Model ETR-4300 MICROPROCESSOR BASED SMARTER LOGIC Controller

Transcription

1 PK487-OMC56 SOFTWARE VERSION.8 and HIGHER Model ETR-4300 MICROPROCESSOR BASED SMARTER LOGIC Controller SMARTER LOGIC LOGIC LOGIC INSTRUCTION MANUAL

2 Warning Symbol This Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury or damage to or destruction of part or all of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met. Use the Manual Installers Basic Function User Enhanced Function User System Designer Expert User Read Chapter, Read Chapter, 3, 5 Read Chapter, 3, 4, 5 Read All Chapters Read Page

3 CONTENTS Chapter Overview - Features - Ordering Code -3 Programming Port & DIP Switch -4 Keys and Displays -5 Menu Overview -6 System Modes -7 Parameter Description Chapter Installation - Unpacking - Mounting -3 Wiring Precautions -4 Power Wiring -5 Sensor Installation Guidelines -6 Thermocouple Input Wiring -7 RTD Input Wiring -8 Linear DC Input Wiring -9 CT / Heater Current Input Wiring -0 Event Input wiring - Output Wiring - Output Wiring -3 Alarm Wiring -4 Alarm Wiring -5 RS RS-3-7 Analog Retransmission -8 Programming Port Page No Chapter 3 Programming the Basic Function 3- Input 3- OUT & OUT Types 3-3 Rearrange User Menu 3-4 Heat Only Control 3-5 Cool Only Control 3-6 Heat - Cool Control 3-7 Dwell Timer 3-8 Process Alarms 3-9 Deviation Alarms 3-0 Deviation Band Alarms 3- Heater Break Alarm 3- Loop Break Alarm 3-3 Sensor Break Alarm 3-4 SP Range 3-5 PV Shift 3-6 Failure Transfer 3-7 Bumpless Transfer 3-8 Self-tuning 3-9 Auto-tuning 3-0 Manual Tuning Signal Conditioner DC Power Supply 3- Manual Control 3-3 Display Mode 3-4 Heater Current Monitoring 3-5 Reload Default Values Chapter 4 Programming the Full Function 4- Event Input 4- Second Set Point 4-3 Second PID Set 4-4 Ramp & Dwell 4-5 Remote Set Point 4-6 Differential Control 4-7 Output Power Limits 4-8 Data Communication 4-9 Analog Retransmission 4-0 Digital Filter 4- Sleep Mode 4- Pump Control 4-3 Remote Lockout Chapter 5 Applications 5- Pump / Pressure Control 5- Variable Period Full Wave SSR ( VPFW SSR ) 5-3 Heat Only Control 5-4 Cool Only Control 5-5 Heat - Cool Control 5-6 Ramp & Dwell 5-7 Remote Set Point 5-8 Differential Control 5-9 Dual Set Point / PID 5-0 RS RS-3 5- Retransmit Chapter 6 Calibration Chapter 7 Error Codes & Troubleshooting Chapter 8 Specifications Appendix A- Menu Existence Conditions A- Factory Menu Description A-3 Glossary A-4 Index A-5 Memo A-6 Warranty Page No

4 Chapter Overview Features High accuracy 8-bit input A D High accuracy 5-bit output D A Fast input sample rate ( 5 times / second) Two complexity level choices Easy to use menus Pump control Fuzzy + PID microprocessor-based control Automatic programming Differential control Auto-tune function Self-tune function Sleep mode function " Soft-start " ramp and dwell timer Programmable inputs( thermocouple, RTD, ma, VDC ) Analog input for remote set point and CT Event input for changing function & set point Programmable digital filter Hardware lockout + remote lockout protection Loop break alarm Heater break alarm Sensor break alarm + Bumpless transfer RS-485, RS-3 communication Analog retransmission Signal conditioner DC power supply A wide variety of output modules available Safety UL / CSA / IEC00 EMC / CE EN636 Unique Valuable The ETR Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright, easy to read 4-digit LED display, indicating process value. The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time, with minimal overshoot during power-up or external load disturbance. The units are housed in a /4 DIN case, measuring 96 mm x 96 mm with 53 mm behind panel depth. The units feature three touch keys to select the various control and input parameters. Using a unique function, you can place 5 parameters in front of the user menu by using SEL to SEL5 contained in the setup menu. This is particularly useful to OEM's as the controller s menu can be set to suit the specific application. The ETR is powered by a VAC or -6 VAC/VDC supply, incorporating dual amp. output control relays and dual amp. alarm relays as standard. Alternative output options include SSR drive, triac, 4-0 ma and 0-0volts. The ETR is field programmable for PT00, thermocouple types J, K, T, E, B, R, S, N, L, 0-0mA, 4-0mA and voltage signal inputs, with no need to modify the unit. The input signals are digitized by using an 8-bit A to D converter. Its fast sampling rate allows the ETR to control fast processes such as pressure and flow. A standard feature, self- tune can be used to optimize the control parameters as soon as an undesired control result is observed. Unlike auto-tune, Self-tune will produce less disturbance to the process during tuning and can be used any time. 4

5 Digital communications RS-485, RS-3 or 4-0 ma retransmission are available as an additional option. These options allow the ETR-4300 to be integrated with a supervisory control system and software, or alternatively drive a remote display, chart recorder or data-logger. Three different methods can be used to program the ETR Use the ETR keys on the front panel to program the unit manually,. Use a PC and setup software to program the unit via an RS-485 or RS-3 COMM port or 3. Use the PA, a hand-held programmer, to program the unit via programming port. Although PID control has been used and proven to be an efficient controlling method by many industries, PID tuning is difficult to achieve with some sophisticated systems such as second and higher order systems, long time-lag systems, during set point change and/or load disturbances. The PID principle is based on a mathematic model which is obtained by tuning the process. Unfortunately, many systems are too complex to precisely describe in numerical terms. In addition, these systems may vary from time to time. In order to overcome the imperfection of PID control, Fuzzy Technology was introduced. What is Fuzzy Control? For example, take an automobile driver. Under different speeds and circumstances, he can control a car well based on prior experience. The driver does not need an in depth knowledge in the applied science of kinetic theory. Fuzzy Logic like our driver from above uses a linguistic control which is different from the numerical PID control. It controls the system based on experience and does not need to analyze process metrics as does PID. PID + FUZZY CONTROL MV PROCESS PID + + FUZZY Fuzzy Rule PV _ + SV Figure. Fuzzy PID System Block Language information Digital information Fuzzifier Fuzzy Inference Engine Defuzzifier Digital information The function of Fuzzy(Smarter) Logic is to adjust the PID parameters internally in order to manipulate the output value (MV) and adapt to various processes. The Fuzzy Rule works like this If temperature difference is large, and temperature rate is large, then If temperature difference is large, and temperature rate is small, then MV is large. MV is small. 5

