Sixth Sense AI-100 Operating Manual

The Sixth Sense AI-100

1/32 DIN Fuzzy Logic controller

User‘s Manual

a division of TTI, Inc.

8 Leroy Road, P.O. Box 1073, Williston, VT 05495-1073

1-800-884-4967• US & Canada

Fax: [phone] • Phone: [phone]

www.ttiglobal.com • Email: sales

@

ttiglobal.com

sixth sense

INTRODUCTION

General Description

The AI-100 is a fully programmable, microprocessor-based
temperature/process controller. It offers superior control with 200
msec sampling rate and by using fuzzy logic to enhance its P, I and
D parameters. The 4-digit 0.4” red LED display offers excellent
visibility on a unit that is 1/32 DIN in size.

The AI-100 is available with either 20-32V AC/DC or 90-264V AC
power supply. This is a single universal input unit that will accept
8 different thermocouple types, Pt100 RTDs, and a variety of linear
mA and VDC signals. The wide range of options for the two avail­able outputs include relays, SSR drives, 4-20mA, 0-20mA, or
0-10VDC. Output #1 can be used in either a direct or reverse
action control situation with a programmable ramp rate. Output #2
can be used as a control output, as an alarm, or as a dwell timer.

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

The communications software package, COMM 4851, offers excel­lent graphics, bar and trend displays, and supports easy-to-use
database control and back-up capability.

FUZZY LOGIC

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

2

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Fuzzy Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Input Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Model Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Wiring & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Negotiating the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Learning the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Primary Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Changing Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Begin Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Flow Chart of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Setting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Scaling Analog Inputs/Setting Setpoint Limits . . . . . . . . . . . . . .24

Ramp Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Ramp & Soak/Dwell Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Tool Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Flow Chart of Tool Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Programmable Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Cooling Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Configurable Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Locking Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

1

4

SPECIFICATIONS

INPUT

Thermocouple(T/C): Type J,K,T,E,B,R,S,N
RTD: Pt100 ohm RTD (DIN or JIS)
Linear: Scalable. Refer to table on p.5
Accuracy: Refer to table on p.5
External Resistance: 100 ohm max.(for thermocouple)
Normal Mode Rejection: 60dB
Common Mode Rejection: 120dB
Sample Rate: 5 times/sec

CONTROL

Proportional Band: 0-360°F, 0-200°C, 0-3600 Process Units
Reset (Integral): 0-3600 seconds
Rate (derivative): 0-1000 seconds
Ramp rate: 0-55.55°C/min, 0-99.99°F/min,

0-99.99 Process Units(P.U.)/min
Dwell: 0-9999 minutes
Hysteresis: 0.1-11.0°C, 0.1-19.9°F, 0.1-199 P.U.
Cycle Time: 0-99 seconds
Control Action: Direct (cooling) and reverse(heating)

OUTPUT

Relay: SPST, 3A/240 VAC (resistive)
DC pulse: 24 VDC/20 mA max.
4 to 20 mA: Linear, max. load 500 ohms
0 to 20 mA: Linear, max. load 500 ohms
0 to 10 V: Linear, min. input impedance 500K ohms

ALARM

Relay: SPST, 3A/240 VAC (resistive)

INDICATION

Process Display: 0.4” red LED, 4 digits
Status Indicator: Control output and alarm

3

Figure 2. PID with fuzzy logic

Figure 3. PID vs. PID and fuzzy logic

PID control with proper tuning

PID + Fuzzy control

able to control a car well at a variety of speeds and under varying
circumstances by using knowledge gained through previous
experience.
Fuzzy Logic combined with PID control has been proven to be an
efficient method to improve control stability. This is illustrated in
figure 3.

