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Yudian AI-526 Operation Instruction Manual

Artificial intelligence industrial controller
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Yudian Automation Technology Co. Ltd.
Website:
http://www.yudian.us http://www.yudian.com.hk
Email:
sales@yudian.com.hk
Tel: +852-2770 8785 Fax: +852-2770 8796
AI-526 / AI-526P
ARTIFICIAL INTELLIGENCE INDUSTRIAL CONTROLLER
Operation Instruction
Ver. 8.2
(Applicable for accurate controls of
Temperature, Pressure, Flow, Level and Humidity etc.)

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Summary of Contents for Yudian AI-526

  • Page 1 Yudian Automation Technology Co. Ltd. Website: http://www.yudian.us http://www.yudian.com.hk Email: sales@yudian.com.hk Tel: +852-2770 8785 Fax: +852-2770 8796 AI-526 / AI-526P ARTIFICIAL INTELLIGENCE INDUSTRIAL CONTROLLER Operation Instruction Ver. 8.2 (Applicable for accurate controls of Temperature, Pressure, Flow, Level and Humidity etc.)

  • Page 2: Table Of Contents

    CONTENTS SUMMARY ................................1 EATURES RDERING EFINITION ODULES 1.3.1 Slots of modules 1.3.2 Commonly used modules: 1.3.3 Installation and replacement of modules 1.3.4 Electric isolation of the modules 1.3.5 Further descriptions about module applications TECHNICAL SPECIFICATION ERMINAL AYOUT AND IRING DISPLAYS AND OPERATIONS ...........................17...
  • Page 3 RONT ANEL ESCRIPTION ARAMETER ETTING HART PERATION ESCRIPTION 2.3.1 Parameter Setting 2.3.2 Set Value Setting 2.3.3 Auto Tuning PARAMETERS AND SETTINGS .........................24 ARAMETER IELD ARAMETERS ARAMETER ABLE DDITIONAL EMARKS OF PECIAL UNCTIONS 3.3.1 Single-phase phase-shift trigger output 3.3.2 Alarm blocking at the beginning of power on 3.3.3 Setpoints switch...
  • Page 4 3.3.4 Communication function 3.3.5 Temperature re-transmitter / Program generator / Manual current output 4. FURTHER DESCRIPTION FOR THE OPERATION OF AI-526P SERIES INSTRUMENT ......47 4.1 C ONCEPTS AND FUNCTIONS ROGRAM StEP: StEP time: Running time: Jump: Run/Hold: Stop: Power cut/resume event handling: PV startup and PV preparation function (rdy function) : Curve fitting:...
  • Page 5 5. PROGRAMMING AND OPERATION (FOR AI-526P ONLY) .................50 5.1 R (PAF : B=0) 5.2 S (PAF : B=1) OAK MODE Time setting Program arrangement of multi-curve operation...

  • Page 6: Summary

    ISO9001,CE and UL 61010-1 certified, achieving world class level of quality, anti-interference ability and safety. POINTS FOR ATTENTION ● This manual is AI-526/AI-526P ARTIFICIAL INTELLIGENCE INDUSTRIAL CONTROLLER Version 8.2. Certain functions in this manual are probably not applicable for the instrument of other version. When the power is on, instrument model and software version will be displayed.

  • Page 7: Ordering Code Definition

    ⑨ It shows that the model of this instrument is AI-526, front panel dimension is A size(96×96mm), no module is installed in MIO slot, X3 linear current output module is installed in OUTP (main output), ALM (alarm) is L5 (dual relay contact...
  • Page 8 AI-526 Economical type instrument with measurement accuracy 0.25%F.S. It adopts artificial intelligent control technology, and has the functions of control, alarm, retransmission and communication. AI-526P Base on AI-526 added 30 segments programmable functions. ② Shows the front panel dimension A(A2) Front panel 96×96mm(width×height), cut out 92×92mm, depth behind mounting surface 100mm.
  • Page 9 "24VDC" means the power supply of 20~32V DC or AC power ⑨ Shows the optional extended graduation spec (If none, leave it blank). AI-526 series instruments support many input types including popular thermocouples, RTDs, linear voltage, current and resistance inputs. If needed, an additional specification not mentioned in input type selection (InP) table can be extended.

