Measurement & Control Instruments

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Certificate No: 368027

PID CONTROLLER model 6002

6002 controllers features (full configuration):
* Inputs:
- Max 8 Temperature Inputs - Pt100 (model 6002-R) or
- 1 TC or RTD Input, 2 RTD Inputs, 2 Current Inputs, Input for
Potentiometer, 2 digital inputs (model 6002)
- Input 4-20mA DC for external setting of Set Variable (SV) -
additional
* Outputs:
- Max 4 5A/250V SPDT relay outputs or 4 Solid State Relay
or 4 discrete outputs (Open Collector)
- Max 2 Isolated Current Outputs - for control or proportional
to the measured value (not powered)
- Galvanic isolated interface RS485 - additional
- 24V DC/50mA power supply for transmitter - additional
* Indication:
- 4 digit red LED display for process value (PV)
- 3 digit green LED display for Output (OUT)
- 4 digit green LED display for Set Variable (SV)
- 2 digit green display for symbols
- LED bargraph
- 7 LEDs
* Mounting:
- Dimensions - 96 x 96 x 135mm, panel mountable
- Panel cutout 92 x 92mm
* Power Supply 90 - 250V AC/DC

GENERAL INFORMATION
The control relay (LED A1 on the front panel) can be configured for PID or ON/OFF control action.
ON/OFF control:
The following parameters have to be set:
1. Set Point (SP)
2. Hysteresis (HSt).
3. Type of the limit level - High (Hi) or Low (Lo) (Heating or Cooling)

The way the control relay commutates is shown on Figure 1 and Figure 2.
High Limit Level
PV
Relay is OFF

L- set point
h-hysteresis time

Relay is ON

Figure 1
A typical application of a High Limit Level ON/OFF control action is the heating process control. When
the temperature is above the SP the relay output is not active and there is no heating. The heating
begins when the temperature falls below the SP minus hysteresis (SP - HSt).
Measurement & Control
Instruments
 PV Low Limit Level

h-hysteresis Relay is ON

time

L- set point

Relay is OFF

Figure 2
A typical application of a Low Limit Level ON/OFF control action is a temperature process controlled with
cooling. When the temperature is below the SP the cooling is OFF. When the PV (temperature) is above
SP plus hysteresis (SP + HSt) the relay output is activated and the cooling is started.
If the ON/OFF control action is not satisfactory enough PID control action could be used.

PID control:
The general logic of the action of the PID control is given by the expression:

 t
dPVn 
u(t ) = K  en + ∫ e (s )ds + Td
1 1

T dt 
 i 0 
where:
e = SP-PVc - The closed loop error; SP - Set Point, PV -Process Variable;
en=e/Range - Normalized error;
dPVn
- Change of the normalized process variable (not normalized error);
dt
K - Proportional Constant;
Ti - Integral Time (Ti);
Td - Derivative Time (Td);
u - PID normalized output 0-1.0;

The following parameters have to be set:

- SP - Set Point
- K - Proportional Constant
- Ti - Integral Time
- Td - Derivative Time

Auto-Tune function
The operator can start a simple automatic identification of the process only when PID control is used (not
ON/OFF). The identification procedure is "relay feedback identification". An ON/OFF control action
around the SP is used to identify the process properties (ultimate gain, ultimate period), and than to cal-
culate the optimal (if it is possible) PID parameters. The identification procedure is shown on the figure
below. The temperature process has to be without any load disturbances during the identification (i.e. the
temperature process has to be with constant parameters and under constant conditions).
The build-in method could be successful even when processes have a relatively long dead time.
The SP during the identification has to be as close as possible to the working Set-Point. After the para-
meters are calculated and saved the controller exits the auto-tune function and enters its basic display
mode. Indication for this is the switching off of the blinking "tu" caption on the 2-digit display.
The identification procedure can be stopped manually if there are undesirable effects.

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 o
tC

End Of Identification. Calculation

of the PID parameters

Set point

Controller ON/OFF PID

output

time

Figure 3
Influence of PID parameters to the controlled process:
The influence of the parameters (K, Ti and Td) to the process is graphically shown on the figure below.
Simulated transient responses and responses to load disturbance with different PID parameters are
shown on the different parts of the figure.
20
18
K3 K3>K2>K1 Ci1 Ci1< C i 2<Ci 3
18
16
16
K2 Ci2
K1 14
K1
14
Ci 3
K2 12 Ci 1
12

10
10

8
8
K3
6 6

4
4
2
2 Ci 3
0
0 5 10 15 20

Time (Seconds)
25 30 35 40
0
0 5 10 15 20 25 30
Change of proportional gain K Change of integral time Ti
18
Cd1
16 Cd1<Cd 2<Cd3
Cd2
14 Cd3

12

10

0
0 5 10 15 20 25 30

Change of derivative time Td

Figure 4
The above figures can be sumariezed as follows:

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The output from the controller is PWM (Pulse With Modulation). The operator has to set the PWM cycle.
The logic of PWM is shown on figure below.

u(t)*Tcicle

Relay On Relay Off

Tcicle
Figure 5
The time Tcycle can be set from the front panel in seconds. The time, in which the relay output is ON, is
calculating like u(t)*Tcycle where u(t) is the PID action output and is from 0 to 1 (or from 0% to 100%).

Alarm relay outputs:

The operator has to configure the following properties for those outputs:
1. Set-Point (SPx)
2. Hysteresis (HStx).
3. Type of the Alarm Limit (Lx) - Low or High

The way those relay outputs work is shown on Figure 1 and Figure 2.

