Advanced Temperature Controller

Ramp and Soak Temperature Controller

User Manual
1 Front panel and operation
1:PVdisplay: Indicatesthesensor readout, or processvalue(PV)
2:SVdisplay: Indicatestheset value(SV) or output value(%)
3:OUT1: Output indicator, It issynchronizedwithcontrol output andthepower totheload. Whenit ison, theheater (or cooler)
ispowered.
Thiscontroller isintendedtocontrol equipment under normal operatingconditions. If failureor malfunctionof thecontroller mayleadtoabnormal operatingconditions
that mayresult inpersonal injuryor damagetotheequipment or other property, devices(limit or safetycontrols) or systems alarm or supervisory intended to warn
of or protect against failure or malfunctionof thecontroller must beincorporatedintoandmaintainedaspart of thecontrol system.
4:OUT2: Output 2isnot applicablefor thisinstrument.
5:ALM2: It lightsupwhenAL2relayison
6:AUX: Auxiliaryoutput indicator, whenauxiliaryfunctionincorporatedandactivated, theindicator lightsup.
7:AL1: It lightsupwhenAL1relayison
9:A/M: Auto/manual control functionkey/ datashift key
10:Decrement key/Runor STOPtheprogram
11:Increment key/Stoptheprogramkey
SET
AUX OUT1 OUT2
ALM1 ALM2
A/ M RUN/ HOLD STOP
PV
SV
1
2
3
4
5
6
7
8
9 10
11
1.1 Display Status
Displaymode1: Whenthepower isturnedon, theupper displaywindowshowsthemeasuredvalue(PV) andthelower windowshowstheset value(SV)
Displaymode2: Presstheset keytochangethedisplaystatusintomode2, theupper displaywindowshowstheprocessvalue(PV) andthelower
displaywindowshowstheoutput value, thispictureshowstheoutput percentageis60%wheninautomatic(PID) control mode.Pressingthe<A/Mkey
will switchthecontroller betweenPIDandmanual control modewiththeoutput unchanged. Thisbumplesstransfer allowsthecontroller tobeswitched
betweenmanual andautomaticmodewithout theoutput suddenlybumping toadifferent value.
Displaymode3:Presstheset keyunder displaymode2tochangethedisplayintomode3, whichtheupper displayshowsStEPandlower display
showstheStEP beingexecuted.
Displaymode4:Presstheset keyunder displaymode3tochangethedisplayintomode4, theupper displayshowstheStEPtimebeingexecuted. the
lower displayshowsthetimethat thecurrent StEPhasbeenrunning.
Displaymode5:Presstheset keyunder displaymode1 for 2secondstoenter thedisplaymode5, whereuser canconfigurevarioussystemparameters
Displaymode6: Pressthe<A/Mkeyunder displaymode1toenter thedisplaymode6, whereuserscanconfigureadesiredramp/soakprogram.
Power on
<A/M
A60 meansoutput
value=60%onautomatic
mode
M60 meansoutput
value=60%onmanual
mode
PV
SV
Displaymode1
Displaymode2
Displaymode3 Displaymode4
SET
2S
<A/M+ SET
Displaymode5
SET
Next parameter
SET
Displaymode6
SET
2S
<A/M+
Next parameter
SET SET
<A/M
Figure1. Front Panel
Figure2. Displaymodes
1.2 Basic Operation
1.2.1 ChangingSet Value
Press the or key once,andthenreleaseit Thedecimal point onthelower right corner will start toflash Press the or key tochangeSVuntil
thedesiredvalueis displayed If thechangeof SVis large press theA Mkeytomovetheflashingdecimal point tothedesireddigit that needs tobe
changed Thenpress the or key tostart changingSVfromthat digit Thedecimal point will stopflashingafter nokey is pressedfor seconds The
changedSVwill beautomaticallyregisteredwithout pressingtheSETkey.
1.2.2 Displaychange
PresstheSETkeytochangethedisplaymode. Thedisplaycanbechangedbetweendisplaymodes1and2
1 2. Manual Automatic modeswitch
Bumpless switchingbetweenPIDmodeandManual modecanbeperformedby pressingtheA Mkey. InManual mode theoutput amplitudecanbe
increasedor decreasedby pressing and display mode
1.2.4Parameter SetupMode
When the display mode is 1, press SET and hold for roughly 2 seconds until the parameter setupmenuisdisplayed(displaymode5). Please refer
to figure 3 setupflowchart
PV
SV
SET 2S
Processhighalarm
Processlowalarm
DeviationHighalarm
Deviationlowalarm
HysteresisBand
SET
SET
SET
SET
SET
SET
Control mode
SET
Inputoffset
Outputmode
SET
Outputlowlimit
SET
HIAL
LoAL
dHAL
dLAL
dF
CtrL
SET
Derivativetime
Proportional Band
M5
P SC
oP1
oPL
Outputhighlimit
oPH
SET
Alarmoutputdefinition
ALP
SET
Systemfunctionselection
CF
SET
SET
Communicationaddress
Addr
Communicationbaud
bAud
SET
PVinputfilter
dL
SET
SET
Systemrunningstatus
run
Configurationpriviledge
Loc
SET
SET Fieldparameterdefinition
EP1----EP8
Figure3. systemparameter setupflowchart
SET
SET
SET
SET
Integral time
Cycletime
Inputtype
Decimal pointposition
Displaylowlimit
t
Ct1
Sn
dIP
dIL
SET
Displayhighlimit
dIH
SET
SET
1.3 Setupflowchart
Code Des cription S etting Range Initial s etting Remarks
HIA L P roces s high alarm 1999~+9999 C 9999
LoA L P roces s low alarm 1999~+9999 C -1999
dHA L Deviation high alarm 0 9999C 999.9
dLA L Deviation low alarm 0 9999C 999.9
dF Hys teres is B and
0~200.0 C
or 0~2000 for linear input
0.3
CtrL Control mode 0~4 3
M5 Derivative time 0 999.9 C 128.2
P P roportional band 0 9999 C 120
t Intergral time 0~2000 88
Ct1 cycle time 0~125
5 for S S R
20 for relay
S n Input type 0~37 0
dIP Decimal point pos ition 0~3 0
dIL Dis play low limit 1999~+9999 C 0
dIH Dis play high limit 1999~+9999 C 100
S C Input offs et -1.99 +400.0 C 0.0
oP 1 Output mode 0~4 0
oP L Output low limit 0~110 % 0
oP H Output high limit 0~110 % 100
A LP A larm output definition 0~31 0
CF S ys tem funtion s election 0~19 0
A ddr Communication addres s 0 5555 1
bA ud Communication baud 0~20 9600
dL P V input filter 0~19200 5
0~2 2
0~127 2
Loc Configuration priviledge 0~9999 808
E P 1~E P 8 F ield parameters definition nonE ~ A -M nonE
run S ys tem runing s tatus
Table1SystemParameters
1.4 ParameterSetting
8:SETkey:Whenit ispressedmomentarily, thecontroller will switchthelower (SV) displaybetweenset valueandpercentage
of output. Whenpressedandheldfor twosecondswill put thecontroller intoparameter settingmode.
