Omega Products CN491A-D1 Installation Manual

User’sGuide

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OMEGA®

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CN491A SERIES

1/32 DIN Temperature/Process Controllers

omega.com®

OMEGA®

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The information contained in this document is believed to be correct, but OMEGA Engineering, Inc. accepts no liability for any errors it contains, and reserves the right to alter specifications without notice. WARNING: These products are not designed for use in, and should not be used for, patient-con- nected applications.

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fuzzy Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Input Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Model Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Wiring & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Negotiating the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Learning the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Primary Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Changing Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Begin Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Flow Chart of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Setting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Scaling Analog Inputs/Setting Setpoint Limits . . . . . . . . . . . . . .24 Ramp Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Ramp & Soak/Dwell Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Tool Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Flow Chart of Tool Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Programmable Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Cooling Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Configurable Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Locking Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

1

INTRODUCTION

General Description

The CN491A is a fully programmable, microprocessor-based temperature/process controller. It offers superior control with 200 msec sampling rate and by using fuzzy logic to enhance its P, I and D parameters. The 4-digit 0.4” red LED display offers excellent visibility on a unit that is 1/32 DIN in size.

The CN491A is available with either 20-32V AC/DC or 90-264V AC power supply. This is a single universal input unit that will accept 8 different thermocouple types, Pt100 RTDs, and a variety of linear mA and VDC signals. The wide range of options for the two available outputs include relays, SSR drives, 4-20mA, 0-20mA, or 0-10VDC. Output #1 can be used in either a direct or reverse action control situation with a programmable ramp rate. Output #2 can be used as a control output, as an alarm, or as a dwell timer.

Optional features include 2-wire RS-485 serial communications with Windows 95™-based software, and Analog Retransmission of process variable, setpoint variable or the percentage of control output, as a 0-20 mA/4-20 mA DC signal.

The communications software package, CN491A-SOFT, offers excellent graphics, bar and trend displays, and supports easy-to- use database control and back-up capability.

FUZZY LOGIC

The function of Fuzzy Logic is to adjust the PID parameters internally in order to make the control output more flexible and adaptive to the process. One of the best analogies would compare Fuzzy Logic to the abilities of a good driver. The driver is

2

able to control a car well at a variety of speeds and under varying circumstances by using knowledge gained through previous experience.

Fuzzy Logic combined with PID control has been proven to be an efficient method to improve control stability. This is illustrated in figure 3.

Figure 1. PID only

Figure 2. PID with fuzzy logic

PID control with proper tuning

PID + Fuzzy control

Figure 3. PID vs. PID and fuzzy logic

3

CONTROL

Proportional Band: Reset (Integral): Rate (derivative): Ramp rate:

Dwell:

Hysteresis:

Cycle Time: Control Action:

OUTPUT

Relay: DC pulse:

4 to 20 mA:

0 to 20 mA:

0 to 10 V:

INDICATION

Process Display:

Status Indicator:

SPECIFICATIONS

INPUT

Thermocouple(T/C): Type J,K,T,E,B,R,S,N RTD: Pt100 ohm RTD

(DIN 43760/BS 1904 or JIS) Linear: Scalable. Refer to table on p.5

Range: User configurable, refer to table on p.5 Accuracy: Refer to table on p.5

Cold-Junction Compensation: 0.1°C / °C ambient (typical) External Resistance: 100 ohm max.(for thermocouple) Normal Mode Rejection: 60dB

Common Mode Rejection: 120dB Sample Rate: 200 msec

0-360°F, 0-200°C, 0-3600 Process Units 0-3600 seconds

0-1000 seconds

0-55.55°C/min, 0-99.99°F/min,

0-99.99 Process Units(P.U.)/min

0-9999 minutes

0.1-11.0°C, 0.1-19.9°F, 0.1-199 P.U. 0-99 seconds

Direct (cooling) and reverse(heating)

3A/240 VAC (resistive) 24 VDC/20 mA max.

Linear, max. load 500 ohms Linear, max. load 500 ohms

Linear, min. input impedance 500K ohms

0.4” red LED, 4 digits Control output and alarm

4

POWER
Rating:	90-264VAC nominal, 264V excursion (max)
	50/60Hz or 20-32V AC/DC
Consumption:	Less than 5VA
ENVIRONMENTAL & PHYSICAL
Safety:	CE & CSA Approved, & UL Recognized
Protection:	NEMA 4X (indoor use), IP65
Operating Temperature:	-10 to 50°C (14 to 122°F)
Humidity:	0 to 90%RH (non-condensing)
Insulation:	20 Mohm min. (500 VDC)
Breakdown:	AC2000V. 50/60Hz. 1 minute
Vibration:	10-55Hz. amplitude 1mm
Shock:	200 m/s2 (20g)
Weight:	110 grams
Dimension:	24(H) x 48(W) x 99mm (depth behind panel)
Panel cutout:	22.2mm(H) (+.3/-0) 45 mm(W) (+.5/-0)

