modes include : Sleep Mode, Manual Mode, Failure Mode, Calibration Mode and Auto Tuning Mode. All these modes perform in an open loop control except the auto-tuning mode which performs ON-OFF plus PID close loop control. The mode transfer is governed by the priority as shown in Figure 1.6.

Figure 1.6 System Mode Priority

High

Low

? Mode

Sleep Mode?

Yes

Manual Mode?

Yes

System Modes

Sleep Mode: See Section 4-11 Manual Mode: See Section 3-23 Failure Mode: See Section 3-17 Calibration Mode: See Chapter 6 Auto-tuning Mode: See Section 3-20 Normal Control Mode: See Section 3-24, 3-26, 4-1

Failure Mode?

Yes

Request Calibration Mode

Request Auto-tuning Mode

Request Normal Control Mode

The calibration mode, auto-tuning mode and normal control mode are in the same priority level.

Page 13

1-7 Parameter Descriptions

Table 1.4 Parameter Description (1 of 7)

Contained

Basic

Function

Parameter

Notation

SP1

TIME

A1SP

A1DV

A2SP

A2DV

RAMP

OFST

REFC

SHIF

PB1

TI1User

TD1

CPB

SP2

PB2

TI2

TD2

O1HY

A1HY

A2HY

PL1

PL2

FUNC

Display

Format

Parameter

Description

Set point1

DwellTime

Alarm 1Set point

Alarm 1 DeviationValue

Alarm 2Set point

Alarm 2 DeviationValue

Ramp Rate

Offset Value forPcontrol

Reference Constantfor Specific Function

PV1 Shift (offset) Value

Proportional Band 1Value

IntegralTime 1Value

DerivativeTime 1Value

Cooling Proportional Band Value

Heating-CoolingDead Band NegativeValue= Overlap

Set point2

Proportional Band 2Value

IntegralTime 2Value

DerivativeTime 2Value

Output1ON-OFFControl Hysteresis

Hysteresis ControlofAlarm 1

Hysteresis ControlofAlarm 2

Output1Power Limit

Output2Power Limit

Function Complexity Level

Low:

SeeTable 1.5, 1.6

Low:

SeeTable 1.5, 1.7

Low:

SeeTable 1.5, 1.8

Low:

SP1L SP1H

0 6553.5 minutes 0.0

-200.0 C

(-360.0 F)

-200.0 C

(-360.0 F)

-200.0 C

(-360.0 F)

-36.0

0.1

Basic Function Mode

Full Function Mode

Range

High:

200.0 C

( 360.0F)

200.0 C

( 360.0F)

500.0C

(900.0 F)

100.0 %

200.0 C

( 360.0F)

500.0C

(900.0 F)

1000 sec

360.0 sec

255 %

36.0%

500.0C

(900.0 F)

1000 sec

360.0 sec

55.6C

( 100.0F)

10.0C

(18.0F)

10.0C

(18.0F)

100%

Default

Value

100.0C

(212.0 F)

100.0C

(212.0 F)

10.0C

(18.0 F)

100.0C

(212.0 F)

10.0C

(18.0 F)

0.00

25.0

0.0

10.0C

(18.0 F)

100

25.0

100

37.8 C

(100.0 F)

10.0C

(18.0F)

100

25.0

0.1

100

Setup Menu

COMM

PROT

Communication Interface Type

COMM Protocol Selection

No communication function

RS-485 interface

RS-232 interface

4-20 mA analog retransmission output

0-20 mA analog retransmission output

0-1V analog retransmission output

0-5V analog retransmission output

1-5V analog retransmission output

0-10V analog retransmission output

Modbus protocol RTU mode

Page 14

Table 1.4 Parameter Description (continued 2 of 7)

Contained

Basic

Function

Parameter

Notation

ADDR

Display

Format

Address Assignmentof Digital COMM

BAUD

DATA

PARI

Baud Rateof Digital COMM

DataBit countof Digital COMM

ParityBit of Digital COMM

Parameter

Description

Range

Low:

18data bits

0.3Kbits/s baudrate

0.6Kbits/s baudrate

1.2Kbits/s baudrate

2.4Kbits/s baudrate

4.8Kbits/s baudrate

9.6Kbits/s baudrate

14.4Kbits/s baudrate

19.2Kbits/s baudrate

28.8Kbits/s baudrate

38.4Kbits/s baudrate

7 data bits

Even parity

Odd parity

No parity bit

High:

Default

Value

5521

Setup Menu

STOP

AOFN

AOLO

AOHI

IN1

Stop Bit Countof Digital COMM

Analog Output Function

Analog OutputLow Scale Value Analog Output High Scale Value

IN1 SensorType Selection

Low:

One stop bit

Two stop bits

RetransmitIN1 process value

RetransmitIN2 process value

RetransmitIN1 IN2 difference process value

RetransmitIN2 IN1 difference process value

Retransmitset point value

Retransmit output1manipulation value

Retransmit output2manipulation value

Retransmit deviation(PV-SV) Value

-19999

Jtypethermocouple

Ktypethermocouple

Ttypethermocouple

Etypethermocouple

Btypethermocouple

Rtypethermocouple

Stypethermocouple

High:

45536

(32.0F)

100.0C

(212.0F)

(0)

Page 15

Table 1.4 Parameter Description (continued 3 of 7)

Contained

Basic

Function

Parameter

Notation

Display

Format

Setup Menu

IN1

IN1U

DP1

IN1L

IN1H

IN1 Sensor Type Selection

IN1 Unit Selection

IN1 Decimal Point Selection

IN1 Low Scale Value

IN1 High Scale Value

Parameter

Description

Low:

Range

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

0-1V linear Voltage input

0-5V linear Voltage input

1-5V linear Voltage input

0-10V linear Voltage input

Special defined sensor curve

Degree C unit

Degree F unit

Process unit

No decimal point

1 decimal digit

2 decimal digits

3 decimal digits

-19999

High:

45536

Default

Value

(0)

(1)

1000

IN2

IN2U

DP2

IN2L

IN2H

OUT1

O1TY

IN2 Signal Type Selection

IN2 Unit Selection

IN2 Decimal Point Selection

IN2 Low Scale Value

IN2 High Scale Value

Output 1 Function

Output 1 Signal Type

SameasIN1U

Sameas DP1

-19999

Low:

-19999

Low:

IN2 no function

Current transformer input

0-1V linear voltage input

0-5V linear voltage input

1-5V linear voltage input

0-10V linear voltage input

Perform Event input function

High:

45536

High:

45536

Reverse (heating ) control action

Direct (cooling) control action

Relay output

Solid state relay drive output

Solid state relay output

4-20 mA current module

1000

Page 16

Table 1-4 Parameter Description (continued 4 of 7)

Contained

Basic

Function

Parameter

Notation

Display

Format

O1TY

CYC1

O1FT

Output 1 Signal Type

Output 1 CycleTime

Output 1 Failure Transfer Mode

Parameter

Description

Range

Low:

SelectBPLS(bumpless transfer)or 0.0 ~ 100.0 %to continue output1control function as the unit fails, power starts or manual mode starts.

0-20 mA current module

0-1V voltage module

0-5V voltage module

1-5V voltage module

0-10V voltage module

0.1

High:

100.0 sec 18.0

Default

Value

BPLS

Setup Menu

OUT2

O2TY

CYC2

O2FT

A1FN

Output 2 Function

Output 2 Signal Type

Output 2 Cycle Time

Output 2 Failure Transfer Mode

Alarm1Function

: Output2no function

:PID cooling control

:Perform alarm2function

:DC power supply module

installed

Sameas O1TY

High:

0.1

Low:

SelectBPLS(bumpless transfer)or 0.0 ~ 100.0 %to continue output2control function as the unit fails, power starts or manual mode starts.

7IN1 process value low alarm

8 IN2 process value high alarm

14 Loop break alarm

15 Sensor break or A-D fails

No alarm function

Dwell timer action

Deviation high alarm

Deviation low alarm

Deviation band outof band alarm

Deviation band in band alarm

IN1 process value high alarm

IN2 process value low alarm

IN1or IN2 process value high

alarm

IN1or IN2 process value low alarm

IN1 IN2 difference process value high alarm

IN1 IN2 difference process value low alarm

100.0 sec

18.0

BPLS

A1MD

Alarm1Operation Mode

Normal alarm action

Latching alarm action

Hold alarm action

Latching & actionHold

Page 17

Table 1-4 Parameter Description (continued 5 of 7)

Contained

Basic

Function

Parameter

Notation

A1FT

Display

Format

Alarm 1 FailureTransfer Mode

A2FN

A2MD

A2FT

Alarm 2 Function

Alarm 2 Operation Mode

Alarm 2 FailureTransfer Mode

Parameter

Description

Range

Same as A1FN

Same as A1MD

Same as A1FT

1SP2 activated to replace SP1

Alarm output OFF as unit fails

Alarm outputONas unit fails

Event input no function

PB2, TI2, TD2 activatedtoreplace

PB1, TI1, TD1

SP2,PB2,TI2, TD2 activated to replace SP1,PB1, TI1, TD1

Reset alarm 1 output

Default

Value

Setup Menu

EIFN

Event Input Function

PVMD PV Mode Selection

FILT

Filter DampingTime ConstantofPV

Reset alarm 2 output

Reset alarm1&alarm 2

Disable Output1

Disable Output2

Disable Output1&Output2

LockAll Parameters

Use PV1 as process value

Use PV2 as process value

Use PV1 PV2 (difference) as process value

Use PV2 PV1 (difference) as process value

0 second time constant

0.2 second time constant

0.5 second time constant

1 second time constant

2 seconds time constant

5 seconds time constant

10 seconds time constant

20 seconds time constant

30 seconds time constant

60 seconds time constant

SELF

SLEP

SelfTuning Function Selection

Sleep mode Function Selection

Self tune function disabled

Self tune function enabled

Sleep mode function disabled

Sleep mode function enabled

Page 18

SP2F

DISF

Formatof set point2Value

Display Format

set point 2(SP2) is an actual value

set point 2(SP2) isadeviation value

SPMD Set point Mode Selection

Use SP1 or SP2 (depends on EIFN) as setpoint

Use minute ramp rate as set point

Use hour ramp rateas set point

Use IN1 processvalueas set point

Use IN2 processvalueas set point

Selected for pump control

SEL1 Select 1'st Parameter

ParameterPB2 put ahead

Parameter TI2 put ahead

ParameterTD2 put ahead

No parameter put ahead

Display PV value

Display SV value

Parameter TIME put ahead

ParameterA1SP put ahead

ParameterA1DV put ahead

ParameterA2SP put ahead

ParameterA2DV put ahead

ParameterRAMP put ahead

ParameterOFST put ahead

ParameterREFC put ahead

ParameterSHIF put ahead

ParameterPB1 put ahead

Parameter TI1 put ahead

ParameterTD1 put ahead

ParameterCPB put ahead

ParameterSP2 put ahead

ParameterDB put ahead

SEL2

SEL3

SEL4

Same as SEL1

Low:

High:

SP1L

SP1H

SP1Low Scale Value

SP1High Scale Value

-19999

45536

(32.0F)

1000.0 C

(1832.0 F)

Table 1-4 Parameter Description (continued 6 of 7)

Select 2'ndParameter

Select 3'rd Parameter

Select 4'th Parameter

Select 5'th Parameter

SEL5

Same as SEL1

AD0

ADG

V1G

AtoDZero Calibration Coefficient

AtoDGain Calibration Coefficient

Voltage Input1Gain Calibration Coefficient

-360 360

-199.9 199.9

Low:

High:

Low:

High:

CJTL

ColdJunction Low Temperature Calibration Coefficient

-5.00C 40.00 C

Calibration Mode Menu

Setup Menu

Parameter

Description

Range

Default

Value

Contained

Basic

Function

Parameter

Notation

Display

Format

Page 19

Table 1.4 Parameter Description (continued 7 of 7)

Contained

Calibration Mode Menu

Display Mode Menu

Basic

Function

Parameter

Notation

CJG

REF1

SR1

MA1G

V2G

PVHI

PVLO

MV1

MV2

PV1

PV2

CJCT

PVR

PVRH

PVRL

Display

Format

Cold Junction Gain Calibration Coefficient

Reference Voltage 1 Calibration Coefficientfor RTD1

Serial Resistance 1 Calibration Coefficientfor RTD1

mA Input1Gain Calibration Coefficient

Voltage Input2Gain Calibration Coefficient

Historical Maximum Valueof PV Historical Minimum Valueof PV

Current Output 1Value

Current Output 2Value

Current Deviation(PV-SV) Value

IN1 Process Value

IN2 Process Value

Current Proportional Band Value

Current Integral Time Value

Current Derivative Time Value

ColdJunction Compensation Temperature

Current Process Rate Value

Maximum Process Rate Value

Minimum Process Rate Value

Parameter

Description

Range

-199.9

Low:

-199.9

Low:

-199.9

Low:

-199.9

Low:

-199.9 199.9

Low:

-19999

Low:

-19999

Low:

-12600

-19999

-40.00C

-16383

High:

199.9

45536

100.00 %

12600

45536

500.0 C

(900.0 F)

4000 sec

1440 sec

90.00C

16383

Default

Value

Page 20

Table 1.5 Input (IN1 of IN2) Range

Range

InputType

, A2SP or SP2 is configured with respect to

CT input, its adjustment range is unlimited.

Range Low

Range High

J_TC

-120C

(-184 F)

1000 C

(1832 F)

K_TC

-200C

(-328 F)

1370C

(2498 F)

T_TC

-250 C

(-418 F)

400 C

(752 F)

E_TC

-100 C

(-148 F)

900 C

(1652F)

B_TCCTR_TC

(32 F)

1820 C

(3308F)

(32 F)

1767.8C (3214F)

S_TC

(32F)

1767.8 C (3214F)

Input Type

Range Low

Range High

N_TC

-250 C

(-418 F)

1300 C

(2372 F)

L_TC

-200 C

(-328 F)

900 C

(1652 F)

Table 1.6 Range Determination for A1SP

If A1FN =

of A1SP

same as range of

PV1.H, PV1.L

Table 1.7 Range Determination for A2SP

If A2FN=

Range of A2SP

sameas range of

PV1.H, PV1.L

Table 1.8 Range Determination for SP2

If PVMD =

of SP2

same as range of

IN1

PV1

IN1

PT.DN

-210 C

(-346 F)

700C

(1292 F)

PT.JS

-200 C

(-328 F)

600C

(1112F)

PV2.H,PV2.L

0 Amp

90 Amp

IN2

PV2

IN2

Linear (V, mA) or SPEC

-19999

45536

P1.2.H, P1.2.L D1.2.H, D1.2.L

IN1, IN2

P1.2.H, P1.2.L D1.2.H, D1.2.L

IN1,IN2

P1 2, P2 1

IN1, IN2

Exception:If any of A1SP

Page 21

Chapter 2

22.2

Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any 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 safe location.

To minimize the possibility of ﬁre or shock hazards, do not expose this instrument to rain or excessive moisture. This control is not to be used in hazardous locations.

Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The controller is only intended for installation in safe areas, or inside properly rated enclosures.

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 is noticed, report and ﬁle a claim with the carrier. Record 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 the 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.

MOUNTING CLAMP

SCREW

98.0mm

+0.3

+0.5

Panel

12.5mm

10.0mm

Figure 2.1 Mounting Dimensions

Page 22

2-3 Wiring Precautions

Fuse

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 is 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.

The “ stripped “ leads as speciﬁed in Figure 2.2 below are used for power and sensor connections.

Beware not to over-tighten the terminal screws.

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 8 are not exceeded.

Electric power in industrial environments contain a certain amount of noise in the form of transient voltage and spikes. This electrical noise can enter and adversely affect the operation of microprocessor-based controls. For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to ground at one end only.

Figure 2.2 Lead Termination

2.0mm

0.08" max.

4.57.0 mm

0.18" 0.27"

2-4 Power Wiring

The controller can operate at 11-26 VAC / VDC or 90-264VAC. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller.

This equipment is designed for installation in an enclosure that will provide 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 unauthorized persons access to the power terminals.