6 PID + Fuzzy Control has been proven to be an efficient method to improve process stability as shown by the comparison curves below Temperature PID control with properly tuned PID + Fuzzy control Set point Warm Up Load Disturbance Figure. Fuzzy PID Enhances Control Stability Time 6

7 Ordering Code ETR Power Input VAC, 50/60 HZ 5-6 VAC or VDC Signal Input Standard Input Input - Universal Input Thermocouple J, K, T, E, B, R, S, N, L RTD PT00 DIN, PT00 JIS Current 4-0mA, 0-0mA. Voltage 0-V,0-5V,-5V, V Input -CT and Analog Input** CT 0-50Amp. AC Current Transformer Analog Input 4-0 ma, 0-0mA, 0-V,0-5V, V,0-0V. - 0V. Input 3 - Event Input ( EI ) Example Standard Model ETR operating voltage Input Standard Input Output Relay Output Relay Alarm Form C Relay RS- 485 Communication Interface Alarm 0 None Form C Relay A / 40VAC Output Relay A/40VAC Pulsed voltage to drive SSR, 5V/30mA 3 Isolated 4-0mA/0-0mA 0-4 Isolated - 5V/ 0-5V 5 Isolated 0-0V 6 Triac Output A / 40VAC,SSR C Pulsed Voltage to drive SSR 4V/30 ma * * * ** Alarm 0 None Relay A / 40VAC Output Communications 0 None RS-485 RS-3 3 Retransmit 4-0mA /0-0mA 4 Retransmit - 5V /0-5V 5 Retransmit 0-0V 0 None Relay A/40VAC Pulsed voltage to drive SSR, 5V / 30mA 3 Isolated 4-0mA/ 0-0mA* 4 Isolated - 5V/ 0-5V* 5 Isolated 0-0V 6 Triac Output, A / 40VAC, SSR 7 Isolated 0V / 5mA DC Output Power Supply 8 Isolated V / 40 ma DC Output Power Supply 9 Isolated 5V / 80mA DC Output Power Supply C Pulsed Voltage 4V / 30 ma Range set by front keyboard Need to order an accessory CT94- if Heater Break detection is required. * * Accessories CT94- = 0-50 Amp. AC Current Transformer OM95-3 = Isolated 4-0 ma/0-0 ma Analog Output Module OM95-4 = Isolated -5V/0-5V - Analog Output Module OM95-5 = Isolated 0-0V Analog Output Module OM94-6 = Isolated A / 40VAC Triac Output Module ( SSR ) DC94- = Isolated 0V / 5mA DC Output Power Supply DC94- = Isolated V / 40mA DC Output Power Supply DC94-3 = Isolated 5V / 80mA DC Output Power Supply CM94- = Isolated RS-485 Interface Module CM94- = Isolated RS-3 Interface Module CM94-3 = Isolated 4-0 ma/0-0 ma Retransmission Module CM94-4 = Isolated -5V/0-5V - Retransmission Module CM94-5 = Isolated 0-0V Retransmission Module CC94- = RS-3 Interface Cable (M) = ETR-4300 User's Manual Related Products PA = Hand-held Programmer for ETR Series Controller SNA0A = Smart Network Adaptor for Third Party Software, Converts 55 channels of RS-485 or RS-4 to RS-3 Network SNA0B = Smart Network Adaptor for ETR-Net Software, Converts 55 channels of RS-485 or RS-4 to RS-3 Network VPFW0 = 0 Amp. Variable Period Full Wave SSR AC Power Module VPFW50 = 50 Amp. Variable Period Full Wave SSR AC Power Module VPFW00 =00 Amp. Variable Period Full Wave SSR AC Power Module 7

8 3 Programming Port and DIP Switch Rear Terminal Front Panel ON DIP 34 Access Hole Figure.3 Access Hole Overview The programming port is used to connect to the PA hand-held programmer for automatic programming, also can be connected to ATE system for automatic testing & calibration. TC, RTD, mv DIP Switch ON OFF 3 4 Input Select Lockout 0-V, 0-5V, -5V, 0-0V 0-0 ma, 4-0 ma All parameters are Unlocked Only SP, SEL SEL5 are unlocked * Only SP is unlocked All Parameters are locked Table. DIP Switch Configuration Factory Default Setting The programming port is used for off-line automatic setup and testing procedures only. Don't attempt to make any connection to these pins when the unit is used for a normal control purpose. When the unit leaves the factory, the DIP switch is set so that TC & RTD are selected for input and all parameters are unlocked. Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode. However, the menu can still be viewed even under lockout condition. * SEL- SEL5 represent those parameters which are selected by using SEL, SEL,...SEL5 parameters contained in the Setup menu. Selected parameters are then allocated at the beginning of the user menu. 8