RANGE AND ACCURACY OF INPUTS

SENSOR	INPUT TYPE	RANGE (°F)	RANGE (°C)	ACCURACY
J	Iron-Constantan	-58 to 1830	-50 to 999	±3.6°F/±2°C
K CHROMEGA − ALOMEGA		-58 to 2500	-50 to 1370	±3.6°F/±2°C
T	Copper-Constantan	-454 to 752	-270 to 400	±3.6°F/±2°C
E	CHROMEGA -Constantan	-58 to 1382	-50 to 750	±3.6°F/±2°C
B	Pt30%Rh/Pt6%Rh	572 to 3272	300 to 1800	±3.6°F/±2°C
R	Pt13%Rh/Pt	32 to 3182	0 to 1750	±3.6°F/±2°C
S	Pt10%Rh/Pt	32 to 3182	0 to 1750	±3.6°F/±2°C
N	Nicrosil-Nisil	-58 to 2372	-50 to 1300	±3.6°F/±2°C
RTD	Pt100 ohm (DIN)	-328 to 842	-200 to 450	±0.72°F/±0.4°C
RTD	Pt100ohm (JIS)	-328 to 842	-200 to 450	±0.72°F/±0.4°C
LINEAR INPUTS (All scalable)
Input type			Range	Accuracy
4-20 mA, 0-20 mA, 0-1V, 0-5V, 1-5V, 0-10V			-1400 to 9400	±0.05% FS

5

CN491A MODEL CONFIGURATION

Model No	Description
CN491A-R1	Relay Output
CN491A-D1	DC Pulse Output
CN491A-F1A	4-20mA Output
CN491A-F1B	0-20mA Output
CN491A-V1	0-10V Output
SECOND OUTPUT/ALARM
Suffix	Description
-R2	Relay
-D2	DC pulse
-F2A	4-20mA
-F2B	0-20mA
-V2	0-10V
AUXILIARY OPTIONS
Suffix	Description
-C4	RS-485 Communications
-PVSV	0-20mA/4-20mA retransmission
OPTIONAL POWER SUPPLY
Suffix	Description
-LV	20-32V AC/DC

6

INSTALLATION

MOUNTING

Install mounting clamp(s). Gently tighten clamp until the controller fits snugly against the front panel.

NEMA brackets

Collar bracket

Make panel cutout as shown in figure

1/32 DIN

WIRING

The following connections for outputs and inputs are provided on the wiring diagram located at the rear of the housing:

Rear Terminal Connections

7

POWER SUPPLY

The controller is supplied to operate on either 90-264V AC or 2032V AC/DC. Check that the supply voltage corresponds to that indicated on the product label before connecting power to the controllers.

1A

L

90~264V AC or N 20-32VAC/DC

Power Supply Connections

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

THERMOCOUPLE INPUT

Thermocouple input connections are shown in the illustration below. The thermocouple extension wire must be of proper type and gauge, and should be run in a conduit, separate from any

power wiring. The resistance of the entire run should not exceed 100Ω.

Thermocouple Input Connections

Pt100 Ohm RTD INPUT

RTD connections are shown in the illustration below with the compensating lead connected to terminal 11. For two-wire RTD inputs, terminals 10 and 11 should be linked.

Pt100

RTD input Connections

8

DC LINEAR INPUT

DC linear voltage and current input connections are shown below.

VDC

mADC

RELAY OUTPUT DIRECT DRIVE

The illustration below shows connections for using the internal relay to drive a small load. The current should not exceed 3 amps.

Relay Direct Drive Connections

RELAY OUTPUT CONTACTOR DRIVE

The illustration below shows connections for using an external relay to drive heavier loads.

Relay Contactor Drive Connections

9

DC PULSE (SOLID-STATE RELAY DRIVE) OUTPUT

Controllers fitted with the DC pulse output produce a time-propor- tional non-isolated pulse voltage (0-24V nominal, output impedance 660Ω ). The connections are shown in the illustration below.

	/
2nd	1

Pulsed DC output Connections

DC LINEAR OUTPUT

There are three types of linear output modules that can be selected for the output. The connections are shown in the illustration below.

	/
2nd	1

Linear DC output Connections

RS-485 COMMUNICATIONS/ANALOG RETRANSMISSION

RS-485 serial communications or Analog retransmission of process variable, setpoint, or manipulated variable can be selected as an optional feature. The connections are shown in the illustration below.

TX1

13

14 TX2

RS-485 Communications

13

14

Analog retransmission

10

NEGOTIATING THE CN491A MENU

When the controller is powered up it automatically displays the Process Variable (PV).

From the Process Variable (PV) display you can easily:

Press either the or key momentarily to view set-point. or

Press the key momentarily to enter the Primary Program Menu. or

Press the key and the key simultaneously to enter the Tool Program Menu.

				CN491
	TOUCH KEYS	FUNCTION		DESCRIPTION
		Up key		Press to select digit to change. Press and hold
				to increase value for parameter
		Down key		Press to select digit to change. Press and hold
				to decrease value for parameter
		Scroll key		Press to select parameter in direct sequence
				or to select tool program parameters
		Long scroll/		Use to select protected parameters in higher
	press for 3.2 seconds	Enter key		security level or to actuate selected tool program
	&	Reverse scroll/		Use to select parameter in reverse sequence or
		Calibration		to verify display accuracy for input types during
		Verification		calibration
	&	Lock key		Use to disable keypad operation to protect
	press for 3.2 seconds			parameters
	&	Tool program key		Press to select tool program in sequence
	&	Reset/Exit key		Press to unlock keypad operation, to reset
				display, to exit tool program, or to end autotune
				and manual control execution.
	&	Autotune key		Hold both keys for 3.2 seconds then release to
	press for 3.2 seconds			start autotune.

11