12. ORDER CODES ..................................................................... 29
3
4
1. APPLICATION
The PCE-RE22 controller co-operates directly with resistance
thermometers (RTD) and thermocouples (TC) or quantity converters
into a standard signal.
It is destined for temperature control in plastics, food, glass, cera-
mics, dehydration industries and everywhere when it is necessary to
stabilize temperature changes.
The measuring input is universal for resistance thermometers and
thermocouple sensors or for linear standard signals.
The relay output, with a make-brake configuration ( with NOC or NCC
contacts) allows to the direct control of low power objects.
The manual control and soft-start are also possible.
One can protect the controller against the undesirable change of
parameters by means of a password.
The auto-tuning function permits to select the PID setting in order to
a quick output signal adaptation to object parameters.
5
2. CONTROLLER SET
1
RE22
1234
OUT
SP
MAN
AT
The controller set is composed of:
1. controller ........................................................ 1 pc
2. plug with 6 screw terminals ........................... 1 pc
3. plug with 8 screw terminals ........................... 1 pc
4. holder to fix in the panel ................................ 2 pcs
5. users manual ................................................ 1 pc
When unpacking the controller, please check whether the type
and option code on the data plate correspond to the order.
3. CONTROLLER PREPARATION TO WORK
3.1. Safety
The PCE-RE22 controller fulfils requirements concerning the
safety of automation measuring instruments acc. to the EN 61010-1
standard, requirements concerning the fastness against
electromagnetic interference acc. to EN 61000-6-2 standard and
emission of electro-magnetic interference occurring in the
industrial environment, acc. to the EN 61000-6-4 standard.
6
3.2. Controller installation in the panel
Fix the controller in the panel by means of two screw holders acc.
to the fig.1. The hole in the panel should have 45
dimensions. The material thickness what the panel is made of cannot
exceed 15 mm.
Fig.1. Controller fixing.
Controller overall dimensions are presented on the fig. 2.
+0.6
x 45
+0.6
mm
48
RE22
OUT SP MAN
48
AT
Fig.2. View of controller connection strips.
70
8max. 93
max.15
7
3.3. Electrical connections
Carry out electrical connections to terminal strips and next, insert
strips into controller sockets.
Input
signals
Pt100
JUMPER
Pt100 resistance
thermometer
in 2-wire system
Thermocouple
8
Fig.3. View of controller connection strips.
8
7
6
Pt100 resistance
thermometer
in 3-wire system
Current input
0/4..20mA
Fig.4. Connection of input signals.
Pt1000
Voltage input
Output
Supply
JUMPER
Pt1000
resistance
thermometer
0..5/10V
8
7
6
Load
+
+
-
-
Load
SSR
Supply
10
11
9
10
Supply
11
SupplyOutput - relay
Output - binary voltage
to control SSR
Fig.5. Connection of the supply and load circuit.
When connecting the supply, one must remember that an automatic
cut-off should be installed near the device, easily accessible for the
operator and suitably marked.
3.4. Installation recommendations
The PCE-RE22 controller fulfils requirements concerning the
fastness against electromagnetic interference occurring in the
industrial environment acc. to obligatory standards.
In order to obtain a full immunity of the controller against elec-
tromagnetic interference in an unknown environment interference
level it is recommended to observe following principles:
- do not supply the controller from the network near devices
generating high impulse interference and do not use common
earthing circuits with them,
- apply network filters,
- apply metallic shields in the shape of tubes or braided screens to
conduct supplying wires,
- wires supplying the measuring signal should be twisted in pairs,
and for resistance thermometers in a 3-wire connection, twisted
from wires with the same length, cross-section and resistance,
and led in a shield as above,
9
- all screens should be one side earthed, and led the nearest
possible to the controller,
- apply the general principle that wires leading different signals
should be led the farthest possible between them (not less than
30 cm), and their crossing executed at a right angle.
4. STARTING TO WORK
RE22
Display indicating
the measured value,
set point menu
Active output
mark
Mark of set
point display
OUTSPMAN
AT
Auto-tune mark
Manual work mark
3 push-buttons
Fig.6. View of the controller frontal plate.