9 4 Keys and Displays The unit is programmed by using three keys on the front panel. The available key functions are listed in following table. Table. Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION Press for at least 3 seconds Press for at least 6 seconds Up Key Down Key Scroll Key Enter Key Start Record Key Press and release quickly to increase the value of parameter. Press and hold to accelerate increment speed. Press and release quickly to decrease the value of parameter. Press and hold to accelerate decrement speed. Select the parameter in a direct sequence. Allow access to more parameters on user menu, also used to Enter manual mode, auto-tune mode, default setting mode and to save calibration data during calibration procedure. Reset historical values of PVHI and PVLO and start to record the peak process value. Press Press Press Press for at least 3 seconds Press Reverse Scroll Key Mode Key Reset Key Sleep Key Factory Key Select the parameter in a reverse sequence during menu scrolling. Select the operation Mode in sequence. Reset the front panel display to a normal display mode, also used to leave the specific Mode execution to end up the auto-tune and manual control execution, and to quit the sleep mode. The controller enters the sleep mode if the sleep function ( SLEP ) is enabled ( select YES ). By entering correct security code to allow execution of engineering programs. This function is used only at the factory to manage the diagnostic reports. The user should never attempt to operate this function. Output Indicator Output Indicator Alarm Indicator Alarm Indicator Upper Display, to display process value, menu symbol and error code etc. ETR-4300 Process Unit Indicator Lower Display, to display set point value, parameter value or control output value etc. How to display a 5-digit number? For a number with decimal point the display will be shifted one digit right will be displayed by will be displayed by 4553 For a number without decimal point the display will be divided into two alternating phases will be displayed by 3 Buttons for ease of control setup and set point adjustment. Figure.4 Front Panel Description Table.3 Character legend A E I N S X B F J O T Y C G K P U Z c H L Q V? D h M R W = Characters displayed w/ a symbol will be displayed by will be displayed by 9

10 Power On ETR-4300 All segments of display and indicators are left off for 0.5 second. Figure.5 Display Sequence of Initial Message ETR-4300 All segments of display and indicators are lit for seconds. ETR-4300 Display program code of the product for.5 seconds. The left diagram shows program no. 4 ( for ETR-4300 ) with version 39. Program Code Program Version Program No. ETR-4300 Display Date Code and Serial number for.5 seconds. The left diagram shows Year 00, Month May (5),Date 'nd and Serial number 9. This means that the product is the 9 'nd unit produced on May 'nd, 00. Note that the month code A stands for October, B stands for November and C stands for December. Date Code Date (3'st) Month (December) Year (00) ETR-4300 Display the used hours for.5 seconds. The left diagram shows that the unit has been used for hours since production. 0

11 5 Menu Overview PV Value SV Value User Menu * SEL SEL SEL3 SEL4 SEL5 Setup Menu Hand (Manual) Control Mode Auto-tuning Mode Display Mode Default Setting Mode Calibration Mode FILE for 3 seconds To execute the default setting program Entering these modes will break the control loop and change some of the previous setting data. Make sure that the system will be stable without the controller if these modes are accessed. for 3 seconds Press for 3 seconds to enter the auto-tuning mode H C PVHI PVLO H C DV PV PV PB TI TD CJCT PVR PVRH PVRL AD0 ADG VG CJTL CJG REF SR MAG VG MAG * FUNC COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN INU DP INL INH IN INU DP INL INH OUT OTY CYC OFT OUT OTY CYC OFT AFN AMD AFT AFN AMD AFT EIFN PVMD FILT SELF SLEP SPMD SPL SPH SPF SEL SEL SEL3 SEL4 SEL5 * TIME ASP ADV ASP ADV RAMP OFST REFC SHIF PB TI TD CPB DB SP PB TI TD OHY AHY AHY PL PL for 3 seconds Display Return The menu will revert to the PV/SV display after minutes except when in the Display or Manual Mode Menus. However, the menu will revert back to the PV / SV display at any time by pressing and. * The flow chart shows a complete listing of all parameters. For actual application the number of available parameters depends on setup conditions, and should be less than that shown in the flow chart. See Appendix A- for the existence conditions of each parameter. * You can select at most 5 parameters put in front of the user menu by using SEL to SEL5 contained at the bottom of setup menu.

12 6 System Modes The controller performs close loop control under its normal control mode condition. The controller will maintain its normal control mode when you are operating user menu, setup menu or display mode, reloading default values or applying an event input signal. Under certain conditions the control will transfer to an Exception Mode. The exception modes include Sleep Mode, Manual Mode, Failure Mode, Calibration Mode and Auto-tuning Mode. All these modes perform in an open loop control except the auto-tuning mode which performs ON-OFF plus PID close loop control. The mode transfer is governed by the priority conditions. A lower priority mode can not alter a higher priority mode, as shown in Figure.6. Priority? Mode System Modes Sleep Mode See Section 4-. Manual Mode See Section 3-. Failure Mode See Section 3-6. Calibration Mode See Chapter 6. Auto-tuning Mode See Section 3-9. Normal Control Mode See Section 3-3, 3-5, 4- High Sleep Mode? No Yes Manual Mode? No Figure.6 System Mode Priority Yes Failure Mode? No Low Yes Request Calibration Mode Request Auto-tuning Mode Request Normal Control Mode The calibration mode, auto-tuning mode and normal control mode are in the same priority level. The sleep mode is in the highest priority.