Figure 2.3 Rear Terminal Connection Diagram

OUT2 ALM2

PTA

8910

90-264VAC 47-63 Hz,15VA

8 9

RTD

TC+

PTB PTB

121314

V,CT EI ,TC

2A/240VAC 2A/240VAC

Figure 2.4 Power Supply Connections

V+ ,CT+ EI+,COM

OUT1

AO+

TX1 TX2

12 13 14

ALM1

)TUPTUOCIGOL(1MLA

ALM1

CAT. II

90 264 VA Cor 11 26 VAC/VD

Page 23

2-5 Sensor Installation Guidelines

Figure 2.5 Thermocouple Input Wiring

DIP Switch

Thermocouple

Type

Cable

Material

British

American

ASTM

German

DIN

French

NFE

Copper ( Cu ) Constantan

( Cu-Ni )

+ blue

red

* blue

+ red

brown

* brown

+ yellow

blue

* blue

Iron ( Fe ) Constantan

( Cu- Ni )

+ white

red

* black

+ red

blue

* blue

+ yellow

black

* black

Nickel-Chromium

( Ni-Cr )

Nickel-Aluminum

( Ni-Al )

+ brown

blue

* red

+ yellow

red

* yellow

+ red

green

* green

+ yellow

purple

* yellow

R S

Pt-13%Rh,Pt Pt-10%Rh,Pt

+ white

blue

* green

+ black

red

* green

+ red

white

* white

+ yellow

green

* green

Pt-30%Rh Pt-6%Rh

+grey

red

* grey

Table 2.1 Thermocouple Cable Color Codes

*Color of overall sheath

+ white

blue

* blue

+ yellow

blue

* black

Use Copper Wire

+red

grey

* grey

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 close to the heater. In a process where the heat demand is variable, the probe should be close 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.

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, anti-vibration, antiseptic, etc.

Standard sensor limit s of error are 4˚F (2˚C) or 0.75% of sensed temperature (half that for special) plus drift caused by improper protection or interference.

2-6 Thermocouple Input Wiring

Proper sensor installation can eliminate many problems. Thermocouple input connections are shown in Figure 2.5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the distance between the controller and the thermocouple, ensuring that the correct polarity is observed throughout. Joints in the cable should be avoided, if possible.

If the length of thermocouple plus the extension wire is too long, it may affect the temperature measurement. A 400 ohms K type or a 500 ohms J type thermocouple should be used.

8910

121314

Page 24

2-7 RTD Input Wiring

Figure 2.6 RTD Input Wiring

DIP Switch

Figure 2.10 Input 2 Linear Current Wiring

IN2 = 0-5 V or 1-5 V

Figure 2.9 Input 2 Linear Voltage Wiring

1~5V, 0~10V

RTD connections are shown in Figure 2.6, with the compensating lead connected to terminal 9. For two-wire RTD inputs, terminals 9 and 10 should be linked. The three-wire RTD offers the capability of lead resistance compensation provided that the third wire is installed into PIN 9 as shown in Figure 2.6.

Two-wire RTD should be avoided, if possible, for the purpose of accuracy. A 0.4 ohm lead resistance of a two-wire RTD will produce a 1° C temperature variance every 50ft of lead length.

8910

121314

8910

121314

RTD RTD

Three-Wire RTD

Two-Wire RTD

2-8 Linear DC Input Wiring

DC linear voltage and linear current connections for input 1 are shown in Figure 2.7 and Figure 2.8 .

DC linear voltage and linear current connections for input 2 are shown in Figure 2.9 and Figure 2.10 .

Figure 2.7 Input 1 Linear Voltage Wiring

8910

121314

Figure 2.8 Input 1 Linear Current Wiring

8910

121314

0~1V, 0~5V 1~5V, 0~10V

8910

0~1V, 0~5V

121314

0~20 mA or 4~20 mA

8910

0~20 mA or 4~20 mA

121314

R = 250 Ohms

Page 25

2-9 CT/Heater Current Input Wiring

Figure 2.11 CT Input Wiring for Single Phase Heater

Supply

Figure 2.12 CT Input Wiring for Three Phase Heater

Make sure the total current through CT94-1 does not exceed 50A rms

Supply

Heater 1

Heater 2

Heater Supply

DIN Rail

Heater 3

Current Transformer

CT94 1

Contactor

8910

Contactor

Fuse

121314

CT Signal Input

Main

Current Transformer

CT941

DIN Rail

8910

121314

CT Signal Input

Three Phase Heater Power

Fuse

Main

Page 26

2-10 Event Input Wiring

Open Collector Input

Figure 2.13 Event Input Wiring

8910

121314

The event input can accept a switch signal as well as an open collector signal. The event input function (EIFN) is activated as the switch is closed or an open collector signal is initiated.

Also refer to Section 4-1 for event input function.

2-11 Output 1 Wiring

Figure 2.14 Output 1 Wiring

8910

Switch Input

121314

8910

121314

Relay or Triac (SSR) Output to Drive Contactor

Max. 2A Resistive

Load

121314

Relay Output Direct Drive

Three Phase Delta

Heater Load

Contactor

120V/240V Main Supply

120V /240V Main Supply

Three Phase Heater

Power No Fuse Breaker

Page 27

120V/240V Main Supply

Max. 2A Resistive

Load

Relay Output Direct Drive

Figure 2.14 Output 1 Wiring

8910

121314

Relay or Triac (SSR) Output to Drive Contactor

120V /240V Main Supply

No Fuse Breaker

Three Phase Heater Power

Three Phase Delta

Heater Load

8910

121314

Contactor

30 mA/5V

Pulsed Voltage

SSR

Internal circuit

Load

120V /240V Main Supply

8910

121314

Pulsed Voltage to Drive SSR

0 - 20mA, 4 - 20mA

Load

Maximum Load

500 ohms

121314

Linear Current

8910

0 - 1V, 0 - 5V 1 - 5V, 0 - 10V

Linear Voltage

Load

Minimum Load

10K ohms

Max. 1A/240V

Load

Triac

8910

121314

Triac (SSR) Output Direct Drive

120V /240V Main Supply

Page 28

2-12 Output 2 Wiring

Figure 2.15 Output 2 Wiring

Max. 2A Resistive

Load

120V/240V Main Supply

8910

30 mA/5 V

Pulsed

Voltage

121314

8910

121314

Relay Output Direct Drive

120V /240V Main Supply

Three Phase Delta Heater Load

Contactor

No Fuse Breaker

Relay or Triac (SSR) Output to Drive Contactor

SSR

Internal Circuit

Load

120V /240V Main Supply

Three Phase Heater Power

8910

Pulsed Voltage to Drive SSR

Page 29

Minimum Load

Figure 2.16 Alarm Wiring

0 - 20mA, 4 - 20mA

8910

121314

Linear Current

2-13 Alarm 1 Wiring

Load

Maximum Load 500 ohms

Max. 1A /240 V

Triac

8910

Triac (SSR) Output Direct Drive

Load

121314

8910

120V /240V Main Supply

0 - 1V, 0 - 5V 1 - 5V, 0 - 10V

Linear Voltage

Load

10 K ohms

8910

121314

8910

Internal Circuit

121314

5V DC Relay

Max. 2A Resistive

Load

Single Phase Load

5V DC Relay

Three Phase Delta Heater Load

120V/240V Main Supply

Contactor

120V /240V Mains Supply

Three Phase Heate Power

No Fuse Breaker

Three Phase Load

Page 30

2-14 Alarm 2 Wiring

Figure 2.17 Alarm 2 Wiring

8910

121314

Max. 2A Resistive

Load

Relay Output Direct Drive

120V/240V MainSupply

120V/240V MainsSupply

8910

121314

Three Phase Delta Heater Load

Relay Output to DriveContactor

Contactor

Three Phase Heate

Power No Fuse Breaker

Page 31

Figure 2.18 RS-485 Wiring

2-15 RS-485

8910

TX1

Twisted-PairWire

TX1

TX2

RS-485

RS-485 to RS-232 network adaptor

SNA10A or SNA10B

RS-232

TX1

TX2

8910

Max. 247 units can be linked

TX1

TX2

Terminator 220 ohms/0.5W

Page 32

2-16 RS-232

Figure 2.19 RS-232 Wiring

Figure 2.20 Location of Jumper J51/J52

ort

Figure 2.21 Configuration of RS-232 Cable

8910

121314

COM

TX1TX2

9-pin RS-232 port

CC94-1

NOTE: If the ETR-3400 is configured for RS-232 communication, the input 2 and EI (Event Input)ar

disconnected internally. The unit can no longer perform event input function (EIFN) and input 2 function.

When you insertaRS-232 module (CM94-2) to the connectorson CPU board (C250), the jumper

J51 and J5 must be modified as following: J52 must be shorted and J51 mustbecut and left open.

Location of jumper is shown in the following diagram.

Jumper

25J

15J

25U

15WS

PIDNO

432

55NC

45NC

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.

ETR-3400

TX1

TX2

COM

TX1RD

TX2TD

COMGND

To DTE(PC)RS-232 P

1DCD

2RD 3TD 4DTR 5 GND 6DSR 7 RTS 8 CTS

Female DB-9

9RI

Display

Page 33

2-17 Analog Retransmission

Figure 2.22 Analog Retransmission Wiring

8910

121314

The total effectiveresistanceofserial loads can't exceed500 ohms.

8910

Load

0-20mA, 4-20mA

Retransmit Current

121314

Load

1-5V,0-5V 0-10V

Retransmit Voltage

Load

Indicators PLC's Recorders Data loggers Invertors etc.

The total effective resistance of parallel loads should be greater than 10K Ohms.

Indicators

Load

+++

Load

PLC's Recorders Data loggers Invertors etc.

Page 34

2-18 Programming Port

Don't attempt to make any connectionto these jumpers while the unitisoperating.

Figure 2.23 Programming Port Wiring

520A

See Figure 1.3 in Section 1-3 to find the programming port location.

Programmer connector and ATEconnector inserted here

PIDNO

432

Programmer P11A

Access hole on the bottom view

INPT1

Switch Unit

DMM

SW6400

HP 34401A

Calibrator

NOTE

The programming port is usedfor off-line automatic setup andtestingprocedures only.

Fluke5

Page 35

Chapter 3 Programming the Basic Function

This unit provides a useful function parameter “FUNC”, this is used to select the Function Complexity Level before setup. If the Basic Mode (FUNC = BASC) is selected for a simple application, then the following functions are ignored and deleted from the full function menu:

RAMP, SP2, PB2, TI2, TD2, PL1, PL2, COMM, PROT, ADDR, BAUD, DATA, PARI, STOP, AOFN, AOLO, AOHI, IN2, IN2U, DP2, IN2L, IN2H, EIFN, PVMD, FILT, SLEP, SPMD and SP2F.

Basic Mode Capabilities:

(1) Input 1: Thermocouple, RTD, Volt, mA (2) Input 2: CT for heater break detection (3) Output 1: Heating or Cooling ( Relay, SSR,

SSRD, Volt, mA )

(4) Output 2: Cooling ( Relay, SSR, SSRD, Volt, mA ),

DC Power supply.

(5) Alarm 1: Relay for Deviation, Deviation Band,

Process, Heater Break, Loop Break, Sensor Break, Latch, Hold or Normal Alarm.

(6) Alarm 2: Relay for Deviation, Deviation Band,

Process, Heater Break, Loop Break, Sensor

Break, Latch, Hold or Normal Alarm. (7) Dwell Timer (8) Heater Break Alarm (9) Loop Break Alarm (10) Sensor Break Alarm (11) Failure Transfer (12) Bumpless Transfer (13) PV1 Shift (14) Programmable SP1 Range (15) Heat-Cool control (16) Hardware Lockout (17) Self-Tune (18) Auto-Tune (19) ON-OFF, P, PD, PI, PID Control (20) User Deﬁned Menu (SEL) (21) Manual Control (22) Display Mode (23) Reload Default Values (24) Isolated DC Power Supply (25) PV or SV Selection

If You don’t need:

(1) Second set point (2) Second PID (3) Event input (4) Soft start (RAMP) (5) Remote set point (6) Complex process value (7) Output power limit (8) Digital communication (9) Analog retransmission (10) Power shut off (Sleep Mode) (11) Digital ﬁlter (12) Pump control (13) Remote lockout

Then you can use Basic Mode

Page 36

3-1 Input 1

Figure 3.1 Conversion Curve for Linear Type Process Value

Press to enter Setup Mode. Press to select parameter. The upper display indicates the parameter symbol, and the lower display indicates the selection or the value of parameter.

IN1: Selects the sensor type and signal type for Input 1. 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, 0-1V, 0-5V, 1-5V, 0-10 Default: J-TC if F is selected, K-TC if C is selected.

IN1u: Selects the process unit for Input 1. Range: C, F, PU ( process unit ) If the unit is neither C nor F, then selects PU. Default: C or F.

DP1: Selects the location of the decimal point for most (not all) process related parameters. Range: (For T/C and RTD) NO.DP, 1-DP (For Linear) NO.DP, 1-DP, 2-DP, 3-DP

Default: 1-DP IN1L: Selects the low scale value for the Linear type input 1. T/C Hidden if: or RTD type is selected for IN1.

IN1H: Selects the high scale value for the Linear type input 1. T/C Hidden if: or RTD type is selected for IN1.

How to use IN1L and IN1H : If 4 - 20mA is selected for IN1,let SL speciﬁes the input signal low (i.e. 4mA), SH speciﬁes the input signal high (i.e. 20mA), S speciﬁes the current input signal value, the conversion curve of the process value is shown as follows:

process value

IN1H

PV1

IN1L

SL SHS

S - SL

Formula: PV1 = IN1L + ( IN1H IN1L )

SH - SL

Example: A 4-20mA current loop pressure transducer with range 0 - 15 kg/cm2 is connected to input 1, then perform the following setup : IN1 = 4 - 20 IN1L = 0.0 IN1U = PU IN1H = 15.0 DP1 = 1-DP Of course, you may select another value for DP1 to alter the resolution.

input signal

Page 37

3-2 Out1 & Out2 Types

o1ty: Selects the signal type for Output 1. The selection should be consistent with the output 1 module installed. The available output 1 signal types are : RELY : Mechanical relay SSRD : Pulsed voltage output to drive SSR SSR : Isolated zero-switching solid state relay 4 - 20 : 4 - 20mA linear current output 0 - 20 : 0 - 20mA linear current output 0 - 1V : 0 - 1V linear voltage output 0 - 5V : 0 - 5V linear voltage output 1 - 5V : 1 - 5V linear voltage output 0 - 10V : 0 - 10V linear voltage output

o2ty: Selects the signal type for Output 2 The selection should be consistent with the output 2 module installed. The available output 2 signal types are the same as for O1TY

The range for linear current or voltage may not be very accurate. For 0% output, the value for 4 - 20mA may be

3.8mA to 4mA; while for 100% output, the value for 4 - 20mA may be 20mA to 21mA. However, this deviation will not degrade the control performance at all.

3-3 Rearrange User Menu

The ETR-3400 has the ﬂexibility to provide selection of User Parameters which are most signiﬁcant to your process. These parameters are placed in front of the display sequence.

sel1: Selects the most signiﬁcant parameter for view and change. sel2: Selects the 2nd signiﬁcant parameter for view and change. sel3: Selects the 3rd signiﬁcant parameter for view and change. sel4: Selects the 4th signiﬁcant parameter for view and change. sel5: Selects the 5th signiﬁcant parameter for view and change.

Range: NONE, TIME, A1.SP, A1.DV, A2.SP, A2.DV, RAMP, OFST, REFC, SHIF, PB1, TI1, TD1, C.PB, SP2, PB2, TI2, TD2

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.

Example:

A1FN selects TIMR A2FN selects DE.HI PB1 = 10 TI1 = 0 SEL1 selects TIME SEL2 selects A2.DV SEL3 selects OFST SEL4 selects PB1 SEL5 selects NONE Now, the upper display scrolling becomes:

Page 38

3-4 Display SV Instead of PV

SP1+O1HY/2

SP1

O1HY

Figure 3.2 Heat Only ON-OFF Control

In certain applications where set point value (SV) is more important than process value (PV) for the user, the parameter disf (display format) then can be used to achieve this purpose.

Press keys to enter setup menu set, then press several times until disf appears on the display. If you need the process value to be displayed, then select by using or key for DISF, If you need set point value instead of process value to be displayed, then select S for DISF. Also refer to the ﬂow chart in Section 1-5 to see the location of DISF.

3-5 Heat Only Control

Heat Only ON-OFF Control: Select REVR for OUT1, Set PB1 to 0, SP1 is used to adjust set point value, O1HY is

used to adjust dead band for ON-OFF control, TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). The output 1 hysteresis (O1HY) is enabled in case of PB1 = 0. The heat only on-off control function is shown in the following diagram:

SP1

O1HY/2

OUT1 Action

OFF

The ON-OFF control may still introduce excessive process oscillation if hysteresis achieve a is minimized to the smallest. If ON-OFF control is set (i.e. PB1 = 0), TI1, TD1, CYC1, OFST, CPB and PL1 will be hidden and have no function to the system. The manual mode, auto-tuning, self-tuning and bumpless transfer will be disabled too.

Heat only P (or PD) Control: Select REVR for OUT1, set TI1 to 0, SP1 is used to adjust set point value, TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). OFST been enabled in case of TI1 = 0 is used to adjust the control offset (manual reset). Adjust CYC1 according to the output 1 type (O1TY).Generally, CYC1= 0.5 ~ 2 sec for SSRD and SSR, CYC1=10 ~ 20 sec for relay output .CYC1 is ignored if linear output is selected for O1TY. O1HY is hidden if PB1 is not equal to 0.

