NOVUS N480 User Manual

Page 1

Controller N480

TEMPE RAT URE CONTROLLER – OPERATION MANUAL – V2.6x

1. ASSEMBLY

The control ler should be inst alled in a panel cut out as speci fied in item 2. 1. First rem ove the mounting clam p and insert the c ontroller into the panel c ut out . P lace t he unit into t he panel c ut-out and sl ide the mounting clamp from the rear to a fi rm grip at the panel.

The internal circ uitry can be f ully remov ed from t he housing without disconnect ing any wiring. By us ing the thumb just press the tab in the lower part of the f ront panel, grab firm ly the f ront panel and pull out the circuitry from the housing.

1.1. ELECTRICAL CONNECTIONS Figure 1 shows the electrical te rm i nal s of the cont rol ler.

RELAY OUTPUT

4-20m A O UTPUT

PULSE OUTPUT

CONTROL

OUTPUT

OR ALARME 1

SENSOR INPUT

2. SPECIFICATIONS

2.1. GENERAL

• Dimensions : 48x48x106mm (1/ 16 DIN).

• Panel cut-out : 45,5x45,5mm

• Weight: 140g (1 relay), 160g (3 relays)

• Power: 85 to 264Vdc/ac, 50/60Hz, 3VA max . Optional: 15

to 30Vdc/ac

• Operation: 0 to 55°C, hum i d i ty 20 to 85%

OUT-A

OUT-B

4-20mA

PULSE

1 2 3 4 5 13 14 15

7 8 9 10 11 12

Figure 1 - Electr ic al connections

AL2

POWER

AC/DC

85-264V

15-30V

6 16 17 18

ALARM 2

POWER

N480

2.5. TEMPERATURE SENSOR INPUT

• Pt100: 3-wire connection. E xcitation current: 170µA

• Thermocouple input i m pedance: 10MΩ

• A/D conv erter resolution: 15000 steps

• Sampling rate: 10 measurements per second

• Accuracy: 0.2% of full scale for Pt100 and 0.25% of full

scale ±1°C for T/C

Thermocouples are connec ted to term inals 8 and 9 with pos itive in terminal 8.

Pt100 sensors are c onnect ed to t erminal s 7, 8 and 9, as indicated in figure 1. For full c ompensation of cable resist ance only c ables with equal wire electri cal resistance should be used.

Table 1 shows the sensor types accepted and their respective codes. v i a keyboard.

TYPE CODE RANGE

J K S

Pt100 (Resolution 0,1°C)

Pt100 (Resolution 1°C)

E N R

Table 1 - Sensor types, codes and ranges

-50 to 760°C (-58 to 1400°F)

0000

-90 to 1370°C (-130 to 2498°F)

1111

0 to 1760°C (32 to 3200°F)

2222

-199.9 to 530.0°C (-199.9 to 986.0°F)

3333

-200 to 530°C (-328 to 986°F)

4444 5555

-100 to 400 °C (-148 to 752°F)

6666

-30 to 720°C (-22 to 1328°F)

7777

-90 to 1300°C (-130 to 2372°F)

8888

0 to 1760°C (32 to 3200°F)

3. CONFIGURATION AND OPERATION

Prior to firs t operation the c ontroller should be f ully conf igured. The user mus t set bas ic parameters as temperature t ype (“TYPE desired c ontrol s et poi nt (“ SP “SPA2

SPA2”), etc.

SPA2SPA2

SP “), the alarm s s et poi nts (“ SPA1

SPSP

TYPE”), the

TYPETYPE

SPA1” and

SPA1SPA1

2.2. CONTROL OUTPUT

• Relay output: SPST (U type) relay. Maximum current 3A/250Vac.

• Voltage pulse output: 5Vdc/20m A

Both outputs are available in the basic model and the desired main control output is user selected via keyboard (refer to “

Cntr

Cntr “ prompt ). The remaining output can then be us ed as an

CntrCntr

alarm output.

In case of sensor break or failure an error "Erro

Erro" message is

ErroErro

displayed and t he control output i s turned off.

