Document 400260

Instruction Manual
Digital Temperature Controlling and Monitoring Unit
ThermControl TC400-RMR
44866 Bochum – Gewerbestraße 17
Tel.:
+49 2327 9837-0
Fax:
+49 2327 9837-20
e-mail:
[email protected]
Table of Contents
1
2
3
Identification of Type of Device ................................................................... 3
Assembly........................................................................................................ 4
Electric Connection ....................................................................................... 4
3.1
Installation Instructions............................................................................. 4
3.2
Connection of the Operator’s and Indicator Unit TC400-PA .................... 5
3.3
Connection ATEX-Limiter TC400-LI......................................................... 5
3.4
Terminal Diagram ..................................................................................... 6
4 Start-Up........................................................................................................... 7
4.1
Display Elements...................................................................................... 7
4.2
Operating Element.................................................................................... 9
5 Operation........................................................................................................ 9
5.1
In Operation.............................................................................................. 9
5.2
Parametrization ...................................................................................... 10
5.2.1
Menu Structure................................................................................ 10
5.2.2
Starting the parameter menu and navigation.................................. 10
5.2.3
Parameter........................................................................................ 11
6 Extended Description of Functions ........................................................... 19
6.1
Current Monitoring.................................................................................. 19
6.2
Group interrupts (Output at Cascade Module TC400-CM) .................... 20
6.3
Setpoint Selection................................................................................... 20
6.4
Parameter 111 "Switching Off Controller Outputs" ................................ 20
6.5
Parametrization ...................................................................................... 20
01/13-4.0-3.1
1
Safety Regulations
The device may only be taken into operation by an electrically skilled person or
instructed persons who are familiar with the valid regulations of operational safety
and accident prevention. Please consider the VDE regulations as well as the local
regulations especially with regard to protective measures.
• Concerning transport, storage and operation, please observe the requirements
according to EN 60068-2-6 (according the technical data).
• Unauthorised alterations will terminate the warranty.
• The device is not suitable for use in hazardous areas and must be built in a fire
protection cabinet / electrical protection cabinet (switch gear cabinet). Dust
and humidity may lead to interferences of function.
• Please care at all outputs at capacitive and inductive loads for a sufficient
suppressor circuit. A missing or damaged suppressor circuit may lead to failure malfunction of the device.
• The device must be built in under special consideration of the required distances according to VDE 0106 part 100.
Intended Use
Within the device combination together with the cascade module TC400-CM and
the ATEX-limiter TC400-LI the temperature monitoring unit TC400-RMR presents
the main unit with four independent temperature channels.
The device combination is assembled by means of the back-mounted bus connecter TC400-BC.
A maximum of 12 pieces TC400-RMR may be connected to the TC400-CM.
The module may only be operated for temperature controlling in connection with
the device group TC400-CM and TC400-LI.
Scope of Supply
The supply contents the controller module TC400-RMR with screw-type terminals
and 2 pieces of 5-pole bus connector TC400-BC.
01/13-4.0-3.1
2
1
Identification of Type of Device
The identification plate is at the side of the device. The connected power supply
must be identical with the power supply given on the identification plate.
All necessary adjustments are given in this instruction manual.
Nevertheless, should any difficulties occur during the start-up, we ask you to get
in contact with us. Not allowed manipulation at the device will lead to the expiry of
the warranty claim!
Read this instruction manual before taking the device into operation. Keep the
instruction manual at a place which is at every time accessible for all users.
For technical queries:
Phone: +49 2327 9837-0
Fax: +49 2327 9837-20
e-mail: [email protected]
Indication on the type plate:
Type:
TC400-RMR-option
1. digit
2. digit
3. digit
-Options
01/13-4.0-3.1
R = Measurement input Pt100
T = Measurement input thermo element type K
A = Analog Input
for later use
R = Output relay
D = Output semiconductor
PID = activated PID-controller
0-5V (Analog input 0-5V)
3
2
Assembly
The temperature controller TC400-RMR is built in a 45 mm cabinet. The assembly is executed on a top-hat rail (TS35) 35 x 7.5 mm.
