Fuji Electric PYX Operating Manual

Instruction Manual

FUZZY CONTROLLER X

Type: PYX

SEL

OUT1

OUT2

ALM1

ALM2

INP-TN1PYXf-E

Contents

I. PREPARING THE OPERATION ............................... 4

1. THE BASIC INSTALLATION PROCEDURE .................... 5

2. CHECK OF SPECIFICATIONS ........................................ 6

2.1 PYX4 MODEL CONFIGURATION ........................... 6

2.2 PYX5/9 MODEL CONFIGURATION ........................ 7

3. ACCESSORIES................................................................ 8

4. INSTALLATION ................................................................ 8

4.1 INSTALLATION PLACE ........................................... 8

4.2 INSTALLATION PROCEDURE ................................ 9

4.3 CAUTION ON SAFETY ............................................ 10

4.4 PANEL CUT DIMENSIONS ..................................... 18

5. WIRING ............................................................................ 19

5.1 PYX4 WIRING DIAGRAM [When the output 1 is relay (SPST) output,

SSR drive output or current output].......................... 19

5.2 PYX4 WIRING DIAGRAM

[When the output 1 is relay (SPDT) output].............. 21

5.3 PYX5/9 WIRING DIAGRAM

(NOT UNIVERSAL OUTPUT) .................................. 23

5.4 PYX5/9 WIRING DIAGRAM

(UNIVERSAL OUTPUT) ........................................... 26

5.5 NOTES ..................................................................... 28

II. FRONT PANEL LAYOUT .......................................... 30

III. OPERATION PROCEDURE ...................................... 33

1. OPERATION MODE/PARAMETER SETTING MODE ..... 33

2. VIEWING PARAMETERS ................................................ 33

3. CHANGING PARAMETERS............................................. 35

IV.SETTING INPUT AND OUTPUT TYPES .................. 37

Changing input ............................................................................. 37

Changing scale (voltage/current input) ......................................... 41

Changing output (universal output) .............................................. 42

V. FUNCTIONS .............................................................. 44

Lock .............................................................................................. 44

Auto-tuning ................................................................................... 47

Control function ............................................................................ 51

Alarm ............................................................................................ 55

Ramp soak ................................................................................... 60

Two set-points .............................................................................. 64

Analog output (AO) ....................................................................... 65

Digital output................................................................................. 67

Manual operation .......................................................................... 69

Remote SV ................................................................................... 71

Output monitoring ......................................................................... 72

VI.SET-UP PARAMETER .............................................. 73

Input filter ...................................................................................... 73

PV shift ......................................................................................... 74

Control type .................................................................................. 75

Output setting in input abnormal................................................... 76

Output limits.................................................................................. 77

Set point value limits..................................................................... 78

Output cycle time .......................................................................... 79

Direct/reverse control action......................................................... 81

Control processing cycle time....................................................... 82

APPENDIX...................................................................... 83

1. ERROR MESSAGES........................................................ 83

2. POWER FAILURE ............................................................ 83

3. SPECIFICATIONS............................................................ 84

4. TROUBLESHOOTING...................................................... 89

5. PARAMETER LIST........................................................... 91

I. PREPARING THE OPERATION

We thank you for the purchase of this PYX (Fuzzy Temperature Controller). Employing FUZZY LOGIC the PYX virtually eliminates system overshoot and effectively suppresses fluctuation of the process variable due to external disturbances. Please read this manual, when programed and operated within the guidelines setforth in this manual, your PYX controller will give you years of precise, reliable control.

PYX

The product conforms to the requirements of the Electromagnetic compatibility Directive 89/336/EEC as detailed within the technical construction file number TN510401. The applicable standards used to demonstrate compliance are :

EN50081-1 : 1992 Conducted and Radiated emissions EN50082-1 : 1992 Radiated immunity, ESD and FBT (The unit meets Class A limits for Conducted Emissions.)

The unit also complies with the part of Immunity standards.

IEC1000-4-2 : 1995 level 3, IEC1000-4-3 : 1995 level 3 IEC1000-4-4 : 1995 level 3, IEC1000-4-8 : 1993 level 4

* E.U. indicates Engineering Units.

1. THE BASIC INSTALLATION PROCEDURE

Is given here as to the basic flow from the installation to operate the PYX. For detailed description of each step, see the pages correspondent. See the section “Operation Procedure” on the pages 33 to 36 for calls and changes the specific parameter.

Installation of

Main Unit

Connection

Selecting Input

and Output Types

Selecting PID

or Fuzzy

Install the main unit on the panel, using the attached panel mounting bracket. (See page 8 to 18 for details.)

