Instruction Manual Micro-controller X Model : PXR5/9 INP-TNPXR5/9f-E International Sales Div Sales Group Gate City Ohsaki, East Tower, -, Osaki -chome, Shinagawa-ku, Tokyo 4-, Japan http://www.fujielectric.com Phone: 8--545-78, 78 Fax: 8--545-745 http://www.fujielectric.com/products/instruments/ Thank you for your purchasing Fuji Digital Temperature Controller. Please check that the product is exactly the one you ordered and use it according to the following instructions. (Please refer to a separate operation manual for details.) Dealers are cordially requested to ensure the delivery of this Instruction Manual to hands of the endusers. NOTICE The contents of this document may be changed in the future without prior notice. We paid the utmost care for the accuracy of the contents. However, we are not liable for direct and indirect damages resulting from incorrect descriptions, omission of information, and use of information in this document. CONTENTS Contents... Check of specifications and accessories... The related documents... Safety Precautions... Index... 9. Installation/mounting.... Wiring.... Usage... 4. Display and operation... 5. Setting methods of temperature and parameters... 5 st block parameter... 5 nd block parameter... 6 rd block parameter... 7 6. Functions... 8 6- ON/OFF control... 8 6- Auto-tuning... 9 6- Self-tuning... 6-4 Alarm function [option]... 6-5 Ramp/soak function [option]... 4 6-6 Communication function [option]... 5 6-7 Digital input (DI function) [option]... 6 6-8 Other function... 7 6-9 Re-transmission output function... 8 6- Remote function... 8 7. Setting of input type and control algorithm... 9 8. Error indications... [Table ] Input type code... [Table ] Control output action code... [Table ] Input range (Standard range)... [Table 4] Alarm action type code... 4 [Table 5] Control operation type code... 5 PXR Model Code Cofiguration... 6 Specification... 7
Check of specifications and accessories Before using the controller, check if the type and specifications are as ordered. (A table of Model code configuration is given in Page 5). Check that all of the following accessories are included in the package box. Temperature controller unit Instruction manual copy Mounting fixtures pcs. I/V unit (5Ω resistor) pc. (4-mA DC input type only) Watertight packing pc. The related documents Contents Specifications Operation method Communication functions Name Catalogue MICRO-CONTROLLER X (Model:PXR5/9) OPERATION MANUAL COMMUNICATION FUNCTIONS (MODBUS) INSTRUCTION MANUAL COMMUNICATION FUNCTIONS (Z-ASCII) INSTRUCTION MANUAL Document No. ECNO:5 ECNO:46 INP-TN564-E INP-TN5644-E
Safety Precautions Before using this product, the user is requested to read the following precautions carefully to ensure the safety. Safety precautions must be taken by every user to prevent accidents. The safety requirements are classified into Warning and Caution according to the following interpretations : Warning Caution Suggesting that the user's mishandling can result in personal death or serious injury. Suggesting that the user's mishandling can result in personal injury or damage to the property. WARNING Over-temperature Protection Any control system design should take into account that any part of the system has the potential to fail. For temperature control systems, continued heating should be considered the most dangerous condition, and the machine should be designed to automatically stop heating if unregulated due to the failure of the control unit or for any other reason. The following are the most likely causes of unwanted continued heating: ) Controller failure with heating output constantly on ) Disengagement of the temperature sensor from the system ) A short circuit in the thermocouple wiring 4) A valve or switch contact point outside the system is locked to keep the heat switched on. In any application where physical injury or destruction of equipment might occur, we recommend the installation of independent safety equipment, with a separate temperature sensor, to disable the heating circuit in case of overheating. The controller alarm signal is not designed to function as a protective measure in case of controller failure.
. Warning. Installation and wiring This controller designed to be installed at the following conditions. Operating temperature - to +5 [ C ] Operating humidity 9%RH or less (Non condensation) Installation category II Pollution degree Conforming to IEC- The controller must be installed such that with the exception of the connection to the mains, creepage and clearance distances shown in the table below are maintained between the temperature probe and any other assemblies which use or generate a voltage shown in the table below. Failure to maintain these minimum distances would invalidate the EN 6 safety approval. Voltage used or generated by any assemblies Clearance (mm) Creepage (mm) Up to 5Vrms or Vdc.. Up to Vrms or Vdc..4 Up to 5Vrms or Vdc.5.6 Up to Vrms or Vdc.5. Above Vrms or Vdc Contact with our sales office. If the voltage shown above exceeds 5Vdc (i.e. hazardous voltage), the basic insulation is required between all terminals of this controller and the ground, and supplementary insulation is required for the alarm output. Isolation class of this controller is as shown below. Be sure to check that the isolation class of the controller satisfies your requirements before installation. : Basic insulation, : Non-insulation, : Functional insulation Mains (Power source) Control output (relay output) Control output (relay output) Alarm outout (AL) Alarm outout (AL) Alarm outout (AL) or Heater burnout alarm output (HB) Measured value input, CT input, Remote input Internal circuit Control output, (SSR drive output / Current output) Re-transmission Communication (RS-485) circuit Digital input (DI). 4
If there is a danger of a serious accident resulting from a failure or a defect in this unit, provide the unit with an appropriate external protective circuit to prevent an accident. The unit is normally supplied without a power switch and fuses. Make wiring so that the fuse is placed between the main power supply switch and this controller. (Main power supply: pole breaker, fuse rating: 5V, A) When wiring the power supply terminal, use vinyl insulated 6 volt cable or equivalent. To avoid the damage and failure of controller, supply the power voltage fitting to the rating. To avoid an electric shock and controller failure, do not turn ON the power before all wiring is completed. Be sure to check that the distance is kept to avoid electric shock or firing before turning the power ON. Keep away from terminals while the circuit is energized in order to avoid an electric shock and a malfunction. Never attempt to disassemble, fabricate, modify, or repair this unit because tampering with the unit may result in a malfunction, electric shock, or a fire.. Maintenance precautions Be sure to turn off the power before this controller is installed or removed in order to avoid an electric shock, malfunction, and fault. Regular maintenance is recommended a longer service life of this controller. Some parts of this controller have a limited life span, or they will be deteriorated with the lapse of time. One-year warranty is guaranteed for this unit including accessories, provided that the controller is properly used. 5
