West Control Solutions Pro-8 User Manual
Industrial Controller Pro-8
West Pro-8 user manual – 59560
BlueControl
More efficiency in engineering,
more overview in operating:
The projecting environment for the West Pro controllers
Description of symbols:
g General information
a General warning
l Attention: ESD sensitive devices
West Control Solutions
rights reserved. No part of this document may bereproduced or published in any form
All
or by any means without prior written permission from the copyright owner.
Contents
1 Mounting .............................. 5
2 Electrical connections ....................... 7
2.1 Connecting diagram......................... 7
2.2 Connecting diagram for the options card ..............8
2.3 Terminal connection ........................ 8
3 Operation ............................. 12
3.1 Front view ............................. 12
3.2 Behaviour after power-on ..................... 13
3.3 Operating level .......................... 13
3.4 Maintenance manager / Error list ................14
3.5 Self-tuning ............................. 16
3.5.1 Preparation before self-tuning ......................16
3.5.2 Self-tuning start ............................17
3.5.3 Self-tuning cancellation ........................17
3.5.4 Acknowledgement of failed self-tuning .................17
3.5.5 Optimization after start-up or at the set-point ..............17
3.5.6 Selecting the method ( ConF/ Cntr/ tunE).............18
3.5.7 Optimization at the set-point for 3-point stepping controller ......21
3.5.8 Examples for self-tuning attempts ..................22
3.6 Manual tuning ........................... 23
3.7 Second PID parameter set .....................24
3.8 Alarm handling .......................... 25
3.9 Operating structure ........................27
4 Configuration level ........................28
4.1 Configuration survey ....................... 28
4.2 Configurations ........................... 29
4.3 Set-point processing ........................ 38
4.3.1 Set-point gradient / ramp ........................38
4.4 Pro-8 cooling functions ..........
4.4.1 Standard ( CyCl= 0 )..........................38
Pro-8
3
..............
38
4.4.2 Switching attitude linear ( CyCl= 1 ) ................39
4.4.3 Switching attitude non-linear ( CyCl= 2 )..............39
4.4.4 Heating and cooling with constant period ( CyCl= 3 )........40
4.5 Configuration examples ...................... 41
4.5.1 On-Off controller / Signaller (inverse) .................41
4.5.2 2-point and continuous controller (inverse) ...............42
4.5.3 3-point and continuous controller ...................43
4.5.4 3-point stepping controller (relay & relay) ...............44
4.5.5 D - Y - Off controller / 2-point controller with pre-contact ......45
4.5.6 Pro-8 with measured value output .
...................
46
5 Parameter setting level ...................... 48
5.1 Parameter survey ......................... 48
5.2 Parameters ............................. 49
5.3 Input scaling ............................ 52
5.3.1 Input Inp.1 ...............................52
5.3.2 Input InP.2 ...............................52
6 Calibration level ......................... 53
7 Programmer ........................... 56
8 Special functions ......................... 57
8.1 Start-up circuit ........................... 57
8.2 Boost function ........................... 58
8.3 Pro-8 as Modbus master ......
.................
59
8.4 Linearization............................ 60
9 BlueControl ............................ 61
10 Versions .............................. 62
11 Technical data .......................... 64
12 Safety hints ............................ 67
12.1 Reset to default .......................... 69
4
Pro-8
1 Mounting
oder:
*
Ü
*
Ü
96
(3.78")
48 (1.89")
min.48 (1.89")
10
(0.4")
1..10
(0.04..0.4")
118
(4.65")
45
+0,6
(1.77" )
+0.02
92
+0,8
(3.62" )
+0.03
125
126
SP.X
run
Err
Ada
è
%
max.
95% rel.
max.
60°C
0°Cmin.
Safety switches
Loc
10V i mA/Pt
U i I
Pro-8
Mounting
Safety switch:
For access to the safety switches, the controller must be withdrawn from the housing. Squeeze the top and bottom of the front bezel between thumb and forefinger
and pull the controller firmly from the housing.
Pro-8
5
Mounting
a
Name of safety
switch
10V i mA/Pt right Current signal / Pt100 / thermocouple at
Loc open Levels as set using the BlueControl®eng. tool
U<-> I
only valid for
KS5.-1.4-.....-...
KS5.-1.5-.....-...
