MPS SERIES INSTALLATION and TECHNICAL MANUAL PV AT M AL1 AL2 SP1 4 PV AT SV SV M SP1 SP2 AL1 AL2 AL3 P SP2 P MPS 4 MPS 5 PV M AL1 SV AT SP1 AL2 SP2 AL3 P MPS 9 ITALMEC ELETTRONICA P.O. Box 34 40069 ZOLA PREDOSA (Bologna) ITALY Tel. (+39)051755613-051754800 Fax 051753429 e-mail: italmec.elettronica@iol.it www.italmec-elettronica.it
MPS4 - MPS5 - MPS9 MICROPROCESSOR CONTROLLER This manual is dedicated to all MPS series microprocessor controllers (MPS 4: 48*48, MPS 5: 48*96 and MPS 9: 96*96). It contains all the necessary informations and in particular about all programming and configuration parameters. Please note that part of the parameters may not appear in a specific instrument, because they refer to hardware options or software options not installed on that instrument. IMPORTANT: This manual applies to the standard options available for the MPS series controllers. Other special options are available, which are not described in the present document. For theese models with option the present manual is supplied implemented with the relevant documentation. INDEX 1. : INSTALLATION AND OPERATOR INSTRUCTION...2 1.1. : DIMENSIONS...2 1.2. : WIRING...3 1.3. : FRONTAL DESCRIPTION...4 1.4. : SET-POINT...4 1.5. : ERROR MESSAGES...5 1.6. : OTHER INDICATORS...5 2. : CONTROLLER S PARAMETERS OPERATION...5 2.1. : CONTROLLER S PARAMETERS SETTING...6 2.2. : USE OF THE AUTOTUNING FUNCTION...7 3. : CONFIGURATION...8 3.1. : INPUT CONFIGURATION...9 3.2. : OUTPUT LOGIC AND OUTPUT SAFETY VALUE...10 3.3. : ALARMS CONFIGURATION...11 3.4. : ALARMS SETTING RANGE...12 4. : H.B. (HEATER BREAK) ALARM...13 5. : "MASKING" OF PARAMETER'S DISPLAYING...13 6. : TECHNICAL SPECIFICATION...14 7. : ORDER CODE - MODEL IDENTIFICATION...15 1
1. : INSTALLATION AND OPERATOR INSTRUCTION The State of the Art advises: 1) To keep the signal cable (probe and digital transmitter) far or indipendent from power cables and circuits. Route theese lines with screened cables. 2) To install the intrument not too close to component like contactors, motors, tranformers, inverter etc. Make electrical connections according to the following wiring diagram. Supply power to the controller with a separate line. Never connect this line directly to components that may generate electrical noise or use the controller's terminals to supply power to such components. If strong electrical noise is present, use a suitable mains filter. The internal relays are rated at 5A/250V ac on resistive loads. To increase contact life, use external contactors when the load is more than 3 4 A. Remember that, when driving reactive loads, contacts rating is lower. In this case, use external auxiliary relays. When switching noise is present, install suitable RC filters across load coils. 1.1. : Dimensions 2
1.2. : Wiring Everyone of following terminal blocks correspond to a particular model of the MPS series. The terminal blocks of your controller, if standard, is included in this page. If necessary, compare your label with following. 3
1.3. : Frontal description Legenda 1. PV Display: It shows input value. 2. SV Display: It shows Set-Point value. 3. AT Led: It shows if Autotuning function is ON. 4. M Led: Work relay. 5. AL1 Led: Alarm 1 relay 6. AL2 Led: Alarm 2 relay 7. AL3 Led: Alarm 3 relay (not present for MPS4 version). 8. SP1 Led: It shows Set-Point 1. 9. SP2 Led: It shows Set-Point 2 (if present). 10. Key: It increases the selected parameter value. 11. Key: It decreases the selected parameter value. 12. P Key: It is used to roll up parameters and to memorize selected values. 1.4. : Set-Point Display [1] PV shows input value (PROCESS VALUE). Display [2] SV shows operating Set Point value (SET VALUE), and LEDs SP1 (8) and SP2 (9) indicate which one of the two programmable Set Points is active, in instruments equipped with option 1 (see note 1, page 8). If option 1 is not installed, SP1 LED is always ON, SP2 always OFF. PUSH DESCRIPTION or Press the key to increase or decrease the Set-Point value, hold the key for quickly modify the parameter. 4