. Caution. Cautions on installation Avoid the following places for installation. A place where the ambient temperature may reach beyond the range of from to 5 C while in operation. A place where the ambient humidity may reach beyond the range of from 45 to 85% RH while in operation. A place where a change in the ambient temperature is so rapid as to cause condensation. A place where corrosive gases (sulfide gas and ammonia gas, in particular) or combustible gases are emitted. A place where the unit is subject directly to vibration or shock. A place exposed to water, oil, chemicals,steam and vapor. (if immersed with water, take the inspection by sales office to avoid an electrical leakage and firing ) A place where the unit is exposed to dust, salty air, or air containing iron particles. A place where the unit is subject to interference with static electricity, magnetism, and noise. A place where the unit is exposed to direct sunshine. A place where the heat may be accumulated due to the radiation of heat.. Caution on installation on panel Attach the supplied fixtures ( pcs.) to PXR5/9 at the top and the bottom, and fasten them using a screwdriver. The fastening torque should be approximately.5n m (.5kg cm). If the plastic fixture is fastened at excessive torque, it is split horizontally around the center, thus allowing the torque to be released. If a split appears around the center, there is no problem with the use of the instrument. (The case is made of plastic. Therefore, be careful not to fasten them excessively.) The front side of this controller conforms to NEMA 4X(equivalent with IP66). To ensure the waterproofness between the instrument and the panel, use packings that are provided as accessories in the following manner: (The improper fitting of packings will ruin the waterproofness.) q As shown in Figure, fit a packing to the case of the unit and then insert it in the panel. w Tighten screws on the fixtures so that no gaps are given between the front of controller and packing and between panels as shown in Fig.. Check that there are no deviation and deformation of packing as shown in Fig.. If panel strength is weak, it may cause a gap between the packing and the panel, thus impairing water resistance. Mounting fixture Unit Screw Packing Packing Case Case Front Packing Panel Panel Screw Mounting fixture (Bad) (Good) Fig. Fig. Fig. 6
Standard : Vertical mounting, flush on the panel. (The controller is horizontal.) When mounting the controller on tilted surface, the maximum tilt angle is (degree) from vertical. (Caution) Don t block the openings around the controller, or radiation effect will be reduced. Don t block the ventilation openings at the top of the terminal block. In the case of PXR9, place the mounting fixture into the mounting hole at the center of the main body. 7
. Precautions in wiring connection For the thermocouple sensor type, use thermocouple compensation wires for wiring. For the RTD type, use a wiring material with a small lead wire resistance and no resistance differentials among three wires. Keep input lines away from power line and load line to avoid the influence from noise induced. For the input and output signal lines, be sure to use shielded wires and keep them away from each other. If a noise level is excessive in the power supply, the additional installation of an insulating transformer and the use of a noise filter are recommended. (Example: ZMBR5- Noise Filter manufactured by TDK) Make sure that the noise filter is installed to a place such as a panel that is properly grounded. The wiring between the noise filter output terminal and the instrument power supply terminal should be made as short as possible. None of fuses or switches should be installed to the wiring on the noise filter output side because the filter effect will be degraded by such an installation. A better anti-noise effect can be expected by using stranded power supply cable for the instrument. (The shorter the stranding pitch is, the better the anti-noise effect can be expected.) For the unit with an alarm against a failure (burn-out) in the heater, use the same power line for connection of the power supplies for the heater and the controller. A setup time is required for the contact output when the power is turned on. If the contact output is used as a signal for an external interlock circuit, use a delay relay at the same time. Use the auxiliary relay since the life is shortened if full capacity load is connected to the output relay. SSR/SSC drive output type is preferred if the output operations occur frequently. [Proportional interval] relay output: seconds or more, SSR/SSC: one second or more If inductive load such as magnetic switches connected as a relay output load, it is recommended to use Z-Trap manufactured by Fuji Electric to protect a contact from switching surge and keep a longer life. Model : ENC4D-5A (power supply voltage: V) ENC47D-5A (power supply voltage: V) Where to install : Connect it between contacts of the relay control output. Example) Z-Trap connection.4 Requirement for key operation/operation in abnormalities Prior to the operation, be sure to check alarm functions, since a failure in the proper setting will result in a failure in the proper output of an alarm in case of an abnormality. A display of UUUU or LLLL will appear in case of a break in the input. Be sure to turn off the power when a sensor is replaced..5 Others Do not use organic solvents such as alcohol and benzine to wipe this controller. Use a neutral detergent for wiping the controller. 8
Index <Reference items> Confirming type specification Installation/mounting Wiring Power on *Note Usages Display and operation Setting method of temperature and parameters Functions Setting of input type and control algorithm. Operation Error indications <Description> Confirming that the delivered controller is equal to the ordered one. Outline dimensions Panel cutout dimensions Mounting method on the panel Terminal connection diagram Set value change method Basic operation method List of parameters List of input/output/alarm codes Setting of input type and ranges Selecting of control method (Note) *To start the operation, wait for about minutes after the power-on for warm up. 9
Installation/mounting Outline and Panel Cutout Dimensions Outline dimensions (unit:mm) Panel cutout dimensions (unit:mm) PXR5 96 48 Mounting fixture (fastening torque :.5N m) 78 9.5 5.5 Max 6. 4 5 6 7 8 9 - -4 5-6 4 5 6 Mounting n units Horizontal close-fit mounting (Water proof is impossible in case of horizontal close-fit mounting) Packing for water proof t t 8 Panel Terminal screw M ty PXR9 Mounting fixture (fastening torque :.5N m) 96 79.5 7-48 49-6 6-7 - -4 5-6 Mounting n units 9 +.8 96 9.5 5.5 Max TOP TOP 4 5 6 7 8 9 4 5 6 6. 9 +.8 Min 6 Min t t 8 Packing for water proof Panel Terminal screw M Note ) Panel cutout dimensions should also satisfy the above values after the panel is coated. Cautions on close-fit mounting With the power supply of VAC or more, a maximum ambient temperature is 45 C. (It is recommended to use a fan for cooling.) When there is another instrument (larger than 7mm) or a wall on the right side of this controller, be sure to install the controller keeping a space of more than mm. Cautions on wiring Wiring should be started from the left side terminal (No. to No. ). Use crimped terminals matched to the screw size. Tightening torque should be.8 N m. Do not connect anything to terminals not used.
