Samson Trovis 6400, Trovis 6412, Trovis 6442 Mounting And Operating Instructions

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Automation System TROVIS 6400

Process Control Stations TROVIS 6412 and 6442

Edition July 2007

Firmware C 1.3 Firmware Si 1.4

Mounting and Operating Instructions

EB 6412 EN

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Page 3

Contents

1. Notes on these mounting and operating instructions...................................... 5

1.1. Documentation ............................................................................................. 5

1.2. Abbreviations used in this manual.................................................................. 5

2. Description................................................................................................... 6

2.1. Features ....................................................................................................... 6

2.2. Versions ....................................................................................................... 6

2.3. The process control station (overview)............................................................. 7

2.4. Technical data .............................................................................................. 8

3. Installing the process control stations .......................................................... 11

3.1. TROVIS 6412 (panel-mounting unit)............................................................. 11

3.2. TROVIS 6442 (rack-mounting unit for 19inch racks)...................................... 12

3.3. Opening the controller case......................................................................... 12

4. Soldering jumpers...................................................................................... 14

4.1. Determining the input signals....................................................................... 14

4.1.1. Input board 1 (IB1)...................................................................................... 14

4.1.2. Input board 2 (IB2)...................................................................................... 15

4.1.3. Input board 3 (IB3)...................................................................................... 16

4.1.4. Input board 4 (IB4)...................................................................................... 17

4.2. Soldering jumpers on the logic board........................................................... 19

4.3. Soldering jumper for implementing the code number..................................... 19

4.4. Soldering jumpers on the interface board ..................................................... 20

5. Electrical connections.................................................................................. 22

5.1. TROVIS 6412 (panel-mounting unit)............................................................. 22

5.2. TROVIS 6442 (rack-mounting unit for 19inch racks)...................................... 24

5.3. Balancing the line resistance for the connection of Pt 100 sensors................... 26

5.4. Wiring technique with regard to electromagnetic compatibility....................... 26

6. Operation.................................................................................................. 28

6.1. Process display and control panel elements................................................... 28

6.2. OPERATING level........................................................................................ 28

6.2.1. Modifying the internal set point (reference variable) ...................................... 29

6.2.2. Power supply failure.................................................................................... 30

6.2.3. Manual adjustment of the output variable ..................................................... 30

6.3. PARAMETER level........................................................................................ 32

6.3.1. Operating the PARAMETER level .................................................................. 32

6.3.2. Example how to modify a parameter............................................................ 34

6.4. CONFIGURATION level .............................................................................. 36

6.4.1. Operating the CONFIGURATION level......................................................... 36

6.4.2. Example how to modify a configuration block............................................... 38

6.5. I-O level (displaying all input and output variables) ....................................... 40

6.6. Si level (setting the RS-485 interface)............................................................ 40

6.7. Ai level (adjustment and calibration) ............................................................ 41

6.8. Fir level (displaying the firmware number) .................................................... 43

6.9. CHE level (checking the display panel).......................................................... 43

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6.10. PA level (code number for the PARAMETER level) ..............................44

6.11. CO level (code number for the CONFIGURATION level)....................44

6.12. Ini level (resetting the process control station to its default values) ....................45

6.13. AdP level (adaptation of the control parameters) ............................................46

6.13.1. Single adaptation (adaptation during the start-up phase)................................48

6.13.2. Scheduling dependent on the actual value signal or output variable signal.......51

6.13.3. Scheduling dependent on an external signal..................................................53

6.13.4. Notes on adaptation....................................................................................53

6.13.5. Summary of the adaptation parameters.........................................................54

7. TROVIS 6482 Configuration and Parameterization Program.........................56

8. COPA pen...................................................................................................58

9. Interface RS-485 .........................................................................................60

9.1. Interface mode ............................................................................................60

9.2. Network construction ...................................................................................60

9.3. Network interconnections .............................................................................62

9.4. Operation...................................................................................................62

9.5. Functions supported by the Modbus protocol .................................................62

9.5.1. Function code 01 (Read Coil Status)..............................................................62

9.5.2. Function code 02 (Read Input Status).............................................................63

9.5.3. Function code 05 (Force Single Coil).............................................................63

9.5.4. Function code 03 (Read Holding Register) .....................................................63

9.5.5. Function code 04 (Read Input Register)..........................................................64

9.5.6. Function code 06 (Preset Single Register).......................................................64

9.5.7. Function code 15 (Force Multiple Coils).........................................................64

9.5.8. Function code 16 (Preset Multiple Register) ....................................................65

9.5.9. Error messages ...........................................................................................65

9.5.10. Other functions............................................................................................66

9.6. Retrofitting the RS-485 interface....................................................................66

10. Start-up procedure......................................................................................67

10.1. Optimization (tuning the process control station to the controlled system) .........67

Appendix A Data point list for the RS-485 interface.......................................................71

Appendix B Error messages ..........................................................................................90

Appendix C Checklist....................................................................................................94

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Notes on these mounting and operating instructions Documentation

1.Notes on these mounting and operating instructions

1.1.Documentation

Two manuals constitute the documentation for the TROVIS 6412 and 6442 Process Control Stations: Mounting and Operating Instructions EB 6412 EN and Configuration Manual KH

6412 EN. EB 6412 EN contains information about the installation, electrical connection and operation of

the control stations. Also introduced is how to work with the COPA pen, the COPA adapter and the associated TROVIS 6482 Configuration and Parameterization Program. In addition, the function of the RS-485 interface is described.

Configuration Manual KH 6412 EN presents a detailed description of the optional control modes of the process control station, which can be defined by selecting the corresponding configuration blocks and parameters.

1.2.Abbreviations used in this manual

The parameter names and input and output abbreviations used in this manual are those appearing on the front-panel display of the TROVIS 6412 Process Control Station. These are not always the same as the ones defined in the relevant DIN standards or often used in other documents.

Caution!

Assembly, commissioning and operation of this process control station may only be performed by experienced personnel.

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2.Description

2.1.Features

The TROVIS 6412 and 6442 Process Control Stations are microprocessor-controlled devices used to automate industrial and process engineering plants. They are suitable not only for constructing simple control loops, but for solving complex control problems as well. The TROVIS 6412 and TROVIS 6442 Process Control Stations only differ from each other in their design (see section 2.2.).

Function blocks which are permanently stored in memory allow the user to easily define pre-configured control systems and select various functions. The control mode selected determines which configuration blocks can be set, and these configuration blocks in turn determine the adjustable parameters.

The process control stations are available with various input boards with either three or four analog inputs. Furthermore, each control station has three binary inputs.

The analog inputs of the input boards are suitable for either standardized current and voltage signals, potentiometers, Pt 100 temperature sensors, thermocouples or transmitter supply. The input board 4 in the Technical data (page 8 and following) is no longer available. As a result, the use of thermocouples is restricted.

Standard outputs include: One continuous control output, one on-off/three-step output and one binary output for error messages.

The functional range of the process control stations can be optionally enhanced with the following: One additional continuous control output, one analog output, two limit switches and two binary outputs.

The process control stations can be operated, configured, and parameterized directly on the control panel via several keys. The functions associated with the respective keys can be disabled.

An optional program - TROVIS 6482 - allows configuration and parameterization of the process control station via a PC (see page 56). Apart from this, all configuration blocks and parameters can also be transferred to the process control stations, using a configuration and parameterization pen (COPA pen) (see page 58).

The process control stations can be equipped with a RS-485 serial interface for use in a higher level process control system.

2.2.Versions

TROVIS 64 2 Panel-mounting unit

Rack-mounting unit

Features Description

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Description The process control station (overview)

2.3.The process control station (overview)

Y +

Y -

Control elements

Control mode−Filtering, root extraction, func-

Software functions:

−

Ai 1

Ai 2

tion generation of input variables−Combination of input variables

Ai 3

Ai 4

(addition, subtraction, multiplica-

tion, calculation of mean value,

comparison, ratio)

Operation with two set points−Set point ramp and output

variable ramp

−

Optionally linear and non-linear

control algorithms and compen-

sation algorithms−Output signal limitation (fixed,

−

variable or by means of an input

variable)

Split-range operation−Definition of starting and

−

pen/

adapter

restart conditions, limit alarms

Adaptation of control parameters

or parameter control by an

external signal−Selection control (limiting control)

−

Optional equipment

Fig. 1 ⋅ Block diagram of the process control station

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2.4.Technical data

Inputs

Input board 1 2 3 4

Input 1 mA, V,

potentiometer,

transmitter

supply

Pt 100 in 2/3 or 4-wire

circuit

Thermocouple

(int./ext.

reference

junction)

Input 2

mA, V input,

transmitter supply

Pt 100

in 2/3

or 4-wire

circuit

mA, V,

transmitter

supply

Input 3 mA or V

input

mA, V,

transm. supply

Omitted Omitted

Input 4

mA, V or potentiometer

mA, V,

potentiometer,

transmitter

supply

mA, V or

potentiometer

mA or V input

Measuring ranges 4(0) to 20 mA or

2(0) to 10 V; 0.2(0) to 1 V; 1(0) to 5 V Meas. range switch-over Soldering jumpers Max. permissible values

Current ± 50 mA, voltage ± 25 V Internal resistance

Current R

= 50 Ω; voltage Ri = 200 k

Permissible DC voltage

0 to 10 V

Error Zero point < 0.2 %, span < 0.2 %, linearity < 0.2 % Temperature influence Zero point < 0.1 %/10 K; span < 0.1 %/10 K

Pt 100 temperature sensors

Measuring ranges

−

50 to 100 °C; 0 to 200 °C; 100 to 600 °C Meas. range switch-over Soldering jumpers and configuration Line resistances

Two-wire R

+ R

< 10 Ω,

Three-wire R

= RL2 = RL3 < 50 Ω,

Four-wire, each R

< 100

Error Zero point, gain, linearity < 0.2 % Temperature influence Zero point < 0.2 %/10 K; span < 0.2 %/10 K

Potentiometer Measuring range

0 to 1kΩ, ± 100 Ω, three-wire

Line resistance

< 10 Ω each Error Zero point < 0.2 %, gain < 0.2 % Temperature influence Zero point < 0.1 %/10 K; gain < 0.2 %/10 K

Thermocouple

Specifications on request Transmitter supply 16 to 23 V, max. 50 mA, short-term short-circuit protected Binary inputs 3 binary inputs,

switching contacts (load 36 V DC, approx. 3 mA) or

external switching voltage (24 V DC, ± 30 %,

maximum 6 mA), selection via soldering jumpers

Technical data Description

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Description Technical data

Outputs

Continuous control output

Signal range

Output control range

4(0) to 20(22) mA, permissible load < 750 Ω or 2(0) to 10 V, permissible load > 3 kΩ

−10 to 110 %

Error Zero point < 0.3 %, nominal end value < 0.3 %,

linearity < 0.3 %

Temperature influence Zero point < 0.1 %/10 K; nominal end value < 0.1 %/10 K

Switching output 1 on-off or three-step output,

250 V AC (1A AC, cos ϕ = 1)

Binary output (BO 3) Electrically isolated transistor output,

= 3 V DC,U

min

= 42 V DC, I

max

= 30 mA DC

max

Options Control output 1 continuous control output for split-range operation;

signal range, output control range, error and temperature influence same as first continuous control output (see above)

Analog output

4(0) to 20 mA, permissible load < 750 Ω or 2(0) to 10 V or −10 to 10 V, permissible load > 3kΩ

Error and temperature influence same as first continuous control output (see above)

Limit relay 2 relays, floating contacts, maximum 250 V AC

(1 A AC, cos ϕ = 1) or maximum 250 V DC (0.1 A DC)

Binary outputs 2; floating contacts; maximum 42 V AC (0.1 A AC);

42 V DC (0.05 A DC)

Interfaces

Serial interface on the front-panel

Communications protocol TROVIS 6482 SAMSON Protocol Number of stations 1

RS-232 in conjunction w. SAMSON cable no. 1170-1141

Length of cable < 2 m Transmittable data Configuration, parameters, input and output signals for

graphic display

COPA pen Read/write pen for transmitting the CONFIGURATION and

PARAMETER data to/from the process controls station via the front-panel serial interface

Serial interface RS-485 (optional)

Communications protocol Modbus RTU 584 Data transmission Asynchronous, half duplex, 4-wire or 2-wire Character format RTU (8 bit), 1 start bit, 8 data bits, 1(2) stop bit(s),

optional parity bit Baud rate 300 to 19200 bit/s Number of addressable

246 stations

Number of stations 32 (can be extended with repeater) Length of cable and

transmitting medium Transmittable data Configuration, parameters, operating state,

< 1200 m, with repeater maximum 4800 m, 4-wire (2

wires twisted, stranded in pairs, with static screen)

process variables, error messages

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General specifications

Displays Read-off angle Readable from all sides, high-contrast and lighted

Liquid Crystal Display (LCD)

Displays

⁄

-digit set point (reference variable) display and

⁄

-digit controlled variable display; bar graph displays

for deviation (i.e. error) and output variable; LED displays for range exceeding, alarm messages when limits are exceeded, manual operation, faults etc.; parameter display (only in the PARAMETER level)

Configuration Permanently stored function blocks for fixed set point

control, follow-up control with or without internal/external set point change-over, cascade control, synchro control, ratio control, SPC control, limiting control, DDC backup fixed set point control via binary contact

Power supply 230 V AC (200 to 250 V AC),

120 V AC (102 to 132 V AC), 24 V AC (21.5 to 26.5 V AC), Option 24 V DC (19 to 34 V DC);

48 to 62 Hz Power consumption Approx. 18 VA Temperature range

0 to 50 °C (operation),

−

20 to 70 °C (shipping and storage)

Degree of protection

Panel-mounting unit: Front IP 54, case IP 30,

terminals IP 00;

Rack-mounting unit: IP 00 Overvoltage category II Degree of contamination 2 Conformance to European standards EN 61010, edition March 1994 Electrical

connection

Functional earthing Panel-mounting unit: On case w. Cu-flex. lead > 2.5 mm

Rack-mounting unit: Connector, Type F

(DIN 41 612), Cu-flex. lead > 2.5 mm

Power voltage and process signals

Panel-mounting unit: Screw terminals 1.5 mm2;

Rack-mounting unit: Two connectors, Type F

(DIN 41 612), soldering or crimp types

Total delay time

Approx. 100 ms Resolution Input and output, approximately 11 bits Dimensions See Fig. 3 and Fig. 4 Weight Panel-mounting unit, approx. 1.9 kg; rack-mounting unit, 1 kg

The input board 4 (thermocouple at input 1) is no longer available

Specific measuring ranges on request

Depending on how many functions are configured

Technical data Description

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Installing the process control stations TROVIS 6412 (panel-mounting unit)

3.Installing the process control stations

3.1.TROVIS 6412 (panel-mounting unit)

The TROVIS 6412 Process Control Station is designed for panel-mounting and has the front-frame dimensions 72 x 144 mm. Perform the following steps in order to mount the controller:

1. Make a panel cut-out with the dimensions 68

+0.7

x 138

2. Push the process control station in the panel cut-out from the front side.

3. Install one supplied mounting bracket, both on the top and bottom of the control station following steps 1) and 2) shown in Fig. 2 .

4. Turn the threaded rods in the direction of the control panel, using a screwdriver so that the case is clamped against the panel ((step 3), Fig. 2 ).

16.5

(0.65)

+1.0

mm.

226

(8.90)

Fig. 3 ⋅ Dimensions (panel-mounting unit)

137.5

(5.41)

144

(5.67)

(2.83)

1 Label 2Screws

1) Insert on pin (pivot) and turn

Fig. 2 ⋅ Installation (panel-mounting unit)

2) Click into place

3) Screw tight

4 Mounting bracket 5Pin 6 Threaded rods 7 Front-panel bezel

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TROVIS 6442 (rack-mounting unit for 19inch racks) Installing the process control stations

3.2.TROVIS 6442 (rack-mounting unit for 19inch racks)

The TROVIS 6442 Process Control Station is a rack-mounting unit designed for mounting in 19inch racks. It has to be installed as follows:

1. Push the control station along the guiding rails into the corresponding rack unit, making sure it does not become tilted. Push until the connectors connect.

2. Secure the process control station to the rack unit by fastening it from the front, using two screws (see 1, Fig. 4 ).