After connecting to the power, the controller carries out the display
test and displays the re22 inscription, the program version,
and next, displays the measured value.
A character message can appear on the display, informing about
abnormalities. (table 4).
The algorithm of ON-OFF control with a 2oC hysteresis is set by
the manufacturer.
10
Change of the set point
The way to change the set point during the normal work is shown on
the fig. 7. The change limitation is set by SPL and SPH parameters.
Measured
value
or
OUTOUTSPSPMANMANATAT
RE22RE22
Change of set point
Set
point
Fig.7. Change of the set point during the normal work..
5. PROGRAMMING OF CONTROL PARAMETERS
5.1. Scheme of the controller menu
After pressing and holding the push-button during at least 2
sec., it is possible to program parameters. The transition between
parameters is carried out by means of and push-buttons.
The return to the normal working mode follows after the simultaneous
pressure of and push-buttons, or automatically, after
30 sec from the last push-button pressure.
Some parameters can be invisible - it depends on the current controller
configuration.
11
Monitoring of control signal
h___
AT
MAN
SP
OUT
tune
AT
MAN
SP
OUT
parameter
parameter
Fig.8.
Menu of controller
servicing
2sec
Manual
work
2sec
auto-tuning
start
Next
Previous
Mode of normal work
Measured
value
AT
MAN
SP
OUT
active
access
code
N
+
inpt
t-li
r-li
C,C
C,/t
dp
iNlo
iNHi
shif
sPrr
ramp
spl
spH
pb
ti
td
to
Hy
out
fail
aTfn
seCU
Start of changes
or
Acceptation of change
Cancellation of changes
+
Decrease
of value
2sec
T
code
SP
OUT
T
correct
code?
Mode of
parameter
change
Start of changes
Acceptation of changes
Cancellation of changes
+
or previous accounted
Mode of set
point change
Set point
SP
OUT
AT
MAN
N
3sec
1-dp
OUT
Decrease of value
parameter
AT
MAN
Increase
of value
err
SP
OUT
MAN
SP
Increase of value
or next accounted
parameter
AT
MAN
AT
12
The access to parameters can be protected by a code. If the safety
code is set (parameter seCU is higher than zero), one must give it.
If the value will not be given or will be erroneous, the inscription err
appears on displays, and the user will be only able to monitor para-
meter values.
5.2. Setting change
The change of parameter setting begins after pressing the push-
button. By means of and push-buttons we make
the choice of the setting, and by the push-button we accept it.
The cancellation of the change follows after the simultaneous
pressure of and lpush-buttons or automatically after
30 sec. from the last push-button pressure. The way of setting
change is presented on the fig.9.
+
Start of change
1234
cancellation
of change
acceptation
of change
increase
the value
next
parameter
+
cancellation
of change
acceptation
of change
Start of change
decrease
the value
oNof
previous
parameter
Fig.9. Setting change of numerical and textual parameters.
13
5.3. List of parameters
The list of controller parameters is presented in the table 1.
parameter
symbol
inpt
t-lj
parameter
description
kind of input
(description in
table 2)
line type (2-wire
or 3-wire line)
1)
range of parameter changes
sensorlinear signal
[pt1]: Pt100
pt10: Pt1000
t-,: thermocouple of J type
t-t: thermocouple of T type
t-k: thermocouple of K type
t-s: thermocouple of S type
t-r: thermocouple of R type
t-b: thermocouple of B type
t-e: thermocouple of E type
t-n: thermocouple of N type
t-l: thermocouple of L type
[2-p]: 2-wire line
3-p: 3-wire line
0-20:
lin. current 0-20 mA
[4-20]:
lin. current 4-20 mA
0-5:
lin. voltage 0-5 V
0-10:
lin. voltage 0-10 V
Table 1
r-li
C,C
C,/t
dp
14
resistance of
2-wire line, for
Pt100 sensor
way of cold ends
compensation for
thermocouples
temperature of
cold ends during
the manual
compensation
2)
[°C x10]
position of the
decimal point
0.0...20.0 W
[0.0]
[auto]: automatic
2)
compensation
Hand: manual
compensation
0.0...50.0°C
[0.0]
0_dp: without decimal
place
1_dp: 1 decimal
place
0_dp: without
decimal place
1_dp: 1 decimal
place
2_dp: 2 decimal
place
parameter
symbol
iNlo
inHi
shjf
parameter
description
indication for the
lower threshold
of analog input
indication for
the upper
threshold of
analog input
shift of the
measurend
value
range of parameter changes
sensor
-99.9...99.9 °C
[0.0]
linear signal
-1999...9999
[0.0]
-1999...9999
[100.0]
-999...999
[0.0]
3)
3)
3)
sPrr
ramp
spl
spH
pb
accretion rate of
the set point
time unit for the
accretion rate of
the set point
lower setting
limitation of
the set point
upper setting
limitation of
the set point
proportional
band
0...999.9 / unit
[0.0]
[min]: minute
Hour: hour
acc. to table 2
[-199.0]
acc. to table 2
[850.0]
0...999.9 °C
[0.0]
3)
3)
0...999.9 / jedn.