Position Remark Factory
setting
l
InP.1
left Voltage signal at InP.1
(default):
- Access to controller off / self-tuning / extended
operating level = enabled
- Password PASS= OFF
- Access to parameter setting level /
configuration level /
calibration level= disabled
close all levels accessible wihout restriction l
right (I) Current / logic on output 3 "OUT3" l
left (U) Voltage on output 3 "OUT3"
Safety switch 10V i mA/Pt and U<-> I always in position left or right.
Leaving the safety switch open may lead to faulty functions!
l
Caution! The unit contains ESD-sensitive components.
6
Pro-8
Electrical connections
L
N
90...250V
24V AC/DC
mA
mA
0..10 V
HC
di1
INP1
INP2
OUT3
OUT2
OUT1
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
ab c d
U
Logic
KS 5_-1. -.....-...
KS 5_-1. -.....-...
2
3
C
N/O
N/O
C
N/O
N/C
L
N
90...250V
24V AC/DC
mA
0..10 V
di1
INP1
OUT3
OUT2
OUT1
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
ab c d
U
Logic
C
N/O
N/C
N/O
C
N/C
2 Electrical connections
2.1 Connecting diagram
Electrical connections for all types KS 5x-1 exept KS 5_-1_4-_ 00_ _-_ _
Electrical connections for KS 5_-1_4-_____-__
* Safety switch 10Vi mA/Pt (input INP1 current”10V” i mA/Pt/mV)
** Safety switch U i I (output OUT3 current”U” i voltage”I”)
Connecting diagram 7
Pro-8
2.2 Connecting diagram for the options card
di2
di3
U
T
Option
RXD-B
GND
RXD-A
TXD-B
TXD-A
RS485 RS422
Modbus RTU
RGND
DATA B
DATA A
+24V DC
24V GND
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
1
3
4
5
6
7
8
9
10
11
12
13
14
15
17
(2)
(16)
OUT5
OUT6
24 VDC
24 VDC
KS5_-1..- ....-...8
Electrical connections
Pro-8
g
According to order the controller is fitted with:
flat-pin terminals combined for 1 x 6,3mm or 2 x 2,8mm to DIN 46 244
w
w
2.3 Terminal connection
or screw terminals for conductor cross section from 0,5 to 2,5mm²
On instruments with screw terminals, the stripping length must be min. 12
mm. Select end crimps accordingly.
Power supply connection 1
See chapter 11 "Technical data"
Connection of input INP1 2
Input for variable x1 (process value)
a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)
c current (0/4...20mA)
d voltage (0/2...10V) *Note: consider the safety switches.
8 Connecting diagram for the options card
Electrical connections
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
L
N
Logic
+
_
SSR
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
L
N
+
Connection of input INP2 3
3 INP2 current tansformer
Sensor type 0...50mA AC or
0/4 ... 20 mA DC for heating current input,
external set-point or
external correcting variable Y.E.
Connection of input di1 4
Digital input, configurable as a switch direct /
inverse or a push-button. ***
Connection of outputs OUT1/2 5
Relay outputs 250V/2A normally open with
common contact connection
Connection of output OUT3 6
Relay-output
KS5_-1_0-_00_ _-_ _ _ or
KS5_-1_1-_00_ _ -_ _ _
- Relay (250V/2A), potential-free changeover contact
Universal-output
5 OUT1/2 heating/cooling
KS5_-1_2-_00_ _-_ _ _or
KS5_-1_3-_00_ _-_ _ _
- Current (0/4...20mA)
- Voltage (0/2...10V)
- Transmitter power supply
- Logic (0..20mA / 0..12V)
Connection of inputs di2/3 7 (option)
Configurable as a switch direct / inverse
or as a push-button. ***
- Opto-coupler input
KS5_-1_ _-100_ _-_ _ _
Digital inputs (24VDC external)
galvanically isolated.
