Datalogic TH Series Instruction Manual

TH-TS series MICROPROCESSOR BASED TEMPERATURE CONTROLLER INSTRUCTION MANUAL Rev. 04 1 - INSTRUMENT DESCRIPTION 1 - Key P : This is used to access the programming parameters and to confirm selection. 2 - Key DOWN : This is used to decrease the values to be set and to select the parameters. If the key is held down, the user returns to the previous programming level until he exits the programming mode. Outside the programming mode it permits visualisation of the current measured by the TAHB input. 3 - Key UP : This is used to increase the values to be set and to select the parameters. If the key is held down, the user returns to the previous programming level until he exits the programming mode. Outside the programming mode it permits visualisation of the output control power. 4 - Key T : This is a key with a function programmable by par. “USrb”. It can be set to : Activate Auto-tuning and Self-tuning functions, swap the instrument to manual control, silence the alarm, change the active Set Point, deactivate control. 5 - Led OUT1 : indicates the state of output OUT1 6 - Led OUT2 : indicates the state of output OUT2 7 - Led SET : when flashing, it indicates access to the programming mode. 8 - Led AT/ST : indicates that the Self-tuning function is activated (light on) or that Auto-tuning (flashing ) is in progress. 9 - Led – Shift index: indicates that the process value is lower than the one programmed on par. “AdE”. 10 - Led = Shift index: indicates that the process value is within the range [SP+AdE ... SP-AdE] 11 - Led + Shift index: indicates that the process value is higher than the one set on par. “AdE”. 2 - PROGRAMMING 2 .1 - FAST PROGRAMMING OF THE SET POINT This procedure permits rapid programming of the active Set Point and possibly the alarm thresholds (see par 2.3) Push key “P”, then release it and the display will visualise “SP n” (where n is the number of the Set Point active at that moment) alternatively to the programmed value. To modify the value, press “UP” key to increase it or the “DOWN” key to decrease it. These keys change the value one digit at a time but if they are pressed for more than one second, the value increases or decreases rapidly and, after two seconds in the same condition, the changing speed increases in order to allow the desired value to be reached rapidly. Once the desired value has been reached, by pushing key P it is possible to exit by the fast programming mode or it is possible to visualise the alarm thresholds (see par. 2.3). To exit the fast Set programming it is necessary to push key P, after the visualisation of the last Set Point, or alternatively, if no key is pressed for approx. 15 seconds, the display will return to normal functioning automatically. 2.2 - SELECTION OF THE CONTROL STATE AND PARAMETER PROGRAMMING By pushing key "P" and holding it down for approx. 2 sec. it is possible to enter into the main selection menu. Using the "UP" or DOWN” keys, it is then possible to roll over the selections: "OPEr" to enter into the operating parameters menu "ConF" to enter into the configuration parameters menu To enter the menu “OPEr”, select the option “OPEr” and press the key “P”. The display will now show the code identifying the first group of parameters (“ ]SP “) and by pressing the “UP” and “DOWN” keys it will be possible to select the group of parameters to be modified. Once the desired group of parameters has been selected, the code identifying the first parameter of the selected group will be visualised by pushing the “P” key. Again using the “UP” and “DOWN” keys, it is possible to select the desired parameter and, if the key “P” is pressed, the display will alternatively show the parameter’s code and its programming value, which can be modified by using the “UP” or “DOWN” keys. Once the desired value has been programmed, push key “P” once more: the new value will be memorised and the display will show only the code of the selected parameter. By using the “UP” or “DOWN” keys, it is then possible to select a new parameter (if present) and modify it as described above. To select another group of parameters, keep the “UP” or “DOWN” key pressed for approx. 2 sec., afterwards the display will return to visualise the code of the group of parameters. Release the key and by using the “UP” and “DOWN” keys, it will be possible to select a new group (if present). To exit the programming mode, no key should be pressed for approx. 20 seconds, or keep the “UP” or “DOWN” pressed until exit from the programming mode is obtained. To enter the menu "ConF" a PASSWORD is required. At this request, enter, using keys “UP” and “DOWN”, the number 381 and push key “P”. If an incorrect password is entered, the instrument returns to the previous control state. If the password is correct, the display will visualise the code identifying the first group of parameters (“ ]SP “) and with keys “UP” and “DOWN” it will be possible to select the desired group of parameters The programming and exit modes for the “ConF” menu are the same as those described for menu “OPEr”. THT Series