The supplied bus connections will be plugged into each other and will be fixed on
the top-hat rail (nose to the left side). Hereafter the controller can be snapped on.
For the release of the controller draw the fixing strap with a screwdriver downwards and take off upwards the controller and unhook it.
In order to reduce off times when changing the controller, all terminals are designed in a pluggable version (permanent wiring).
6,7
45
114,5
99
3
Electric Connection
3.1
Installation Instructions
When determining the material for the cables, during the installation, when protecting the device and for the electric connection of the device the regulations of
VDE100 “Regulations for the erection of electrical power installations with nominal
voltages lower 1.000 V” or the respective regulation of the country must be considered.
The electric connection may only be carried out by qualified personnel.
The electromagnetically compatibleness is in accordance with norms and regulations given in the technical data. Protect the device during the installation and
during the operation against electrostatic discharge.
Besides an inaccurate installation also falsely adjusted parameter may affect the
subsequent process in its correct function or may lead to damages. The adjustments should only be possible for qualified personnel (locking parameters for
01/13-4.0-3.1
4
non-operating personnel). In this connection, please consider the appropriate
safety regulations.
Attention! At inappropriate adjustment of the parameter an instable control is
possible. The actual value should therefore be controlled with regard to its stability and knowledge of the controlled system should be collected.
The load circuit must be protected to the maximum relay current to avoid, in case
of a short circuit here, a weld fuse of the contacts.
Separate the device from the supply system when parts may be touched which
are under tension.
3.2
Connection of the Operator’s and Indicator Unit TC400-PA
At the temperature controller TC400-RMR it is possible to connect over a frontsided RJ45-socket (exclusively) the operator’s and Indicator module TC400-PA
by means of a high-quality network data cable, execution at least CAT 5. The
power supply and the data communication for the display is executed by the data
cable. The maximum cable length is 10 m.
3.3
Connection ATEX-Limiter TC400-LI
The temperature controller TC400-RMR provides a digital 24V-input for a serial
communication with the ATEX limiter TC400-LI. The terminal is indicated with
ATX.
Should the ATEX module TC400-LI be feeded with a separate voltage, a 0 V
connection must be produced with the clamp GND. The ATX clamp is decoupled
in high-resistance.
When connecting the limiter, the channel 5 at the indicator module will be activated to display the set und actual value of the limiter.
01/13-4.0-3.1
5
Terminal Diagram
Tout
15
Tin14
Iout
10
Iin
9
Tin
13
11
AL1
32
31
Communication
ATEX limiter
44
12
AL2
Alarm output 1
43
Alarm output 1
8
ATX
Reset
24
FUSE
Fuse
monitoring
20
RST
Tout16
3.4
Analog output
actual temperature value
Analog input
setpoint selection
Analog output
thyristor power controller
Analog input
Current monitoring
Analog input 0-5 V
+5V
Input sensor 1 - 4
GND
+5V
GND
+5V
GND
FE FK F- FE FK F- FE FK F- FE FK F1 2 3 5 6 7 17 18 19 21 22 23
Channel 3
Channel 2
Channel 1
TC 400-RMR
Indicator module
TC400-PA
BUS IN
Channel 4
Channel 1
+5V
26
14
25
13
Channel 2
GND
28
24
27
23
Channel 3
Relay output 1 - 4
30
34
29
33
Channel 4
Please regard the appropriate instruction regulations for the details of the electric
connection and typical circuits.
01/13-4.0-3.1
6
4
Start-Up
4.1
Display Elements
The description refers to the operator’s and indicator unit TC400-PA.
