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PPI neuro 104 User Manual

Open loop motorised valve controller
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neuro 104
Open Loop Motorised Valve
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User Manual

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Summary of Contents for PPI neuro 104

  • Page 1 104 Open Loop Motorised Valve Controller User Manual...
  • Page 2 104 User Manual CONTENTS FRONT PANEL LAYOUT BASIC OPERATION PAGES AND PARAMETERS CONTROL PARAMETERS ALARM PARAMETERS CONFIGURATION PARAMETERS SUPERVISORY PARAMETERS PROFILE PARAMETERS OP3 FUNCTION PARAMETERS TUNING 11. SETPOINT PROFILE 12. HARDWARE ASSEMBLY & CONFIGURATIONS 13. MECHANICAL INSTALLATION 14. ELECTRICAL CONNECTIONS...

  • Page 3: Front Panel Layout

    104 User Manual Section 1 FRONT PANEL LAYOUT The controller front panel comprises of digital readouts, LED indicators and membrane keys as shown in Figure 1.1 below Figure 1.1 neuro104 P P I Upper Readout Manual Indicator Lower Readout...
  • Page 4 104 User Manual Indicator Function Indicates Output-2 ON/OFF status while the controller is Ÿ driving the motor to travel the valve in Reverse (Close) direction. Indicates Profile status if the Profile mode is Enabled. Flashes while the controller is executing ramp/soak Ÿ...

  • Page 5: Basic Operation

    104 User Manual Section 2 BASIC OPERATIONS POWER-UP Upon switching on the power to the controller, all displays and indicators are lit on for approximately 3 seconds during which time the controller runs through a self-test sequence. This is followed by the indication of the controller model name the Upper Readout and the firmware version on the Lower Readout, for approximately 1 second.
  • Page 6 104 User Manual The motorised valve algorithm operates in the boundless mode, which does not require a position feedback potentiometer for control purpose. The control demand signals are voltage pulses (that drive either Forward or Reverse Relay) the duration of which are computed based on the set values for the parameters: ‘Motor Run Time’, ‘Valve Inertia Time’, ‘Valve Backlash Time’...
  • Page 7 Valve Position in steps to bring the PV to a desired level and then transferring the control to Automatic mode operation. The neuro 104 controller incorporates highly advanced “X-PRESS” algorithm. The Overshoot Inhibit block of the X-PRESS algorithm can be enabled in PAGE-13 parameter list to overcome the start-up overshoot problem and thus eliminating the need of Manual mode operation during process start-up.
  • Page 8 104 User Manual 3. Press DOWN key to select (no) on the Upper Readout. Press ENTER key to register the YES Command. Upon pressing ENTER key, the controller resets and restarts followed by turning ON the output and alarm signal (if alarm condition exists) and reverts to MAIN display (Auto mode).
  • Page 9 104 User Manual 1. Press PAGE key. The Lower Readout displays (PAGE) and the Upper Readout displays (0). 2. Press ENTER key until the Lower Readout displays (Start) and the Upper Readout displays (No). 3. Press UP key to select (Yes) on the Upper Readout.
  • Page 10 Mode which was operated prior to Tuning. OPERATOR PARAMETERS The PPI neuro series controllers facilitate a separate PAGE for Operator Parameters to provide the operational ease for normal day-to-day operations and to avoid unauthorized access to the controller’s Program Mode.
  • Page 11 104 User Manual 3. Use UP/DOWN key to set the values and press ENTER key to register the set value and scroll to next parameter. Upon pressing ENTER key while last parameter in the list, the controller returns to MAIN Display Mode.
  • Page 12 104 User Manual Settings Parameter Description (Default Value) PROFILE ABORT COMMAND This parameter is available and applicable only if its availability in Operator Parameter list is enabled under supervisory level in PAGE- 13 parameter list and Profile Cycle is already started. It has two possible settings.
  • Page 13 104 User Manual Settings Parameter Description (Default Value) Tuning. Note that the Tuning operation is always performed with respect to the Control (Main) Setpoint (SP). When, the Auxiliary Setpoint mode is disabled (by selecting the option to other than ‘Auxiliary Setpoint’) in PAGE-13 parameter list, the controller...
  • Page 14 104 User Manual Figure 2.2 Table 2.2 neuro104 Message PV Error Type P P I Over-range (PV above Max. Range) Under-range (PV below Min. Range) Open (Sensor open / broken) Notes: 1. In case of Over-range and Under-range PV Error condition, the Output-2 Relay is kept continuously ON to drive the motor for turning the valve in Reverse (Close) direction completely.
  • Page 15 104 User Manual Table 2.3 PV ERROR TYPE ALARM TYPE ALARM STATUS Process Low Process High Under-range Negative Deviation Positive Deviation Window Band Process Low Process High Negative Deviation Over-range or Open Positive Deviation Window Band SENSOR BREAK PROTECTION The controller facilitates the Sensor Break Protection for Temperature Sensors like Thermocouples (J, K, T, R, S, B, N &...