3 - INFORMATION ON INSTALLATION AND USE 3.1 - PERMITTED USE The instrument has been projected and manufactured as a measuring and control device to be used according to EN61010-1 for the altitudes operation until 2000 ms. The use of the instrument for applications not expressly permitted by the above mentioned rule must adopt all the necessary protective measures. The instrument CAN’T be used in dangerous environments (flammable or explosive) without adequate protection. The installer must ensure that EMC rules are respected, also after the instrument installation, if necessary using proper filters. Whenever a failure or a malfunction of the device may cause dangerous situations for persons, thing or animals, please remember that the plant has to be equipped with additional devices which will guarantee safety. DATALOGIC AUTOMATION and its legal representatives do not assume any responsibility for any damage to people, things or animals deriving from violation, wrong or improper use or in any case not in compliance with the instrument’s features. 3.2 – MECHANICAL MOUNTING The instrument, in DIN case 48 x 48 mm, is designed for flush-in panel mounting. Make a hole 45 x 45 mm and insert the instrument, fixing it with the provided special bracket. We recommend that the gasket is mounted in order to obtain the front protection degree as declared. Avoid placing the instrument in environments with very high humidity levels or dirt that may create condensation or introduction of conductive substances into the instrument. Ensure adequate ventilation to the instrument and avoid installation in containers that house devices which may overheat or which may cause the instrument to function at a higher temperature than the one permitted and declared. Connect the instrument as far away as possible from sources of electromagnetic disturbances such as motors, power relays, relays, solenoid valves, etc. The instrument can be removed from its housing from the front side : it is recommended that the instrument be disconnected from the power supply when it is necessary to carry out this operation. 3.3 - ELECTRICAL CONNECTION Carry out the electrical wiring by connecting only one wire to each terminal, according to the following diagram, checking that the power supply is the same as that indicated on the instrument and that the load current absorption is no higher than the maximum electricity current permitted. As the instrument is built-in equipment with permanent connection inside housing, it is not equipped with either switches or internal devices to protect against overload of current: the installation will include a two-phase circuit-breaker, placed as near as possible to the instrument, and located in a position that can easily be reached by the user and marked as instrument disconnecting device which interrupts the power supply to the equipment. It is also recommended that all the electrical circuits connected to the instrument must be protect properly, using devices (ex. fuses) proportionate to the circulating currents. It is strongly recommended that cables with proper insulation, according to the working voltages and temperatures, be used. Furthermore, the input cable of the probe has to be kept separate from line voltage wiring. If the input cable of the probe is screened, it has to be connected to the ground with only one side. We recommend that a check should be made that the parameters are those desired and that the application functions correctly before connecting the outputs to the actuators so as to avoid malfunctioning that may cause irregularities in the plant that could cause damage to people, things or animals. 