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neuro 104

User Manual

Open Loop Motorised Valve
Controller

Summary of Contents for neuro 104

Page 1: ...neuro 104 User Manual Open Loop Motorised Valve Controller...

Page 2: ...TERS 4 18 CONTROL PARAMETERS 5 ALARM PARAMETERS 20 6 CONFIGURATION PARAMETERS 23 7 SUPERVISORY PARAMETERS 26 8 28 PROFILE PARAMETERS 9 OP3 FUNCTION PARAMETERS 32 10 TUNING 35 11 SETPOINT PROFILE 39 12...

Page 3: ...ists each LED indicator identified by the front panel legend and the associated status it indicates User Manual neuro 104 The controller front panel comprises of digital readouts LED indicators and me...

Page 4: ...Indicates Output 2 ON OFF status while the controller is driving the motor to travel the valve in Reverse Close direction Indicates Profile status if the Profile mode is Enabled Flashes while the con...

Page 5: ...rammed to operate in one of the four modes of operation viz Automatic Manual Hand Standby and Profile mode These modes are described below Automatic Auto Mode In this mode the controller automatically...

Page 6: ...anual mode is active and it is Disabled in PAGE 13 parameter list the controller gets locked in Manual mode with the last set Valve Position That is the Manual mode can neither be de activated using E...

Page 7: ...thus eliminating the need of Manual mode operation during process start up For detailed working of the Overshoot Inhibit function refer Section 11 The X PRESSAlgorithm Standby Mode In this mode of op...

Page 8: ...can not be adjusted in the Standby mode 4 The Standby mode cannot be activated in the following conditions That is upon entering PAGE 0 the Standby mode activation Command can not be issued as pressi...

Page 9: ...eadout displays PAGE and the Upper Readout displays 0 2 Press ENTER key until the Lower Readout displays Abort and the Upper Readout displays No 3 Press UPkey to select Yes on the Upper Readout Press...

Page 10: ...urs prior to pressing ENTER key upon resumption of power the controller will not store the altered value and retain the previous set value 2 The SPis adjustable to any value between the Setpoint Low a...

Page 11: ...ly if Profile mode is enabled in PAGE 14 parameter list and the Profile Cycle is not yet started aborted or over It has two possible settings It serves as a Command to start run the Profile Cycle and...

Page 12: ...he PV at this Setpoint unless the Manual or Standby mode is activated or a Profile Cycle is running The Control Setpoint SP is expressed in the same unit and resolution as that for PV If the parameter...

Page 13: ...ble only if Alarm Type is selected to Deviation Band and sets a deviation band above or below the SP depending upon the Negative or Positive value for this parameter respectively The Alarm is activate...

Page 14: ...m if selected in PAGE 11 parameter list gets activated Refer Section 7 Alarm Parameters for further details ALARM STATUS UNDER PV ERROR CONDITIONS The alarm status under PV error conditions depend upo...

Page 15: ...or Break Indication on the controller Upper Readout and the alarm is activated if set as Process High While detecting Sensor Break the PV rises rapidly before Sensor Break Condition occurs The Sensor...

Page 16: ...Display Mode to Program Mode requires appropriate setting of the PAGE NUMBER Follow the steps below to open a desired PAGE for setting the parameter values Figure 3 1 1 Press and release PAGE key The...

Page 17: ...o the MAIN Display Mode CONDITIONALPARAMETERS As discussed above the various parameters user set values are grouped and listed in separate PAGES For convenience each PAGE contains a list of parameters...

Page 18: ...eration to the operator by enabling or disabling the Manual mode in PAGE 13 parameter list prior to Lock enabled 4 The Parameter Locking is not applied for PAGE 0 i e Operator Parameters However the s...

Page 19: ...in case the controller is removed from a particular application and fitted on a different application it is recommended to reset all the parameters to their default values before configuring the contr...

Page 20: ...ction MOTOR RUN TIME TRAVEL TIME This parameter defines the time taken by the motor to travel the valve from its fully Close position one physical end to the fully Open position the other physical end...

