VFL Series PID Controllers INSTRUCTION MANUAL ■FRONT PANEL DESCRIPTION： PV－Process Value SV－Setting Value AT－Auto tuning LED MA－Manual mode LED A1－Alarm 1 LED A2－Alarm 2 LED C1－Control 1 LED C2－Control 2 LED －SET KEY. Press once to access the next programmable parameter. Press and hold this key for 5 seconds to reset alarm timer. －UP KEY. Press to increase the set point or parameter value. －DOWN KEY. Press to decrease the set point or parameter value. －SHIFT KEY. Press the shift key for 5 seconds to execute Auto Tune process (Yes. 1 mode). To abort an Auto Tune process, press and hold the shift key for 5 seconds. －Press the SET and UP keys once to return the normal operation. －LEVEL KEYS. Press and hold the SET & SHIFT keys simultaneously for 5 seconds to select the programming level, and then press the SET key to enter the selected level. ---Press the UP & DOWN keys simultaneously for 5 seconds to access “LnLo” & “LnHi” parameters. ■PANEL CUTOUT： Model A B C D E a b c d 48VFL 48 48 6 100 45 45+0.5 45+0.5 60 48 96VFL 96 96 10 80 91 92+0.5 92+0.5 120 96 (Units: mm) 48VFL & 96VFL v1.2 07/13 ■ WIRING DIAGRAM ■Wiring Precautions: 1. Before wiring, verify the controller label for correct model number and options. 2. For thermocouple input, use the appropriate compensation wire. And note the polarity of input signal. 3. To avoid noise induction, keep input signal wires away from instrument power lines, load lines and power lines of other electrical equipment. 48VFL & 96VFL v1.2 07/13 ■ PROGRAMMING LEVEL PARAMETERS ■ lst. Prog. Level 2nd. Prog. Level 3rd. Prog. Level 4th Prog. Level 5th. Prog. Level + 1. When 2nd Output (Cooling) is not selected, CPb、Cti、 Ctd、HYS2 and db parameters are not available. 2. When Pb≠0.0， HYS1 will be skipped. 3. When CPb≠0.0，HYS2 will be skipped. 4. When Pb＝0.0，ti、td will be skipped. 5. When CPb＝0.0，Cti、Ctd will be skipped. 48VFL & 96VFL v1.2 07/13 ■PARAMETER DESCRIPTION： LEVEL Selection Press keys for at least 5 seconds to access Soft Level. Use key to select programming level. Then press or key to enter this level. Description LEVEL SoFt Level PID Level Option Level USER LEVEL CODE DESCRIPTION RANGE LoLt － HiLt Set point value of control Alarm 1 set point value/Timer set value while A1FU is set to T.on or T. off, the unit can be HH.MM or MM.SS. It depends on the “P.tnE” parameter. Alarm 2 set point value/ Timer set value while A2FU is set to T.on or T. off, the unit can be HH.MM or MM.SS. It depends on the “P.tnE” parameter. Default 500 -1999 － 9999/ 00.00~99.59 10 -1999 － 9999/ 00.00~99.59 10 ：Auto-tuning is disable ：Standard type auto-tuning. no Autotune PV is compared wit SV during auto tuning. ：Low PV type auto-tuning. PV is compared with SV-10%FS during Auto-tuning. ：Disable the manual mode Manual control no ：Enable the manual mode. Output percentage. Adjustable when “Hand” is set to “Yes” -100.0 － 0.0 100.0 SOFT LEVEL Code Description Ramp rate for the process value to limit an abrupt Change of process (℃/min) Set point value of soft-start Output percentage of soft-start Range 0 - 9999 （0.0 – 999.9） Default 0.0 LoLt － HiLt ０ 0.0 - 100.0 100.0 PID LEVEL CODE DESCRIPTION Proportional band variable. Set to 0.0 for ON/OFF control mode Integral time (Reset). This value is automatically calculated by activating the Autotune function. If desired, the user can later RANGE Default 0.0-300.0% 10.0 0-3600sec 240 48VFL & 96VFL v1.2 07/13 adjust this parameter to better suit the application. When PB=0.0, this parameter will be not available. When set to zero, Pb & td ≠ 0 for PD control Derivative (Rate). This value is automatically calculated by activating the Auto tune function. If desired, the user can later 0-900sec 60 0-100sec 15 0.0-300.0% 10.0 0-3600sec 240 0-900sec 60 0-100sec 15 Hysteresis for ON/OFF control on output 1 0-2000(0.0-200.0) 1 Hysteresis for ON/OFF control on output 2 0-2000(0.0-200.0) 1 Hysteresis of alarm 1 0-2000 1 Hysteresis of alarm 2 0-2000 1 -1000-1000 (-100.0-100.0) 0 -1000-1000 (-100.0-100.0) 0 -1000-2000 (-100.0-200.0) 0 adjust this parameter to better suit the application. When PB=0.0, this parameter will be not available. When set to zero, Pb & td ≠ 0 for PI control Proportional cycle time of output 