13 7 Parameter Description Table.4 Parameter Description Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value SP Set point Low SPL High SPH 00.0 C (.0 F) TIME Dwell Time Low 0 High minutes 0.0 ASP Alarm Set point See Table.5, C (.0 F) ADV Alarm Deviation Value Low C ( F) High 00.0 C ( F) 0.0 C (8.0 F) ASP Alarm Set point See Table.5, C (.0 F) ADV Alarm Deviation Value Low C ( F) High 00.0 C ( F) 0.0 C (8.0 F) RAMP Ramp Rate Low 0 High C (900.0 F) 0.0 User Menu OFST REFC SHIF PB TI Offset Value for P control Reference Constant for Specific Function PV Shift (offset) Value Proportional Band Value Integral Time Value Low Low Low Low Low C ( F) 0 0 High High High High High 00.0 % C ( F) C (900.0 F) 000 sec C (8.0 F) 00 TD Derivative Time Value Low 0 High sec 5.0 CPB Cooling Proportional Band Value Low High 55 % 00 DB Heating-Cooling Dead Band Negative Value= Overlap Low High 36.0% 0 SP PB TI TD OHY AHY AHY PL PL Set point Proportional Band Value Integral Time Value Derivative Time Value Output ON-OFF Control Hysteresis Hysteresis Control of Alarm Hysteresis Control of Alarm Output Power Limit Output Power Limit See Table.5,.8 Low Low Low Low Low Low Low Low 0 High High High High High High High High C (900.0 F) 000 sec sec 55.6 C ( 00.0 F) 0.0 C (8.0 F) 0.0 C (8.0 F) 00 % 00 % 37.8 C (00.0 F) 0.0 C (8.0 F) FUNC Function Complexity Level 0 Basic Function Mode Full Function Mode 0 No communication function RS-485 interface RS-3 interface Setup Menu COMM Communication Interface Type ma analog retransmission output ma analog retransmission output V analog retransmission output 6 0-5V analog retransmission output 7-5V analog retransmission output 8 0-0V analog retransmission output PROT COMM Protocol Selection 0 Modbus protocol RTU mode 0 3

14 Table.4 Parameter Description ( continued /7 ) Contained in Basic Parameter Function Notation ADDR Display Parameter Format Description Address Assignment of Digital COMM Low Range High 55 Default Value Kbits/s baud rate 0.6 Kbits/s baud rate. Kbits/s baud rate 3.4 Kbits/s baud rate Kbits/s baud rate BAUD Baud Rate of Digital COMM Kbits/s baud rate Kbits/s baud rate 7 9. Kbits/s baud rate Kbits/s baud rate Kbits/s baud rate DATA Data Bit count of Digital COMM 0 7 data bits 8 data bits 0 Even parity PARI Parity Bit of Digital COMM Odd parity 0 No parity bit Setup Menu STOP Stop Bit Count of Digital COMM 0 One stop bit Two stop bits 0 Retransmit IN process value 0 Retransmit IN process value Retransmit IN IN difference process value 3 Retransmit IN IN difference process value AOFN Analog Output Function 4 Retransmit set point value 0 5 Retransmit output manipulation value 6 Retransmit output manipulation value 7 Retransmit deviation(pv-sv) Value AOLO AOHI Analog Output Low Scale Value Analog Output High Scale Value Low Low High High C (3.0 F) 00.0 C (.0 F) 0 J type thermocouple K type thermocouple T type thermocouple IN IN Sensor Type Selection E type thermocouple B type thermocouple R type thermocouple (0) 6 S type thermocouple 4

15 Table.4 Parameter Description ( continued 3/7 ) Contained in Basic Parameter Function Notation Display Format Parameter Description Range Default Value 7 N type thermocouple 8 L type thermocouple 9 PT 00 ohms DIN curve 0 PT 00 ohms JIS curve IN IN Sensor Type Selection 4-0 ma linear current input 0-0 ma linear current input (0) V linear Voltage input 4 0-5V linear Voltage input 5-5V linear Voltage input 6 0-0V linear Voltage input 7 Special defined sensor curve INU IN Unit Selection 0 Degree C unit Degree F unit Process unit 0 () 0 No decimal point DP IN Decimal Point Selection decimal digit decimal digits Setup Menu INL IN Low Scale Value 3 Low decimal digits High INH IN High Scale Value Low High IN no function Current transformer input 4-0 ma linear current input ma linear current input IN IN Signal Type Selection V linear voltage input 5 0-5V linear voltage input 6 7-5V linear voltage input 0-0V linear voltage input INU IN Unit Selection Same as INU DP IN Decimal Point Selection Same as DP INL INH OUT IN Low Scale Value IN High Scale Value Low Low High High Reverse (heating ) control action Output Function 0 Direct (cooling) control action 0 Relay output Solid state relay drive output Solid state relay output OTY Output Signal Type ma current module 0 5

16 Table.4 Parameter Description ( continued 4/7 ) Contained in Basic Parameter Function Notation Display Format Parameter Description Range Default Value ma current module V voltage module OTY Output Signal Type 6 0-5V voltage module 0 7-5V voltage module 8 0-0V voltage module CYC Output Cycle Time Low 0. High 00.0 sec 8.0 OFT Output Failure Transfer Mode Select BPLS ( bumpless transfer ) or 0.0 ~ 00.0 % to continue output control function as the unit fails, power starts or manual mode starts. BPLS 0 Output no function OUT Output Function PID cooling control 0 3 DC power supply module installed OTY Output Signal Type Same as OTY 0 CYC Output Cycle Time Low 0. High 00.0 sec 8.0 OFT Output Failure Transfer Mode Select BPLS ( bumpless transfer ) or 0.0 ~ 00.0 % to continue output control function as the unit fails, power starts or manual mode starts. BPLS Setup Menu 0 No alarm function Dwell timer action Deviation high alarm 3 Deviation low alarm 4 Deviation band out of band alarm 5 Deviation band in band alarm 6 IN process value high alarm 7 IN process value low alarm AFN Alarm Function 8 IN process value high alarm 9 IN process value low alarm 0 IN or IN process value high alarm IN or IN process value low alarm IN IN difference process value high alarm 3 IN IN difference process value low alarm 4 Loop break alarm 5 Sensor break or A-D fails 0 Normal alarm action Latching alarm action AMD Alarm Operation Mode Hold alarm action 0 3 Latching & Hold action 6