3 Press one protective nipple (enclosed in the delivery) into each bore made for the screws.

14.5

(0.57)

Fig. 4 ⋅ Dimensions of the 19inch rack-mounting unit

162.5

(6.40)

190

(7.48)

100 (3.94)

128.5

(5.06)

70.5

(14 HP)

(2.77)

1Screw with

protective nipple

3.3.Opening the controller case

ATTENTION!

The case may only be opened by experienced personnel when the power to the process control station has been cut off!

Re-jumpering (see section 4.) or retrofitting the process control station with an interface board requires that the case be opened as follows:

1. With panel-mounting cases, remove small paper labels (see 1, Fig. 3 ) if necessary. With 19inch rack-mounting units, remove the two protective nipples. Unscrew the two screws located on the front-panel of the case (see Fig. 3 or Fig. 4 , depending on the type of case).

2. Withdraw controller section towards the front. Then, proceed as described for the respective PCB to be modified.

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Installing the process control stations Opening the controller case

Modify input (5, Fig. 5 ) or/ and interface board (6, Fig. 5 ):

3. Unscrew the four screws (1, 2) and remove the two distance bolts (4).

4. Carefully withdraw the input and/or interface board from the case.

5. Modify the board as desired (see sections 4.1., 4.4.).

6. Carefully reinstall the interface or/and input board by plugging it/them into the associated connectors. Make sure the connections are made correctly! Terminals 1 and 21 of each connector are marked.

7. Reinstall the two distance bolts (3) and the four screws (1, 2).

Proceed as described under 8. to 10.

Modify the logic board (7, Fig. 5 ) as follows:

3. Unscrew the two screws (1).

4. Remove cover plate (3).

5. Modify the board as desired (s. sections 4.2. and 4.3.).

6. Reinstall cover plate, making sure that its curved part bends towards the outside.

7. Reinstall the two screws (1).

Proceed as described under 8. to 10.

8. Record any modifications made on the label located on the cover plate. With panel-mounting units, additionally mark modifications on the label on the outside case wall!

9. Insert controller section and fasten it with the two associated screws.

10. If necessary, reinsert small labels and protective nipple on the front-panel of the control station.

1Screws 2Screws 3 Cover plates 4 Distance bolts 5Input board 6Interface board 7Logic board 8 Power supply board 9 Case section (only

panel-mount. unit)

Fig. 5 ⋅ Location of the boards in the controller case

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Determining the input signals Soldering jumpers

4.Soldering jumpers

ATTENTION!

The soldering jumpers may only be modified by experienced personnel when the power to the process control station has been cut off!

Several functions of the process control station are determined by means of soldering jumpers. Open the case as described in section 3.3. to modify the jumpers. The soldering jumpers are marked on the soldering sides of the PCBs.

4.1.Determining the input signals

4.1.1.Input board 1 (IB1)

Note: Select the desired input signal and close the related soldering jumpers listed in line 3 or the following ones of the table below (depending on type of signal selected)! Open all remaining jumpers associated with the corresponding input (line 2)! See Fig. 5 for the location of the input board.

Input signal Input 1

(Ai 1)

Jumpers: 10 to 19

Current 0 to 20 mA 11 21 31 41, 45

4 to 20 mA 11, 14 21, 24 31, 34 41, 44, 45

−20 to 20 mA

Voltage 0 to 1 V11213141

0 to 5 V 12 22 32 42

0 to 10 V 13 23 33 43

0.2 to 1 V 11, 14 21, 24 31, 34 41, 44 1 to 5 V 12, 14 22, 24 32, 34 42, 44

2 to 10 V 13, 14 23, 24 33, 34 43, 44

Potentiometer

0 to 1kΩ

11, 15, 16 21, 25, 26

12, 17, 18

Input 2 (Ai 2)

Jumpers: 20 to 26

−−

Input 3 (Ai 3)

Jumpers: 31 to 34

−−

Input 4 (Ai 4)

Jumpers: 41 to 47

42, 46, 47

Transmitter supply 10, 11, 14, 19

Soldering jumpers associated with the binary inputs for all input boards:

Switching contact 50, 51 60, 61 70, 71 External switching voltage Jumpers mentioned above are open

Binary input 1 (bi 1)

Jumpers

20, 21, 24

Binary input 2 (bi 2)

Jumpers

−−

Binary input 3 (bi 3)

Jumpers

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Soldering jumpers Determining the input signals

4.1.2.Input board 2 (IB 2)

Input signal Input 1

(Ai 1)

Input 2 (Ai 2)

Input 3 (Ai 3)

Input 4 (Ai 4)

Jumpers: 10 to 19

Current 0 to 20 mA

Jumpers: 20 to 26

Jumpers: 30 to 34

Jumpers: 41 to 47

21 31 41, 45

4 to 20 mA 21, 24 31, 34 41, 44, 45

−20 to 20 mA

21, 25, 26

−−

Voltage 0 to 1 V 213141

0 to 5 V 22 32 42

0 to 10 V 23 33 43

−

0.2 to 1 V 21, 24 31, 34 41, 44 1 to 5 V 22, 24 32, 34 42, 44

2 to 10 V 23, 24 33, 34 43, 44

Potentiometer

Transmitter supply

0 to 1kΩ−−

20, 21, 24

30, 31, 34

42, 46, 47

−

Pt 100 2 /3-wire 4-wire

10, 12, 13,

15, X

Measuring ranges

−50 to 100 °C 0 to 200 °C 100 to 600 °C

Select one measuring range and the corresponding soldering jumper. In the PA level, adjust the measuring range by means of the parameters GWK

For specific measuring ranges (on request), soldering jumper X must be open and soldering jum-

11, 14, 16,

and GWK1 .

−

per 17 must be closed.

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Determining the input signals Soldering jumpers

4.1.3.Input board 3 (IB 3)

Input signal Input 1

(Ai 1)

Input 2 (Ai 2)

Input 4 (Ai 4)

Current 0 to 20 mA

4 to 20 mA 41, 44, 45

Jumpers: 10 to 19

−−

Jumpers: 20 to 29

Jumpers: 41 to 47

41, 45

−20 to 20 mA −

Voltage 0 to 1 V 41

0 to 5 V 42

0 to 10 V 43

0.2 to 1 V 41, 44 1 to 5 V 42, 44

2 to 10 V 43, 44

Potentiometer

0 to 1kΩ

42, 46, 47

Transmitter supply 40, 41, 44,

45, 48

Pt 100 2 /3-wire 4-wire 2 /3-wire 4-wire

10, 12, 13,

15, X

Measuring ranges

−50 to 100 °C 0 to 200 °C 100 to 600 °C

Select one measuring range and the corresponding soldering jumper. In the Pa level, adjust the measuring range by means of the parameters GWK

Select one measuring range and the corresponding soldering jumper. In the PA level, adjust the

measuring range by means of the parameters GWK

For specific measuring ranges (on request), soldering jumper X must be open and soldering jum-

19 18 17

11, 14, 16, X

20, 22, 23,

25, XX

and GWK1 .

and GWK2 .

21,24,

29 28 27

26,

−

per 17 must be closed.

For specific measuring ranges (on request), soldering jumper XX must be open and soldering jumper 27 must be closed.

Page 17

4.1.4.Input board 4 (IB 4)

Input board 4 is no longer available.

Input signal

Input 1 (Ai 1)

Input 2 (Ai 2)

Input 3/4 (Ai 3/4)

Jumpers: 10 to 19

Jumpers: 20 to 26

Jumpers: 41 to 47

Current 0 to 20 mA

−

21 41, 45

4 to 20 mA 21, 24 41, 44, 45

−

20 to 20 mA

21, 25, 26

−

Voltage 0 to 1 V 21 41

0 to 5 V 22 42

0 to 10 V 23 43

0.2 to 1 V 21, 24 41, 44 1 to 5 V 22, 24 42, 44

2 to 10 V 23, 24 43, 44

0 to 50 mV 17

−−

0 to 100 mV 16

−

50 to 50 mV

−

100 to 100 mV

Potentiometer

0 to 1k

Ω− −

42, 46, 47

Transmitter supply

−

20, 21, 24, 29

40, 41, 44, 45, 49

Thermocouples

Type U

0 to 200 °C

−−

150 to 400 °C

300 to 600 °C

0 to 600 °C

Type R

0 to 700 °C

500 to 1200 °C

1000 to 1700 °C

0 to 1700 °C

Type T

0 to 150 °C

100 to 250 °C

200 to 400 °C

0 to 400 °C

Soldering jumpers Determining the input signals

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Determining the input signals Soldering jumpers

Input signal Input 1

(Ai 1)

Jumpers: 10 to 19

Type S

Type L

Type B

Type J

0 to 700 °C

500 to 1200 °C

1000 to 1700 °C

0 to 1700 °C

0 to 350 °C 250 to 600 °C 500 to 900 °C

0 to 900 °C

200 to 1200 °C 1000 to 1500 °C 1300 to 1800 °C

200 to 1800 °C

0 to 400 °C

350 to 800 °C

17 16 15 14 17 16 15 14 17 16 15 14 17 16

Input 2 (Ai 2)

Jumpers: 20 to 26

Input 3/4 (Ai 3/4)

Jumpers: 41 to 47

−−

Type E

Type K

Reference junction temperature for external reference junction

700 to 1200 °C

0 to 1200 °C

0 to 400 °C

300 to 700 °C

600 to 1000 °C

0 to 1000 °C

0 to 500

°C

400 to 900 °C

800 to 1300 °C

0 to 1300 °C

0 °C

20 °C

50 °C

15 14 17 16 15 14 17 16 15 14 11

Page 19

Soldering jumpers Soldering jumpers on the logic board

4.2.Soldering jumpers on the logic board

See Fig. 5 for the location of the logic board

Soldering jumper: X closed, 0 open

11 13 21 23 31 33 37 38 SZ LB 1 LB 2 LB 3

Continuous control output Y1

Continuous control output Y2

Analog output Ao1

Operation with code number X Operation with interface X X X

0(4) to 20 mA X 0

0(2) to 10 V 0 X

0(4) to 20 mA X 0

0(2) to 10 V 0 X

0(4) to 20 mA X 0 X 0

−10 to 10 V 0(2) to 10 V 0 X X 0

0X0X

4.3.Soldering jumper for implementing the code number

The CONFIGURATION level and the PARAMETER level can be protected against unauthorized use by means of code numbers. To activate this function, the soldering jumper SZ located on the logic board must be closed (see table in section 4.2.). This jumper SZ is open when the controller is delivered, meaning that the configuration and parameter data of the process control station can be modified without having to enter a corresponding code number. Refer to section 6.10 and 6.11 on how to define the code numbers for CONFIGURATION level and the PARAMETER level.

Page 20

Soldering jumpers on the interface board Soldering jumpers

4.4.Soldering jumpers on the interface board

See. Fig. 5 for the location of the interface board and Fig. 6 for the location of the soldering jumpers.

Important! In the interface mode, the soldering jumpers LB1, LB2 and LB3 on the logic board must also be closed (see section 4.2., page 19). This must be observed when retrofitting the process control station with the interface board.

Soldering jumper (LB) Default setting:

X closed, 0 open Enable parity bit PARITAET 0 Parity odd UNGERADE 0 2 stop bits RES 0 Baud rate Modbus Select a soldering jumper

300 bit/s 300 0 600 bit/s 600 0 1200 bit/s 1200 0 2400 bit/s 2400 0 4800 bit/s 4800 0 9600 bit/s 9600 X

19200 bit/s 19200 0 Termination BUSABSCHLUSS (4 LBs) 0 Two-wire mode 2LEITER (2 LBs) 0 Four-wire mode 4LEITER (2 LBs) X

Page 21

Soldering jumpers Soldering jumpers on the interface board

Fig. 6 ⋅ Location of the soldering jumpers on the interface board

Page 22

TROVIS 6412 (panel-mounting unit) Electrical connections

5.Electrical connections

When making the electrical connections, note the VDE 0100 regulations and the regulations valid in the country where the control station is intended to be installed.

Use shielded cables for the signal lines of the analog and binary inputs, which are installed outside the control cabinets, in order to avoid measuring errors or other interferences. Inside the control cabinets, these lines have to be installed separately from the control and power supply lines.

The shieldings of the lines are to be grounded on one side at the neutral point of the measuring and control system.

5.1.TROVIS 6412 (panel-mounting unit)

The device has plug-in terminals for wires with cross-sections of 0.5 to 1.5 mm2 (DIN 45 140).

Binary inputs Switching contact External switching voltage

81 82

bi 1

bi 2

bi 3

81 82

bi 1

–

bi 2

–

bi 3

Continuous control outputs Switching output Analog output

Binary outputs Limit relay

88 89

bo 1

bo 2

–

bo 3

47 48

–

G1 G2

34 35

–

Ao 1

1),2)

Optional equipment

Power supply Serial interface RS-485

Fig. 7 ⋅ Terminal assignment of TROVIS 6412

T(A)

T(B)

R(B)

R(A)

For 2-wire bus Terminals 96 and 97

Page 23

Electrical connections TROVIS 6412 (panel-mounting unit)

Inputs

Input board 1 (IB 1)

Input board 2 (IB 2)

Ai 1

–

0...1000

13 14

–

11 12

2-wire transmitter 2-wire transmitter

Ai 2

–

Ai 3

–

Ai 4

0...1000

–

Input board 3 (IB 3)

Input board 4 (IB 4)

With reference junction sensor (item no. 1070-8472)

–

mV source

Pt 100

2-wire transmitter 2-wire transmitter

–

2-wire transmitter

–

Pt 100

–

2-wire transmitter

0...1000

–

Fig. 8 ⋅ Terminal assignment of TROVIS 6412 (continued)

2-wire transmitter + −

–

Page 24

TROVIS 6442 (rack-mounting unit for 19inch racks) Electrical connections

5.2.TROVIS 6442 (rack-mounting unit for 19inch racks)

The device has two plug connectors, style F (DIN 41612). The signal lines are assigned to one of these two connectors, whereas the power supply lines are assigned to the other one, meaning these lines are installed separately (see Fig. 9 and Fig. 10 ).

Binary inputs Switching contact External switching voltage

d 4

bi1

bi2

bi3

Binary output 3 Serial interface RS-485

–

bo3

R(B)

R(A)

For 2-wire bus terminals d 22 and d 24

T(A)

T(B)

bi1

–

bi2

Continuous control outputs Switching output Analog output

14 16

–

810

–

Ao 1

–

bi3

Power supply Binary outputs

z 24

d 6

Fig. 9 ⋅ Terminal assignment of TROVIS 6442

Limit relay

bo1

bo2

24 26 28

G1 G2L

20 22 24

Page 25

Electrical connections TROVIS 6442 (rack-mounting unit for 19inch racks)

Inputs

Input board 1 (IB 1)

Input

board 2 (IB 2)

Ai 1

–

0...1000

28 26

32 30

–

2-wire transmitter 2-wire transmitter

Ai 2

–

Ai 3

–

Ai 4

z 6

–

0...1000

–

Input board 3 (IB 3)

Input board 4 (IB 4)

With reference junction sensor (item no. 1070-8472)

Pt 100

–

mV source

–

2-wire transmitter 2-wire transmitter

Pt 100

–

2-wire transmitter

–

2-wire transmitter

2-wi re transmit te r

0...1000

–

0...1000

–

0...1000

–

Fig. 10 ⋅ Terminal assignment of TROVIS 6442 (continued)

Page 26

Balancing the line resistance for the connection of Pt 100 sensors Electrical connections

5.3.Balancing the line resistance for the connection of Pt 100 sensors

When Pt 100 sensors are connected to the control station in a two-wire circuit, the line resistance is to be balanced to 10 Ω at the external resistor Rj in order to avoid measuring errors:

1. Short-circuit the line at the Pt 100 sensor or potentiometer.

2. Switch the resistor R

in the line.

3. Measure the resistance in the total circuit, using a suitable ohmmeter.

4. Adjust the resistor R

until the line resistance is 10 Ω.

In three-wire circuits, the line resistance must not be balanced. Zero and span, however, should be checked and re-adjusted if necessary.

In four-wire circuits, balancing the line resistance is also not necessary.

5.4.Wiring technique with regard to electromagnetic compatibility

All input, output and data lines have to be run in shielded cables for reasons of electromagnetic compatibility (EMC).

The power supply lines, as well as the protective conductors and the functional earthing line (FE) are to be connected separately from each controller to the corresponding multi-terminal bus bar.

With 19inch racks, a conductive connection between the functional earthing line and the rack has to be made. The shielded cables are to be grounded at one end (see Fig. 11 and Fig. 12 ).