Page 21: ...This parameter defines the time taken by the valve and motor to stop moving after the drive pulse is removed This is due to the mechanical inertia of the valve and motor and is independent of the dir...

Page 22: ...is to avoid fluctuations in alarm status near boundary conditions For End of Profile Alarm the controller energizes output module OP3 for approximately 10 seconds to alert the user for end of Profile...

Page 23: ...lay SSR energizes under alarm condition and remains de energized otherwise For Reverse setting the Relay SSR de energizes under alarm condition and remains energized otherwise Generally the Direct set...

Page 24: ...V Alarm Setpoint Alarm Hysterisis Output ON ON The Figures 5 3 a and 5 3 b below illustrate the effect of setting the Alarm Inhibit parameter to Yes and No respectively The example shown is for Proces...

Page 25: ...asurement Ensure proper hardware jumper settings if required UNIT SELECTION FOR PV Available for Thermocouple RTD Inputs Selects temperature measurement units in C or F RESOLUTION FOR PV NotAvailable...

Page 26: ...ive the final PV that is displayed and compared for alarm control Final PV Measured PV Offset DIGITAL FILTER FOR PV Sets the time constant in seconds for the low pass digital filter applied to the mea...

Page 27: ...00 to 1700 C 392 to 3092 F 0 to 1300 C 32 to 2372 F Fixed 1 C 1 F 0 to 20mA DC current 4 to 20mA DC current 0 to 50mV DC voltage 0 to 200mV DC voltage 0 to 1 25V DC voltage 0 to 5 0V DC voltage 0 to 1...

Page 28: ...PID control only Set to Yes to initiate a new tuning cycle or set to No to abort a tuning operation in progress OVERSHOOT INHIBIT Available for PID control only Enabling this feature controls the PV...

Page 29: ...e controller for identification by the host Set the value as required by the host COMMUNICATION WRITE ENABLE Setting to No disallows the host to set or modify any parameter value The value however can...

Page 30: ...and resolution as that for PV SOAK HOLD BAND This parameter sets the allowable deviation of PV from the Target Setpoint while executing a soak segment Should the PV fall outside this band the controll...

Page 31: ...yed PV resolution If set to 0 the Ramp Setpoint immediately equals to the Target Setpoint 2 TARGET SETPOINT 2 This parameter sets the target level for the second ramp segment The Setpoint ramps to thi...

Page 32: ...Setpoint ramps from Target Setpoint 3 to Target Setpoint 4 The setting resolution of this parameter is independent of the displayed PV resolution If set to 0 the Ramp Setpoint immediately equals to th...

Page 33: ...er completion of a running Profile Cycle If this parameter is set to Yes the controller keeps the Control Output s OFF until a next Profile Start Command is issued or the Profile Cycle is aborted If h...

Page 34: ...ted de activated as perAlarm status RECORDER OUTPUT TRANSMISSION This parameter is available and applicable only if Output 3 Function is selected for Retransmission Recorder output and allows the user...

Page 35: ...Minimum Maximum Output signal levels do not match exactly with the available Recorder Minimum Maximum signal levels follow the steps below to interface the same The steps below illustrate as an examp...

Page 36: ...o 180 0 and Recorder Low value to 20 0 the controller outputs 10 mAwhen the PV is 100 0 RH and 0 mA when the PV is 20 0 RH By default the Recorder Low and Recorder High parameter value are settable wi...

Page 37: ...ements of the process s initial parameters that are used to control overshoots undershoots General Procedure for Self Tuning Whether Self Tuning the controller near the SP or from the ambient the gene...

Page 38: ...ses Processes where Overshoots or Undershoots are not desirable Processes which are taking too much time for Tuning may be due to some external influences like excessive heating in the adjoining chamb...

Page 39: ...tiate valve movement 6 Reduce Proportional Band value until the PV oscillates Since the controller is operating in proportion only mode the PV oscillations shall occur with an offset error Ignore this...

