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WEST 8800 Operating Manual

Process controller
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Process controller 8800
Operating manual
English
9499-040-70611
Valid from: 8405

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  • Page 1 Process controller 8800 Operating manual English 9499-040-70611 Valid from: 8405...
  • Page 2 8800/8840 Configurator More efficiency in engineering, more overview in operating: The projecting environment for the West controllers 8800/8840 Description of symbols: General information General warning Attention: ESD sensitive devices © West Instruments • Printed in Germany All rights reserved. No part of this document may bereproduced or published in any form or by any means without prior written permission from the copyright owner.

  • Page 3: Table Of Contents

    Switching attitude non-linear ( CyCl= 2 ) ....51 4.4.4 Heating and cooling with constant period ( CyCl= 3 ) ..52 8800 process controller...
  • Page 4 8800 process controller as Modbus master ... . 75 8800/8840 configurator ..... . 76 Versions .

  • Page 5: Mounting

    Squeeze the top and bottom of the front bezel between thumb and forefinger and pull the controller firmly from the housing. open Access to the levels is as adjusted by means of 8800/8840 configurator (engineering tool) 2 closed all levels accessible wihout restriction...

  • Page 6: Electrical Connections

    Profibus DP Modbus RTU Dependent of order, the controller is fitted with : w flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 or w screw terminals for 0,5 to 2,5mm² Connecting diagram 8800 process controller...

  • Page 7: Terminal Connection

    Set-point (0/4...20mA) b Potentiometer input for position feedback Connection of input INP3 6 (16) As input INP1, but without voltage Connection of inputs di1, di2 7 Digital input, configurable as switch or push-button 8800 process controller Terminal connection...
  • Page 8 PROFIBUS DP or RS422/485 interface with Modbus RTU protocol 8 9 di2/3, 2-wire transmitter supply OUT3 (16) +24VDC 17,5V 22mA (16) If the universal output OUT3 or OUT4 is used there may be no external galvanic connection between measuring and output circuits! Terminal connection 8800 process controller...
  • Page 9 (16) (16) DATA A DATA A DATA A R=100 Ohm RS485-RS232 converter max. 1000m RGND connection optional "Twisted Pair” cable R = 120...200 Ohm * Interface description Modbus RTU in speperate manual: see page 75. 8800 process controller Terminal connection...
  • Page 10 Electrical connections 3 OUT3 as logic output with solid-state relay (series and parallel connection) Series connection Parallel connection I =22mA I =22mA Logic 8800 process controller connecting example: 6700 Limit controller Standard version: fuse fuse N6700Z21 fuse other versions on request...

  • Page 11: Operation

    LEDs: In the upper display line, the process value is always displayed. At parameter, configuration, calibration as well as extended operating level, the bottom display line changes cyclically between parameter name and parameter value. 8800 process controller Front view...

  • Page 12: Behaviour After Power-On

    After supply voltage switch-on, the unit starts with the operating level. The unit is in the condition which was active before power-off. If the 8800 process controller was in manual mode at supply voltage switch-off, the controller will re-start with the last output value in manual mode at power-on.

  • Page 13: Error List / Mainenance Manager

    Name Description Reason Possible remedial action E. 1 Internal error, - E.g. defective EEPROM - Contact West service cannot be removed - Return unit to our factory E. 2 Internal error, can be - e.g. EMC trouble - Keep measurement and power supply...
  • Page 14 Internal error in DP - self-test error - Switch on the instrument again module E. 5 - internal communication - Contact West service interrupted No access by bus - bus error - Check cable master dp. 1 - connector problem...
  • Page 15 Output is blocked Check the drive for blockage Wrong method of operation Wrong phasing, defect motor capacitor Fail at Yp measurement Check the connection to the Yp input Calibration error Manual calibration necessary 8800 process controller Error list / Mainenance manager...