Wiring Terminal Connection Diagram ( to 4 AC, 4V AC/4V DC) Digital input Digital input RS485 com. Digital input RS485 com. RS485 com. Digital input DI DI In the case of digital input point (the th, th, or th digit of the code N.C. 4 symbol is S ), connect the digital input terminal between terminals q and w. Remote input Remote input 4 Re-transmission output Re-transmission output 5 4 CT input Digital input CT input 4 4 4 Control output Current output SSR/SSC drive output Relay output 5 5 5 4 5 6 Control output SSR/SSC drive output Current output Relay output Remote input 5 CT input 5 6 6 In the case of digital input points + heater break alarm, or digital input points + remote specifications, connect the CT input and remote input terminals between terminals t and y. 6 Power supply 6 4V AC/DC 5/6Hz 6 6 7 Alarm output 8 COM 7 9 AL 8 Measured value inut 4 AL Thermocouple Resistance bulb Current/voltage 9 A 5 4 AL B 6 5 5 5 to 4V AC 6 B 6 6 (Note ) 5/6Hz (Note ) Note : Check the power supply voltage before installation. Note : Connect the I/V unit (5Ω resistor) (accessory) between the terminal #5 and #6 in case of current input.
Usage (Read before using) Name of Functional Parts and Functions 5 6 7 C C AL AL AL 8 PXR 4 Setting keys S S S Name Select key Up key Down key S S S Model : PXR5/9 Function The key shifting to the st, the nd or the rd block parameter, switching the display between parameter and the data at the st, the nd and the rd block. The numerical value is increased by pressing the key once. The numerical valuekeeps on increasing by pressing the key continuously. For searching parameters within the st, the nd and the rd block. The numerical value is decreased by pressing the key once. The numerical value keeps on decreasing by pressing the key continuously. For searching parameters within the st, the nd and the rd block. Display/Indication Name q w e r t y u i Process value ()/parameter name display Set value () indication lamp Set value ()/parameter setting display Auto-tuning/self-tuning indicator Control output indication lamp Alarm output (AL) indication lamp (Note ) Alarm output (AL) indication lamp (Note ) Alarm output (AL) indication lamp (Note ) Function ) Displays a process value (). ) Displays the parameter symbols at parameter setting mode. ) Displays various error indications (refer to the 8. Error indications ). The lamp is lit while a set value () is displayed. ) Displays a set value (). ) Displays the parameter settings at parameter setting mode. ) Flickers at Standby mode. 4) Displays the set value ( ) and - alternately when the witching function is used. 5) Displays the set value () and r alternately while in remote operation. The lamp flickers while the PID auto-tuning or the self-tuning is being performed. C : The lamp is lit while the control output is ON. C : The lamp is lit while the control output is ON. (Note ) The lamp is lit when the alarm output is activated. It flickers during ON-delay operation. (Note ) The lamp is lit when the alarm output is activated. It flickers during ON-delay operation. (Note ) The lamp is lit while the alarm output or the heater break alarm output is ON. The lamp flickers while in ON delay operation. (Note ) Note ) Control output and alarm function are optional. Note ) The lamp does not flicker while the timer is activated.