Page 27

Electrical connections Wiring technique with regard to electromagnetic compatibility

L N PE

N PE

Controller 1 Controller n

Fig. 11 ⋅ Electrical connections for panel-mounting units

Cu-flex. lead ≥ 1.5 mm

Cu-flex. lead ≥ 2.5 mm

Cu-flex. lead ≥ 10 mm

d12

d18

z2 z4

d18

d12

d18

z2 z4

d18

Controller 1 Controller n

1Plug connector

Signal lines

2Plug connector

Control lines Cu-flex. lead

≥ 1.5 mm Cu-flex. lead

≥ 2.5 mm Cu-flex lead

≥ 10 mm

L N PE

Fig. 12 ⋅ Electrical connections for 19inch rack-mounting units

Page 28

Process display and control panel elements Operation

6.Operation

This section describes how to operate the process control stations directly on the control panel. Unfold the last page of this manual to obtain a better understanding of this description!

The process control stations are designed according to a three-level, logic operating structure:

1) OPERATING level, 2) PARAMETER level and 3) CONFIGURATION level. These levels are described in sections 6.2. to 6.13. Depending on the selected level (mode), the visual displays on the LCD panel and the keys assume different functions.

6.1.Process display and control panel elements

The process control station is operated via eight front-panel keys. The front panel also contains a clear display field, which shows different variables and symbols, depending on the selected operating level. Note that some parameters available in the PARAMETER and ADAPTATION PARAMETER level can be a combination of several variables and symbols.

All process display and control panel elements are listed and explained on the last two pages of this manual. Optional error messages are described in Appendix B .

6.2.OPERATING level

This is the standard operating level of the process control station (control mode). In this level, the control station operates according to the pre-set control mode and the defined parameters.

The values of the set point (reference variable) (3) and the controlled variable (8) are numerically indicated on the display panel. The control deviation (error) (7) and the output variable (14) are represented as a percentage by means of bar graphs. In addition, a LED (19) indicates whether the control station is in the AUTOMATIC or MANUAL mode. If the F key is pressed, the numerical value of the output variable appears in the upper line of the display field (3).

The OPERATING level allows the operator to modify the value of the internal set point (reference variable), abort the restart condition option after a start-up procedure or a power supply failure has occurred, or open the cascade when the controller is in the follow-up control mode. The output variable can be modified manually when having changed over the process control station to the MANUAL mode. These functions are described in the following sections. All other levels can be accessed from the OPERATING level.

Page 29

Operation OPERATING level

6.2.1.Modifying the internal set point (reference variable)

In the OPERATING level, the internal set point WIN can be modified by pressing the C or D key, provided that these keys have not been disabled in the CONFIGURATION level (C59-2 or C59-4). Pressing the respective key briefly modifies the last digit of the indicated number by one. The key must be held down to further advance the number. In this case, the displayed value changes more quickly. While this modification is made, W display. W be configured to display other values than W

disappears after approximately 3 s. Note that the digital display field (3) can also

(see configuration block C4).

Pressing the C key increases the set point (reference variable). Pressing the D key decreases the set point (reference variable).

is additionally indicated on the

Fig. 13 ⋅ Display of the set point (reference variable) in the OPERATING level

3 Set point (reference variable) 7 Control deviation (error) 8 Controlled variable 14 Manipulated variable display 16 Indicator "internal set point valid" 19 AUTOMATIC mode

Page 30

OPERATING level Operation

6.2.2.Power supply failure

Configuration block C 43 (restart condition) defines the behaviour of the process control station after switching on the power supply in the start-up phase or after detecting a power supply failure (> approx. 1 s). This restart condition determines the operating mode, the set point (reference variable) and the output variable for output Y1 or Y2.

If one of the restart conditions C43-1 to C43-6 is set, it is necessary to confirm the setting by pressing the F key in order to return to the normal control mode. In both cases, the digital displays for the set point and the controlled variable flash until the F key is pressed. The settings C43-5 and C43-6 cause the process control station to remain in the MANUAL mode, even when the F key is pressed. This is indicated by the symbol in (19).

The settings C43-7 to C43-12 must not be confirmed in order to return to the normal control mode. The process control station automatically operates in the control mode according to the restart conditions implemented with configuration block C 43.

The following table is a short summary of the optional restart conditions.

C43 Set point Output variable Oper. mode Press F-key Comment

-1, -2 Last active Y

-3, -4 W

-5, -6 Last active Y1K1, Y2K

-7, -8 Last active Y

-9, -10 Internal Y

-11, -12 External Y

, Y2K

1K1

Y1K1, Y2K

, Y2K

1K1

, Y2K

1K1

, Y2K

1K1

Automatic Yes Automatic Yes WS overwrites W

Manual Yes

Automatic No Automatic No Automatic No

After pressing F, still MANUAL mode

6.2.3.Manual adjustment of the output variable

In MANUAL mode, the connected control valve can be manually moved to the desired position, using the G and H keys, provided that these keys have not been disabled in the configuration mode (C59-2 or C59-4). The corresponding key must be pressed until the desired output variable is adjusted. The bar graph (13) indicates the change in the output variable. If the F key is pressed, the numerical value of the output variable is also displayed in the digital display field (2).

Bumpless change-over from MANUAL to AUTOMATIC mode and vice versa is carried out via the MANUAL/AUTOMATIC key (E).

Pressing the G key increases the output variable. Pressing the H key decreases the output variable.

Page 31

Page 32

PARAMETER level Operation

6.3.PARAMETER level

The control parameters can be displayed and modified in the PARAMETER level. When the control station operates with a code number (code number mode) (see 4.3.), the parameters can only be modified after having entered the valid code number.

Only parameters that are supported by the controller’s configuration can be displayed and modified. All dynamic parameters (e.g.. X, W

, Z, XD, Y1, Y2), however, cannot be modified.

6.3.1.Operating the PARAMETER level

See last page of this manual for the designations of the keys and displays! The process control station is in the OPERATING level. Fig. 14 is a simplified representation of how to set a parameter.

Accessing the PARAMETER level and displaying the parameter values

1. Press A key. I-O appears on the display.

2. Press C key. PA appears on the display.

3. Press A key. Now, the control station is in the parameter mode. The LCD panel additionally shows the value of the currently selected parameter in the digital display field (3), the control deviation (error) bar graph (7), the parameter table (21), and the bar graph representing the output variable (14). The selected parameter flashes. When accessing the PARAMETER level for the first time, the flashing parameter is always the one which was selected last during a former modification process.

4. All parameters can be displayed by pressing the C or D key. Attention: the parameters can be combinations of several symbols, e.g. Y

1K1

Modifying parameter values

1. Follow steps 1 to 3 listed under "Accessing the PARAMETER level and displaying the parameter values".

2. Select the parameter to be modified by pressing the C or D key.

3. Press A key when the selected parameter flashes in the parameter table. What comes up on the display now depends on whether the process control station

operates either with or without a code number. If no code number was entered, PA flashes on the display. Hold down the A key for approx.

3 s. Continue as described under 4. If a code number was entered, PA and flash on the display. Use the C and D keys to

set the code number in the upper line of the display (3). Then, press A key. Now the parameter table should reappear on the display. If not, the wrong code number was entered. Re-enter the code number, using the C and D keys or cancel by pressing the F key.

4. The selected parameter and PA flash on the display. Now a new parameter value can be set by pressing the C and D keys. Then, press A key to accept.

5. Select next parameter with the C and D keys. Press A key, and modify them as described under 4.

Exiting the PARAMETER level

1. Press F key. The process control station returns to the OPERATING level.

Page 33

Operation PARAMETER level

Fig. 14 ⋅ Simplified parameter setting diagram

…

keys

Page 34

PARAMETER level Operation

6.3.2.Example how to modify a parameter

This section describes how to modify a parameter, using KP as an example. All other parameters have to be modified accordingly.

Fig. 15 The process control station is in the standard operating mode and the display is, for example as shown in Fig. 15 .

Fig. 16 Press A key. I-O comes up on the display.

Fig. 15 Fig. 16

Fig. 17 Fig. 18

Fig. 19 Fig. 20

Fig. 17 Press C key. PA appears on the display.

Fig. 18 Press A key. The LCD panel shows, for example this display. The parameter which was changed last (here T

) flashes.

Fig. 19 Press C or D key several times until K (only K

!). The valid KP value, here 1.8, is

flashes

displayed in the upper line of the display.

Fig. 20 Press A key. If no code number was entered (factory default) PA flashes on the display. Hold down the A key for approximately 3 s. If a code number was entered (not shown in this figure), PA and flash. Use C and D keys to set the code number in the upper line of the display (3). Then, press A key.

Page 35

Operation PARAMETER level

Fig. 21 K

and PA flash.

Enter new K

value by pressing the C and D

keys (in this example, 3.2). Fig. 22 Press A key to accept. The new K

Fig. 21 Fig. 22

value is stored. Only K

flashes.

Fig. 23 Press F key. The process control station has returned to the OPERATING level.

Fig. 23

Page 36

CONFIGURATION level Operation

6.4.CONFIGURATION level

The configuration blocks can be displayed and modified in the CONFIGURATION level. When the control station operates with a code number (code number mode), the configuration blocks can only be modified after having entered the valid code number. Configuration blocks determine the control functions. These blocks and the associated functions are described in more detail in Configuration manual KH 6412 E.

The configuration blocks are designated C1 to C59. The control mode selected determines which configuration blocks are relevant. Only these blocks can be displayed and modified.

6.4.1.Operating the CONFIGURATION level

See last page of this manual for the designations of the keys and displays! Operation of this CONFIGURATION level is described, starting from the OPERATING level. Fig. 24 is a simplified representation of how to set a configuration block.

Accessing the CONFIGURATION level and displaying the configuration blocks

1. Press A key. I-O appears on the display.

2. Press C key several times until CO appears on the display.

3. Press A key. Now, the upper line of the display shows the setting of the configuration block (e.g. - 1), and the associated designation of this block (e.g. C 1) is indicated in the lower line of the display. When accessing the CONFIGURATION level for the first time, the display always shows the configuration block which was viewed or modified last.

4. The individual configuration blocks can be viewed by pressing the C or D key.

Modifying configuration blocks

1. Follow steps 1 to 3 listed under "Accessing the CONFIGURATION level and displaying the configuration blocks".

2. Select the configuration block to be modified by pressing the C or D key.

3. Press A key. What comes up on the display now depends on whether the process control station

operates either with or without a code number. If no code number was entered, CO flashes on the display. Hold down the A key for

approx. 3 s. Continue as described under 4. If a code number was entered, CO and flash on the display. Use the C and D keys to

set the code number in the upper digital display field (3). Then, press A key. Should CO and still flash on the display, the wrong code number was entered. Re-enter the code number or exit the CONFIGURATION level as described below.

4. C and − flash on the display.

5. Select new value for the configuration block, using the C and D keys. Then, press A key to accept.

6. Select other configuration block with the C and D keys. Press A key. Continue as described under 5. or exit the CONFIGURATION level.

Exiting the CONFIGURATION level

1. Press F key. After having modified the configuration blocks, the control station returns to the OPERATING level and is in the MANUAL mode.

Page 37

Operation CONFIGURATION level

Fig. 24 ⋅ Simplified configuration diagram

…

keys

Page 38

CONFIGURATION level Operation

6.4.2.Example how to modify a configuration block

This section describes how to modify a configuration block, using C5 (configuration of controller outputs) as an example. All other configuration blocks have to be modified accordingly.

Fig. 25 The process control station is in the standard operating mode and the display is, for example as shown in Fig. 25 .

Fig. 26 Press A key. I-O comes up on the display.

Fig. 25 Fig. 26

Fig. 27 Fig. 28

Fig. 29 Fig. 30

Fig. 27 Press C key twice. CO appears on the display.

Fig. 28 Press A key. The configuration block modified last and its setting are displayed (here C 8 and -1).

Fig. 29 Press C or D several times until C 5 is displayed. The valid setting for C 5 (here - 2) is shown in the upper line of the display.

Fig. 30 Press A key. If no code number was entered (factory default) CO flashes on the display. Hold down the A key for approximately 3 s. If a code number was entered (not shown in this figure), CO and flash. Use C and D keys to set the code number in the upper line of the display (3). Then, press A key.

Page 39

Operation CONFIGURATION level

Fig. 31 C and - flash. Select new setting for C 5 by pressing the C and D keys (in this example 7).

Fig. 32 Press A key to accept. The new setting C 5-7 is stored. The display stops flashing.

Fig. 31 Fig. 32

Fig. 33 Press F key. The process control station has returned to the OPERATING level and is in the MANUAL mode.

Fig. 33

Page 40

I-O level (displaying all input and output variables) Operation

6.5.I-O level (displaying all input and output variables)

In the I-O level (Input-Output), all input and output signals of the process control station, except of bo3, can be displayed as absolute values.

This level is also used to check the software assignment of the respective analog inputs to an internal signal.

Accessing the I-O level

The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press A key to open the I-O level. "in 1" for analog input 1 comes up on the display.

3. Press C key to display other inputs and outputs. By pressing the D key, it is possible to go through the displays in a reverse order.

Exiting the I-O level

1. Press F key. The process control station returns to the OPERATING level.

6.6.Si level (setting the RS-485 interface)

The station number (Stn), the timeout period information (tiF), the status timeout period information (tiF on/oFF) and the status of the RS-485 interface (Si on/oFF) are defined in this level. For further details, see section 9.1., p. 60.

Accessing the Si level

The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press C several times until Si appears on the display.

3. Press A key. Si is indicated in the lower line of the display and the status of the RS-485 interface is shown in the upper line of the display (on or oFF).

4. Press A key. What comes up on the display now depends on whether the process control station

operates either with or without code number. If no code number was entered, Si flashes on the display. Hold down the A key for approx.

3 s. Continue as described under 5. If a code number was entered, CO and flash on the display. Use C and D keys to set

the code number in the upper line of the display (3). Then, press A key. Should CO and

still flash, the wrong code number was entered. Re-enter the code number or leave the

Si level as described below.

5. The Si level is open. Stn (for station number) comes up in the lower line of the display and the entered number is indicated in the upper line of the display.

6. The parameters of the Si level can be viewed by pressing the C or D key.

Page 41

Operation Ai level (adjustment and calibration)

Modifying parameters in the Si level

1. Access the Si level as described above.

2. Select a parameter (Stn, TiF, TiF on/oFF, Si on/oFF) by pressing either the C or D key .

3. Press A key. The parameter flashes.

4. Modify setting or value, using the C or D key. Then, press A key to accept.

5. If an other parameter is to be modified, continue as described under 2. Proceed as described below to exit the Si level.

Exiting the Si level

1. Press F key. The process control station returns to the OPERATING level.

6.7.Ai level (adjustment and calibration)

This level is used to display the inputs Ai 1 to Ai 4 as standardized values. When setting configuration block C14-2, the user can adjust zero and span for inputs Ai 1 to

Ai 4 or calibrate the input characteristic via 5 coordinates. This calibration procedure can compensate for small non-linearities in the measurement of the connected transmitters. The span can be calibrated for the controller outputs Y1 and Y2 and the analog output Ao 1.

The zero adjustment range is ±3 %, the span adjustment range is ±6 %.

Accessing the Ai level

The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press C key several times until Ai appears on the display.

3. Press A key. Ai 1 appears in the lower line of the display, and the associated value is indicated in the upper line of the display.

Exiting the Ai level

1. Press F key. The process control station returns to the OPERATING level.

Displaying the analog inputs Ai 1 to 4 as standardized values

1. Access the Ai level as described above.

2. Select an input Ai 1 to Ai 4, using the C key. The associated value is indicated in the upper line of the display.

3. Exit the Ai level as described above.

Requirements for calibration

In principle, the soldering jumpers used to define the inputs and outputs are assumed to be set as required for the respective application (see section 4., p.14).

In addition, the following steps have to be carried out:

1. Set C14-2 in the CONFIGURATION level (see section 6.4., p. 36).

2. Press F key to exit the CONFIGURATION level.

Page 42

Ai level (adjustment and calibration) Operation

Zero and span adjustment for the inputs Ai 1 to Ai 4

1. Make the settings required for calibration (see previous section).

2. Access the Ai level as described above.

3. Select the input to be adjusted ( Ai 1 to Ai 4) by pressing the C key. CAL oFF appears on the display (see "Calibrating the input characteristic" below).