  • Page 16: Self-Tuning

    - Minimum cycle time 1 (heating) in [s] r only, unless Adt0 was set to “no self-tuning” during ® configuration by means of 8800/8840 configurator - Proportional band 2 (cooling) in engineering units [e.g. °C] - Integral time 2 (cooling) in [s]...

  • Page 17: Optimization After Start-Up Or At The Set-Point

    - tunE = 2 The controller outputs 0% correcting variable or Y. L o and waits, until the process is at rest (see start-conditions on page 16). Subsequently, a correcting variable step change to 100% is output. 8800 process controller Self-tuning...
  • Page 18 ( PArA/ SETP/ r. S P≠ OFF), the set-point gradient is started from the process value and there isn't a sufficient set-point reserve. Self-tuning 8800 process controller...
  • Page 19 With a 3-point controller, optimization for the “heating“ or “cooling” parameters occurs dependent of the instantaneous condition. These two optimizations must be started separately. 1 If the correcting variable is too low for reduction in lined out condition it is increased by max. 20%. 8800 process controller Self-tuning...
  • Page 20 20 %, and re-opened by 20 % subsequently. As a result, the controller knows that there is a 20% reserve for the attempt. Self-tuning 8800 process controller...

  • Page 21: Self-Tuning Start

    ± 0,5% of (rnG. H - rnG. L ). w For self-tuning start after start-up, a 10% difference from (SP. L O ... SP. H i) is required. ® Self-tuning start can be blocked via 8800/8840 configurator (engineering tool) ( P. L oc). Strt = 0 Only manual start by pressing keys Ù...
  • Page 22 Display of error list at extended operating level. After acknowledgement of the error message, the controller continues control in automatic mode using the old parameters. Cancellation causes: r page 15: "Error status self-tuning heating ( ADA. H ) and cooling ( ADA. C )" Self-tuning 8800 process controller...

  • Page 23: Examples For Self-Tuning Attempts

    (3). After determining its cooling parameters Pb2, ti2, td2 and t2 (4) from the process characteristics , control operation is started using the new parameters (5). During phase 3, heating and cooling are done simultaneously! 8800 process controller Self-tuning...

  • Page 24: Manual Self-Tuning

    The control parameters can be determined from the values calculated for delay time T , maximum rate of increase v , control range X and characteristic K according to the formulas given below. Increase Pb1, if line-out to the set-point oscillates. Manual self-tuning 8800 process controller...

  • Page 25: Second Pid Parameter Set

    The process characteristic is frequently affected by various factors such as process value, correcting variable and material differences. To comply with these requirements, the 8800 process controller can be switched over between two parameter sets. Parameter sets PArA and PAr. 2 are provided for heating and cooling.

  • Page 26: Alarm Handling

    L. 1 HYS. 1 HYS. 1 HYS. 1 HYS. 1 1: normally closed ( ConF/ Out. x / O. A ct=1 ) 2: normally open ( ConF/ Out. x / O. A ct= 0 ) Alarm handling 8800 process controller...
  • Page 27 If measured value monitoring + alarm status storage is chosen ( ConF / Lim / Fnc. x = 2/4), the alarm relay remains switched on until the alarm is resetted in the error list ( Lim 1..3 = 1). 8800 process controller Alarm handling...

  • Page 28: Operating Structure

    When safety switch Loc is open, only the levels enabled by PASS means of 8800/8840 configurator (engineering tool) are visible and accessible by entry of the password also adjusted by means of 8800/8840 configurator (engineering tool). Individual parameters accessible without password must be copied to the extended operating level.