4 Display and operation Standby mode To perform standby operation, set "STby" as ON in the st block parameter. Standby mode: (Output) Control outputs ( and ) and alarm outputs (all) are not C C AL AL AL provided. However, depending on setting of "P-n", control action, control outputs are provided at the abnormal input. No alarm output is provided at standby mode, even in (Fault-condition). PXR Caution Be careful since the equipment does not provide output of the alarm of the main unit abnormality during the standby operation. (Control) Control is not performed. (Display) display flickers. Caution The display does not flicker while the st, nd and rd block parameters are displayed. (Setting) and parameter settings are able to perform. Operation mode Change of set value () Shift to the st, nd and rd block parameter When the lamp is lit, the set value () is displayed at the lower line. To shift to the other blocks, press the key. Switching by st block STby settings C C AL AL AL Caution Depending on the pressing time of you can select the block to shift. key, PXR The set value () can be changed. Caution After the data setting, the data are registered automatically in seconds. pressing time Shifting block About sec pressing st block About sec pressing st block About 5 sec pressing st block Switching by the key
Parameter setting mode Switching by the key Press the for sec. Parameter selection Parameter settings Shift to operating condition C C AL AL AL C C AL AL AL Operation mode Parameter setting procedure Select a parameter you want to set by pressing the or key. - Press the key to allow the parameter to change. (Under the changing condition, the parameter set value flickers). - Pressing the or key, to change the parameter set value. - After the parameter has been changed, press the key for registration. Press the once. PXR Parameter search. Press the. Press the. C C AL AL AL PXR Parameter change. Increases parameter set value Decreases parameter set value Registers parameter set value, returning to the parameter shift mode. To shift to Operation/Standby mode, press the key for sec. PXR By repeating the same procedure, the parameters can be displayed according to the parameter list shown in 5, Setting methods of temperature and parameters. Note : If the upper display () comes off (or kept distinguished), make the setting once again by adding 64 to the set value of parameter DP. 4
5 Setting methods of temperature and parameters Operation/Standby mode Alarm status Control output status Operation Standby value indication value indication When the set value () is displayed at the lower line, the lamp is lit. C C AL AL AL PXR C C AL AL AL PXR If no operation status continues for seconds, the screen is restored to the / display just after the power is turned on. Press for about sec. Press for about sec. Parameter display symbol STbY CMod ProG LACH A-L A-H LoC Parameter Standby settings st block parameter Default setting OFF AT Auto-tuning : Stop, : Standard AT start, : Low type AT start TM- Timer display Time displays indicating the remining time at the timer TM- Timer display mode. TM- Timer display AL Alarm set value (appears only with alarm action type to ). Setting range: Note A-L Alarm low limit (appears only with alarm action type 6 to ). set value Setting range: Note A-H AL AL A-L A-H Control mode Ramp/soak control Alarm latch cancel Alarm high limit set value Alarm set value Alarm low limit set value Alarm high limit set value Alarm low limit set value Alarm high limit set value Key lock Description of contents Switches RUN or Standby of the control. ON: Control standby (output: OFF, alarm: OFF) OFF: Control RUN Switches Local and Remote operations. : Local operation : Remote operation OFF: stop, run: Start, HLd: status hold Releases alarm latch. : Alarm latch release (appears only with alarm action type 6 to ). Setting range: Note (appears only with alarm action type to ). Setting range: Note (appears only with alarm action type 6 to ). Setting range: Note (appears only with alarm action type 6 to ). Setting range: Note Alarm set value (appears only with alarm action type to ). Setting range: Note (appears only with alarm action type 6 to ). Setting range: Note (appears only with alarm action type 6 to ). Setting range: Note Setting of key lock status. All parameters, MV LoC Front key Comm- Front key Communication unication 4 5 : Setting enable, : Setting disable Note ) Setting range : to %FS (in case of absolute value alarm) - to %FS (in case of deviation alarm) Some parameters may not be displayed on the screen, depending upon the types. OFF Remarks Table 4 (Page ) Note 5
Operation/Standby mode Alarm status Control output status Operation Standby value indication value indication When the set value () is displayed at the lower line, the lamp is lit. C C AL AL AL PXR C C AL AL AL PXR If no operation status continues for seconds, the screen is restored to the / display just after the power is turned on. Press for about sec. Press for about sec. Parameter display symbol P I D HYS CooL db CTrL TC TC P-n P-SL P-SU P-dP nd block parameter Parameter Proportional band Description of contents Setting range:. to 999.9% Default setting 5. ON/OFF control when P = Integral time (reset) Setting range: to sec. 4 No integral action when I = Derivative action time Setting range:. to 999.9 sec. 6. No derivative action when d = Hysteresis for ON/OFF contorol Setting range: to 5% FS Proportional band coefficient on cooling side Deadband/overlap Control algorithm Setting of decimal point position Sets the proportional band coefficient on the cooling side. (Setting range :. to.) ON/OFF control when Cool = Shifts the output value on the cooling side. (Setting range: -5. to 5.%) Type of control algorithm. (Setting range: PID, FUZZY, F).. As ordered Remarks Cycle time (control output ) Sets cycle time of control output. / Note (Setting range: to 5 sec) Cycle time (control output ) Sets cycle time of control output. / Note (Setting range: to 5 sec) Input type code Type of input As ordered Table (Page ) Lower limit of input range Lower limit of input range As ordered (Setting range: -999 to 9999) Upper limit of input range Upper limit of input range As ordered (Setting range: -999 to 9999) Select a decimal point position of display. (Setting range: to ) PID Table (Page ).. : No decimal point OF offset Shift the display of process value (). (Setting range: - to %FS) P-dF Time constant of input filter Time constant (Setting range:. to 9. sec.) 5. ALM Type of alarm /5 ALM Type of alarm Setting types of alarm action (Setting range: to 4) /9 ALM Type of alarm Table 4 (Page ) STAT Ramp/soak status Displays the current Ramp/Soak status. No setting can be made. PTn Ramp/soak execute type Selects the ramp/soak execute type. : Executes st to 4th segment.. Executes 5th to 8th segment.. Executes st to 8th segment. - Ramp target - to -8 %FS to -8 Sets the target for each ramp segment. (Setting range: to %FS) TMr st ramp segment time to. to 8th ramp segment time Sets the time for each ramp segment. (Setting range: to 99 hours and 59 minutes) TM8r TMS st soak segment time to. to TM8S 8th soak segmentl time Sets the time for each soak segment. (Setting range: to 99 hours and 59 minutes) Mod Setting of ramp/soak mode Sets ramp/soak operation mode Table 5 (Page 4) Note ) When using the heater break alarm, set the parameter TC to or more. Set the CT (current transformer) so that it measures the current of the heater connected to the control output. Disconnection of the control output cannot be detected. Never set TC / TC =. Some parameters may not be displayed on the screen, depending upon the types. 6