3.4 - ELECTRICAL WIRING DIAGRAM 4 – FUNCTIONS 4.1 - MEASURING AND VISUALIZATION All the parameters referring measurements are contained in the group “]InP”. We recommend to switch on and off the instrument when these parameters are modified, in order to obtain a correct measuring. For the instruments with input for temperature probes (tc, rtd) it’s possible to select, through par. “Unit”, the unit of measurement (°C, °F) and, through par. “dP” (Pt100, PTC and NTC only) the desired resolution (0=1°; 1=0,1°). The instrument allows for measuring calibration, which may be used to recalibrate the instrument according to application needs, by using par. “OFSt” and “rot”. Programming par. “rot”=1,000, in par. “OFSt” it is possible to set a positive or negative offset that is simply added to the value read by the probe before visualisation, which remains constant for all the measurements. If instead, it is desired that the offset set should not be constant for all the measurements, it is possible to operate the calibration on any two points. In this case, in order to decide which values to program on par. “OFSt” and “rot”, the following formulae must be applied : “rot” = (D2-D1) / (M2-M1) “OFSt” = D2 - (“rot” x M2) where: M1 =measured value 1 D1 = visualisation value when the instrument measures M1 M2 =measured value 2 D2 = visualisation value when the instrument measures M2 It then follows that the instrument will visualise : DV = MV x “rot” + “OFSt” where: DV = visualised value MV= measured value By using par. “FiL” it is possible to program time constant of the software filter for the input value measured, in order to reduce noise sensitivity (increasing the time of reading). In case of measurement error, the instrument supplies the power as programmed on par. “OPE”. This power will be calculated according to cycle time programmed for the PID controller, while for the ON/OFF controllers the cycle time is automatically considered to be equal to 20 sec. By using par. “InE” it is also possible to decide the conditions of the input error, allowing the instrument to give the power programmed on par. “OPE” as output. The possibilities of par. “InE” are : = Or : the condition occurs in case of over-range or probe breakage = Ur : the condition occurs in case of under-range or probe breakage = Our : the condition occurs in case of over-range or under-range or probe breakage

Using par. “diSP”, located in the group “]PAn”, it is possible to set normal visualization of the display which can be the process variable (dEF), the control power (Pou), the active Set Point (SP.F) the Set Point operating when there are active ramps (SP.o) or alarm threshold AL1 (AL1). Again in the group “]PAn” the par. “AdE” is present that defines the 3 led shift index functioning. The lighting up of the green led = indicates that the process value is within the range [SP+AdE ... SP-AdE], the lighting up of the led – indicates that the process value is lower than [SP-AdE] and the lighting up of the led + indicates that the process value is higher than [SP+AdE]. 4.2 - OUTPUTS CONFIGURATION The instrument’s outputs can be programmed by entering the group of parameters “]Out, where the relative parameters “O1F” and “O2F” (depending on the number of outputs available on the instrument) are located. The outputs can be set for the following functions : - Main control output (1.rEG) - Secondary control output (2.rEG) - Alarm output normally open (ALno) - Alarm output normally closed (ALnc) - Alarm output normally closed with led reverse indication (ALni) - Output deactivated (OFF) The coupling outputs number outputs – number alarms can be made in the group referring to the alarm to the alarm (“]AL1”). 4.3 – ON/OFF CONTROL (1rEG) All the parameters referring to the ON/OFF control are contained in the group “]rEG”. This type of control can be obtained by programming par."Cont" = On.FS or = On.FA and works on the output programmed as 1.rEG, depending on the measure, on the active Set Point “SP”, on the functioning mode "Func” and on the hysteresis "HSEt". The instrument carries out an ON/OFF control with symmetric hysteresis if “Cont" = On.FS or with asymmetrical hysteresis if “Cont” = On.Fa. The control works in the following way : in the case of reverse action, or heating (“FunC”=HEAt), it deactivates the output, when the process value reaches [SP + HSEt] in case of symmetrical hysteresis, or [SP] in case of asymmetrical hysteresis and is then activated again when the process value goes below value [SP - HSEt]. Vice versa, in case of direct action or cooling ("Func”=CooL), it deactivates the output, when the process value reaches [SP - HSEt] in case of symmetrical hysteresis, or [SP] in case of asymmetrical hysteresis and is activated again when the process value goes above value [SP + HSEt]. 