- Potential-free contact input
KS5_-1_ _-800_ _-_ _ _
Connection of output U
8 (option)
T
Supply voltage connection for external energization
Connection of outputs OUT5/6 9
(option)
Digital outputs (opto-coupler), galvanic isolated, common positive control voltage, output rating: 18...32VDC
Terminal connection 9
Connection of bus interface 0 (option)
RS422/485 interface with Modbus RTU protocol
*** Adjustment is possible only in common for all digital inputs.
Pro-8
Electrical connections
1
2
3
K
+
-
+
-
13V
22mA
1
3
4
5
6
7
8
9
10
11
12
13
14
15
17
(2)
(16)
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
1
2
3
K
+
-
+
-
+
-
17,5V
22mA
OUT3
J
Option KS5_-1_ _-100 _ _-_ _ _
1
2
3
4
5
+24VDC
5mA
5mA
0V
Option KS5_-1_ _-800 _ _-_ _ _
1
2
3
4
5
7
8
9
7
8
9
3
4
7
5
8
6
9
10
+
_
SSR
+
_
SSR
+
_
SSR
Series connection
Parallel connection
+
_
SSR
7
8
9
Logic
4V
4V
4V
12V
I =22mA
max
I =22mA
max
12V
8 2-wire transmitter supply with U
Connection of outputs OUT1 ! and OUT2 "
Relay-output KS5_-1_4-_00_ _-_ _ _ and KS5_-1_5-_00_ _-_ _ _
- Relay (250V/2A), potentialfree changeover contact
Connection of output OUT3 §
T
6 OUT3 transmitter supply
Universal output KS5_-1_4-_00_ _-_ _ _and KS5_-1_5-_00_ _- ___
Note:
Mind the safety switch.
- current (0/4...20mA)
- voltage(0/2...10V)
- Transmitter power supply
- Logic (0..20mA / 0..12V)
a
The analog outputs OUT3 and transmitter supply voltage UTare connected to
different voltage potentials. For this reason, an external galvanic connection of
OUT3 and U
7 Connection of inputs di 2/3
Pro-8
is not permissible for analog outputs.
T
6 OUT3 as logic output with solid-state relay
(series and parallel connection)
10 Terminal connection
Electrical connections
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
RGND RGND
RGND
RT
converter
RS485-RS232
PC
DATA A
DATA B
DATA A
DATA B
DATA A
DATA B
J
max. 1000m
”Twisted Pair”
10
RT
R=100 Ohm
RGND connection optional
R = 120...200 OhmT
R = 120...200 OhmT
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
Logic
+
_
L1
L2
N1
N2
fuse
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
TB 40-1
Temperature limiter
1
KS 5_-1
SSR
reset
contactor
heating
1 TB 40-1 Temperature limiter
Standard version (3 relays):
TB40-100-0000D-000
other versions on requestr
+
+
fuse
fuse
0 RS485 interface (with RS232-RS485 interface converter) ****
****see Interface description Modbus RTU 9499-040-63611 .
KS5_-1_2-_00_ _-_ _ _. connecting example:
systems where overtemperature implies a fire hazard or
other risks.
a
CAUTION: Using a temperature limiter is recommendable in
Terminal connection 11
Pro-8
Operation
125
126.
SP.x
run
Err
Ada
123OK
3
1
2
3
4
0
5
!
6
"
7
8
§
9
$
%
è
&
3 Operation
3.1 Front view
LED colours:
LED 1, 2, 3: yellow
LED OK: green
other LEDs: red
1 For function states /
see LED assignment
(Conf/othr/LEd)
2 Lit with limit value 1
( PArA / Lim ) not exceeded
3 Process value display
4 Set-point, controller output
5 Signals ConF and PArA level
6 Programmer running
7 Self-tuning active
8 Entry in error list
9 Set-point SP.2 or SP.E is
effective
0 Set-point gradient effective
! Manual/automatic switch-over:
Off: Automatic
On: Manual
(changing possible)
Blinks: Manual
(changing not possible
(r ConF/ Cntr/ MAn)
" Enter key:
calls up extended operating
level / error list
§ Up/down keys:
changing the set-point or the
controller output value
$ Manual mode /spec. function
(® ConF / LOGI )
% PC connection for
BlueControl (engineering
tool)
& Freely programmable function
key
In the upper display line, the process value is always displayed. At parameter,
configuration, calibration as well as extended operating level, the bottom display
line changes cyclically between parameter name and parameter value.
g
Front view 12
Pro-8
3.2 Behaviour after power-on
125
126
y21
126
y21
126
Ò
Ò
Ù
Ù
Ù
Ù
125
126
Automatic
Extended operating level
Manual
i
i
È
Ì
È
Ì
È
Ì
only
display
126
FbF.1
Err
2
126
Err
switching
display
Errorliste (if error exists)
time
out
time
out
time
out
After supply voltage switch-on, the unit starts with the operating level.