  • Page 29: Configuration Level

    After the last configuration of a group, donE is displayed and followed by automatic change to the next group Return to the beginning of a group is by pressing the Ù key for 3 sec. 8800 process controller Configuration survey...
  • Page 30 = mean output. The maximum permissible output can be adjusted with parameter Ym. H . To prevent determination of inadmissible values, mean value formation is only if the control deviation is lower than parameter L. Y m. Configuration parameters 8800 process controller...
  • Page 31 Manual start of auto-tuning Manual or automatic start of auto-tuning at power on or when oscillating is detected Adt0 Optimization of T1, T2 (only visible with 8800/8840 configurator!) Automatic optimization No optimization 1 rnG. L and rnG. H are indicating the range of control on which e.g. the self-tuning is refering InP.
  • Page 32 Scaling (at PArA level) In. f -1999...9999 Alternative value for error at INP1 fAI1 Forcing INP1 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface 1 with current and voltage input signals, scaling is required (see chapter 5.3) Configuration parameters...
  • Page 33 Scaling (at PArA level) In. F -1999...9999 Alternative value for error at INP2 fAI2 Forcing INP2 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface 1 with current and voltage input signals, scaling is required (see chapter 5.3) InP. 3...
  • Page 34 Automatic calibration (DAC) In. F -1999...9999 Alternative value for error at INP3 fAI3 Forcing INP3 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface 1 with current and voltage input signals, scaling is required (see chapter 5.3) Configuration parameters...
  • Page 35 Measured value monitoring + alarm status storage. A stored è limit value can be reset via error list, -key, Ò-key or a digital input ( -> LOGI/ Err. r ) signal change (change/minute) signal change and storage (change/minute) 8800 process controller Configuration parameters...
  • Page 36 Measured value monitoring + alarm status storage. A stored è limit value can be reset via error list, -key, Ò-key or a digital input ( -> LOGI/ Err. r ) signal change (change/minute) signal change and storage (change/minute) Configuration parameters 8800 process controller...
  • Page 37 If ti1=0 LOOP alarm is inactive! dAc. A DAC alarm function DAC alarm switched off / inactive DAC alarm active Hour OFF...999999 Operating hours (only visible with 8800/8840 configurator!) Swit OFF...999999 Output switching cycles (only visible with 8800/8840 configurator!) Out. 1 Name...
  • Page 38 FAi. 3 INP3 error signal not active aktiv fOut Forcing OUT1 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface Out. 2 Configuration parameters Out.2 = Out.1 except for: Default Y. 1 = 0 Y. 2 = 1...
  • Page 39 O.TYP=0) not active active HC. A L Heating current alarm signal (only visible when O.TYP=0) not active active HC. S C Solid state relay (SSR) short circuit signal (only visible when O.TYP=0) not active active 8800 process controller Configuration parameters...
  • Page 40 (process value - set-point) measured value position feedback Yp measured value INP1 measured value INP2 measured value INP3 fOut Forcing OUT3 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface Out. 4 Name Value range Description Default O.
  • Page 41 Out. 0 -1999...9999 Scaling of the analog output for 0% (0/4mA or 0/2V, only visible when O.TYP=1..5) Out. 1 -1999...9999 Scaling of the analog output for 100% (20mA or 10V, only visible when O.TYP=1..5) 8800 process controller Configuration parameters...
  • Page 42 Weff control deviation xw (process value - set-point) measured value position feedback Yp fOut Forcing OUT1 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface Out. 5 Configuration parameters Out.2 = Out.1 except for: Default Y. 1 = 0 Y. 2 = 0 Out.
  • Page 43 Ò - key switches m. L oc Blockage of hand function no function (switch-over via interface is possible) DI1 switches DI2 switches (only visible with OPTION) DI3 switches (only visible with OPTION) è - key switches 8800 process controller Configuration parameters...