PV High Alarm Level

Relay is ON

SPAL- set point

HiSt-hysteresis time

Relay is OFF

Figure 6

When the Alarm relay is configured as High Limit:

- The relay is switched on when PVx > SPx
- The relay is switched off when PVx <= SPx - HStx
PVx - Process Variable for channel x
SPx - Set-Point for relay output x
HStx - Hysteresis for relay output x
PV Low Alarm Level

HiSt-hysteresis Relay is OFF

time

SPAL- set point

Relay is ON

Figure 7
When the Alarm relay is configured as Low Limit:
- The relay is ON when PVx < SPx
- The relay is OFF when PVx >= SPx + HStx

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 KEY OPERATIONS
Basic display mode:
When the controller is switched on the display enters its basic mode. The currently measured tempera-
ture (Process Variable) is shown on the upper 4 digit display. The assigned Set-Point is shown on the
lower 4 digit display. The caption Err appears on the upper display and LED FLT starts blinking when there
is an error in the input circuit.
LED A1 corresponds to the control relay and LEDs A2 and A3 - to alarm relay 1 and alarm relay 2 accord-
ingly. When one of the relay outputs is ON (the normally open contact is closed) the corresponding LED
is on.
Setting the Set-Point:
Press the MODE button when in basic operating mode to enter the mode for setting the SP. The caption
SP oC appears on the lower display. The currently set value of the SP appears on the lower display and
the least significant digit is blinking. Using the "<" and "^" buttons change the current value to the desired
one. The value of the Set-Point is in physical units (oC). Press ENT to save the new value of the SP. Press
MODE to enter the basic operating mode. Press MODE instead of ENT if you want to enter the basic
operating mode without changing the SP.
PID controller parameters setting:
ALL PARAMETERS CAN BE CHANGED ONLY AFTER CORRECT IDENTIFICATION OF THE CORRE-
SPONDING PASSWORD.
Password type in: Press MODE and ENT or ENT and "^" simultaneously to exit the instruments basic
operating mode. 0000 is visualized on the upper display of the controller. Using the "<" and "^" buttons
enter the password. Press ENT. After the correct identification of the password the caption PASS appears
on the display. Press MODE to begin the parameters setting.
The value of the desired parameter can be changed with the "<" and "^" buttons. Press ENT to save the
new value. If you press MODE you switch to the next parameter without saving the new value. Pressing
A/M you can switch to the previous parameter. After the last parameter from the menu is viewed the con-
troller enters its basic operating mode.
The parameters are dynamically shown or hidden in the menu depending on the controller's configura-
tion. The full parameter configuration is shown below. Some of the parameters may not be visible in the
menu because of the instruments current configuration.
Entering of PID parameters:
Press ENT and MODE simultaneously and enter the 1111 password. After the correct identification of the
password you can change the following parameters:

Changing the parameters of the alarm relays:

- Set-Point
- Hysteresis
- Alarm limit type
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Press ENT and MODE simultaneously and enter one of the following passwords:
2222 - alarm relay output 1
3333 - alarm relay output 2
After the correct identification of the password you can change the following parameters:

Starting Auto-tune
1. The Set-Point (SP) has to be correctly entered before activation of the auto-tune procedure.
2. The controlled object has to be put to work in constant condition during the identification (without any
load disturbances, with constant parameters, with relatively constant ambient temperature, constant SP,
etc.).
3. Press A/M and MODE simultaneously. Digit 1 starts blinking on the upper display. Caption Autotu is
visualized on the lower display. Press ENT to start the auto-tune procedure. The instrument enters its
basic operating mode and caption tu starts blinking on the two-digit display. Press ENT instead of MODE
and the controller enters its basic operating mode without starting the auto-tune procedure.
Press the A/M and MODE buttons again in order to stop the auto-tune procedure. Caption StoP appears
on the upper display. Press ENT to stop the identification without calculating the parameters. Press
MODE (without pressing ENT) to enter the basic operating mode of the instrument without stopping the
auto-tune procedure.
NOTE: As ON/OFF control is implemented in the process, the temperature may rise significantly. The
maximal temperature value that will be reached at that point should not exceed the end of the instrument
measuring range. In case of reaching the end of the range, the Set-Point could be corrected to some
lower value. The identification will take time that is very much dependent on the characteristics of the con-
trolled object. If the identification procedure has been stopped before its completion, new PID parameters
will not be computed. If an error occurs in the measurement the identification is automatically stopped.

OVERALL DIMENSIONS

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CONNECTION DIAGRAM

Terminal No Description
1, 2, 3 Pt100 RTD
4, 5 Power supply 90-250V AC/DC
6, 7 Control relay output NO contact
7, 8 Control relay output NC contact
9, 10 Alarm relay output 1 NO contact
10, 11 Alarm relay output 1 NC contact
12, 13 Alarm relay output 2 NO contact
13, 14 Alarm relay output 2 NC contact

SPECIFY ON ORDER
- type of the controlled industrial process - temperature, pressure, level, etc.
- type of the controlled mechanism - motor, valve, heater, etc.
- type of the input signal - TC, Pt100, current 4-20mA, etc.
- type of the output signal (for control) - relay, current
- input for external setting of SV, interface RS485, AUTO-TUNE function, etc.

Office: 23, A. Saharov blvd., Mladost 1, 1784 Sofia, Bulgaria

tel.: (+359 2) 974 62 36, 974 62 37, fax: (+359 2) 974 62 04
E-mail: delta@deltainst.com, deltamm@mail.techno-link.com
http://www.deltainst.com