Actual value
Manipulating factor
Setpoint
Channel display
State
Actual value
108
Display of the actual value
Setpoint
125
Channel
display
OFF
1-4
5
A
Display of the setpoint and the scale
unit (°C / °F)
All outputs/channels are switched off
CH1 … CH4
Output 1 - 4
LIM
ATEX limiter
AL1 … AL2
Alarm 1 and 2
01/13-4.0-3.1
Actual displayed internal channel
ATEX-limiter
Current monitoring
Relay released
Relay picked up
Failure
ATEX limiter not available
ATEX limiter normal operation
ATEX limiter failure
No alarm
Alarm switched on
7
SENS
Sensor monitoring
SP
Monitoring
analog input
set point input
CH
Monitoring limiter
channels
MIN
Temperature
alarm
MAX
Temperature
alarm
Temperature over maximum
I↑
↑↓
Monitoring
Heating current
FUSE
Fuse monitoring
Analog input deactivated
Analog input activated, faultless
Failure current monitoring
Fuse monitoring deactivated
Faultless
Failure
Normal operation
Fault signal
Fault signal has been accepted (concerns alarm outputs at the cascade
module TC400-CM)
Display of the actual manipulating
factor in 10 % steps
State
Manipulating
factor
01/13-4.0-3.1
Analog output
Thyristor power
controller
Failure temperature sensor
(break / short circuit)
Concurrent the actual value display
changes to Err and the setpoint
display e.g. to 2 1.
1
The first digit describes the faulty
channel (1 – 4), the second digit the
failure.
Sensor short circuit = 1
Sensor break = 2
Monitoring deactivated
Monitoring activated / faultless
Failure (e.g. break down, range of
values <>)
Normal operation
Exceeding temperature of a channel
which is configured as limiter (after
the actual value falls below the setpoint reset with key „Quit/Reset“)
Alarm bypass time runs
Temperature under minimum
8
4.2
Operating Element
Quit
Reset
Quit / Reset
Accepting fault signal /
Switch off controller output
CH
Selection of
channel
Selection of the displayed channel
Cycle
Display of channels changes circular
trough all activated channels
Up
Increase value
Down
Decrease value
Enter
Save changes
5
Operation
5.1
In Operation
CH
With each push of key the display changes to the next active
channel.
Each activated channel will be displayed for 3 seconds.
Increase or decrease the actual setpoint within the determined
limits.
This function has to be activated within the parameter menu and is
not available for channels with safety controller or limiter function.
Saving of the altered setpoint.
Quit
Reset
01/13-4.0-3.1
Accepting activated collective alarms at the cascade module. The
alarm outputs at the controller module are not affected. Reset of
the recorded collective alarms.
Special function: Switch off controller output.
Please regard details under point 5.2.3 "Parameter".
9
5.2
Parametrization
5.2.1
Menu Structure
The parameter menu is subdivided into the following main groups:
100
General parameter
200
Control parameter of channels 1 – 4
300
Analog input / output
400
Configuration alarm indication
500
Configuration group interrupts
600
Bus adjustment etc.
Please see further details under point 5.2.3 "Parameter".
5.2.2
Starting the parameter menu and navigation
The parameter menu can be reached as follows:
+
2s
= Parameter menu (display of SET within actual value)
Assignment of keys within menu:
= Selection of parameter / change of value
= Selection of menu point / confirmation of value
= Menu point back
= Selection of channel
CH
Example for the change of the setpoint of channel 3 (parameter 231):
+
2s
= Parameter menu
Display of actual value:
SET
2x
2x
2x
CH
or
= Selection Menu 200
Display of actual value:
200
= Confirmation menu 200
Display of actual value:
210
= Selection menu 230
Display of actual value:
230
= Confirmation menu 230
Display of actual value:
231
= Confirmation menu 231
Display of actual value:
231
= Selection channel 3
Channel display:
3
= Change setpoint
= Recording changed setpoint
4x
= Quitting parameter menu
After 30 seconds without any inputs the menu will be quitted automatically.
01/13-4.0-3.1
10
5.2.3
Parameter
Hint: Some parameters are adjustable separately for each channel. This is signalled by an activated channel display with the active channel number.
Parameter
No.
General parameters
Switch off
111
controller outputs
Value
Description
ON - OFF
Selection
temperature unit
Delay time
alarms
Heater test
112
°C - °F
121
0…999
999 s
Function On:
On
If the button "Quit/Reset" is pressed
for 3 seconds all controller outputs
will be switched off. The interruption
is signalised by the value OFF in the
setpoint display.
