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ACS contsys MIR-491 Operating Manual

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ACS-Control System GmbH
Industrial and process controller MIR-491
MIR-491
MIR-491
Operating manual
English
BAL-491-65511
Valid from: 07/2002

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  • Page 1 ACS-Control System GmbH Industrial and process controller MIR-491 MIR-491 MIR-491 Operating manual English BAL-491-65511 Valid from: 07/2002...
  • Page 2 General warning Attention: ESD sensitive devices © ACS-Control System GmbH • Printed in Germany (0207) All rights reserved. No part of this document may be reproduced or published in any form or by any means without prior written permission from the copyright owner.

  • Page 3: Table Of Contents

    Set-point processing ......39 MIR-491 cooling functions ....40 4.4.1...
  • Page 4 – motor actuator monitoring MIR-491 as Modbus master ....60 BlueControl ......61 Versions .

  • Page 5: Mounting

    Access to the levels is as adjusted by means of BlueControl (engineering tool) closed all levels accessible wihout restriction Factory setting Default setting: display of all levels suppressed, password PASS = OFF Caution! The unit contains ESD-sensitive components. Operating manual MIR-491...

  • Page 6: Electrical Connections

    OUT6 24V GND RXD-B RGND RXD-A DATA B TXD-B (16) DATA A TXD-A RS485 RS422 Modbus RTU The controller is fitted with flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 Connecting diagram Operating manual MIR-491...

  • Page 7: Terminal Connection

    As input INP1, but without voltage Connection of inputs di1, di2 7 Digital input, configurable as switch or (16) push-button Connection of inputs di2/3 8 (option) Digital inputs (24VDC external), galvanically isolated, configurable as switch or push-button Operating manual MIR-491 Terminal connection...
  • Page 8 (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 62. Terminal connection Operating manual MIR-491...
  • Page 9 Electrical connections 3 OUT3 as logic output with solid-state relay (series and parallel connection) Series connection Parallel connection I =22mA I =22mA Logic MIR-491 connecting example: Fuse Fuse Fuse TB 40-1 MIR-491 Temperature limiter Contactor Logik Reset (16) Heating 1 TB 40-1 Temperature limiter...

  • Page 10: 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. Front view Operating manual MIR-491...

  • Page 11: 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 MIR-491 was in manual mode before power-off, the controller starts with correcting value Y2 after switching on again.

  • Page 12: Mainenance Manager / Error List

    - Check INP3 connection Sht. 3 Short circuit INP3 - Sensor defective - Replace sensor INP3 - Faulty cabling - Check INP3 connection - Faulty cabling - Reverse INP3 polarity POL. 3 INP3 polarity Mainenance manager / Error list Operating manual MIR-491...
  • Page 13 Error status Signification Existing error Change to error status 1 after error removal Stored error Change to error status 0 after acknowledgement in error list No error/message not visible, except with acknowledgement Operating manual MIR-491 Mainenance manager / Error list...

  • Page 14: Self-Tuning

    Self-tuning start can be locked via BlueControl (engineering tool) ( P. L oc). ti and td are taken into account only, if they were ≠ OFF previously. Self-tuning Operating manual MIR-491...

  • Page 15: Selecting The Method ( Conf/ Cntr/ Tune)

    If the process value is higher than the set-point minus 60 K (X ≥ SP - 60 K) and self-tuning is started manually, the control to the set-point is using the old parameters followed by an optimization at the set-point. Operating manual MIR-491 Self-tuning...

  • Page 16: Optimization At The Set-Point

    ( PArA/ SETP/ r. S P≠ OFF) and manual self-tuning start or self-tuning start after power on w with active start-up circuit ( ConF / Cntr / SP. F n = 10) and manual self-tuning start or self-tuning start after power-on Self-tuning Operating manual MIR-491...

  • Page 17: Self-Tuning Cancellation

    (2), the power is switched on (3). 100% At the reversal point, the self-tuning Start r t reversal point attempt is finished and the new parameter are used for controlling to blinks set-point W. Operating manual MIR-491 Self-tuning...
  • Page 18 (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! Self-tuning Operating manual MIR-491...