  • Page 44: Configuration Parameters

    F n Function of digital inputs (valid for all inputs) direct inverse toggle key function fDI1 Forcing di1 (only visible with 8800/8840 configurator!) No forcing Forcing via serial interface fDI2 Forcing di2 (only visible with 8800/8840 configurator!) No forcing...
  • Page 45 Profibus address bc. u p Behaviour as backup controller No backup functionality With backup functionality FrEq Switching 50 Hz / 60 Hz (only visible with 8800/8840 configurator!) 50 Hz 60 Hz ICof Block controller off (only visible with 8800/8840 configurator!)
  • Page 46 Configuration level Name Value range Description Default IAda Block auto tuning (only visible with 8800/8840 configurator!) Released Blocked IExo Block extended operating level (only visible with 8800/8840 configurator!) Released Blocked ILat Suppression error storage Released Blocked Pass OFF...9999 Password (only visible with 8800/8840 configurator!)
  • Page 47 Resetting the controller configuration to factory setting (Default) r chapter 11.1 (page 82) 8800/8840 configurator - the engineering tool for the West controller series 3 engineering tools with different functionality facilitating 8800 process controller configuration and parameter setting are available (see chapter 9: Accessory equipment with ordering information).

  • Page 48: Set-Point Processing

    This gradient is effective in positive and negative direction.. With parameter r. S P set to OFF (default), the gradient is switched off and set-point changes are realized directly. (for parameter: see page48 ) Set-point processing 8800 process controller...

  • Page 49: Switching Behaviuor

    Configuration level 4.4 Switching behaviuor With 8800 process controller, configuration parameter CYCL (ConF/ Cntr/ CYCL) can be used for matching the cycle time of 2-point and 3-point controllers. This can be done using the following 4 methods. 4.4.1 Standard ( CyCl= 0 ) The adjusted cycle times t1 and t2 are valid for 50% or -50% correcting variable.

  • Page 50: Switching Attitude Non-Linear ( Cycl= 2 )

    F. H 2O: adaptation of (non-linear) characteristic ( PArA / Cntr) Water cooling t. o n: Pulse duration water cooling t. o ff: min. pause water cooling E. H 2O: min. temperature for water cooling Switching behaviuor 8800 process controller...

  • Page 51: Heating And Cooling With Constant Period ( Cycl= 3 )

    Parameters to be adjusted: t1 : Min. cycle time 1 (heating) [s] ( PArA/ Cntr) t2 : min. cycle time 2 (cooling) [s] min. pulse length [s] 8800 process controller Switching behaviuor...

  • Page 52: Configuration Examples

    = -1999...9999 set-point limit low for Weff SP. H i = -1999...9999 set-point limit high for Weff For direct signaller action, the controller action must be changed (ConF / Cntr / C. A ct = 1 ) process value setpoint output Configuration examples 8800 process controller...

  • Page 53: 2-Point Controller (Inverse)

    SP. L O = -1999...9999 set-point limit low for Weff SP. H i = -1999...9999 set-point limit high for Weff For direct action, the controller action must be changed (ConF / Cntr / C. A ct = 1 ). setpoint process value output 8800 process controller Configuration examples...

  • Page 54: 3-Point Controller (Relay & Relay)

    2 (cooling) = 0...9999 neutr. zone in units of phys.quantity PArA / SEtP: SP. L O = -1999...9999 set-point limit low for Weff SP. H i = -1999...9999 set-point limit high for Weff Configuration examples 8800 process controller...

  • Page 55: 3-Point Stepping Controller (Relay & Relay)

    SP. H i = -1999...9999 set-point limit high for Weff For direct action of the 3-point stepping controller, the controller output action must be changed ( ConF / Cntr / C. A ct = 1 ). setpoint process value output 1 output 2 8800 process controller Configuration examples...

  • Page 56: Continuous Controller (Inverse)

    To prevent control outputs Out. 1 and Out. 2 of the continuous controller from switching simultaneously, the control function of outputs Out. 1 and Out. 2 must be switched off ( ConF / Out. 1 and Out. 2 / Y. 1 and Y. 2 = 0 ). Configuration examples 8800 process controller...

  • Page 57: Y - Off Controller / 2-Point Controller With Pre-Contact

    = -1999...9999 trigg. point separation suppl. cont. ∆ / Y / Off in units of phys. quantity PArA / SEtP: SP. L O = -1999...9999 set-point limit low for Weff SP. H i = -1999...9999 set-point limit high for Weff 8800 process controller Configuration examples...