The remaining indications as well
as alarms that are based upon the
switch off are not affected.
To deactivate the complete controller all active channels has to be
switched off (Par. 211).
211
(for further information see point 6.5
parametrization)
° Celsius
° Fahrenheit
0…999 seconds
131
0…100
100 h
Duration
heater test
Password
for access to
parameter menu
Activate password
request
132
0…10
10 s
141
000…999
000 999
Change of current position with
key CH .
142
ON - OFF
Password protection on / off.
01/13-4.0-3.1
All channels that are configured as
controller are switched on after the
entered time. They are switched on
for the set time in parameter 132
132.
0 = Heater test deactivate
Turn on duration for heater test.
11
Parameter
No.
Value
Control parameters off the channels
Activate channel
OFF
211
ON
EXT
Input
configuration
212
Pt
tC
Controller function
213
Controller type
221
HEA
COL
2_P
ScT
Selection of
output
222
LI
PID
rEL (D_0
D_0)
D_0
An
Selection of
channel for
current monitoring
01/13-4.0-3.1
223
On
Off
Description
Channel deactivated
Channel uses the internal set-point
Channel uses the external set-point
Hint:
Hereafter only channels that are
activated are selectable with the
key CH .
Pt100
Thermo element
Display only. Sensors are determined
by the hardware.
Heating
Cooling
Two-sep controller without feedback
Safety Controller (as limiter without
restart lockout)
Limiter with restart lockout
PID controller with feedback (Option)
Relay or solid-state relay (determined
by the hardware configuration of the
Controller)
Analog output Iout (Option, only
selectable by Controller type PID and
only for just one channel)
Selection of the channels that are
responsible for the current consumption.
Possible channels:
1-4 (5 ATEX limiter)
For detailed information see chapter
"Extended Description of Functions".
12
Parameter
No.
Value
Description
Parameters two-step controller, safety controller, limiter
Setpoint
-50...650
Temperature setpoint
-50 650
231
Hysteresis
1
...50
50
232
Setpoint
T (°C/°F)
Hys
t
On
Off
Output
Example for controller function
"Heating".
01/13-4.0-3.1
13
Parameter
No.
Value
Description
Parameters PID-controller (Option)
Setpoint
-50...650
Temperature setpoint
-50 650
241
Proportional gain
1
...200
200
Proportional
component
242
Integral-action
0...999
999 s
Integral-action component
243
time
Derivative action
0...999
999 s
Differential component
244
time
Operating
2...240
240 1/min If a switching output is used instead
245
frequency
of the analog output.
On relay outputs a maximum of
3 switching operations/min is adjustable.
Reference
0...999
999 s
246
variable former
Minimum manipu- 247
0...100
100 %
Increasement of manipulating factor
lating factor
at 0%.
Maximum ma0...100
100 %
Decreasement of manipulating
248
nipulating factor
factor at 100%.
Enabling setpoint change
Enabling
ON - OFF
If enabled, the setpoint can be
251
setpoint change
adjusted without entering the setup
menu. The setpoint is adjustable
within the range of parameter 252
and 253.
253 Channels that are configured as safety controller or limiter
are excluded.
Change setpoint:
Save setpoint:
Setpoint limit low
-50...650
The lowest setpoint that is adjust-50 650
252
able.
Setpoint limit high 253
-50...650
The highest setpoint that is adjust-50 650
able.
01/13-4.0-3.1
14
Parameter
No.