The unit is in the condition which was active before power-off.
If the controller was in manual mode before power-off, the controller starts with
the last correcting value after switching on again.
3.3 Operating level
The content of the extended operating level is determined by means of BlueControl (engineering tool). Parameters which are used frequently or the display of
which is important can be copied to the extended operating level.
Operation
Pro-8
13 Behaviour after power-on
Operation
125
126
SP.x
run
Ada
Err
3.4 Maintenance manager / Error list
With one or several errors, the extended operating level always starts with the error list. Signalling an actual entry in
the error list (alarm, error) is done by the Err LED in the
display. This is applicable only, if at least one limit value
function, the loop alarm or the heating current alarm is activated. For display of the error list, press Ù twice.
Err LED status Signification Proceed as follows
blinks
(Status 2)
lit
(Status1)
off
(Status 0)
Alarm due to existing
error
Error removed,
Alarm not acknowledged
No error,
all alarm entries deleted
Determine the error type in the error list after
removing the error the device changes to Status1
Acknowledge the alarm in the error list pressing key
È or Ì the alarm entry is deleted (Status 0).
not visible, exept when ackowledging
Error list:
Name
E.1
Internal error,
cannot be removed
E.2
Internal error, can be
reset
E.4
Hardware error Codenumber and hardware are
FbF.1
Sht.1
POL.1
FbF.2
Sht.2
POL.2
HCA
SSr
Sensor break INP1 Sensor defective
Short circuit INP1 Sensor defective
INP1polarity error Faulty cabling Reverse INP1 polarity
Sensor break INP2 Sensor defective
Short circuit INP2 Sensor defective
INP2 polarity Faulty cabling Reverse INP2 polarity
Heating current
alarm (HCA)
Heating current short
circuit (SSR)
Description Cause Possible remedial action
E.g. defective EEPROM Contact PMA service
Return unit to our factory
e.g. EMC trouble Keep measurement and power
supply cables in separate runs
Ensure that interference
suppression of contactors is
provided
Contact PMA service
not identical
Electronic-/Optioncard must be
exchanged
Replace INP1 sensor
Faulty cabling
Check INP1 connection
Replace INP1 sensor
Faulty cabling
Check INP1 connection
Replace INP2 sensor
Faulty cabling
Check INP2 connection
Replace sensor INP2
Faulty cabling
Heating current circuit
interrupted, I< HC.A or I>
Check INP2 connection
Check heating current circuit
If necessary, replace heater band
HC.A (dependent of
configuration)
Heater band defective
Current flow in heating circuit
at controller off
SSR defective
Check heating current circuit
If necessary, replace solid-state
relay
Maintenance manager / Error list 14
Pro-8
Operation
g
Name
LooP
Description Cause Possible remedial action
Control loop alarm
(LOOP)
Input signal defective or not
connected correctly
Output not connected correctly
Check heating or cooling circuit
Check sensor and replace it, if
necessary
Check controller and switching
device
AdA.H
Self-tuning heating
alarm
See Self-tuning heating error
status
see Self-tuning heating error
status
(ADAH)
AdA.C
Self-tuning heating
alarm cooling
See Self-tuning cooling error
status
see Self-tuning cooling error
status
(ADAC)
LiM.1
Lim.2
Lim.3
Inf.1
Inf.2
stored limit alarm 1 adjusted limit value 1 exceeded check process
stored limit alarm 2 adjusted limit value 2 exceeded check process
stored limit alarm 3 adjusted limit value 3 exceeded check process
time limit value
message
duty cycle message
(digital ouputs)
adjusted number of operating
hours reached
adjusted number of duty cycles
reached
application-specific
application-specific
Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital
input di1/2/3, the è-key or the Ò-key or the.
Configuration, see page 36: ConF / LOGI / Err.r
g
If an alarm is still valid that means the cause of the alarm is not removed so far
(Err-LED blinks), then other saved alarms can not be acknowledged and deleted.
Not applicable to heating current alarm.