Operation/Standby mode Alarm status Control output status Operation Standby value indication value indication When the set value () is displayed at the lower line, the lamp is lit. C C AL AL AL PXR C C AL AL AL PXR If no operation status continues for seconds, the screen is restored to the / display just after the power is turned on. Press for about 5 sec. Press for about sec. Parameter display symbol P-n -L -H dly dly dly AhY AhY AhY AoP AoP AoP di- Parameter Control action Lower limit of Upper limit of ON delay time of alarm ON delay time of alarm ON delay time of alarm Hysteresis for alarm Hysteresis for alarm Hysteresis for alarm Additional function of alarm Additional function of alarm Additional function of alarm rd block parameter Description of contents Lower limit of (Setting range: to %FS) Upper limit of (Setting range: to %FS) ON delay time setting for alarm output (Setting range: to 9999 sec) Sets ON-OFF hysteresis for alarm output. (Setting range: to 5%FS) Additional function of alarm output (Setting range: to ) Alarm latch (:use, :not use) Alarm of error status (:use :not use) De-energized (:use :not use), Note. 7 Default setting Remarks /4 Table (Page ) %FS %FS CT Heater current value Indicates the heater current value. Hb HB alarm set value Sets current value to detect the heater break alarm. (Setting range:. to 5.A, : OFF) DI function Selects the control action. Selects digital input (DI) function (Setting range: to ) (OFF) di- DI function Selects digital input (DI) function (Setting range: to ) STno Station No. Communication station No. (Setting range: to 55) CoM Parity setting Parity setting. Baud rate is fixed at 96 bps. (Setting range: to ) PCoL Communication protocol Switches communication protocols. : Modbus protocol : Z-ASCII protocol (OFF) As ordered Ao-T Re-transmission Switches signals to be output for Re-transmission output type Ao-L Re-transmission output Lower limit of the scaling for Re-transmission output scale lower limit (Setting range: - to %) Ao-H Re-transmission output Upper limit of the scaling for Re-transmission output scale upper limit (Setting range: - to %) remo Remote input Zero point compensation value for remote input zero point adjustment (Setting range: -5 to 5%FS) rems Remote input Span point compensation value for remote input span point adjustment (Setting range: -5 to 5%FS) r-df Remote input Filter time constant for remote input. filter constant (Setting range:. to 9. second) r Remote input Remote input value (industrial value) value (Display only: -999 to 9999) dsp to dsp Parameter mask Specifying parameter mask Note 6-7 (Page 5) 6-7 (Page 5) 6-6 (Page 4) Note ) When using the heater break alarm, set the parameter TC to or more. Set the CT (current transformer) so that it measures the current of the heater connected to the control output. Disconnection of the control output cannot be detected. Never set TC / TC =. Note ) De-energized: Contact opens when the alarm ON. Some parameters may not be displayed on the screen, depending upon the types.
6 Functions 6- ON/OFF control At ON/OFF control mode,output signal is as shown below. Set parameter P = for selecting the ON/OFF control mode. Set the hysteresis to avoid chattering. (Default setting: HYS = ) Parameter setting and operation example Example : Reverse operation Parameter P P-n HYS Setting value. (or ) Any value ON HYS when increases Relation between and > < Output OFF ON ON when decreases Example : Direct operation Parameter P P-n HYS Setting value. (or ) Any value HYS ON when increases Relation between and > < Output ON OFF ON when decreases 8
6- Auto-tuning (AT) Auto-tuning is the automatic calculation and entering of the control parameters (P,I and D) into memory. Prior to the auto-tuning, complete the setting of input range (P-SL,P-SU, P-dP), a set value (), alarm setting (AL, AL), and cycle time (TC). How to start the auto-tuning Set the parameter AT as either or by using or key, and press the key to start the auto-turning. Then the point indicator at the lower right starts blinking. At the completion of Auto-tuning, the point indicator stops blinking, then parameter AT is automatically set to. When auto-tuning is cancelled or not performed. Standard type (auto-tuning at ) Low type (autotuning at %FS below.) Setting code (AT) q Standard type (AT=) w Low type (AT=) : Overshoot decreased at tuning. Start of AT End of AT Start of AT End of AT Set value () Set value () -%FS PID control PID control (a) The P.I.D. parameter calculated by auto-tuning remains even if the power is turned off. If the power is turned off before the auto-tuning is completed, you must restart the auto-tuning. (b) The may be changed greatly depending on the process, because the control output is ON/OFF action (two position operation) in the auto-tuning. So, do not use the auto-turning if the process does not allow a significant variation of. In addition, the auto-tuning should not be used in any process such as pressure control and flow control, where a quick-response is required. (c) If the auto-tuning isn t completed in four hours, the auto-tuning is suspected to fail. In this case, check the wiring and parameters such as the control action, input type, etc. (d)carry out the auto-tuning again, if there is any change in, input range (P-SL, P- or P-dP) or process condition. Perform the auto-tuning if fuzzy control is selected as the control algorithm. (e) While carring out auto-tuning, operates as shown in Figs and. (f) Execute the auto-tuning also when fuzzy control is selected in control type setting. (g) When resetting the AT parameter, set the parameter to once, then reset it. 9
6- Self-tuning ) At power on, changing a set value or the external disturbance, tuning is made automatically so that the PID parameters are re-optimized. It is useful where modification of PID parameters is required repeatably due to frequent change in process condition. If high controllability is important, select the PID or fuzzy control algorithm and use auto-tuning. ) Setting for self-tuning q Turn on the power and set the. w Select F at CTrL (control algorithm) parameter. e Turn off the power once. r Turn on the power of the whole system. The controller should be turned on at the same time with the other equipments or even later. Otherwise, the self tuning might not be performed successfully. t Self-tuning starts. Then the point indicator at the lower right corner starts blinking until the PID parameters are re-optimized. Note) Whenever it is necessary to re-try the self-tuning, please set CTrL = PID once, and then start the above setting procedure from the beginning. nd block parameter Set CTrL (control algorithm) as F. PID PID control FUZY Fuzzy control Caution F Self-tuning control Setting CTrL to F starts self-tuning. ) Self-tuning indication C C AL AL The point indicator at the lower right corner keeps blinking while self-tuning is underway. Tuning L : Dead time T : Delay time L T
4) Self-tuning is executed by any of the following conditions. q During temperature rise at power ON. w During temperature rise at changing if necessary. e When control is out of stable condition and is judged as being out of stable condition continuously. 5) Self-tuning is not executed under the following conditions: q During standby mode w During ON/OFF control e During auto-tuning r During ramp/soak operation t During input error y With dual output ( P-n 4) u When P, I, D or Ar is manually set Under the following coditions, self-tuning is canceled. q When is changed. w When Self-tuning can not be completed in about 9 hours after the start. 6) Cautions Turn on the power of the whole system. The controller should be turned on at the same time with the other equipments or even later. Otherwise, the selftuning might not be performed successfully. Don t change the while the self-tuning is executing. Once PID parameters are optimized, the self-tuning is not executed at the next power on unless is changed. After the execution of self-tuning, if the controlability is not your expected level, please select PID or FUZZY at CTrL parameter, and then, start the auto-tuning.