1.5. : Error Messages -In case of an open probe circuit or input value higher than full scale value, PV display (1) shows hhh. -In case of a shorted probe (Pt100 only) or input value lower than minimum scale value, PV display shows LLL. 1.6. : Other Indicators -LED M (MAIN) (4) indicates that the MAIN output is energized (relay: MPS_R_ or external SSR: MPS_S_). -LEDS AL1 (5), AL2 (6) and AL3 (7) indicate when the corresponding ALARM relay is energized. (Alarms AL2 and AL3 are options, and they may not be installed. In this case, the corresponding LEDs are always off). -AT LED is on during the AUTOTUNING process (refer to 2.2). 2. : CONTROLLER S PARAMETERS OPERATION The controller may be programmed to operate in ON/OFF or in P.I.D. control mode. -ON/OFF mode is used when the controlled system has a high thermal delay (e.g.: environments heating or cooling) or when it drives loads wich cannot be switched too often (e.g.: compressors or burners). -P.I.D. (Proportional + Integral + Derivative) operation is used when a very accurate control is needed, with loads having low thermal delays. The controller output can be continuos (0 20 ma, 4 20 ma or 0 10 V) or time proportional discontinuos (relay or external SSR). In this case the relay is energised at prefixed intervals (parameters t.c.: CYCLE TIME) with variable duty cicle, able to control the mean power supplied to the load. For relay output, the correct value for t.c., must be selected considering that short values (< 10 sec.) will shorten relay contacts life, differently long values will result a not very accurate control. Proportional action (sometimes referred as GAIN) is the control action that changes output value according to the error deviation between input value and Set-Point. This action operates in a zone around the Set-Point, whose defines the range the parameter P: PROPORTIONAL BAND. The effect of the proportional action is to stabilize the controlled variable at a constant value. Integral action (sometimes referred as RESET) is the control action that changes output value depending on the average time deviation between input value and Set-Point. This output correction is made with a speed that depends on the value of parameter i: INTEGRAL TIME. The effect of integral action is to eliminate any deviation between controlled variable and Set-Point. At first switch on, the integral can be inhibited throught the A.r. (ANTI - RESET WINDUP TIME) parameter. This allow to compensate for the reset windup effect, typical of P.I.D. controllers. Derivative action (sometimes referred as RATE) is the control action that changes the output value according to the rate of change of the controlled variable, reducing or increasing the output when the input value is fast approaching the Set-Point. This output correction is made with a speed that depends on the value of parameter d: DERIVATIVE TIME. The effect of derivative action is to reduce the over and undershoots when the system is switched on or the Set-Point is changed. Proportional, Integral and Derivative actions may be excluded by setting 0 value to the omonimous parameter. The controller operates in ON/OFF mode when P=0. 5
2.1. : Controller s Parameters Setting PUSH DESCRIPTION Press the key and select the parameter, or Increase or decrease the value with up & down key, Confirm the value and exit pushing the key. IMPORTANT: some parameters may not appear because they refer to hardware options not installed or because they were masked during the initial configuration process (see 5). TABLE 1: CONTROLLER PARAMETERS CODE PARAMETERS SETTING RANGE NOTE o.f.s. OFFSET 2nd SET POINT -199 999 / -19.9 99.9 1 A.L.1. ALARM 1 (see alarm type) 2 A.L.2. ALARM 2 (see alarm type) 2 A.L.3. ALARM 3 (see alarm type) 2 h.b. HEATER BREAK ALARM 0 99% 3 h.l. LOWER HISTERESYS 1 99 / 0.1 9.9 4 h.h. UPPER