4. Use a highly-accurate adjustment device to adjust the initial value of the input signal range. When the input signal is within the adjustment range, three black bars appear in the left bottom corner of the display. In addition, the selected input, e.g. Ai 1 and AdJ (for adjust) alternate in the lower line of the display.

5. Press A key to accept the zero point adjustment. 0.0 appears in the upper line of the display.

6. Use a highly-accurate adjustment device to adjust the maximum value of the input signal range (span adjustment). When the input signal is within the adjustment range, three black bars appear in the right bottom corner of the display field. In addition, the selected input, e.g. Ai 1 and AdJ (for adjust) alternate in the lower line of the display.

7. Press A to accept the span adjustment. 100.0 appears in the upper line of the display.

8. Repeat steps 3. to 6. to adjust zero and span for the next input or exit the Ai level (see above).

Calibrating the input characteristic via 5 coordinates

The five coordinates for the calibration curve are set at 0; 25; 50; 75 and 100 % of the input signal. For an input signal in the range from 4 to 20 mA, these coordinates are, for example, 4; 8; 12; 16 and 20 mA.

Proceed as follows:

1. Make the settings required for calibration.

2. Access the Ai level as described above.

3. Press C key until CAL oFF appears on the display.

4. Press A key. "on" flashes in the upper line of the display.

5. Press A key until "on" stops flashing (approx. 5 s).

6. Press C key. Ai 1 for input 1 and CAL alternate on the display.

7. Select the desired input (Ai 1 to Ai 4), using the C key.

8. Use a highly-accurate adjustment device to set the input signal to 0 %. In the above mentioned example, this would be 4 mA. When the input signal is within the calibration range, a scale (0 to 100 %) comes up at the bottom of the display and two black bars appear over the valid value (0 %). CAL and the selected input alternate in the lower line of the display.

9. Press A key to accept the first coordinate value.

10. Repeat steps 8 and 9 in order to set the other four coordinate values (25; 50; 75; 100 %) one after the other.

11. Repeat steps 7. to 10. for the next input or exit the Ai level by pressing the F key.

Note:

The inputs must be re-calibrated in the Ai level after exchanging the EPROM or the input board.

Page 43

Operation Fir level (displaying the firmware number)

Calibrating the span for the outputs Y1, Y2 and Ao1

When calibrating the span for the outputs Y1, Y2 and Ao1, proceed as follows: Connect a highly-accurate meter to the output to be calibrated. First, follow steps 1. to 6. listed under "Calibrating the input characteristic via 5 coordinates"

(see above).

7. Select desired output Y1, Y2 or Ao1 by pressing the C key. A scale from 0 to 100 % comes up at the bottom of the display.

8. Use the G and H keys to adjust the desired end value of the output signal range. Check this value with the highly-accurate meter. When the output signal is within the calibration range, CAL and the selected output alternate in the lower line of the display.

9. Press A key to accept the calibrated end value.

10. Repeat steps 7 to 9 to calibrate the other outputs or exit the Ai level by pressing the F key.

6.8.Fir level (displaying the firmware number)

This level is used to view the version number of the EPROM used in the process control station, as well as the current RS-485 interface version. Should you have any inquiry about the device, always specify the version number of your process control station because the software might have been modified for the following versions.

Proceed as follows: The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press D key until "Fir" comes up on the display.

3. Press A key. C (for controller = process control station) appears in the lower line of the display, and the valid version number is indicated in the upper line of the display.

Press C key. Si (for serial interface) appears in the lower line of the display, and the valid version number is indicated in the upper line of the display. If 0.0 appears here, this means that no interface board is installed.

5. Press F key to exit the Fir level.

6.9.CHE level (checking the display panel)

This level is used to check proper functioning of all the display elements shown on the last page of this manual.

Proceed as follows: The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press D key until CHE comes up on the display.

3. Press A key. All display elements are indicated on the display, as shown on the last page of this manual.

4. Press F key to exit the CHE level.

Page 44

PA level (code number for the PARAMETER level) Operation

6.10.PA level (code number for the PARAMETER level)

This level can be used to define the code number for the PARAMETER level. The level is only accessible, however, when the process control station operates in the code number mode (see section 4.3., p. 19) and the operator knows the code number for servicing. In order to prevent this code number for servicing from being accessed by unauthorized persons, either cut out or scribble over the number on page 97.

To modify the code number for the PARAMETER level, take the following steps: The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press C or D key until PA and are displayed.

3. Press A key. flashes on the display. "1" comes up in the upper line of the display.

4. Enter the code number for servicing in the upper line of the display, using the C or D key.

5. Press A key. The currently valid code number is displayed and PA flashes.

6. Enter the new code number with the C or D key.

7. Press A key. PA no longer flashes.

8. Press F key to exit this level.

6.11.CO level (code number for the CONFIGURATION level)

This level can be used to define the code number for the CONFIGURATION level. The level is only accessible, however, when the process control station is in the code number mode (see section 4.3., S. 19) and the operator knows the code number for servicing. In order to prevent this code number for servicing from being accessed by unauthorized persons, either cut out or scribble over the number on page 97.

To modify the code number for the CONFIGURATION level, take the following steps: The process control station is in the OPERATING level.

1. Press A key. I-O appears on the display.

2. Press C or D key until CO and are displayed.

3. Press A key. flashes on the display. "1" comes up in the upper line of the display.

4. Enter the code number for servicing in the upper line of the display, using the C or D key.

5. Press A key. The currently valid code number is displayed and CO flashes.

6. Enter the new code number with the C or D key.

7. Press A key. CO no longer flashes.

8. Press F key to exit this level.

Page 45

Operation Ini level (resetting the process control station to its default values)

6.12.Ini level (resetting the process control station to its default values)

Resetting the process control station to its default values can be useful in the start-up phase or when the control tasks to be solved with the process control station have changed. This function is based on the setting of configuration block C56. The Ini level can only be accessed when C56 > 1.

C56 Resetting to default values

-1 No

-2 Configuration and parameterization

-3 Configuration

-4 Parameterization

-5 Zero and span adjustment of the analog inputs

-6 Span adjustment of the analog outputs

-7 Code number

-8 Controller ID number

-9 Adaptation parameters

The following steps have to be carried out: The process control station is in the OPERATING level.

1. Set configuration block C56>1 (see above and section 6.4., p.36), then exit the CONFIGURATION level again.

2. Press A key. I-O appears on the display.

3. Press D key. Ini appears on the display.

4. Press A key twice. End and Ini appear on the display.

5. Press F key to exit this level.

Note:

After having executed this function, configuration block C56 is only reset to C56-1 when it was previously set to C56-2 or C56-3! With all other settings, the Ini level remains active! We therefore recommend to reset the configuration block to C56-1 after carrying out the function, in order to prevent the control station from starting up by mistake.

Page 46

AdP level (adaptation of the control parameters) Operation

6.13.AdP level (adaptation of the control parameters)

The objective of this adaptation function is to calculate the optimum control parameters without the need to make many adjustments on the process control station or without having much previous knowledge of the process to be controlled.

The TROVIS 6412/42 Process Control Station supports the following adaptation procedures: – Single adaptation (adaptation during the start-up phase) (see section 6.13.1.) – Scheduling dependent on the actual value signal or output variable signal (see section

6.13.2.) – Scheduling dependent on an external signal (see section 6.13.3.) These adaptation procedures are suitable to be used for self-regulating processes, simple

integrating controlled systems, and systems with dead times, as well as for oscillating systems. After having terminated the adaptation procedure, the process control station uses the calcula-

ted adaptation parameters as long as − AdP on − is set in the ADAPTATION level. Otherwise, it operates with the control parameters set in the PARAMETER level. The calculated adaptation parameters can be viewed in the ADAPTATION PARAMETER level −PA AdP− at any time and can also be modified by the user, except for the parameters K K

characterizes the type of the controlled system. K3=1 characterizes a self-regulating system,

whereas K

=2 stands for a system which is not self-regulating.

The adaptation parameters calculated by the adaptation algorithm ensure an optimum behaviour of the controlled system when disturbances occur in the process. The parameter K5 can be used to activate an adjustable filter for the set point (reference variable) in order to obtain satisfactory reference action of the process control station when there is a step change in the set point (reference variable).

, TN, TV and K3. The parameter

The current values of the controlled variable and the output variable are indicated on the display during the entire adaptation run.

Note:

Configuration block C56-9 resets all parameters calculated in the adaptation procedure to their default values (see also p. 45).

Requirements for adaptation

The following adjustments have to be made before conducting the adaptation:

1. Use configuration block C51 to configure the desired type of adaptation and, for cascade

control, additionally C52 (for cascade control, note section 6.13.4., p. 53; how to set a configuration block is described in section 6.4., p. 36).

2. Regulate the controlled system, preferably in the MANUAL mode, and check whether the

system has assumed a calm state.

3. Access the ADAPTATION level and set the adaptation parameters required for the desired

adaptation procedure, see sections 6.13.1. to 6.13.3. (how to set a parameter is described in the following sections).

Page 47

Operation AdP level (adaptation of the control parameters)

Opening the ADAPTATION level and accessing the adaptation steps

The process control station is in the OPERATING level. All settings required for adaptation have been made (1. and 2.).

1. Press A key.

2. Press C key twice. AdP appears on the display.

3. Press A key. AdP and oFF appear on the display.

4. Press A key. oFF changes to on which flashes on the display.

5. Press A key. The display no longer flashes.

6. Use C and D keys to change over between the following adaptation steps: AdP and flashing PA (adaptation parameters can be set) AdP and flashing Aut (controller conducts adaptation automatically) AdP and flashing nb (noise measurement can be initiated manually) AdP and flashing idF (identification can be initiated manually; not possible until after noise

measurement) AdP and flashing Scd and AdP (calculation of section factors can be manually initiated for

scheduling; not possible until after noise measurement and identification) AdP and on (adaptation can be switched on/off)

7. Selected the desired adaptation step, then press the A key. The selected adaptation step is executed.

Modifying adaptation parameters

1. Follow steps 1. to 6. as described above under "Opening the ADAPTATION level and accessing the adaptation steps". For step 6, select PA AdP .

2. Press A key. The parameter table and AP or AP 1 appear on the display. AP stands for the adaptation parameters of the fixed set point, follow up, ratio or synchro controller; AP1 stands for the parameters of the master controller.

3. The individual adaptation parameters can be selected and modified in the same way as the parameters in the PARAMETER level (see p. 32).

Completing or aborting an adaptation step

1. When defining the adaptation parameters, the parameter table and AP or AP1 appear on the display. Press F key. Press A key for all other adaptation steps. The process control station remains in the ADAPTATION level. An other adaptation step can be selected.

Completing or aborting the adaptation

1. Press F key. The process control station switches to the OPERATING level.

Page 48

AdP level (adaptation of the control parameters) Operation

6.13.1.Single adaptation (adaptation during the start-up phase)

Use C 51-2 to select single adaptation. Also use C52-2 with cascade control. The following adaptation parameters must be set before starting the adaptation algorithm: GW X Min. limit for the controlled variable test range in %

GW X Max. limit for the controlled variable test range in % GW Y GW Y T

S K3

The adaptation algorithm runs through the steps noise band measurement (nb) and identification (idF).

In the noise measurement procedure, the noise band of the controlled variable is determined in several tests. The sequence of operations can be followed on the display of the process control station where changing status displays appear (see Fig. 34 ).

For the identification procedure, the operator has to excite the controlled system with a control pulse (T change in behaviour of the controlled system and permanently monitors the response of the controlled variable. If the controlled variable is stationary while the pulse is still active, the adaptation algorithm determines the type of control process, the process gain, and the dynamic behaviour of the controlled process, and calculates the control parameters for, e.g. an increasing output signal.

Min. limit for the output variable test range in %

Max. limit for the output variable test range in %

Pulse duration of the output test signal in s (for positive values) and min (for negative values)

Factor for set point (reference variable) filter

) whose time and amplitude is limited. Then, the process control station waits for any

SK3

The controlled variable is considered to be stationary when it does not exceed or fall below a factory-adjusted deviation for a certain period of time.

The control pulse is switched off when the control parameters for the increasing output signal have been calculated. The control station monitors the behaviour of the controlled system again. When the controlled variable is stationary, the control station calculates the parameters for a decreasing output signal.

Should the controlled variable not become stationary, the process control station will provide an error message (see p. 90).

If the controlled variable threatens to leave the test range (adjusted by the operator) after exciting the controlled system, the control pulse is inactivated. A new amplitude-corrected pulse value is calculated from the characteristic of the controlled variable until the time when the pulse is switched off, and the procedure described above is repeated.

The pulse is also switched off when it exceeds the pulse time. Then, the same takes place as described above.

In the identification procedure, the adaptation steps are indicated on the display of the process control station in the sequence illustrated in Fig. 35. Individual steps are omitted, depending on which type of controlled system was determined. The adaptation procedure can run automatically. Then, the adaptation step −Aut AdP− has to be accessed in the ADAPTATION level (see p. 46). At the end of the adaptation cycle, End Aut comes up on the display. The operator can carry out each adaptation step individually. In this case, first access adaptation step −nb AdP− , then −IbF AdP− (see p 46).

Page 49

Operation AdP level (adaptation of the control parameters)

Display field Status display Sequence of operations

0 Checks starting condition

1Start

Measurement 1st interval

2 Measurement 2nd interval

Calculates noise band

3 Measurement 3rd interval

Calculates noise band

4 Measurement 4th interval

Calculates noise band

5 Measurement 5th interval

Calculates noise band

End

End of noise measurement

Fig. 34 ⋅ Operational flow chart for noise measurement

Page 50

AdP level (adaptation of the control parameters) Operation

Display field Status

display

t >TsK

X >GWX t >TsK

System with self-regulation

System without self-regulation

End

Sequence of operations

0 Checks starting condition

Checks if system has assumed a calm state

1 Checks if pulse was imposed

on system

2 Activates control pulse

Waits for system response 3 System response determined 4 Controlled system stationary

First calculation of control

parameter set 1 (basic values)

Inactivates control pulse

for system response 5 Inactivates control pulse for

system response 6 Inactivates control pulse

First calculation of control

parameter sets 1 and 2 (basic

values).

Changes over to selected

operating mode or

calculates correction of

control pulse

Waits for system

to become stationary 7 Activates corrected control

pulse

Waits for system response 8 System response determined

Waits for system to

become stationary

First calculation of control

parameter set 1 (basic values) 9 Inactivates control pulse

Waits for system response

10 System response determined

Waits for system to

become stationary

First calculation of control

parameter set 2 (basic values)

Changes over to selected

operating mode

End of identification

IdF

Fig. 35 ⋅ Operational flow chart for identification

Page 51

Operation AdP level (adaptation of the control parameters)

6.13.2.Scheduling dependent on the actual value signal or output variable signal

Scheduling dependent on the actual value signal has to be selected with configuration block C51-3, whereas scheduling dependent on the output variable signal has to be configured with C51-4. In the cascade control mode, C52-3 or C52-4 can be set to implement adaptation for the master controller loop. Note that scheduling is only supported in systems with self-regulation.

The following parameters must be set before starting the adaptation algorithm: All parameters as for single adaptation (see section 6.13.1.) and additionally:

GW K GW K K

Min. limit for the adaptation range in %

Max. limit for the adaptation range in %

Number of sections (maximum 7)

For scheduling dependent on the actual value signal, the control station must be put to the AUTOMATIC mode.

Scheduling has the objective to compensate for measurable, static non-linearities occurring in a process. This scheduling procedure is used to determine the optimum controller settings for definable sections of a selected adaptation range. The operator can choose among two scheduling procedures: 1) scheduling dependent on the controlled variable (CO 51-3) or 2) scheduling dependent on the output variable (CO 51-4). As already described above, limits for the adaptation range have to be entered, meaning, for example a range for the controlled variable. In addition, the number of sections into which this adaptation range shall be divided have to be defined. In the scheduling procedure, the controller calculates a factor for each of these sections, which modifies the proportional-action coefficient K stored as parameters K

to K7. The reference points for the scheduling procedure are

These section factors are

located in the middle of each section. The control parameters are linearly interpolated between these reference points. The values calculated before the first and after the last reference point are maintained constant.

First, the scheduling algorithm runs through the steps described in section 6.13.1.. Then, the process control station goes to the lower limit of the defined adaptation range and waits for the controlled system to become stationary. As soon as the system is stationary, the control station accesses the first operating point. This is done abruptly (step change) with scheduling dependent on the output variable and regularly (controlled) with scheduling dependent on the controlled variable. The operating points are located exactly on the limits of the individual sections. After having gone to the operating point, the process control station waits again for the controlled system to become stationary. Subsequently, the adaptation algorithm calculates the factor for the respective section. The procedure described above is repeated for each section.