6-4 Alarm function (option) ) Kinds of alarm Absolute value alarm, deviation alarm, combination alarm, and zone alarm are available. (For details, see Table 4, Alarm action type codes.) ON delay function ON Alarm OFF Without ON delay function With ON delay function Energizing/de-energizing function ON Alarm OFF ON OFF ON OFF ON delay setting time Without De-energizing function With De-energing function ON OFF ON OFF Caution When the power is turned OFF or in Standby mode, even if de-energizing function is turned ON, it cannot be output (it is kept OFF). ) Alarm function No. Function Description Parameters to set q Hysteresis Set the hysteresis to avoid chattering. Alarm : Alarm : Alarm : w ON delay e Alarm latch The alarm is turned on with delay of a certain seconds as previously set after goes in the alarm band. Keeps the alarm ON status once an alarm is turend ON. To cancel the alarm latch, please take one of the following procedure. i) Turn ON the controller again. ii) Turn the alarm latch settings to OFF once. Alarm : Alarm : Alarm : Alarm : Alarm : Alarm : r Error status alarm iii) Use alarm latch cancel parameter. iv) Cancel by Digital input. v) Cancel by communication function. Alarm is turned on when error indications are displayed. t De-energizing Alarm output can be de-energized., Alarm : Alarm : Alarm : Alarm : Alarm : Alarm :
Please see the table as shown below. O: Possible combination X: Impossible combination Note Alarm latch De-energizing ON delay Alarm in error status Combination of alarm functions Without HOLD/Timer O O O X With HOLD O O Note X With Timer X O X X The alarm is not turned on the first time the measured value is in the alarm band. Instead it turns on only when the measured value goes out of the band and enters it again. Cautions on alarms No. Cautions Items/Classification Note that the ON delay function is effective for alarm in error status. Alarm in error status Even during "Err" display, alarms in error status work. Alarm at error Even when LLLL or UUUU is displayed, an alarm function works normally. indication 4 Alarm action type codes in No. to 5 are also included in No.4 to 7. Alarm action type It is, therefore, recommended to use No.4 to 7. In addition, please note code when selecting No. to 5, setting in ALM, dly, and Ahy are effective. 5 With the HB alarm, ON delay function, de-energizing function and latch HB alarm function cannot be used. 6 The minimum alarm set value is 99.9. Alarm set value 7 As the alarm action type changed, the alarm set value may also be changed accordingly. 8 Note that all of alarm outputs are not provided at the standby condition. Alarm at standby 9 Error status alarm is not provided at the standby mode. mode. The HOLD function is effective even if the value is in the hysteresis area when the power is turned ON. Select for alarm action type code to use error status alarm.
6-5 Ramp/soak function [option]. Function Changes the set value () as the time elapses according to a predetermined program pattern, as shown below. Either 4 ramp/soak x patterns or 8 ramp/soak x pattern can be programmed. The first ramp starts from the process value () just before the programming is executed. -8-7 - -4 - -5 - -6 TMr TMs TM4r TM4s TM5r TM5s TM8r TM8s Time st 4 ramp/soak and/or nd 4 ramp/soak 8 steps. Setting Select the program pattern (PTn) and set the run at ProG parameter. PTn Pattern Ramp/Soak 4 Ramp/soak pattern can not be changed while ramp/soak pro- 4 gram is running. + 8 Note: The ramp/soak program is canceled if the controller becomes to standby mode. Then, if the controller becomes to operation mode, the program doesn t run again. 4
6-6 Communication function [option] ) Function Internal data can be read/written via MODBUS or ASCII communications. ) To use the function, the following three parameters must be set. rd block parameter Set the station No. at STno (station No. setting paramter). [Sample: station No. = 8] Set the parity at COM. CoM Odd Even No parity [Sample: Odd parity] Set the communication protocols. PCoL Modbus ASCII ) Caution Station No. can be set in the range of to 55. (No communication is allowed when Modbus is selected, or Stno=.) After changing the setting of parity at COM, please power off and re-start the controller. Baud rate is fixed to 96 bps. 5
6-7 Digital input (DI function) [option] ) Function With Digital input, the follwing functions are available. q switching w Control mode; RUN/STANDBY selection e Ramp/soak RUN/RESET selection r Auto-tuning start/stop t Alarm latch cancel y Timer start/reset ) To use DI function; Select the function with the parameter di- or di- refering to the Table shown below. rd block parameter or DI function code ( to ) ) Table of DI function DI function Function Description code Set value () switching Switching between local and " " " " " " Control mode, RUN/STANDBY At standby mode, control is not provided and flickers. Auto-tuning (standard) start Start/Stop can be switched at the time of DI raising up or dropping down. 4 Auto-tuning (low ) start 5 All alarm latch cancel 6 Alarm latch cancel When this function is not used, DI is not effective. 7 Alarm latch cancel 8 Alarm latch cancel 9 ALM timer ON/OFF delay timer operation is available. The remaining ALM timer time of the timer can be checked with timer- and - ALM timer display parameters (first block). Ramp/soak RUN/RESET RUN/RESET of ramp/soak can be performed at the time of DI raising up or dropping down. 6