[0.0]
[min]: minute
Hour: hour
INLO...INHI
[0.0]
INLO...INHI
[100.0]
0...9999
[0.0]
3)
3)
3)
15
parameter
symbol
ti
parameter
description
integration
time-constant
range of parameter changes
sensor
4)
0...9999 s
[0]
linear signal
0...9999 s
[0]
td
to
Hy
out
differentiation
time-constant
pulse repetition
period of the
4)
output
histeresis
5)
output
configuration
4)
0...999.9 s
[0.0]
0.5...99.9 s
[20.0]
0.2...99,9
[2.0]
dir: cooling signal
[inu]: heating signal
control signal
fail
of the output for
proportional
control in case of
sensor damage
aTfn
seCU
1)
The parameter is visible only for Pt100 resistance thermometer.
2)
The parameter is visible only for the execution with thermocouple inputs.
3)
Resolution what the given parameter is shown with, depends on
the dp parameter - position of the decimal point.
4)
The parameter is invisible at ON-OFF control.
5)
The parameter is visible at ON-OFF control
6)
The parameter is hidden in the parameter review mode only for readout.
auto-tuning
function
safety code
6)
0...100.0 %
[0.0]
4)
off: locked
[on]: unlocked
0...9999
[0]
0...999.9 s
[0.0]
0.5...99.9 s
[20.0]
0.2...999
[2.0]
0...100.0 %
[0.0]
0...9999
[0]
(for readout only)
3)
16
Measuring ranges for inputsTable 2
SymbolInput / sensorMinimumMaximum
pt1Resistance thermometer Pt100-199°C850°C
pt10Resistance thermometer Pt1000-199°C850°C
t-,Thermocouple J type-100°C1200°C
t-tThermocouple T type-100°C400°C
t-kThermocouple K type-100°C1372°C
t-sThermocouple S type0°C1767°C
t-rThermocouple R type0°C1767°C
t-bThermocouple B type0°C1820°C
t-eThermocouple E type-100°C999°C
t-nThermocouple N type-100°C1300°C
t-lThermocouple L type-100°C800°C
0-20Linear current 0-20 mA-19999999
4-20Linear current 4-20 mA-19999999
0-5Linear voltage 0-5 V-19999999
0-10Linear voltage 0-10 V-19999999
6. INPUTS AND OUTPUTS OF THE CONTROLLER
6.1. Measuring input
The controller has one measuring input, which on can connect diffe-
rent types of sensors or standard signals to.
The choice of the input signal is performed by the inpt parameter.
For different types of inputs, depending on the option code, one must
give additional parameters.
For the Pt100 resistance thermometer, one must choose the kind
of connection. In a three-wire connection, the line resistance com-
pensation goes on automatically.
In a two-wire connection, one can give additionally the line resistance,
for thermocouples, one must give the way of temperature compensation
of cold ends - automatic or manual, and at manual compensation -
the temperature of cold ends.
17
For linear inputs, one must give indications for the lower and upper
threshold of the analog input. The position of the decimal point is an
additional parameter, the parameter dp.
For temperature sensors, it defines whether the measured tempera-
ture and the set point temperature is to be shown with a place after
the decimal point.
For linear inputs, it defines the resolution which the measured value
and values of some parameters are shown with.