OFDT Function: OFST is measured by % with range 0 - 100.0%. In the steady state (i.e. process has been stabilized) if the process value is lower than the set point by a deﬁnite value, say 5˚C, while 20˚C is used for PB1, that is lower 25%, then increase OFST 25%, and vice versa. After adjusting OFST value, the process value will be varied and eventually, coincide with set point. Using the P control (TI1 set to 0), the auto-tuning and self-tuning are disabled. Refer to section 3-21 “ manual tuning “ for the adjustment of PB1 and TD1. 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.

Dead band=

Time

Setup ON-OFF:

OUT1 = reyr PB1 = 0

Adjust: SP1, O1HY, TIME (if enabled)

Setup P:

OUT1 = reyr Tl1 = 0 CYC1 (if RELAY, SSRD or SSR is selected for O1TY Adjust: SP1, OFST, TIME (if enabled) PB1 (≠0), TD1

Page 39

Heat Only PID Control: Selecting REVR for OUT1, SP1 is used to ad-

SP1+O1HY/

SP1

O1HY

Time

Figure 3.3 Cool Only ON-OFF Control

just set point value. TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). PB1 and TI1 should not be zero. Adjust CYC1 according to the output 1 type (O1TY). Generally, CYC1 = 0.5 ~ 2 sec for SSRD and SSR, CYC1 = 10 ~ 20 sec for relay output. CYC1 is ignored if linear output is selected for O1TY.

In most cases the self-tuning can be used to substitute the autotuning. See section 3-19.

Section 3-19: If self-tuning is not used (select NONE for SELF), then use auto-tuning for the new process, or set PB1, TI1 and TD1 with historical values. See section 3-20 for auto-tuning operation. If the control result is still unsatisfactory, then use manual tuning to improve the control . See section 3-21 for manual tuning. ETR-3400 contains a very clever PID and Fuzzy algorithm to acheive a very small over-

Setup PID:

OUT1 = reyr O1TY CYC1 (if RELAY, SSRD or SSR is selected for O1TY) SELF = NONE or YES Adjust: SP1, TIME ( if enabled ), PB1 (= 0), TI1 (= 0), Td1. Auto Tuning: Used for new process. during initial tuning Self Tuning: Used for a process any time Manual Tuning: May be used if selftuning and auto-tuning are inadequate.

shoot and very quick response to the process if it is properly tuned.

3-6 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 in section 3-5 for heat only control except that the output variable (and action) for the cool control is inverse to the heat control, such as the following diagram shows:

SP1

O1HY/2

OUT1 Action

OFF

Setup ON-OFF:

OUT1 = dirt

Dead band =

Time

Page 40

3-7 Heat Cool Control

: Has no influence : Adjust to meet process requirements

Table 3.1 Heat-Cool Control Setup

Control Modes

Heat Uses

Cool Uses

Setup Values

OUT1 OUT2 O1HY OFST

PB1 TI1 TD1

CPB

A2FN A2MD A2HY

Heat :ON-OFF Cool : ON-OFF

Heat :ON-OFF Cool :P(PD)

Heat :ON-OFF Cool : PID

Heat :P(PD) Cool : ON-OFF

Heat : PID Cool : ON-OFF

Heat : PID Cool : PID

OUT1

OUT2

OUT1

OUT2

OUT1

OUT2

REVR

DIRT

REVR

=AL2

COOL

DE.HI

PV1.H

DE.LO

PV1.L

DE.LO

PV1.L

DE.HI

PV1.H

DE.HI

PV1.H

NORM

The Heat-Cool Control can use one of 6 combinations of control modes. Setup of parameters for each control mode are shown in the following table.

NOTE: The ON-OFF control may result in 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, A2SP, A2DV 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. If OUT2 is conﬁgured for ON-OFF control (by selecting = AL2), the OUT2 acts as alarm output, and the process alarm as well as deviation alarm (see section 3-9 & 3-10) can be used. Adjust A2SP to change set point if process alarm is used, and adjust SP1 (with preset A2DV) to change set point if deviation alarm is used.

Examples: Heat PID+Cool ON-OFF: Set OUT1= REVR, OUT2 = AL2, A2FN= PV1.H, A2MD=NORM, A2HY=0.1, PB1=0, TI1=0,TD1=0, and set appropriate values for O1TY and CYC1.

Heat PID+Cool PID: Set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1=0, TI1=0, TD1=0 and set appropriate values for O1TY, CYC1, O2TY, CYC2.

If you have no idea about a new process, then use self-tuning program to optimize the PID values by selecting YES for SELF to enable the self-tuning program. See section 3-19 for self-tuning description. You can use the auto-tuning program for the new process or directly set the appropriate values for PB1, TI1 & TD1 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 3-21 for manual tuning.

Page 41

CPB Programming: The cooling proportional band is measured by % of PB with range 1~255. Initially set 100% for

Timer starts

Figure 3.4 Dwell Timer Function

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 self-tuning and auto-tuning procedures.

Adjustment of CPB is related to the cooling media used. For air used as cooling media, adjust CPB at 100(%). For oil used as cooling media, adjust CPB at 125(%). For water 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 PB1 (or PB2 if PB2 is selected). 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.

3-8 Dwell Timer

Alarm 1 or alarm 2 can be conﬁgured as dwell timers by selecting TIMR for A1FN or A2FN, but not both, otherwise Er07 will appear. As the dwell timer is conﬁgured, the parameter TIME is used for dwell time adjustment. The dwell time is measured in minutes ranging from 0 to 6553.5 minutes. Once the process reaches the set point, the dwell timer starts to count from zero until time out. The timer relay will remain unchanged until time out.

Same case is for alarm 2.

Example:

Set A1FN=TIMR or A2FN=TIMR but not both. Adjust TIME in minutes A1MD ( if A1FN=TIMR ) or A2MD ( if A2FN=TIMR ) is ignored in this case. If alarm 1 is selected for dwell timer, an external 5V DC relay is required to drive AC load.

If alarm 1 is conﬁgured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden.

SP1

or A2

TIME

Time

Page 42

3-9 Process Alarms

195

Figure 3.5 Normal Process Alarm

A A1MD = NORM A1FN=PV1.H

There are at most two independent alarms available by adjusting OUT2. If AL2 is selected for OUT2, then OUT2 will perform alarm 2 function. Now A2FN can’t be selected with NONE, otherwise Er06 will be displayed. A process alarm sets an absolute trigger level (or temperature). When the process (could be PV1, PV 2 or PV1-PV2) exceeds that absolute trigger level an alarm occurs. A process alarm is independent from set point. Adjust A1FN (Alarm 1 function) in setup menu. One of 8 functions can be selected for process alarm. These are: PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H, P1.2.L, D1.2.H, D1.2.L. When the PV1.H or PV1.L is selected the alarm examines the PV1 value. When the PV2.H or PV2.L is selected the alarm examines the PV2 value. When the P1.2.H or P1.2.L is selected the alarm occurs if the PV1 or PV2 value exceed the trigger level. When the D1.2.H or D1.2.L is selected the alarm occurs if the PV1-PV2 (difference) value exceeds the trigger level. The trigger level is determined by A1SP (Alarm 1 set point) and A1HY ( Alarm 1 hysteresis value ) in User Menu for alarm 1. The hysteresis value is introduced to avoid interference action of alarm in a noisy environment. Normally A1HY can be set with a minimum (0.1) value. A1DV and/or A2DV are hidden if alarm 1 and/or alarm 2 are set with process alarm.

Normal Alarm: A1MD = 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: A1MD = 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 alarms are disabled when the power is shut off or if event input is applied with proper selection of EIFN.

Holding Alarm: A1MD = HOLD

A holding alarm prevents an alarm from power up. The alarm is enabled only when the process reaches the set point value (may be SP1or SP2, See section 4-1 event input). Afterwards, the alarm performs same function as normal alarm.

Latching / Holding Alarm: A1MD = LT.HO

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

Examples:

A1SP = 200 A1HY = 10.0 A1MD = NORM A1FN = PV1.H

8 Types of Process Alarms:

PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H, P1.2.L, D1.2.H, D1.2.L

Process Alarm 1 Process Alarm 2

Setup: A1FN, A1MD Setup: OUT2, A2FN, A2MD Adjust: A1SP, A1HY Adjust: A2SP, A2HY Trigger level = A1SPA1/2 A1HY Trigger level = A2SPA1/2 A2HY

Reset Latching Alarm

1. Power off

2. Apply Event input in accordance with proper selection of EIFN

Process proceeds

205

195

1SP = 200 A1HY=10.0

205

195

205 205 20

195 195

OFF

Page 43

Figure 3.6 Latching Process Alarm

A1MD=LTCH A1FN=PV1.H

Process proceeds

210

195

Figure 3.7 Holding Process Alarm

A1MD=HOLD A1FN=PV1.L

0 5

Figure 3.8 Latching/Holding Process Alarm

A1MD=LT.HO A1FN=PV1.L

205

195

205

195

205

195

A1SP=200 A1HY=10.0

Process proceeds

205

195

205

195

210210 210 205

195 195 195

205 205

A1SP=200 A1HY = 10.0 SP1 = 210

205

195

205

195

OFF

Process proceeds

205

195

205

195

210 210 210 21 205

195 195 195 195

205 205 20

A1SP=200 A1HY=10.0 SP1 = 210

Although the above descriptions are based on alarm 1, the same conditions can be applied to alarm 2.

Page 44

3-10 Deviation Alarm

Process proceeds

OUT2 can be conﬁgured as alarm 2 by selecting=AL2. If OUT2 selects=AL2, then output 2 will perform alarm 2 function. Now A2FN can’t be selected with NONE, otherwise Er06 will appear.

A deviation alarm alerts the user when the process deviates too far from set point. The user can enter a positive or negative deviation value (A1DV, A2DV) for alarm 1 and alarm 2. A hysteresis value (A1HY or A2HY) can be selected to avoid interference problem of alarm in a noisy environment. Normally, A1HY and A2HY can be set with a minimum (0.1) value.

Trigger levels of alarm are moving with set point. For alarm 1, Trigger levels=SP1+A1DV 1/2 A1HY. For alarm 2, Trigger levels=SP1+A2DV 1/2 A2HY.

A1SP and/or A2SP are hidden if alarm 1 and/or alarm 2 are set with deviation alarm. One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are: Normal alarm, Latching alarm, Holding alarm and Latching/ Holding alarm. See Section 3-9 for descriptions of these alarm modes.

2 Types of Deviation Alarms: DE.HI, DE.LO Deviation Alarm 1 Deviation Alarm 2:

Setup: A1FN, A1MD Setup: OUT2, A2FN, A2MD Adjust: SP1, A1DV, A1HY Adjust: SP1, A2DV, A2HY Trigger levels = SP1+A1DV 1/2A1HY Trigger levels = SP1+A2DV 1/2A2HY

Figure 3.9

Normal Deviation

Alarm

Figure 3.10

Latching Deviation

Alarm

Figure 3.11

Holding Deviation

Alarm

112

108

100

A1FN=DE.HI, A1MD=NORM, SP1=100, A1DV=10,A1HY=4

Process proceeds

112 108

100

A1FN=DE.HI, A1MD=LTCH, SP1 = 100, A1DV=10, A1HY=4

Process proceeds

100

A1HY=DE.LO, A1MD = HOLD, SP1 = 100, A1DV= -10, A1HY=4

100

112 108

100

112 108

100

112 108

100

112 108

100

112 108

100

112 108

100

OFF

100

OFF

112 108

100

112 108

100

Figure 3.12

Latching/Holding

Deviation Alarm

Process proceeds

100

A1HY= DE.LO, A1MD=LT. HO, SP1 = 100, A1DV= -10, A1HY=4

100

100100

100

Page 45

3-11 Deviation Band Alarm

A deviation band alarm presets two reference levels relative to set point. Two types of deviation band alarm can be conﬁgured for alarm 1 and alarm 2. These are deviation band high alarm (A1FN or A2FN select DB.HI) and deviation band low alarm (A1FN or A2FN select DB.LO). If alarm 2 is required, then select =AL2 for OUT2. Now A2FN can’t be selected with NONE, otherwise er06 will appear. A1SP and A1HY are hidden if alarm 1 is selected with deviation band alarm. Similarly, A2SP and A2HY are hidden if alarm 2 is selected with deviation band alarm.

Trigger levels of the deviation band alarms will move with the set point. For alarm 1, the trigger level=SP1 A1DV. For alarm 2, the trigger level=SP1 A2DV.

One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are: Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm.

See Section 3-9 for descriptions of these alarm modes.

Process proceeds

Figure 3.13

Normal Deviation

Band Alarm

Figure 3.14

Latching Deviation

Band Alarm

Figure 3.15

Holding Deviation

Band Alarm

105 100

A1FN=DB.HI, A1MD=NORM, SP1=100, A1DV=5

A1FN=DB.LO, A1MD=LTCH, SP1 = 100, A1DV=5

105 100

105 100 95

OFF

105

100

Process proceeds

105

100

Process proceeds

105

100 95

105

100

105

100 95

105

100

105

100

105

100 95

105

100

OFF

105

100 95

105

100 95

105

100

105 100 95

Figure 3.16

Latching/Holding

Deviation Band Alarm

A1FN=DB.HI, A1MD=HOLD,SP1 = 100, A1DV=5

Process proceeds

105105 105 105105 105 100100 100 100 100 100 95 95 95 95 95 95

A1FN=DB.HI, A1MD=LT.HO, SP1 = 100, A1DV=5

Page 46

3-12 Heater Break Alarm

Figure 3.17 Heater Break Alarm

A current transformer (part No. CT94-1) should be installed to detect the heater current if a heater break alarm is required. The CT signal is sent to input 2, and the PV2 will indicate the heater current in 0.1 Amp. resolution. The range of the current transformer is 0 to 50.0 Amp. For more detailed descriptions about heater current monitoring, please see Section 3-25.

Example:

A furnace uses two 2KW heaters connected in parallel to warm up the process. The line voltage is 220V and the rating current for each heater is 9.09A. If we want to detect any one heater break, set A1SP=13.0A, A1HY=0.1 A1FN=PV2.L, A1MD=NORM, then

Heater Break Alarm 1 Heater Break Alarm 2

Setup: IN2 = CT Setup: IN2 = CT A1FN = PV2.L A2FN = PV2.L A1MD = NORM A2MD = NORM A1HY = 0.1 A2HY = 0.1 Adjust: A1SP Adjust: A2SP Trigger levels: A1SP 1/2 A1HY Trigger levels: A2SP 1/2 A2HY

Limitations:

1. Linear output can’t use heater break alarm.

2. CYC1 should use 1 second or longer to detect heater current reliably.

No heater breaks 1 heater breaks 2 heaters break

20 30

Alarm !

20 30

Alarm!

Page 47

3-13 Loop Break Alarm

A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if alarm 2 is required to act as a loop break alarm, then set OUT2 withAL2 and A2FN with LB.

TIME, A1SP, A1DV and A1HY are hidden if alarm 1 is conﬁgured as a loop break alarm. Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is conﬁgured as a loop break alarm.

One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are : Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm. However, the Holding mode and Latching/Holding mode are not recommended to be chosen for loop break alarm since loop break alarm will not perform holding function even if it is set with holding or latching/holding mode. See Section 3-9 for the descriptions of these alarm modes.

Loop Break Conditions are detected during a time interval of 2TI1 (double of integral time, but 120 seconds maximum). Hence the loop break alarm doesn’t respond quickly as it occurs. If the process value doesn’t increase (or decrease) while the control variable MV1 has reached to its maximum (or minimum) value within the detecting time interval, a loop break alarm ( f conﬁgured) will be actuated.

Loop Break Alarm 1 Loop Break Alarm 2

Setup: A1FN = LB Setup: OUT2 = =AL2 A1MD = NORM, LTCH A2FN = LB A2MD = NORM, LTCH

Figure 3.18 Loop Break Sources

Heater

Process

Switching Device

Controller

Loop Break Sources: Sensor, Controller, Heater, Switching Device

Loop Break Alarm (if conﬁgured) occurs when any following condition happens:

1. Input sensor is disconnected (or broken).

2. Input sensor is shorted.

3. Input sensor is defective.

4. Input sensor is installed outside (isolated from) the process.

5. Controller fails (A-D converter damaged).

6. Heater (or generally, chiller, valve, pump, motor etc.) breaks or fails or uninstalled.

7. Switching device (used to drive heater) is open or shorted.

Sensor

Page 48

3-14 Sensor Break Alarm

IN1H (or sensor range high)

IN1L (or sensor range low)

Figure 3.19 SP1 Range

Alarm 1 or alarm 2 can be conﬁgured as sensor break alarm by selecting SENB for A1FN or A2FN. If alarm 2 is required for sensor break alarm, then OUT2 should be selected with = AL2.