1 Proportional band variable for secondary control output (cooling). Set 0.0 for ON/OFF Integral time for secondary control output. When PB=0.0, this parameter will be not available. When set to zero, Pb & td ≠ 0 for PD control Derivative time for secondary control output. When Pb=0.0, this parameter will be not available. When set to zero, Pb & ti ≠ 0 for PI control Proportional cycle time of output 2 Dead band value. This defines the area in which output 1 and output 2 are both active (negative value) or the area in which output 1 and output 2 are both inactive (positive value) Set point offset. This value will be added to SV to perform control. It mainly used to eliminate offset error during Pb control Process value offset. Permits the user to offset the PV indication from the actual PV Parameter lock. This security feature locks out selected levels or single parameters prohibiting tampering and inadvertent programming changes 0000 All parameters are locked out 0001 Only SP is adjustable 0010 Only USER level is adjustable 0011 USER and PID levels are adjustable 0100 USER,PID,OPTI levels are adjustable 0101 USER, SOFT, PID, OPTI levels are adjustable 0100 0101~0111 All parameters in all levels are unlocked 1000~1111 1000=0000,1001=0001,1010=0010,1011=0011,1100=0100 The only difference is that Output 2 is unlocked 48VFL & 96VFL v1.2 07/13 OPTION LEVEL CODE DESCRIPTION RANGE Default Refer to figure. K Input type selection. tYPE J K T E B R S N C D-PT J-PT LINE RANGE(℃) RANGE(℉) -50 ～ 1000 -58 ～ 1832 -50 ～ 1370 -58 ～ 2498 -270 ～ 400 -454 ～ 752 -50 ～ 750 -58 ～ 1382 0 ～ 1800 32 ～ 3272 0 ～ 1750 32 ～ 3182 0 ～ 1750 32 ～ 3182 -50 ～ 1300 -58 ～ 2372 -50 ～ 1800 -58 ～ 3272 -200 ～ 850 -328 ～ 1652 -200 ～ 650 -328 ～ 1202 -1999 ～ 9999 Unit of process value ：Degrees C ℃ ：Degrees F : Engineer units for linear input Decimal point selection 0000：No decimal point 000.0：0.1 resolution 00.00：0.01 resolution, used for linear input only 0.000：0.001 resolution, used for linear input only 0000 000.0 0000 00.00 0.000 Output 1 control action. : Reverse action for heating : Direct action for cooling Low limit of span or range. Set the low limit lower than the lowest expected SV and PV display High limit of span or range. Set the high limit higher than highest expected SV and PV display Software filter. Full range 0 Full range 1000 0.0-99.9 10.0 00.00~99.59 00.00 Time scale for timer alarm. Hours:Minutes; Minutes:Seconds None, Hi, Lo, dif.H, dif.L, bd.Hi , bd.Lo If A1FU=None, the alarm function is cancelled t.on, t.oFF none, Stdy, Alarm 1 mode. Refer to alarm mode section for detail.. Lath, St.La Alarm 2 function. Refer to alarm function section for detail none, Hi, Lo, dif.H, Alarm 1 function. Refer to alarm section for details 48VFL & 96VFL v1.2 07/13 If A2FU=None, it means alarm function is cancelled. dif.L, bd.Hi, bd.Lo t.on, t.oFF none, Stdy, Lath, St.La Alarm 2 mode. Refer to alarm mode section for details Controller address. For use with PC RS-485 interface 0 - 255 0 Baud rate. 2.4k=2400bps, 4.8k=4800 bps, 9.6k=9600 bps, 2.4k, 4.8k 19.2k=19200 bps 9.6k, 19.2k 9.6k Description Code Default Range Low Scale of Linear Input -1999~9999(-199.9~999.9) 0.0 High Scale of Linear Input -1999~9999(-199.9~999.9) 100.0 Scaling for Linear Input 1. Press and hold the UP and DOWN keys simultaneously for 5 seconds to access the “LnLo” parameter. 2. Adjust “LnLo” setting to correspond to the low scale; after adjustment, press key once to access “LnHi” 3. Adjust “LnHi” setting to correspond to the high scale; after adjustment press key once to exit ALARM FUNCTION A1FU/A2FU ALARM TYPE ALARM OUTPUT OPERATION Alarm function OFF Output OFF Process high alarm ▲ SP PV Process low alarm ▲ SP PV Deviation high alarm PV ▲ SP+ALSP Deviation low alarm PV ▲ SP+ALSP Band high alarm OFF ▲ ▲ ▲ PV SP-ALSP SP SP+ALSP Band low alarm OFF ▲ SP-ALSP OFF ▲ ▲ PV SP SP+ALSP On-timer ALSP ▲ ▲ SP Off-timer ALSP ▲ ▲ SP PV PV ALARM MODE 48VFL & 96VFL v1.2 07/13 A1MD/A2MD DESCRIPTION Normal alarm mode/ When timer function is selected, with the PV<SV, the timer function is disabled Standby mode When selected, in any alarm function, an alarm on power-up is prevented. The alarm is enabled only when the process value