  • Page 10: Modules

    1.3 Modules 1.3.1 Slots of modules AI-526/526P series instruments have five slots for modules to be installed (D dimension instruments have 3 slots: OUTP, AUX and COMM/AL1; D2 dimension instruments have 2 slots: OUTP and COMM/AUX). By installing different modules, the controller can meet the requirements of different functions and output types.

  • Page 11: Commonly Used Modules

     Alarm (ALM): Commonly used as alarm output. Support 1 norma open + normally close relay output (AL1) by installing L1 or L2 module or 2 normally open relay outputs (AL1+AL2) by installing L5 module.  Auxiliary output (AUX): In a heating/refrigerating dual output system, module X3, X5, L1, L4, G, W1, W2 can be installed for the second control output.

  • Page 12: Installation And Replacement Of Modules

    Single-phase thyristor zero crossing trigger output module (can trigger one loop of a TRIAC or a pair of inverse parallel SCR with current of 5-500A) Three-phase thyristor zero crossing trigger output module (can trigger 3-phase circuit; each loop can trigger TRIAC or a pair of inverse parallel SCR with current of 5-500A) K5/K6 Single-phase 220VAC/380VAC thyristor phase-shift trigger output module (can trigger one loop of TRIAC or...

  • Page 13: Electric Isolation Of The Modules

    and the slot on motherboard to remove the old module, and then install a new module. Changing module type needs to modify the corresponding parameters. 1.3.4 Electric isolation of the modules There are a group of 24V and a group 12V power supply built in the instrument and isolated to the main circuit. The 24V power commonly supplies voltage output module, such as V24/V12/V10/V5, I2 and I4.
  • Page 14 COMM.  No contact switch module: W1 and W2 are new types of no contact switch module which apply the advanced technology of “burn proof” and zero crossing conduction. It can replace the relay contact switch. Compared to the relay contact output module, W1 and W2 have longer life and lower interference. They can be largely lower the interference spark of the equipment, and greatly improve the stability and reliability of the system.

  • Page 15: Technical Specification

    1.4 TECHNICAL SPECIFICATION  Input type: (Either of below specifications can be used selectively in the one instrument) Thermocouple: K, S, R, E, J, N, T, B, WRe3-WRe25, WRe5-WRe26. Resistance temperature detector: Cu50, Pt100 Linear voltage: 0～5V, 1～5V, 0～1V, 0～100mV, 0～20mV, 0~500mV etc. Linear current (external precise shunt resist needed): 0～10mA,0～20mA, 4～20mA, etc.
  • Page 16  Response time : ≤0.5s ( when digital filter parameter FILt=0)  Alarm function : High limit, low limit, deviation high limit and deviation low limit; providing the function of alarm blocking at the beginning of power on.  Control period : 0.24～300.0 seconds selectable, and it should be integer times of 0.5 second. ...
  • Page 17  Isolation withstanding voltage : Between power, relay contact or signal terminals ≥2300VDC; between isolated electroweak terminals ≥600V  Power supply : 100～240VAC, -15%, +10% / 50-60Hz; 120～240VDC; or 24VDC/AC, -15%, +10%.  Power consumption: ≤5W  Operating Ambient : Temperature 0～60℃; humidity ≤90%RH ...

  • Page 18: Rear Terminal Layout And Wiring

    1.5 Rear Terminal Layout and Wiring Wiring graph of instruments Note 1: For linear voltage input, if the range is below 100-240VAC~ Thyristor trigger output（K1/K3） 500mV, connect to terminals 19 and 18. 0～5V or 1～ 5V signal can be inputted from terminals 17 and 18. OUTP Thyristor trigger output（K3）...
  • Page 19 Wiring graph of D dimension instruments (72×72mm) Note 1: Linear voltage signal of range below 500mV should be inputted from terminals 13 and 12, and signal of 0～5V 100-240VAC~ Thyristor trigger output and 1～5V should be inputted from terminals 11 and 12. （...
  • Page 20 (heating/refrigerating) control (Auxiliary output doesn’t support analog current output); if I2 is installed and bAud = 1, then it can input on-off signal to switch SP1 and SP2 (AI-526) or switching the program status RUN / Stop (AI-526P) by connecting a switch between terminals number 3 and 5.
  • Page 21 SCR Pow er Module Capacitor Resistor Varistor 1N4001 Absorber Circuit 100~380VAC Thyristor trigger output SCR X2 5~500A Load IN4001 Capacitor Resistor Varistor Absorber Circuit TRIAC Thyristor trigger output 5~500A 100~380VAC Load Note 1: According to the voltage and current of load, choose a suitable varistor to protect the thyristor. resistor-capacitor circuit (RC circuit) is needed for inductance load or phase-shift trigger output.