Connect the unit to power supply and input and output devices. (See page 19 to 29 for details)

Power up, then select and check input types (such as types of sensors), input temperature range, decimal point used or not used and so on. In case of the universal output type, set and check the output switch pins inside the main unit. (See page 37 to 43 for details.)

Either the conventional PID control mode or the fuzzy control mode, which is effective in minimizing overshoot rate and outer condition effects, can be selected. Select by setting the parameter , where the default set is PID. (See page 75 for details.)

Tuning

Ready

Normal

Operation

System power up then, execute auto-tuning to define the control parameters. (See page 47 to 50 for details.)

Basic preparations are completed. Carry on settings for the optional functions (alarm, two set points, transmission, ramp soak, analog output etc.), following this instruction.

See page 44, as setting values (SV) can be set in the same manner as the Lock parameter on page 44.

2. CHECK OF SPECIFICATIONS

Please make sure that specifications of this product is according with your request. The product specifications are provided on the main unit as model configuration following.

2.1 PYX4 MODEL CONFIGURATION

12345678 910111213 PYX

4 1-

T A

Y A B C D E F G H

Y A B C D

0 1 2 3 4

Note 1: Fuji Electric CC data line protocol Note 2: Modbus RTU protocol

Contents

Input type TC/PT input Voltage/Current input TC/PT/Voltage/Current multi input

Control output1 Without Relay (SPST) rev. act. Relay (SPST) dir. act. SSR drive rev. act. SSR drive dir. act. Current (DC 4~20mA) rev. act. Current (DC 4~20mA) dir. act. Relay (SPDT) rev. act. Relay (SPDT) dir. act.

Control output2 Without Relay (SPST) rev. act. Relay (SPST) dir. act. SSR drive rev. act. SSR dirve dir. act.

Alarm function Without 1pt. 2pts. HB alarm HB alarm + 1pt.

Input type code See Page 21.

Input range code

Y P Q R S M N A B C

J E F K

See Page 21. Additional function

Without 2 set points 4 ramp soak with start/reset RS-485 transmission RS-485 transmission RS-485 transmission RS-485 transmission + 4 ramp soak Auxiliary analog output Auxiliary analog output + 4 ramp soak Remote SV Front panel Japanese English (

English (

English (%)

+ 4 ramp soak

Note 1 Note 2

2.2 PYX5/9 MODEL CONFIGURATION

12345678 910111213 PYX

5 9

Front panel dimensions: 48×96 mm 96×96 mm

Input type

T A

Y C D E F G H J K

Y C D E F G H

0 1 2 3 4

TC/Pt input Voltage/Current input TC/Pt/Voltage/Current multi-input

Control output 1 Without SSR/SSC drive rev. act. SSR/SSC drive dir. act. Current (DC4-20mA) rev. act. Current (DC4-20mA) dir. act. Relay rev. act. (SPDT) Relay dir. act. (SPDT) Universal output rev. act. Universal output dir. act.

Control output 2 Without SSR drive rev. act. SSR drive dir. act. Current (DC4-20mA) rev. act. Current (DC4-20mA) dir. act. Relay rev. act. (SPDT) Relay rev. dir. (SPDT)

Alarm function Without 1pt. 2pts. HB alarm HB alarm + 1pt.

Contents

Y P Q R S

Note 1: Fuji Electric CC data line protocol Note 2: Modbus RTU protocol

M N A B C

Input type code See Page 21.

Input range code See Page 21.

Additional functions Without 2 set points 4 ramp soak with start/reset RS-485 transmission RS-485 transmission + 4 ramp soak RS-485 transmission RS-485 transmission + 4 ramp soak Auxiliary analog output Auxiliary analog output + 4 ramp soak Remote SV

Front panel

J E F K

Japanese English ( English (°F) English (%)

Note 1 Note 2

3. ACCESSORIES

In addition to the main unit, the following accessories are shipping in the same package.

Accessories Quat.

Instruction manual (this manual) (INP-TN1PYX-E)

Panel mounting bracket set

Current input resistance (250Ω)

* Not delivered for TC/PT input type

* Suffix means revision control

4. INSTALLATION

4.1 INSTALLATION PLACE

Please verify if where the controller is mounted there is no: (1) splash of water, (2) mechanical vibration,

(3) extreme temperature (4) no corrosive gases, (5) dust or oil smoke, (6) electric noise.