Error status:
Self-tuning heating ( ADA.H) and cooling ( ADA.C) error status:
Error status
0
3
4
5
6
7
8
9
No error
Faulty control action Re-configure controller (inverse i direct)
No response of process
variable
Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or
Danger of exceeded set-point
(parameter determined)
Output step change too small
{y > 5%)
(
Set-point reserve too small Increase set-point (invers), reduce set-point (direct)
Impulse tuning failed The control loop is perhaps not closed: check sensor,
Description Behaviour
The control loop is perhaps not closed: check sensor,
connections and process
decrease ( ADA.C) min. output limiting Y.Lo
If necessary, increase (inverse) or reduce (direct)
set-point
Increase ( ADA.H) max. output limiting Y.Hi or
reduce ( ADA.C) min. output limiting Y.Lo
or increase set-point range
(r PArA / SEtp / SP.LO and SP.Hi )
connections and process
Pro-8
15 Maintenance manager / Error list
Operation
3.5 Self-tuning
For determination of optimum process parameters, self-tuning is possible.
After starting by the operator, the controller makes an adaptation attempt, whereby the process characteristics are used to calculate the parameters for fast line-out
to the set-point without overshoot.
The following parameters are optimized when self-tuning:
Parameter set 1:
3.5.1
Pb1
ti1
td1
t1
Pb2
ti2
td2
t2
Parameterset 2: according to Parameterset 1 (see page 24)
Proportional band 1 (heating) in engineering units [e.g. °C]
Integral time 1 (heating) in [s] r only, unless set to OFF
Derivative time 1 (heating) in [s] r only, unless set to OFF
Minimum cycle time 1 (heating) in [s]. This parameter is optimized only, unless
parameter Cntr/Adt0 was configured for “no self-tuning” using BlueControl
Proportional band 2 (cooling) in engineering units [e.g. °C]
Integral time 2 (cooling) in [s] r only, unless set to OFF
Derivative time 2 (cooling) in [s] r only, unless set to OFF
Minimum cycle time 2 (cooling) in [s]. This parameter is optimized only, unless
parameter Cntr/Adt0 was configured for “no self-tuning”using BlueControl
Preparation before self-tuning
As a prerequisite of process evaluation, a stable condition is required. For this
w
reason, the controller waits, until the process has reached a stable condition
after self-tuning start.
The rest condition is considered as reached, when the process value oscillation is smaller than ± 0,5% of (rnG.H - rnG.L). The limits of the control range
must be adjusted for the controller operating range, i.e. rnG.L and rnG.H
must be adjusted to the limits within which control must take place (ConfigurationrControllerrspan start and end of control range) ConFrCntrr
rnG.L and rnG.H
®
®
For starting the self-tuning after start-up, a clearance of 10% of (SP.LO...
w
SP.Hi) is required. As the values PArA/SEtp/SP.LO and
PArA/SEtp/SP.Hi mustl always be within the control range, no restriction
is applicable if these values are adjusted correctly.
Determine which parameter set must be optimized.
w
-The currently effective parameter set is optimized.
r activate the corresponding parameter set (1 or 2).
Determine which parameter must be optimized (see the list given above)
w
Select the method for self-tuning
w
See Chapter 3.5.6
- Step attempt after start-up
- Pulse attempt after start-up
- Optimization at the set-point
Self-tuning 16
Pro-8
3.5.2 Self-tuning start
125
126
SP.x
run
Ada
Err
Operation
g
3.5.3
Self-tuning start can be disabled using BlueControl®(engineering tool)
(Conf/Othr/IAdA).
Starting the self-tuning:
Self-tuning is started by pressing the Ù and È keys simultaneously, or via the
interface. If parameter Conf/Cntr/Strt is set to 1 self-tuning starts also after power-on and when detecting process value oscillations.
Self-tuning status display
Ada-LED-Status Meaning
blinks Waiting until process is at rest
lit seft tuning running
off self tuning not active e.g. ready
Self-tuning cancellation
By the operator:
w
Self-tuning is cancelled by pressing the Ù and È keys simultaneously.
Switching over to manual operation also causes cancellation of the self-tuning procedure.
After self-tuning cancellation, the controller continues operating using the parameters valid prior to self-tuning start.
3.5.4
By the controller:
w
If the Err LED starts blinking during self-tuning, successful self-tuning is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller. The controller continues operating using the parameters valid before self-tuning start.