HISTERESYS 1 99 / 0.1 9.9 4 P. PROPORTIONAL BAND (GAIN) 0 999 / 0.0 99.9 5 i. INTEGRAL TIME (RESET) 0 999 sec 5 d. DERIVATIVE TIME (RATE) 0 999 sec 5 A.r. ANTI-RESET WINDUP TIME 0 999 sec 5 t.c. CYCLE TIME 1 99 sec A.t. AUTOTUNING 0, 1 6 b.l.o. KEYBOARD LOCK 0, 1, 2, 3 7 NOTE 1: o.f.s. parameters is shown only in instruments equipped with option 1: dual SET Point. The controller operates with the first Set Point (SP1), but when rear terminals 3 and 4 are shorted, the operating Set Point becomes SP2 = SP1 + o.f.s. e.g.: SP1 = 100, o.f.s. = 10: SP2 = 110 Sp1 = 100, o.f.s. = -10: SP2 = 90 When changing Set Point value (see 1.4), the operating Set Point is affected, and both SP1 and SP2 values are modified, keeping their value difference (o.f.s.) constant. NOTE 2: Alarms setting range depends on the alarm logic type, that may be field configured (see 3.3). NOTE 3: h.b. parameter is shown only in instruments equipped with the optional HEATER BREAK alarm circuitry. In these instruments, parameters A.L.2 and A.L.3 do not appear. 6
NOTE 4: parameters h.h. and h.l. operate only when the instrument is programmed for ON/OFF control (setting P=0). In this case parameters i., d., A.r. and t.c. are not used. Total histeresys (dead band) value is h.l.+ h.h., and thus it is symmetric when h.l. = h.h. and asymmetric when h.l + h.h. NOTE 5: The controller operates in P.I.D. mode if P > 0. In this case parameters h.h. and h.l. are not to be considered. NOTE 6: refer to 2.2: USE OF THE AUTOTUNING FUNCTION NOTE 7: Parameter b.l.o. may have one of four values: b.l.o. = 0: access to Set Point, Parameters and Configuration b.l.o. = 1: access to Set Point and Parameters only b.l.o. = 2: access to Set Point only b.l.o. = 3: fully locked keyboard. If b.l.o. value has been set to 2 or 3, it may be modified again only by keeping the P key depressed for at least 10 seconds. The b.l.o. parameter will be displayed and it is value may be changed to 0 or 1 to gain access to parameters. 2.2. : Use of the Autotuning Function PUSH DESCRIPTION Press the key and select the A.t. parameter, Set it = 1 Confirm and wait the controller automatically save the better parameters for the system. The controller will generate a signal to the system (to be controlled) and will analyze the load characteristics, on the base of the system response, the controller will calculate the optimum values for every single parameter P., i., d. and A.r.. This operation will last some time, depending on the system characteristics. At the end of the AUTOTUNING process the AT LED will switch off, the new parameters' values will be stored, and the controller will operate with these new values. Every time the controller will be switched on, it will use theese new parameters, and a new AUTOTUNING is not needed and will not be executed. The AUTOTUNING process may be aborted at any time, by resetting parameter A.t. value to 0 or switching off the controller. In this case the parameters will not be changed in the memory. ATTENTION: During the AUTOTUNING process the controller will operate in the ON/OFF mode, and the controlled variable may have large oscillations (overshoot). If this is considered to be dangerous, it is suggested to start the AUTOTUNING process at a set point lower than normal operation, and set the operation Set-Point only after AUTOTUNING completion. 7