  • Page 16: Pages And Parameters

    104 User Manual Section 3 PAGES AND PARAMETERS ORGANIZATION The controller requires various user settings that determine how the controller will function or operate. These settings are called Parameters. The parameters are always presented in a fixed format: The Lower Readout displays the parameter prompt (Identification Tag) and the Upper Readout displays the set value.
  • Page 17 104 User Manual Note that some parameters (examples; ‘Alarm Setpoint’, ‘Proportional Band’, etc.) have numeric values while others (examples; ‘Control Logic’, ‘Alarm Inhibit’, etc.) have a series of options. If adjusting a numeric value; depressing the UP/DOWN key once, increases/decreases the parameters value by one digit. For parameters having a series of options, depressing the UP/DOWN key once takes you to the next/previous option.
  • Page 18 104 User Manual Locking 1. Press and release PAGE key while the controller is in the MAIN Display Mode. The Lower Readout shows PAGE and the Upper Readout shows 0. 2. Adjust the Upper Readout to the value 123 using UP/DOWN keys.
  • Page 19 104 User Manual SETTING DEFAULT VALUES The controller is shipped from the factory with all the parameter set to their default factory set values. Thus, for the first-time installation there is no need for re-setting the parameters to their default values. However, 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 controller for new installation.

  • Page 20: Control Parameters

    104 User Manual Section 4 CONTROL PARAMETERS The Control Parameters are grouped on PAGE-10 and define the constants required by a particular control algorithm for the purpose of computing and outputting the control signals. The Table 4.1 below lists the parameters followed by the definitions for each parameter.
  • Page 21 104 User Manual Settings Parameter Description (Default Value) If the ‘Valve Inertia Time’ is set to 5 seconds, ‘Valve Backlash Time’ is set to 3 seconds and ‘Minimum ON Time’ is set to 4 seconds; as per the above example; the Final Pulse Time will be calculated as: Final Pulse Time = (30 - 5) + 3 + 4 = 32 seconds The ‘Motor Run Time’...

  • Page 22: Alarm Parameters

    104 User Manual Section 5 ALARM PARAMETERS The Alarm Parameters are grouped on PAGE-11. The controller is provided with 1 “soft” alarm, that is, the alarm can be set and generated even if the corresponding output module is not fitted or assigned to other function. The front panel indicator A indicates the alarm status.
  • Page 23 104 User Manual Settings Parameter Description (Default Value) ALARM HYSTERESIS 1 to 999 Sets differential (dead) band between Alarm-1 switching ON and (Default :2) OFF states. ALARM LOGIC This parameter is available and applicable only if the alarm type is other than ‘None’...
  • Page 24 104 User Manual Window Alarm Deviation Alarm Band Hysterisis Band Hysterisis (c) Deviation Band Alarm (d) Window Band Alarm The ‘Direct’ and ‘Reverse’ Alarm Logics for ‘Process High’ alarm type are illustrated below in Figures 5.2(a) and 5.2(b). Figure 5.2...

  • Page 25: Configuration Parameters

    104 User Manual Section 6 CONFIGURATION PARAMETERS The Configuration Parameters are grouped on PAGE-12 and allows the user to configure the controller to match with the available input sensor and the load drive. It also present s the parameters for conditioning the input sensor signal and sensor break protection.
  • Page 26 104 User Manual Settings Parameter Description (Default Value) Setpoint Low to Max. Range SETPOINT HIGH for the selected Input Type (Default : 1300) Sets maximum permissible control setpoint value. OFFSET FOR PV -1999 to 9999 This value is algebraically added to the measured PV to derive the (Default : ) final PV that is displayed and compared for alarm / control.
  • Page 27 104 User Manual Table 6.2 Range Option What it means Resolution (Min. to Max.) Type J Thermocouple 0 to +760°C / +32 to +1400°F Type K Thermocouple -200 to +1300°C / -328 to +2372°F Type T Thermocouple -200 to +350°C / -328 to +662°F Type R Thermocouple 0 to +1700°C / +32 to +3092°F...

  • Page 28: Supervisory Parameters

    104 User Manual Section 7 SUPERVISORY PARAMETERS The Supervisory Parameters are grouped on PAGE-13 and pertain to the controller’s supervisory utility feature to exercise the supervisory control over the operator level. All the parameters except Serial Communication and Auxiliary Setpoint are software modules that are supplied as standard features.
  • Page 29 104 User Manual Settings Parameter Description (Default Value) ALARM SP ADJUSTMENT Disable ON OPERATOR PAGE Enable Supervisory permission for Alarm setpoint adjustments on Operator Page. Set to ‘Enable’ for permission. (Default : Disable) Disable STANDBY MODE Enable Supervisory control over availability of Standby (entry / exit) command on Operator Page.