2.3. ALARM OUTPUTS

• Alarm Output 1: SPST relay 3A/250Vac or 5Vdc/20mA pulse

• Alarm Output 2: SPST relay 3A/250Vca (optional)

2.4. POWER Mains power is connected to terminals 5 and 6. Chec k the upper

side of the housing for proper power indicati on.

3.1. PARAMETERS FLOW CHART The programming parameters are organized in 4 different sets or

levels:

• Operation level

• Alarms and tuning level

• Configuration level

• Calibration level

At power up the c ontroller di splays a prompt at t he Operation Lev el and remains in this level whil e under normal operation.

The other lev els are only acc ess ed when a c hange of parameters is necessary (except for Set Point change). To reach these other parameters the us er must keep the INDEX Key (

) pressed for about three sec onds. Af ter this time t he control ler will show the first parameter of the nex t level. By keeping the INDEX key pressed for another 3 seconds the next level w ill be accessed.

Release the

to go to the next prom pt in the same level.

the

key when t he desi red lev el is reached. Pres s onc e

When a parameter is shown the displ ay will alternate its name and value. The v alue can then be changed by pressing the

key.

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Controller N480

After the l ast paramet er in one lev el is reac hed the control ler returns to operation level and the display will indicate the measured temperature.

The display will also go back to the measured temperature whenever the display is inacti ve for 20 seconds or m ore.

When a paramet er val ue is c hanged via key board the control ler will only ac cept the new value af ter the us er presses the INDEX key t o go to next prompt or if the keyboard is left inac tive for 20 seconds.

For disabl ing the keyboard, move the internal strap to the posit ion KEY DISABLE. All parameters will be protected, accept the SP parameter.

KEY DISABLE

Figure 2 – St r ap in nor m al operating

position (enabled)

3.2. OPERATION LEVEL

TEMPERATURE

INDICATION

END

Set Point

rAte

rAtE

T Sp

time for soak

Rvn

run

3.3. TUNING AND ALARMS LEVEL

Atvn

Auto tune

Proportional

band

integral rate

derivative

time

Cycle time

KySt

HYSterisis

A1SP

SP Alarm 1

A2SP

SP Alarm 2

TEMPERATURE measured by the sensor.

At power up, the upper di splay shows the process temperature value. It also shows the messages described in c hapter 5 of this m anual .

The lower di splay s s hows the s et point v alue which is the tem perature value desired f or the process.

TEMPE RATURE RATE OF RIS E: The us er defines the rate of temperature rise from the starting temperature to t he value set in “ SP Rate is defi ned i n °C / minute.

TIME FOR SOAK: Time in minutes which the temperature will remain at the selected “ SP Refer to item 4.

RUN: At thi s prompt the user sets the c ontrol output and alarms to ac tive or to inac tive.

0 - inactive outputs; 1111 - active outputs;

AUTO-TUNE: Activates the auto-tuning of PID parameters.

0000 - Auto-tune is off; 1111 - Auto-tune is on;

PROPORTI ONAL BAND: percentage of maxim um input span.

When set ot z ero (0), control acti on is ON/OFF. INTEGRAL RATE: Integral time constant in

repetitions per minute (Res et). This const ant is not used when controller is set to ON/OFF action (Pb=0).

DERIVATIVE TIME: Derivative time constant in seconds. This c onstant i s not used when controller is set to ON/OFF action (Pb=0).

CYCLE TIME: Pulse Width Modulation (PWM) period in seconds. This term is not used when controller is set to ON/OFF action (Pb=0).

CONTROL HYSTERESIS: Is the hysteresis for ON/OFF cont rol (set in temperat ure uni ts).

This param eter is only us ed when the controll er is in ON/OFF mode (Pb=0).

SETPOINT for Alarm 1: Triping point for alarm 1

SETPOINT for Alarm 2: Triping point for alarm 2

Figura 3 – St r ap pos it ion for inhibiting the

KEY DISABLE

keyboard

SP ”.

SPSP

SP “.