reaches the alarm set point. Also known as “Startup inhibit” (useful for avoiding alarm trips during startup) Latch mode. When selected, the alarm output and indicator “latch” when the alarm occurs. The alarm output and indicator will remain energized even if the alarm condition has been cleared (unless the power to the meter is removed) Standby and latch mode ■AUTOMATIC AND MANUAL OUTPUT CONTROL Automatic control is the normal mode of controller operation. In automatic control mode the controller automatically adjusts the control output percentage, using PID, to bring the PV equal to the SV. The PID parameters Pb, Ti and Td can be automatically determine using the Auto Tune procedure. Manual control allows the user to manually drive the output percentage from 0.0 to 100.0%. To access the manual mode, set the “ ”parameter to “ ”, the right-most ” parameter will then alternately decimal (MA) on the SV display will flash. The “ and the process value. The output percentage can then be adjusted using display the UP or DOWN keys. To abort the manual control, simply set “ ■AUTO TUNE ” to “ ”. In order to automatically set the PID parameters in the PID level (“Pb” proportional band, “ti: integral time, also known as ‘reset’, and “td” derivative time, also known as ‘rate’), first adjust the controller’s set point to a value that closely approximates the application at ” parameter to “ ” for standard applications or “ ” for hand. Set the “ minimizing SV overshoot (see diagram below). The right-most decimal point (AT) on the PV display will flash in Auto Tune mode. This procedure will run two cycle oscillations. After that, the controller performs PID control with the “learned” PID value to verify the results. Finally the PID values will be entered into the nonvolatile memory and then starts the Fuzzy enhanced PID control. The auto tune process can last from several minutes up to two hours, depending on the process in question. A time out error will occur if the auto tune process can not be completed within two hours, in this case, try to set the PID parameters manually. To abort an auto tune process, simply set the “ ” parameter to ”. “ 48VFL & 96VFL v1.2 07/13 The controller can also be set to ON/OFF, PI, PD and P control mode. Set Pb = 0 for ON/OFF control mode. Set ti = 0 for PD control mode. Set td = 0 fro PI control mode and ti, td = 0 fro P control mode. The Hysteresis (dead band) for ON/OFF control operates as follows: ON OFF SP-HYST SP+HYST ▲ SP When the second control output (output 2) is used, the proportional band of output 2 and the dead band interact as detailed below: Output Heating Cooling PV Overlap Dead Band Band ■ERROR MESSAGE AND TROUBLESHOOTING 48VFL & 96VFL v1.2 07/13 Symptom Probable Solution - Sensor break error - Replace sensor - Sensor not connected - Check that the sensor is connected correctly - Unit must be repaired or replaced - A/D converter damage - Check for outside source of damage such as transient voltage spikes - Auto tune time out error Set Pb, ti, td manually Keypad not - Keypad is locked - Set” functioning - Keypad is defective - Have unit repaired Process value unstable No heat or output LEDs and display not lighting up Process Value changed abnormally Entered data lost ”to an appropriate value - Improper setting of Pb, Ti, Td and - Start AT process to set Pb, Ti, Td automatically CT - No heater power or fuse open - Output device defective or incorrect output used - Set Pb, Ti, Td manually - Check output wiring and fuse - Replace output device - No power to controller - Check power lines connection - SMPS failure - Replace or repair meter - Electromagnetic Interference (EMI) or Radio Frequency Interference (RFI) - EEPROM error - Suppress arcing contacts in system to eliminate high voltage spike sources. Separate the sensors and the controller wiring from “noisy” power lines. Ground heaters - Replace or repair meter 48VFL & 96VFL v1.2 07/13 Controller Overview Controller Wiring The controller must be wired before use. The controller’s input, outputs, and AC power are connected via its rear terminals. Refer to the wiring diagram for details. Programming Menus The controller uses a menu-based programming format. The menu