Page 40: ...tional Band value to eliminate the oscillations Some control loops have certain physical characteristics which prevent them from being tuned with derivative action For example in a process where air g...

Page 41: ...at the controller generates Figure 11 2 Soak Segments Ramp Segments Process Value Time Each ramp segment has an associated slope called the RAMP RATE and is defined as the ratio of change in and is de...

Page 42: ...limits That is a band is required to be generated around the ramp segment that will force the Setpoint Generator to Holdback if the PV falls outside this band as depicted in the Figure 11 3 below The...

Page 43: ...alarm sets a symmetrical band around the SP It defines both Upper and Lower deviation limits However in Profile mode while ramp the Window Band Alarm is applicable to Ramp Setpoint and while soak the...

Page 44: ...ramp up the PV to Target Setpoint L1 with a Ramp Rate r1 and then hold the PV at L1 for indefinite time Figure 11 5 r1 L1 Set the following parameters as described Ramp Rate 1 r 1 Target Setpoint 1 L1...

Page 45: ...ing a fresh Profile Cycle 2 If the parameter values pertaining to a segment which is yet to be executed are altered the altered values become effective from the current Profile Cycle itself That is th...

Page 46: ...nical Installation Notice the nomenclatures used to identify the various parts as the same are used throughout the sections describing installation configuration and electrical connections ELECTRONICA...

Page 47: ...rts Output 2 Relay module which is mandatary to drive the motor to travel the valve in Reverse Close direction and 2 optional modules viz Output 3 Relay SSR DC Linear module and Serial Communication A...

Page 48: ...for Current or Voltage selection The required output can be selected by setting the value for the Recorder OutputType parameter in PAGE 15 parameter list The Figures 12 6 below illustrate how to moun...

Page 49: ...e module s follow the steps below 1 Gently pull apart the Power supply board and the CPU board until the projections of the module board come out of the slots 2 Pull the module outward to unlock the s...

Page 50: ...c or electromagnetic interference 4 The controller should not be subject to direct vibration or shock 5 The controller should not be exposed to dust salt air direct sunlight or radiant heat OUTER DIME...

Page 51: ...d until it is firmly in contact with the rear face of the mounting panel and the tongues of the clamp engage in the ratchets on the controller enclosure as shown in Figure 13 3 Ensure that the springs...

Page 52: ...e care not to over tighten the terminal screws while making connections 6 Make sure that the controller supply is switched off while making removing any connections or removing the controller from its...

Page 53: ...rminal 1 as shown in Figure 14 2 c The DC Current source is also connected in the similar way 3 2 1 Figure 14 2 b Figure 14 2 c 3 2 1 OUTPUT 1 Terminals 4 5 and 6 OUTPUT 2 Terminals 7 8 and 9 The Outp...

Page 54: ...of the option set for the parameter Control Logic as Reverse heat logic or Direct cool logic the OP1 Relay always drives the motor to travel the valve in Forward Open and OP2 Relay always drives the m...

Page 55: ...imately 1 5 times the actual load rating Use appropriate Heat Sink for mounting the SSR for load rating exceeding 10 A in case the OP3 Alarm Function is used for tripping the loads DC Linear Current V...

Page 56: ...conduit use a separate conduit for communication cables 3 Communication cables may run through low level signal cables like Thermocouple RTD inputs DC Linear Current Voltage outputs if these cables ar...

Page 57: ...e controller is configured inAuxiliary SP mode The connections are shown below in Figure 14 8 c d 0 5 V Auxiliary SP Mode Figure 14 8 d 14 15 0 6 V Main SP Mode Figure 14 8 c 14 15 DC Pulse Voltage 0...

Page 58: ...a n e t Process Precision Instruments 101 Diamond Industrial Estate Navghar Vasai Road E Dist Palghar 401 210 Maharashtra India 0250 2391722 33 37 42 07498799226 09321985369 support ppiindia net sales...

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