The correction of measured value indications is carried out by the
shifparameter.
6.2. Output
The controller has one measuring input with a switch over contact.
It is possible to select the ON-OFF control or proportional (PID) control
at the output. For the proportional control, one must additionally set
the pulse repetition period. The pulse repetition period is the time
which expires between successive switches of the output during the
proportional control. The length of the pulse repetition period must be
chosen depending on dynamic properties of the object and suitably
to the output device for quick-acting processes, it is recommended to
apply SSR relays. The relay output is used to control contactors in
slow-acting processes.
The use of a high pulse repetition period to control quick-acting
processes can give unwanted effects in the shape of oscillations.
Theoretically, smaller the pulse repetition period better the control is,
but for the relay output it should be as high as possible in order to
extend the relay life.
Recommendations concerning the pulse repetition period. Table 3
OutputPulse repetition period isLoad
electromagneticrecommended >20 s2 A/230 V a.c.
relaymin. 10 sor contactor
min. 5 s1 A/230 V a.c.
transistor output1...3 sSemi-conductor
relay (SSR)
18
7. CONTROL
7.1. ON-OFF control
To select the ON-OFF control, one must set the parameter pb=0.
Next, set the hysteresis value - Hy. The action of the output on
heating (fig. 10.) is set by the parameter out=inu, and on cooling,
by the parameter out=dir.
output
Hy
enabled
disabled
sp
Fig.10. Operation way of the heating type output
7.2. PID control
The choice of PID control, or also PI, PD or P control, consists on
a suitable setting of parameter values - proportional band (pb),
integrating element (ti) and differentiating element(td).
The switching of the giving element off, consists on setting the para-
meter on zero. The operation way of the heating type output is
chosen by setting the parameter out1=inu, and the cooling type
by setting the parameter out=dir. The successive parameter to
set is the pulse repetition period of the output (to).
measured
value
19
8. ADDITIONAL FUNCTIONS
8.1. Display of the control signal
After pressing the push-button, the value of the control signal
(0...100%) appears on the display. On the first digit, the mark h
is displayed. The return to the normal operation follows after the
simultaneous pressure of and push-buttons.
8.2. Manual control
The manual control gives the possibility, among other things, to identify
and test the object or control it after the sensor damage.
The entry into the manual control mode follows after holding down
the push-button when displaying the control signal. The manual
control is signaled by the diode pulsation, marked as MAN.
The controller breaks the automatic control and begins the manual
control of the output. The value of the control signal is displayed on
the lower display, preceded by the symbol h.
and push-buttons serve to change the control signal,
which is displayed on the lower display. The exit to the normal working
mode follows after the simultaneous pressure of and
push-buttons.
After setting the ON-OFF control on the output 1 (parameter PB = 0),
one can set the control signal on 0% or 100% of power, however
when the PB parameter is greater than zero, the control signal can
be set on any value from the 0...100% range.
8.3. Controller reaction (response) after the sensor damage
It is possible to configure the output state after the sensor damage.
- at output configuration for proportional control(PB>0)
the control signal value is defined by the failparameter,
- at output configuration for the ON-OFF control, the output will be
disabled - at output operation as heating, or enabled - at output
operation as cooling.
20
8.4. Rate of the set point change - soft-start
The limitation of the temperature accretion rate is performed through
the gradually change of the set point. This function is activated after
switching the controller supply on and during the change of the set
point. This function allows to reach in a gentle way the achievement
from the current temperature to the set point. One should write the
accretion value to the sprr parameter and the time unit to the ramp
parameter.
An accretion value equal to zero means, that the soft-start is disabled.
8.5. Manufacturers settings
One can restore manufacturers settings during the supply switching
on by holding down and push-buttons till the moment
when the inscription fabr appears on the upper display.
9. SELECTION OF PID PARAMETER SETTINGS
9.1. Auto-tuning
The controller has the function of the automatic PID setting choice.
These settings ensure the optimal control in the majority of cases.
To start the auto-tuning, one must transit to the tune parameter
(acc. to the fig.8) and hold down the push-button during
at least 2 sec. If the proportional band is equal zero or the atfn
parameter is set on off, there will not be possible to start the
auto-tuning.