  • Page 58: 8800 Process Controller With Measured Value Output

    Configuration level 4.5.7 8800 process controller with measured value output phys. quantity Out. 1 mA / V phys. quantity Out. 0 0/4mA 20mA 0/2V 90...250VAC 24VUC OUT3 OUT4 (16) INP1 ConF / Out. 3 / 4: O. t YP = Out.

  • Page 59: Continuous Controller With Integrated Positioner ( Cntr/ C. F Nc = 6 )

    (e.g. °C) = 1...9999 Integral action time 1 (heating) in sec. = 1...9999 Derivative action time t 1 (heating) in sec. = 0,4...9999 Minimal cycle time 1 (heating) = 0...9999 Neutral zone in phys. units (e.g.°C) 8800 process controller Configuration examples...

  • Page 60: Parameter Setting Level

    Return to the beginning of a group is by pressing the Ù key for 3 sec. If for 30 sec. no keypress is excecuted the controler returns to the process value and setpoint display ( Time Out = 30 sec. ) Parameter survey 8800 process controller...
  • Page 61 Sensor temperature (in engineering units e.g. °C) With oxygen measurement (O ) (see page 70) 1 Valid for ConF/ othr/ dP = 0. With dP = 1 / 2 / 3 also 0,1 / 0,01 / 0,001 is possible. 8800 process controller Parameters...

  • Page 62: Parameters

    Set-point 2. r. S P 0...9999 Set-point gradient [/min] -1999...9999 Set-point (only visible with 8800/8840 configurator!) SP. L O and SP. H i should be within the limits of rnGH and rnGL see configuration r Controller page17 InP. 1 Name...
  • Page 63 Lower limit 3 H. 3 -1999...9999 Upper limit 3 HYS. 3 0...9999 Hysteresis limit 3 dEl. 3 0...9999 Alarm delay from limit value 3 Resetting the controller configuration to factory setting (Default) r chapter 11.1 (page 82) 8800 process controller Parameters...

  • Page 64: Input Scaling

    OuH. 2 0 … 20 mA 0 … 50 mA In addition to these settings, InL. 2 and InH. 2 can be adjusted in the range (0...20/ 50mA/Ω) determined by selection of S. t YP. Input scaling 8800 process controller...

  • Page 65: Calibration Level

    InL. 1 2-point correction ( ConF/ InP. 1 / Corr = 2 ): display standard setting 2-point correction w is possible off-line with process value simulator OuH. 1 OuH. 1 OuL. 1 OuL. 1 InL. 1 InH. 1 8800 process controller...
  • Page 66 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 ÈÌ . Subsequently, he confirms the display value by pressing key Ù. 8800 process controller...
  • Page 67 Subsequently, he confirms the display value by pressing key Ù. The parameters (OuL. 1 , OuH. 1 ) changed at CAL level can be reset by adjusting the parameters below the lowest adjustment value (OFF) by means of decrement key Ì . 8800 process controller...

  • Page 68: Special Functions

    After solving the technical problem the DAC errror can be acknowledged in the error list. Thereafter the controller works again in normal operation mode. See also chapter 3.4 "Mainenance manager / Error list", page 12 ff. 8800 process controller – motor actuator monitoring ®...
  • Page 69 Also in manual mode it is not possible to exceed these limits. Because no controller with continuouse output and Yp input is defined there won't be the DAC function for this controlling type. 8800 process controller – motor actuator monitoring ®...

  • Page 70: O 2 Measurement

    Heated lambda probes Controlled heating which ensures constant temperature is integrated in the heated λ probe. This temperature must be entered in the 8800 process controller parameter Probe temperature. Parameter r Controller r Probe temperature r ..°C (/°F - dependent of...

  • Page 71: Configuration

    : % Whether the temperature of the non-heated λ probe is specified in °C or °F can be selected during configuration. Other r Unit r 1: in Celsius 2: in Fahrenheit othrr Unit °C othrr Unit °F 8800 process controller measurement...