3. : CONFIGURATION The instrument is software configurable, allowing user selection of input type and range, main output logic and alarm logic (for installed alarms). This process has been carried on at the factory, according to the order code, but it can be repeated by the customer if any modification is needed. Be sure to have set b.l.o. value to 0, then keep P key pressed for at least 10 seconds. The SV display (2) will show the mnemonic code of the first configuration parameter, and the PV display (1) will display the corresponding value. This may be modified using the (10) and (11) keys. Press the P key (12) to store the new value and display the following parameter. After the last parameter or after 60 seconds from last key release, the instrument quits automatically the configuration phase. TABLE 2: CONFIGURATION PARAMETERS COD PARAMETER SETTING RANGE NOTES i.s. Input shift -99 99 / -9.9 9.9 8 i.n. Input type and range see 3.1 S.h. Upper scale value -199 999 / -19.9 99.9 9 S.L. Lower scale value -199 S.h. / -19.9 S.h. 9 L.0. Main output logic & Safety value see 3.2 L.1. Alarm 1 logic see 3.3 10 L.2. Alarm 2 logic see 3.3 10 L.3. Alarm 3 logic see 3.3 10 h.a.l. Alarms histeresys 1 999 / 0.1 99.9 11 d.s.1. Parameters masking 0 127 vedi 5 d.s.2. Parameters masking 0 127 vedi 5 NOTE 8: parameter I.S. shifts (offsets) the PV value (displayed and used for control) in respect to the effective input value. NOTE 9: parameters S.h. and S.L. are the upper and lower Set Point limits. Their values must be inside the maximum range corresponding to the I.n. value selected, according to table 3. For linear inputs (current 0 20 or 4 20 ma and voltage 0 10 V) S.h. and S.L. represent also the upper and lower input scale limits (span and zero). 8
3.1. : Input Configuration PUSH DESCRIPTION Push the key for not less of 20 sec. to get into parameters configuration By pushing in sequence the key select i.n. parameter or Modify the input value, following the table n 3 and the kind of probe Confirm the value by key P and get out of parameters routine. TABLE 3: INPUT TYPE I.n. INPUT RESOLUTION MAX RANGE ORD. CODE 0 J TYPE THERMOCOUPLE 1 C 0 870 C J1 1 J TYPE THERMOCOUPLE 1 F 0 999 F J2 2 K TYPE THERMOCOUPLE 1 C 0 999 C K1 3 K TYPE THERMOCOUPLE 1 F 0 999 F K2 4 Pt100 DIN RTD 0.1 C -19.9 99.9 C P1 5 Pt100 DIN RTD 0.1 F -19.9 99.9 F P2 6 Pt100 DIN RTD 1 C -199 500 C P3 7 Pt100 DIN RTD 1 F -199 900 F P4 8 Linear 0 20 ma 1-199 999 A1 9 Linear 0 20 ma 0.1-19.9 99.9 A2 10 Linear 0 20 ma 0.01-1.99 9.99 A3 11 Linear 4 20 ma 1-199 999 A4 12 Linear 4 20 ma 0.1-19.9 99.9 A5 13 Linear 4 20 ma 0.01-1.99 9.99 A6 14 Linear 0 10 V 1-199 999 V1 15 Linear 0 10 V 0.1-19.9 99.9 V2 16 Linear 0 10 V 0.01-1.99 9.99 V3 9
3.2. : Output Logic and Output Safety Value PUSH DESCRIPTION Push the key for not less of 20 sec. to get into parameters configuration By pushing in sequence the key select L.o. parameter or Modify the value of the output logic following the table n 4 Confirm the value by key P and get out of parameters routine. TABLE 4: OUTPUT LOGIC AND OUTPUT VALUE FOR SENSOR BREAK L.O OUTPUT LOGIC OUTPUT FOR SENSOR BREAK (SAFETY) 0 Normal (heating) 0 % (Output de-energized) 1 Reverse (cooling) 0 % (Output de-energized) 2 Normal (heating) 100 % (Output energized) 3 Reverse (cooling) 100 %( Output energized) Output safety value is the value that is assigned to the main output in case of sensor breakdown or when the input signal is out of the measurement range ( when PV display reads hhh or LLL). 10
3.3. : Alarms Configuration All instruments have at least one alarm relay installed (AL1). Alarms AL2 and AL3 are options. In instruments equipped with Heater Break Alarm option, alarms AL2 and AL3 are not available. Operating logic of installed alarms is programmable. PUSH DESCRIPTION Push the key for not less of 20 sec. to get into parameters configuration By pushing in sequence the key select L._ (1, 2, 3) parameter or Modify the value of the output logic following the table n 5 Confirm the value by key P and get out of parameters routine. TABLE 5: ALARMS LOGIC (parameters L.1., L.2., L.3.) L._ ALARM LOGIC 0 Absent (not installed) or defeated 1 Lower, absolute (process) setting 2 Same as 1, but inhibited at switch on 3 Upper, absolute (process) setting 4 Same as 3, but inhibited at switch on 5 Lower, relative (deviation) setting 6 Same as 5, but inhibited at switch on 7 Upper relative, (deviation) setting 8 Same as 7, but inhibited at switch on 9 Window alarm, symmetric to Set-Point, internal on 10 Window alarm, symmetric to Set-Point, external on 11 Same as 10, but inhibited at switch on NOTE 10: The value of parameters L2 (MPS4) and L3 (MPS5 - MPS9) can be set to 12 (Heater Break Alarm). This value may be used if the instrument is equipped with the optional circuits. The order code described in 7 must contain HB in the ff fields (MPS4) or in the gg fields (MPS5 - MPS9). NOTE 11: ALARM HISTERESYS: h.a.l. parameter Alarm histeresys is asymmetric, and it's position depends on the alarm type. Refer to previous drawing. 11