  • Page 22: Displays And Operations

    ⑤ Data decrease key, and also run switch ② 号 ⑥ Data increase key, and also stop key 输 ⑦ LED indicator: “MAN” led is non-applicable for AI-526 series. ⑦ 入 “RUN” led on, it mean AI-526P running program. MIO, OP1, ⑥...
  • Page 23 Basic display status : When power on, the upper display window of the instrument shows the process value (PV), and the lower window shows the set point (SV). This status is called basic display status. Symbol description was shown as following table: Symbol Description Input specification setting is incorrect...

  • Page 24: Parameter Setting Flow Chart

    Parameter Setting Flow Chart Note: Status screen ,  and  will only by shown on AI-526P.

  • Page 25: Operation Description

    2.3 Operation Description 2.3.1 Parameter Setting In basic display status, press and hold for about 2 seconds can access Field Parameter Table. Press 、 can go to the next parameter; press can modify a parameter. Press and hold return to the previous parameter. Press (don't release) and then press key simultaneously can escape from the parameter table.
  • Page 26 decreasing or inscreasing value get quick. The range of setpoint is between the parameter SPL and SPH. The default range is 0~400. ● Program segment setting: Press the key once and release in the display status, the instrument will be in the setup program status. The set point of the current program StEP will be displayed.

  • Page 27: Auto Tuning

    can activate by parameter setting (Srun). At Hold status, the program is still executing, and the process value is controlled same as setpoint, but the timer stop working, and the running time and setpoint remains. At Hold status, press and hold the key for about 2 seconds until the lower display window displays the "Run"...
  • Page 28 parameter value. If you want to escape from auto tuning status, press and hold the key for about 2 seconds until the "At" parameter appear again. Change “At” from “on” to “oFF”, press to confirm, then the auto tuning process will be cancelled. (P.S. If parameter “SPr” activate and the heating was running, then will stop the “At” until completed the heat up process.

  • Page 29: Parameters And Settings

    3. PARAMETERS AND SETTINGS Parameter Lock (Loc) and Field Parameters Parameter was protected by LOC (Parameter LOCK) to prevent setting error. The function was shown as below: √ : allow to modify data or execute X : not allow to modify data or execute Run, Stop, Hold.