  • Page 30: Profile Parameters

    104 User Manual Section 8 PROFILE PARAMETERS The Profile Parameters are grouped on PAGE-14 and pertain to the Ramp / Soak Profile utility. The controller comes with an in-built 4 Ramp + 4 Soak Profile (Refer Section 12: Setpoint Profile for details). The Table 8.1 below lists the parameters followed by the definition of each parameter.
  • Page 31 104 User Manual Settings Parameter Description (Default Value) This parameter is expressed in the same unit and resolution as that for PV. By default, this parameter value is set to the Minimum Range value specified for the selected ‘Input Type’. If the ‘Input Type’...
  • Page 32 104 User Manual Settings Parameter Description (Default Value) TARGET SETPOINT-3 This parameter sets the target level for the Third ramp segment. The Setpoint ramps to this level with Ramp Rate-3 from Target Min. to Max. Range Specified Setpoint-2. for the Selected Input Type...
  • Page 33 104 User Manual Settings Parameter Description (Default Value) OUTPUT OFF This parameter allows the user to set the strategy as regards what the controller shall do after 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’...

  • Page 34: Op3 Function Parameters

    104 User Manual Section 9 OP3 FUNCTION PARAMETERS The OP3 Function Parameters are grouped on PAGE-15 and allow the user to configure the controller for the following function if the respective hardware module is fitted. Configure OP3 Function to Alarm Output.
  • Page 35 104 User Manual Settings Parameter Description (Default Value) RECORDER HIGH The ‘Recorder Low’ and ‘Recorder High’ defines the PV / SP range for which the controller outputs the DC Linear Signal as Retransmission (Recorder) Output that is linearly proportional to Min.
  • Page 36 104 User Manual = mx + c = 8 X 20 + 20.0 = 160 + 20.0 = 180.0% RH Set this value of y (180.0) as the ‘Recorder High’ value. Figure 9.1 % RH 180.0 100.0 20.0 x mA The graph shown in Figure 9.1 above represents the straight line calculated in the above example with the respective (x, y)

  • Page 37: Tuning

    TUNING SELF-TUNING The PPI model neuro 104 incorporates, as a standard feature, the tune-on-demand Tuning, called the Self-Tuning. The Self-Tuning is a one-time Tuning (or tune-on-demand) which works by switching ON/OFF the Forward and Reverse Relay to travel the valve in fully Forward direction (Open) and fully Reverse direction (Close) for inducing oscillations in the PV. From the amplitude and period of oscillations, it calculates the tuning parameter (PID) values.
  • Page 38 5. Avoid applying Self-Tuning in the following processes As the 'Relay-Amplitude' Tuning method implemented in neuro 104 requires oscillations of PV around a predetermined level Ÿ (calculated based on the SP value), avoid Self-Tuning to the processes that can be disturbed due to temporary moving the valve in fully Forward (Open) and fully Reverse (Close) direction for inducing oscillations in PV.
  • Page 39 104 User Manual Figure 10.2 Process Value (PV) Setpoint (SP) Follow the steps below for Tuning the controller manually. 1. Set the value of the SP at which the Manual Tuning is desired or slightly below if the overshoots caused by the oscillations near the operating value are damaging.
  • Page 40 104 User Manual Table 10.1 Proportion Integral Derivative Type Of Control Band Time Time Proportional Only 2 X P Proportional + Integral 2.22 X P 0.8 X T (P + I) Proportional + Integral 1.67 X P 0.5 X T 0.13 X T...

  • Page 41: Setpoint Profile

    There are a host of applications that require the PV to follow a series of straight-line segments, called “Profile”. The neuro 104 controller incorporates software modules, the Setpoint Generator module and the Timer module, which generate a fixed-format, 8-segment Profile: 4 Ramp + 4 Soak, each Ramp followed by a Soak. The Setpoint Generator module generates the ramp segment in accordance with the set values of Ramp Rate and the Target Setpoint.
  • Page 42 Hold Time neuro 104 allows specifying this band by setting the value of the parameter ‘Ramp Hold Band’. Whenever, the absolute difference between the Ramping Setpoint and the measured PV exceeds this band value, the controller stops ramping of the Setpoint until PV enters the band.
  • Page 43 104 User Manual One typical application of the soak band is implementing guaranteed soak, that is, to start counting the time pulses only when the measured PV enters the set band limit and keep counting as long as it does not fall outside the limit. Besides guaranteed soak, it is also useful in many heat treatment applications to ensure that the Soak Timer does not start until the PV reaches the ‘Target Setpoint’...
  • Page 44 104 User Manual STATE OF CONTROLLER AFTER END OF PROFILE CYCLE What the controller shall do after the end of a Profile Cycle depends upon the setting of the parameter (‘Output Off’) available in PAGE 14 parameter list (Profile Parameters).
  • Page 45 104 User Manual Figure 11.6 Free falling Maintain Here For this application; the Profile Parameters are set as required. The SP is set to the predetermined level where the PV is to be maintained until the beginning of a next Profile Cycle.

