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PPI neuro 105 User Manual

Programmable profile controller
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neuro 105
Programmable Profile
Controller
n e u r o 1 0 5
R
S
O P 3
User Manual

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Summary of Contents for PPI neuro 105

  • Page 1 105 Programmable Profile Controller n e u r o 1 0 5 O P 3 User Manual...

  • Page 2: Table Of Contents

    105 User Manual CONTENTS For Size 48X48 FRONT PANEL LAYOUT BASIC OPERATION PAGES AND PARAMETERS CONTROL PARAMETERS ALARM PARAMETERS INPUT / OUTPUT PARAMETERS UTILITY PARAMETERS OP2 & OP3 FUNCTION PARAMETERS PROFILE : SEGMENT PARAMETERS 10. PROFILE : BAND / EVENT PARAMETERS 11.

  • Page 3: Front Panel Layout

    105 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 neuro105 Upper Readout Ramp Indicator Lower Readout Soak Indicator Output-2 Indicator...
  • Page 4 105 User Manual KEYS There are four tactile keys provided on the front panel for configuring the controller, setting-up the parameter values and selecting operation modes. The Table 1.2 below details the key functions. Table 1.2 Symbol Function Press to enter or exit set-up mode.

  • Page 5: Basic Operation

    105 User Manual Section 2 BASIC OPERATION 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 on the upper readout and the firmware version on the lower readout, for approximately 1 second.
  • Page 6 105 User Manual Remember that the flashing decimal point on the leftmost digit of the lower readout is an indication of the controller being operated in Hand (Manual) Mode. 3. Adjust the output power using the UP and DOWN keys. Note that the power adjustment is allowed only within the set Power Low and Power High limits.
  • Page 7 105 User Manual If a profile-program is being executed, the controller respects the ramp setpoint and attempts to maintain the PV at the ramp setpoint. The Ramp Set point value is determined by the profile segment (ramp segment or soak segment) that is in progress.
  • Page 8 105 User Manual 2. The desired operation can be selected on the lower readout by pressing ENTER key. The available operations are Advn (Advance), HoLd (Hold) and Abrt (Abort). Skip While the controller displays Advn ( Advance) on the lower readout and no (No) on the upper readout; press UP key to select YES (Yes) and then press ENTER key.
  • Page 9 105 User Manual QUICK ADJUSTMENT OF THE CONTROL SETPOINT Except in the case of Hand mode or Profile mode operation; the control setpoint is quickly adjustable in the lower readout if the quick setting mode is enabled in PAGE-12 parameter list. If enabled, step through the following sequence to adjust the control setpoint: 1.

  • Page 10: Pages And Parameters

    The controller requires various user settings that determine how the controller will function or operate. These settings are called Parameters. The PPI neuro series controllers are packed with various advanced features and as such require many user settable parameters to activate the features. For the convenience and ease of operation, the various parameters have been grouped separately depending upon the functions they define.
  • Page 11 105 User Manual 3. The controller returns to the MAIN display. 4. Repeat steps 1 and 2. This time the controller returns to the MAIN display with the LOCK disabled (open). Notes : 1. If the quick adjustment mode for the control setpoint is enabled in PAGE-12 parameter list, the setpoint can be adjusted in the lower readout even under LOCK condition.
  • Page 12 105 User Manual CONDITIONAL PARAMETERS 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 that relate to some specific functions or operations. Note, however, that not all parameters are always presented to the user. Some parameters are presented only if the corresponding function or operation mode is selected.

  • Page 13: Control Parameters

    105 User Manual Section 4 CONTROL PARAMETERS PAGE-10 presents the list of parameters that 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 these parameters followed by the definitions for each parameter.
  • Page 14 105 User Manual Settings Parameter Description (Default Value) COOL CYCLE TIME 0.5 to 120.0 Sets the On + Off cycle time in seconds for time proportional (Default : 20.0) power output through OP2 Relay / SSR. POWER LOW LIMIT...