4.4 - NEUTRAL ZONE ON/OFF CONTROL (1rEG - 2rEG) All the parameters referring to Neutral Zone ON/OFF control are contained in the group “]rEG”. This type of control can be obtained when 2 outputs are programmed respectively as 1rEG and 2rEG and the par. “Cont” = nr . The Neutral Zone control is used to control plants in which there is an element which causes a positive increase (ex. Heater, humidifier, etc.) and an element which causes a negative increase (ex. Cooler, de-humidifier, etc). The control functions works on the programmed outputs depending on the measurement, on the active Set Point “SP” and on the hysteresis "HSEt". The control works in the following way : it deactivates the outputs when the process value reaches the Set Point and it activates the output 1rEG when the process value goes below value [SP - HSEt], or it activates the output 2rEG when the process value goes above [SP + HSEt]. Consequently, the element causing a positive increase has to be connected to the output programmed as 1rEG while the element causing a negative increase has to be connected to the output programmed as 2rEG. If 2rEG output is used to control compressor is possible to use the “Compressor Protection” function that has the meaning to avoid compressor “short cycles”. This function allows a control by time on the output 2rEG activation, independently by the temperature control request. The protection is a “delayed after deactivation” type. This protection permits to avoid the output activation for a time programmable on par. “CPdt” (expressed in sec.); the output activation will occurs only after the elapsing of time “CPdt”. The time programmed on parameter “CPdt” is counted starting from the last output deactivation. Obviously, whether during the time delay caused by the compressor protection function, the regulator request should stop, the output activation foreseen after time “CPdt” would be erased. The function is not active programming “CPdt” =OFF. The led relative to 2rEG output blinks during the phases of output activation delay, caused by “Compressor Protection” function. 4.5 - SINGLE ACTION PID CONTROL (1rEG) All the parameters referring to PID control are contained in the group “]rEG”. The Single Action PID control can be obtained by programming par."Cont" = Pid and works on the output 1rEG depending on the active Set Point “SP”, on the functioning mode "Func” and on the instrument’s PID algorithm with two degree of freedom. In order to obtain good stability of the process variable, in the event of fast processes, the cycle time “tcr1” has to have a low value with a very frequent intervention of the control output. In this case use of a solid state relay (SSR) is recommended for driving the actuator. The Single Action PID control algorithm foresees the setting of the following parameters : "Pb" – Proportional Band "tcr1" – Cycle time of the output 1rEG "Int" – Integral Time "rS" – Manual Reset (if “Int =0 only) "dEr" – Derivative Time “FuOC” - Fuzzy Overshoot Control This last parameter allows the variable overshoots at the start up of the process or at the changing of the Set Point to be avoided.

Please remember that a low value on this parameter reduces the overshoot while a high value increase it. 1: Value “FuOC” OK 2: Value “FuOC” too high 3: Value “FuOC” too low 4.6 - DOUBLE ACTION PID CONTROL (1rEG - 2rEG) All the parameters referring to PID control are contained in the group “]rEG”. The Double Action PID control is used to control plants where there is an element which causes a positive increase (ex. Heating) and an element which causes a negative increase (ex. Cooling). This type of control can be obtained when 2 outputs are programmed respectively as 1rEG and 2rEG and the par. “Cont” = Pid. The element causing a positive increase has to be connected to the output programmed as 1rEG while the element causing a negative increase has to be connected to the output programmed as 2rEG. The Double Action PID control works on the outputs 1rEG and 2rEG depending on the active Set Point “SP” and on the instrument’s PID algorithm with two degrees of freedom. In order to obtain good stability of the process variable, in case of fast processes, the cycle times “tcr1” and “tcr2” have to have a low value with a very frequent intervention of the control outputs. In this case use of solid state relays (SSR) to drive the actuators is recommended. The Double Action PID control algorithm needs the programming of the following parameters : "Pb" – Proportional Band "tcr1" – Cycle time of the output 1rEG “tcr 2” – Cycle time of the output 2rEG "Int" – Integral Time "rS" – Manual Reset (if “Int =0 only) "dEr" – Derivative Time “FuOC” - Fuzzy Overshoot Control "Prat" - Power Ratio or relation between power of the element controlled by output 2rEG and power of the element controlled by output 