Page1/5
1.4.1Alarmparameters
This controlleroffers fourtypes ofalarm,HIALLoALdHALdLAL
HIAL: Highlimit absolutealarm. If theprocessvalueisgreater thanthevaluespecifiedas HIAL+dF (dF is the Hysteresis Band),thenthealarmwill turnon. It will
turnoff whenthe processvalueislessthanHIAL-dF
LoAL: Lowlimit absolutealarm. If theprocessvalueislessthanthevaluespecifiedasLoAL-dF thenthealarmwill turnon,andthealarmwill turnoff if theprocess
valueisgreater thanLoAL+dF.
dHAL: Deviationhighalarm. If thetemperatureisaboveSV+dHAL-dF thealarmwill turn on, andthealarmwill turnoff if theprocessvalueislessthanSV+dHAL-dF
(wewill discusstheroleof dFinthelater section)
dLAL: Deviationlowalarm. If thetemperatureisbelowSV-dLAL-dF,thealarmwill turnon, andthealarmwill turnoff if thetemperatureisgreater thanSV-dLAL+dF
Thethings youshouldknowaboutalarm
2)AlarmSuppressionfeatureSometimes, user maynot want thelowalarmtobeturned onwhenstartingthecontroller at atemperaturebelowthelowalarm
setting. TheAlarm Suppressionfeaturewill suppressthealarmfromturningonwhenthecontroller ispowered up(or SVchanges). Thealarmscanonlybe
activatedafter thePVhasreachedSV.
1) Absolutealarmanddeviationalarm
High(or low) limit absolutealarmisset bythespecifictemperaturesthat thealarmwill beon. Deviationhigh(or low) alarmisset byhowmany
degreesabove(or below) thecontrol target temperature(SV) that thealarmwill beon.e.g. AssumingHIAL=1000 C, dHAL=5 C, SV=700 C. When
theprobetemperature(PV) isabove705, thedeviationalarmwill beon. Whenthetemperatureisabove1000 C, theprocesshighalarmwill beon.
Later, whenSVchangesto600 C, thedeviationalarmwill bechangedto605but processhighalarmwill remainthesame. HeretheHysteresisBand
(dF) settingisignored. Pleasesee1.5.2for details.
3) ActivatetheAL1andAL2bytimeinsteadof temperature
For thecontrollerswiththerampandsoakfunction, AL1andAL2canbeactivatedwhentheprocessreachesaspecific time. Thisis discussedinthe
section3.7of SupplementaryInstructionManual for ramp/soakversion.
1.4.2HysteresisBanddF
TheHysteresisBandparameter dFisalsoreferredasDeadBand, or Differential. It permitsprotectionof theon/off control fromhighswitching
frequencycausedbyprocessinput fluctuation. HysteresisBandparameter isusedfor on/off control, 4-alarmcontrol aswell astheon/off control at auto
tuning. For example: 1) Whencontroller isset for on/off heatingcontrol mode,theoutput will turnoff whentemperaturegoesaboveSV+dFandonagain
whenit dropstobelowSV-dF. 2) If thehighalarmisset at 800 Candhysteresisisset for 2 C, thehighalarmwill beonat 802 C(ALM1+dF) and
off at 798 F(ALM1-dF). Pleasenotethat thecycletimecanalsoaffect theaction. If thetemperaturepassesthedFset point right after thestart of a
cycle, thecontroller will not respondtothedFset point until thenext cycle. If cycletimeisset to20seconds, theactioncanbedelayaslongas20
seconds. Userscanreducethecycletimetoavoidthedelay.
1.4.3Control mode Ctrl
Ctrl=0On/off control. It workslikeamechanical thermostat. It issuitablefor devicesthat donot liketobeswitchedat highfrequency, suchasmotor and
valves
Ctrl=1Getsthecontroller readytostart theAutotuningprocessbypressingtheA/Mkey.
Ctrl=2Start autotuning. Thefunctionisthesameasstartingautotuningfromfront panel.
Ctrl=3Thisconfigurationisautomaticallyset after autotuningisdone. Autotuningfromthefront panel isinhibitedtoprevent accidental re-startingof the
autotuningprocess. Tostart autotuningagain, set Ctrl=1or Ctrl=2.
1.5Control actionexplanations
1.5.1PID
Pleasenotethat becausethiscontroller usesfuzzylogicenhancedPIDcontrol software, thedefinitionof thecontrol constants(P, I andd) aredifferent than
that of thetraditional proportional, integral, andderivativeparameters. Inmost casesthefuzzylogicenhancedPIDcontrol isveryadaptiveandmaywork
well without changingtheinitial PIDparameters. If not, usersmayneedtouseauto-tunefunctiontolet thecontroller determinetheparametersautomatically.