The sensor break alarm is activated as soon as failure mode occurs. Refer to Section 3-17 for failure mode conditions. Note that A-D Failure also creates a sensor break alarm. TIME,A1SP, A1DV, and A1HY are hidden if alarm 1 is conﬁgured as a sensor break alarm. Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is conﬁgured as a sensor break alarm.

One of 4 kinds of alarm modes can be selected for sensor break alarm. These are: Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm. However, the Holding alarm and Latching/Holding alarm are not recommended to be chosen for sensor break alarm since sensor break alarm will not perform holding function even if it is set with holding or latching/holding mode. See Section 3-9 for the descriptions of these alarm modes.

Sensor Break Alarm 1 Sensor Break Alarm 2

Setup: A1FN=SENB Setup: OUT2= =AL2 A1MD=NORM, LTCH A2FN=SENB Hidden: TIME, A1SP, A1DV A1HY A2MD=NORM, LTCH Hidden: TIME , A2SP, A2DV, A2HY

3-15 SP1 Range

SP1L ( SP1 low limit value ) and SP1H ( SP1 high limit value ) in setup menu are used to conﬁne the adjustment range of SP1.

Setup: SP1L, SP1H Example: A freezer is working in its normal temperature range -10˚F to -15˚F.

In order to avoid an abnormal set point, SP1L and SP1H are set with the following values: SP1L = -15˚F SP1H = -10˚F Now SP1 can only be adjusted within the range from -10˚F to -15˚F.

SP1H

SP1L

Page 49

3-16 PV Shift

35 dif SHIF

Supply more heat

Figure 3.20 PV1 Shift Application

In certain applications it is desirable to shift the controller display value from its actual value. This can be easily accomplished by using the PV1 shift.

Press the “scroll” key until the control reaches the parameter SHIF. The value you adjust here, either positive or negative, will be added to the actual value. The SHIF function will PV1 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˚F, and the desired temperature at the subject to be heated is 200˚F, the controlling value or the temperature at the sensor should be 235˚F. You should input -35˚F as to subtract 35 F 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

Heat

Transfer

165 F 165F 200F

F F F

F temperature

ferenceis observed

Adjust SHIF SHIF= -35

Heat Transfer

° F

Displayis stable SHIF=-35 F PV=SV

tcejbuStcejbuStcejbuS

etaeHretaeHretaeH

Heat Transfer

F532F002F002

rosneSrosneSrosneS

Page 50

3-17 Failure Transfer

The controller will enter failure mode as one of the following conditions occurs:

1. SB1E occurs (due to the input 1 sensor break or input 1 current below 1mA if 4-20 mA is selected or input 1

voltage below 0.25V if 1-5 V is selected) if PV1, P1-2 or P2-1 is selected for PVMD or PV1 is selected for SPMD.

2. SB2E occurs (due to the input 2 sensor break or input 2 current below 1mA if 4-20 mA is selected or input 2

voltage below 0.25V if 1-5 V is selected) if PV2, P1-2 or P2-1 is selected for PVMD or PV2 is selected for SPMD.

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

Failure Mode Occurs as:

1. SB1E

2. SB2E

3. ADER

Failure Transfer of outout 1 and output 2 occurs as: Failure Transfer Setup:

1. Power start (within 2.5 seconds) 1. O1FT

2. Failure mode is activated 2. O2FT

3. Manual mode is activated 3. A1FT

4. Calibration mode is activated 4. A2FT

Failure Transfer of alarm 1 and alarm 2 occurs as:

1. Failure mode is activated The output 1 and output 2 will perform the failure transfer function as one of the following conditions occurs:

1. During power starts (within 2.5 seconds).

2. The controller enters the failure mode.

3. The controller enters the manual mode.

4. The controller enters the calibration mode.

Output 1 Failure Transfer, if activated, will perform:

1. If output 1 is conﬁgured as proportional control (PB1 = 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 (PB1 = 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 (PB1 = 0), then output 1 will be driven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT.

Output 2 Failure Transfer, if activated, will perform:

1. If OUT2 selects 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 selects COOL, and a value of 0 to 100.0 % is set for O2FT, then output 2 will perform failure transfer. Thereafter the value of O1FT will be used for controlling output 2.

Alarm 1 Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm 1 will transfer to the ON or OFF state preset by A1FT.

Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is conﬁgured for A1FN, the alarm 1 will be switched to ON state independent of the setting of A1FT. If Dwell Timer (TIMR) is conﬁgured for A1FN, the alarm 1 will not perform failure transfer.

Alarm 2 Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT.

Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is conﬁgured for A2FN, the alarm 2 will be switched to ON state independent of the setting of A2FT. If Dwell Timer (TIMR) is conﬁgured for A2FN, the alarm 2 will not perform failure transfer.

Page 51

3-18 Bumpless Transfer

Figure 3.21 Benefits of Bumpless Transfer

The bumpless transfer function is available for output 1 and output 2 (provided that OUT2 is conﬁgured as COOL).

Bumpless Transfer is enabled by selecting BPLS for O1FT and/or O2FT and activated as one of the following cases occurs:

1. Power starts (within 2.5 seconds).

2. The controller enters the failure mode. See section 3-17 for failure mode descriptions.

3. The controller enters the manual mode. See section 3-23 for manual mode descriptions.

4. The controller enters the calibration mode. See chapter 6 for calibration mode descriptions.

As the bumpless transfer is activated, the controller will transfer to open-loop control and uses the previous averaging value of MV1 and MV2 to continue control.

Bumpless Transfer Setup:

1. O1FT = BPLS

2. O2FT = BPLS

Bumpless Transfer Occurs as:

1. Power Starts (within2.5 seconds)

2. Failure mode is activated

3. Manual mode is activated

4. Calibration mode is activated

Without

Bumpless

Transfer

Set point

Power interrupted

Sensorbreak

Set point

Large deviation

Time

With

Bumpless

Transfer

Power interrupted

Sensor break

Load varies

Small

deviation

Time

Since the hardware and software need time to be initialized, the control is abnormal as the power is recovered and results in a large disturbance to the process. During the sensor breaks, the process loses power.

After bumpless transfer is conﬁgured, the correct control variable is applied immediately as the power is recovered, the disturbance is small. During the sensor breaks, the controller continues to control by using its previous value. If the load doesn’t change, the process will remain stable. Thereafter, once the load changes, the process may run away. Therefore, Therefore, you should not rely on a bumpless transfer for a longer time. For fail safe reason, an additional alarm should be used to announce the operator when the system fails. For example, a Sensor Break Alarm, if conﬁgured, will switch to failure state and announces the operator to use manual control or take a proper security action when the system enters failure mode.

Page 52

3-19 Self Tuning

Self-tune Menu

-tuning

Default

SELF=NONE

The Self-tuning which is designed by using an innovative algorithm provides an alternative option for tuning the controller. It is activated as soon as SELF is selected with YES. When Self-tuning is working, the controller will change its working PID values and compares the process behavior with previous cycle. If the new PID values achieve a better control, then changing the next PID values in the same direction, otherwise, changing the next PID values in reverse direction. When an optimal condition is obtained, the optimal PID values will be stored in PB1, TI1, TD1 or PB2, TI2, TD2 which is determined by Event Input conditions. See Section 4-1. When Self-tuning is completed, the value of SELF returns to NONE.

When the Self-tuning is enabled, the control variables are tuned slowly so that the disturbance to the process is less than auto-tuning. Usually, the Self-tuning algorithm has a longer run time until ideal conditions are achieved compared to auto-tuning.

Exceptions: The Self-tuning will be disabled as soon as one of the following conditions occurs:

1. SELF is selected with NONE.

2. The controller is used for on-off control, that is PB=0.

3. The controller is used for manual reset, that is TI=0.

4. The controller is under loop break condition.

5. The controller is under failure mode (e.g. sensor break).

6. The controller is under manual control mode.

7. The controller is under sleep mode.

If the self-tuning is enabled, the auto-tuning can still be used any time. The self-tuning algorithm will otherwise run until complete.

Selects

Disable Self

Enable Self-tuning

Beneﬁts of Self-Tuning:

1. Unlike auto-tuning, Self-tuning will produce less disturbance to the process.

3. Changing set point during Self-tuning is allowable. Hence, Self-tuning can be used for ramping set point control

Beneﬁts of Self-Tune:

1. Less disturbance to the process.

2. Perform PID control during tuning period.

3. Available for ramping set point control and remote set point control.

Operation:

The parameter SELF is contained in setup menu. Refer to Section 1-5 to obtain SELF for initiating a self-tuning.

Unlike auto-tuning, Self-tuning doesn’t change control mode during tuning period. It always performs PID control.

as well as remote set point control.

Page 53

3-20 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 setpoint is undesired.

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

Operation

1. The system has been installed normally.

2. Use the default values for PID before tuning.

The default values are : PB1=PB2=18.0 F TI1=TI2=100 sec, TD1=TD2=25.0 sec, Of course, you can use other

reasonable values for PID before tuning according to your previous experiences. But don’t use a zero value for PB1 and TI1 or PB2 and TI2, otherwise, the auto-tuning program will be disabled.

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 until A_t appears on the display.

5. Press ning.

Applicable Conditions:

PB1=0, TI1=0 if PB1,TI1,TD1 assigned PB2=0, TI2=0, if PB2, TI2, TD2 assigned

for at least 3 seconds. The upper display will begin to ﬂash and the auto-tuning procedure is begin-

NOTE: Any ramp function, remote set point or pump function, if used, will be disabled once auto-tuning is activated.

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). See Figure 3.22.

If the auto-tuning begins apart from the set point (Cold Start), the unit enters Warm-Up Cycle. As the process reaches the set point value, the unit enters Waiting Cycle. The waiting cycle elapses a double integral time (Ti1 or TI2, dependent on the selection, see Section 4.1) then it enters a Learning Cycle. The double integral time is introduced to allow the process to reach a stable state. Before learning cycle, the unit performs Pre-Tune function with a PID control. While in learning cycle the unit performs Post-Tune function with an ON-OFF control. Learning cycle is used to test the characteristics of the process. The data are measured and used to determine the optimal PID values. At the end of the two successive ON-OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory.

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

During pre-tune stage the PID values will be modiﬁed if any unstable phenomenon which is caused by incorrect PID values is detected. Without pre-tune stage, like other conventional controllers, the tuning result will be strongly related to the time when the auto-tuning is applied. Hence different values will be obtained every time as autotuning is completed without pre-tune.

Pre-tune Function Advantage: Consistent tuning results can be obtained

Page 54

Auto-tuning

Set

Figure 3.22 Auto-tuning Procedure

Begins

Auto-tuning Complete

Warm-up Cycle

Waiting Cycle

=2 Integral

Time

Point

Pre-tune Stage

PID Control

Auto-tuning Begins

Pre-tune Stage

Waiting Cycle

=2 Integral

Time

Point

Pre-tune Stage

Learning Cycle

Post-tune Stage

ON-OFF Control

Cold Start

Learning Cycle

Post-tune Stage

New PID Cycle

PID Control

Time

Auto-tuning Complete

New PID Cycle

PID Control

ON-OFF Control

Warm Start

PID Control

Time

If the auto-tuning begins near the set point (warm start), the unit passes the warm-up cycle and enters the waiting cycle. Afterward the procedures are the same and a new PID cycle begins.

ATer 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˚F or 500.0˚C).

• or if TI exceeds 1000 seconds.

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

• or if event input state is changed so that set point value is changed.

Solutions to ATer

1. Try auto-tuning once again.

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

3. Don’t change event input state during auto-tuning procedure.

4. Use manual tuning instead of auto-tuning. (See section 3-21).

5. Touch any key to reset ater message

Page 55

3-21 Manual Tuning

zero.

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

Connect the controller to the process and perform the procedures according to Figure 3.23.

Figure 3.23 Manual Tuning Procedure

Use initial PID values to control the process

Wait and Examine the Process

Is steady state reached?

Yes

Does the process oscillate?

Yes

1 Flag

2PB1 PB1

Wait and Examine the Process

steady state reached ?

0 Flag

0.5PB1 PB1

Wait and Examine theProcess

steady state reached?

the process oscillate?

PB1 PBu

Oscillating period Tu

Load newPID values

1.7PBu PB1

0.3Tu TD1

Yes

Does

Yes

Tu TI1

END

Yes

Does the process oscillate?

NOTE:

The finalPID valuescan't be If PBu=0 then set PB1=1. If Tu <1sec, then set TI1=1 sec.

Yes

Flag=0 ? Flag=1 ?

Yes

1.6PB1 PB1 0.8PB1 PB1

Yes

The above procedure may take a long time before reaching a new steady state since the P band was changed. This is particularly true for a slow process. So the above manual tuning procedures will take from minutes to hours to obtain optimal PID values.

Page 56

The PBu is called the Ultimate P Band and the period of oscillation Tu is called Ultimate Period the in the ﬂow

Set

Time

Figure 3.24 Critical Steady

Ta ble 3.2PID Adjustment Guide

Figure 3.25 Effects of PID Adjustment

Time

Set

chart of Figure 3.23. When this occurs, the process is called in a critical steady state. Figure 3.24 shows a critical steady state scenario.

point

If the control performance by using above tuning is still unsatisfactory, the following troubleshooting techniques can be attempted.

ADJUSTMENT SEQUENCE

(1) Proportional Band(P)

PB1 and/or PB2

(2) Integral Time(I)

TI1 and/or TI2

(3) Derivative Time(D)

TD1 and/or TD2

If PB=PBu the process sustains to oscillate

SYMPTOMSOLUTION

Slow Response

High overshoot or Oscillations

Slow Response

Instabilityor Oscillations

Slow Response or Oscillations

High Overshoot

Decrease PB1 or PB2

Increase PB1 or PB2

Decrease TI1 or TI2

Increase TI1 or TI2

Decrease TD1 or TD2

Increase TD1 or TD2

Figure 3.25 shows the effects of PID adjustment on process response

P action

Perfect

point

PB too high

PB too low

Page 57

Time

Set

Figure 3.25 (Continued) Effects of PID Adjustment

Set point

I action

TI too high

Perfect

TI too low

Time

D action

point

TD too low

Perfect

TD too high

Page 58

3-22 Signal Conditioner DC Power Supply

Figure 3.26 DC Power Supply Applications

Three types of isolated DC power supply are available to supply an external transmitter or sensor. These are 20V rated at 25mA, 12V rated at 40 mA and 5V rated at 80 mA. The DC power supply applications are shown in Figure

3.26.

Two-line Transmitter

8910

4-20mA

121314

Three-line Transmitter

OUTCOM

or sensor

Set

OUT2=

(DC Power Supply)

Bridge Typ Sensor

8910

121314

+ +

VormA

Caution: Don’t use the DC power supply beyond its rating current to avoid damage. Purchase a correct voltage to suit your external devices. See ordering code in section 1-2.

Page 59

3-23 Manual Control

The manual control may be used for the following purposes:

1. To test the process characteristics in obtaining a step response as well as an impulse response for data needed in tuning a controller.

2. To use manual control instead of a close loop control as the sensor fails or the controller’s A-D converter fails. NOTE that a bumpless transfer can not be used for a long time. See section 3-18.

3. In certain applications it is desirable to supply a process with a constant demand.

Operation

Press until Hand (Hand Control) appears on the display. Press for 3 seconds then the upper display will begin to ﬂash and the lower display will show H___. The controller now enters the manual control mode. Pressing

the lower display will show C___ and H___ alternately where H___ indicates output 1 (or heating) control

variable value MV1 and C___ indicates output 2 (or cooling) control variable value MV2. Now you can use updown key to adjust the percentage values for H or C.

The controller performs open loop control as long as it stays in manual control mode. The H value is exported to output 1 (OUT1) and C value is exported to output 2 provided that OUT2 is performing cooling function (i.e. OUT2 selects COOL).

Exception

If OUT1 is conﬁgured as ON-OFF control (i.e. PB1=0 if PB1 is assigned or PB2=0 if PB2 is assigned by event input), the controller will never perform manual control mode.

Exit Manual Control

Pressing the keys the controller will revert to its previous operating mode (may be a failure mode or normal control mode).

H384 Means MV1=38.4 % for OUT1 (or Heating)

C763 Means MV2=7.63 % for OUT2 (or Cooling)

3-24 Display Mode

Operation

Press several times until disp (Display) appears on the display. Then press to enter the display mode. You can select more parameters to view by pressing or pressing in reverse sequence. The system mode of the controller and its operation will remain unchanged.

Entering the Display Mode, the upper display will show the parameter value and the lower display will show the parameter symbol except H___ and C___. H___ shows the percentage value for output 1 and C___ shows the percentage value for output 2 on the lower display while the upper display shows the current process value.