The flickering upper display informs about the activity of the auto-
tuning function. The duration of the auto-tuning function depends on
object dynamic properties and can last maximally 10 hours. During
the auto-tuning, or directly after, overshoots can occur and therefore,
one must set a smaller set point, if it is possible.
21
The auto-tuning is composed of following stages:
- switching the control signal off, and stabilization of the object
temperature (from 2 minutes till 3 hours),
- switching the control signal (100%) on, and determination of
the object characteristic (maximally 10 hours),
- calculation of PID settings and their storage in
the non-volatile memory,
- switching the PID control on with new settings.
The auto-tuning process may not start or be interrupted without
the PID control if:
- the set point is too near to the measured value, i.e. the control
deviation is smaller than 6.25% of the range,
- the time of the preliminary object stabilization or the admissible
auto-tuning duration time will be overrun,
- a controller supply decay will occur,
- the push-button has been pressed,
- calculated parameter values are beyond the range.
In such cases, the control with previous users settings will start.
22
9.2. Manual selection of PID parameter settings
Method of response to a unitary jump
Y[%]
100
0
measured
value
∆PV
∆t
T
0
t[s]
t[s]
Fig.11. Selection of settings by the method of response
to a unitary jump.
One must read out the delay time To and the maximal temperature
accretion rate from the object characteristic presenting the controlled
value in the function of time, from the dependence:
DPVmax
Vmax =
Dt
Calculate PID settings acc. to following formulas:
Pb=1.1.Vmax.T0- proportional band
ti=2.4.T0- integration time constant
td=0.4.T0- differentiation time constant
Oscillation method around the set point
Set the ON-OFF control with a minimal hysteresis. Set the set point
on a normal work level (or on a lower one, if overshoots would cause
damages) and normal load conditions.
23
Measured value
T
t[s]
t[s]
100%
P
Y[%]
Fig.12. Selection of settings by the oscillation method.
Calculate controller settings acc. to given formulas:
Pb = P
ti = T
td = 0.25 * T
Correction of PID settings
Since PID parameters interact between them, one must introduce
changes only of one parameter.
The best is to choose parameters changing the value into a twice
greater or twice smaller one.
During changes, one should be guided by following principles:
a) Slow jump answer:
- decrease the proportional band,
- decrease the integration and differentiation time.
b) Over-regulations:
- increase the proportional band,
- increase the differentiation time.
c) Oscillations:
- increase the proportional band,
- increase the integration time,
- decrease the differentiation time.
d) Instability:
- increase the integration time.
24
10. SIGNALLING OF ERRORS
Character messagesTable 4
Error code
(upper display)
lerr
Herr
ater
erad
Reason
Exceeding of
the measuring
range downwards
or short-circuit
occurring in the
sensor circuit
Exceeding of
the measuring
range upwards
or break in
the sensor circuit
The auto-tuning
has not been
finished
successfully
Discalibrated
input
Check if the type of chosen sensor
is in compliance with the connected
one.
Check if values of input signals are
situated in the appropriate range.
If so, check whether there is no short-
circuit in the sensor circuit.
Check if the type of chosen sensor
is in compliance with the connected
one.
Check if values of input signals are
situated in the appropriate range.
If so, check whether there is no short-
circuit in the sensor circuit.
Check reasons of breaking
the tuning process
in auto-tuning point
Connect again the controller supply
and if it cannot help, contact
the nearest authorized service shop.
Procedure
25
11. TECHNICAL DATA
Input signals and measuring ranges for sensor inputs.