1rEG. If par. “Prat” = 0, the output 2rEG is disabled and the control behaves exactly as a single action PID controller, through output 1rEG. 4.7 - AUTOTUNING AND SELFTUNING FUNCTIONS All the parameters referring to the AUTOTUNING and SELFTUNING functions are contained in the group “]rEG”. The AUTOTUNING and SELFTUNING functions permit the automatic tuning of the PID controller. The AUTOTUNING function permits the calculation of the PID parameters by means of a FAST type tuning cycle and, at the end of this operation, the parameters are stored into the instrument’s memory and remain constant during control. The SELFTUNING function (rule based "TUNE-IN") instead allows control monitoring and the continuous calculation of the parameters during control. Both functions automatically calculate the following parameters : "Pb" – Proportional Band "tcr1" – Cycle time of the output 1rEG "Int" – Integral Time "dEr" – Derivative Time “FuOC” - Fuzzy Overshoot Control and, for the Double Action PID control, also : “tcr 2” – Cycle time of the output 2rEG "Prat" - Ratio P 2rEG/ P 1rEG To activate the AUTOTUNING function proceed as follows : Press the T pushbutton, at this point the Auto-tuning function is activated and is indicated by the flashing led AT/ST. The regulator carries out several operations on the connected plant in order to calculate the most suitable PID parameters. If “Auto” = 1 or “Auto” = 2, and if, at the Auto-tuning start, the condition for the lower process value is not found (with “Func” =HEAt) than [SP- |SP/2|] or higher (with “Func” =CooL) than [SP+ |SP/2|], the display will show “ErAt” and the instrument will be swapped to normal control conditions according to the previously programmed parameters. To make the error “ErAt” disappear, swap the instrument to the OFF control (OFF) and then turn it to automatic control (rEG). The Autotuning cycle duration has been limited to 12 hours maximum. If Auto-tuning is not completed within 12 hours, the instrument will show "noAt" on the display. In case of probe error, the instrument automatically stops the cycle in progress. The values calculated by Auto-tuning are automatically stored in the instrument’s memory at the end of the correct PID parameters tuning. Note : The instrument is already programmed in our factory to carry out autotuning at every instrument switch on ("Auto" = 1). To activate the SELFTUNING function proceed as follows 1) Program par. "SELF" = yES 2) Exit from the parameter programming. 3) Connect the instrument to the controlled plant. 4) Activate Self-tuning selecting par. “tunE” in the main menu (or by correctly programming key “U”). When the Self-tuning function is active, the led AT/ST is permanently lit up and all the PID parameters ("Pb", "Int", "dEr", etc.) are no longer visualized. 4.8 - REACHING OF THE SET POINT AT CONTROLLED SPEED AND AUTOMATIC SWITCHING BETWEEN TWO SET POINTS (RISE RAMP, FALL RAMP AND DWELL TIME) All the parameters referring to the ramps functioning are contained in the group “]rEG”. It is possible to reach the set point in a predetermined time (in any case longer than the time the plant would naturally need). This could be useful in those processes (heating or chemical treatments, etc.) where the set point has to be reached gradually, in a predetermined time. Once the instrument has reached the first Set Point (SP1) it is possible to have automatic switching to the second Set Point (SP2) after a set time, thus obtaining a simple automatic thermic cycle. These functions are available for all the programmable controls (PID single and double action, ON/OFF and Neutral Zone ON/OFF). The function is determined by the following parameters : "SLor" - Gradient of rise ramp (Process value < Set point) expressed in unit/minute "SLoF" - Gradient of fall ramp (Process value > Set point) expressed in unit/minute. "dur.t" – Dwell time of Set Point SP1 before automatic switching to Set Point 2 SP2 (expressed in hrs. and min.). The functions are deactivated when the relative parameters are = InF. When the Set Point value is changed or at switch on, the instrument automatically determines which of the two values “SLor” or “SLoF” it has to use. Note: In case of PID control, if Auto-tuning is desired whilst the ramp function is active, this will not be carried out until the tuning cycle has been completed. It is therefore recommended that Auto-tuning be started avoiding activating the ramp function and, once the tuning is finished, deactivate Auto-tuning (“Auto” = OFF), program the desired ramps and, if it automatic tuning is desired, enable the Self-tuning function.