  • Page 15: Alarm Parameters

    105 User Manual Section 5 ALARM PARAMETERS PAGE-11 presents the Alarm related parameter list. The controller is provided with 2 independent “Soft” alarms, that is, the alarms can be set and generated even if the corresponding output modules are not fitted or assigned to other function. The alarm statuses are also available via digital communication, if the communication module is fitted.
  • Page 16 105 User Manual Settings Parameter Description (Default Value) ALARM-1 INHIBIT Set to Yes to suppress Alarm-1 activation upon power-up or (Default : No) process start-up. ALARM-2 TYPE ALARM-2 SETPOINT ALARM-2 DEVIATION BAND ALARM-2 WINDOW BAND ALARM-2 HYSTERESIS ALARM-2 LOGIC ALARM-2 INHIBIT The Parameter description &...
  • Page 17 105 User Manual ABSOLUTE AND RELATIVE ALARM The Process Low and the Process High alarms are known as Absolute alarms as these have set values (Alarm Setpoint) that are independent of the control setpoint. On the other hand, the Deviation and the Window Band alarms are known as Relative alarms as these are always referenced to the control setpoint.
  • Page 18 105 User Manual Notes : 1. Available only if the Alarm type is Process-Low or Process-High. 2. Available only if the Alarm type is Deviation. 3. Available only if the Alarm type is Band. 4. Not available if Alarm type is End of Profile (EOP).

  • Page 19: Input / Output Parameters

    105 User Manual Section 6 CONFIGURATION PARAMETERS PAGE-12 parameter list allows the user to configure the controller to match with the available input sensor and the load drive. It also presents the parameters for conditioning the input sensor signal and to exercise the supervisory control over the operator level.
  • Page 20 105 User Manual Settings Parameter Description (Default Value) Refer Table 6.3 for the available PV RANGE HIGH max/min Ranges & Resolution for each input type. Sets process value corresponding to maximum DC Linear signal input (e.g., 5V, 10V, 20mA, etc.)
  • Page 21 105 User Manual Sensor Input Type - Table6.3 shows below. Table 6.3 Range Resolution Option (Minimum to What it means (Fixed or Settable) Maximum) Type J Thermocouple 0 to +760ºC Type K Thermocouple -200 to +13000ºC Type T Thermocouple -200 to +350ºC...

  • Page 22: Utility Parameters

    105 User Manual Section 7 UTILITY PARAMETERS PAGE-13 presents the list of parameters that pertain to the controller’s utility features. The utilities include Self-tune, start-up Overshoot Inhibit function and Digital Communication (RS485, 2-wire, half-duplex, serial). The Self-tune and Overshoot Inhibit utilities are software modules that are supplied as standard features. The Digital Communication, however, is a firmware (software plus hardware) and thus requires optional hardware module to be fitted in the controller for its operation.

  • Page 23: Op2 & Op3 Function Parameters

    105 User Manual Section 8 OP2 & OP3 FUNCTION PARAMETERS PAGE-14 presents the list of parameters that allow the user configure the controller for Bidirectional Control (Heat - Cool Control) Ÿ Retransmission (recorder) Output Ÿ Assignment of OP2 or OP3 modules to Alarms Ÿ...
  • Page 24 105 User Manual Settings Parameter Description (Default Value) RECORDER HIGH Range Low to (Available if OP3 function is recorder) Range High Set the maximum parameter value (SP or PV) that shall (Default : 0) correspond to the maximum recorder output signal level (20mA or 10 V or 5V).

  • Page 25: Profile : Segment Parameters

    105 User Manual Section 9 PROFILE : SEGMENT PARAMETERS The profile segment parameters are contained in PAGE-15. These parameters allow the user to build profiles SET by SET. As detailed in Section 13 of this manual, each SET of a profile comprises a ramp segment and a soak segment. The configuration of ramp and soak segments required 3 parameters, viz., the Ramp Rate, the Target Setpoint and the Soak Time.
  • Page 26 105 User Manual Settings Parameter Description (Default Value) SOAK TIME 0 to 9999 This parameter sets the time duration in Minutes for which the (Default : 0) setpoint is maintained at the Target Setpoint. This segment is skipped if set to 0, that is, the setpoint immediately starts ramping to the next Target Setpoint.