4.2 INSTALLATION PROCEDURE

;

Panel mounting bracket (accessorie)

Panel

Clamping screw Main unit

Panel mounting bracket (accessorie)

Clamping screw

For PYX4

For PYX5/9

• For PYX4 Slide the enclosed plastic panel mounting bracket (shipped with every PYX4) up the back of the controller until it makes contact with the back of the panel. Push the mounting bracket until the tabs seat themselves in the molded tab ridges, located on the front of the controller’s outer case. Tighten the two screw on the mounting bracket for added pressure; do not use excessive force.

• For PYX5/9 The mounting bracket’s tabs fit into the two holes on both the top and bottom of the controller’s outer case. With an instrument screwdriver, turn the screw in the mounting bracket until the end of it touches the back of the panel. Do this to both brackets. Making sure that the face of the controller is flush and straight, tighten both mounting bracket screws. Your controller should now be firmly set. If the controller is still loose, tighten the mounting bracket screw a little more. Do not use excessive force.

4.3 CAUTION ON SAFETY

First of all, read this "Caution on Safety" carefully,

and then use the instrument in the correct way.

The cautionary descriptions listed here contain important information about safety, so they should always be observed. Those safety precautions are classified in 2 ranks, WARNING and CAUTION.

The following shows the meaning of WARNING and CAUTION.

Wrong handling may cause a dangerous situation,

WARNING

CAUTION

1. WARNING

1.1 Caution on wiring

1) For the safe operation of the controller, where the temperature probe is to be installed into an environment where voltage exceed 50VDC, it is essential that reinforced isolation or basic isolation and earth the maintained between all connections to the rear of the temperature controller, and that supplementary isolation is required for the alarm outputs.

in which there is a possibility of death or heavy injury.

Wrong handling may cause a dangerous situation, in which there is a possibility of injury or physical damage.

The outputs from the controller are all less than 50VDC. When wiring the power supply terminal, use vinyl insulated 600 volt cable

or equivalent. A switch breaking both poles of the mains supply should be installed together with a fuse with a rating of 250 volt 1 Amp. The fuse should be installed between the mains switch and the controller.

The level of insulation provided by the temperature controller is:-

MAIN = BASIC HEATER = BASIC INPUTS = BASIC

Prior to operation of the installed system the wiring should be checked to ensure that the required levels of insulation have been provided.

2) When a fault in the instrument is likely to lead to a serious trouble, use a suitable protective circuit on the outside for protection against trouble.

3) This unit is not provided with power switch, fuse, etc. These parts can be installed separately, if required (fuse rating; 250V, 1A).

4) Use of Fuji's Z-Trap is recommended to protect the relay output from switching surge and to ensure a long life.

Type: ENC241D - 05A (power voltage; 100V)

ENC471D - 05A (power voltage; 200V)

Mounting position: Connected to relay control output terminals

ex) PYZ4 Socket (ATX2PSB)

65 43

1.2 Operating condition

Operating temperature : -10 to 50°C Operating humidity : 90%RH or less (non condensing) Installation category : Pollution degree : 2

PYZ9

Ⅱ

1.3 Power source

1) Use a power source of rated voltage to prevent damage or trouble.

2) Do not turn ON the power until the wiring is completed to prevent shock hazard or trouble.

1.4 Prohibition of use in gas

The instrument is not an intrinsic safety explosion - proof type. Do not use it in a place exposed to combustible or explosive gas.

1.5 Contact to unit

1) This unit must not be disassembled, modified or repaired to prevent malfunction, shock hazard or fire accident.

2) When the power is ON, do not touch the terminals to prevent shock hazard or malfunction.

1.6 Caution on maintenance

1) Before mounting or removing the module or unit, turn OFF the power in advance to prevent shock hazard, malfunction or trouble.

2) Periodical maintenance is recommended to ensure continuous and safe operation of the instrument. Some parts of the instrument are limited in life or are subject to secular change.

WARNING

It is essential that, when the controller is introduced into a system which uses or generates a hazardous voltage, the minimum creepage and clearances specified in the table below are maintained on the temperature probe. A hazardous voltage is one that exceeds 42.4V peak AC or 60V DC. If you have any doubt, seek advice from a

competent engineer before installing the controller into the host equipment.

The equipment must be installed such that with the exception of the connection to the mains, creepage and clearance distances shown in the table below are maintained between the temperature probe and any other assemblies which use or generate a voltage shown in the

table below. Failure to maintain these minimum distances would

Clearance (mm) Creepage (mm) Voltage used or generated

by the other assemblies

0.2 1.2 Up to 50V

rms or V DC

0.2 1.4 Up to 100Vrms or V DC

0.5 1.6 Up to 150Vrms or V DC

1.5 3.0 Up to 300Vrms or V DC Above 300Vrms or V DC

For a host or other assemblies fitted in the system, using or

generating voltages greater than 300V(rms or DC),advice from

a competent engineer must be obtained before installation of

the relevant equipment.

invalidate the EN61010 safety approval.