The last part of the scheduling procedure can be followed on the display of the process control station as described in Fig. 36 .

As for single adaptation, the scheduling steps either run automatically (AdP Aut) one after the other or each step can be accessed individually (nb-idF-Scd), see. p. 46. Also, it is possible to set all parameters to be calculated in the ADAPTATION PARAMETER level.

Page 52

AdP level (adaptation of the control parameters) Operation

Display field Status display Sequence of operations

0 Checks starting condition

Control pulse Beginning of adaptation range Waits for system to become stationary

1 Control pulse for 1st section

Waits for system to become stationary Calculates section factor K

2 Control pulse for 2nd section

Waits for system to become stationary Calculates section factor K

3 Control pulse for 3rd section

Waits for system to become stationary Calculates section factor K

4 Control pulse for 4th section

Waits for system to become stationary Calculates section factor K

5 Control pulse for 5th section

Waits for system to become stationary Calculates section factor K

6 Control pulse for 6th section

Waits for system to become stationary Calculates section factor K

7 Control pulse for 7th section

Waits for system to become stationary Calculates section factor K Changes over to selected operating mode

End

End of scheduling

Scd

Fig. 36 ⋅ Operational flow chart for scheduling

Page 53

Operation AdP level (adaptation of the control parameters)

6.13.3.Scheduling dependent on an external signal

Scheduling dependent on the Y

-signal has to be selected with configuration block C51-5,

Actuat

whereas scheduling dependent on the Z-signal has to be configured with C51-6. In the cascade control mode, C52-5 or C52-6 can also be set to implement adaptation for the master controller loop.

The following parameters must be set before starting the adaptation algorithm: All parameters as for single adaptation (see section 6.13.1.) and additionally:

GW K GW K

Min. limit for the adaptation range in %

Max. limit for the adaptation range in %

K4 Number of sections (maximum 7)

to K7 Factor for sections 1 to 7

The scheduling procedure dependent on an external signal is the same as the one dependent on the controlled variable or output variable signal (see section 6.13.2.). The section factors, however, are not calculated by the adaptation algorithm, but have to be entered manually in the ADAPTATION PARAMETER level PA AdP.

The adaptation range set in the factory is 10% to 90 %. The section factors are assigned the value 1.

6.13.4.Notes on adaptation

In a cascade control arrangement, adaptation must be first carried out in the follow-up or secondary control loop. The operator has to open the cascade in the OPERATING level (press B key). Then, a

appears in the top right corner of the display. The control station can be put

either in the MANUAL or AUTOMATIC mode. After having carried out adaptation for the follow-up control loop, the cascade must be closed (press B key) and the controller must be set to the AUTOMATIC mode. Subsequently, adaptation can be implemented for the master controller loop.

The factory settings for the controlled variable test range and the output variable test range for adaptation are from 10 % to 90 %. If the operator modifies these two values, the two values should always be the same in the beginning. Should the control station indicate insufficient oscillation of the controlled variable during adaptation (cin 202, accept with A key), the output variable test range (GWY length of the control pulse (T

, GWY1) has to be expanded or, if this is not permitted, the

) has to be increased.

SK3

In case of an error, the adaptation algorithm provides different error messages. These are described in more detail in the table Error messages starting on page 90.

Page 54

AdP level (adaptation of the control parameters) Operation

6.13.5.Summary of the adaptation parameters

The parameters characterized by AP apply for fixed set point, follow-up, ratio, and synchro control, as well as for the follow-up control loop in cascade control arrangements.

The parameters characterized by AP1 apply for the master control loop in a cascade control arrangement.

Parameter

GWK GWX GWX GWY1 GWY1 GWK GWK T

SK3

TZK

PK1

NK1

VK1

PK2

NK2

VK2

Parameter-

Designation Range of values Factory

default

set AP Proportional-action coefficient 0.1 … 100.0 AP Reset time -1999 … 1999 AP Rate time -1999 … 1999 AP Type of controlled system

0 … 20 AP Factor for set point (reference variable) filter 0.00 … 19.99 0.00 AP Noise bandwidth 0.1 … 10.0 0.0

AP Min. limit for the controlled variable test range 0.0 … 110.0 10.0 AP Max. limit for the controlled variable test range 0.0 … 110.0 90.0 AP Min. limit for the output variable test range 0.0 … 110.0 10.0 AP Max. limit for the output variable test range 0.0 … 110.0 90.0 AP Min. limit for the adaptation range 0.0 … 110.0 10.0

AP Max. limit for the adaptation range 0.0 … 110.0 90.0

AP Pulse duration, control pulse (output test signal) -1999 … 1999 50.0 AP System gain (increasing output signal) 0.1 … 100.0 0.0 AP Dead time (increasing output signal) -1999 … 1999 0.0 AP System gain (decreasing output signal) 0.1 … 100.0 0.0 AP Dead time (decreasing output signal) -1999 … 1999 0.0 AP Basic value (increasing output signal) P-coeff. 0.1 … 100.0 1.0 AP Basic value (increasing output signal) reset time -1999 … 1999 60.0 AP Basic value (increasing output signal) rate time -1999 … 1999 5.0 AP Basic value (decreasing output signal) P-coeff. 0.1 … 100.0 1.0 AP Basic value (decreasing output signal) reset time -1999 … 1999 60.0 AP Basic value (decreasing output signal) rate time -1999 … 1999 5.0 AP Number of sections 1 … 75 AP Section factor 1 0.00 … 19.99 1.00 AP Section factor 2 0.00 … 19.99 1.00 AP Section factor 3 0.00 … 19.99 1.00 AP Section factor 4 0.00 … 19.99 1.00 AP Section factor 5 0.00 … 19.99 1,00 AP Section factor 6 0.00 … 19.99 1.00 AP Section factor 7 0.00 … 19.99 1.00 AP1 Proportional-action coefficient 0.1 … 100.0

Page 55

Operation AdP level (adaptation of the control parameters)

Parameter

Parameter-

Designation Range of values Factory

set

GWK GWX GWX GWY1 GWY1 GWK GWK T

SK3

TZK

PK1

NK1

VK1

PK2

NK2

VK2

1: System with self-regulation

AP1 Reset time -1999 … 1999 AP1 Rate time -1999 … 1999 AP1 Type of controlled variable AP1 Factor for set point (reference variable) filter 0.00 … 19.99 0.00 AP1 Noise bandwidth 0.1 … 10.0 0.0

AP1 Min. limit for the controlled variable test range 0.0 … 110.0 10.0 AP1 Max. limit for the controlled variable test range 0.0 … 110.0 90.0 AP1 Min. limit for the output variable test range 0.0 … 110.0 10.0 AP1 Max. limit for the output variable test range 0.0 … 110.0 90.0 AP1 Min. limit for the adaptation range 0.0 … 110.0 10.0

AP1 Max. limit for the adaptation range 0.0 … 110.0 90.0

AP Pulse duration, control pulse (output test signal) -1999 … 1999 50.0 AP1 System gain (increasing output signal) 0.1 … 100.0 0.0 AP1 Dead time (increasing output signal) -1999 … 1999 0.0 AP1 System gain (decreasing output signal) 0.1 … 100.0 0.0 AP1 Dead time (decreasing output signal) -1999 … 1999 0.0 AP1 Basic value (increasing output signal) P-coeff. 0.1 … 100.0 0.1 AP1 Basic value (increasing output signal) reset time -1999 … 1999 240 AP1 Basic value (increasing output signal) rate time -1999 … 1999 20.0 AP1 Basic value (decreasing output signal) P-coeff. 0.1 … 100.0 0.1 AP1 Basic value (decreasing output signal) reset time -1999 … 1999 240 AP1 Basic value (decreasing output signal) rate time -1999 … 1999 20.0 AP1 Number of sections 1 … 75 AP1 Section factor 1 0.00 … 19.99 1.00 AP1 Section factor 2 0.00 … 19.99 1.00 AP1 Section factor 3 0.00 … 19.99 1.00 AP1 Section factor 4 0.00 … 19.99 1.00 AP1 Section factor 5 0.00 … 19.99 1.00 AP1 Section factor 6 0.00 … 19.99 1.00 AP1 Section factor 7 0.00 … 19.99 1.00

2: System without self-regulation

default

0 … 20

Page 56

7.TROVIS 6482 Configuration and Parameterization Program

The TROVIS 6482 Configuration and Parameterization software program is a user-friendly MS Windows application. In addition to entering configuration and parameter data, this program also contains functions for documenting the process control station. These functions are, for example editing of plant texts, printing of configuration and parameter data, storage of different parameter and configuration data, and graphical display of analog inputs and outputs, as well as binary status displays.

The TROVIS 6482 Configuration and Parameterization program runs under Windows 3.1 or higher. The user is required to have previous knowledge of other Windows programs, which should enable him to easily operate TROVIS 6482.

TROVIS 6482 comes together with a special COPA adapter (configuration and parameterization adapter, order no. 1170-1141). This adapter enables the user to couple the process control station with a PC via the front-panel serial interface. One side of the COPA adapter is a connector, designed for connecting it to the front-panel of the process control station, whereas the other side is a 9 pin D sub socket which connects to the Com1 or Com2 interface of the PC.

Page 57

COM1/ COM2/

COM3/ COM4

Fig. 37 ⋅ Connecting the COPA adapter to the PC

Page 58

8.COPA pen

The COPA pen (COnfiguration and PArameterization pen) can be used to write to or read from the process control station all data applicable to the CONFIGURATION or PARAMETER levels. In this way, it is possible to quickly transfer data to other TROVIS 6412 or 6442 Process Control Stations.

The COPA pen is assigned an identification number which is transferred to it when data is written to the pen. This number can only be defined in the TROVIS 6482 Configuration and Parameterization Program as any value between 0 and 1999, and can be used, for example for a special configuration. When plugging the COPA pen into the process control station, the control station first compares the identification number of the COPA pen with its own identification number. If these ID numbers do not correspond, COP and the identification number of the COPA pen, as well as C and the identification number of the process control station alternate on the display. In this case, data transfer is only possible when:

– The ID number of the COPA pen is 0 or – The ID number of the process control station is 0 or was reset respectively. The ID number

of the process control station can be reset with C56-8, see section 6.12., p. 45.

Proceed as follows to transfer data to or retrieve data from the COPA pen:

1. Plug COPA pen with the white marking facing upwards into the associated connector (1) located on the front-panel of the process control station. COP and the ID number appear on the display. If the ID numbers of pen and process control station do not correspond, the display alternates as described above.

2. Press A key. C and out (flashes) appear on the display. With this setting, data can be read from the process control station.

If the data contents of the COPA pen shall be written to the process control station, press C or D key so that COP appears in the upper line of the display.

3. Press A key. After approx. 1 s End comes up in the lower line of the display.

4. Remove COPA pen. After having transferred data from the COPA pen to the process control station, the MANUAL mode is active.

Fig. 38 ⋅ Connecting the COPA pen

1 Interface for COPA

pen (adapter)

Page 59

Fig. 39 ⋅ Simplified diagram showing how to use the COPA pen

Page 60

Interface mode Interface RS-485

9.Interface RS-485

The process control station can be optionally equipped with a serial RS-485 interface. This interface enables the user to integrate TROVIS 6412 into a process control system and, by means of a suitable software, establish a complete automation system for process control applications. The hardware configuration needed for such an automation system is described in section 9.2. The serial interface hardware meets the RS-485 (RS = Recommended Standard acc. to EIA) requirements. Communication is based on the Modbus protocol. The functions supported by the Modbus protocol are described in section 9.5. Other data are listed in the table "Technical data", starting on page 8.

The RS-485 interface of the process control station is a PCB (printed circuit board) which is installed in the associated slot of the controller case (see p. 13 , Fig. 5 ). If the TROVIS 6412 process control station is retrofitted with this interface board, proceed as described in section 9.6..

Fig. 7 , p. 22 and Fig. 9 , p. 24 show how to connect the data lines, based on the controller case version used.

9.1.Interface mode

Several settings of the RS-485 interface are made by means of soldering jumpers. Please note section 4.4., p. 20. The soldering jumpers on the interface board determine the baud rate, the bus termination, two-wire or four-wire connection, and the character parity.

When the RS-485 interface is to be used for communication, the following parameters have to be set in the Si level (See also section 6.6., p. 40).

– Station number (Address of process control station, range of values from 1 to 246) – Timeout period (During this time, the central control station must have interrogated the

process control station at least once. Otherwise an error is indicated on the display of the process control station. The Timeout period is only valid, when the status Timeout period is switched on (see below); range of values: −1999 to −1 for minutes; 0.1 to 1999 for seconds.)

– Status Timeout period (Timeout period can be switched −on− or −oFF−) – Status RS-485 interface (switch interface mode −on− or −oFF−) The interface mode is active as soon as the status RS-485 interface is switched on. If internal communication between the process control station and the RS-485 interface is

interrupted, an error is indicated after 10 s. At the same time, the symbol

for "external

system not ready" flashes on the display.

9.2.Network construction

Fig. 40 shows an example how to construct a network for an automation system in which data exchange is based on the Modbus protocol. A total amount of maximum 246 devices can be interrogated. First a converter, which converts the RS-232 signal from the PC into a RS-485 signal, has to be connected to the PC. A repeater is to be provided if the connecting lines are longer than 1200 m or more than 32 stations are connected to the bus. We recommend to connect a maximum of three repeaters in series. In this way, the connecting lines can cover a distance of up to 4800 m. A max. of 10 such lines can be connected in parallel when further expanding the network. A bus termination is to be provided at the end of each line segment, for example between converter and repeater, in order to discharge highly-resistive voltages.

Page 61

Interface RS-485 Network construction

1Converter 2 Repeater 3 TROVIS 6412

RS 485

RS 232

Maximum 28 devices

RS 485

Maximum 28 devices

Maximum

30 devices

Fig. 40 ⋅ Constructing a network with converters and repeaters

RS 485

Maximum 31 devices

Page 62

Network interconnections Interface RS-485

9.3.Network interconnections

The individual network components can communicate with each other via the Modbus protocol, both in a four-wire system and in a two-plus-two-wire system.

In a four-wire system, the repeaters automatically switch over the direction of data transmission. In the two-plus-two-wire system, the direction of data transmission is determined by two control

lines.

9.4.Operation

The RS-485 interface is assigned its own operating level which is described in section 6.6., p. 40.

9.5.Functions supported by the Modbus protocol

The Modbus protocol covers the rules for communication between the process control station and the central control station. It is a master-slave protocol where the central control station is the master and the process control station is the slave. The process control station (slave) can therefore only reply to queries from the central control station. The Modbus function codes supported by the process control station are described in the following and explained by means of examples.

9.5.1.Function code 01 (Read Coil Status)

This function code allows to read binary information such as fault alarms, relay states or operating messages from the process control station and transmit these to the central control station.

Example: Read coils 10 to 21 from the process control station with the address 11.

Query from the central control station

Address Function Starting address Quantity of coils Checksum

high low high low low high

0B 01 00 0A 00 0C 1C A7

Response of the process control station

Address Function Quantity

of bytes

0B 01 02 A3 02 D8 CC

In this example, coils 10, 11, 15, 17 and 19 are set to "1". The coils in the byte have to be read from the right to the left.

Coil 17 16 15 14 13 12 11 10

Byte 1 Byte 2 Checksum

Coil 10…17 Coil 18…21 low high

10100011= A3

The second byte contains the coils 18 to 21. The first four bits are "0".

Coil X X X X 21201918

00000010= 02

Page 63

Interface RS-485 Functions supported by the Modbus protocol

9.5.2.Function code 02 (Read Input Status)

This function code allows to read the current status of the binary inputs bi 1, bi 2 and bi 3 directly at the input of the slave, no matter whether the respective binary input was configured in the process control station.

For the query from the central control station and the response from the process control station, see Read Coil Status (Function code 01).

9.5.3.Function code 05 (Force Single Coil)

The central control station can modify a logic condition in the process control station. Example: Write coil 09 (MANUAL/AUTOMATIC changeover).

coil 09 must set to "0" in order to place the process control station in the AUTOMATIC mode. In this example, the address of the process control station is 12.