  • Page 72: Linearization

    Condition for these configuration parameters is an ascending order. In. 1 < In. 2 < ...< In. 1 6 and Ou. 1 < Ou. 2 ...< Ou. 1 6. In. 1 6 In 1 Ou. 1 ..... Ou. 1 6 Linearization 8800 process controller...

  • Page 73: 8800 Process Controller As Modbus Master

    Number of data that should be transmitted by the Modbus master. The 8800 process controller can be used as Modbus master ( ConF / othr / MASt = 1 ). The Modbus master sends ist data to all slaves (Broadcast message, controller adress 0).

  • Page 74: 8800/8840 Configurator

    The mini version is - free of charge - at your disposal as download at West homepage www.westinstruments.com or on the West-CD (please ask for). At the end of the installation the licence number has to be stated or DEMO mode must be chosen.

  • Page 75: Versions

    Interface description Modbus RTU English 9499-040-70811 Interface description Profibus German 9499-040-70918 Interface description Profibus English 9499-040-70911 8800/8840 configurator (engineering tool) Mini Download www.westinstruments.com 8800/8840 configurator (engineering tool) Basic Insert order-no. 8800/8840 configurator (engineering tool) Expert Insert order-no. 8800 process controller...

  • Page 76: Technical Data

    CONTROL INPUTS DI1, DI2 Special measuring range Configurable as switch or push-button! 8800/8840 Configurator (engineering tool) can Connection of a potential-free contact suitable be used to match the input to sensor KTY 11-6 for switching “dry” circuits.
  • Page 77 Internal voltage drop: ≤ 1 V with I Max.contact rating: 500 VA, 250 V, 2A at 48...62 Hz, Protective circuit: built-in against short circuit, resistive load overload, reversed polarity (free-wheel diode Min. contact rating: 5V, 10 mA AC/DC for relay loads). 8800 process controller...
  • Page 78 Shock: FRONT INTERFACE Duration: 11ms Connection of PC via PC adapter (see "Accessory equipment"). The 8800/8840 Electromagnetic compatibility Configurator software is used to configure, set Complies with EN 61 326-1 parameters and operate the 8840 profiler. (for continuous, non-attended operation)
  • Page 79 DIN 46 244 or screw terminals for 0,5 to 2,5mm² Mounting Panel mounting with two fixing clamps at top/bottom or right/left, High-density mounting possible Mounting position: uncritical Weight: 0,27kg Accessories delivered with the unit Operating manual Fixing clamps 8800 process controller...
  • Page 80 Resolution (Ô) 0-10 Volt ß 0,1 % 0,6 mV ~ 110 kΩ -2,5-115 mV ß 1MΩ 0,1 % 6 µV -25-1150 mV ß 1MΩ 0,1 % 60 µV 0-20 mA ß 0,1 % 20 Ω 1,5 µA 8800 process controller...

  • Page 81: Safety Hints

    If the controller is connected with other equipment in the same signal loop, check that other equipment in the output circuit is not affected before switch-off. If necessary, suitable protective measures must be taken. 8800 process controller...

  • Page 82: Resetting To Factory Setting

    The cleaning of the front of the controller should be done with a dry or a wetted (spirit, water) kerchief. 11.1 Resetting to factory setting In case of faulty configuration, 8800 process controller can be reset to the default condition. For this, keep the following two keys pressed during power-on : È...

  • Page 83: Notes

    Notes Notes 8800 process controller...
  • Page 84 Notes 8800 process controller...
  • Page 85 Notes 8800 process controller...
  • Page 86 DAC ....70 - 71 Notes....86 - 87 8800 process controller...
  • Page 87 Cancelation ... 23 Cancelation causes..24 Set-point processing ..50 Thermocouple measuring range ..78 8800 process controller...
  • Page 88 Subject to alterations without notice West Instruments The Hyde Business Park Brighton BN2 4JU Printed in Germany 9499-040-70611 (08/2003)

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