PVHI/PVLO

show the historical extreme (maximum or minimum) values of the process on the upper display. The historical extreme values are saved in a nonvolatile memory even if it is unpowered. Press for at least 6 seconds to reset both the historical values PVHI and PVLO and begin to record new peak process values.

MV1/MV2

show the process value on the upper display and H___ shows the percentage control value for the output 1, C___ shows the percentage control value for the output 2.

Page 60

D shows the difference value between process and set point (i.e. PV-SV). This value is used to control

the output 1 and output 2.

P 1 shows the process value of input 1 on the upper display. P 2 shows the process value of input 2 on the upper display. PB shows the current proportional band value used for control. TI shows the current integral time used for control. TD shows the current derivative time used for control. CJCT shows the temperature at the cold junction, measured in C independent of the unit used. P R shows the changing rate of the process in C ( F or PU) per minute. It may be negative if the process

is going down.

P RH/ P RL The maximum and minimum changing rate of the process since power up, are measured in C (F or

PU) per minute. PVRH is a positive value while PVRL is a negative value.

NOTE: The controller will never revert to its PV/SV display from Display Mode unless you press the keys.

3-25 Heater Current Monitoring

A current transformer, CT94-1, should be installed to measure the heater current. Select CT for IN2. The input 2 signal conditioner measures the heater current while the heater is powered and the current value will remain unchanged during the heater’s off-state. The PV2 will indicate the heater process variable against which the CT is measured.

NOTES

If the heater to be measured is controlled by output 1, then CYC1 should select 1 second or longer and O1TY should use RELY, SSRD or SSR . Similarly, if the heater to be measured is controlled by output 2, then CYC2 should select 1 second or longer and O2TY should use RELY, SSRD or SSR to provide an adequate time for A to D converter to measure the signal. Since CT94-1 can detect a full-wave AC current only, a DC or half-wave AC current should not be used.

Accessory Installed: CT94-1 Setup: IN2=CT, O1TY or O2TY=RELY, SSRD or SSR CYC1 or CYC2 >1 sec Limitations:

1. Linear output type can’t be used.

2. CYC1 (or CYC2) should select 1second or longer to detect heater current reliably.

3. Only full-wave AC current can be detected.

3-26 Reload Default Values

The default values listed in Table 1.4 are stored in the memory as the controller leaves the factory. During certain circumstances, it may be helpful to retrieve these values after the parameter values have been changed. Here is an overview of that procedure.

Operation

Press several times until deft. Then press . The upper display will show File use up-down key to select 0 to 1. If C is required select FILE 0 and for F select FILE 1. Then Press for at least 3 seconds. The display will ﬂash a moment and the default values are reloaded.

CAUTION

The procedures mentioned above will change all previous setup data to the factory settings. Before reloading the default values, record the parameters in the controller incase they need to be referenced again.

Page 61

Chapter 4 Programming the Full Function

4-1 Event Input

Refer to Section 2-10 for wiring an event input. The Event input accepts a digital type signal. TWO types of signal: (1) relay or switch contacts and open collector

pull low, can be used to switch the event state.

One of ten functions can be chosen by using Eifn (EIFN) contained in

NONE: Event input no function If chosen, the event input function is disabled. The controller will use PB1, TI1 and TD1 for PID control and SP1 (or other values determined by SPMD) for the control logic.

PID2: If chosen, the second PID set PB2, TI2 and TD2 will be used to replace PID1. SP.P2: If chosen, the SP2, PB2, TI2 and TD2 will replace SP1, PB1, TI1 and TD1 for control.

NOTE: If the second PID set is chosen during Auto-tuning and/or Self-tuning RS.A1: Reset Alarm 1 as the event input is activated. However, if alarm 1 condition is still existent, the alarm 1 will

be retriggered again while the event input is activated. RS.A2: Reset Alarm 2 as the event input is activated. However, if alarm 2 condition is still existent, the alarm 2 will

be retriggered again while the event input is activated. R.A1.2: Reset both Alarm 1 and Alarm 2 as the event input is activated. However, if the alarm 1 and/or alarm 2 are

still existent, the alarm 1 and/or The RS.A1, RS.A2 and R.A1.2 are particularly suitable to be used for all events.

D.O1: Disable Output 1 as the event input is activated. The output 1 control variable MV1 is cleared to zero. D.O2: Disable Output 2 as the event input is activated. The output 2 control variable MV2 is cleared to zero. D.O1.2: Disable both Output 1 and Output 2 by clearing MV1 and MV2 values as soon as the event input is acti-

vated activated.

When any of D.O1, D.O2 or D.O1.2 is selected for EIFN, the output 1 and/or output 2 will revert to their normal conditions as soon as the event input is released.

LOCK: All parameters are locked to prevent from being changed. SP2F = Format of SP2 Value

ACTU: SP2 is an actual value DEVI: SP2 is a deviation value

SP2F Function: Deﬁne format of SP2 value . If SP2F in the setup menu is selected with ACTU, the event input function will use SP2 value for its second set point. If SP2F is selected with DEVI, the SP1 value will be added to SP2. The sum of SP1 and SP2 (SP1+SP2) will be used by the event input function for the second set point value. In certain applications it is desirable to move second set point value with respect to set point 1 value. The DEVI function for SP2 provides a convenient way in this case.

Modiﬁcation from RS-232 to Event input:

Because of limitation on terminals, pin 11 is used for both Event input and RS-232. If you want to change function of ETR-3400 from RS-232 to event input, you must modify jumper J51 and J52 on CPU board by opening jumper J52 and shorting jumper J51. Refer to for Section 2-16 the location of jumper J51/J52.

Page 62

4-2 Second Set Point

In certain applications it is desirable to change the set point automatically without the need to adjust the set point. You can apply a signal to event input terminals (pin 10 and pin 11).The signal applied to event input may come from a Timer, a PLC, an Alarm Relay, a Manual Switch or other devices. Select SP2 for EIFN which is contained in setup menu.

This is available only in the case that SP1.2, MIN.R or HR.R is used for SPMD, where MIN.R and HR.R are used for the ramping function.

Application 1: A process is required to be heated at a higher temperature as soon as its pressure exceeds a certain limit. Set SPMD=SP1.2, EIFN=SP2 (or SP.P2 if the second PID is required for the higher temperature too).

The pressure gauge is switched ON as it senses a higher pressure. Connect the output contacts of the pressure gauge to the event input. SP1 is set with a normal temperature and SP2 is set with a higher temperature. Choose ACTU for SP2. Once the higher temperature is exceeded, the output is closed.

Setup: EIFN choose SP2 or SP.P2 Availability: SPMD Choose SP1.2 or inr or Hr.r Application 2: An oven is required to be heated at 300 C from eight o’clock AM to six o’clock PM. After six o’clock

PM it is desirable to be maintained at 80˚C. Use a programmable 24 hours cycle timer for this purpose. The timer output is used to control event input. Set SPMD=SP1.2, and EIFN=SP2 (or SP.P2 if the second PID is required for the higher temperature too).

SP1 is set with 300˚C and SP2 is set with 80˚C. Choose ACTU for SP2F. After six o’clock PM the timer output is closed. The event input function will select SP2 (=80˚C) to control the process.

Format of SP2 Value

SP2F choose Actu (Actual Value) or de . (Deviation Value)

Refer to Section 4-1 for more descriptions about SP2F function.

4-3 Second PID Set

In certain applications the process characteristics are strongly related to the process value. The ETR-3400 provides two sets of PID values. When the process is changed to different set point, the PID values can be switched to match the new values.

Auto-tuning Second PID:

The optimal PID values for a process may vary with its process value and set point. Hence if a process is used for a wide range of set point, dual PID values are necessary to optimize the control performance. If the ﬁrst PID set is selected (event input is not applied) during auto-tuning procedure, the PID values will be stored in PB1, TI1 and TD1. Similarly, if the second PID set is selected (event input is applied while PID2 or SP.P2 is selected for EIFN) during auto-tuning, the PID values will be stored in PB2, TI2 and TD2 as soon as auto-tuning is complete.

Application 1: Programmed by Set Point (EIFN = SP.P2)

Choose for then both set point and PID values will be switched to another set simultaneously. The signal applied to event input may come from

Application 2: Programmed by Process Value (EIFN = PID2)

If the process value exceeds a certain limit, 500˚F for example, it is desirable to use another PID values to optimize the control performance. You can use a process high alarm to detect the limit of the process value. Choose PV1H for A1FN, A1MD selects NORM, adjust A1SP to be equal to 500˚F, and choose PID2 for EIFN. If the temperature is higher than 500˚F, then alarm 1 is activated. The alarm 1 output is connected to event input, the PID2 for EIFN so that a lower temperature is achieved.

Refer to Section 5-9 for more details.

Page 63

4-4 Ramp & Dwell

200

100

(minutes)

Figure 4.1 RAMP Function

Time (minutes)

minutes

Figure 4.2 Dwell Timer

Ramp

The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for SPMD, the unit will perform the ramping function. The ramp rate is programmed by using RAMP which is shown as degrees per minute.

Example without Dwell Timer

Select MINR for SPMD, IN1U selects F, DP1 selects 1-DP, Set RAMP=10.0. SP1 is set to 200˚F initially, and changed to 100˚F after 30 minutes since power up. The starting temperature is 30˚F. After power up the process is running like the curve shown below:

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

30 40

Time

Dwell

The Dwell timer can be used separately or accompanied with a Ramp. If A1FN selects TIMR, the alarm 1 will act as a dwell timer. Similarly, alarm 2 will act as a dwell timer if A2FN selects TIMR. The timer is programmed by using TIME which is contained in user menu. The Timer starts to count as soon as the process reaches its set point, and triggers an alarm as time out. Here is an example:

Example without Ramp

Select TIMR for A1FN, IN1U selects F, DP1 selects NODP, Set TIME=30.0 SP1 is set to 400˚F initially, and corrected to 200˚F before the process reaches 200˚F. As the process reaches set point (ie. 200˚F) the timer starts to count. The TIME value can still be corrected without disturbing the Timer before time out. The TIME is changed to 40.0 after 28 minutes since the process reached its set point. The behavior of process value and alarm 1 are shown below.

SP1 changed to 200˚F

PV reaches set point

TIME changed to 40.0

minutes

200˚F

Alarm 1 ON

Alarm 1 OFF

Page 64

Once the timer output was energized it will remain unchanged until power reaches setpoint.

(minutes)

40.

30.

Figure 4.3 Ramp Accompanied with a Dwell Timer

Note: The TIMR can’t be chosen for both A1FN and A2FN simultaneously (Er07 Error Code). Ramp & Dwell

A ramp may be accompanied with a dwell timer to control the process. Here is an example.

Example with Ramp & Dwell

Select HRR for SPMD, IN1U selects PU, DP1 select 2-DP, Set RAMP=60.00 A2FN selects TIMR, Set TIME=20.0 As power is applied the process value starts from 0.00 and set SP1=30.00, SP2=40.00. The timer output is used to switch between dwell and ramp functions.

Alarm2OFF

50 60

Alarm 2ON

Time

4-5 Remote Set Point

SPMD selecting PV1 or PV2 will enable the ETR-3400 to accept a remote set point signal. If PV1 is selected for SPMD, the remote set point signal is sent to Input 1, and Input 2 is used for process signal input. If PV2 is selected for SPMD, the remote set point signal is sent to Input 2, and Input 1 is used for process signal. To achieve this, set the following parameters in the Setup: FUNC = FULL SPMD = PV2, PVMD = PV1 or SPMD = PV1, PVMD = PV2.

Case 1: Use Input 2 to accept remote set point FUNC=FULL IN2, IN2U, DP2, IN2L, IN2H, are set according to remote signal. PVMD=PV1 IN1, IN1U, DP1, are set according to the process signal IN1L, IN1H if available, are set according to the process signal SPMD= PV2

Case 2: Use Input 1 to accept remote set point FUNC=FULL IN1, IN1U, DP1, IN1L, IN1H, are set according to remote signal. PVMD=PV2 IN2, IN2U, DP2, are set according to the process signal IN2L, IN2H if available, are set according to the process signal SPMD= PV1

NOTE: If PV1 are chosen for both SPMD and PVMD, an Er01 Error Code will appear. If PV2 are chosen for both SPMD and PVMD, an Er02 Error Code will appear. You should not use these cases, otherwise, the ETR-3400 will not function.

Page 65

4-6 Differential Control

Figure 4.4

In certain applications it is desirable to control a second process such that its process value always deviates from the ﬁrst process with a constant value. To set up differential control, see below.

Setup: PVMD = P1-2 or PVMD = P2-1, SPMD=SP1.2

FUNC=FULL IN1,IN1L,IN1H are set according to input 1 signal IN2,IN2L,IN2H are set according to input 2 signal IN1U, DP1, IN2U, DP2, are set according to input 1 and input 2 signal PVMD=P1-2 or P2-1 SPMD=SP1.2

Relation between PV1 and PV2 for a Differential Control

PV1

PV2

PV=PV1 PV2 or PV2 PV1

=Set point

Set point=SP1or SP2

Time

The PV display will indicate PV1-PV2 value if P1-2 is chosen for PVMD, or PV2-PV1 value if P2-1 is chosen for PVMD. If you need PV1 or PV2 to be displayed instead of PV, you can use the Display Mode to select PV1 or PV2 to have either value shown.

Error Messages

If PVMD selects P1-2 or P2-1, while SPMD selects PV1 or PV2, an Er03 will appear.

In this case the signals used for input 1 and input 2 should be the same unit and same decimal point, that is, IN1U=IN2U, DP1=DP2, otherwise Er05 Error Code will appear.

Page 66

4-7 Output Power Limits

100%

Figure 4.5 Power Limit Function

In certain systems the heater (or cooler) is over-designed such that the process is too heavily heated or cooled. To avoid an excessive overshoot and/or undershoot you can use the Power Limit function.

Output 1 power limit PL1 is contained in User Menu. If output 2 is not used for cooling (that is COOL is not selected for OUT2), then PL2 is hidden. If the output power limit feature is required for cooling, set OUT2 to COOL. See below example.

Operation:

Press for 3 seconds, then press several times to reach PL1 and PL2.

Example:

OUT2=COOL, PB1=10.0 F, CPB=50, PL1=50, PL2=80 The output 1 and output 2 will act as following curves:

MV1

50%

Note: Adjusting the range of MV1 (H) and MV2 (C) for manual control and/or failure transfer are not limited by PL1 and PL2.

10 F

OUT1

MV2

80%

OUT2

Page 67

4-8 Data Communication

Two types of interface are available for Data Communication. These are RS-485 and RS-232 interface. Since RS485 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. 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 can make for a very economic and powerful package.

RS-485 Beneﬁts: Long Distance, Multi-Units. (Order ETR-3400-XXXXX1 for RS-485) RS-232 Beneﬁts: Direct Connect to a PC. (Order ETR-3400-XXXXX2 for RS-232)

Setup

Enters the setup menu. Select FULL (Full function) for FUNC. Select 485 for COMM if RS-485 is required, or 232 if RS-232 is required. Select RTU (i.e. Modbus protocol RTU mode) for PROT. 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.

RS-485 Setup: FUNC=FULL, COMM=485, PROT=RTU, ADDR=Address, BAUD=Baud Rate, DATA=Data Bit Count, PARI=Parity Bit, STOP=Stop Bit Count

RS-232 Setup: FUNC=FULL, COMM=232, PROT=RTU, ADDR=Address, BAUD=Baud Rate, DATA=Data Bit Count, PARI=Parity Bit, STOP=Stop Bit Count

Note: If the ETR-3400 is conﬁgured for RS-232 communication, the EI (Event Input) and input 2 are disconnected internally. The unit can no longer perform until an RS-232 module is connected.

When you insert an RS-232 module (CM94-2) to the connectors on the CPU board (C250), you also need to modify the jumper J51 and J52 according to Section 2-16.

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 2-16.

Page 68

4-9 Analog Retransmission

AOLO AOVAOHI

Figure 4.6 Conversion Curve for Retransmission

The Analog Retransmission is available for model number ETR-3400-XXXXXN

Setup

Select FULL for FUNC in the setup menu.

COMM selects a correct output signal which should be accordant with the retransmission option used. Five types of retransmission outputs are available. These are : 4-20 mA, 0-20mA, 0-5V, 1-5V and 0-10V. There are 8 types of parameters that can be retransmitted according to the Analog Function (AOFN) selected. These are : PV1, PV2, PV1 PV2, PV2 PV1, SV, MV1, MV2 and PV SV. Refer to Table 1.4 for a complete description. AOLO selects a value corresponding to output zero and AOHI selects a value corresponding to output signal High.

Setup Menu:

Func = FUNC Comm = COMM AoFn = AOFN Aolo = AOLO Aohi = AOHI

How to Determine Output Signal

AOLO and AOHI are set to map to output signal LOW SL (e.g. 4mA) and output signal High SH (e.g. 20mA) respectively. The analog output signal AOS corresponding to an arbitrary value of parameter AOV is determined by the following curve.