  • Page 30: The Parameter Table

    instead of by pressing in basic display status, and only take HIAL and HdAL as field parameter. The EP paramters and Loc should be set as follows: EP1=HIAL, EP2=HdAL, EP3=At, EP4=nonE, Loc=1 3.2 The Parameter Table The parameters can be divided to 8 groups including alarm, control, input, output, communication, system, setpoint and field parameter definition.
  • Page 31 Alarm on when PV-SV<LdAL; Alarm off when PV-SV>LdAL+AHYS Deviation low When the value set to Min. will disable this function HdAL and LdAL can also be used LdAL alarm as high limit and low limit alarms when needed. (Refer to the description of parameter AF) Alarm 0～2000...
  • Page 32 Alarm LdAL HdAL LoAL HIAL Output to (x 1000) (x100) (x10) (x1) None Alarm output Example: 0～4444 allocation LdAL HdAL LoAL HIAL It shows that HdAL and LdAL are sent to AU1, LoAL has no output, HIAL is sent to AL1.
  • Page 33 If the parameter Pno=0(Non timing limitation mode), controller will HoLd functioning same at AI-526, if Pno>0 (in program mode),and Srun was set as “HoLd”, means the timer stops and the temperature remains; user can resume the timer by...
  • Page 34 rE: Reverse acting. Increase in measured variable causes a decrease in the output, such as heating control. dr: Direct acting. Increase in measured variable causes an increase in the output, such as refrigerating control. Acting method rEbA: Reverse acting with low limit alarm and deviation low alarm blocking at the rEbA beginning of power on.
  • Page 35 0～9999 Time of Integral No integral effect when I=0 seconds 0～999.9 Time of No derivative effect when d=0 Derivative seconds Small value can improve control accuracy. For SSR, thyristor or linear current output, it is generally 0.5 to 3 seconds. For Relay output or in a heating/refrigerating dual output control system, generally 15 to 40 seconds, because small value will cause the frequent on-off action of mechanical switch or frequent heating/refrigerating switch, and shorten its service life.
  • Page 36 The 2 proportional band in PID and APID control. Instead of percentage of the measurement range, the unit is the same as PV. 1~32000 Proportional Generally, optimal P, I, D and CtI can obtained by auto tuning. They can also be units band manually inputted if you already know the correct values.
  • Page 37 Input spec. Input spec. Cu50 Pt100 Pt100 (-80～+300.00℃) * 0~75mV voltage input 0～80ohm resistor input 0～400ohm resistor input Input 0～20mV voltage input specification 0～37 0～100mV voltage input Code WRe3-WRe25 0～60mV voltage input WRe3-Wre26 0～500mV voltage input Extended input 100～500mV voltage input specification F2 radiation type pyromter 1～5V voltage input...
  • Page 38 0 ～ 20mA (installed I4 0～10V module in MIO) 2～10V K (0～300.00℃) * 0～20V J (0～300.00℃) * Four formats (0, 0.0, 0.00, 0.000) are selectable 0 / 0.0 / Display Note 1: For thermocouples or RTD input, only 0 or 0.0 is selectable, and the internal 0.00 / Resolution resolution is 0.1.
  • Page 39 The value of FILt will determine the ability of filtering noise. When a large value is set, the measurement input is stabilized but the response speed is slow. Generally, it can be set to 1 to 3. FILt PV input filter If great interference exists, then you can increase parameter “FILt”...
  • Page 40 slot. 4-20: 4～20mA linear current output. X3 or X5 module should be installed in OUTP slot. (Not applicable for heating/refrigerating bidirectional control.) PHA: Single-phase phase-shift output. K5 module should be installed in OUTP slot. PHA is only for 50Hz power supply, and don’t support bidirectional control system.
  • Page 41 Define AUX only when AUX is worked as the auxiliary output of a heating/refrigerating bidirectional systerm. SSr: to output SSr driver voltage or thyristor zero crossing trigger signal. G or K1 module should be installed. The output power can be adjusted by adjusting the on-off time proportion.
  • Page 42 OUTP works for refrigerating, and AUX works for heating. In a bidirectional system, OPL for define the limitation of maximum cooling output. So, when the OPL= -100%, means no limitation on cooling output. If set OPL=-110%, it can made current output excess 10% on maximum output. When the output type is SSR output or relay output, maximum of cooling output should not set more than 100% Output upper...
  • Page 43 2 sec, program switch to stop. Event input rest / SP1.2 : Switching between setpoint 1 and setpoint 2 when use AI-526 or Pno=0 at type SP1.2 / AI-526P. MIO in open status, SV=SP1, when MIO in close status, SV=SP2...
  • Page 44 AF is used to select advanced function. The value of AF is calculated as below: AF=Ax1 + Bx2 + Cx4 + Dx8 + Ex16 + Fx32 + Gx64 + Hx128 A=0, HdAL and LdAL work as deviation high and low limit alarms; A=1, HdAL and LdAL work as high and low limit alarms, and the instrument can have two groups of high and low limit alarms.
  • Page 45 G=0, When the thermocouple or RTD input is burnt out, PV value will increase and trigger the high limit alarm. G=1, When the thermocouple or RTD input is burnt out, PV value will increase and NOT trigger the high limit alarm. After it was sets, High Limit alarm will have 30 sec. delay for trigger in normal usage.
  • Page 46 For Soak mode, SPr had effect on each step. To define the number of program in use. No. of Program Pno= 0, disable the program running mode, then AI-526P will same as AI-526, step (Only for 0~30 meanwhile, can set the parameter “SPr” to limit the ramp time.
  • Page 47 Cont : Continue to run the program from the original break point. If STOP STATUS was activated before power cut, then it (the program) will keep stop status after power restart. Program run Cont / StoP : Stop the program after power restart mode after StoP / run1 : Start to run the program from step 1 unless the instrument was in “stop”...
  • Page 48 PAF = Ax1 + Bx2 + Cx4 + Dx8 + Ex16 + Fx32 When A=0, Enable ready (rdy) function A=1, Disenable ready (rdy) function B=0, Ramp mode. B=1, Soak mode, Program C=0, Time unit in Minute, the range is 0.1~3200. Running mode C=1, Time unit in Hour, the range is 0.1~3200 (Only for...