Examples with starts from values lower than SP and with decreasing of SP. 4.9 - SOFT-START FUNCTION All the parameters referring to the Soft -Start functioning are contained in the group “]rEG”. The Soft-Start function only works through PID control and allows the limitation of control power when the instrument is switched on, for a programmable period of time. This is useful when the actuator, driven by the instrument, may be damaged excess power supplied when the application is not yet in the normal rating. (ex. for certain heating elements). The function depends on the following parameters : “St.P” – Soft-Start power “Sst” – Soft-Start time (expressed in hh.mm) The possible function modes are the following : 1) If both parameters are programmed with values other than OFF, when switched on the instrument gives an output power as programmed on par. “St.P” for the time programmed on par. “SSt”. Practically, the instrument works in manual condition and switches to automatic control at the elapsing of time “SSt”. It is advisable not to program a power “St.P” that is too high as the function is not deactivated when the automatic control power is found to be lower than the programmed one. 2) If par. “St.P” = OFF and a value is set on par. “SSt” , at the switch on, the power calculated by the PID controller is divided by the time “SSt”, in order to calculate a ramp. The output power starts from 0 and is progressively increased, depending on the calculated ramp, until the “SSt” time is reached or until the power overcomes the power calculated by the PID controller. To disable the Soft-Start function simply program par. “Sst” = OFF Whenever, a measurement errors occurs during the Soft-Start execution, the function is interrupted and the instrument gives an output power as programmed on par. “OPE”. If the measurement is restored, the Soft-Start is still deactivated. If it’s desired to activate the Autotuning with Soft-Start set par. “Auto”=4. The Autotuning will start automatically at the end of programmed Soft-Start cycle at the condition that the process value is lower (with “Func” =HEAt) than [SP- |SP/2|] or higher (with “Func” =CooL) than [SP+ |SP/2|]. 4.10 – ALARM FUNCTIONING (AL1) 4.10.1 – ALARM OUTPUT CONFIGURATION The alarm is depending on the process value (AL1) and before to set his functioning it’s necessary to establish to which output the alarm has to correspond to. First of all it’s necessary to configure, in the parameters group “]Out”, the parameters relative to the outputs required as alarm (“O1F” , “O2F”) programming the parameter relative to the desired output as follows : = ALno if the alarm output has to be ON when the alarm is active, while it’s OFF when the alarm is not active = ALnc if the alarm output has to be ON when the alarm is not active, while it’s OFF when the alarm is active = ALni if the alarm output has to be ON when the alarm is not active, while it is OFF when the alarm is active but with reverse led indication (led ON= alarm OFF). Have now access at the group “]AL1”, and program on par. “OAL1” , to which output the alarm signal has to be sent. The alarm functioning is instead defined by parameters : "AL1t " – ALARM TYPE "Ab1" – ALARM CONFIGURATION “AL1” – ALARM THRESHOLD “AL1L” – LOW ALARM THRESHOLD (for band alarm) OR MINIMUM SET OF AL1 ALARM THRESHOLD (for low or high alarm) “AL1H” - HIGH ALARM THRESHOLD (for band alarm) OR MAXIMUM SET OF AL1 ALARM THRESHOLD (for low or high alarm) “HAL1” - ALARM HYSTERESIS “AL1d” – ALARM ACTIVATION DELAY (in sec.) "AL1i" – ALARM BEHAVIOUR IN THE EVENT OF MEASUREMENT ERROR "AL1t" – ALARM TYPE : the alarm output can behave in six different ways. LoAb = ABSOLUTE LOW ALARM: The alarm is activated when the process value goes below the alarm threshold set on parameter "AL1”. With this mode is possible to program the minimum and the maximum set of “AL1” by “AL1L” and “AL1H” parameters. HiAb = ABSOLUTE HIGH ALARM: The alarm is activated when the process value goes higher than the alarm threshold set on parameter "AL1". With this mode is possible to program the minimum and the maximum set of “AL1” by “AL1L” and “AL1H” parameters. LHAb = ABSOLUTE BAND ALARM: The alarm is activated when the process value goes under the alarm threshold set on parameter "AL1L" or goes higher than the alarm threshold set on parameter "AL1H". LodE = DEVIATION LOW ALARM: The alarm is activated when the process value goes below the value [SP + AL1]. With this mode is possible to program the minimum and the maximum set of “AL1” by “AL1L” and “AL1H” parameters. HidE = DEVIATION HIGH ALARM: The alarm is activated when the process value goes above the value [SP + AL1]. With this mode is possible to program the minimum and the maximum set of “AL1” by “AL1L” and “AL1H” parameters. LHdE = DEVIATION BAND ALARM: The alarm is activated when the process value goes below the value [SP + AL1L] or goes above than the value [SP + AL1H]