Output Signal

AOS

Formula:

AOS=SL(AOV AOLO)+

AOV=AOLO(AOSSL)+

SH SL

AOHI AOLO

AOHI AO

SH SL

Notes: The setup values used for AOHI and AOLO must not be equal, otherwise, an incorrect value will be achieved. However, AOHI can be set either higher or lower than AOLO. If AOHI is set higher than AOLO it could result in a direct conversion. If AOHI is set lower than AOLO it could result in a reverse conversion.

Example: A control uses 4-20 mA analog output to retransmit difference value between input 1 and input 2 (Pv1 Pv2). It is required that if the difference value is -100, 4mA will be exported, and if the difference value is 100, 20mA will be exported. Make the following Setup for ETR-3400: IN1U PU, DP1 NODP, IN2U PU, DP2 NODP, FUNC FULL, COMM 4-20, AOFN P1-2, AOLO -100, AOHI 100.

Parameter Value

Page 69

4-10 Digital Filter

Figure 4.7 Filter Characteristics

In certain applications the process value is too unstable to be read. To improve this, a programmable low pass ﬁlter incorporated in the ETR-3400 can be used. This is a ﬁrst order ﬁlter with a time constant speciﬁed by the FILT parameter which is contained in the setup menu. 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.

FILT=0

1 sec

FILT=1

FILT=30

Note: The Filter is available only for PV1, 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.

1 sec

4-11 Sleep Mode

To enter Sleep Mode:

FUNC selects FULL to provide full function. SLEP selects YES to enable the sleep mode. Press for 3 seconds, the unit will enter its sleep mode.

During sleep mode:

(1) Shut off all display except a decimal point which is lit periodically. (2) Shut off all outputs and alarms.

To Exit Sleep Mode:

(1) Press to leave the sleep mode. (2) Disconnect the power.

Sleep Function can be used to replace a power switch to reduce the system cost.

Default: SLEP=NONE, Sleep mode is disabled. Note: If the Sleep mode is not required by your system, the SLEP should select NONE to disable sleep mode

against undesirable occurrence.

Sleep Mode Features: Setup Menu, Shut off display, Shut off outputs, Green Power, Replace Power Switch Set Up Menu: FUNC = FULL, SLEP = YES

Page 70

4-12 Pump Control

Pump Control function is one of the unique features of the ETR-3400. Using this function, the pressure in a process can be controlled precisely. The pressure in a process is commonly generated by a pump driven by a variable speed motor. The complete system has the following characteristics which affects the control behavior:

1. The system is very noisy

2. The pressure is changed very rapidly.

3. The pump characteristics is ultra nonlinear with respect to its speed

4. The pump can’t generate any more pressure as its speed is lower than half of its rating speed

5. An ordinary pump may slowly vibrate or show movement.

Obviously a conventional controller can’t fulﬁll the conditions mentioned above. Only the superior noise rejection capability in addition to the fast sampling rate owned by ETR-3400 can realize such application. To achieve full functionality, see below.

FUNC = FULL SELF = NONE EIFN = NONE SPMD = PUMP PVMD = PV1 SP2F = DEVI FILT = 0.5

and program the following parameters in the user menu: REFC= Reference constant SP2= A negative value is added to SP1 to obtain the set point for idle state

Since the pump can’t produce any more pressure at lower speed, the pump may not stop running even if the pressure has reached the set point. If this happens, the pump will get worn out and waste additional power. To avoid this, the ETR-3400 provides a Reference Constant REFC in the user menu. If PUMP is selected for SPMD, the controller will periodically test the process by using this reference constant after the pressure has reached its set point. If the test shows that the pressure is still consumed by the process, the controller will continue to supply appropriate power to the pump. If the test shows that the pressure is not consumed by the process, the controller will gradually decrease the power to the pump until the pump stops running. As this happens, the controller enters idle state. The idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below this set point. The idle state is provided for the purpose of preventing the pump from completely stopping and restarting too frequently.

Pump Control Features:

1. Minimum oscillation of pressure

2. Rapidly stabilized

3. Guaranteed pump stop

4. Programmable pump stopping interval

The pump functions are summarized as follows:

1. If the process is demanding material (i.e. lose pressure), the controller will precisely control the pressure at set point.

2. If the process no longer consumes material, the controller will shut off the pump as long as possible.

3. The controller will restart the pump to control the pressure at set point as soon as the material is demanded again while the pressure falls below a predetermined value (i.e. SP1+SP2).

Page 71

Programming Guide:

1. Perform auto-tuning to the system under such a condition that the material (i.e. pressure) is exhausted at typical rate. A typical value for PB1 is about 10 Kg/cm2, TI1 is about 1 second, TD1 is about 0.2 second.

2. If the process oscillates around the set point after auto-tuning, then increase PB1 until the process can be stabilized at set point. The typical value of PB1 is about half to two times of the range of pressure sensor.

3. Increasing FILT (Filter) can further reduce oscillation amplitude. But a value of FILT higher than 5 (seconds) is not recommended. A typical value for FILT is 0.5 or 1 .

4. Close the valves and determine if the controller will shut off the pump each time. The value of REFC is adjusted as small as possible so that the controller can shut off the pump each time when all the valves are closed. A typical value for REFC is between 3 and 5.

5. An ordinary pump may slowly lose the pressure even if the valves are completely closed. Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time as the valves are closed. A typical value for SP2 is about -0.50 Kg/cm2.

An Example is given in section 5-1 for pump control.

4-13 Remote Lockout

The parameters can be locked out to prevent any changes by using either Hardware Lockout (see Section 1-3) or Remote Lockout or both. If you need the parameters to be locked by using an external switch (remote lockout function), then connect a switch to terminals 10 and 11 (see Section 2-10), and choose LOCK for EFIN (see Sec- tion 4-1).

If remote lockout is conﬁgured, all parameters will be locked as the external switch is closed. When the switch is left open, the lockout condition is determined by internal DIP switch (hardware lockout, see Section 1-3).

Hardware Lockout: Can be used only during initial setup Remote Lockout: Can be used any time

Page 72

Chapter 5 Applications

Figure 5.1 A water Supply System

Water

5-1 Pump / Pressure Control

A regulated water supply system is widely used in residence, water plant, chemical plant, electrical plant, semiconductor plant ... etc. Taking the advantage of PUMP function, the ETR-3400 can be used for these types of applications.

ETR-3400-4137XX

Kg/cm

Pressure Reservoir

Pressure Sensor

ETR-3400

OUT1

4-20

IN1

Speed Control

4-20mA

OUT2

Motor

C20V

Wate

Pump

Inverter

The water pressure is required to be controlled at 10 Kg/cm

, to achieve this, the following devices are used for

this example:

Inverter: To supply a variable frequency AC voltage to the motor. Motor: A 3-Ø induction motor. Pump: An economical type Presser Sensor: A three-wire or two-wire type pressure transducer with 0-20 Kg/cm cm2 range Pressure Reservior: Providing a smoother pressure for the system. ETR-3400-4237XX: Order a ETR-3400 with standard input, 4-20 mA output 1, 20V DC output 2 for sensor power.

Page 73

Set the following parameters in the setup menu:

Control Input

Figure 5.2 Block Diagram of VPFW SSR

FUNC=FULL OUT1=REVR FILT=1

COMM: optional O1TY=4-20 SELF=NONE

IN1=4-20 O1FT=0 SLEP=NONE

IN1U=PU OUT2=DCPS SPMD=PUMP

DP1=2-DP A1FN: optional SP1L=5.00

IN1L=0 EIFN=NONE SP1H=15.00

IN1H=20.00 PVMD=PV1 SP2F=DEVI

IN2=NONE

Adjust the following parameters in the user menu: A1SP: optional Key menu:

REFC= 3 SPMD PB1=10.00 SP2F TI1=1 REFC TD1=0.2 SP2

SP2= -0.50

PL1=100

Also refer to Section 4-12 for more details.

5-2 Variable Period Full Wave SSR (VPFW SSR)

VPFW SSR is a variable period full wave solid-state relay. It can provide a zero cross output with superior controllability compared to a conventional SSR with cycle time adjustment.

Input

Output

Pulsed Voltage

Page 74

Unlike a conventional SSR, the VPFW SSR always give the output an even number of half cycles (full wave) as

Control

Figure 5.3 VPFW SSR vs. Conventional SSR

Ta ble 5.1 Function Comparison between Conventional SSRand VPFW SSR

shown in the following diagram.

VPFW SSR Conventional SSR

Input

ower Input

ower Output

The VPFW switches the load without DC current, hence minimizing the harmonic current and stress on the load. The load life is prolonged.

As the duty cycle (i.e. output power level) of the control input is small, the off period will be extended to keep the output resolution so that the conversion error is minimized. As low as 0.1% of timing error can be achieved. Hence, VPFW SSR is particularly suitable for a smoother control.

NOTES:

1. The VPFW SSR can be used to drive resistant load and some types of inductance load such as relay, contactor, magnetic switch, solenoid valve etc. However, it can not drive Motor and Capacitance Load.

2. Only AC power can supply VPFW SSR, otherwise, it will not operate properly.

The advantages of VPFW SSR over conventional SSR are summarized as following table:

Functions

Zero Cross Switching

Time Base Va riable Fixed

Proportional Timing Error

Control Achievement

Half on Cycles

DC Load Current

Harmonic Current

Stress on the Load

Load ( Heater ) Life

VPFW SSRConventionalSSR

0.1%

Excellent

Even

Zero

Low

Longer

The output 1 and output 2 of ETR-3400 can be connected to VPFW SSR directly provided that a pulsed voltage drive output (ETR-3400-XX2XXX or ETR-3400-XXX2XX) is ordered.

1% ( for 1 sec.

cycle time )

Good

Even and Odd

Nonzero

Higher

Shorter

Page 75

Here is an example:

Figure 5.4 VPFW SSR Application Example

ETR-3400-XX22XX

ETR-3400

OUT1=REVR O1TY=SSRD CYC1=1.0 (sec)

OUT2=COOL O2TY=SSRD

CYC2=1.0 (SEC)

_ _

VPFW SSR

AC Power

Three phase VPFW SSR’s are also available upon request.

5-3 Heat Only Control

An oven is designed to dry the product at 150˚F for 30 minutes and then stay unpowered for another batch. An ETR-3400 equipped with dwell timer is used for this purpose. The system diagram is shown as follows:

Figure 5.5 Heat Control Example

Set

SP1=150.0 TIME=30.0

ETR-3400

Oven

T/C

Heater

OUT1

Timer ( ALM2)

Mains Supply

OFF

Page 76

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

Figure 5.6 Cooling Control Example

Supply

SetupSummary:

UserMenu:

FUNC = BASC (Basic function) IN1 = K_TC IN1U = F DP1 = 1_DP OUT1 = REVR O1TY = RELY CYC1 = 18.0 O1FT = BPLS A2FN = TIMR A2FT = ON SELF = NONE

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

5-4 Cool Only Control

An ETR-3400 is used to control a refrigerator at temperature below 32˚F. To avoid the set point adjustment beyond the desired range, SP1L is set at 14˚F and SP1H is set at 32˚F. 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, PB1 is set with zero and O1HY is set at 0.1˚F.

FUNC = BASC IN1 = PT.DN IN1U = F DP1 = 1-DP OUT = DIRT O1TY = RELY SP1L = 14F SP1H = 32F

PB1 = 0(F) O1HY = 0.1(F)

Refrigerator

RTD

ETR-3400

Mains

Page 77

5-5 Heat-Cool Control

Figure 5.7 Heat-Cool Control Example

An injection mold needs to be controlled at 120˚F to ensure a consistent quality for the parts. An oil pipe is buried in the mold. Since plastics are injected at a higher temperature (e.g. 250˚F), the circulation oil needs to be cooled as its temperature rises. Here is an example:

Plastics

Freezer

4-20 mA

OUT2

Injection Mold

120 F

Oil Pump

OilTank

RTD

Heater Supply

OUT1

ETR-3400

IN1

Page 78

The PID Heat-Cool is used for the preceeding example.

FUNC = BASC IN1 = PT.DN IN1U = ˚F DP1 = 1-DP OUT1 = REVR O1TY = RELY CYC1 = 18.0 (sec) O1FT = BPLS OUT2 = COOL O2TY = 4-20 O2FT = BPLS SELF = STAR

Adjust SP1 at 120.0 F and CPB at 100 (%). Apply Auto-Tuning at 120˚F for a new system to get an optimal PID values. See Section 3-20.

The ETR-3400 is designed without heating-cooling dead band. The dead band, however, is implicitly contained in a very clever program such that if the process value increases (not necessarily exceeds the set point), the cooling control will provide an optimal amount of cool to the process. If the process value decreases, the controller will adjust its adaptive dead band to increase the heating action and decrease the cooling action immediately. While in the steady state the heating and cooling will not operate simultaneously. This is because the controller has been designed to minimize energy consumption. Also refer to Section 3-7 for more details.

5-6 Ramp & Dwell

Example 1: Temperature cycling Chamber

EIFN = SP.P2 A1FN = TIMR OUT1 = REVR, Relay Output OUT2 = COOL, 4-20mA Output SPMD = MINR IN1U = ˚F DP1 = 1-DP

A chamber is used to test the temperature cycling effect on personal computers. An external cycle timer is used to control the event input for switching the set point. The products under test are required to stay at 60˚F for 1 hour and -10 F for 30 minutes. The transition interval between high-low temperature is required to be 5 minutes. Make the following setup:

Page 79

The circuit diagram and its temperature proﬁle are shown below:

TIME = 60.0 (minutes) SP1 = 60.0˚F SP2 = -10.0˚F CPB = 100(%) RAMP = 14.0 (F/minute)

Figure 5.8 Temperature Cycling Chamber

Figure 5.9 Temperature Profile of Chamber

Chamber

Freezer

Heater

3AC

1 Mains

Inverter

RTD

5V DC

Relay

60 minutes 60 minutes

8910

121314

OFF

Cycle Timer

5 minutes

-10 F -10 F

minutes

65 minutes

minutes

Page 80

ETR-3400 provides 4-20 mA signal to control the speed of the Inverter SP.P2 being chosen for EIFN is for the

Figure 5.10 A Bread Baking Oven

180

down

Figure 5.11 Temperature Profile of Baking Oven

purpose of accomplishing a dual PID control. You can perform auto-tuning twice at SP1 and SP2 for initial setup to the dual values.

Bread is baked in batches. A ramp is incorporated to control the thermal gradient to suit for making the bread. A dwell timer is used to shut off the oven power and signal the baker. The system is conﬁgured as shown in the following diagram.

AC Relay

Heater

220VA Main

Baking Oven

Heater

8910

121314

OFF

5V DC Relay

Push ON switch to start a batch. The temperature will rise with a ramp rate determined by RAMP value. Bread is baked with the set point temperature for a deﬁnite time which is programmed by TIME value, and then the power is shut off. The temperature proﬁle is shown in the following Figure.

30 F

minutes

180 F

minutes

30 F/min

Restart a new batch

Cooling

A1FN = TIMR SPMD = MINR Time = 40.0 (minutes) RAMP = 30.0 (˚F/min) Alarm1: Form B Rela

Time ( minutes )

Page 81

5-7 Remote Set Point

Master

Figure 5.12 Remote Set Point Application

An on-line multiple zone oven is used to dry paint. Since heat demand is various at different positions in the production line, multiple zones with individual controls should be used to ensure a consistent temperature proﬁle.

If you order a ETR-3400 with a retransmission unit for the master controller, and retransmit its set point to the input 2 of the rest of slave controllers, each zone will be synchronized with the same temperature. Here is an example:

To Control Zone 1 Heater

To Control Zone 2 Heater

OUT1 OUT1 OUT1 OUT1

ETR-3400 ETR-3400 ETR-3400ETR-3400

13 12 10 10 1011 11 11

+ + +

SlaveSlave Slave

Set the following parameters in the setup menu:

For Master Unit: For Slave Units

FUNC= FULL FUNC= FULL COMM= 1-5 V IN2= 1-5 V AOLO= 0˚F IN2L= 0˚F AOHI = 300˚F IN2H= 300˚F PVMD= PV1 PVMD= PV1 SPMD= SP1.2 SPMD= PV2

To Control Zone 3Heater

To Control Zone 4Heater

NOTE: AOHI and IN2H should be set with values higher than the set point range used.

Page 82

5-8 Differential Control

Figure 5.13 Differential Control Example

In certain applications controlling a second process such that its process value always deviates from the ﬁrst process with a constant value may be required. Water tank 1 is 5.12 meters height and water tank 2 level is desirable to be maintained at 1 meter lower than tank 1 level.