  • Page 19: Manual Self-Tuning

    With 2-point and 0,5 * K 3-point controllers, 2,6 * K 6 * Tu the cycle time must be adjusted to t1 / t2 ≤ 0,25 * Tu 3-point-stepping 1,7 * K 2 * Tu Operating manual MIR-491 Manual self-tuning...

  • Page 20: 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 Operating manual MIR-491...

  • Page 21: Operating Structure

    BlueControl (engineering tool). Individual parameters accessible without password must be copied to the extended operating level. Factory setting: Safety switch Loc closed: all levels accessible without restriction, password PASS = OFF. Operating manual MIR-491 Operating structure...

  • Page 22: Configuration Level

    Configuration level Configuration level Configuration survey Configuration survey Operating manual MIR-491...

  • Page 23: Configuration Parameters

    = 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. Operating manual MIR-491 Configuration parameters...
  • Page 24 C (0...2315°C), W5%Re-W26%Re thermocouple type D (0...2315°C), W3%Re-W25%Re thermocouple type E (-100...1000°C), NiCr-CuNi thermocouple type B (0/100...1820°C), PtRh-Pt6% special thermocouple Pt100 (-200.0 ... 100,0 °C) Pt100 (-200.0 ... 850,0 °C) Pt1000 (-200.0 ... 200.0 °C) Configuration parameters Operating manual MIR-491...
  • Page 25 (e.g. transmitter input instead) S. t YP Sensor type selection 0...20mA / 4...20mA 1 0...50mA AC 1 Potentiometer ( 0...160 Ohm) 1 with current and voltage input signals, scaling is required (see chapter 5.3) Operating manual MIR-491 Configuration parameters...
  • Page 26 K (-100...1350°C), NiCr-Ni thermocouple type N (-100...1300°C), Nicrosil-Nisil thermocouple type S (0...1760°C), PtRh-Pt10% thermocouple type R (0...1760°C), PtRh-Pt13% thermocouple type T (-200...400°C), Cu-CuNi thermocouple type C (0...2315°C), W5%Re-W26%Re thermocouple type D (0...2315°C), W3%Re-W25%Re Configuration parameters Operating manual MIR-491...
  • Page 27 (process value - set-point) control deviation xw (with suppression after start-up and set-point change) measured value INP1 1 with current and voltage input signals, scaling is required (see chapter 5.3) Operating manual MIR-491 Configuration parameters...
  • Page 28 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 ) Configuration parameters Operating manual MIR-491...
  • Page 29 Value range Description Default O. A ct Method of operation of output OUT1 direct / normally open inverse / normally closed Y. 1 Controller output Y1 not active active Y. 2 Controller output Y2 not active active Operating manual MIR-491 Configuration parameters...
  • Page 30 INP3 error signal not active aktiv FOut Forcing OUT1 (only visible with BlueControl!) No forcing Forcing via serial interface Out. 2 Configuration parameters Out.2 as Out.1 except for: Default Y. 1 = 0 Y. 2 = 1 Configuration parameters Operating manual MIR-491...
  • Page 31 Valve monitoring (DAC) (only visible when O.TYP=0) not active active LP. A L Interruption alarm signal (LOOP) (only visible when O.TYP=0) not active active HC. A L Heating current alarm signal (only visible when O.TYP=0) not active active Operating manual MIR-491 Configuration parameters...
  • Page 32 0 ... 20 mA continuous (only visible with current/logic/voltage) 4 ... 20 mA continuous (only visible with current/logic/voltage) 0...10 V continuous (only visible with current/logic/voltage) 2...10 V continuous (only visible with current/logic/voltage) transmitter supply (only visible without OPTION) Configuration parameters Operating manual MIR-491...
  • Page 33 Solid state relay (SSR) short circuit signal (only visible when O.TYP=0) not active active FAi. 1 INP1 error (only visible when O.TYP=0) not active active FAi. 2 INP2 error (only visible when O.TYP=0) not active active Operating manual MIR-491 Configuration parameters...
  • Page 34 Configuration parameters Out.2 as Out.1 except for: Default Y. 1 = 0 Y. 2 = 0 Method of operation and usage of output Out. 1 to Out. 6 : Is more than one signal chosen active as source, those signals are OR-linked. Configuration parameters Operating manual MIR-491...
  • Page 35 Switching to fixed control output Y. E no function (switch-over via interface is possible) always activated (manual station) DI1 switches DI2 switches (only visible with OPTION) DI3 switches (only visible with OPTION) è - key switches Ò - key switches Operating manual MIR-491 Configuration parameters...
  • Page 36 Switching of the actual process value between Inp1 and X2 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 Configuration parameters Operating manual MIR-491...
  • Page 37 °F Decimal point (max. number of digits behind the decimal point) no digit behind the decimal point 1 digit behind the decimal point 2 digits behind the decimal point 3 digits behind the decimal point Operating manual MIR-491 Configuration parameters...
  • Page 38 Display 3 controller operating level (only visible with BlueControl!) No value / only text Display of value Output value as bargraph Control deviation as bargraph Process value as bargraph Resetting the controller configuration to factory setting (Default) r chapter 11.1 (page 69) Configuration parameters Operating manual MIR-491...