6-8 Other functions The parameters bal and Ar are masked at default setting. If necessary to appear these parameters, please refer to the following procedure. ) Function bal and Ar are functions to suppress overshoot. (Usually it is not necessary to change the setting.) ) If they aren't optimum value, sometime you don't get the good control. Usually it is not necessary to set them. ) "Ar"(Anti-reset wind-up) is automatically set by "Auto tuning". bal MV is calculated by adding the offset (bal) to MV, the result of PID calculation, from and. Control output (MV) % PID MV' + + Operation value MV 5% bal increase bal bal % Set value () Proportional band bal decrease MV' () Ar The integral range is ±Ar. Integral action don't work when is out of the range. Integral action Don't work Ar Ar Work Don't work Time Mask/Unmask bal and Ar To unmask q Display the "dsp" in the third block parameter and then subtract 8 from current value. w Display the "dsp4" in the third block parameter and then subtract from current value. To mask q Display the "dsp" in the third block parameter and then add 8 to current value. w Display the "dsp4" in the third block parameter and then add to current value. 7
6-9 Re-transmission output function ) Function Outputs,, MV, and DV as a unified 4 to ma signal. ) To use the Re-transmission output function, () Set the output type to be outputted to Re-transmission output at. Ao-T Output type MV DV () If output scaling is required, make the scaling setting at and. 6- Remote function ) Function Controls (set value) by inputting to 5V voltage signals by an external device. to 5V voltage signal ) To perform remote operation. () Connect the remote voltage signal to the remote input terminal. () If required, perform zero point or span point adjustment of remote input. Parameter for zero point compensation of remote input Parameter for span point compensation of remote input () Changing parameter to switches to remote operation. * is the setting for remote input filter. Use the equipment with the value set to. (set at the time of delivery) unless the change is required. 8
7 Setting of input type and control algorithm Setting of the input type * Skip this procedure if the input type is specified when you order. qplease check if the input type set at P-n is same as what you use. Choose the sensor type you use from Table shown below, and set the code at P-n. (Example) For T thermocouple, set P-n =7. (Note) Please refer to the following table for the modification of the input type. TC RTD (within Group I)* Can be modified by changing P-n. TC/RTD to 5Vdc (Group I)* 4 to madc (Group II)* Modification not possible TC : Thermocouple RTD : Resistance bulb (*Please refer to table ) wetting of input temperature range suitable for the sensor you use? Standard range to each sensor is shown in Table. Select the temperature range suitable for the equipments you use, set lower/upper limit values to P-SL / P-SU respectively. (Example) For temperature range to 8 [ C] : Set P-SL and P-SU to and 8 respectively. (Note) If the span of setting ranges is smaller than the one of minimum standard range, the accuracy (% full scale) is influenced. (Note) No standard range is given in case of to 5VDC (4 to ma DC) input. Please set the range within the following limitation. Maximum span : 9999 Lower limit : -999 Upper limit : 9999 Note: Please set P-n : Input sensor type and P-SL/P-SU/P-dP : input range setting prior to any other parameter settings. When P-n and/or P-SL/P-SU/P-dP is changed, some other parameters may also be influenced. Please check all parameters before starting control. 9
Setting of the algorithm * Read if the control doesn't work as you expect. qselect the type of control output action. Heating Cooling Control output action Reverse Direct Description As increases, MV decreases. As decreases, MV increases. As increases, MV also increases. As decreases, MV also decreases. Setting procedure Set parameter P-n = or. (Refer to Table ) Set parameter P-n = or. (Refer to Table ) wcontrol algorithm (ON/OFF, PID or fuzzy) Type of control ON/OFF control PID control Fuzzy control PID control with self-tuning. Description Output is either ON (%) or OFF (%). (Suitable when frequent output switching is inconvenient.) The output signal changes within the range at to % according to PID calculation which determine the proportional of ON to OFF in each TC (cycle time). Fuzzy operation is added to PID providing control with less overshoot. At power on, changing a set value or the external disturbance, tuning is made automatically so that the PID parameters are re-optimized. It is useful where modification of PID parameters is required repeatably due to frequent change in process condition. Setting procedure Set P =.. Refer to 6- ON/OFF control. Select PID at CTrL. Execute auto-tuning so that optimum P.I.D can be calculated automatically. (PID parameters can be set spontaneously). *Refer to 6- Auto-tuning. Select FUZy at CTrL. Then execute the auto-tuning so that FUZZY control starts. Select F at CTrL. Refer to 6- Self-tuning.