Set the following parameters in the setup menu: FUNC= FULL IN1, IN1L, IN1H : According to Sensor 1 signal IN1U= PU DP1= 2-DP IN2, IN2L, IN2H: According to Sensor 2 signal (Current signal has to be converted to a voltage signal through a shunt resistor before sending to the controller input)

IN2U= PU DP2= 2-DP OUT1= REVR O1TY= 4-20 PVMD= P1-2 SPMD=SP1.2

From Controller Output

SV=1.00 PV=1.00 PV1=5.12 PV2=4.12

ETR-3400

4-20 mA Valve Control Output

OUT1

Water Tank 1

Level Sensor 1

5.12MHeight

Outlet

WaterTank 2

Level Sensor 2

4.12 MHeight

Outlet

IN1IN2

Adjust SP1(here it is 1.00) to control the difference between PV1 and PV2. Choosing P1-2 for PVMD, the PV display will show the difference value (PV1-PV2) between PV1 and PV2, and this value will be stabilized to the set point If you need PV1 or PV2 instead of PV, you can use the Display Mode to select PV1 or PV2 to be displayed. See Section 3-24. The above diagram indicates PV2 instead of PV.

Page 83

5-9 Dual Set Point / PID

Figure 5.14 Dual PID Furnace

800

Figure 5.15 Dual PID Crossover

The ETR-3400 will switch between the two PID sets based on the process value, the set point or either of the event input. As the control ramps up to the higher process value, the process characteristics change. As this happens, the original PID values are no longer valid. To achieve optimal control over the entire range, a second PID set is used.

Example 1: Single Set Point / Dual PID

A heat treating furnace is used over the range of 400˚F to 1200˚F

1. Set the following parameters in the Setup menu:

FUNC= FULL A1FN= PV1H A1MD= NORM EIFN= PID2 PVMD= PV1 SPMD= MINR

2. Adjust the following parameters in the User menu:

A1SP= 800˚F A1HY= 1.0˚F PL1= 100 (%) RAMP: According to the process requirement SP1: According to the process requirement

3. Tune ﬁrst PID set at SP1= 500˚F and tune second PID set at SP1=1100˚F, or set the proper values for PB1, TI1, TD1, PB2, TI2 and TD2 directly according to the previous records to eliminate auto-tuning sequence.

The circuit diagram and its temperature proﬁle are shown as follows:

8910

121314

To Furnace Heater

Alarm 1controls Event input

Process Value

AC powe

Power Input

UsePID

PID CrossoverValue

UsePID

Time

Page 84

Example 2: Dual Set Point / PID

Figure 5.16 Dual Set Point /PID Profile

1000

Time(Minutes )

A heat treating furnace is required to harden the mold at a high temperature (1000˚F) for 30 minutes, then the mold is cooled down with a programmable ramp (20˚F/minute) toward a lower set point (200˚F). Use the dual set point / PID and ramp / dwell functions for this application.

1. Set the following parameters in the Setup menu: FUNC= FULL A1FN= TIMR EIFN= SP.P2 PVMD= PV1 SPMD= MINR

2. Adjust the following parameters in the User menu: TIME= 30.0 (Minutes) RAMP= 20.0 (˚F/Minute) SP1= 1000˚F SP2= 200˚F PL1= 100 (%)

3. Set the proper values for PB1, TI1, TD1,PB2, TI2 and TD2 directly according to the previous records. For a new system tune ﬁrst PID set at SP1=800˚F and tune second PID set at SP2=400˚F.

The circuit diagram is same as shown in Figure 5.14. The temperature proﬁle is shown as below:

200

Use SP1,PID1 Use SP2,PID2

minutes

Page 85

5-10 RS-485

Figure 5.17 RS-485 Applications

A ﬁle making plant has 5 production lines. Each production line is equipped with 16 units of ETR-3400 to control the temperature for the kiln. The company wishes to program the controllers and monitor the process in the control room for the purpose of improving the quality and productivity. A cost effective solution for the above application is to use 80 units of ETR-3400 plus a SNA 10B Smart Network Adaptor and PC based software for this purpose.

The system is installed as shown in the following diagram.

Kiln1

ETR-3400

TX1

TX2

Terminator, 220 ohms/0.5W

TX1

TX2

ETR-3400

TX1TX1

TX2TX2

Kiln 2 Kiln 3 Kiln 4

Kiln 5

ETR-3400

TX1

TX2

ControlRoom

(ETR-Net )

RS-232

SNA10B

TX1TX2

ETR-3400 ETR-3400

TX1

TX2

TX1TX1

TX2TX2

ETR-3400

TX1

TX2

Tw isted-pair wire, max. distance 1Km

Page 86

Setup

Enter the setup mode to conﬁgure each ETR-3400. Choose FULL for FUNC, 485 for COMM, RTU for PROT and select an unequal address (ADDR) for each unit. Use the same values of BAUD, DATA, PARI and STOP for each ETR-3400, SNA10B and ETR-Net. Also refer to Section 2-15 and Section 4-8.

Taking advantage of ETR-Net software, the operator can monitor the process on the PC screen, program the set point as well as other control parameters such as PID values, down load the ramp and soak proﬁle to the control-

lers, execute the manual control or trigger an auto-tuning.....etc., and print out a report as required. The historical

data can be saved on ﬂoppy disc, hard disc or a CD for permanent storage purpose.

5-11 RS-232

Suppose a chemical experiment is performed in a laboratory. An engineer desires to ﬁnd the relation between a chemical reaction and temperature. He uses an ETR-3400 to control the temperature of the solution under test. A test report containing the relation between the concentration and temperature can then be recorded and analyzed in detail.

For a single unit application it is adequate to order a ETR-3400-xxxxx2 with RS-232 communication and a ETR- Net software. By using the ETR-Net software, the temperature data can be viewed and stored in a ﬁle. The user can program the temperature as well as other control parameters such as PID values. He can setup the controller,

down load a ramp and soak proﬁle, also execute the manual control or auto-tuning procedure..... etc. The results

can be easily be read and reviewed as well as adjusted.

5-12 Retransmit

An air-conditioned room uses two units of an ETR-3400 to control its temperature and humidity. The temperature and humidity need to be recorded on a chart recorder. The required ranges for these two quantities are: 20˚F to 30˚F and 40% RH to 60% RH. The recorder inputs accept 0 - 5 V signal. To achieve this, set the following parameters in the Setup menu.

Unit 1 Unit 2

FUNC = FULL FUNC = FULL COMM = 0-5 V COMM = 0-5 V AOFN = PV1 AOFN = PV1 AOLO = 20.0(˚F) AOLO = 40.0 (%) AOHI = 30.0(˚F) AOHI = 60.0 (%) IN1= PTDN IN1 = 0 - 1 V (According to humidity sensor ) IN1U = ˚F IN1U = PU DP1= 1-DP DP1 = 1-DP

Page 87

SP1=

25.0

SP1L= SP1H=

Figure 5.18 Retransmission Application

SP1L and SP1H are usedto limit the adjustment range of set point.

20.0

30.0

SP1= 50.0 SP1L= 40.0

SP1H= 60.0

%R H

ETR-3400 ETR-3400

12 13 13

0-5V 0-5V

Retransmission Output

1. 20-30F 2. 40-50%

Chart Recorder

Page 88

Chapter 6 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 the system is in a safe position to enter calibration mode.

Equipment needed before calibration:

1. A high accuracy calibrator (Fluke 5520A Calibrator recommended) with A test chamber providing 25˚C - 50˚C temperature range

2. A switching network (SW6400, optional for automatic calibration)

3. A following functions:

0 - 100 mV millivolt source with 0.005% accuracy 0 - 10 V voltage source with 0.005% accuracy 0 - 20 mA current source with 0.005% accuracy 0 - 300 ohm resistant source with 0.005% accuracy

4. A calibration ﬁxture equipped with programming units (optional for automatic calibration)

5. A PC installed with calibration software ETR-Net and Smart Network Adaptor SNA10B (optional for automatic calibration)

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

Since it needs 30 minutes to warm up a unit before calibration, calibrating the units one by one is quite inefﬁcient. An automatic calibration system for small batches is recommended.

Manual Calibration Procedures

Perform Step 1 to enter Calibration Mode.

1. Set the lockout DIP switch to the unlocked condition ( both switches 3 and 4 are off ).

Press both scroll and down keys and release them quickly. The operation mode menu will appear on the dis-

play. Repeat the operation several times until CALi appear on the display.

Press Scroll key for at least 3 secdonds. The display will show Ad0 and the unit enters calibration mode. The

output 1 and output 2 use their failure transfer values to control.

*Perfrom step 2 ro calibrate Zero of the A to D converter and step 3 to calibrate gain of the A to D converter.

The DIP switch is set for T/C input.

2. Short terminals 10 and 11 , press the scroll key for at least 3 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 -360 or 360, then the calibration fails.

3. Press scroll key until the display shows adg. Send a 60 mV signal to terminals 10 and 11 in correct polarity . Press the scroll key for at least 3 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 step 4 to calibrate voltage function (if required) for input 1.

4. Change the DIP switch for the Voltage input. Press scroll key until the display shows. Send a 10 V signal to terminals 10 and 11 in correct polarity. Press scroll key for at least 3 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 5 and 6 to calibrate RTD function (if required) for input 1.

Page 89

5. Change the DIP switch for the RTD input . Press scroll key until the display shows ref.1. Send a 100 ohms

Figure 6.1 RTD Calibration

Figure 6.2 Cold Junction Calibration Setup

signal to terminals 8, 9 and 10 according to the connection shown below:

100 ohms

ETR-3400

DIP Switch Position

T/C input

1 2 3 4

DIPSwitch Position

010V input

1 2 3 4

DIP SwitchPosition

RTD input

1 2 3 4

Press scroll key for at least 3 seconds . The display will blink a moment, otherwise the calibration fails.

6. Press the scroll key and the display will show Sr.1. Change the ohm’s value to 300 ohms .Press scroll key for at least 3 seconds. The display will blink a moment and two values are obtained for SR1 and REF1 (last step). Otherwise, if the display didn’t blink or if any value obtained for SR1 and REF1 is equal to -199.9 or 199.9, then the calibration fails.

Perform step 7 to calibrate mA function (if required) for input 1.

7. Change the DIP switch for mA input. Press the scroll key until the display shows a1.g. Send a 20 mA signal to terminals 9 and 10 in correct polarity. Press scroll key for at least 3 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 step 8 to calibrate voltage as well as the CT function (if required) for input 2.

8. Press scroll key until the display shows 2.G. Send a 10 V signal to terminals 10 and 11 in correct polarity. Press scroll key for at least 3 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 step 9 to calibrate offset of cold junction compensation if required. The DIP switch is set for T/C input.

9. Setup the equipment according to the following diagram for calibrating the cold junction compensation. Note that a K type thermocouple must be used.

DIP Switch Position

mA input

1 2 3 4

DIP Switch Position

TC input

1 2 3 4

5520A Calibrator

K-TC

K+

ETR-3400

Must remain at least 20 minutes in still-air room with a temperature of 253˚C

The 5520A calibrator is conﬁgured as K type thermocouple output with internal compensation. Send a 0.00˚C

signal to the unit under supervision.

Page 90

The unit under calibration is powered in a still-air room with temperature 25˚ ±3˚C. Leave at least 20 minutes for

warming up. The DIP Switch is located at TC input.

Perform step 1 stated above, then press scroll key until the display shows Cjt.l. Apply up/down key until value

0.00 is obtained. Press scroll key at least 3 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.

Perform step 10 to calibrate gain of cold junction compensation if required, junction test otherwise, perform

step 10N to use a nominal value for the cold junction gain if a test chamber for calibration is not available.

10. Setup the equipment same as step 9. The unit under calibration is powered in a still-air room with temperature 50˚ ±3˚C. Stay at least 20 minutes for warming up. The calibrator source is set at 0.00˚C with internal compensation mode.

Perform step 1 stated above , then press the scroll key until the display shows CJ.G. Apply up/down key until

value 0.0 is obtained. Press scroll key for at least 3 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.

Perform step 1 stated above, then press scroll key until the display shows CJ.G. Apply up/down key until value

0.1 is obtained. Press scroll key for at least 3 seconds. The display will blink a moment and the new value 0.0 is obtained. Otherwise, the calibration fails.

CAUTION: it is not recommended to use this step 10N, since the cold junction will prevent accurate readings.

11. Set the DIP switch to your desired position (refer to section 1-3)

Automatic Calibration Procedures

The programming port (see Section 2-18) of ETR-3400 can be used for automatic calibration.

Page 91

Chapter 7 Error Codes & Troubleshooting

Figure 7.1 Dismantling the Controller

This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage is possible. Take proper precautions before proceeding.

Troubleshooting Procedures:

1. If an error message is displayed, refer to Table 7.1 to see what cause it is and apply a corrective action to the failed unit.

2. Check each point listed below. Most Temperature control problems are not related directly to the control itself.

• Line wires are improperly connected

• No voltage between line terminals

• Incorrect voltage between line terminals

• Connections to terminals are open, missing or loose

• Thermocouple is open at tip

• Thermocouple lead is broken

• Shorted thermocouple leads

• Short across terminals

• Open or shorted heater circuit

• Open coil in external contactor

• Burned out line fuses

• Burned out relay inside control

• Defective solid-state relays

• Defective line switches

• Burned out contactor

• Defective circuit breakers

3. If the points listed on the above chart have been checked and the controller does not function properly, it is recommended that the instrument be returned to the factory for inspection.

Do not attempt to make repairs without qualiﬁed engineer and proper technical information. This may create

costly damage. Also, it is advisable to use adequate packing materials to prevent damage in transportation.

4. Dismantle the controller according to Figure 7.1

Refer to Table 7.2 for some probable causes and actions

Press both sides of the latch located on rear terminal block. Hold tightly and remove the terminal block from the housing.

Expand the rear edge of the housing by using a tool. Pull out the PCB from the housing

ETR-3400

Page 92

Table 7.1 Error Codes

Display

Error Code

Symbol

Error Description

Illegal setup values been used: PV1 is usedfor both PVMD and SPMD.Itis meaninglessfor control.

Illegal setup values been used: PV2 is usedfor both PVMD and SPMD.Itis meaninglessfor control

Illegal setup values been used: P1-2or P2-1is used for PVMD while PV1 or PV2 is usedfor SPMD. Dependent values usedfor PV andSV will create incorrect result of control

Illegal setup values been used: Before COOLisused for OUT2, DIRT ( cooling action)has already been used for OUT1, or PID modeisnot usedfor OUT1(thatisPB1 or PB2 =0, and TI1or TI2 =0)

Illegal setup values been used: unequal IN1U and IN2Uor unequalDP1 andDP2 while P1-2or P2-1is usedfor PVMD or, PV1 or PV2 is usedfor SPMD or, P1.2.H, P1.2.L, D1.2.H or D1.2.Lare usedfor A1FN or A2FN.

Illegal setup values been used: OUT2 select =AL2 but A2FN select NONE

Illegal setup values been used: Dwell timer (TIMR)is selectedfor both A1FN and A2FN.

Communication error:bad function code

Communication error: register address out of range

Communication error: accessanon-existent parameter

Corrective Action

Check and correct setup valuesof PVMD and SPMD.PV andSV can'tuse the same valuefor normal control

Sameas error code1

Check and correct setup valuesof PVMD and SPMD. Differenceof PV1 and PV2 can'tbe usedfor PV while PV1 or PV2 is usedfor SV

Check and correct setup valuesof OUT2, PB1, PB2, TI1, TI2 and OUT1. IF OUT2is requiredfor cooling control, the control shoulduse PID mode(PB =0,TI=0)and OUT1 shoulduse reverse mode (heating action), otherwise, don't use OUT2for cooling control

Check and correct setup valuesof IN1U, IN2U, DP1, DP2, PVMD, SPMD, A1FN or A2FN. Same unit and decimal point shouldbe usedif both PV1 and PV2 are usedfor PV,SV, alarm1or alarm2.

Check and correct setup valuesof OUT2and A2FN. OUT2 willnot perform alarm functionif A2FN select NONE.

Check and correct setup valuesof A1FN and A2FN. Dwell timercan onlybe properly usedfor single alarm output.

Correctthe communication softwareto meetthe protocol requirements.

Don't issuean over-range addresstothe slave.register

Don't issueanon-existent parametertothe slave.

Communication error: attemptto writearead-only data

Communication error: writeavalue whichis out of rangeto a register

Failto perform auto-tuning function

EEPROM can'tbe written correctly

Input 2(IN2)sensor break,or input2current below1mA if 4-20mAis selected,or input2voltage below 0.25Vif 1-5V is selected

Input 1(IN1)sensor break,or input1current below1mA if 4-20mAis selected,or input1voltage below 0.25Vif 1-5V is selected

AtoDconverteror related component(s) malfunction

Don't writearead-only dataoraprotected datatothe slave.