If theautotuningresultsarenot satisfactory, youcanmanuallyfine-tunethePIDconstantsfor improvedperformance. Or youcantrytomodifytheinitial PID
valuesandperformautotuneagain. Sometimesthecontroller will get thebetter parameters. Theauto-tunecanbestartedintwoways. 1) Set Ctrl=2. It will
start automaticallyafter 10seconds. 2) Set Ctrl=1. Thenyoucanstart theauto-tuneanytimeduringthenormal operationbypressingtheA/Mkey. During
autotuning, theinstrument executeson-off control. After 2-3timeson-off action, themicroprocessor intheinstrument will analyzetheperiod, amplitude,
waveformof theoscillationgeneratedbytheon-off control, andcalculatetheoptimal control parameter value. Theinstrument beginstoperformaccurate
artificial intelligencecontrol after autotuningisfinished. If youwant toexit fromautotuningmode, pressandholdthe(A/M) keyfor about 2secondsuntil the
blinkingof "At" symbol isstoppedinthelower displaywindow. Generally, youwill onlyneedperformautotuningonce. After theautotuningisfinished. The
instrument will set parameter Ctrlto3, whichwill prevent the(A/M)key from triggering auto-tune.Thiswill prevent anaccidental repeat of theauto-tuning
process.
1.5.2On/off control mode
It isnecessaryfor inductiveloadssuchasmotors, compressors, or solenoidvalvesthat donot liketotakepulsedpower. It workslikeamechanical
thermostat. Whenthetemperaturepassestheset point, theheater (or cooler) will beturnedoff. Whenthetemperaturedropsbacktobelowthehysteresis
band(dF) theheater will turnonagain.TousetheOn/off mode, set Ctrl=0. Then, set theHytothedesiredrangebasedoncontrol precisionrequirements.
Smaller dFvaluesresult intighter temperaturecontrol, but alsocausetheon/off actiontooccur morefrequently.
1.5.3. Manual mode
Manual modeallowstheuser tocontrol theoutput asapercentageof thetotal heater power. It islikeadial onastove. Theoutput is
independent of thetemperaturesensor reading. Oneapplicationexampleiscontrollingthestrengthof boilingduringbeer brewing. Youcan
usethemanual modetocontrol theboilingsothat it will not boil over tomakeamess. Themanual modecanbeswitchedfromPIDmodebut
not fromOn/off mode. Thiscontroller offersabumpless switchfromthePIDtomanual mode. If thecontroller outputs75%of power at
PIDmode, thecontroller will stayat 75%whenit isswitchedtothemanual mode, until it isadjustedmanually. SeeFigure2 for howtoswitch
thedisplaymode.
1.6Cycletimet
It isthetimeperiod(inseconds) that thecontroller usestocalculateitsoutput. e.g. Whent=2, if thecontroller decidesoutput shouldbe10%,
theheater will beon0.2secondandoff 1.8secondsfor every2seconds. Smaller t valuesresult inmoreprecisioncontrol. For SSRoutput,
it isset at 5secondsor youcanchangeto2S. For relayor contractor output, it shouldbeset longer toprevent contactsfromwearingout too
soon.Normallyit isset to20~40seconds.
SNCODE
0
1
3
4
5
6
7
20
21
Input Device
K(Thermocouple)
S(Thermoucouple)
T(Thermocouple)
E(Thermocouple)
J(Thermocouple)
B(Thermocouple)
N(Thermocouple)
Cu50
Pt100
Display Range(Celcius)









2
2
2
2










0~20mV
0~100 mV
0~60 mV
0~1V
V
mA w Resistor
V
mA w Resistor






1.7 Decimal point settingdIP
1) Incaseof thermocoupleor RTDinput, dPisusedtodefinetemperaturedisplayresolution.
dP=0, temperaturedisplayresolutionis1 C
dP=1, temperaturedisplayresolutionis0.1 C. Thetemperaturewill bedisplayedat theresolutionof 0.1 Cfor input below1000 Cand1
Cfor input over 1000 C.
2) For linear input devices(voltage, current or resistanceinput, Sn=26-37)
Table3. dPparameter setting
dIP Value
Display format 0000 000.0 00.00 0.000
0 1 2 3
1.9Limitingthecontrol range, dIL anddIH
1) For temperaturesensor input, thedILanddIH valuesdefinetheset valuerange. dIL isthelowlimit, anddIH isthehighlimit.
e.g. Sometimes, youmaywant tolimit thetemperaturesettingrangesothat theoperator cant set averyhightemperaturebyaccident. If you
set thedIL=100anddIH=130, operator will onlybeabletoset thetemperaturebetween100and130.
2) For linear input devices, dILanddIH areusedtodefinethedisplayspan. e.g. If theinput is0-5V. dIL isthevaluetobedisplayedat 0Vand
dIHisthevalueat 5V.
1.10Input offset SC
SCisusedtoset aninput offset tocompensatetheerror producedbythesensor or input signal itself. For example, if thecontroller displays
0 0
5 Cwhenprobeisinice/water mixture, settingSC=-5, will makethecontroller display0 C.
1.11Output definitionoP1
Thisparameter isnot usedfor thismodel. It shouldnot bechanged.
1.12Output rangelimitsoPL andoPH
oPLandoPHallowyouset theoutput rangelowandhighlimit. oPL isauseful featurefor asystemthat needstohaveaminimumamount
of power aslongasthecontroller ispowered. e.g. If oPL=20, thecontroller will maintainaminimumof 20%power output evenwheninput
sensor failed. oPH canbeusedwhenyouhaveanoverpoweredheater tocontrol asmall subject. e.g. If youset theoPH=50
Table2. Codefor Snanditsrange.
Page2/5
e.g. If youset theoPH=50, the5000watt heater will beusedas2500Wheater (50%) evenwhenthePIDwantstosend100%output.
1.13Alarmoutput definitionALP
Parameter ALP maybeconfiguredintherangeof 0to31. It isusedtodefinewhichalarms( HIAL LoAL dHAL anddLAL isoutput toAL1or
AL2. Itsfunctionisdeterminedbythefollowingformula
ALP=AX1+BX2+CX4+DX8+EX16
If A=0, thenAL2isactivatedwhenProcesshighalarmoccurs; If A=1, thenAL1isactivatedwhenProcesshighalarmoccurs
If B=0, thenAL2isactivatedwhenProcesslowalarmoccurs; If B=1, thenAL1isactivatedwhenProcesslowalarmoccurs
If C=0, thenAL2isactivatedwhenDeviationhighalarmoccurs; If C=1, thenAL1isactivatedwhenDeviationhighalarmoccurs
If D=0, thenAL2isactivatedwhenDeviationlowalarmoccurs If D=1, thenAL1isactivatedwhenDeviationlowalarmoccurs
If E=0, thenalarmtypes, suchasHIAL andLoAL will bedisplayedalternativelyinthelower displaywindowwhenthealarmsareon.