3.4. : Alarms Setting Range Alarms setting range (range of parameters A.L.1., A.L.2. and A.L.3.) depend on the value assigned to parameters L.1., L.2. and L.3.. ALARMS SETTING RANGE For ABSOLUTE SETTING alarms (L_= 1, 2, 3, 4) and for RELATIVE SETTING alarms (L_= 5, 6, 7, 8), the setting range is: AL_ = -199 999 or -19.9 99.9 For WINDOW SIMMETRICS TYPE alarms (L_ = 9, 10, 11),the setting range is: AL_ = 0 999. If the alarm has an absolute (process) setting (L._ = 1, 2, 3 or 4), A.L._ may be set to any value inside the instrument range, and the alarm operation will not depend on Set-Point value, but will depend just on A.L._ value. If L._. is set to 1 or 2 (LOWER ABSOLUTE ALARM) the AL_ relay will be ON when the input is lower than A.L._ value. If L._. is set to 3 or 4 (UPPER ABSOLUTE ALARM) the AL_ relay will be ON when the input is higher than A.L._. value. If the alarm has a relative (deviation) setting (L._. set to 5, 6, 7, or 8), the alarm operation point will be SP + A.L._., where SP is the Set-Point value and A.L._. is the value set for the alarm (A.L._. may be set positive or negative). Eg: SP = 100, A.L._. = 20, alarm will operate at 100+20 = 120 SP = 100, A.L._. = -20, alarm will operate at 100-20 = 80. If L._. is set to 5 or 6 (LOWER RELATIVE ALARM), the AL_ relay will be ON when the input is lower than SP + A.L._. If L._. is set to 7 or 8 (UPPER RELATIVE ALARM), the AL_ relay will be ON when the input is higher than SP+A.L._. If the alarm has a window setting (L._. set to 9, 10 or 11) the AL_ relay will be ON inside (L._.= 9) or outside (L._.=10 or 11) a symmetrical window centered on the Set-Point. Window widht is 2 x A.L._. eg: if L._.= 9, SP = 100 and A.L._. = 10, the relay will be ON for inputs inside the range 100-10 = 95 to 100 + 10 = 110. if L._.= 10, SP = 100 and A.L._. = 10, the relay will be ON for inputs lower than 100-10 = 90 and higher than 100 + 10 = 110. If L._. is set to 2, 4, 6, 8 or 11, the alarm operation is inhibited when the instrument is switched on. The alarm circuit will be allowed to operate the first time the input will reach an alarm condition, and the relay will be ON only if the input reaches again an alarm condition. If L._. is set to 1 and A.L._. = 30, then the relay will be ON when the input is lower than 30, but if the input is lower than 30 at switch on, the alarm WILL NOT operate. When the input reaches 30, alarm circuit is reset and the alarm will operate the first time the input reaches a value lower than 30. 12
4. : H.B. (HEATER BREAK) ALARM This option (n.2) is available only in instruments equipped with discontinuous output (R: relay or S: external SSR drive). It requires an external current transformer (CT) with 200 A secondary rating,having a primary current rating higher than the maximum current on load. Italmec elettronica can supply suitable current transformers with 25, 50 or 100 A primary rating. The value of parameter h.b. is set in percent of the current transformer s primary rating (0 to 99%). Alarm histeresys is 1%. To set the correct h.b. value, we suggest to operate when the controller s output is continuosly energized (input value much lower than Set-Point), and decrease the value set for h.b. parameter, starting from 99%, until AL3 relay switches off. This is the threshold value of h.b.. To avoid abnormal alarm interventions, we suggest to use a value lower than this. It is possible to set h.b. value when the controller is operating at the Set-Point. In this case, after any change of the value of h.b., the operator must wait for two or three cycles of the main output to check for AL3 operation and determine the threshold value of h.b. After setting the value of h.b., the instrument will continuosly monitor load current and, if for any cause this decreases to a percent value lower than h.b. setting, AL3 relay will be energised. The instrument compensates automatically for line voltage fluctuations. 