Don't writean over-range datatothe slave register.

1.The PID values obtained after auto-tuning procedure are outof range. Retry auto-tuning.

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

3. Don't change Event input state during auto-tuning procedure.

4.Use manual tuning insteadof auto-tuning.

Returnto factory for repair.

Replace input2sensor.

Replace input1sensor.

Returnto factory for repair.

Page 93

Table 7.2 Common Failure Causes and Corrective Actions

Symptom

1) Keypad does not function

2) LED's will not light

3) Somesegmentsofthe display or LEDlamps not lit or lit erroneously.

4) Display Unstable

5) Considerable errorin temperature

indication

6) Display goesinreverse direction ( counts down scale as processwarms )

7) No heator output

8) Heatoroutput staysonbut indicator reads normal

9) Control abnormalor operation incorrect

10) Display blinks; entered values change

by themselves

-Badconnection betweenPCB &keypads

-Nopower to instrument

- Power supplydefective

-LED displayor LED lamp defective

- RelatedLED driver defective

-Analog portion or A-D converter defective

- Thermocouple,RTD or sensor defective

- Intermittent connection of sensor wiring

-Wrong sensoror thermocouple type, wrong input mode selected.

-Analog portionof A-D converter defective

- Reversedinput wiringof sensor

-Noheaterpower(output), incorrect output deviceused

- Output device defective

- Open fuse outsideofthe instrument

- Output deviceshorted, or power service shorted

-CPU or EEPROM ( non-volatile memory ) defective. Keyswitch defective

- Incorrect setup values

- Electromagnetic interference(EMI ), or Radio Frequency interference(RFI)

- EEPROM defective

snoitcAevitcerroCsesuaCelbaborP

- Cleancontact areaonPCB

- Replace keypads

- Checkpower line connections

- Replace power supply board

- Replace LED displayorLED lamp

- Replace the relatedtransistororIC chip

- Replace related componentsor board

- Check thermocouple,RTD or sensor

- Check sensor wiring connections

- Check sensoror thermocouple type andif proper input mode was selected

- Replace related componentsor board

- Checkand correct

- Checkoutput wiringand output device

- Replace output device

- Replace output fuse

- Checkand replace

- Readthe setup procedure carefully

- Suppress arcing contactsin system to

eliminate high voltage spike sources. Separate sensorand controller wiring from " dirty"powerlines, groundheaters

- Replace EEPROM

Page 94

Chapter 8 Speciﬁcations

Power

90 264 VAC, 47 63 Hz, 15VA, 7W maximum 11 26 VAC / VDC, 15VA, 7W maximum

Input 1

Resolution: .......................................................... 18 bits

Sampling Rate ..................................................... 5 times/second

Maximum rating: .................................................. -2 VDC minimum, 12 VDC maximum (1 minute for mA input)

Temperature Effect: ............................................. 1.5 uV/ C for all inputs except mA input

3.0 uV/ C for mA input

Sensor Lead Resistance Effect: .......................... T/C: 0.2uV/ohm

3-wire RTD: 2.6 C/ohm of resistance difference of two leads 2-wire RTD: 2.6 C/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 & mV inputs, 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 sec. for TC, RTD & mV inputs, 0.1 sec. for 4-20 mA

and 1 - 5 V inputs.

Characteristics:

Type Range Accuracy @ 25˚C Input Impedance

J -120˚C to 1000˚C (-184˚F to 1832˚F) 2˚C 2.2 MΩ

K -200˚C to 1370˚C (-328˚F to 2498˚F) 2˚C 2.2 MΩ

T -250˚C to 400˚C (-418˚F to 752˚F) 2˚C 2.2 MΩ

E -100˚C to 900˚C (-148˚F to 1652˚F) 2˚C 2.2 MΩ

B 0˚C to 1820˚C (- 32˚F to 3308˚F) 2˚C (200˚C to 1820˚) 2.2 MΩ

R 0˚C to 1767.8˚C (-32˚F to 3214˚F) 2˚C 2.2 MΩ

S 0˚C to 1767.8˚C (-32˚F to 3214˚F) 2˚C 2.2 MΩ

N -250˚C to 1300˚C (-418˚F to 2372˚F) 2˚C 2.2 MΩ

L -200˚C to 900˚C (-328˚F to 1652˚F) 2˚C 2.2 MΩ

PT100 (DIN) -210˚C to 700˚C (-346˚F to 1292˚F) 0.4˚C 1.3 KΩ

PT100 (JIS) -200˚C to 600˚C (-328˚F to 1112˚F) 0.4˚C 1.3 KΩ

mV -8 mV to 70 mV 0.05% 2.2 MΩ

mA -3 mA to 27 mA 0.05% 70.5Ω

V -1.3 V to 11.5 V 0.05% 302 KΩ

Input 2

Resolution: .......................................................... 18 bits

Sampling Rate: .................................................... 1.66 times / second

Maximum Rating: -2 VDC minimum, 12 VDC maximum Temperature Effect: 1.5 uV/˚C

Common Mode Rejection Ratio (CMRR): ........... 120dB

Normal Mode Rejection Ratio (NMRR): 55dB

Sensor Break Detection: ..................................... below 0.25 V for 1-5 V input, unavailable for other inputs.

Sensor Break Responding Time: ......................... 0.5 second

Page 95

Characteristics:

Type Range Accuracy @ 25˚C Input Impedance

CT94-1 0 to 50.0 A 2% of Reading 0.2 A 265 KΩ

V -1.3 to 11.5 V 0.05% 265 K

Input 3 (Event Input)

Logic Low: ........................................................... -10V minimum, 0.28V maximum.

Logic High: .......................................................... Open or 0.32V minimum, 10V maximum

External pull-down Resistance: ........................... 200 KΩ maximum

External pull-up Resistance: ............................... not necessary

Functions: ............................................................

disable output 1 and/or output 2, remote lockout.

Select second set point and/or PID, reset alarm 1 and/or alarm 2,

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 Zero Tolerance Span Tolerance Load Capacity

4-20 mA 3.8 to 4 mA 20 to 21 mA 500 Ω max.

0-20 mA 0 mA 20 to 21 mA 500 Ω max.

0-5 V 0 V 5 to 5.25 V 10 KΩ min.

1-5 V 0.95 to 1 V 5 to 5.25 V 10 KΩ min.

0-10 V 0 V 10 to 10.5 V 10 KΩ min.

Linear Output

Resolution: .......................................................... 15 bits

Output Regulation: .............................................. 0.01 % for full load change

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

Isolation Breakdown Voltage: .............................. 1000 VAC

Temperature Effect: 0.0025% of SPAN/˚C

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

DC Voltage Supply Characteristics (Installed at Output 2)

Type Tolerance Max Output Current Ripple Voltage Isolation Barrier

20 V 0.5 V 25 mA

12 V 0.3 V 40 mA

5 V 0.15 V 80 mA

0.2 Vp-p

0.1 Vp-p

0.05 Vp-p

500 Vac.

Page 96

Alarm 1 / Alarm 2

Alarm 1: ............................................................... 5V DC logic output, max. source current 100mA, short circuit

unprotected.

Alarm 2 Relay: .....................................................

Alarm Functions: .................................................

Deviation Band High/Low Alarm, PV1 High/Low Alarm PV2 High/Low Alarm, PV1 or PV2 Hig /Low Alarm PV1-PV2 High/Low Alarm, Loop Break Alarm, Sensor Break Alarm.

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

Dwell Timer: ......................................................... 0 - 6553.5 minutes

Form A, Max. rating 2A/240VAC, life cycles 200,000 for resistive load. Dwell timer, Deviation High / Low Alarm

Data communication

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

Protocol: .............................................................. Modbus Protocol RTU mode

Address: .............................................................. 1 - 247

Baud Rate: ........................................................... 0.3 ~ 38.4 Kbits/sec

Data Bits: ............................................................. 7 or 8 bits

Parity Bit: ............................................................. None, Even or Odd

Stop Bit: .............................................................. 1 or 2 bits

Communication Buffer: ....................................... 50 bytes

Analog Retransmission

Functions: ............................................................ PV1, PV2, PV1-PV2, PV2-PV1, Set Point, MV1, MV2,

PV-SV deviation value

Output Signal: ..................................................... 4-20 mA, 0-20 mA, 0 - 1V, 0 - 5V, 1 - 5V, 0 - 10V

Resolution: .......................................................... 15 bits

Accuracy: ............................................................ 0.05 % of span 0.0025%/˚C

Load Resistance: ................................................. 0 - 500 ohms ( for current output)

10 K ohms minimum (for voltage output)

Output Regulation: .............................................. 0.01% for full load change

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

Isolation Breakdown Voltage: .............................. 1000 VAC min.

Integral Linearity Error: ........................................ 0.005% of span

Temperature Effect: ............................................. 0.0025 % of span/˚C

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: ................................... Upper 0.4” (10 mm), Lower Port (8mm)

Keypad: ............................................................... 3 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 1~255% of PB

ON-OFF: .............................................................. 0.1 - 100.0(˚F) hysteresis control (P band = 0)

P or PD: ............................................................... 0 - 100.0 % offset adjustment

PID: ...................................................................... Fuzzy logic modiﬁed, Proportional band 0.1 ~ 900.0˚F.,

Integral time 0-1000 seconds, Derivative time 0-360.0 seconds

Cycle Time: .......................................................... 0.1 - 100.0 seconds

Manual 100.0 (˚F) Control: ................................... Heat (MV1) and Cool (MV2)

Auto-tuning: ......................................................... Cold start and warm start

Self-tuning: .......................................................... Select None and YES

Failure Mode: ....................................................... Auto-transfer to manual mode while sensor break or

A-D converter damage

Sleep Mode: ........................................................ Enable or Disable

Ramping Control: ................................................ 0 - 900.0 F/minute or 0 - 900.0 F/hour ramp rate

Page 97

Power Limit: ........................................................ 0 - 100 % output 1 and output 2

Pump / Pressure Control: .................................... Sophisticated functions provided

Remote Set Point: ............................................... Programmable range for voltage or current input

Differential Control: .............................................. Control PV1-PV2 at set point

Digital Filter

Function: .............................................................. First Order

Time Constant: .................................................... 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable

Environmental & Physical

Operating Temperature: ....................................... -10 C to 50˚C

Storage Temperature: .......................................... -40 C to 60˚C

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

Insulation Resistance: ......................................... 20M ohms 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

Shock Resistance: ............................................... 200 m/s2 (20 g)

Moldings: ............................................................. Flame retardant polycarbonate

Dimensions: .........................................................

Weight: ................................................................ 120 grams

50mm(W) x 26.5mm(H) x 110.5mm(D), 98.0 mm depth behind panel

Approval Standards

Safety: ................................................................. UL873 (11th edition, 1994), CSA C22.2 No. 24-93,

EN61010-1 (IEC1010-1)

Protective Class: .................................................

EMC: .................................................................... EN61326

NEMA 4X (IP65) front panel, indoor use, IP 20 housing & terminals

Page 98

A-1 Menu Existence Conditions

Menu Existence Conditions Table

Parameter

User

Setup Menu

Notation Existence Condition

SP1 Exists unconditionally

TIME Exists if A1FN selects TIMR or A2FN selects TIMR

A1SP Exists if A1FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L

A1DV Exists if A2FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L

A2SP Exists if A1FN selects DEHI, DELO, DBHI, or DBLO

A2DV Exists if A2FN selects DEHI, DELO, DBHI, or DBLO

RAMP Exists if SPMD selects MINR or HRR

OFST Exists if TI1 is used for control (depends on Event input and EIFN selection) but TI1= 0

and PB1=0 or if TI2 is used for control (depends on Event input and EIFN selection) but TI2= 0 and PB2=0

REFC Exists if SPMD selects PUMP

SHIF

PB1

TI1

TD1

CPB, DB Exists if OUT2 select COOL

SP2 Exists if EIFN selects SP2 or SPP2, or if SPMD selects PUMP

PB2 Exists if EIFN selects PID2 or SPP2

TI2

TD2

O1HY If PID2 or SPP2 is selected for EIFN, then O1HY exists if PB1= 0 or PB2 = 0. If PID2 or

A1HY Exists if A1FN selects DEHI, DELO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H, or

A2HY Exists if A2FN selects DEHI, DELO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H, or

PL1 If PID2 or SPP2 is selected for EIFN, then PL1 exists if PB1= 0 or PB2 = 0. If PID2 or

PL2 Exists if OUT2 selects COOL

FUNC Exists unconditionally

COMM Exists if FUNC selects FULL

PROT

ADDR

BAUD

DATA

PARI

STOP

AOFN Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10

AOLO

AOHI

Exists unconditionally

Exists if PB1= 0

Exists if EIFN selects PID2 or SPP2 provided that PB2= 0

SPP2 is not selected for EIFN, then O1HY exists if PB1= 0

D12L

SPP2 is not selected for EIFN, then PL1 exists if PB1= 0

Exists if COMM selects 485 or 232

Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10 and AOFN is not MV1 and MV2

Page 99

Setup

(cont’d.)

Parameter

Notation Existence Condition

IN1

Exists unconditionallyIN1U

IN1L

IN1H

Exists if IN1selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10

IN2 Exists if FUNC selects FULL

IN2U

DP2

IN2L

Exists if IN2 selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10

IN2H

OUT1

O1TY

CYC1

Exists unconditionally

O1FT

OUT2

O2TY

Exists if OUT2 selects COOLCYC2

O2FT

A1FN Exists unconditionally

A1MD

Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H, D12L, LB or SENB

A1FT Exists if A1FN is not NONE

A2FN Exists unconditionally

A2MD Exists if A2FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H,

P12L, D12H, D12L, LB or SENB

A2FT Exists if A2FN is not NONE

EIFN

Exists if FUNC selects FULLPVMD

FILT

SELF Exists unconditionally

SLEP

SPMD

SP1L

SP1H

Exists if FUNC selects FULL

Exists unconditionally

SP2F Exists if EIFN selects SP2 or SPP2, or if SPMD selects PUMP

SEL1

SEL2

SEL3

Exists unconditionally

SEL4

SEL5

Page 100

A-2 Factory Menu Description

Parameter

Notation

EROR

PROG

MODE

CMND

JOB

DRIF

AD0

ADG

V1G

CJTL

CJG

REF1

SR1

MA1G

V2G

SIG1*

IND1*

SIG2*

IND2*

SIG3*

IND3*

SIG4*

IND4*

SIG5*

IND5*

SIG6*

IND6*

SIG7*

IND7*

SIG8*

IND8*

SIG9*

IND9*

TYPE*

DATE

HOUR

Display

Format Parameter Description Range

Eror Prog

D___

CJtL

ref1

sig1 ind1 sig2 ind2 sig3

ind3 sig4 ind4 sig5 ind5 sig6 ind6 sig7 ind7 sig8 ind8 sig9 ind9 type date

Hour

Current Error Code Low: 0 High: 40 —

Program Identiﬁcation Code Contains Program Number and Version Number

Contains Lockout Status Code and Current

ode

System Mode

Command Password Low: 0 High: 65535 —

Job Password Low: 0 High: 65535 —

Job

Warm-up Drift Calibration Factor Low: -5˚C High: 5.0˚C —

A to D Zero Calibration Coefﬁcient Low: -360 High: 360 —

Ad0

A to D Gain Calibration Coefﬁcient Low: -199.9 High: 199.9 —

Adg

Voltage Input 1 Gain Calibration Coefﬁcient Low: -199.9 High: 199.9 —

Cold Junction Low Temperature Calibration Coefﬁcient

Cold Junction Gain Calibration Coefﬁcient Low: -199.9 High: 199.9 —

Cjg

Reference Voltage 1 Calibration Coefﬁcient for RTD 1

Serial Resistance 1 Calibration Coefﬁcient for

sr1

RTD 1

mA Input 1 Gain Calibration Coefﬁcient Low: -199.9 High: 199.9 —

A1g

Voltage Input 2 Gain Calibration Coefﬁcient Low: -199.9 High: 199.9 —

Point 1 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 1 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 2 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 2 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 3 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 3 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 4 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 4 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 5 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 5 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 6 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 6 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 7 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 7 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 8 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 8 Indication Value of Special Sensor Low: -19999 High: 45536 —

Point 9 Signal Value of Special Sensor Low: -19999 High: 45536 —

Point 9 Indication Value of Special Sensor Low: -19999 High: 45536 —

Signal Type of Special Sensor Low: 0 High: 3 —

Manufacturing Date of Product Low: 0 High: 3719 —

Serial Number of Product Low: 1 High: 999 —

Working Hour Value Low: 0 High: 65535 —

Low: 0 High: 15.99 —

Low: 0 High: 3.5 —

Low: -5.00 High: 40.0˚C —

Low: -199.9 High: 199.9 —

Default

Value