Sensor typeStandardNotationRangeSymbol
Pt100
Pt1000
Fe-CuNi
Cu-CuNi
NiCr-NiAl
PtRh10-Pt
PtRh13-Pt
PtRh30-PtRh6
NiCr-CuNi
NiCrSi-NiSi
chromel-kopel
The measurement error is defined for the range 0...1820°C
*
EN 60751+A2Pt100-199...850°Cpt1
EN 60751+A2Pt1000-199...850°Cpt10
EN 60584-1J-100...1200°Ct-,
EN 60584-1T-100...400°Ct-t
EN 60584-1K-100...1372°Ct-k
EN 60584-1S0...1767°Ct-s
EN 60584-1R0...1767°Ct-r
EN 60584-1B0...1820°C*t-b
EN 60584-1E-100...999°Ct-e
EN 60584-1N-100...1300°Ct-n
GOST R 8.585L-100...800°Ct-l
Input signals and measuring ranges for
linear inputs
Sensor typeNotationRangeSymbol on
Linear current inputI0...20 mA0-20
Linear current inputI4...20 mA4-20
Linear voltage inputU0...5 V0-5
Linear voltage inputU0...10 V0-10
Input signals:
- for sensor inputsacc. to table 5
- for linear inputsacc. to table 6
Basic error of true value measurement:
0.2%, for RTD inputs,
0.3%, for TC inputs (0.5% - for B, R, S),
0.2% ± 1 digit, for linear inputs
Table 5
on the
display
Table 6
the display
26
Measurement time:
- for sensor inputs0.33 s
- for linear inputs0.16 s
Input resistance:
- for voltage input150 kW
- for current input4 W
Detection of error in
the measuring circuit:
- thermocouple, Pt100, PT1000 overrunning of
- 0...10 Vover 11 V
- 0...5 Vover 5,25 V
- 0...20 mAover 22 mA
- 4...20 mAunder 1 mA and over 22 mA
Control algorithm:P, PD, PI, PID,
Range of controller
parameter settings:see table 1
Kind of outputs:
- relayswitch over contact
- binary voltage (without isolation voltage 5 V
from the sensor side)resistance limiting the current 66 W;
Way of output action:
- reversefor heating
- directfor cooling
Signalling:
- output switching on
- display of set point
- manual control mode
- auto-tuning mode
the measuring range
too-state with hysteresis
maximal load-carrying capacity:
voltage: 250 V a.c., 150 V d.c.
current: 5 A 250 V a.c., 5 A 30 V d.c.
resistance load: 1250 VA, 150 W
27
Rated service conditions:
- supply voltage230 V a.c. ± 10 %
- supply voltage frequency50/60 Hz
- ambient temperature0...23...50 °C
- storage temperature-20...+70 °C
- relative air humidity< 85 % (without
- external magnetic field< 400 A/m
- preheating time30 min
- work positionany
- resistance of wires connecting
the resistance thermometer
with the controller< 20 W
Power consumption< 3 VA
Weight< 0.25 kg
IP protection ensured through
the housing: acc. to EN 60529
- from the frontal side IP40
- from terminal side IP20
Additional errors in rated
working conditions caused by:
- compensation of the thermocouple
cold junction£ 2oC,
- ambient temperature change£ 100% of the basic error
Safety requirements acc. to EN 61010-1
- installation categoryIII
- level of pollution2
- maximal working voltage in relation to ground:
- for supply circuit, outputs300 V
- for input circuits 50 V
Electromagnetic compatibility:
- immunity acc. to EN 61000-6-2
- emission acc. to EN 61000-6-4
110 V a.c. ± 10 %
24 V a.c. ± 10 %
condensation)
value/10 K.
28
12. ORDER CODES
Coding way is given on the table 7.
Controller PCE-RE22 -
Input
universal for thermocouples and RTD .......... 1
universal linear current 0/4..20 mA,
and linear voltage 0...5/10 V ......................... 2
on order ......................................................... X
binary 0/5 V to SSR control ................................ 2
on order ............................................................... X
Supply
230 V 50/60 Hz .......................................................... 1
110 V 50/60 Hz........................................................... 2
24 V 50/60 Hz ............................................................ 3
on order ...................................................................... X
Kind of option
standard .......................................................................... 00
custom-made* ............................................................... XX
Additional
without a quality inspection certificate .................................... 8
with a quality inspection certificate ......................................... 7
acc. to customers agreement ** ............................................ X
* The option code is established by the manufacturer.
** After agreement with the manufacturer.
Ordering example:
The code: PCE-RE22-1-2-3-00-7 means:
RE22 - controller with universal input + 1 output
1 - universal input for RTD and TE
2 - binary output 0/5 V to SSR control
3 - supply: 24 V a.c.
00 - standard option
7- with an extra quality inspection certificate
Table 7
X X X XX X
29
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