5. : "MASKING" OF PARAMETER'S DISPLAYING Configuration parameters d.s.1. and d.s.2. are used to "mask" the display of controller's parameters (table 1). Masking inhibits the display parameter's code and value, and is useful for two purposes: 1: parameters related to hardware options not installed or software options not relevant for the operator are skipped during the programming phase, simplifying operator's work 2: critical parameters (e.g.: alarms) can be programmed to the correct value, then masked. In this way the operator cannot modify the value, configurated by our customer. The value of d.s.1. and d.s.2. ranges from 0 to 127, and is obtained by adding to the parameters to be masked the fixed value assigned according to the following tables: d.s.1. = 0 127 d.s.2. = 0 127 o.f.s. 1 h.l. 1 A.L.1. 2 h.h. 2 A.L.2. 4 P. 4 A.L.3. 8 i. 8 h.b. 16 d. 16 A.t. 32 A.r. 32 b.l.o. 64 t.c. 64 Instrument is supplied alredy configurated with the correct values for d.s.1. and d.s.2. according to the installed options and software configuration as per order code.to mask a parameter, add the value corresponding to that parameter to the indicated d.s.1. or d.s.2. value. 13
6. : TECHNICAL SPECIFICATION Installation: Panel assembly Case: Black ABS, autoestingush degree V0 as UL94 Frontal protection: IP 65, Nema 4X Precision: ± 0.2 % v.f.s. for Pt100 and Thermocouple input ± 0.1 % v.f.s. for ma and V input Sampling time: 400 msec. Functioning temperature: - 10 + 55 C Stocking temperature: -10 +70 C Absorbed Power: 5 VA Maximum Humidity: 90% not condensing Dielectric rigidity: Like EN 61010-1 CE branding: This instrument is branded CE and it is conforming to directive 89/336/CEE. (Reference standard EN 61000-6-3 and EN 61000-6-2) and to directive 73/23/CEE and 93/68/CEE (Reference standard EN 61010-1). Installation Category: II 14
7. : ORDER CODE - MODEL IDENTIFICATION The label on the side of the case contains model identification code and other informations, including serial number and power supply voltage. The model order code contains the following data: MPS- a - b - c - dd - ee - ff - gg - h - i - l where the letter legenda is: a: panel size: 4: 48 x 48, 124 mm depth 5c: 48 x 96, 90 mm depth 9: 96 x 96, 85 mm depth b: output type: A: 4 20 ma dc (on request, 0 20 ma dc) R: relay, 5A/250V ac S: 24 V dc drive for external SSR V: 0 10 V dc c: control type: 1: ON/OFF 3: P.I.D. with AUTOTUNING dd: input type and range: P1: Pt100, -19.9 99.9 C P2: Pt100, -19.9 99.9 F P3: Pt100, -199 500 C P4: Pt100, -199 900 F J1: J type TC, 0 870 C J2: J type TC, 0 999 F K1: K type TC, 0 999 C K2: K type TC, 0 999 F A1: 0 20 ma dc, resolution 1 A2: 0 20 ma dc, resolution 0.1 A3: 0 20 ma dc, resolution 0.01 A4: 4 20 ma dc, resolution 1 A5: 4 20 ma dc, resolution 0.1 A6: 4 20 ma dc, resolution 0.01 V1: 0 10 V dc, resolution 1 V2: 0 10 V dc, resolution 0.1 V3: 0 10 V dc, resolution 0.01 ee: alarm 1 (always installed) logic: refer to table 5 (default configuration is 01) ff: alarm 2 (optional) logic: refer to table 5 gg: alarm 3 (optional) logic refer to table 5. If the heater break alarm option (HB) is installed, set gg = HB and ff = 00 (alarm 2 is not available). h: output logic and output safety value: refer to table 6 i: options: 0: none 1: dual Set Point, selected with external contact 2: heater break alarm l: power supply: 0: 110/220 V ac 1: 110 V ac 2: 220 V ac 3: 24 V ac 15