MODEL CONFIGURATION

6

A

I10 -

0

POWER INPUT

4 90-264VAC
5 20-32V AC/DC

INPUT SIGNAL

0 J - Iron-Constantan
1 K - Chromel-Alumel
2 T - Copper-Constantan
3 E - Chromel-Constantan
4 B - Pt30%Rh/Pt6%Rh
5 R - Pt13%Rh/Pt
6 S - Pt10%Rh/Pt
7 N - NICROSIL-NISIL
8 RTD - Pt100 (DIN)

9 RTD - Pt100 (JIS)
A 4-20mA
B 0-20mA
C 0-10V
D 1-5V
E 0-5V

F 0-1V

OUTPUT #1 OPTIONS

0 None

1 Relay

2 SSR Drive

3 4-20mA

4 0-20mA

5 0-10V

ALARM/OUTPUT #2 OPTIONS

0 None

1 Relay

2 SSR Drive

3 4-20mA

4 0-20mA

5 0-10V

AUXILIARY OPTIONS

0 None

1 RS-485 Communications

2 Retransmission 4-20mA/0-20mA

5

POWER

Rating: 90-264VAC, 50/60Hz or 20-32V AC/DC
Consumption: Less than 5VA

ENVIRONMENTAL & PHYSICAL

Safety: CE, UL & CSA Approved
Protection: NEMA 4X, IP66 (front panel)
Operating Temperature: -10 to 50°C (14 to 122°F)
Humidity: 0 to 90%RH (non-condensing)
Insulation: 20 Mohm min. (500 VDC)
Breakdown: AC2000V, 50/60Hz, 1 minute
Vibration: 10-55Hz, amplitude 1mm
Shock: 200 m/s2(20G)
Weight: 110 grams (3.87 oz.)
Dimension: 24(H) x 48(W) x 99mm (depth behind panel)
Panel cutout: 22.2mm(H) (+.3/-0) 45 mm(W) (+.5/-0)
Warranty: 2 years

RANGE AND ACCURACY OF INPUTS

SENSOR INPUT TYPE RANGE (°F) RANGE (°C) ACCURACY

J Iron-Constantan -58 to 1830 -50 to 999 ±3.6°F/±2°C
K Chromel-Alumel -58 to 2500 -50 to 1370 ±3.6°F/±2°C
T Copper-Constantan -454 to 752 -270 to 400 ±3.6°F/±2°C
E Chromel-Constantan -58 to 1382 -50 to 750 ±3.6°F/±2°C
B Pt30%Rh/Pt6%Rh 572 to 3272 300 to 1800 ±3.6°F/±2°C
R Pt13%Rh/Pt 32 to 3182 0 to 1750 ±3.6°F/±2°C
S Pt10%Rh/Pt 32 to 3182 0 to 1750 ±3.6°F/±2°C

N Nicrosil-Nisil -58 to 2372 -50 to 1300 ±3.6°F/±2°C
RTD Pt100 ohm (DIN) -328 to 842 -200 to 450 ±0.72°F/±0.4°C
RTD Pt100ohm (JIS) -328 to 842 -200 to 450 ±0.72°F/±0.4°C

LINEAR INPUTS (All scalable)
Input type Range Accuracy

4-20 mA, 0-20 mA, 0-1V, 0-5V, 1-5V, 0-10V -1400 to 9400 ±0.05% FS

8

POWER SUPPLY

The controller is supplied to operate on either 90-264V AC or 20­32V AC/DC. Check that the supply voltage corresponds to that
indicated on the product label before connecting power to the
controllers.

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

THERMOCOUPLE INPUT

Thermocouple input connections are shown in the illustration
below. The thermocouple extension wire must be of proper type
and gauge, and should be run in a conduit, separate from any
power wiring. The resistance of the entire run should not exceed
100Ω.

Pt100 Ohm RTD INPUT

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

Power Supply Connections

Thermocouple Input Connections

RTD input Connections

Pt100

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

L
N

1A

INSTALLATION

MOUNTING

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

Make panel cutout as
shown in figure

1.772”(W) X 0.874”(H)

WIRING

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

7

NEMA brackets Mounting collar (non-NEMA)

Rear Terminal Connections

Units: mm

DC PULSE (SOLID-STATE RELAY DRIVE) OUTPUT

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

DC LINEAR OUTPUT

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

RS-485 COMMUNICATIONS/ANALOG RETRANSMISSION

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

10

Pulsed DC output Connections

Linear DC output Connections

RS-485 Communications

Analog retransmission

DC LINEAR INPUT

DC linear voltage and current input connections are shown below.

RELAY OUTPUT DIRECT DRIVE

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

RELAY OUTPUT CONTACTOR DRIVE

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

9

VDC

mADC

Relay Contactor Drive Connections

Relay Direct Drive Connections

2nd

/

1

/

2nd

1

TX1

13

TX2

14

13
14