If the self-tuning method with step attempt was used and
started from the manual mode, the controller uses the last valid correcting variable after self-tuning start, until the self-tuning error message is acknowledged. Subsequently, the controller continues operating using the parameters
valid before self-tuning start.
Causes of cancellation:
® Page 8: " Self-tuning heating (ADA.H) and cooling (ADA.C) error status"
self-tuning was
Acknowledgement of failed self-tuning
When pressing the Ù key, the controller switches over to correcting variable dis-
play (Y ....). After pressing the Ù key again, the controller goes to the error list
of the extended operating level. The error message can be acknowledged by switching the message to 0 using the D or the I key.
After acknowledging the error message, the controller continues operating in the
automatic mode, using the parameters valid prior to self-tuning start.
Pro-8
17 Self-tuning
Operation
3.5.5 Optimization after start-up or at the set-point
The two methods are optimization after start-up and at the set-point.
As control parameters are always optimal only for a limited process range, various methods can be selected dependent of requirements. If the process behaviour
is very different after start-up and directly at the set-point, parameter sets 1 and 2
can be optimized using different methods. Switch-over between parameter sets
dependent of process status is possible (see page ).
Optimization after start-up: (see page 18)
Optimization after start-up requires a certain separation between process value
and set-point. This separation enables the controller to determine the control parameters by evaluation of the process when lining out to the set-point.
This method optimizes the control loop from the start conditions to the set-point,
whereby a wide control range is covered.
We recommend selecting optimization method “Step attempt after start-up”
with tunE = 0 first. Unless this attempt is completed successfully, we then recommend a “Pulse attempt after start-up”.
3.5.6
Optimization at the set-point: (see page 19)
For optimizing at the set-point, the controller outputs a disturbance variable to the
process. This is done by changing the output variable shortly. The process value
changed by this pulse is evaluated. The detected process parameters are converted into control parameters and saved in the controller.
This procedure optimizes the control loop directly at the set-point. The advantage
is in the small control deviation during optimization.
Selecting the method ( ConF/ Cntr/ tunE)
Selection criteria for the optimization method:
Step attempt after start-up Pulse attempt after start-up Optimization at the set-point
tunE =0
tunE =1
tunE =2
sufficient set-point reserve is
provided
sufficient set-point reserve is
provided
Only step attempt after start-up
required
Sufficient set-point reserve:
inverse controller:(with process value < set-point- (10% of rnGH - rnGL)
direct controller: (with process value > set-point + (10% of rnGH - rnGL)
sufficient set-point reserve is not
provided
sufficient set-point reserve is not
provided
inverse controller:
process value is (10% of rnGH - rnGL) below the set-point
direct controller:
process value is (10% of rnGH - rnGL) above the set-point
Self-tuning 18
Pro-8
Step attempt after start-up
Condition: - tunE = 0 and sufficient set-point reserve provided or
- tunE =2
The controller outputs 0% correcting variable or Y.Lo and waits, until the process
is at rest (see start-conditions on page 8).
Subsequently, a correcting variable step change to 100% or Y.Hi is output.
The controller attempts to calculate the optimum control parameters from the process response. If this is done successfully, the optimized parameters are taken
over and used for line-out to the set-point.
With a 3-point controller, this is followed by “cooling”.
After completing the 1st step as described, a correcting variable of -100% or
Y.Lo (100% cooling energy) is output from the set-point. After successfull determination of the “cooling parameters”, line-out to the set-point is using the optimized parameters.
Operation
Pulse attempt after start-up
Condition: - tunE = 1 and sufficient set-point reserve provided.
The controller outputs 0% correcting variable or Y.Lo and waits, until the process
is at rest (see start conditions page 8)
Subsequently, a short pulse of 100% or Y.Hi is output (Y=100%) and reset.
The controller attempts to determine the optimum control parameters from the
process response. If this is completed successfully, these optimized parameters
are taken over and used for line-out to the set-point.
With a 3-point controller, this is followed by “cooling”.
After completing the 1st step as described and line-out to the set-point, correcting
variable "heating" remains unchanged and a cooling pulse (100% cooling energy)
is output additionally. After successful determination of the “cooling parameters”, the optimized parameters are used for line-out to the set-point.