Thismakesit easier todeterminewhichalarmsareon. If E=1, thealarmwill not bedisplayedinthelower displaywindow(except for orAL)
Generally this setting is used when the alarm output is used for control purposes. For example, inorder toactivateAL1whenaProcesshigh
alarmoccurs, trigger AL2byaProcesslowalarm, Deviationhighalarm, or Deviationlowalarm, andnot showthealarmtypeinthelower display
window, set A=1, B=0, C=0, D=0, andE=1. Parameter ALP shouldbeconfiguredto: ALP=1X1+0X2+0X4+0X8+1X16=17 thisisthefactory
default setting)Note: Unlikecontrollersthat canbeset toonlyonealarmtype(either absoluteor deviationbut not bothat sametime), thiscontroller
allowsbothalarmtypestofunctionsimultaneously. If youonlywant onealarmtypetofunction, set theother alarmtypeparameterstomaximumor
minimum(HIAL, dHALanddLALto9999, LoAL to-1999) tostopitsfunction.
1.14 SystemfunctionselectionCF
Parameter CF isusedtoset theheatingor cooling, alarmsuppressionandpower restrictionfunction. Itsvalueisdeterminedbythefollowing
formula: CF=AX1+BX2+CX16
A=0, reverseactioncontrol modefor heatingcontrol.
A=1, direct actioncontrol modefor coolingcontrol.
B=0, without alarmsuppressingwhenturnedonor whenset point changes.
B=1, alarmsuppressingat power upor set point changes.
C=0, without power restrictedfunction
C=1, withpower restrictedfunction
ThefactorysettingisA=0, B=0, C=0(heating, without alarmsuppression, without power restrictedfunction, ThereforeCF=0X1+0X2+0x16=0
1.15Input digital filter dL
If measurement input fluctuatesduetonoise, thenadigital filter canbeusedtosmooththeinput. dL maybeconfiguredintherangeof 0to20.
Stronger filteringincreasesthestabilityof thereadout display, but causesmoredelayintheresponsetochangeintemperature. dL=0disablesthe
filter.
1.16Manual andAutomaticModeSelection run
Parameter runisfor selectingautomaticor manual control mode.
run=0, manual control mode
run=1, automaticcontrol mode(either PIDor On/off control)
run=2, automaticcontrol mode, inthisstatemanual operationisprohibited
This parameterfunctions differentlyforcontrollers withtheramp/soakfunction(seesupplemental manual fordetails).
1.17Lockupthesettings, fieldparameter EP andparameter LocK
Toprevent theoperator fromchangingthesettingsbyaccident, youcanlocktheparameter settingsafter initial setup. Youcanselect which
parameter canbeviewedor changedbyassigningoneof thefieldparameterstoit. Upto8parameterscanbeassignedintofieldparameter
EP1-EP8. Thefieldparameter canbeset toanyparameter listedinTable2, except parameter EPitself. WhenLocKisset to0, 1, 2, andsoon,
onlyparametersor settingvaluesof programdefinedinanEPcanbedisplayed. Thisfunctioncanspeedupparameter modificationandprevent
critical parameters(likeinput, output parameters) frombeingmodified. If thenumber of fieldparametersislessthan8, thendefinethefirst unused
parameter asnone. For example, if onlyALM1andALM2needtobemodifiedbyfieldoperators, theparameter EPcanbeset asfollowing:
LocK=0, EP1=HIAL, EP2=LoAL, EP3=nonE. Inthiscase, thecontroller will ignorethefieldparametersfromEP4toEP8. If fieldparametersarenot
neededafter theinstrument isinitiallyadjusted, simplyset EP1tononE. Lockcode0, 1and2will givetheoperator limitedprivilegestochangesome
of theparametersthat canbeviewed. Table5showstheprivilegesassociatedwitheachlockcode.
Lock Value SV adjustment EP1-EP8 adjustment Other parameters
0
1
2
3 and UP
808
yes
yes
No
No
yes
No
yes
No
Locked
Locked
Locked
Locked
Unlocked
Quick Guide for Advanced Temperature Controller
1. Wiring
1) Power tothecontroller. Connect the90-260VACpower toterminals1and2.
2) Control output connection. Connect terminals3and5 for SSRDriveoutput, 3for negativeand5for positive.
3) Sensor connection. For thermocouples, connect thepositivewiretoterminal 10, thenegativetoterminal 11.
For athree-wireRTDwithstandardDINcolor code, connect thetworedwirestoterminals10and11, andconnect thewhitewiretoterminal 9.
For atwo-wireRTD, connect thewirestoterminals10and11, Then, jumpawirebetweenterminals9and10.
2. Set sensor type
Set Snto0for aKtypethermocouple(default), 5for aJtypethermocouple, and21for aPt100RTD.
3. Switchingbetweenautomaticandmanual mode
Set run=0toactivemanual mode. PresstheA/Mkeytoswitchbetweenautomaticandmanual mode.
4. Settingthecontroller for coolingcontrol.
For coolingcontrol, set CF=1, theinitial settingisCF=0for heatingcontrol
Setting target temperature SV
Pressthe or keyonce, andthen release it The decimal point on thelower right corner will start to flash Press the or key
tochangeSVuntil the desired value is displayed The decimal point will stop flashing after no keyispressed for seconds You can press
the A/M key to move the flashingdecimal point to the desired digit that needs to change Then press the or key to change SV
starting from that digit
6. Auto-tune
Youcanusetheauto-tunefunctiontodeterminethePIDconstantsautomatically. Therearetwowaystostart auto-tuning:
1) Set Ctrl=2. It will start automaticallyafter 10seconds.
2) Set Ctrl=1. Thenduringthenormal operation, presstheA/Mkeytostart theauto-tune. Theinstrument will performaccurateartificial intelligence
control after autotuningisfinished.
7.On/off mode
Set Ctrl=0toactivetheon/off control mode. Set theHysteresisBandparameter dFtobeadesiredvalue.