levels are USER, PID, OPTION, and SOFT-START. Each menu includes a series of parameters that customize the controller. The menu structure and parameter descriptions are detailed in the instructions on reverse side of this sheet. Inputs The controller accepts an input from a Thermocouple, RTD, or Analog signal. Wire the input as shown in the wiring diagram. The measurement (PV for Process Variable) is displayed on the controller’s top LED readout in red. Setpoint Value (SV) The Setpoint Value (SV) is the process application target value. For example, in an oven application the desired oven temperature is the SV. This SV is changed adjusted as described in the operating instructions. The SV is shown on the controller’s lower LED display digits in green. Control Outputs The control outputs (C1 & C2) are to be wired to an external control device such as a heater, valve, switch, etc. The controller automatically adjusts external devices to bring the Process Variable (PV) in line with the Setpoint Variable (SV). Available outputs are Relay, Pulsed DC, and 4-20mA Analog Output. Tuning The controller must be tuned for every new application. It is strongly recommended that user run the Auto Tune function (AT). Note that the controller must be wired and ready to go before Auto Tune is started. Auto Tune optimizes the controller’s response to exactly match the characteristics and dynamics of the process at hand. Although auto tuning will be sufficient in most cases, there may be times when manual adjustments are required. Qualified personnel can Manually Tune the controller using the PID parameters in the PID Menu Level. Note that improper tuning can cause sever process disturbances; Use Auto Tuning when possible. Again, use Auto Tune whenever possible. Alarm Outputs The controller has alarm output relays (A1 & A2) that can be used to switch on/off a lamp, sound a buzzer, shut down a heater, etc. at a programmed alarm setpoint. Refer to the discussion of Alarms on the main instruction page. System Reset To revert all of the parameters to their original factory default settings, press and hold the UP and DOWN arrow keys simultaneously while turning the controller ON. Release the keys after the display switches on. Security LOCK To lock the controller, in order to avoid setpoint and program tampering, refer to the information provided in this manual for the ‘LOCK’ parameter. 48VFL & 96VFL v1.2 07/13 Specifications General Specifications Display Dual 7-segment 4-digit LED: Red digits for Process Variable (PV) and green digits for Setpoint Variable (SV) Display range -1999 to 9999 Indicating accuracy ± (0.2% full scale + 1 digit) Display update rate 4 readings per second Output status indication Front panel Alarm (A1 and A2) and Control (C1 and C2) status LED’s inform the user when an output switches on or off. Out-of-range indication PV display flashes. ‘No input’ indication PV displays ‘OPEN’ when input terminals are disconnected. Auto Tune indication Right-most decimal on the PV display flashes while the controller is in the auto tune mode. Calibration data Stored in non-volatile memory along with user parameter edits. Meter construction Case is ABS plastic and the front panel is drip- and dust-proof Lexan material (NEMA and IEC IP55 equivalent) Power requirement 90 to 264VAC 50/60Hz (automatically accommodates any voltage between 90 to 264VAC) Power consumption < 5VA Insulation Resistance > 50M Noise rejection Common Mode: 120 dB; Normal Mode: 60 dB (typical) Operating conditions 14 to 122oF (-10 to 50oC); 90% Relative Humidity max. Storage temperature -4 to 140 F (-20 to 60 C) Panel cut-out dimensions o o 1.77 x 1.77" ±0.02" (45.0 x 45.0mm ±0.5mm) for 48VFL 3.62 x 3.62" ±0.02" (92.0 x 92.0mm ±0.5mm) for 96VFL Thermocouple Input Specifications Thermocouple (TC) types J, K, T, E, B, R, S, N, and C (user programmable) Temp. Indication Accuracy <1000 degrees ±3.6F (2.0C) >1000 degrees ±7.6F (4.0C) TC Break protect Upscale and Downscale Lead wire effect 0.015% / ohm Input impedance > 10M Repeatability 0.83oC Temperature stability 5uV/oC typical TC Ranges Type K: -58 to 2498 F (-50 to 1370 C) Type J: -58 to 1830 F (-50 to 1000 C) Type B: 32 to 3272oF (0 to 