8 Error indications Error indications This controller has a display function to indicate several types of error code shown below. If any of the error codes is displayed, please eliminate the cause of error immediately. After the cause is eliminated, turn off the power once, and then re-start the controller. Error code Possible cause Control output Group q Thermocouple burnt out. w RTD (A) line burnt out. e value exceeds P-SU by 5% FS. q The RTD line (B or C) burnt out. w The RTD line (between A and B or A and C ) short. e value is below P-SL by 5%FS. r to 5 VDC or 4 to madc wiring open or short. q when the burn-out control output is set as the lower limit (standard): OFF or 4 ma or less w when the burn-out control output is set as the upper limit: ON or ma or larger I q value < -99.9 Note) In case of RTD input, "LLLL" is not displayed even if the temperature becomes below -5 C. Control is continued until the value reaches -5% FS or less, after which burn-out condition will occur. AL lamp lit Break of the heater (when provided with heater break alarm) Normal control II Incorrect range setting (P-SL/P-SU). OFF or 4mA or less ( indication flickers) not displayed Incorrect DP setting. Add 64 to set value of DP to display. Normal control
[Table ] Input type code Parameter : Group Input type Code Group Input type Code I RTD Pt (IEC) Thermocouple J K R B S T E N PL-II 4 5 6 7 8 II to 5V DC, 4 to ma DC 6 In case of 4 to ma DC input, mount a 5Ω resistor enclosed in the package box. Modification TC RTD (within Group I) to 5 V DC TC/RTD 4 to ma DC (Group I) (Group II) Input signals can be selected within the same group. Can be modified by changing "P-n". Modification is not possible. [Table ] Control output action code Parameter : Code 4 5 6 7 8 9 4 5 6 7 8 9 Output Single (Control output ) Dual Control output and. Control output action Output Output Reverse action Direct action Reverse action Direct action Reverse action Direct action --- Direct action Reverse action Output at Burn-out* Output Output Lower limit Upper limit --- Lower limit Upper limit Lower limit Lower limit Upper limit Lower limit Upper limit Upper limit Lower limit Lower limit Upper limit Lower limit Upper limit Upper limit Lower limit Lower limit Upper limit Lower limit Upper limit Upper limit Lower limit Lower limit Upper limit Lower limit Upper limit Upper limit (*) Outputs when Error Indication Group I. Please refer to 8. Error indications. This is effective even in Standby mode. Lower limit: OFF or 4mA or less Upper limit: ON or ma or more [Caution for dual output] (option) () Parameter I and D can not be set separately. () In case P = (ON/OFF control) for heating side, cooling side becomes ON/OFF control automatically. () In case Cool =., cooling side becomes ON/OFF control. And hysteresis is fixed at.5%fs.
[Table ] Input range (Standard range) Parameter :,, Input signal type Range ( C) Range ( F) Input signal type Range ( C) Range ( F) RTD (IEC) PtΩ PtΩ PtΩ PtΩ PtΩ PtΩ PtΩ PtΩ J J K K K to 5 to to 5 to 6-5 to - to -99 to 6-99 to 85 to 4 to 8 to 4 to 8 to to to 57 to 9 to -58 to -48 to 9-8 to -8 to 56 to 75 to 47 to 75 to 47 to 9 Thermocouple Thermocouple DC voltage R B S T T E E N PL-II to 5VDC to 6 to 8 to 6-5 to -5 to 4 to 8-5 to 8 to to to 9 to 7 to 9-8 to 9-8 to 75 to 47-8 to 47 to 7 to 7-999 to 9999 (Scaling is possible) Maximum span : 9999 Lower limit : -999 Upper limit : 9999 Note ) Except for the following, the input accuracy is ±.5% FS ± digit ± C (Input accuracy does not be guaranteed for the ranges of measurement other than in the table above.) R thermocouple to 5 C : in these ranges, this controller may display an incorrect B thermocouple to 4 C process value due to the characteristic of the sensor. Note ) In case a measuring range of -99 to 6 C or -99 to 85 C is used for resistance bulb input, temperatures below -99 C does not be indicated correctly. Therefore, LLLL does not appear despite a continuous fall below -99 C. Note ) If the resistance bulb or thermocouple is used at a temperature below the lowest value in the measurement range, the input accuracy cannot be guaranteed. Note 4) Addition of decimal point is impossible if the input range or span is larger than 999.9 at the RTD/thermocouple input.
[Table 4] Alarm action type code Parameter :,, Standard alarm code Absolute value alarm Deviation alarm Zone alarm Timer code Timer ALM 4 5 6 7 ALM ALM ALM ALM ALM Alarm type Action diagram Alarm type Action diagram No alarm High alarm High alarm (with hold) Low alarm (with hold) ALn Low alarm ALn 4 4 5 5 High alarm 6 6 7 7 8 8 8 9 ALM 9 9 Low alarm High/Low alarm High alarm (with hold) Low alarm (with hold) ALn ALn ALn High/Low ALn ALn alarm (with hold) High/Low deviation alarm (ALM/ independent action) High/Low absolute alarm AL AL 4 5 ALM High/Low deviation alarm High absolute /Low deviation alarm High deviation /Low absolute alarm Alarm type ON delay timer OFF delay timer 4 4 ALM 4 ON/OFF delay timer DI OUT DI OUT DI OUT AL ALn ALn ALn AL AL ALn ALn ALn ALn AL AL ALn Action diagram dlyn dlyn dlyn dlyn Alarm code with dual set value High /Low limit alarm Zone alarm Point 6 6 7 7 8 8 9 9 4 4 5 5 6 6 7 7 8 8 9 9 4 6 7 8 9 4 5 6 7 8 9 High/Low absolute alarm High/Low deviation alarm High absolute /Low deviation alarm High deviation /Low absolute alarm High/Low absolute alarm (with hold) High/Low deviation alarm (with hold) High absolute /Low deviation alarm (with hold) High deviation /Low absolute alarm (with hold) High/Low absolute alarm High/Low deviation alarm High absolute /Low deviation alarm High deviation /Low absolute alarm High/Low absolute alarm (with hold) High/Low deviation alarm (with hold) High absolute /Low deviation alarm (with hold) High deviation /Low absolute alarm (with hold) An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-L An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H An-H What is alarm with hold? The alarm is not turned ON immediately even when the process value is in the alarm band. It turns ON when it goes out the alarm band and enters again. Power ON Lower limit alarm Lower limit alarm (with hold) Power OFF (process value) off off on Power ON off on on off off Period where lower limit alarm is output Note) When alarm action type code is changed, alarm set value may also become different from previous settings. Please check these parameters, turn off the power once, and then re-start the controller, before starting control. When selecting No. to 5, setting in ALM, dly, and Ahy are effective, and output to the AL relay. ALn means alarm set value (AL, AL or AL). An-H means alarm set value (A-H, A-H or A-H). An-L means alarm set value (A-L, A-L or A-L). dlyn means alarm set value (dly, dly or dly).