8. Error Messageandtroubleshooting
8.1DisplayorAL
Thisisaninput error message. Thepossiblereasonsare: thesensor isnot connectedcorrectly; theinput setting is wrong type;or the sensor is defective
Inthiscase, theinstrument terminatesitscontrol functionautomatically, andtheoutput valueisfixedaccordingtotheparameter oPL. If thishappenswhenusing
thermocouplesensor, youcanshort terminal 10and11withacopper wire. If thedisplayshowsambient temperature, thethermocoupleisdefective.
If it still displaysorAL, checktheinput setting, Sn, tomakesureit isset totheright thermocoupletype. If theSnsettingiscorrect, thecontroller isdefective.
For RTDsensors, checktheinput settingfirst becausemost controllersareshippedwiththeinput set for thermocouples. Thencheckthewiring. Thetwo
redwiresshouldbeconnectedtoterminals10and11. Theclear wireshouldbeconnectedtoterminal 9.
8.2Noheating
Whenthecontroller output isset for relayoutput, theOUT LEDissynchronizedwithoutput relay. If heat isnot output whenit issupposedto, checktheOUT
LEDfirst. If it isnot lit, thecontroller parameter settingsarewrong. If it ison, checktheexternal switchingdevice(if therelayispulled-in, or theSSRsredLEDis
on). If theexternal switchingdeviceison, thentheproblemiseither theexternal switchingdeviceoutput, itswiring, or theheater. If theexternal switchingdevice
isnot on, thentheproblemiseither thecontroller output, or theexternal switchdevice.
8.3Poor Accuracy
Pleasemakesurecalibrationi sdonebyimmersingtheprobeinliquid.Comparingthereferenceinair isnot recommendedbecauseresponsetimeof
thesensor dependsonitsmass. Someof our sensorshaveresponsetime> minutesintheair. Whentheerror islarger than C, themost common
problemisanimproper connectionbetweenthethermocoupleandthecontroller. Thethermocoupleneedstobeconnecteddirectlytothecontroller
unlessathermocoupleconnector andextensionwireisused. Copper wireor athermocoupleextensionwirewiththewrongpolarityconnectedonthe
thermocouplewill causethereadingtodrift morethan5C.
8.4Onon/off mode
Althoughhysteresisisset to0.3, theunit isrunning5degreesaboveandbelow. If thedF isverysmall andtemperaturechangesveryquickly, users
will needtoconsider thedelayof thecycletime(theparameter t). For example, if cycletimeis20seconds, whenthetemperaturepassestheSV+dF
after thebeginningof a20secondscycle, therelaywill not act until thestart of thenext cycle20secondslater. Usersmaychangethecycletimetoa
smaller value, suchas2seconds, toget better precisioncontrol.
Supplementary Instruction Manual
For the Ramp/Soak option of Programmable Controller
Version 6.58
Thisisasupplementarymanual for theRamp/Soakcontroller. It isonlyfor operatingtheprogrammablesteps(rampandsoaksteps) functions. Themain
manual for theRamp/Soak isthesameastheadvancedtemperaturecontroller. It coversall theregular set upandoperationinstructions. TheRampand
Soak seriesprogrammable controllers withtheramp/soakoption aredesignedfor applicationswhereit isdesirabletohavetheset point automatically
adjust itself over time.
1. Features
50stepsof programcontrol for rampingandsoakingprocess.Highflexibilityinprogramandoperation. It hasprogrammable/maneuverablecommands
suchasjump(for loops), run, holdandstop.Theprogramcanevenbemodifiedwhileit isrunning.Theprogramcanalsocontrol thetworelaysthat are
usedfor alarms. Thisfeaturecanbeusedtonotifytheoperator of thestageof theoperation, or tosignal other equipment. Thesafetystart andready
functionmayallowstheprogramtorunmoreefficiently. 6power-off/power-onevent handling(see3.10) modescanbeselected. Thiscanprevent the
programcontrol frombeingadverselyaffectedbyunexpectedpower interruptions.
2. TermsandFunctions
ProgramStEP: Thevalueof theprogramStEPcanrangefrom1to50. Thecurrent StEPistheprogramStEPbeingexecuted.
StEPtemperature, CXX: TheStEPtemperatureistheset temperatureat thebeginningof thestepXX(whereXXcanbeanyvaluefrom01to50).
StEPtime, tXX: TheStEPtimeistherampingtimefromthecurrent steptemperaturetothenext steptemperature. Theunit isinminutesandthe
availablevaluerangeisfrom1to9999.
Runningtime: Therunningtimeisthetimethat thecurrent StEPhasbeenrunning. WhentherunningtimereachestheStEPtime,theprogramwill jump
tothenext StEPautomatically.
Jump: Theprogramcanjumptoanyother stepsintherangeof 1to30automaticallyasyouprogrammedintheprogramStEP. It canalsobeusedto
performcyclecontrol. If StEPnumber ismodified, theprogramwill alsojump. Furthermoreif theprogramStEPreachesandfinishesthe50th
StEP, theprogramwill jumpbacktothefirst StEPandrunautomatically.
Run: Whentheprogramisintherunningstatus, thetimer countsdown, andtheset point valuechangesaccordingtothepreset rampcurve.
Hold: Whentheprogramisintheholdstatus, thetemperatureisstill controlled, but thetimer ispausedsothecurrent set point remains.
Stop: Whenthestopoperationisactivated, theprogram, timer, andoutput control will stop, andtherunningtimeandevent output switchwill reset. If
therun operationisactivatedwhiletheinstrument isinthestopstatus, theprogramwill start-upandrunfromtheStEP1.
Powerinterrupt: It meansthepower hasturnedoff or anunexpectedpower failurehasoccurredduringrunningstatus. 6handlingmodesare
availabletotheuser.
Eventoutput: Event output canbeprogrammedintothecontroller. It cantrigger twoalarmrelaystomakeexternal equipment operatewithinterlock.
Safetystart: If thedifferencebetweenthePVandSVislarger thanthedeviationalarmsettingat thebeginningof astep(or whenpoweredup), the
controller will adjust thePVuntil thealarmisturnedoff beforethetimer starts. See3.10for example.