  • Page 46: Hardware Assembly & Configurations

    104 User Manual Section 12 HARDWARE ASSEMBLY & CONFIGURATIONS OUTER CASE Figure 12.1 Ventilations Rear Terminals Panel Mounting Clamp Panel Sealing Gasket ( C L Bezel N / C R S E N / O L E Y Enclosure...
  • Page 47 104 User Manual Placing Back 1. Hold the bezel with the front label upright. 2. Hold the Enclosure such that the UP inscribed on the Enclosure is on the topside. Insert the bezel gently with the boards on either side sliding into the guides provided inside of the Enclosure.
  • Page 48 104 User Manual Figure 12.4 Jumper Setting-B Jumper Setting-A shown in above Figure, there are 2 jumper arrangements marked A and B. The selection between Relay and SSR requires both these jumpers A and B to be set appropriately as shown in Table 12.1 below. The double headed arrows show the adjoining Pins that require shorting using the Link.
  • Page 49 104 User Manual Figure 12.6 Mounting Output-3 Module Plug & Socket Connector Output Module Projections CPU Board Slots Front Label Upside-down For plugging out the 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.

  • Page 50: Mechanical Installation

    104 User Manual Section 13 MECHANICAL INSTALLATION The following precautions should be strictly observed while installing the controller: 1. The place of installation should be free of corrosive/combustible gases and electrically conductive pollution. 2. Ensure that the place of installation is not subject to rapid ambient changes that can cause condensation. Also the Ambient Temperature and Relative Humidity surrounding the controller should not exceed the maximum specified for the proper operation of the controller.
  • Page 51 104 User Manual PANEL MOUNTING Follow the steps below for mounting the controller on panel: 1. Prepare a square cutout to the size shown in Figure 13.2. 2. Remove the Panel Mounting Clamp from the controller Enclosure. 3. Insert the rear of the controller housing through the panel cutout from the front of the mounting panel.

  • Page 52: Electrical Connections

    104 User Manual Section 14 ELECTRICAL CONNECTIONS WARNING MISHANDLING / NEGLIGENCE C A N R E S U LT I N P E R S O N A L DEATH OR SERIOUS INJURY. 1. The user must rigidly observe the Local Electrical Regulations.
  • Page 53 104 User Manual DESCRIPTIONS The back panel connections are described as under: INPUT (Terminals : 1, 2, 3) The controller accepts Thermocouples (J, K, T, R, S, B, N & Reserved), 3-wire RTD Pt100 and DC Linear Current/Voltage (mV/V/mA) as input. The types and ranges are described in Section 6 : Configuration Parameters.
  • Page 54 104 User Manual Figure 14.4 (a) MOTORIZED VALVE OPEN CLOSE The controller is designed to switch on either Output-1 or Output-2 (to Open or Close the valve). However, under fault conditions, both Output-1 and Output-2 Relays could be switched on simultaneously. For safety purpose, an interlock can be included which connects the Motor Supply to the valve via “Normally Closed (N/C)”...
  • Page 55 104 User Manual Figure 14.5 (a) Figure 14.5 (b) Figure 14.5 (c) Relay Connections SSR Connections DC Linear Current/ Voltage Connections Relay Potential-free Relay changeover contacts N/O (Normally Open), C (Common) and N/C (Normally Close) rated 2A/240 VAC (resistive load) are provided as Relay output.
  • Page 56 104 User Manual SERIAL COMMUNICATION PORT (Terminals : 14 , 15) If the optional plug-in communication board is fitted, connect terminal 15 and 14 of the controller to (+) and (-) terminals of the Master device. In case of RS485 port, connect terminal 15 and 14 of the controller to positive (+) and negative (-) terminals of the master device.
  • Page 57 104 User Manual Figure 14.8 (a) Figure 14.8 (b) OPEN : Main CLOSE : Auxiliary SP Mode SP Mode In TTL-compatible Digital Input, when the DC pulse voltage is greater than 0.6 Volts, the controller is configured in Main SP mode and when the DC pulse voltage is less than 0.5 Volts, the controller is configured in Auxiliary SP mode.
  • Page 58 Process Precision Instruments 101, Diamond Industrial Estate, Navghar, Vasai Road (E), Dist. Palghar - 401 210.Maharashtra, India 0250 - 2391722/33/37/42 07498799226, 09321985369 sales@ppiindia.net, support@ppiindia.net w w w . p p i i n d i a . n e t...

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