  • Page 49: Additional Remarks Of Special Functions

    3.3 Additional Remarks of Special Functions 3.3.1 Single-phase phase-shift trigger output When OPt is set to PHA, installing a K5 or K6 module in OUTP slot can single-phase phase-shift trigger a TRIAC or 2 inverse parallel SCRs. It can continuously adjust heating power by control the conduction angle of thyristor. With non-linear power adjustment according to the characters of sine wave, it can get ideal control.

  • Page 50: Setpoints Switch

    If an I2 module is installed in MIO slot (or bAud=1 and I2 installed in COMM slot). User can connect external on off switch to realize some control function. Set Et = rest, can switching program run and stop. For AI-526, or AI526P when its Pno=0, set Et = SP1.2, can switching between setpoint 1 and setpoint 2.

  • Page 51: Temperature Re-Transmitter / Program Generator / Manual Current Output

    Besides AI PID, stand PID control and on-off control, if the output is defined as current output, the instrument can also retransmit PV (process value) or SV (setpoint) into linear current and output from OUTP. The precision of current output is 0.2%FS. Base on that ability, AI-526 can become temperature re-transmitter and AI-526P can become program generator The corresponding parameters are set as below: When CtrL=POP, PV is retransmitted to linear current, the instrument works as temperature re-transmitter.

  • Page 52: Further Description For The Operation Of Ai-526P Series Instrument

    4. Further description for the operation of AI-526P series instrument AI-526P v8.0 program type temperature controller is used in the application where the setpoint should be changed automatically with the time. It provides 30 segments program control which can be set in any slope and the function of jump, run, hold and stop can also be set in the program.

  • Page 53: Jump

    Jump: The program can jump to any other steps in the range of 1 to 30 automatically as you programmed in the program Step, and realize cycle control. Run/Hold: When program is in the running status, timer works, and set point value changes according to the preset curve. When program is in the holding status, timer stops, and set point remains to make temperature hold also.

  • Page 54: Pv Startup And Pv Preparation Function (Rdy Function)

    PV startup and PV preparation function (rdy function) : At the beginning of starting a program, resuming a program after power cut or continuing to run a program after it is just modified, the PV (process value) are often quite different from the set point. PV startup function and PV preparation function can make PV and set point consistent, and avoid unexpected result.

  • Page 55: Programming And Operation (For Ai-526P Only)

    heating-up, cooling-down and constant temperature curves automatically. The degree of the smooth is relevant with the system’s lag time t (t=d+CtI) ; the longer of the lag time, the curve will more smooth. On the opposite the smooth function will be weaker. Generally the shorter of the process lag time (such as temperature inertia), the better of the program control on effect.
  • Page 56 StEP2: SP 2=400 , t 2=60.0 Temperature raised to 400 , slope of raising curve is 10 /minute, The program take 60 minutes to raise temperature to SP3 (400 degree). It means keep the same temperature in 60 minutes. StEP3: SP 3=400 , t 3=120.0 This is the step for temperature cooling down, slope of cooling curve is 2 /minute, and the time needed is 120 minutes to reach SP4 (160degree).

  • Page 58: Time Setting

    5.2 Soak mode(PAF : B=1) Suitable for the process which does not need to establish the temperature slope, can simplify the programming and more effective. Each step also can set parameter “SPr” to define temperature raise slope, if “SPr=0” raising speed will set to maximum.

  • Page 59: Program Arrangement Of Multi-Curve Operation

    When set -XXX.1, AL1 activate, AL2 release -XXX.2, AL1 release, AL2 activate -XXX.3, AL1 and AL2 activate -XXX.4, AL1 and AL2 release Example: Example 1 : t -5 = -1.1 ; means when the program arrived step 5, AL1 activate, AL2 release and will jump to step 1 continues running Example 2 : t-6 = -0.3 ;...
  • Page 60 separately arranged on StEP2-StEP4, StEP5-StEP7, StEP8-StEP10. Settings are as follows: t- 1=-2.0 Execute the program of curve 1 (StEP2-StEP4) t- 1=-5.0 Execute the program of curve 2 (StEP5-StEP7) t- 1=-8.0 Execute the program of curve 3 (StEP8-StEP10) Note: Can choose the curves by setting the value of StEP “t-1“ set to -2.0, -5.0 or -8.0 before the program startup.

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Ai-526p

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