SPSP

3.4. CONFIGURATION LEVEL

INPUT TYPE: Selects the input sensor type t o be

Type

tYPE

Vnit

unit

A(t

ACtion

(ntr

Control

spll

SP Low Limit

spKl

SP High Limit

A1fv

Alarm 1 Function

A2fv

Alarm 2 Function

Aiky

A2ky

Alarm HYsteresis

3.5. CALIBRATION LEVEL

These parameters are used to calibrate the temperature measurement and s hould only be dealt with by experienc ed and well equipped personnel.

Inl(

Input Low

Calibration

InK(

Input High Calibration

(j L

Cold Junction Low

Calibration

connected to the controller. This is the first parameter to be set.

0 - Thermocouple type J;

00 1

1 - Thermocouple type K;

11 2

2 - Thermocouple type S;

22 3

3 - Pt100 with 0,1° resolution;

33 4

4 - Pt100 with 1° resolution;

44 5

5 - Thermocouple type T;

55 6

6 - Thermocouple type E;

66 7

7 - Termopar tipo N;

77 8

8 - Termopar tipo R;

TEMPERATURE UNIT: Selects display indication for degrees Celsius or F arenhei t.

0 - degrees Celsius ( °C );

00 1

1 - degrees Farenheit ( °F );

CONTROL ACTIO N:

0 - reverse action. Generally used for heating.

00 1

1 - direct ac tion. Generally used for cooling.

CONTROL OUTP UT :

0 - Sets c ontrol output to terminals OUT A.

00 1

1 - Sets c ontrol output to terminals OUT B.

As control output is defined to terminals OUT A, alarm output is automatic al l y set to OUT B.

If cont rol output is defined to OUT B alarm 1 will then be automati cally set to OUT A.

SET POINT LOW LIMIT: sets t he lower range for SV

SET POINT HIGH LIMIT

FUNCTION OF ALARM 1: Refer to table 2 for function des cription and res pective codes to set at this prompt.

FUNCTION OF ALARM 2: Refer to table 2 for function des cription and res pective codes to set at this prompt.

ALARM 1 AND ALARM 2 HYSTERESIS: Defines the differential range between the PV value at which t he alarm is turned on and the value at which it is t urned off (in engineering units).

A T E N T I O N

SENSOR OFFSET CALIBRATION. Sets the

temperature sensor low calibration (offset). The display shows only the correc ted temperature and not the offset added. A signal simulat or should be used to injec t a low value signal to properly adjust the offset.

INPUT HI GH CALI BRATI ON. S ets the s ensor input circuit gain or high cal i bration.

A signal simul ator should be used to inject a high value signal to properl y adjust the offset.

COLD JUNCTION OFFSET CALIBRATION: Sets the cold junction offset calibration. A good thermometer or a temperature sim ulator should be used to properly adj ust this param eter.

: Sets the upper range for SV.

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Controller N480

4. RAMP TO SOAK FUNCTION CHARACTERISTICS

This func tion m akes the proc ess t emperature ri se gradually from the starting point (present PV) to the temperature value set in “ SP (Ramp). The user def ines the rate of ri se in degrees per minute at the “rAtE

rAtE” prompt.

rAtErAtE

When SP is reac hed the temperat ure is lev eled at this point for 1 to 9999 minutes as programmed at the “ t SP (zero) at “ t SP

t SP ” defines an i nfinite length soak profile.

t SPt SP

To disable the ramp function Set 0.0 at the “rAtE disable the s oak f unct ion s et 1 at t he “ t SP

t SP ” prompt. Setting 0

t SPt SP

rAtE” prompt. To

rAtErAtE

t SP ” prompt (thus mak ing

t SPt SP

a 1 minute soak ) and the control output will go off in 1 minute. To restart c ontrol set 1 at the “ rvn

rvn ” prompt.

rvnrvn

After a power failure the controller will resume ramp to soak execution at the equivalent previous ramp point. If the proces temperature is the same as the SP (no temperature drop) the controller will repeat the soak segment.

SoakTemperature

Ramp

Figure 2 - Ramp to Soak Function

Time

5. PROBLEMS WITH THE CONTROLLER

Connection and configuration errors state for most of the problems in using the controller. A final revision of parameters will save time and further losses.

Error messages are dis played to help the user to identify possible problems.

: Process temperature is below the selected sensor

range.