17 Table.4 Parameter Description ( continued 5/7 ) Contained Basic Parameter Display in Function Notation Format AFT AFN Parameter Description Alarm Failure Transfer Mode Alarm Function Range 0 Alarm output OFF as unit fails Alarm output ON as unit fails Same as AFN Default Value AMD Alarm Operation Mode Same as AMD 0 AFT Alarm Failure Transfer Mode Same as AFT 0 Event input no function SP activated to replace SP PB, TI, TD activated to replace PB, TI, TD 3 4 SP, PB, TI, TD activated to replace SP, PB, TI, TD Reset alarm output EIFN Event Input Function 5 Reset alarm output 6 Reset alarm & alarm 7 Disable Output 8 Disable Output 9 0 Disable Output & Output Lock All Parameters Setup Menu 0 Use PV as process value Use PV as process value PVMD PV Mode Selection Use PV PV (difference) as process value 3 Use PV PV (difference) as process value second time constant 0. second time constant 0.5 second time constant 3 second time constant FILT Filter Damping Time Constant of PV 4 5 seconds time constant 5 seconds time constant 6 0 seconds time constant 7 0 seconds time constant 8 30 seconds time constant 9 60 seconds time constant SELF Self Tuning Function Selection 0 Self tune function disabled Self tune function enabled 0 SLEP Sleep mode Function Selection 0 Sleep mode function disabled Sleep mode function enabled 0 7

18 Table.4 Parameter Description ( continued 6/7 ) Contained in Basic Parameter Function Notation Display Format Parameter Description 0 Range Use SP or SP (depends on EIFN) as set point Default Value Use minute ramp rate as set point SPMD Set point Mode Selection 3 Use hour ramp rate as set point Use IN process value as set point 0 4 Use IN process value as set point SPL SPH SP Low Scale Value SP High Scale Value 5 Low Low Selected for pump control High High C (3.0 F) C (83.0 F) SPF Format of set point Value 0 set point (SP) is an actual value set point (SP) is a deviation value 0 0 No parameter put ahead Parameter TIME put ahead Parameter ASP put ahead 3 Parameter ADV put ahead 4 Parameter ASP put ahead 5 Parameter ADV put ahead 6 Parameter RAMP put ahead Setup Menu SEL Select 'st Parameter 7 8 Parameter OFST put ahead Parameter REFC put ahead 0 9 Parameter SHIF put ahead 0 Parameter PB put ahead Parameter TI put ahead Parameter TD put ahead 3 Parameter CPB put ahead 4 Parameter DB put ahead Parameter SP put ahead Parameter PB put ahead Parameter TI put ahead Parameter TD put ahead SEL Select 'nd Parameter Same as SEL 0 SEL3 Select 3'rd Parameter Same as SEL 0 Calibration Mode Menu SEL4 Select 4'th Parameter Same as SEL 0 SEL5 Select 5'th Parameter Same as SEL 0 AD0 ADG VG CJTL A to D Zero Calibration Coefficient A to D Gain Calibration Coefficient Voltage Input Gain Calibration Coefficient Cold Junction Low Temperature Calibration Coefficient Low Low Low Low -360 High High High C High C 8

19 Table.4 Parameter Description ( continued 7/7 ) Contained in Basic Parameter Function Notation CJG Display Format Parameter Description Cold Junction Gain Calibration Coefficient Low Range High 99.9 Default Value REF Reference Voltage Calibration Coefficient for RTD Low High 99.9 Calibration Mode Menu SR Serial Resistance Calibration Coefficient for RTD Low High 99.9 MAG VG MAG PVHI PVLO MV ma Input Gain Calibration Coefficient Low Voltage Input Gain Calibration Coefficient ma Input Gain Calibration Coefficient Low Low Historical Maximum Value of PV Low Historical Minimum Value of PV Low Current Output Value Low 0 High High High High High High % MV Current Output Value Low 0 High % Display Mode Menu DV PV PV PB TI TD CJCT PVR Current Deviation (PV-SV) Value IN Process Value IN Process Value Current Proportional Band Value Current Integral Time Value Current Derivative Time Value Cold Junction Compensation Temperature Current Process Rate Value Low Low Low Low Low Low Low Low C High High High High High High High High C (900.0 F) 4000 sec 440 sec C 6383 PVRH Maximum Process Rate Value Low High 6383 PVRL Minimum Process Rate Value Low High

20 Input Type J_TC K_TC T_TC E_TC B_TC R_TC S_TC Range Low Range High -0 C (-84 F) 000 C (83 F) -00 C (-38 F) 370 C (498 F) -50 C (-48 F) 400 C (75 F) -00 C (-48 F) 900 C (65 F) 0 C (3 F) 80 C (3308 F) 0 C (3 F) C (34 F) 0 C (3 F) C (34 F) Input Type N_TC L_TC PT.DN PT.JS CT Linear ( V, ma) or SPEC Range Low -50 C -00 C -0 C -00 C (-48 F) (-38 F) (-346 F) (-38 F) Range High 300 C 900 C 700 C 600 C (37 F) (65 F) (9 F) ( F) 0Amp 90 Amp Table.5 Input ( IN or IN ) Range If AFN = Range of ASP same as range of PV.H, PV.L IN PV.H,PV.L IN P..H, P..L D..H, D..L IN, IN Table.6 Range Determination for ASP If AFN = Range of ASP same as range of PV.H, PV.L IN PV.H,PV.L IN P..H, P..L D..H, D..L IN, IN Table.7 Range Determination for ASP If PVMD = PV PV P, P Range of SP same as range of IN IN IN, IN Table.8 Range Determination for SP Exception If any of ASP, ASP or SP is configured with respect to CT input, its adjustment range is unlimited. 0

21 Chapter Installation Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only. To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture. This control is not to be used in hazardous locations as defined in article 500 and 505 of the National Electric Code. Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 8. Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage. If any damage due to transit, report and file a claim with the carrier. Write down the model number, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) and date code (D/C) are labeled on the box and the housing of control. Mounting Make panel cutout to dimension shown in Figure.. Set both mounting assembly options aside and insert the controller into panel cutout. Install either the mounting clamp or screw set into provided grooves. Gently tighten the screws or slide the clamp till the controller s front panel is snug against the front of the cutout. 9 mm Panel Cutout Figure. Mounting Dimensions 9 mm Panel 53 mm