1800oC) Type T: -454 to 752oF (-270 to 400oC) Type E: -58 to 1382 F (-50 to 750 C) Type R: 32 to 3182 F (0 to 1750 C) Type S: 32 to 3182oF (0 to 1750oC) Type N: -58 to 2372oF (-50 to 1300oC) Type C: -58 to 3272 F (-50 to 1800 C) o o o o o o o o o o 48VFL & 96VFL v1.2 07/13 RTD Input Specifications RTD type Platinum 100 (DIN or JIS) RTD range -328 to 1202 F (-200 to 650 C) Break protection Up- and down-scale Lead wire effect 0.015o / Ohm Repeatability 0.2oC o o Analog (Linear) Input Specifications Current Input 4 to 20mA DC (2.7 input impedance) Voltage Input 1 to 5V DC (>10M input impedance) Display range -1999 to 9999 digits Repeatability Within 1 digit Relay and Pulse DC Output Specifications Relay outputs SPST (dry contact) relays can switch up to 5 Amps @ 110V AC or 24VDC (for resistive loads only) Pulsed DC outputs 0 to 24 VDC output (drives resistive loads to 250 max.) Control actions Indirect or reverse acting (heating) and direct acting (cooling) Control types ON/OFF control with Hysteresis (dead band) Time proportioning control (for relay or pulsed DC output) Standard proportional output (analog output) Automatic tuning Push-button activation. Automatically tunes the proportional band and integral/derivative times. Manual Tuning Proportional Band (Pb): 0.0 to 300.0% of Full Scale Integral time or ‘Reset’ (Ti): 0 to 3000 seconds (includes anti-reset wind-up) Derivative time or ‘Rate’ (Td): 0 to 900 seconds Cycle Time: 0 to 100 seconds (set to ‘0’ for 4-20mA output) Hysteresis: 0.0 to 25.5% of Full Scale ALARM Output Specifications Alarm relay outputs SPST, dry contact relay can switch up to 3 Amps @ 110VAC; (for Resistive Loads) Alarm modes Deviation, Absolute, and Band Alarms with dead band (Hysteresis) adjustment. ANALOG Output Specifications Analog output 4-20mA DC Load limits 600 max. Programming Set Cycle Time (Ct) to ‘0’ to enable the analog output 48VFL & 96VFL v1.2 07/13 Warranty FLIR Systems, Inc. warrants this Extech Instruments brand device to be free of defects in parts and workmanship for one year from date of shipment (a six month limited warranty applies to sensors and cables). If it should become necessary to return the instrument for service during or beyond the warranty period, contact the Customer Service Department for authorization. Visit the website www.extech.com for contact information. A Return Authorization (RA) number must be issued before any product is returned. The sender is responsible for shipping charges, freight, insurance and proper packaging to prevent damage in transit. This warranty does not apply to defects resulting from action of the user such as misuse, improper wiring, operation outside of specification, improper maintenance or repair, or unauthorized modification. FLIR Systems, Inc. specifically disclaims any implied warranties or merchantability or fitness for a specific purpose and will not be liable for any direct, indirect, incidental or consequential damages. FLIR’s total liability is limited to repair or replacement of the product. The warranty set forth above is inclusive and no other warranty, whether written or oral, is expressed or implied. Calibration, Repair, and Customer Care Services FLIR Systems, Inc. offers repair and calibration services for the Extech Instruments products we sell. NIST certification for most products is also provided. Call the Customer Service Department for information on calibration services available for this product. Annual calibrations should be performed to verify meter performance and accuracy. Technical support and general customer service is also provided, refer to the contact information provided below. Support Lines: U.S. (877) 439‐8324; International: +1 (603) 324‐7800 Technical Support: Option 3; E‐mail: [email protected] Repair & Returns: Option 4; E‐mail: [email protected] Product specifications are subject to change without notice Please visit our website for the most up‐to‐date information www.extech.com FLIR Commercial Systems, Inc., 9 Townsend West, Nashua, NH 03063 USA ISO 9001 Certified Copyright © 2013 FLIR Systems, Inc. All rights reserved including the right of reproduction in whole or in part in any form www.extech.com 48VFL & 96VFL v1.2 07/13