Query from the control station Address Function Coil Coil Checksum

high low on off low high

0C 05 00 09 FF 00 5D 25

Response from the process control station Address Function Coil Coil Checksum

high low on/off low high

0C 05 00 09 FF 00 5D 25

The fourth byte contains number 9 (hexadecimal). If a coil is set to "1", byte 5 must transmit the information FF. If it is to be deleted, 00 has to be transmitted.

9.5.4.Function code 03 (Read Holding Register)

Analog variables can be read from the process control station and, after conversion to the numeric format, displayed on the PC (controlled variable, set point (reference variable) etc.),.

Example: Read holding register no. 1 This register contains the device identification. The address of the process control station is 1.

Query from the control station Address Function Holding register no. Quant. of holding registers Checksum

high low high low low high

01 03 00 00 00 01 84 0A

Response from process control station Address Function Quantity of

01 03 02 19 0C B3 D1

Since, in this example, only register 1 is read and this register always contains the decimal value 6412, it can be used to check the device identification.

bytes

Value of register 1 Checksum

high low low high

Page 64

Functions supported by the Modbus protocol Interface RS-485

9.5.5.Function code 04 (Read Input Register)

With this function code, the current status of the analog inputs in 1, in 2, in 3 and in 4 can be read directly at the input of the slave, no matter whether the respective analog input has been assigned the variable X, W

, Z or Y

ACTUAT

For the query from the central control station and response from the process control station, see Read Holding Register (Function code 03).

9.5.6.Function code 06 (Preset Single Register)

With this function code, analog values, such as the value of the set point (reference variable) or K

can be modified.

Example: Write holding register 106. This is the value of the set point (reference variable) which can be written serially. The process control station has the station address 18 and operates as a fixed set point controller. A set point (reference variable) value of 10.0 is to be transmitted from the central control station to the process control station.

Query from the central control station Address Function Holding register no. Value in register 35 Checksum

high low high low low high

12 06 00 6A 00 64 AA 9E

Response from the process control station Address Function Holding register no. Value in register 35 Checksum

high low high low low high

12 06 00 6A 00 64 AA 9E

9.5.7.Function code 15 (Force Multiple Coils)

This function code allows modifying the status of multiple coils. Example: 10 coils, starting at address 20 (13

the address 17. For this purpose, two bytes are transmitted.

Byte 1 = CDH =11001101 Coil no. 2726252423222120 Byte 2 = 00 Coil no. 0000002928

=00000000

), are written to the process control station with

In this example, "1" is written to coils 27, 26, 23, 22 and 20; "0" is written to the remaining coils.

Query from the central control station

Address Function Coil address Quant. of coils Byte count

high low high low 20 to 27 28 to 29 low high

11 0F 00 13 00 0A 02 CD 00 7E CB

Data coil Data coil CRC

field

Page 65

Interface RS-485 Functions supported by the Modbus protocol

Response from the process control station

Address Function Coil address Quantity of coils CRC

high low high low low high

11 0F 00 13 00 0A 26 99

The master only writes to coils that are marked with R/W. When attempts are made to write to Read-Only coils, no error message is issued by the process control station. The Modbus response is sent while the Write command is still being carried out. It is therefore possible that any following Write commands are answered with error code 6 ("Busy").

9.5.8.Function code 16 (Preset Multiple Register)

This function code is used to modify values of multiple holding registers. Example: Two holding registers, starting at address 135, are sent to the process control station

with the device address 17.

Query from the central control station

Address Function Address Quant. holding reg. Byte

high low high low high low high low low high

11 10 00 87 00 02 04 00 0A 01 02 4E BA

count field

1 data value 2 data value CRC

The value 10 (corresponds to 000AH) is placed into holding register 13 and the value 258 (corresponds to 0102

Response from the process control station

Address Function Coil address Quantity of coils CRC

11 10 00 87 00 02 F3 71

) is placed into holding register 136.

high low high low low high

9.5.9.Error messages

The process control station responds with an error message upon illegal operations between the control station (Modbus-Master) and the process control station (Modbus slave):

– Error code 01: Illegal function requested – Error code 02: Query containing an undefined data address – Error code 03: Query containing an illegal data value – Error code 06: Query while the process control station is busy, COPA pin or COPA

adapter with software TROVIS 6482 are being used ("Busy" message)

Page 66

Retrofitting the RS-485 interface Interface RS-485

Example: Query for the undefined holding register 500

Query from the central control station Address Function Addressholding register Quantity holding registers Checksum

high low high low low high

01 03 01 F4 00 01 C4 04

Response from the process control station Address Function Error message Checksum

low high

01 83 02 C0 F1

In case of an error, the function byte is combined exclusive OR with 80H, i.e. bit 7 is set. This indicates the master (central control station) that an error has occurred.

9.5.10.Other functions

Broadcast commands of the central control station are supported.

9.6.Retrofitting the RS-485 interface

Important! When retrofitting the interface board, the soldering jumpers LB1, LB2 and LB3 on

the logic board have to be closed (see section 4.2., p. 19). Install the interface board as follows:

1. Open case of the process control station, see p. 12, section 3.3. , step 1.

2. Withdraw the controller unit from the case from the front side.

3. Unscrew the four screws (1, 2) and remove the two distance bolts (4) (see Fig. 5 , p.13).

4. Carefully withdraw the input board from the case.

5. Insert the interface board in the associated slot (s. p. 13 , Fig. 5 ), making sure that the components on the board face the input board and the logic board.

6. Reinstall the input board.

7. Then proceed as described under 8. to 10. in section 3.3., p. 13.

Page 67

Start-up procedure Optimization (tuning the process control station to the controlled system)

10.Start-up procedure

Before installing or putting the process control station into operation, all characteristics of the input and output signals and the code number have to be determined by means of the associated soldering jumpers (see section 4., p. 14).

When all input and output connections are made and power is supplied to the process control station, it has to be tuned for the respective control task. For this purpose, the process control station must be configured. This can be done either manually by setting the configuration blocks in the CONFIGURATION level (see section 6.4.), by means of a COPA pen (see section 8.), or by using the TROVIS 6482 Configuration and Parameterization Program (see section 7.). The configuration settings made can be recorded in a checklist given in Appendix C . The TROVIS 6482 Configuration and Parameterization Program provides the option of printing a similar list on request. The options assigned to the individual configuration blocks are described in more detail in Configuration manual KH 6412 E.

The parameters K

, TN and Tv can be set and modified either by means of the adaptation

algorithm of the process control station (see section 6.13., p. 46) or in a manual optimization procedure. The latter is described in general in the following section.

10.1.Optimization (tuning the process control station to the controlled system)

The process control station must be tuned to the dynamic behaviour of the loop, using the parameters K by reducing these to zero or maintain them in very confined limits.

If you do not have previous experience in selecting values for the control loop, proceed according to the following basic procedure:

The connected control valve must be closed, before starting the optimization.

1. Switch the MANUAL/AUTOMATIC mode selector key (E) to MANUAL mode. The symbol comes up on the display.

2. Hold down the (H) key until only the first bar of the bar graph for the output variable (14) is displayed.

3. Proceed according to the control mode selected (see below).

Proportional (P) controller

–Specify K – Enter the desired value of the set point (reference variable) in the OPERATING level.

, TN and Tv in order to compensate for control deviations caused by disturbances

= 0.1 in the PARAMETER level.

– Then modify the output variable by pressing the (G) key until the control valve slowly opens

and the error X

is eliminated.

– Switch over to AUTOMATIC mode by pressing the MANUAL/AUTOMATIC key. – Increase the K

value in the PARAMETER level until the controlled systems tends to hunt.

– Slightly reduce the K – Eliminate steady-state deviation as follows: Switch the controller to the MANUAL mode.

Modify the output variable until the error X and enter this value for parameter K

Important: Any modification of the set point (reference variable) causes a change of the operating point K

value until oscillation cannot be determined any more.

= 0. Read off the displayed output variable

Page 68

Optimization (tuning the process control station to the controlled system) Start-up procedure

Proportional-plus-integral (PI) controller

–Specify K

= 0.1 ; TN = 1999 in the PARAMETER level.

– Enter the value of the desired set point (reference variable) in the OPERATING level. – Then modify the output variable by pressing the (G) key until the control valve slowly opens

and the error X

is eliminated.

– Switch over to AUTOMATIC mode by pressing the MANUAL/AUTOMATIC key. –Increase the K – Slightly reduce the K – Reduce the T – Slightly increase the T

value in the PARAMETER level until the controlled system tends to hunt.

value until oscillation cannot be determined any more.

value in the PARAMETER level until the controlled system tends to hunt.

value until oscillation cannot be determined any more.

Proportional-plus-derivative (PD) controller

–Specify K

= 0.1; Tv = 1 and the rate gain TvK1 = 1 in the PARAMETER level.

– Enter the value of the desired set point (reference variable) in the OPERATING level. – Then modify the output variable by pressing the (G) key until the control valve slowly opens

and the error X

is eliminated.

– Switch over to AUTOMATIC mode by pressing the MANUAL/AUTOMATIC key. –Increase the K

value in the PARAMETER level until the controlled system tends to hunt.

– Increase the Tv value until oscillation cannot be determined any more. –Increase the K

value until oscillation reoccurs.

– Increase the Tv value again until oscillation cannot be determined any more. – Repeat this procedure several times until oscillation cannot be suppressed any longer. – Slightly reduce the K

value and the Tv value so that the system can recover.

– Eliminate steady-state deviation as follows: – Set configuration block C28-2. This activates setting of the operating point via the

MANUAL mode. – Switch to MANUAL mode by pressing the MANUAL/AUTOMATIC key. – Modify the output variable until the error X

is eliminated.

– Switch to AUTOMATIC mode by pressing the MANUAL/AUTOMATIC key.

The output variable is stored and applied to the controller output as operating point. Important: Any modification of the set point (reference variable) causes a change of the operating point.

Page 69

Start-up procedure Optimization (tuning the process control station to the controlled system)

Proportional-plus-integral-plug-derivative (PID) controller

–Specify K

= 0.1 ; TN = 1999 and Tv = 1 in the PARAMETER level.

– Enter the value of the desired set point (reference variable) in the OPERATING level. – Then modify the output variable by pressing the (G) key until the control valve slowly opens

and the error X

is eliminated.

– Switch over to AUTOMATIC mode by pressing the MANUAL/AUTOMATIC key. – Increase the K

value in the PARAMETER level until the controlled system tends to hunt.

– Increase the Tv value until oscillation cannot be determined any more. – Increase the K

value until oscillation reoccurs.

– Increase the Tv value again until oscillation cannot be determined any more. – Repeat this procedure several times until oscillation cannot be suppressed any longer. – Slightly reduce the K – Reduce the T

value until the control loop tends to hunt again, and then slightly increase

value and the Tv value so that the system can recover.

value again until oscillation cannot be determined any more.

Page 70

Page 71

Appendix A Data Point List for the RS 485-Interface

Holding Registers Data Point List

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

1 Device identification R 6412 6412 Register only readable;

transmits the device identification

2 Variant/version R 100 … 64999 0…64/1.00…9.99 0 = Standard variant

1 = Special variant 2 = Development variant /version number

Controller inputs according to their assignment to the analog inputs (C10,C11,C12,C13)

3 X

R/W -200 … 1200 -20.0% …120.0%

Internally used variables according to their assignment to the analog inputs; can only be written to when no analog input is assigned

R/W -200 … 1200 -20.0% …120.0%

5 Z

R/W -200 … 1200 -20.0% …120.0%

STELL

R/W -200 … 1200 -20.0% …120.0%

Analog outputs

R -100 … 1100 -10.0% … 110.0% Analog variables which

are available at the respective analog output

R -100 … 1100 -10.0% … 110.0%

9 Ao1

R -100 … 1100 -10.0% … 110.0%

Operating data

10 Set point (reference variable) display 1 acc. to C4 R -100 … 1100 -10.0% … 110.0% 11 Controlled variable display 1 acc. to C4 R -100 … 1100 -10.0% … 110.0% 12 Set point (reference variable) display 2 acc. to C4 R -100 … 1100 -10.0% … 110.0% 13 Controlled variable display 2 acc. to C4 R -100 … 1100 -10.0% … 110.0%

Page 72

No.

Designation of data point Access 1)Transmission

range

Display range Comments

14 Internal Y

PID

-signal R/W -100 … 1100 -10.0% … 110.0% Adjustable in MANUAL

mode

15 Controller ID number R/W

10)

0 … 19990 0.0 … 1999.0 4-digit number to

identify the controller in the plant, see also p. 58

16 Timeout period Interface R/W

10)

-19990… -10 10 … 19990

-1999.0…-1.0 (minutes)

1.0…1999.0 (seconds)

Time during which the device must have been interrogated at least once by the central control station, otherwise cin 6 error display and LED

and bo3 alternate 17 Reserved 18 Reserved 19 Reserved 20 Reserved 21 Reserved

Status messages

22 Transmitter fault R 0 … 65535 0 … 15 Display: Values out of

measuring range 23 Checksum error Data R 0 … 65535 0 … 32

Checksum of

permanently stored data

has changed without

operator intervention;

check data 24 Program error Data R 0 … 65535 0 … 16

Re-program 25 Adaptation Status R 0 … 65535 0 …100

26 Adaptation Program R 0 … 65535 0 … 255

27 Programming Status R 0 … 65535 0 … 255

Page 73

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

28 Programming Error R 0 … 65535 0 …255

29 Reserved

Configuration blocks

7), 10)

Details, see

KH 6412 E

30 C 1 Control mode R/W

10)

0 … 16 0 … 16

31 C 2 Secondary controlled variable/feedforward control R/W

10)

0 … 16 0 … 16

32 C 3 Calculation specification, feedforward control R/W

10)

0 … 16 0 … 16

33 C 4 Configuration of digital displays R/W

10)

0 … 16 0 … 16

34 C 5 Configuration of controller outputs R/W

10)

0 … 16 0 … 16

35 C 6 Inversion of error signal R/W

10)

0 … 16 0 … 16

36 C 7 Function generation R/W

10)

0 … 16 0 … 16

37 C 8 Combination of input variables R/W

10)

0 … 16 0 … 16

38 C 9 Root extraction of input variables R/W

10)

0 … 16 0 … 16

39 C10 Assignment of controller inputs to X - input R/W

10)

0 … 16 0 … 16

40 C11 Assignment of controller inputs to W

- input R/W

10)

0 … 16 0 … 16

41 C12 Assignment of controller inputs to Z - input R/W

10)

0 … 16 0 … 16

42 C13 Assignment of controller inputs to Y

ACTUAT.