22 * * * * * * * * * 3 Wiring Precautions Before wiring, verify the label for correct model number and options. Switch off the power while checking. Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded. It is recommended that the power supplied to of these units is protected by fuses or circuit breakers rated at the lowest value possible. All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools. All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring must be suitable for voltage, current, and temperature rating of the system. Use caution to avoid over-tightening the terminal screws. Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit. Verify that the ratings of the output devices and the inputs as specified in Chapter 8 are not exceeded. Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes. This electrical noise can enter and adversely affect the operation of microprocessor-based controls. For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to ground at one end only. 7.0mm max. 3.mm min. Figure. Lead Termination VAC Hz 5 VA OP OP Alarm + + COM L N C NO 3 4 C NO C NO NC AO+ TX AO TX Alarm V + AI, CT + + EI + A RTD B B Figure.3 Rear Terminal Connection Diagram ALL RELAY CONTACTS RESISTIVE A/40VAC

23 4 Power Wiring The controller is supplied with one of the following, either -6 VAC / VDC or 90-64VAC. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Fuse 90 ~ 64 VAC or ~ 6 VAC / VDC Figure.4 Power Supply Connections This equipment is designed for installation in an enclosure which provides adequate protection against electric shock. The enclosure must be connected to earth ground. - Local requirements regarding electrical installation should be rigidly observed. Precautions should be taken to prevent unauthorized access to the power terminals. 3

24 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater. In a process where the heat demand is variable, the probe should be closed to the work area. Some experiments with probe location are often required to find this optimum position. In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes. Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes the sensor might need to have different requirements such as leak-proof, anti-vibration, antiseptic, etc. Standard sensor limits of error are ±4 F (± C ) or 0.75% of sensed temperature (half that for special ) plus drift caused by improper protection or an over-temperature occurrence. This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement. 4

25 ON Thermocouple Input Wiring Thermocouple input connections are shown in Figure.5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the entire distance between the controller and the thermocouple, ensuring that the correct polarity is observed throughout. Joints in the cable should be avoided, if possible. If the length of thermocouple plus the extension wire is too long, it may affect the temperature measurement. A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce degree C temperature error approximately DIP Switch Figure.5 Thermocouple Input Wiring 0 0 The colour codes used on the thermocouple extension leads are shown in Table.. Table. Thermocouple Cable Colour Codes Thermocouple Type Cable Material British BS American ASTM German DIN French NFE T Copper(Cu) Cu Constantan ( Cu-Ni ) + white blue * blue + blue red * blue +red brown * brown + yellow blue * blue J Iron(Fe) Constantan (Cu-Ni) + yellow blue * black + white red * black +red blue * blue + yellow black * black K Nickel-Chromium ( Ni-Cr ) Nickel-Aluminum ( Ni-Al ) + brown blue * red + yellow red * yellow +red green * green + yellow purple * yellow R S Pt-3%Rh,Pt Pt-0%Rh,Pt + white blue * green + black red * green +red white * white + yellow green * green B Pt-30%Rh Pt-6%Rh Use Copper Wire +grey red * grey +red grey *grey Use Copper Wire * Colour of overall sheath 5

26 3 4 ON 7 RTD Input Wiring RTD connections are shown in Figure.6, with the compensating lead connected to terminal 9. For two-wire RTD inputs, terminals 9 and 0 should be jumpered. The three-wire RTD offers the capability of lead resistance compensation provided that the three leads should be of same gauge and equal length. Two-wire RTD s should be avoided, if possible, for the purpose of accuracy. A 0.4 ohm lead resistance of a two-wire RTD will produce degree C temperature error. ON 3 4 DIP Switch 8 Linear DC Input Wiring DC linear voltage and linear current connections for input are shown in Figure.7 and Figure.8. DC linear voltage and linear current connections for input are shown in Figure.9 and Figure.0. DIP Switch Three-wire RTD RTD Two-wire RTD 0~V, 0~5V ~5V, 0~0V Figure.6 RTD Input Wiring RTD Figure.7 Input Linear Voltage Wiring 6

27 ON DIP Switch ~0mA or 4~0mA Figure.8 Input Linear Current Wiring ~V, 0~5V ~5V, 0~0V Figure.9 Input Linear Voltage Wiring ~0mA or 4~0mA Figure.0 Input Linear Current Wiring 0 0 7

28 9 CT / Heater Current Input Wiring Heater Heater Heater 3 Heater Supply Current Transformer Contactor CT94 + Fuse Mains supply DIN Rail CT Signal Input Figure. CT Input Wiring for Single Phase Heater Contactor Three Phase Heater Power Current Transformer Fuse Mains supply CT CT Signal Input DIN Rail Figure. CT Input Wiring for Three Phase Heater Make sure that the total current through CT94- not exceed 50A rms. 8

29 0 Event Input Wiring Figure.3 Event Input Wiring Open Collector Input Switch Input The event input can accept a switch signal as well as an open collector signal. The event input function ( EIFN ) is activated as the switch is closed or an open collector ( or a logic signal ) is pulled down. Also refer to Section 4- for event input function. 9

30 + + Output Wiring Max. A Resistive Load 0V/40V Mains Supply Figure.4 Output Wiring Relay Output Direct Drive 0V /40V Mains Supply Three Phase Delta Heater Load Contactor No Fuse Breaker Three Phase Heater Power Relay or Triac (SSR) Output to Drive Contactor SSR _ + Load 0V /40V Mains Supply Internal Circuit mA / 5V Pulsed Voltage V 5V Pulsed Voltage to Drive SSR

31 + 0-0mA, 4-0mA Load Maximum Load 500 ohms Linear Current + 0-V, 0-5V -5V,0-0V - 0V Load Minimum Load 0 K ohms Linear Voltage Max.A/40V Load 0V /40V Mains Supply Triac (SSR) Output Direct Drive 3