  • Page 39: Set-Point Processing

    In addition to configuration and parameter setting, the engineering tools are used for data acquisition and offer long-term storage and print functions. The engineering tools are connected to MIR-491 via the front-panel interface "BluePort" by means of PC (Windows 95 / 98 / NT) and a PC adaptor.

  • Page 40: Mir-491 Cooling Functions

    Configuration level MIR-491 cooling functions With MIR-491, 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 41: Water Cooling 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 Operating manual MIR-491 MIR-491 cooling functions...

  • Page 42: 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] MIR-491 cooling functions Operating manual MIR-491...

  • Page 43: Configuration Examples

    SP. L O = -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 Operating manual MIR-491 Configuration examples...

  • Page 44: 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 Configuration examples Operating manual MIR-491...

  • Page 45: 3-Point Controller (Relay & Relay)

    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 of the 3-point controller, the controller action must be changed ( ConF / Cntr / C. A ct = 1 ) Operating manual MIR-491 Configuration examples...

  • Page 46: 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 Configuration examples Operating manual MIR-491...

  • Page 47: 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 ). Operating manual MIR-491 Configuration examples...

  • Page 48: Y - Off Controller

    = -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 Configuration examples Operating manual MIR-491...

  • Page 49: Mir-491 With Measured Value Output

    Configuration level 4.5.7 MIR-491 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. 3 / 4 0...20mA continuous Out.

  • Page 50: Parameter Setting Level

    Parameter setting level Parameter setting level Parameter survey Parameter survey Operating manual MIR-491...

  • Page 51: Parameters

    PAr. 2 Name Value range Description Default Pb12 1...9999 1 Proportional band 1 (heating) in phys. dimensions (e.g. °C), 2. parameter set Pb22 1...9999 1 Proportional band 2 (cooling) in phys. dimensions (e.g. °C), 2. parameter set Operating manual MIR-491 Parameters...
  • Page 52 -1999...9999 Displayed value for the upper scaling point t. F 3 -1999...9999 Filter time constant [s] 1 Valid for ConF/ othr/ dP = 0. With dP = 1 / 2 / 3 also 0,1 / 0,01 / 0,001 is possible. Parameters Operating manual MIR-491...

  • Page 53: Input Scaling

    InP. 3 scaling of input and display values at parameter setting level is required. Specification of the input value for lower and higher scaling point is in the relevant electrical unit (mA/ V). phys. quantity OuH.x phys. quantity mA / V OuL.x InL. x InH. x mA/V Operating manual MIR-491 Input scaling...

  • Page 54: Input Inp. 1 And Inp. 3

    (0...20/ 50mA) determined by selection of S. t YP. Second set of parameters MIR-491 is provided with a second set of parameters ( PArA / PAr. 2 ) for heating and cooling. Switch-over to the second set of parameters is dependent of configuration ( ConF / LOGI/ Pid.

  • Page 55: 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 Operating manual MIR-491...
  • Page 56 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. Operating manual MIR-491...
  • Page 57 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 . Operating manual MIR-491...