Value
Analog input: setpoint selection
Monitoring setON - OFF
311
point input
Setpoint low
Setpoint high
Standardized
signal
312
313
-50...650
-50 650
-50...650
-50
650
U10
I20
Analog input: current monitoring
Input
ON - OFF
321
Ratio
‹0...99
‹0 999
999
322
Reserved
Current consumption
Display current
consumption
314
323
324
ON - OFF
0.0
0...999
999
325
0.0
0...999
999
Description
Monitoring of the standardized
signal for failure, overrange and
underflow
Setpoint at 4 mA / 0 V
Setpoint at 20 mA / 10 V
0 – 10 V
4 – 20 mA
Input activated / deactivated
Transformation ratio of the connected current transformer
(0 – xxA = 0 - 20 mA)
For later use
Current consumption that has to be
monitored of underflow
Displays the actual current consumption
Analog output: actual temperature value
Output
ON - OFF
Output activated / deactivated
331
Channel selection 332
CH1…CH5
CH1 CH5
Selection of channel for analog
temperature output (CH5 = ATEX
limiter)
Actual value low
-50...650
Actual temperature value at
-50 650
333
4 mA / 0 V
Actual value high
-50...650
Actual temperature value at
-50 650
334
20 mA / 10 V
Standardized
U10
0 – 10 V
335
signal
I20
4 – 20 mA
Analog output: thyristor power controller (option)
Output
ON - OFF
Output activated / deactivated
341
This output is only available for the
OPTION PID controller
Standardized
U10
0 – 10 V
342
signal
I20
4 – 20 mA
01/13-4.0-3.1
15
Parameter
No.
Configuration of alarms
Temperature
411
411
monitoring
Value
Description
OFF
Temperature monitoring
deactivated
Absolute alarm
Relative alarm by reference to
actual setpoint.
Absolute alarm
Adjustment below alarm low
(413
413)
413 not possible
Relative alarm
Absolute alarm
Adjustment above alarm high
(412
412)
412 not possible
Relative alarm
Suppress activated / deactivated
On controller start the alarm
low will be suppressed for the
entered time in minutes (415
415).
415
Suppressing time in minutes
A_A
A_r
Alarm high
412
-50...650
-50 650
413
2...50
50
-50...650
-50 650
Suppress low alarm
414
2...50
50
ON - OFF
Suppressing time
415
0...60
60 min
421
ON - OFF
422
A1
423
A0
ON - OFF
Alarm low
Fuse-monitoring
Monitoring
On / Off
Working method of
input
Switch off of controller
outputs
01/13-4.0-3.1
Fuse monitoring
activated / deactivated
24 V at the input = fault
0V at the input = fault
Activated / deactivated
If a fuse has tripped all controller outputs will be switched off.
The remaining indications as
well as alarms that are based
upon the switch off are not
affected.
16
Parameter
No.
Value
Description
Configuration group interrupt (Outputs at cascade module TC400-CM)
Temperature low
OFF,
Activates group interrupt 1…4
OFF AL1...AL4
AL1 AL4
511
Temperature high
Activates group interrupt 1…4
OFF,
512
OFF AL1...AL4
AL1 AL4
Fuse monitoring
Temperature overrange at limiter
channel
Sensor break /
short circuit
Current monitoring
Setpoint selection /
actual temperature
value (failure,
overrange and
underflow)
Storage of
group interrupt 1
Storage of
group interrupt 2
Storage of
group interrupt 3
Storage of
group interrupt 4
Operational mode
of group alarms
01/13-4.0-3.1
513
514
OFF,
OFF AL1...AL4
AL1 AL4
OFF, AL1
AL1...AL4
OFF
AL4
Activates group interrupt 1…4
515
OFF,
OFF AL1...AL4
AL1 AL4
Activates group interrupt 1…4
516
517
OFF,
OFF AL1...AL4
AL1 AL4
OFF, AL1
AL1...AL4
OFF
AL4
Activates group interrupt 1…4
521
ON - OFF
Activated / deactivated
522
ON - OFF
Activated / deactivated
523
ON - OFF
Activated / deactivated
524
ON - OFF
Activated / deactivated
525
ON
OFF
24 V if an alarm occurs
0 V if an alarm occurs
Activates group interrupt 1…4
Activates group interrupt 1…4
17
Parameter
No.
Bus adjustment etc.
CAN-functions
611
Value
Description
ON - OFF
activate - deactivate
On active CAN-functions a CANaddress has to be entered.
Each address has to be used only once
per interconnection.
CAN-address
612
613
1...25
250
250
0-5
614
0-3
LED
615
Function of the Power LED on the
controller module:
0: Power-on
1: Failure detected
2: Receive telegram of indicator module
TC400-PA
3: Write on EE-Prom
4: RS232-communication
5: Profibus
Standard = 0 or 1
Parameter 2 – 5 are only used for diagnostics,
Plausibility of alarm outputs AL1 / AL2.
The alarm outputs on the controller
module are checked with a very short
impulse.
This check can be activated for each
alarm separately.
0: no check
1: Check of transistor of alarm 1
2: Check of transistor of alarm 2
3: Check of transistor of alarm 1+2
Use only for diagnostics
Only for diagnostics on manufacturer
site.
Changes of this Parameter may cause
unintentional controller functions and
result in the revocation of warranty and
liability claims.
For programming and archiving of the parameters the software TC400-SO can be
used (additional equipment).
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18
6
Extended Description of Functions
6.1
Current Monitoring
In order to use the current monitoring it is necessary to connect a current transformer with output 0-20 mA according to installation instructions.
The input variable of the current transformer as well as the monitored current
input are determined with parameter 321 – 325.
325
The channels which are responsible for the current consumption are indicated
with parameter 223.
223
According to the configuration of the channels (controller/safety controller/limiter),
the controller analyse if a current consumption is to be expected or not.
Hereby it is assumed that a switching off by one or several as safety controller /
limiter configured channels preferentially also leads to a cut-off of the outgoing
circuit.
When using several as controller configured channels a current consumption is
expected until all channels have switched off.
The following example presents some exemplary varieties of interconnections:
Example 1
Example 2
Example 3
Configuration
two-step controller
Ch 1
or PID-controller
with switching output
Ch 1
Ch 1
Configuration as
safety controller
or limiter
Ch 2
Ch 3
Ch 2
Ch 2
I< / I>
01/13-4.0-3.1
Ch 3
Ch 4
0-20 mA
I< / I>
Ch 1
Ch 2
Ch 3
0-20 mA
Example 4
0-20 mA
I< / I>
0-20 mA
I< / I>
19
6.2
Group interrupts (Output at Cascade Module TC400-CM)
The group interrupts at the cascade module TC400-CM are configured with the
parameter 511 – 525.
525 Thereby it should be paid attention to the fact that all controllers which are connected to one cascade module are equally configured.
Alarm 1 and 2 are additionally provided at the controller module.
Contrary to the alarm outputs at the cascade module, the alarm outputs at the
controller module will not be cleared with the key „Quit/Reset“ (accepted). Those
will disappear first with the active fault.
A group interrupt at the cascade module can be released (accepted) for other
fault indications with the key „Quit/Reset“ at the controller module which is responsible for the activation. Further faults which will be collected at the activated
controller module, e.g. from other channels, may cause again the release of the
cleared collective alarm.
When the storage of the group interrupt is activated, those alarms will not independently be cleared after correction of the defect, but have to be reset with the
key “Quit/Reset”. Non recorded collective alarms will be reset automatically after
correction of the fault.
6.3
Setpoint Selection
When the standardised signal will be exceeded or fell below, the setpoint of the
upper and lower limit stays active. The appropriate channel will not be disconnected. In this case it is important that the analysis of a fault also will be allocated
to a collective alarm (517
517)
517 and that those will be analysed.
6.4
Parameter 111 "Switching Off Controller Outputs"
When using the parameter „Switching off controller outputs“ (111
111)
111 it should be
paid attention that the function will only be deactivated when controller outputs
are switched on as otherwise controller outputs can not be re-activated with the
key “Quit/Reset”.
6.5
Parametrization
Due to safety and control engineering reasons some combinations of parameter
are not possible. Those are e.g.:
•
External setpoint selections at a channel which is configured as safety controller / limiter.
•
Enabling "Setpoint change" (25
251
251) at a channel which is configured as safety
controller / limiter.
•
Selection of the analog output (222
222)
222 at channels which are configured as
two-step-controller / safety controller / limiter.
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`