32 + + Output Wiring Max. A Resistive Load 0V/40V Mains Supply Relay Output Direct Drive Figure.5 Output Wiring V /40V Mains Supply Three Phase Delta Heater Load Contactor No Fuse Breaker Three Phase Heater Power Relay or Triac (SSR) Output to Drive Contactor 0 0 SSR _ + Load 0V /40V Mains Supply mA / 5V Pulsed Voltage Internal Circuit 0V 5V Pulsed Voltage to Drive SSR 0 0 3

33 0-0mA, 4-0mA Load + Maximum Load 500 ohms Linear Current V, 0-5V -5V,0-0V - 0V Load + Minimum Load 0 K ohms Linear Voltage Max.A/40V Load 0V /40V Mains Supply Triac (SSR) Output Direct Drive 33

34 3 Alarm Wiring Max. A Resistive Load 0V/40V Mains Supply Relay Output Direct Drive Figure.6 Alarm Wiring V /40V Mains Supply Three Phase Delta Heater Load No Fuse Contactor Breaker Relay Output to Drive Contactor Three Phase Heater Power 34

35 4 Alarm Wiring Max. A Resistive Load 0V/40V Mains Supply Relay Output Direct Drive Figure.7 Alarm Wiring V /40V Mains Supply Three Phase Delta Heater Load No Fuse Contactor Breaker Relay Output to Drive Contactor Three Phase Heater Power 35

36 5 RS TX TX RS-485 to RS-3 network adaptor Figure.8 RS-485 Wiring SNA0A or SNA0B Shielded Twisted-Pair Wire TX TX RS-3 PC 3 3 TX DB-9 Serial Cable TX Max. 47 units can be linked 3 3 TX TX Terminator 0 ohms / 0.5W

37 6 RS TX TX PC Figure.9 RS-3 Wiring COM pin RS-3 port CC94- If you use a conventional 9-pin RS-3 cable instead of CC94-, the cable must be modified according to the following circuit diagram. To DTE ( PC ) RS-3 Port ETR-4300 TX TX COM TX TX COM RD TD GND Female DB-9 DCD RD 3TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9RI Figure. Configuration of RS-3 Cable 37

38 7 Analog Retransmission mA, 4-0mA + + Load Load + Load Indicators PLC's Recorders Data loggers Inverters etc The total effective resistance of serial loads can't exceed 500 ohms. Retransmit Current Figure. Analog Retransmission Wiring Load + -5V,0-5V - 0-0V Load + + Load Indicators PLC's Recorders Data loggers Inverters etc The total effective resistance of parallel loads should be greater than 0K Ohms. Retransmit Voltage 38

39 ON DIP Programming Port See Figure.3 in Section -3 to find the programming port location. Programmer connector and ATE connector inserted here Programmer PA Access hole on the bottom view INPT Figure.3 Programming Port Wiring Switch Unit SW6400 DMM HP 3440A Calibrator Fluke 550A NOTE The programming port is used for off-line automatic setup and testing procedures only. Don't attempt to make any connection to these jumpers when the unit is used for a normal control purpose. 39

40 Chapter 3 Programming Basic Functions This unit provides a useful parameter " FUNC " which can be used to select the function complexity level before setup. If the Basic Mode ( FUNC = BASC ) is selected for a simple application, then the following functions are ignored and deleted from the full function menu RAMP, SP, PB, TI, TD, PL, PL, COMM, PROT, ADDR, BAUD, DATA, PARI, STOP, AOFN, AOLO, AOHI, IN, INU, DP, INL, INH, EIFN, PVMD, FILT, SLEP, SPMD and SPF. Basic Mode capabilities () Input Thermocouple, RTD, Volt, ma () Input CT for heater break detection (3) Output Heating or Cooling ( Relay, SSR, SSRD, Volt, ma ) (4) Output Cooling ( Relay, SSR, SSRD, Volt, ma ), DC Power supply. (5) Alarm Relay for Deviation, Deviation Band, Process, Heater Break, Loop Break, Sensor Break, Latch, Hold or Normal Alarm. (6) Alarm Relay for Deviation, Deviation Band, Process, Heater Break, Loop Break, Sensor Break, Latch, Hold or Normal Alarm. (7) Dwell Timer (8) Heater Break Alarm (9) Loop Break Alarm (0) Sensor Break Alarm () Failure Transfer () Bumpless Transfer (3) PV Shift (4) Programmable SP Range (5) Heat-Cool control (6) Hardware Lockout (7) Self-Tune (8) Auto-Tune (9) ON-OFF, P, PD, PI, PID Control (0) User Defined Menu (SEL) () Manual Control () Display Mode (3) Reload Default Values (4) Isolated DC Power Supply If you don't need () Second setpoint () Second PID (3) Event input (4) Soft start (RAMP) (5) Remote set point (6) Complex process value (7) Output power limit (8) Digital communication (9) Analog retransmission (0) Power shut off (Sleep Mode) () Digital filter () Pump control (3) Remote lockout then you can use Basic Mode. 3 Input Press to enter Setup Mode. Press to select parameter. The upper display indicates the parameter symbol, and the lower display indicates the selection or the value of the parameter. IN Selects the sensor type and signal type for Input. Range ( Thermocouple ) J_TC, K_TC, T_TC, E_TC, B_TC, R_ TC, S_TC, N_TC, L_TC ( RTD ) PT.DN, PT.JS (Linear ) 4-0, 0-0, 0-V, 0-5V, -5V, 0-0 Default J_TC if F is selected, K_TC if C is selected. INU Selects the process unit for Input. Range C, F, PU ( process unit ) If the unit is neither C nor F, then selects PU. Default C or F. DP Selects the location of the decimal point for most ( not all ) process related parameters. Range ( For T/C and RTD ) NO.DP, -DP ( For Linear ) NO.DP, -DP, -DP, 3-DP Default -DP 40 IN INU DP