It is essential that following the installation of the system, and prior to powering the system up that it is tested to determine that the correct level of isolation is present to protect the user and other equipment against the hazards of electric shock and fire.

An explanation of creepage and clearance is given in the following diagram.

EXAMPLE INSTALLATION DIAGRAM

TO MAINTAIN SAFETY OF CONTROLLER

Example of how to install Controller into an environment where hazardous voltages may exist is shown below.

Make sure installed system has basic insulation around

Thermocouple, RTD, Voltage or Current

Make sure installed system has basic insulation

Heater Break Circuit

this connection

24V mains supply

Controller

Example Diagram To Explain The Meaning Of Creepage and Clearance Distances Is Shown Below

Communication card

Expansion card

Except for the edge connector which plugs into the host's expansion slot, clearance distance (X mm) and creepage distance (Y mm) as given in the table above, must be maintained between the controller and any other assemblies which use or generate a hazardous voltage.

CAUTION

2.1 Caution on handling

1) Do not install the unit in any of the following places.

• A place where the ambient temperature exceeds the range of -10 50°C

• A place where the ambient humidity exceeds 90%RH

• A place where temperature changes suddenly or dew condensation

occurs

• A place exposed to corrosive gases (sulfuric gas, ammonia, etc.) or combustible gases

• A place where vibration or shock is likely to be directly transmitted to the body.

• A place exposed to water, oil, chemicals, vapor, steam, etc.

• A place with much dust, salt or iron component

• A place with much inductive disturbance, static electricity, magnetism

or noise

〜

• A place exposed to direct sunlight

• A place where heat such as radiant heat stays

2) Mounting

• PYX5/9 For mounting, attach the supplied mounting brackets (2 units) on top

and bottom and tighten with a screwdriver. Tightening torque is about 147N.cm (1.5kg.cm). (The case is made of plastic. Care should be taken not to tighten forcedly)

• PYX4 Insert the supplied mounting frame from the rear side and push it in

until the main unit is secured firmly to the panel. If it has a slight play, tighten the 2 screws until the play is eliminated. (If the screws are tightened forcedly, the mounting frame may be slipped off the stopper)

3) When the unit is exposed to water, it may lead to a short-circuit or fire hazard. Contact your dealer for inspection.

2.2 Caution on cable connection

1) For thermocouple input, use a suitable compensating cable.

2) For resistance bulb input, use a cable with a small lead wire resistance and without resistance difference between 3 wires.

3) When external wiring has much noise, use the following step. When a conducted as load of digital output such as relay contact output or alarm output, connect a surge absorber to the conductor coil. (Example: ENC471D-05A for 200V AC)

4) When the power source has much noise, use an insulating transformer together with a noise filter. Noise filter should be mounted on a panel which has been earthed. The wiring between the noise filter output and the instrument power terminals should be as short as possible. Do not connect a fuse or switch to the noise filter output wiring, as it affects the performance of the filter.

5) Use of a twisted cable for the instrument power source provides better effects (short twist pitch is effective for noise).

6) When a heater burnout alarm is provided, the heater power and controller power should be connected using the same power line.

7) Time for preparation of contact output is required at power ON. When the output signal is used for an external interlock circuit, etc., connect a delay relay to the circuit.

2.3 Other

When cleaning the instrument, do not use organic solvents such as alcohol, benzine, etc. Use neutral detergent.

3. Caution on key operation / trouble

(1) Alarm function should be set correctly. Otherwise, alarm output

cannot be obtained at the time of occurrence of trouble. Be sure to check the function prior to operation.

(2) Do not stop the device forcedly during auto - tuning, as it affects the

control action. When it needs to stop forcedly, be sure to turn OFF the power in advance.

(3) If the input cable is disconnected, the display shows UUUU or LLLL.

When replacing the sensor, be sure to turn OFF the power.

4.4 PANEL CUT DIMENSIONS

65 or more

100 or more

65 or more

+0.5

-0

+0.5

-0

For PYX4

+0.8

-0

+0.8

-0

For PYX9

When mounting one unit When mounting multiple n units (2

+0.8

-0

+0.8

-0

≤

n ≤ 6)

115

or more

+0.8

-0

+0.8

-0

For PYX5

Unitsa2

933141418952376285

Units (mm)

5. WIRING

5.1 PYX4 WIRING DIAGRAM

[When the output 1 is relay (SPST) output, SSR drive output or current output]

Option

11 12

Control output 1

–

AC100-240V 50/60H

Alarm

Input

TC input Pt input Voltage input

N.C. N.C. N.C.