Page3/5
3. Programming
3.1ProgramSetup
PresstheA/Mkeytobringtheinstrument intotheprogramsetupmode; theinstrument will displaythetemperatureset point of thecurrent StEP
indicated byC intheupper displayfollowedbytheStEPnumber). UsetheA/Mkeytochoosewhichdigit toedit (indicatedbytheflashingdecimal
point). After adjustingthetemperatureset point (1999to+9999), presstheSETkeyonceagain, andthecurrent StEPsrampingtimewill bedisplayed
( t intheupper display). IneachprogramStEP, thetemperatureandthe timeisdisplayedinturn. HolddowntheA/MkeyandpressVtogobackto
thepreviousparameter. HoldA/MandpressSETtoexit programsetup mode. Modifyingprogramstepswhileaprogramisrunningispermitted. See
section4for aprogrammingexample. Note: theaboveoperationisinhibitedif theprogramsetupfunctionislocked(refer to . for the introduction
of theLocKparameter
3.2ProgramRamp
Toprogramaramp, youneedtoset thestart temperatureCXX, theendtemperatureCXX+1, andthetimedurationtXX. For example, at step3, if
youwant thecontroller totake60minutestorampupfrom200to300degrees, set C03=200, C04=300, t03=60. Note: Unlessthedeviationalarms
areset toanarrowrange, therampingtimedecideswhentheprogramisgoingtothenext step. Oncetherampingtimeisfinishedthecurrent step,
thecontroller will executethenext stepregardlessif thetemperaturereachesthetarget temperature. Therefore, therampspeedshouldbealways
lower thanthemaximumspeedthat theovencanoffer at thefull power. Inother words, therampingtimeshouldbelonger thantheminimumtime
neededfor oventojumpfromC03toC04at full power. If therampingtimeisshorter thanthat, thetimeprogrammedfor thenext stepwill not be
fulfilled. Whenprogramatemperaturerampsdown, youneedtoconsider thespeedof natural cooling(or forcedair cooling) for thesamereason.
If themaximumspeedof thesystemisunknownor varieswithenvironmental conditions, usersshouldusethesafetystart functiontoensurethat
thetemperatureandtimeduringrampingandsoakingarekept withinareasonablerangerequiredbytheprocess. Thisisdonebysettingthe
deviationalarmclosetotheSV. At thebeginningof astep, thetimer will not start until PVislarger thanSV-dLAL+dFandsmaller thanSV+dHAL-dF.
e. g. Set dHAL=30, dLAL=20, dF=5andSV=100. At thebeginningof thestep, if thetemperatureisbelow85(SV-dLAL+dF=85) degrees, or above125
SV dHAL-dF )degrees,the controller will stop the timer to wait until thetemperatureisabovethan85degreesor belowthan125
degreesbeforecontinuing. PleasenotethatthedF valueshouldbesmallerthanbothdHALanddLAL, Otherwisethecontrollerwill notstartthenextsteps.
3.3ProgramSoak
Thesoakcanbeconsideredasaspecial caseof ramping. It isarampwithazerodegreeslope. Toprogramasoak, youneedtoset thestart andtheend
temperaturetobethesame(CXX=CXX+1), e.g. At step3, if youwant thecontroller tosoakthepartsat 200degreesfor 60minutes, set C03=C04=300,
t03=60. Note: TheStEPtimeisnot howlongthecontroller will stayat theset temperaturefor thecurrent step. It ishowlongthecontroller will takefrom
thecurrent steptemperatureset point tothenext steptemperatureset point. Thesetwoconceptsareverydifferent.
3.4ProgramHold
WhentheprogramreachesaStEPwheretheStEPtimeisset tozero, or whenajumpingStEPtransitionstoanother jumpingStEP, theprogramwill beset
tohold status You can alsomanuallyactivateholdstatusbypressingtheVkeyfor about 2secondsuntil HoLd appearsinthelower displaywindow.
3.5ProgramStop
WhentheprogramreachesaStEPwhere the StEP time is set to-121 thecontroller will stop running The StEP number is reset to1 the
event output iscleared,and the control output is turned off.Youcanalso manually executethe stopoperation by pressing and holding the
keyfor roughly2secondsuntil the lower display window displaysStoP.
3.6 RunProgram
Inorder tocontinuetheprogramwhenthecontroller isinhold mode(or restart it fromstopmode) lower window displaysrun.Whenaprogramis
running,
3.7StEPTime/CommandParameter
WhentXXisbetween1and9999(min), it isusedtoset therampandsoaktime. Whenit isset tozeroor anegativenumber, it isusedfor executingother
commands.
tXX=0Theinstrument isput inholdmodeonStEPnumber XXuntil manuallyreleasedbytheoperator.
tXX=-1to-240representsanoperationcommandsuchasrun, hold, stop,jumpandevent output. Thenumber iscalculatedaccordingtotheequation
tXX=-(A*30+B). Bisthenumber (rangingfrom1to30) of thenext stepfor theprogramtojumptoandA istheevent that istriggered:
A=0noeffect (for jumpfunctiononly)
A=1 switch on AL2
A=2 switch on AL1
A=3 switch on AL1 and AL2
A=4 Stop the instrument(B must be set to1when A=4)
A=5 switch off AL2
A=6 switch off AL2
A=7 switch off AL1 and AL2
Examples
Jump from StEP4to StEP5and switch on AL2
Time setup is t04=-(1x30+5)=-35
Jump from StEP6 to StEP1and switch off AL2.