: Process temperature is above the selected sensor

range

: Controller or sensor error. Ex am pl e:

• Broken thermocouple or Pt100.

• Pt100 badly connec ted, short-c ircuited or hi gh cable

resistance.

5.1. ELECTRONIC SERIAL NUMBER VISUALIZATION To read the 8-digit serial number go to the Operation Level and

press the digits. Keep t he

key for 3 s econds. The display will show the first 4

key press ed for 3 seconds and t he display will

show the last 4 digits.

SERIAL NUMBER

LAST 4 DIGITS FIRST 4 DIGITS

When powering the unit the display will show the software version for a few sec onds.

6. ALARM FUNCTIONS

Low and high alarms are used to signal minimum and maximum temperature values as programmed in the “SPA1 prompts.

Differenti al alarms are used to indi cate deviations from the desired setpoint (SP) t emperature. T hese deviat ions are programmed at the “SPA1

SPA1” and “ SPA2

SPA1SPA1

SPA2” prompts.

SPA2SPA2

Error alarm shows sensor defect s or not properly connected. Alarm hys teresis is fixed and factory set as described below:

• Pt100: 1.1ºC

• Thermocouples: type J: 1.3ºC; types K and S: 2.3ºC

6.1. ALARM INITIAL BLOCKING The initial bl ocking option i nhibits the alarm from being recognized if

an alarm condition i s present when the controller i s first energized.

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SPA1” ande “SPA2

SPA1SPA1

3/3

The alarm will actuate only after the occurrence of a non alarm condition f ol lowed by a new occurrenc e for the alarm.

SP “

SPSP

Table 2 shows eac h alarm function operation wit h their respective code. Alarm 1 is used as an ex am pl e.

TYPE CODE ACTION

LOW

HIGH

LOW

differential

HIGH

differential

deviation

Input sensor error or

heater

break

detection

End of

Program

Alarm

Functions

With alarm inhibition a

power-up

0000

1111

2222

3333

4444

5555

6666

7777 8888 9999

1010 11

1111

Table 2 - Alarm functions and their identific at ion c odes

Alarm ON

SPA1

Alarm ON

SPA1

Negative

SPA1

Positive

SPA1

Negative

SPA1

Positive

SPA1

Negative

SPA1

Positive Alarm is ON whenever:

• Temperature is below/above selected range;

• Termocouple or Pt100 is broken;

• Pt100 is shorted;

• Pt100 is badly connected or wire im pedance is

too high;

• The heater resistence is broken Activated when the programmed s oak time is run

out. Refer to item 4 of this manual. Low limit alarm disabled at power-up High limit alarm disabled at power-up Differential low limit alarm disabled at power-up Differential high limit alarm disabled at power-up Differential alarm disabled at power-up

Alarm ON TEMPERATURE

Alarm

SP + SPA1 SP

Alarm

Alarm ON

TEMPERATURE

SP + SPA1SP

Alarm ON

SP + SPA1SP

SP + SPA1SP - SPA1 SP

TEMPERATURE

Alarm

TEMPERATURE

Alarm

TEMPERATURE

7. PID AUTO TUNE

During auto tune the temperat ure is controlled in ON/OFF mode at the programmed Set Point (SV). Depending on the process characteristics large oscillations above and below SV may occur and auto tuning may take several minutes to be conc l uded.

The recommended procedure i s as follows:

SPA2”

SPA2SPA2

• Program a new SP close to the desi red final temperature other than the present measured temperat ure.

• Enable the auto t une at the “Atvn

• Set 1 at the “rvn

rvn” prompt.

rvnrvn

Atvn” prompt by selecting 1.

AtvnAtvn

During auto tune large oscillations will be induced around the setpoint. Make sure the process can accept these oscillations.

If aut o tuni ng results are not s atisf actory refer to t able 3 for manual fine tuning procedure.

PARAMETER RESPONSE SOLUTION

Proportional Slow Response Decrease

Band Large Oscillation Increase

Integral Slow Response Increase

Rate Large Oscillation Decrease

Derivative Slow Response or

Decrease

Instability

Time Large Oscillation Increase

Table 3 - Suggestions for manual tuning of P ID param et er s