  • Page 58: Special Functions

    In these cases the controller will change to manual operation and the outputs will be switched off. Is the controller switched to automatic operation again or any modification is done the controller activates the DAC function again and the outputs will be setted. Operating manual MIR-491 – motor actuator monitoring ®...
  • Page 59 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. Operating manual MIR-491 – motor actuator monitoring ®...

  • Page 60: Mir-491 As Modbus Master

    The MIR-491 can be used as Modbus master ( ConF / othr / MASt = 1 ). The Modbus master sends ist data to all slaves (Broadcast message, controller adress 0). It transmits its data (modbus adress AdrU) cyclic with the cycle time CYcL to the bus.

  • Page 61: Bluecontrol

    BlueControl BlueControl BlueControl is the projection environment for the controller MIR-491. The following 3 versions with graded functionality are available: Functionality Mini Basic Expert parameter and configuration setting controller and control loop simulation download: writes an engineering to the controller...

  • Page 62: Versions

    Order no. Heating current transformer 50A AC STW-440-50001 PC-adaptor for the front-panel interface STK-540-00001 Operating manual German BAL-401-62918 Operating manual English BAL-401-62911 BlueControl (engineering tool) Mini BCM-400-00002 BlueControl (engineering tool) Basic BCB-400-00002 BlueControl (engineering tool) Expert BCD-400-00003 Operating manual MIR-491...

  • Page 63: Technical Data

    Technical data as for INP1 Effect of source resistance: 1 µV/Ω Potentiometer Cold-junction compensation r Table 2 (page 67 ) Maximal additional error: ± 0,5 K Sensor break monitoring Sensor current: ≤ 1 µA Configurable output action Operating manual MIR-491...
  • Page 64 * All logic signals can be OR-linked! RELAY OUTPUTS OUT1...OUT4 Contact type: potential-free changeover contact Max.contact rating: 500 VA, 250 V, 2A at 48...62 resistive load Min. contact rating: 5V, 10 mA AC/DC Operating life (electr.): 600.000 duty cycles with max. contact rating Operating manual MIR-491...
  • Page 65 0...11 V "Accessory equipment"). The BlueControl Min. load: ≥ 2 kΩ software is used to configure, set parameters Load effect: no effect and operate the MIR-491. Resolution: ≤ 11 mV (0,1%) Accuracy ≤ 20 mV (0,2%) BUS INTERFACE (OPTION) Galvanically isolated...
  • Page 66 Complies with EN 61010-1 (VDE 0411-1): Overvoltage category II Contamination class 2 Working voltage range 300 V Protection class II Certifications Type-tested to DIN 3440 (applied for) For use in: Heat generating plants with outflow temperatures up to 120°C to DIN 4751 Operating manual MIR-491...
  • Page 67 Table 3 Current and voltage measuring ranges Meßbereich Eingangswiderstand Genauigkeit Auflösung (Ô) 0-10 Volt ß 0,1 % 0,6 mV ~ 110 kΩ ß 0-100 mV 0,1 % 1MΩ 6 µV 0-20 mA ß 0,1 % 49 Ω (Spannungsbedarf ß 2,5 V) 1,5 µA Operating manual MIR-491...

  • Page 68: 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. Operating manual MIR-491...

  • Page 69: Resetting To Factory Setting

    The cleaning of the front of the controller should be done with a dry or a wetted (spirit, water) kerchief. Resetting to factory setting 11.1 In case of faulty configuration, MIR-491 can be reset to the default condition. For this, keep the following two keys pressed during power-on : È Ì...

  • Page 70: Notes

    Notes Notes Operating manual MIR-491...
  • Page 71 Notes Operating manual MIR-491...
  • Page 72 Notes Operating manual MIR-491...
  • Page 73 Notes Operating manual MIR-491...

  • Page 74: Index

    Water cooling linear ..40 SP.E - LED ... 10 Water cooling non-linear ..41 Current signal measuring range ..63 Operating manual MIR-491...
  • Page 75 Resetting to factory setting ..69 Resistance thermometer measuring range ..... 63 Operating manual MIR-491...
  • Page 76 Subject to alterations without notice © ACS-Control System GmbH Änderungen vorbehalten Lauterbacherstraße 57 1/2, D84307 Eggenfelden, Germany Sours réserve de toutes modifications Printed in Germany BAL-401-65511 (0207)

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