- input R/W

10)

0 … 16 0 … 16

43 C14 Zero and span adjustment, analog inputs and

outputs

R/W

10)

0 … 16 0 … 16

44 C15 Monitoring of measuring range R/W

10)

0 … 16 0 … 16

45 C16 Set point (reference variable) ramp R/W

10)

0 … 16 0 … 16

46 C17 Configuration of binary input bi 1 R/W

10)

0 … 16 0 … 16

47 C18 Configuration of binary input bi 2 R/W

10)

0 … 16 0 … 16

48 C19 Configuration of binary input bi 3 R/W

10)

0 … 16 0 … 16

49 C20 Set point (reference variable) limitation or

reciprocal set point or actual value ratio

R/W

10)

0 … 16 0 … 16

50 C21 Set point (ref. variable ) upon failure of external system R/W

10)

0 … 16 0 … 16

51 C22 Assignment of internal set point R/W

10)

0 … 16 0 … 16

Page 74

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

52 C23 X-tracking R/W

10)

0 … 16 0 … 16

53 C24 Dynamic behaviour of controller output R/W

10)

0 … 16 0 … 16

54 C25 Dynamic behaviour of controller output (MaC, LiC) R/W

10)

0 … 16 0 … 16

55 C26 Assignment of D-element R/W

10)

0 … 16 0 … 16

56 C27 Filtering of input variables and error signal R/W

10)

0 … 16 0 … 16

57 C28 Operating point adjustment via manual mode R/W

10)

0 … 16 0 … 16

58 C29 Change of control action R/W

10)

0 … 16 0 … 16

59 C30 Operating point adjustment via set point (ref. variable) R/W

10)

0 … 16 0 … 16

60 C31 Output signal ranges R/W

10)

0 … 16 0 … 16

61 C32 Output signal action R/W

10)

0 … 16 0 … 16

62 C33 Externally or internally controlled

output signal limitation

R/W

10)

0 … 16 0 … 16

63 C34 Output ramp or limitation of the

rate of output changes

R/W

10)

0 … 16 0 … 16

64 C35 Output signal limitation R/W

10)

0 … 16 0 … 16

65 C36 Output signal limitation inactivated in manual mode R/W

10)

0 … 16 0 … 16

66 C37 Changeover to manual mode upon transmitter failure R/W

10)

0 … 16 0 … 16

67 C38 Assignment of output variable display R/W

10)

0 … 16 0 … 16

68 C39 Inversion of output variable display R/W

10)

0 … 16 0 … 16

69 C40 Assignment of limit relay G 1 R/W

10)

0 … 16 0 … 16

70 C41 Assignment of limit relay G 2 R/W

10)

0 … 16 0 … 16

71 C42 Display of control valve - closed position R/W

10)

0 … 16 0 … 16

72 C43 Restart conditions following power supply failure R/W

10)

0 … 16 0 … 16

73 C44 Configuration of binary output bo 1 R/W

10)

0 … 16 0 … 16

74 C45 Configuration of binary output bo 2 R/W

10)

0 … 16 0 … 16

75 C46 Repetition rate of digital displays R/W

10)

0 … 16 0 … 16

76 C47 Display range of error signal R/W

10)

0 … 16 0 … 16

Page 75

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

77 C48 Assignment of analog output Ao 1 R/W

10)

0 … 16 0 … 16

78 C49 Power frequency R/W

10)

0 … 16 0 … 16

79 C50 Dynamic behaviour of PD - elements R/W

10)

0 … 16 0 … 16

80 C51 Adaptation of control parameters

(FSP,FU,RC,SY) (FoC,PrC)

R/W

10)

0 … 16 0 … 16

81 C52 Adaptation of control parameters (MaC) R/W

10)

0 … 16 0 … 16

82 C53 Adaptation of measuring range of X-/W

-input R/W

10)

0 … 16 0 … 16

83 C54 Input board used R/W

10)

0 … 16 0 … 16

84 C55 Selection of thermocouple R/W

10)

0 … 16 0 … 16

85 C56 Standard initialization R/W

10)

0 … 16 0 … 16

86 C57 Decimal point in digital display fields R/W

10)

0 … 16 0 … 16

87 C58 Decimal point in digital display fields (PrC, FoC) R/W

10)

0 … 16 0 … 16

88 C59 Locking of operator button/security option for pre-

venting modification of configuration and parameters

R/W

10)

0 … 16 0 … 16

89 C60 Reserved R 0 0 90 C61 Reserved R 0 0 91 C62 Reserved R 0 0 92 C63 Reserved R 0 0 93 C64 Reserved R 0 0

Parameters

Details, see

KH 6412 E

94 Internally used R -19990…19990 -1999.0…1999.0

95 Xmin Min. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

96 Xmax Max. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

97 Internally used R -19990…19990 -1999.0…1999.0

98 WEXmin Min. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

99 WEXmax Max. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

100 Internally used R 0 … 1999 0…19.99

Page 76

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

101 Zmin Min. limitation (RC1, RC2) R/W

10)

0 … 1999 0…19.99

102 Zmax Max. limitation (RC1, RC2) R/W

10)

0 … 1999 0…19.99

103 Internally used R -19990…19990 -1999.0…1999.0

104 Zmin Min. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

105 Zmax Max. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

106 W

Internal set point R/W

10)

-19990…19990 -1999.0…1999.0

107 WINmin Min. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

108 WINmax Max. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

109 WINK1min Set point adjustment range R/W

10)

-19990…19990 -1999.0…1999.0

110 WINK1max Set point adjustment range R/W

10)

-19990…19990 -1999.0…1999.0

111 WIN Internal set point ratio (RC1, RC2) R/W

10)

0 … 1999 0.00…19.99

112 WINmin Min. limitation (RC1, RC2) R/W

10)

0 … 1999 0.00…19.99

113 WINmax Max. limitation R/W

10)

0 … 1999 0.00…19.99

114 W

Safety set point R/W

10)

-19990…19990 -1999.0…1999.0

115 WSmin Min. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

116 WSmax Max. measuring range limit R/W

10)

-19990…19990 -1999.0…1999.0

117 W

Safety set point ratio (RC1, RC2) R/W

10)

0 … 1999 0.00 …19.99

118 Internally used R 0 … 65535 0 … 65535 119 Reserved 26 R 0 0 120 Reserved 27 R 0 0 121 TZX

Dead band, error signal R/W

10)

0 … 1100 0.0 … 110.0

122 X

SDY1

Hysteresis, limiting controller R 0 0

123 X

SDY2

Hysteresis, on-off/3-step output R/W

10)

1 … 1000 0.1 … 100.0

124 X

G1 Hysteresis, limit relay R/W

10)

1 … 1000 0.1 … 100.0

125 X

G2 Hysteresis, limit relay R/W

10)

1 … 1000 0.1 … 100.0

126 TZ Dead band, 3-step output/threshold R/W

10)

1 … 1000 0.1 … 100.0

127 TZY

Dead band point, split-range mode R/W

10)

1 … 1000 0.1 … 100.0

Page 77

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

128 TZY

Dead band point, split-range mode R/W

10)

1 … 1000 0.1 … 100.0

129 K

Proportional-action coefficient R/W

10)

1 … 1000 0.1 … 100.0

130 T

Reset time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

131 T

Rate time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

132 TVK

Rate gain R/W

10)

1 … 100 0.1 …10.0

133 K

PY1

Gain, output variable R/W

10)

1 … 100 0.1 …10.0

134 K

PY2

Gain, output variable R/W

10)

1 … 100 0.1 …10.0

135 K

PK2

Gain, PD-element 1 R/W

10)

1 … 1000 0.1 …100.0

136 T

VK2

Rate time, PD-element 1 R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

137 K

PK3

Gain, PD-element 2 R/W

10)

1 …1000 0.1 …100.0

138 T

VK3

Rate time, PD-element 2 R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

139 Y

1K3

Constant for Y

PID

R/W

10)

-100 …1100 -10.0 …110.0

140 Y

Internally used R -100 …1100 -10.0 …110.0

141 Y

1K1

Safety output value R/W

10)

-100 …1100 -10.0 …110.0

142 Y

min Output variable limit, min. R/W

10)

-100 …1100 -10.0 …110.0

143 Y

max Output variable limit, max. R/W

10)

-100 …1100 -10.0 …110.0

144 Y

Internally used R -100 …1100 -10.0 …110.0

145 Y

2K1

Safety output value R/W

10)

-100 …1100 -10.0 …110.0

146 Y

min Output variable limit, min. R/W

10)

-100 …1100 -10.0 …110.0

147 Y

max Output variable limit, max. R/W

10)

-100 …1100 -10.0 …110.0

148 T

Period/actuating time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

149 TY1min Min. on-time R/W

10)

1 … 100 0.1 …10.0

150 Y

1K2

Gain, threshold R/W

10)

0 … 1100 0.0 … 110.0

151 T

Period/actuating time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

152 TY2min Min. on-time R/W

10)

1 … 100 0.1 …10.0

153 Y

2K2

Gain, threshold R/W

10)

0 … 1100 0.0 … 110.0

154 T

_X Time parameter X-filter R/W

10)

1 … 1000 0.1 … 100.0

Page 78

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

155 T

S_WEX

Time parameter WEX-filter R/W

10)

1 … 1000 0.1 … 100.0

156 T

_Z Time parameter Z-filter R/W

10)

1 … 1000 0.1 … 100.0

157 T

S_Xd

Time parameter Xd-filter R/W

10)

1 … 1000 0.1 … 100.0

158 T

Time parameter, set point ramp R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

159 Y2K3min Min. switch point, maintained signal R/W

10)

-100 … 1100 -10.0 … 110.0

160 Y

2K3

max Max. switch point, maintained signal R/W

10)

-100 … 1100 -10.0 … 110.0

161 T

SK1

Time parameter, output ramp R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

162 TSK

Time parameter, change of control action R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

163 GWG1 Limit value, limit relay 1 R/W

10)

-19990…19990 -1999.0…1999.0

164 GWG2 Limit value, limit relay 2 R/W

10)

-19990…19990 -1999.0…1999.0

165 Reserved 72 R 0 0 166 Reserved 73 R 0 0 167 Reserved 74 R 0 0 168 Reserved 75 R 0 0 169 Reserved 76 R 0 0 170 Reserved 77 R 0 0 171 Reserved 78 R 0 0 172 Reserved 79 R 0 0 173 Reserved 80 R 0 0 174 Reserved 81 R 0 0 175 Reserved 82 R 0 0 176 Reserved 83 R 0 0 177 Reserved 84 R 0 0 178 Reserved 85 R 0 0 179 Reserved 86 R 0 0 180 Reserved 87 R 0 0 181 Reserved 88 R 0 0

Page 79

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

182 Reserved 89 R 0 0 183 Reserved 90 R 0 0 184 Reserved 91 R 0 0 185 Reserved 92 R 0 0 186 Reserved 93 R 0 0 187 Reserved 94 R 0 0 188 Reserved 95 R 0 0 189 Reserved 96 R 0 0 190 Reserved 97 R 0 0 191 Reserved 98 R 0 0 192 Reserved 99 R 0 0 193 Reserved 100 R 0 0 194 Reserved 101 R 0 0 195 Reserved 102 R 0 0 196 Reserved 103 R 0 0 197 Reserved 104 R 0 0 198 Reserved 105 R 0 0 199 Reserved 106 R 0 0 200 Reserved 107 R 0 0 201 Reserved 108 R 0 0 202 Reserved 109 R 0 0 203 K

Y-rate action R/W

10)

-1100 … 1100 -110.0 … 110.0

204 K

min Input signal, coordinate 1 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

205 K1max Output signal, coordinate 1 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

206 K2 Constant

R/W

10)

-1100 … 1100 -110.0 … 110.0

207 K

min Input signal, coordinate 2 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

208 K2max Output signal, coordinate 2 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

Page 80

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

209 K

Constant R/W

10)

0 … 1100 0.0 … 110.0

210 K

min Input signal, coordinate 3 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

211 K3max Output signal 3 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

212 K

Constant R/W

10)

0 … 1999 0.00 … 19.99

213 K4min Input signal, coordinate 4 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

214 K4max Output signal, coordinate 4 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

215 K

Constant R/W

10)

-1100 … 1100 -110.0 … 110.0

216 K

min Input signal, coordinate 5 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

217 K5max Output signal, coordinate 5 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

218 K

Constant R/W

10)

0 … 1100 0.0 … 110.0

219 K

min Input signal, coordinate 6 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

220 K6max Output signal, coordinate 6 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

221 K

Constant R/W

10)

-1100 …1100 -110.0 …110.0

222 K

min Input signal, coordinate 7 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

223 K7max Output signal, coordinate 7 (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

224 K

Correction factor for Y-input R/W

10)

0 … 1999 0.00 … 19.99

225 K8min Min. output signal (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

226 K8max Max. output signal (function generation) R/W

10)

-19990…19990 -1999.0…1999.0

227 K

Constant R/W

10)

-1999 … 1999 -19.99…19.99

228 Reserved 135 R 0 0 229 Reserved 136 R 0 0 230 W

Internal set point (FoC, MaC) R/W

10)

-19990…19990 -1999.0…1999.0

231 WINmin Min. measuring range limit (FoC, MaC) R/W

10)

-19990…19990 -1999.0…1999.0

232 WINmax Max. measuring range limit (FoC, MaC) R/W

10)

-19990…19990 -1999.0…1999.0

233 WINK1min Set point adjustment range (FoC, MaC) R/W

10)

-19990…19990 -1999.0…1999.0

234 WINK1max Set point adjustment range (FoC, MaC) R/W

10)

-19990…19990 -1999.0…1999.0

235 Internally used R -1100 … 1100 -110.0 … 110.0

Page 81

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

236 K

Proportional-action coefficient R/W

10)

1 … 1000 0.1 … 100.0

237 T

Reset time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

238 T

Rate time R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

239 TVK

Rate gain R/W

10)

1 …100 0.1 …10.0

240 K

Y-rate action R/W

10)

-1100 …1100 -110.0 … 110.0

241 Y

min Output variable limit, min. (FoC, MaC) R/W

10)

0 … 1100 0.0 … 110.0

242 Y

max Output variable limit, max. (FoC, MaC) R/W

10)

0 … 1100 0.0 … 110.0

243 K

_X Constant R/W

10)

-1999…1999 -19.99…19.99

244 K1_Z Constant

R/W

10)

-1999…1999 -19.99…19.99

245 K2_X Constant R/W

10)

-1999…1999 -19.99…19.99

246 K2_Z Constant R/W

10)

-1999…1999 -19.99…19.99

247 K1_W

Constant R/W

10)

-1999…1999 -19.99…19.99

248 KPK

Gain Ao 1 - output R/W

10)

1 … 100 0.1 … 10.0

249 Y

1K4

Safety output (FoC, MaC) R/W

10)

-100 … 1100 -10.0 …110.0

250 GWK

min Min. measuring range limit in 1 R/W

10)

-19990…19990 -1999.0…1999.0

251 GWK1max Max. measuring range limit in 1 R/W

10)

-19990…19990 -1999.0…1999.0

252 GWK2min Min. measuring range limit in 2 R/W

10)

-19990…19990 -1999.0…1999.0

253 GWK2max Max. measuring range limit in 2 R/W

10)

-19990…19990 -1999.0…1999.0

254 Y1K5 Constant R/W

10)

0 … 1100 0.0 … 110.0

255 W

INK2

Set point step change R/W

10)

0 … 1100 0.0 … 110.0

256 GWK

Switch point, change of control action R/W

10)

0 … 1100 0.0 … 110.0

257 GWK

Switch point, change of control action R/W

10)

0 … 1100 0.0 … 110.0

258 GWK

Switch point, change of control action R/W

10)

0 … 1100 0.0 … 110.0

259 GWK

Switch point, change of control action R/W

10)

0 … 1100 0.0 … 110.0

260 Reserved 167 R 0 0 261 Reserved 168 R 0 0 262 Reserved 169 R 0 0

Page 82

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

263 Internally used R 1 …1000 0.1 …100.0

264 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

265 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

266 Internally used R 0 … 70 … 7 267 K

_C1 Factor for set point (reference variable) filter (adapt.) R/W

10)

0 … 1999 0.00 … 19.99

268 GWK1_C1 Noise bandwidth (adaptation) R/W

10)

1 … 100 0.1 … 10.0

269 GWXmin_C1 Min. limit for controlled variable test range (adapt.) R/W

10)

0 … 1100 0.0 … 110.0

270 GWXmax_C1 Max. limit for controlled variable test range (adapt.) R/W

10)

0 … 1100 0.0 … 110.0

271 GWY

min_C1 Min. limit for output variable test range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

272 GWY

max_C1 Max. limit for output variable test range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

273 GWK

min_C1 Min. limit for adaptation range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

274 GWK

max_C1 Max. limit for adaptation range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

275 T

SK3

_C1 Pulse duration, control pulse (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

276 K1_C1 System gain (increasing) (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

277 TZK

_C1 Dead time (increasing) (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

278 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

279 K2_C1 System gain (decreasing) (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

280 TZK

_C1 Dead time (decreasing) (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

281 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

282 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

283 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

284 KPK1_C1 Basic value (increas.) P-action coefficient (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

285 T

NK1

_C1 Basic value (increasing) reset time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

286 TVK1_C1 Basic value (increasing) rate time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

287 KPK2_C1 Basic value (decreasing) P-action coeff. (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

288 T

NK2

_C1 Basic value (decreasing) reset time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2),8)

289 TVK2_C1 Basic value (decreasing) rate time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

Page 83

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

290 K

_C1 Number of sections (adaptation) R/W

10)

1 … 71 … 7

291 K

max_C1 Section factor 1 (adaptation) R/W

10)

0 …1999 0.0 …19.99

292 K2max_C1 Section factor 2 (adaptation) R/W

10)

0 …1999 0.0 …19.99

293 K3max_C1 Section factor 3 (adaptation) R/W

10)

0 … 1999 0.0 …19.99

294 K4max_C1 Section factor 4 (adaptation) R/W

10)

0 … 1999 0.0 …19.99

295 K5max_C1 Section factor 5 (adaptation) R/W

10)

0 … 1999 0.0 …19.99

296 K6max_C1 Section factor 6 (adaptation) R/W

10)

0 … 1999 0.0 …19.99

297 K7max_C1 Section factor 7 (adaptation) R/W

10)