Time setup is t06=-(5x30+1)=-151
Stopprogramat StEP8
Time setup is t08=-(4x30+1)=-121
The controller does not let a jump command jump to itself(for example t06=-6) because the Hold status would never be released
3.8
Sometimes it is convenient to jump directly to a particular StEP and executefrom there If the program is still in the middle of the
4th StEP and you wish tofinish it in advance and execute the5th StEP-the StEP modification featurewill meet your need TheRamp
andRampseries controller can start the program from anyone of its steps Press the SET key(briefly)to display the StEP number
Press the V keysto change it The StEP number increases or decreases automatically as theprogram executes If the StEP
number is manually changed the running timewill be cleared to and the program will begin with the new StEP If the StEP
number is not changed pressing the SET key will not affect theoperation of the program
Displaying and modifying the running StEPnumber (StEP) of theprogram
3.9MultipleCurves
Theflexibleprogrammingformat of theRamp&Soakcontroller canbeusedtostoreandrecall multipleprogrammedcurves. If atemperaturecurve
requireall 50steps, theunusedstepscanbeusedtostoreanother program. Several different curvescanbestoredandexecutedindividually, as doesnt
longastherearenot morethan50stepstotal (includingnecessarycontrolssteps). For example, whenaprocesscurveonlyneedsnineprogram
steps, it ispossibletostorethreesuchprocesscurvesintheinstrument. SimplychangetheStEPnumber toinitiateadifferent curve. Suppose8steps
represent threegroupsof processparameters. TheyareseparatelyarrangedonStEP2-StEP9,StEP10-StEP17, StEP18-StEP25. Thesteptimeof step1
canbeset asfollowstochoosethedesiredprogram:
T01=-2Executetheprogramof curve1(StEP2-StEP9)
T01=-10Executetheprogramof curve2(StEP10-StEP17)
T01=-18Executetheprogramof curve3(StEP18-StEP25)
Youcanalsochoosethecurvesbymanuallysettingthevalueof StEPbeforetheprogramstarts. For example, if curve2isneededinthecurrent process,
thenset thevalueof StEPto10.
3.10Control ModeParameter run
Thefunctionof therunparameter isdefineddifferentlyintherampandSoakcontroller thanit isfor thecontroller without theramp/soakoption. Its
operationisdeterminedaccordingtotheequation
run=AX1+BX8
Where A isusedtoselect oneof 4power outage/startupevent handingmodes, andB isusedtoselect SafetyStart andPVpreparationfunction
PowerOutage/StartupModes:
A=0: Whentheinstrument isturnedon, theprogramwill simultaneouslyjumpto29thprogramsegment andclear event output status. Thismodeissuitable
for applicationsinwhichpower failureisnot allowedat anytime. Theuser maydoerror handlinginsegment 29, suchasswitchingontheevent output to
trigger analarm.
A=1: If thereisnodeviationalarmat power up, theprogramwill continuerunningfromtheoriginal breakpoint andtheevent output stateremains.
Otherwise, theprogramwill jumptothe29thsegment andclear event output status.
A=2: After power isturnedon, it will continuetheprogramfromtheoriginal breakpoint, andtheevent output statewill remain. Thismodeissuitablefor
theapplicationsinwhichpower failuredoesnot affect production(default setting).
A=3: After power isturnedon, controller goestoStopstatus
A=4: After power isturnedon, controller goestoHoldstatus, thecontrollerswill goestoStopstatusif thecontroller at Stopmodebeforepower failure.
SafetyStart andPVPreparationfunctions:
B=0, without andPVpreparationfunction, Programisexecutedasplanned. Thismodeguaranteesconstant runningtimeof theprogram,
but it cant guaranteetheintegrityof thewholecurve.
B=1, withthefunctionof SafetyStart andwithout thefunctionPVpreparation
B=2, withthefunctionof PVpreparationandwithout thefunctionof SafetyStart
B=3, withthefunctionof SafetyStart andPVpreparation
About andPVPreparation
SafetyStartFunction
At thefirst stepof program, whentheambient temperatureisdiffer fromtheC01(Set point of first step), thecontroller will automaticallyadjust the
runningtimetomaketheexpectedset point thesameasthecurrent PV.
For example, inasystemwheretheprogramconfiguredfrom25Cto625Cwithin600minutesat thefirst step, but after thepower oninthesystem,
theprocessvalueisalreadyat 100Cwhichishigher thantheoriginal setpoint 25Cfor first step, inthiscase, thecontroller will automaticallyadjust
therunningtimeto75minutesandruntheprogram. Pleasenotedthat SafetyStart functiononlyapplicablefor 1st stepof aprogram
PVPreparationFunction
Inasystemwheretheambient temperatureisdiffer fromtheSet point of executedsteps, thecontroller will adjust thePVtoSVandmaintainthe
integrityof theprogram.
For example, inaheatingstepfrom100Cto600C, thesystemsufferspower off whentemperatureat 125C. andwhenpower comesback, thePV
of thesystemisactuallyat 105C, thecontroller will automaticallyadjust theprocessvalueto125Cwherethepower failedpoint andwithout increase
therunningtimeof thesystem. after processvaluereaches125C, theprogramgoesonasplannedbefore.


SafetyStart
SafetyStart
3.11Privilegefor parameter set LocK
For ramp&soakcontrollerswithramp/soakoption, theLocKhasslightlydifferent functions. Thetable1showstheprivilegeof eachlockcode.
Table1. LocKparameter
LocKvalue EP1-8Adjustment ProgramAdjustment
Stepselection
whenrunning
0
1
2
3andUP
808(default setting)
Yes
Yes
Yes
No
Yes
Yes
No
No
No
Yes
Yes
Yes
No
No
Yes
4. ProgrammingExample
ProgramsintheRamp&Soakcontroller haveauniformformat of temperature-time-temperature. Thetemperatureset point of thecurrent stepwill
linearlychangetotheset point of thenext stepover thetimeinterval of thetwosteps. Thefirst temperatureset point shouldalwaysbetheambient
temperatureat whichtheprocessstartstorampup. DONOTset thefirst temperatureset point tothetarget temperature(seeexample1below) if you
arenot usingthesafety-start function. Thetimeunitsareinminutes. Negativevaluesof thetimeinterval represent programcommands.
4.1Example1
Thefollowingexampleholdstheovenat 800 Cfor 2hours. Inthisexample, it isassumedthat theheater isabletoheat theovenfrom25 Cto800 C
within30minutes. If theheater doesnot havethisability, thesoaksectioncanbeginwhentheovenisbelow800 Cafter the30minutesrampingtime
isup. Pleasenotethat thevalueof Cisthebeginningtemperatureof thestep. e.g. C01isalwaysthetemperatureat thebeginningof thestep1. UsuallyC01
shouldbetheambient temperature, andt01isthetimefromstep1tostep2.
StEP1: C01=25, t01=30Start linear temperatureheatingupfrom25 Cto800 C, over atimeperiodof 30minutes(25.8 C/minute).
StEP2: C02=800, t02=120Maintain800 Cfor 120minutes.