Optimization at the set-point
Conditions:
A sufficient set-point reserve is not provided at self-tuning start (see page 18).
w
tunE is0or1
w
With Strt = 1 configured and detection of a process value oscillation by
w
more than ± 0,5% of (rnG.H - rnG.L) by the controller, the control parameters are preset for process stabilization and the controller realizes an optimiza-
tion at the set-point (see figure “Optimization at the set-point”).
Pro-8
when the step attempt after power-on has failed
w
with active gradient function ( PArA/ SETP/ r.SP¹ OFF), the set-point
w
gradient is started from the process value and there isn't a sufficient set-point
reserve.
19 Self-tuning
Operation
set-point
process value
correcting
variable
Optimization-at-the-set-point procedure:
The controller uses its instantaneous parameters for control to the set-point. In lined out condition, the controller makes a pulse attempt. This pulse reduces the
correcting variable by max. 20% 1, to generate a slight process value undershoot. The changing process is analyzed and the parameters thus calculated are recorded in the controller. The optimized parameters are used for line-out to the
set-point.
Optimization at the set-point
With a 3-point controller, optimization for the “heating“ or “cooling” parameters
occurs dependent of the instantaneous condition.
While the controller is in the "heating-phase" the heating-parameters are determined. If the controller is in the "cooling-phase" the cooling-parameters are
determined.
1 If the correcting variable is too low for reduction in lined out condition it is
increased by max. 20%.
Self-tuning 20
Pro-8
Operation
3.5.7 Optimization at the set-point for 3-point stepping controller
As position feedback is not provided, the controller calculates the actuator position internally by adjusting an integrator with the adjusted actuator travel time.
For this reason, precise entry of the actuator travel time (tt), as time between
stops is highly important.
Due to position simulation, the controller knows whether an increased or reduced
pulse must be output. After supply voltage switch-on, position simulation is at
50%. When the motor actuator was varied by the adjusted travel time in one go,
internal calculation occurs, i.e. the position corresponds to the simulation:
Simulation real position
Pro-8
Internal calculation tt
Internal calculation always occurs, when the actuator was varied by travel time
tt in one go
, independent of manual or automatic mode. When interrupting the
variation, internal calculation is cancelled. Unless internal calculation occurred
already after self-tuning start, it will occur automatically by closing the actuator
once.
Unless the positioning limits were reached within 10 hours, a significant deviation between simulation and actual position may have occurred. In this case, the
controller would realize minor internal calculation, i.e. the actuator would be closed by 20 %, and re-opened by 20 % subsequently. As a result, the controller
knows that there is a 20% reserve for the attempt.
21 Self-tuning
Operation
t
2
100%
Y
0%
X
W
Star t r
1
3
t reversal point
blinks
t
100%
Y
0%
X
W
start r
1
2
t reversal point
blinks
t
2
100%
Y
0%
X
W
1
3
blinks
4
r
t
Start r
t
+100%
Y0%
-100%
X
W
t reversal
point
Start r
1
2
3
4
5
rt
3.5.8 Examples for self-tuning attempts
(controller inverse, heating or heating/cooling)
Start: heating power switched on
Heating power Y is switched off (1).
When the change of process value X
was constant during one minute (2),
the power is switched on (3).
At the reversal point, the self-tuning
attempt is finished and the new parameter are used for controlling to
set-point W.
Start: heating power switched off
The controller waits 1,5 minutes (1).
Heating power Y is switched on (2).
At the reversal point, the self-tuning
attempt is finished and control to the
set-point is using the new parameters.
Self-tuning at the set-point a
The process is controlled to the
set-point. With the control deviation
constant during a defined time (1),
the controller outputs a reduced correcting variable pulse (max. 20%)
(2). After determination of the control parameters using the process characteristic (3), control is started using
the new parameters (4).
Three-point controller a
The parameter for heating and cooling
are determined in two attempts. The heating power is switched on (1). Heating
parameters Pb1, ti1, td1 and t1
are determined at the reversal point. The
process is controlled to the set-point (2).
With constant control deviation, the controller provides a cooling correcting variable pulse (3). After determining its
cooling parameters Pb2, ti2, td2
and t2 (4) from the process characteristics , control operation is started using the new
parameters (5).
a
During phase 3, heating and cooling are done simultaneously!
Self-tuning 22
Pro-8
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