0 … 1999 0.0 …19.99

298 Reserved 205 R 0 0 299 Reserved 206 R 0 0 300 Reserved 207 R 0 0 301 Reserved 208 R 0 0 302 Reserved 209 R 0 0 303 Internally used R 1 … 1000 0.1 … 100.0 304 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

305 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

306 Internally used R 0 … 70 … 7 307 K

_C2 Factor for set point (reference variable) filter (adapt.) R/W

10)

0 …1999 0.00 …19.99

308 GWK1_C2 Noise bandwidth (adaptation) R/W

10)

1 … 100 0.1 … 10.0

309 GWXmin_C2 Min. limit for controlled variable test range (adapt.) R/W

10)

0 … 1100 0.0 … 110.0

310 GWXmax_C2 Max. limit for controlled variable test range (adapt.) R/W

10)

0 … 1100 0.0 … 110.0

311 GWY

min_C2 Min. limit for output variable test range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

312 GWY

max_C2 Max. limit for output variable test range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

313 GWK

min_C2 Min. limit for adaptation range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

314 GWK

max_C2 Max. limit for adaptation range (adaptation) R/W

10)

0 … 1100 0.0 … 110.0

315 T

SK3

_C2 Pulse duration, control pulse (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

316 K1_C2 System gain (increasing) (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

Page 84

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

317 TZK

_C2 Dead time (increasing) (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

318 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

319 K2_C2 System gain (decreasing) (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

320 TZK

_C2 Dead time (decreasing) (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

321 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

322 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

323 Internally used R -19990…19990 -1999.0…1999.0

2), 8)

324 KPK1_C2 Basic value (increas.) P-action coefficient (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

325 T

NK1

_C2 Basic value (increasing) reset time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

326 TVK1_C2 Basic value (increasing) rate time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

327 KPK2_C2 Basic value (decreas.) P-action coefficient (adaptation) R/W

10)

1 … 1000 0.1 … 100.0

328 T

NK2

_C2 Basic value (decreasing) reset time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8)

329 TVK2_C2 Basic value (decreasing) rate time (adaptation) R/W

10)

-19990…19990 -1999.0…1999.0

2), 8]

330 K4_C2 Number of sections (adaptation) R/W

10)

1 … 71 … 7

331 K

max_C2 Section factor 1 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

332 K2max_C2 Section factor 2 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

333 K3max_C2 Section factor 3 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

334 K4max_C2 Section factor 4 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

335 K5max_C2 Section factor 5 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

336 K6max_C2 Section factor 6 (adaptation) R/W

10)

0 … 1999 0.00 … 19.99

337 K7max_C2 Section factor 7 (adaptation) R/W

10)

0 … 1999 0.00 …1 9.99

338 Reserved 245 R 0 0 339 Reserved 246 R 0 0 340 Reserved 247 R 0 0 341 Reserved 248 R 0 0 342 Reserved 249 R 0 0 343 Reserved 250 R 0 0

Page 85

HR No.

Designation of data point Access 1)Transmission

range

Display range Comments

344 Reserved 251 R 0 0 345 Reserved 252 R 0 0 346 Reserved 253 R 0 0 347 Reserved 254 R 0 0

R : Read Only, R/W: Read and Write

For values up to +/- 199.9, one place behind the decimal is supported; from 200.0 onwards, the decimal remains 0

Values from -19.99 to +19.99 (-1999…+1999) are supported

Is reset with Coil 66

Can only be written to when no analog input is assigned

For all configuration blocks and parameters applies: Not all values can be adjusted. For details, see

Configuration manual KH 6412 E

Input of zero is not permitted

Software version 1.3 or higher

10)

Data is written to the non-volatile memory (EEPROM) of the process control station. The lifetime of this type of memory is limited to approx. 100000 write cycles, meaning automatic, permanent writing to it is not permitted.

Page 86

Coil - Status Data Point List for the TROVIS 6412 Industrial Controller

CL No. Designation of data point Access 1)Status Comments

0 (= Off) 1 (= On)

001 Centralized fault R 0= None 1= Active Active when holding registers 22, 23, 24 <> 0 002 Cold restart R 0= None 1= Active

003 Data changes R/W 0= None 1= Were made Active when data were changed by the

operator; reset with COIL 65

004 Local operation R 0= None 1= Active TROVIS 6412 is operated either with the

COPA pen, the TROVIS 6482 program or by

means of the front-panel keys; any displayed

data are not updated 005 Reserved R 0 006 Reserved R 0 007 Reserved R 0 008 Reserved R 0

Operating modes

009 Manual/Automatic mode R/W 0= Automatic mode 1= Manual mode

Cannot be changed when controlled by binary input

010 Master/follower controller R/W

0= Master controller 1= Follower controller

011 Internal/external set point active R/W

0= Internal 1= External 012 External position feedback R 0 1 013 External system ready R 0 1

014 Timeout R/W

01 015 Adaptation on/oFF R/W

016 Adaptation (runs automatically) R/W 0 1 = Activated

If active, holding registers 25, 26 show the current status

Status message

017 Min. limitation of output variable R 0 1 018 Max. limitation of output variable R 0 1

Page 87

CL No. Designation of data point Access 1)Status Comments

0 (= Off) 1 (= On)

019 Min. limitation of reference variable R 0 1 020 Max. limitation of reference variable R 0 1 021 Locking of output variable R 0 1 022 Safety output value master controller R 0 1 Master - PID is compensated 023 Safety output value follower controller R 0 1 Follower - PID is compensated 024 X-tracking R 0 1 025 Output ramp active R 0 1 026 Set point ramp active R 0 1 027 Safety output value Y

R 0 1 Only acts on output

028 Safety output value Y

R 0 1 Only acts on output 029 Reserved R 0 030 Reserved R 0 031 Reserved R 0 032 Reserved R 0

Binary inputs/outputs

033 Binary output bo 3 R 0 1 034 Internally used 035 Binary output Y- R 0 1 036 Binary output Y+ R 0 1 037 Binary output bo 2 R 0 1 038 Binary output bo 1 R 0 1 039 Limit relay output G2 R 0 1 040 Limit relay output G1 R 0 1 041 Binary input bi 1 R/W 0 1

042 Binary input bi 2 R/W 0 1

043 Binary input bi 3 R/W 0 1

044 Reserved R 0

Page 88

CL No. Designation of data point Access 1)Status Comments

0 (= Off) 1 (= On)

045 Reserved R 0 046 Reserved R 0 047 Reserved R 0 048 Reserved R 0 049 Reserved R 0 050 Reserved R 0 051 Reserved R 0 052 Reserved R 0 053 Reserved R 0 054 Reserved R 0 055 Reserved R 0 056 Reserved R 0 057 Reserved R 0 058 Reserved R 0 059 Reserved R 0 060 Reserved R 0 061 Reserved R 0 062 Reserved R 0 063 Reserved R 0 064 Reserved R 0 065 Resetting Cold restart R/W 0= Resetting 1= No effect 066 Resetting Holding Registers 23,24 R/W 0= Resetting 1= No effect

R : Read Only, R/W: Read and Write

External position feedback has priority over MANUAL/AUTOMATIC key

Are combined OR with the hardware binary input

Function determined by the configuration. Details, see KH 6412 EN

Software version 1.3 or higher

Data are written to the non-volatile memory (EEPROM). The lifetime of this type of memory is limited to approx. 100,000 write cycles, meaning automatic, permanent writing to it is not permitted.

Page 89

Input - Status Data Point List for the TROVIS 6412 Industrial Controller

IN No. Designation of data point Access 1)Status Comments

0 (= Off) 1 (= On)

001 Binary input bi 1 R 0

Inputs are displayed even when not assigned via software

002 Binary input bi 2 R 0 1 003 Binary input bi 3 R 0

1 004 NC R 0 005 NC R 0 006 NC R 0 007 NC R 0 008 NC R 0

R : Read Only, R/W: Read and Write

Input Registers Data Point List for the TROVIS 6412 Industrial Controller

IR No.

Designation of data point Access1)Transmission range Display range Comments

001 Input in 1 R -200 … 1200

-20% … 120% Inputs are displayed even when not assigned via software

002 Input in 2 R -200 … 1200 -20% … 120% 003 Input in 3 R -200 …1200 -20% … 120% 004 Input in 4 R -200 … 1200 -20% … 120%

R : Read Only, R/W: Read and Write

Page 90

Appendix B Error Messages

Error Displays on the front panel Acknow-

ledge

Status signals for external signals Change

of output signal

Comment

Display field LED Binary outputs

bo 1 and/or bo 2

Binary output bo 3

No Yes

Input values out of measuring range

On No X X X

See C37, C44-3, C45-3

Writing to internal data memory not possible

3) 4)

Flashes F key

EEPROM defective

Configuration changed without operator intervention

Re-enter data, see C44-4

Parameters /adaptation parameters changed without operator intervention

Adjustment values for analog inputs changed without operator intervention

Code number changed without operator intervention

Communication between central control station and interface is interrupted

See C44-8, C45-8

Contact position after activation

Functional diagram

Alternates with actual value 4)After pressing the A key

Page 91

Error Displays on the front panel Acknow-

ledge

Status signals for external signals Change

of output signal

Comment

Display field LED Binary outputs

bo 1 and/or bo 2

Binary output bo 3

No Yes

Communication between interface and process control station is interrupted

Flashes F key X X

See C44-8, C45-

8; check soldering

jumpers LB1,LB2, LB3, see page 19

Controller status changed without operator intervention

Flashes F key X X X

Re-enter configuration and parameter data, see C44-4

Locking of output signal active

−

A key

Adaptation aborted/error Reset to Start of adaptation

Output signal limitation active

Position feedback active

Limitation of master controller output active

Output value Y

1K1

2K1

active

Output value Y

1K4

active

Contact position after activation

Functional diagram

Alternates with actual value

After pressing the A key

Page 92

Error Displays on the front panel Acknow-

ledge

Status signals for external signals Change

of output signal

Comment

Display field LED Binary outputs

bo 1 and/or bo 2

Binary output bo 3

No Yes

MANUAL mode active (with C 51-3 and C52>1)

−

A key

Adaptation aborted/error Reset to Start of adaptation

No noise band defined

Controlled variable does not change enough

Limits of output signal test range are identical

Output variable out of output variable test range at start of adaptation

Limits of controlled variable test range are identical

Controlled variable out of controlled variable test range at start of adaptat.

Controlled variable not stationary; controlled system does not oscillate

System not calm before being excited with first control pulse

Contact position after activation

Functional diagram

Alternates with actual value 4)After pressing the A key

Page 93

Error Displays on the front panel Acknow-

ledge

Status signals for external signals Change

of output signal

Comment

Display field LED Binary outputs

bo 1 and/or bo 2

Binary output bo 3

No Yes

System does not oscillate or limits for adaptation range are identical

−

A key

Adaptation impossible with selected configuration data

Adaptation aborted/error Reset to start of adaptation

Data error in COPA pen

−

A key

twice

Incompatible data, re-write to COPA pen

Data transmission error, COPA pen

Repeat procedure

COPA pen defective

Use new COPA pen

Data transmission error, process control station

Repeat procedure

Contact position after activation

Functional diagram

Alternates with actual value

After pressing the A key

Page 94

Appendix C Checklist

Process Control Station Type: 6412 or 6442

Controller no.: Software version: Power supply: 230/ 120/24 V, 24 V AC/DC (optional)

Input board: IB 1/ IB 2/ IB 3/ IB 4

Input Ai 1: Input Ai 2: Input Ai 3: Input Ai 4:

Outputs

Y1: Y2 (optional): Ao1 (optional):

G1 (optional): G2 (optional):

Settings made on: Signature:

0 to 20 mA 4 to 20 mA 0 to 10 V 2 to 10 V 0 to 20 mA 4 to 20 mA 0 to 10 V 2 to 10 V 0 to 20 mA

−10 to 10 V

4 to 20 mA 0 to 10 V 2 to 10 V

Configuration protocol

Ex-factory Selected C 1 1 C 2 1 C 3 0 C 4 1 C 5 2 C 6 1 C 7 1 C 8 1 C 9 1 C10 2 C11 1 C12 1 C13 1 C14 1 C15 1 C16 1

C20 1 C21 2 C22 1 C23 1 C24 2 C25 0 C26 1 C27 1 C28 1 C29 1 C30 1 C31 1 C32 1 C33 1 C34 1 C35 1 C36 1

C40 1 C41 1 C42 1 C43 5 C44 1 C45 1 C46 1 C47 2 C48 1 C49 1 C50 1 C51 1 C52 0 C53 0 C54 1 C55 0

C56 1 C17 1 C18 1 C19 1

0 means that the configuration block is skipped.

C37 1 C38 2 C39 1

C57 2

C58 0

C59 1

Page 95

Parameters

PA Parameter set for fixed set point, follow-up, ratio or synchro control PA1 Parameter set for master controller in the cascade control mode PA2 Parameter set for follower controller in the cascade control mode

Parameter PA/

PA1 X X X W

Z Z Z W

WINK

TZX

XSDY

XSDG1 X

TZ TZY

TZY

TVK

KPY

KPK

TVK

PA2 Unit

Parameter PA/

PA1

PK3

TVK

Y1K

Y2K

Y1K

Y2K

TSX T

SWEX

TSZ T

SXd

Y2K

TSK

GWG1 GWG2 K

PA2 Unit

Parameter PA/

PA1

K1X

1WEX

KPK

Y1K

GWK

Y1K

WINK

GWK

PA2 Unit

Page 96

Code number important for servicing 1732

Page 97

Process display and control panel elements

1 Jack for COPA pen or COPA adapter 2 Red LED for messages or faults 33

-digit digital display for set point (ref-

⁄

erence variable) ( can be switched to output variable), parameter values and values of the configuration blocks

4 Indicator for end of range (e.g. when

measuring range and reference variable range are set in the PARAMETER mode)

5 Indicator for start of range (e.g. when

measuring range and reference variable

range are set in the PARAMETER mode) 6 Exchangeable label for physical unit 7 Bar graph for error (control deviation) in % 83

-digit digital display for controlled

⁄

variable and configuration block 9 Indicator for limit relay 1 10 Indicator for limit relay 2 11 Indicator for + with three-step signal

"OPEN" or for on-off output signal 12 Indicator for - with three-step signal

"CLOSED" 13 Indicators for closed position of control

valve at 0 or 100 % 14 Bar graph for output variable 0 to 100% 15 Replaceable label for recording of

measuring point 16 Indicators for "internal set point valid" or

"follower controller set point (reference

variable) valid" in cascade control mode

17 Indicators for "monitoring of measuring

range"

18 Indicators for "external system not

ready", e.g. with SPC or DDC-backup operation

19 Symbol for MANUAL or AUTOMATIC

mode 20 Indicators for external control signal 21 Parameter table with :

Symbol for code number X Controlled variable W

External reference variable

Z Disturbance variable W W X X

Internal set point (reference variable)

Safety set point

Error (control deviation)

Hysteresis

TZ Dead band K T T Y Y T T T

Proportional-action coefficient

Reset time

Rate time

Controller output 1

Controller output 2

Actuating time Y1

Actuating time Y2

Time constant for filter

GW Limit value K

Constants

Page 98

Control panel

13 14

3 4

5 6 7

X

%

d



8 9

G1

X



W

G2



Z



W 

W

+



X



X



TZ 

020406080100%

K

P

1



K

T

2

N



K

T

EX

V



Y 

T 

GW 

3



C



K

1

4



K

2

5



K

Y1

6



K

Y2

7



K

8

S



K

9 



IN 

S  D 

SD 

18 21

19 20

A Display and execute key for all levels B Switch-over key W

(internal/external

I/WEX

reference variable) or open/close cascade

C Cursor key for increasing values (set point

(reference variable)), parameters, configuration blocks)

D Cursor key for decreasing values (set point

(reference variable)), parameters, configuration blocks)

E MANUAL/AUTOMATIC mode selector key F Reset key for switching to the OPERATING

level, for switching digital display (3) from reference variable to output signal or from master to follower controller; override of the

controller startup following power recovery G Key for increasing value of the output variable H Key for reducing value of the output variable

See pervious page for other elements

Page 99

S/Z 2007-07

EB 6412 EN

SAMSON AG ⋅ MESS- UND REGELTECHNIK Weismüllerstraße 3 ⋅ 60314 Frankfurt am Main ⋅ Germany Phone +49 49 4009-0 ⋅ Fax +49 69 4009-1507 Internet: http://www.samson.de

Samson Trovis 6400, Trovis 6412, Trovis 6442 Mounting And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual