ACS contsys MIR-491, Operating Manual

Page 1: ...MIR 491 MIR 491 Industrial and process controller MIR 491 Operating manual English BAL 491 65511 Valid from 07 2002 ACS Control System GmbH...

Page 2: ...copyright owner A publication of ACS Control System GmbH Lauterbachstra e 57 1 2 D 84307 Eggenfelden Germany BlueControl More efficiency in engineering more overview in operating The projecting envir...

Page 3: ...set point 16 3 5 4 Self tuning cancellation 17 3 5 5 Acknowledgement procedures in case of unsuccessful self tuning 17 3 5 6 Examples for self tuning attempts 17 3 6 Manual self tuning 19 3 7 Alarm ha...

Page 4: ...491 with measured value output 49 5 Parameter setting level 50 5 1 Parameter survey 50 5 2 Parameters 51 5 3 Input scaling 53 5 3 1 Input Inp 1 and InP 3 54 5 3 2 Input InP 2 54 5 4 Second set of para...

Page 5: ...of all levels suppressed password PASS OFF l Caution The unit contains ESD sensitive components Mounting Operating manual MIR 491 5 or max 95 rel max 60 C 0 C min 96 3 78 48 1 89 Loc min 48 1 89 10 0...

Page 6: ...3 4 5 6 7 8 9 10 11 12 13 14 15 17 2 16 mA mV mV Volt mA INP2 INP3 INP1 di2 di1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Option 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 16 OUT1 OUT2 OUT3 OUT4 90 250V 24 V U...

Page 7: ...nection of input INP2 5 a Heating current input 0 50mA AC or input for ext set point 0 4 20mA b Potentiometer input for position feedback Connection of input INP3 6 As input INP1 but without voltage C...

Page 8: ...al connection 8 Operating manual MIR 491 1 2 3 K 13V 22mA 13 14 15 11 12 13 17 16 14 15 12 11 10 3 OUT3 transmitter supply 13 14 15 Option 17 16 1 3 4 5 6 7 8 9 10 11 12 13 14 15 17 2 16 24VDC 5mA 5mA...

Page 9: ...SR 4V 4V 4V 12V I 22mA max I 22mA max 12V 11 10 10 11 12 Logic 3 OUT3 as logic output with solid state relay series and parallel connection _ L1 L2 N1 N2 Fuse 1 2 3 4 7 5 8 6 9 10 11 12 13 14 15 Fuse...

Page 10: ...f switching outputs OuT 1 6 2 Process value display 3 Set point controller output 4 Signals display on C or F 5 Signals ConF and PArA level 6 Signals aktive function key 7 Self tuning active 8 Entry i...

Page 11: ...rating level The content of the extended operating level is determined by means of BlueControl engineering tool Parameters which are used frequently or the display of which is important can be copied...

Page 12: ...2 Internal error can be reset e g EMC trouble Keep measurement and power supply cables in separate runs Ensure that interference suppression of contactors is provided E 3 Configuration error can be re...

Page 13: ...al defective or not connected correctly Output not connected correctly Check heating or cooling circuit Check sensor and replace it if necessary Check controller and switching device AdA H Self tuning...

Page 14: ...or connections and process 5 Low reversal point Increase ADA H max output limiting Y Hi or decrease ADA C min output limiting Y Lo 6 Danger of exceeded set point parameter determined If necessary incr...

Page 15: ...t point using the determined parameters 3 point controller as 2 point controller The heating output is frozen and a cooling pulse 100 for the cooling loop is output After determination of cooling para...

Page 16: ...ng pulse I e by optimization at the set point the optimum control parameters either for the heating or the cooling loop are determined The correcting variable pulse can be output by the controller in...

Page 17: ...s controlling using the old parameters in automatic mode The Err LED continues blinking until the self tuning error was acknowledged in the error list 2 Press key if configured The controller goes to...

Page 18: ...the new parameters 4 Three point controller a The parameter for heating and cooling are determined in two attempts The heating power is switched on 1 Heating parameters Pb1 ti1 td1 and t1 are determin...

Page 19: ...ing Formulas K Vmax Tu controller behavior Pb1 phy units td1 s ti1 s With 2 point and 3 point controllers the cycle time must be adjusted to t1 t2 0 25 Tu PID 1 7 K 2 Tu 2 Tu PD 0 5 K Tu OFF PI 2 6 K...

Page 20: ...ed off individually parameter OFF Switching difference HYS x of each limit value is adjustable 1 normally closed ConF Out x O Act 1 2 normally open ConF Out x O Act 0 Operation Alarm handling 20 Opera...

Page 21: ...h the operating levels The controller status is as before power off g PArA level At PArA level the right decimal point of the bottom display line is lit continuously g ConF level At ConF level the rig...

Page 22: ...rr InP 2 Input 2 I F nc S t yP Corr In F InP 3 Input 3 I F nc S L in S Typ Corr In F Lim Limit value functions Fnc 1 Src 1 Fnc 2 Src 2 Fnc 3 Src 3 HC A L LP A L dAc A OUt 1 Output 1 O A ct Y 1 Y 2 Lim...

Page 23: ...5 Mean value InP 1 X2 With sensor error controlling is continued with the remaining process value 6 Switching between InP 1 and X2 LOGI I ChG C Fnc Control behaviour algorithm 1 0 on off controller or...

Page 24: ...to tuning at power on or when oscillating is detected Adt0 Optimization of T1 T2 only visible with BlueControl 0 0 Automatic optimization 1 No optimization 1 rnG L and rnG H are indicating the range o...

Page 25: ...ion of linearization table with BlueControl engineering tool possible The characteristic for KTY 11 6 temperature sensors is preset Corr Measured value correction scaling 0 0 Without scaling 1 Offset...

Page 26: ...t 2 external set point SP E 3 Yp input 4 Second process value X2 5 Y E input 6 no controller input e g transmitter input instead S Lin Linearization only at S tYP 30 0 20mA and 40 0 10V adjustable 0 0...

Page 27: ...0 Ohm Corr Measured value correction scaling 0 0 Without scaling 1 Offset correction at CAL level 2 2 point correction at CAL level 3 Scaling at PArA level 4 Automatic calibration DAC In F 1999 9999 A...

Page 28: ...be reset via error list key key or a digital input LOGI Err r Src 2 Source of limit 2 0 0 process value 1 control deviation xw process value set point 2 control deviation xw with suppression after sta...

Page 29: ...rence x1 x2 HC AL Alarm heat current function INP2 0 0 switched off 1 Overload short circuit monitoring 2 Break and short circuit monitoring LP AL Monitoring of control loop interruption for heating 0...

Page 30: ...L Interruption alarm signal LOOP 0 0 not active 1 active HC AL Heat current alarm signal 0 0 not active 1 active HC SC Solid state relay SSR short circuit signal 0 0 not active 1 active FAi 1 INP1 err...

Page 31: ...peration of output OUT3 only visible when O TYP 0 1 0 direct normally open 1 inverse normally closed Y 1 Controller output Y1 only visible when O TYP 0 0 0 not active 1 active Y 2 Controller output Y2...

Page 32: ...O Src Signal source of the analog output OUT3 only visible when O TYP 1 5 1 0 not used 1 controller output y1 continuous 2 controller output y2 continuous 3 process value 4 effective set point Weff 5...

Page 33: ...tive 1 active Lim 2 Limit 2 signal only visible when O TYP 0 0 0 not active 1 active Lim 3 Limit 3 signal only visible when O TYP 0 0 0 not active 1 active dAc A Valve monitoring DAC only visible when...

Page 34: ...ly visible when O TYP 1 5 0 0 not used 1 controller output y1 continuous 2 controller output y2 continuous 3 process value 4 effective set point Weff 5 control deviation xw process value set point 6 m...

Page 35: ...DI3 switches only visible with OPTION 5 key switches SP E Switching to external setpoint SP E 0 0 no function switch over via interface is possible 1 always active 2 DI1 switches 3 DI2 switches only...

Page 36: ...function switch over via interface is possible 2 DI1 switches 3 DI2 switches only visible with OPTION 4 DI3 switches only visible with OPTION 5 key switches Err r Reset of all error list entries 0 0 n...

Page 37: ...rcing via serial interface othr Name Value range Description Default bAud Baudrate of the interface only visible with OPTION 2 0 2400 Baud 1 4800 Baud 2 9600 Baud 3 19200 Baud Addr 1 247 Address on th...

Page 38: ...ller off only visible with BlueControl 0 0 Released 1 Blocked IAdA Block auto tuning only visible with BlueControl 0 0 Released 1 Blocked IExo Block extended operating level only visible with BlueCont...

Page 39: ...ort by means of PC Windows 95 98 NT and a PC adaptor Description BlueControl see chapter 8 BlueControl page 61 4 3 Set point processing The set point processing structure is shown in the following pic...

Page 40: ...ycle time 1 heating s PArA Cntr t2 min cycle time 2 cooling s 4 4 2 Water cooling linear CyCl 1 For heating Y1 the standard method see chapter 4 4 1 is used For cooling Y2 a special algorithm for cool...

Page 41: ...rrecting variable is very weak Moreover the correcting variable increases very quickly to max possible cooling Parameter F H2O can be used for changing the characteristic curve The standard method see...

Page 42: ...hich require a pulse shorter than the value adjusted in tp this pulse is suppressed However the controller stores the pulse and totalizes further pulses until a pulse of duration tp can be output Para...

Page 43: ...tput Y1 active PArA Cntr SH 0 9999 switching difference symmetrical to the trigger point PArA SEtP SP LO 1999 9999 set point limit low for Weff SP Hi 1999 9999 set point limit high for Weff g For dire...

Page 44: ...its of phys quantity e g C ti1 1 9999 integral time 1 heating in sec td1 1 9999 derivative time 1 heating in sec t1 0 4 9999 min cycle time 1 heating PArA SEtP SP LO 1999 9999 set point limit low for...

Page 45: ...and 2 cooling in units of phys quantity e g C ti1 1 9999 integral time 1 heating in sec ti2 1 9999 derivative time 2 cooling in sec td1 1 9999 integral time 1 heating in sec td2 1 9999 derivative time...

Page 46: ...tity e g C ti1 1 9999 integral time 1 heating in sec td1 1 9999 derivative time 1 heating in sec t1 0 4 9999 min cycle time 1 heating SH 0 9999 neutral zone in units of phy quantity tP 0 1 9999 min pu...

Page 47: ...9999 derivative time 1 heating in sec t1 0 4 9999 min cycle time 1 heating PArA SEtP SP LO 1999 9999 set point limit low for Weff SP Hi 1999 9999 set point limit high for Weff g For direct action of t...

Page 48: ...Cntr Pb1 0 1 9999 proportional band 1 heating in units of phys quantity e g C ti1 1 9999 integral time 1 heating in sec td1 1 9999 derivative time 1 heating in sec t1 0 4 9999 min cycle time 1 heatin...

Page 49: ...aling Out 3 4 for 0 4mA or 0 2V Out 1 1999 9999 scaling Out 3 4 for 20mA or 10V O Src 3 signal source for Out 3 4 is the process value Configuration level Operating manual MIR 491 49 Configuration exa...

Page 50: ...sec g If for 30 sec no keypress is excecuted the controler returns to the process value and setpoint display Time Out 30 sec PArA Parameter setting level Cntr Control and self tuning Pb1 Pb2 ti1 ti2 t...

Page 51: ...lse s OFF tt 3 9999 Motor travel time s 60 Y Lo 120 120 Lower output limit 0 Y Hi 120 120 Upper output limit 100 Y2 120 120 2 correcting variable 0 Y 0 120 120 Working point for the correcting variabl...

Page 52: ...e Description Default InL 1 1999 9999 Input value for the lower scaling point 0 OuL 1 1999 9999 Displayed value for the lower scaling point 0 InH 1 1999 9999 Input value for the upper scaling point 20...

Page 53: ...in the relevant electrical unit mA V Parameter setting level Operating manual MIR 491 53 Input scaling Lim Name Value range Description Default L 1 1999 9999 Lower limit 1 10 H 1 1999 9999 Upper limi...

Page 54: ...ettings InL 2 and InH 2 can be adjusted in the range 0 20 50mA determined by selection of S tYP 5 4 Second set of parameters MIR 491 is provided with a second set of parameters PArA PAr 2 for heating...

Page 55: ...available Offset correction ConF InP 1 Corr 1 w possible on line at the process 2 point correction ConF InP 1 Corr 2 w is possible off line with process value simulator Calibration level Operating ma...

Page 56: ...t value by pressing key OuL 1 The display value of the scaling point is displayed Before calibration OuL 1 is equal to InL 1 The operator can correct the display value by pressing keys Subsequently he...

Page 57: ...point is displayed The operator must adjust the upper input value by means of the process value simulator and confirm the input value by pressing key OuH 1 The display value of the upper scaling poin...

Page 58: ...ameter dAC A 1 and inverse action O Act 1 must be selected for the relevant output OUT 1 OUT 4 in the ConF menu OUt 3 and 4 only possible if O tYP 0 relay logic w ConF OUt x dAc A 1 Motor actuator mon...

Page 59: ...located and stored Simultaneously the motor running time is determined and saved as parameter tt Afterwards the controller sets the drive in the position before calibration Was the controller in autom...

Page 60: ...icates the first target adress where the received data should be stored The following data will be stored at the logically following modbus target adresses With this it is possible e g to specify the...

Page 61: ...loop simulation yes yes yes download writes an engineering to the controller yes yes yes online mode visualisation SIM only yes yes creation of user defined linearizations SIM only yes yes configurat...

Page 62: ...mA V logic 5 No option 0 Modbus RTU U di2 3 OUT5 6 T 1 INP1 and INP2 0 INP1 INP2 and INP3 1 Standard configuration 0 Configuration to specification 9 No operating manual 0 Operating manual german D O...

Page 63: ...d junction compensation Maximal additional error 0 5 K Sensor break monitoring Sensor current 1 A Configurable output action Resistance thermometer r Table 2 page 67 Connection 3 wire Lead resistance...

Page 64: ...tput circuits GALVANIC ISOLATION Safety isolation Function isolation OUTPUTS SURVEY OF OUTPUTS Output Used for OUT1 2 relays Control output heating cooling or Open Close limit contacts alarms OUT3 4 r...

Page 65: ...Protective circuit built in against short circuit overload reversed polarity free wheel diode for relay loads POWER SUPPLY Dependent of order AC SUPPLY Voltage 90 260 V AC Frequency 48 62 Hz Power con...

Page 66: ...Complies with EN 61010 1 VDE 0411 1 Overvoltage category II Contamination class 2 Working voltage range 300 V Protection class II Certifications Type tested to DIN 3440 applied for For use in w Heat...

Page 67: ...iCr CuNi 100 1000 C 148 1832 F 2K 0 1 K B PtRh Pt6 0 100 1820 C 32 212 3308 F 2K 0 3 K Specifications valid for 100 C Table 1 Thermocouples measuring ranges Art Me strom Me bereich Genauigkeit Aufl su...

Page 68: ...d signified The switch or circuit breaker must be installed near by the controller and the user must have easy access to the controller COMMISSIONING Before instrument switch on check that the followi...

Page 69: ...wing work may be done only at workstations with suitable ESD protection Modification maintenance and repair work may be done only by trained and authorized personnel For this purpose the ACS service s...

Page 70: ...12 Notes Notes 70 Operating manual MIR 491...

Page 71: ...Notes Operating manual MIR 491 71...

Page 72: ...Notes 72 Operating manual MIR 491...

Page 73: ...Notes Operating manual MIR 491 73...

Page 74: ...3 as logic output 9 OUT3 transmitter supply 8 RS485 interface 8 Control inputs di1 di2 di3 Technical data 64 Cooling functions Constant period 42 Standard 40 Water cooling linear 40 Water cooling non...

Page 75: ...65 Output OUT6 Configuration 34 Technical data 65 P Parameter setting level Parameter survey 50 Parameters 51 52 Power supply 65 R Resetting to factory setting 69 Resistance thermometer measuring ran...

Page 76: ...to alterations without notice ACS Control System GmbH nderungen vorbehalten Lauterbacherstra e 57 1 2 D84307 Eggenfelden Germany Sours r serve de toutes modifications Printed in Germany BAL 401 65511...