StEP3: C03=800, t03=-121Stoptheprogramandlet theovencool down.Theequationusedtoget thecommandnumber is-(30* Command#+Next
Step) =-(30*4+1)=-121.
Thetemperaturecontrol blockisshownbelow.
>

Page4/5
1.BringUp
2.Constant Temp
3.Natural Cooling
Temp
0
C
Time(Min)
30 150
800
Figure 1. Holdingovenat 800 for 2hours
0
C
25
4.2Example2
Thefollowingexampleincludes6steps: linear temperatureheating, maintainingaconstant temperature, linear temperaturecooling, jumpcycling,
0
ready, holdandevent output. Inthefollowingexample, it isassumedthat thedeviationhighalarmdHAL=dLAL=5 CanddF=0.
StEP1: C01=100, t01=30Start linear temperatureheatingupfrom100 to400 , over atimeperiodof 30minutes(10 /minute).
0
StEP2: C02=400, t02=60Maintain400Cfor 60minutes.
0 0
StEP3: C03=400, t03=120Reducethetemperatureat arateof |C04-C03|/ t03=2C/minutefor 120minutes. Thiswill bringit downto160C.
StEP4: C04=160,t04=-65Alarm1istriggered, andtheprogramjumpsto
StEP5:Thecommandnumber for turningalarm1onis2 The equationusedtoget thecommandnumber is-(30*Command#+Next Step)=-(30*2+5)=-65
StEP5: C05=160,t05=0Atimevalueof zeroputstheprograminaHoldstate. Arunoperationexecutedbytheuser isneededfor theprogramto
continuetoStEP6.
StEP6: C06=100,t06=-181Alarm1isswitchedoff (unlessit isalsobeingtriggeredbyanalarmconditionoutsidetheprogram), andtheprogramjumpsto
StEP1tostart fromthebeginning. Thecommandfor switchingAlarm1off is6,so t06=-(30*6+1)=-181
0
StEP1: C01=100,t01=30Sincethetemperatureisstill at 160C, theprogramwill pauseuntil thecontroller canbringthetemperaturewithinthealarm
0
rangeof thenewset point. Sincethedeviationhighalarmisset to5C, theprogramwill resume(fromthebeginning) assoonasthetemperature
0
dropsbelowSV+dHAL-dF=105C.
Thetemperaturecontrol blockisshownbelow.
0 0 0
C C C
1.Bringup
2.Constant temp
3.Cool down
4.Jumpsection
alarm1on
5.Hold
6.Jumpsection
alarm1off
Readysection
notiming
Circlefrom
selection
Alarmoff
Alarmon
Alarmoff Temp
0
C
Time(Min)
Figure2. Ramp/SoakExample2
5.Quicklist of theNewKeyFunctionsfor theRamp/SoakModel
Thefollowinglist containsabrief descriptionof eachkeyfunctionfor whenthecontroller isinbasicoperationmode.
1)ModeKey(SET)
When pressed momentarily PV display shows the current step that theprogram is processing When pressed again the PV display shows
the set time length of the current step The SV display shows how long the current step has run in minutes Press again to have the
display return to the basicdisplaymode ThePV shows the process temperature and SVcaneither show the set temperature or the status
of the controller(Stopped,Running,or on Hold).Pressing and holding the mode key for two seconds will put the controller intoparameter setting
mode just like the controllers without the ramp/soak option.
2)Auto/Manual functionkey(A/M)
Press this key to have the controller enter step setting mode in order to set the time temperature and action of each step.
3)Decrement key V Press and hold this key for two seconds to start theprocessing Press and hold againto hold theprocessing.
4)Increment key Press and hold this key for two seconds to stop theprocessing of the program
Table2. Summary of New Key Functions
Tostart theprocessing PressVfor 2seconds
Tostoptheprocessing Press
V
for twoseconds
PressVfor 2seconds Toholdtheprocessing
Checkcurrent step
Checkruntimeof current step
GotoStepX
Toprogramthesteps
PressSETbrieflytwice
PressSETbriefly
PressSETbriefly, ThenuseVor
V
togotostep
PressA/Mkeytoenter programming
mode. Then, SETkeytogotonext step.
7.
7.1Whatis thedifferencebetweenHoldandStop.
Holddoesnot stopheating,It holdsthetemperatureat thecurrent setting,( or at oPL,see3.10for details), Stop will stopheating.

Frequently asked questions
If youHoldthe
program(Vkey) andstart Run(Vkey) again, it will start fromthestepthat wasput intohold.However,if youStoptheprogram( )andstart Run(
key)again,it will start fromstep1.
V key
V
7.2HowdoI runthis controlleras aregularcontrollerwithouttheramp/soakfunction?
Herearetwomethods.
1)Programaverylongstep. If youdidnt useupall thestepsfor programming,youcanuseoneof theunusedstepsfor that. For example,assuming
step10and11areunused, set C10=100,C11=10andt10=9999,ThissetsStep10 tocontrol thetemperature at 100degreesfor 9999minutes.To
begintheprogram, start Run(V key),pressSEToncetodisplayStEP,use togotoStEP10. PressSETtwice.Thecontroller will runjust likeregular
controller withPVdisplayedontop and SV in the bottom.Youdont have to do this every time the controller powers up(assumingtheA-M
parameter has not changed from default).It will remain running StEP10until 9999minutes(7days) runs out,or until you reset it for another
application
>
2) Put theprogramonholdmode. Thiscanbedoneeither bymanuallypressingtheHoldbuttonat thedesiredtemperature, or byprogramminga
holdstep(bysettingtXX=0).
7.3I justwanttoruntheovenat800degrees for120minutes.
WhenI set C01=800, t01=120, thecontroller SVfirst displays800, thenit startsdroppingwithtime. DidI dosomethingwrong?
Thisisthemost commonmistakefirst timeusersmake. Sincethisisarampcontroller, not astepcontroller, thetimet01(or tXX) isnot thetimethat
controller will stayat C01(or CXX), it istherampingtimethat controller will takefromtemperatureC01toC02. Toholdthetemperatureconstant for 120
minutes, youneedtoset twostepsat thesametemperature, or a0degreeramp(C02=C03=800inthiscase). Then, set therampingtimefor 120
minutes. Pleaseseeexample1.
Alarm1
100
160
400
30 90 210
V
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