–

Input

Current input

250Ω

NOTE: • For current input (4-20mA), use the accessorie

Ω

resistance (250

• Make sure that the setting pin is in the appropriate position according to page 40.

Control output 1

For relay output For SSR drive output For current output

Alarm

ALM2

ALM1

ALM-COM

Option

DC-V DC 4-20mA

NOTE: Only ALM 1 is available in the case of

the digital output type.

For control output 2

(relay output)

For current transformer input For RS485 transmission

11 12

12 11 12

For control output 2

(SSR drive output)

TRX– TRX+

11 12

For digital input

11 12

For remote SV input

11 12

For AO output

11 12

5.2 PYX4 WIRING DIAGRAM

[When the output 1 is relay (SPDT) output]

Option

11 12

Control output 1

AC100-240V 50/60H

Alarm

Control output 1

–

Input

TC input Pt input Voltage input

N.C. N.C. N.C.

–

Current input

250Ω

Input

NOTE: • For current input (4-20mA), use the accessorie

Ω

resistance (250

• Make sure that the setting pin is in the appropriate position according to page 40.

Control output 1 Alarm

N.C. N.O.

Option

11 12

For control output 2

(relay output)

For digital input

12 11 12

ALM

ALM-COM

For control output 2

(SSR drive output)

For AO output

11 12

For current transformer input For RS485 transmission

TRX– TRX+

11 12

For remote SV input

11 12

5.3 PYX5/9 WIRING DIAGRAM

(Not universal output)

Control output 1

AC100~240V 50/60H

Output

Alarm

Option

Control output 2

Input

–

For TC input For Pt input For voltage input For current input

N.C. N.C. N.C.

–

250Ω

NOTE: • For current input (4-20mA), use the accessorie

Ω

resistance (250

• In the case of multi-input, make sure that the setting pin is in the appropriate position according to page

40.

Control output 1

For relay output For SSR drive output For current output

N.O.

N.C.

DC-V DC 4-20mA

Control output 2

For relay output For SSR drive output For current output

N.O.

N.C.

DC-V DC 4-20mA

Alarm

ALM1

ALM2

ALM-COM

Option

For digital input

For AO output

For current transformer input For RS485 transmission

10 10

TRX+

For remote SV input

TRX–

5.4 PYX5/9 WIRING DIAGRAM

(universal output)

Control output 1

AC100~240V 50/60H

Input

Alarm

Option

Control output 1

Input

–

For TC input For Pt input For voltage input For current input

N.C. N.C. N.C.

–

250Ω

NOTE: • For current input (4-20mA), use the accessorie

Ω

resistance (250

• In the case of multi-input, make sure that the setting

pin is in the appropriate position according to page

40.

Control output 1

For relay output For SSR drive output For current output

Alarm

Option

N.O.

N.C.

ALM1

ALM2

ALM-COM

DC-V DC 4-20mA

For digital input

For AO output

For current transformer input For RS485 transmission

10 10

TRX+

TRX–

For remote SV input

5.5 NOTES

Connection:

• No power switch and fuse are provided on this product. Install them separately if necessary.

• Use designated compensating wire in the case of thermocouple input.

• Use wire with line resistance lower that 10 thermoresistance input.

• To avoid noise induction to input wires separate from the power and output wires also connected to your controller.

• In case of model equipped with heater break alarms, the power supply used should be the same for the PYX and Heater.

Ω

for

• Use shielded wires for input wires. Keep them away from output wires.

Noise: Take the following measures when there is serious noise induction in the external wiring:

• When using a contactor as a load on digital output such as relay contact output and alarm output, supplement a serge absorber to the coil side of the contactor.

Z-Trap (ENB461D-14A for AC220V) manufactured by Fuji Electric

• In the case of noise induction from the power supply, the use of an insulated transformer and a noise filter is recommended.

Noise Filter (ZMB22R5-11) manufactured by TDK

• It is efficacious against noise induction to twist the power wires.

Connection of Load Circuit:

• When the frequency of operation is rather high, in the case of proportional operation for instance, maximum load with respect to the capacity of the output relay will result in shorter life. Use an auxiliary relay in such a case. Type SSR is recommended.

electromagnetic switch: proportion cycle 20 sec. and above SSR: proportion cycle 2 sec. and above

(approximately)

contact output life: mechanical: 10 million times (no load)

electrical: 100 thousand times (nominal

load)

• Relay contacts will be worn out with time. After certain period has passed, locking (a phenomenon in which a contact cannot be released once switched on) may happen. It is advisable to provide an external safety device to protect the system just in case locking happens.

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