41 INL Selects the low scale value for the Linear type input. Hidden if T/C or RTD type is selected for IN. INH Selects the high scale value for the Linear type input. Hidden if T/C or RTD type is selected for IN. INL INH How to use INL and INH If4-0mAisselected selected for IN,let SL specify the input signal low ( ie. 4 ma ), SH specifies the input signal high ( ie. 0 ma ), S specifies the current input signal value, the conversion curve of the process value is shown as follows process value INH PV INL Figure 3. Conversion Curve for Linear Type Process Value SL S SH input signal S SL Formula PV = INL + ( INH INL ) SH SL Example A 4-0 ma current loop pressure transducer with range 0-5 kg/cm is connected to input, then perform the following setup IN=4-0 INL = 0.0 INU = PU INH = 5.0 DP = -DP Of course, you may select other value for DP to alter the resolution. 3 OUT&OUTTypes OUT Types OTY Selects the signal type for Output. The selection should be consistent with the output module installed. The available output signal types are RELY Mechanical relay SSRD Pulsed voltage output to drive SSR SSR Isolated zero-switching solid state relay ma linear current output ma linear current output 0- V 0- V linear voltage output 0-5 V 0-5 V linear voltage output -5 V -5 V linear voltage output 0-0V V linear voltage output OTY Selects the signal type for Output The selection should be consistent with the output module installed. The available output signal types are the same as for OTY. OTY OTY The range for linear current or voltage may not be very accurate. For 0 % output, the value for 4-0mAmaybe3.8mAto4mA;while may 4 ma; for 00 % output, the value for 4-0 ma may be 0 ma to ma. However, this deviation will not degrade the control performance at all. 4

42 3 3 Rearrange User Menu The ETR-4300 has the flexibility for you to select those parameters which are most significant to your process. The selected parameters are then given a first-order priority making them instantly accessible. SEL Selects the most significant parameter for view and change. SEL Selects the nd significant parameter for view and change. SEL3 Selects the 3rd significant parameter for view and change. SEL4 Selects the 4th significant parameter for view and change. SEL5 Selects the 5th significant parameter for view and change. Range NONE, TIME, A.SP, A.DV, A.SP, A.DV, RAMP, OFST, REFC, SHIF, PB, TI, TD, C.PB, DB, SP, PB, TI, TD When using the up-down key to select the parameters, you may not obtain all of the above parameters. The number of visible parameters is dependent on the setup condition. The hidden parameters for the specific application are also deleted from the SEL selection. Example AFN selects TIMR AFN selects DE.HI PB=0 0 TI = 0 SEL selects TIME SEL selects A.DV SEL3 selects OFST SEL4 selects PB SEL5 selects NONE Now, the upper display scrolling becomes SEL SEL SEL3 SEL4 SEL5 PV 4

43 3 4 Heat Only Control Heat Only ON-OFF Control Select REVR for OUT, Set PB to 0, SP is used to adjust the set point value, OHY is used to adjust the dead band for ON-OFF control, TIME is used to adjust the dwell timer (enabled by selecting TIMR for AFN or AFN). The output hysteresis(ohy) is enabled when the proportional band is set to 0(off). The heat only on-off control function is shown in the following diagram PV Setup ON-OFF OUT = PB=0 Adjust SP, OHY, TIME(if enabled) SP+OHY/ SP SP OHY/ OUT Action Dead band = OHY Time Figure 3. Heat Only ON-OFF Control ON OFF Time The ON-OFF control may introduce excessive process oscillation even if hysteresis is minimized. If ON-OFF control is set ( ie. PB =0), TI, TD, CYC, OFST, CPB and PL will be hidden and have no function to the system. The manual mode, auto-tuning, self-tuning and bumpless transfer will be disabled as well. Heat only P (or PD) control Select REVR for OUT, set TI to 0, SP is used to adjust set point value, TIME is used to adjust the dwell timer (enabled by selecting TIMR for AFN or AFN). When TI=0 the OFST parameter is used to adjust the offset or manual reset. Adjust CYC according to the output type (OTY).Generally, CYC= 0.5 ~ sec for SSRD and SSR, the CYC=0 ~ 0 sec for a relay output. CYC is ignored if the linear output is selected for OTY. OHY is hidden if Proportional band(pb) is not equal to 0. OFST Function OFST is measured by % with a range of %. Under a steady state, (ie. the process temperature has been stabilized) if the process value is lower than the set point by a definite value of say 5 C, while 0 C is used for PB, that is lower 5 %, then increase the OFST 5 %, and vice versa. After adjusting the OFST value, the process value will be varied and eventually, coincide with set point. Using the P control ( TI set to 0 ), the auto-tuning and self-tuning are disabled.refer to Section 3-0 " manual tuning " for the adjustment of PB and TD. The Manual reset adjustment (OFST) is not practical because the load may change from time to time and require repetitive OFST adjustments. The PID control will prevent this situation. Heat only PID control Selecting REVR(heating) for OUT, SP is used to adjust the set point value. TIME is used to adjust the dwell timer ( enabled by selecting TIMR for AFN or AFN ). PB and TI should not be set to zero. Adjust CYC according to the output type ( OTY ). Generally, CYC = 0.5 ~ sec for SSRD and SSR, the CYC = 0 ~ 0 sec for a relay output. CYC is ignored if linear output is selected for OTY. In most cases, the self-tuning can be used to substitute the auto-tuning. See Section 3-8. If self-tuning is not used (select NONE for SELF), then use auto-tuning for the new process, or set PB, TI and TD with historical values. See section 3-9 for auto-tuning operation. If the control result is still unsatisfactory, then use manual tuning to improve the control. See Section 3-0 for manual tuning. ETR contains a very sophisticated PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned. Setup P OUT = TI=0 CYC ( if RELAY, SSRD or SSR is selected for OTY ) Adjust SP, OFST, TIME ( if enabled ), PB(=0),TD Setup PID OUT = OTY CYC ( if RELAY, SSRD or SSR is selected for OTY ) SELF = NONE or YES Adjust SP, TIME ( if enabled ), PB (=0), TI(=0),Td. Td. Auto-tuning Used for new process. during initial tuning Self-tuning Used for a process any time. Manual Tuning May be used if self-tuning and auto-tuning are inadequate. 43