  • Page 27: Profile : Band / Event Parameters

    105 User Manual Section 10 PROFILE : BAND / EVENT PARAMETERS The PAGE-16 parameter list allows : Setting up ramp and soak Holdback Bands for each profile. Ÿ Programming Event Outputs (if fitted) for every ramp and soak segment of each profile.
  • Page 28 EVENT OUTPUT EXAMPLE The Event Output function provided in neuro 105 can be best explained using an example. Refer Figure 10.1 that illustrates the application example. The output relay OP-3 is to be used as an Event Output. The requirements and the corresponding settings are as under.
  • Page 29 105 User Manual Figure 10.1 soak-2 Ramp-2 soak-1 Ramp-1 OP3 Status Time 3. The output should remain OFF throughout the ramp-2 (segment-3) duration of 20 Minutes. Set the parameters for SEGMENT - 3 as below : OP 3 Event Time 20 Minutes Ÿ...

  • Page 30: Building Profile-Programs

    105 User Manual Section 11 BUILDING PROFILE-PROGRAMS PAGE-17 allows the user to build Profile-Programs by Sequentially Joining (linking) multiple profiles. Also, the numbers of repeat cycles can be set. Note that the PAGE-17 parameter values can not be altered while the controller is executing a profile-program.

  • Page 31: Profile : Configuration Parameters

    105 User Manual Section 12 PROFILE : CONFIGURATION PARAMETERS The Profile and Profile-Programs can be configured using parameters presented in PAGE-18 Configuration involves setting- up the controller for the desired numbers of profiles, the numbers of sets (ramp + soak segment) per profile, the numbers of programs to be built, the output status at the end of profile-program,etc.
  • Page 32 105 User Manual Settings Parameter Description (Default Value) NUMBERS OF SETS FOR THE SELECTED PROFILE This parameter in conjunction with the parameter ‘Select Profile Number’ allows the user to configure each profile for the numbers of ramp + soak sets. A maximum of 8 sets (8 Ramp + 8 Soak) can be set for each profile.

  • Page 33: Setpoint Profile & Profile-Programs

    105 User Manual Section 13 SETPOINT PROFILES & PROFILE-PROGRAMS SETPOINT PROFILE There are a host of applications that require the PV to follow a series of straight-line segments, called PROFILE. A typical profile is illustrated in the following Figure 13.1.
  • Page 34 Profile is followed by the execution of the next profile until the last profile in the program is executed. Note that the neuro 105 controller executes profile-programs rather than stand-alone profiles. This feature allows the user to make the optimum use of the total number of profile segments provided in the controller.
  • Page 35 105 User Manual to maximum configured in PAGE-18 parameter list. 3. Now select the Set number on the upper readout while the lower readout shows Set. The available numbers are from 1 to maximum configured for the selected number of profile in PAGE-18 parameter list.
  • Page 36 2 element as terminator (Profile Number 0). The neuro 105 controller provided an easy way of initializing all selected profiles as stand-alone through parameter rSt.P (Reset Program Set-up) in PAGE-18. When applied, the controller clears all the previous program set-ups and assigns each profile number as a stand-alone element to the corresponding program number.
  • Page 37 HOLD BACK The neuro 105 controller provides a feature called the Holdback. While a ramp or a soak segment is being executed, the controller can be forced to enter a HOLD state following the failure to meet certain user-specified conditions. During hold state, depending upon the segment type, ramp or soak, the setpoint generator module suspends setpoint ramping or the timer module stops counting the time pulses, respectively.
  • Page 38 Applied Above The neuro 105 allows specifying this band by setting the value of the parameter S.bnd (Soak Band) in PAGE-16. Note that, like ramp band, this parameter value too is settable independently for each profile and is applied to all the soak segments of the profile.
  • Page 39 105 User Manual Window Alarm As already mentioned, this alarm sets a symmetrical band around the respective setpoint. It defines both upper and lower deviation limits. In Profie mode, while RAMP, the Window Alarm is applicable for Ramping Setpoint and while SOAK, the Window Alarm is applicable for Target Setpoint.
  • Page 40 105 User Manual Soak Segment If a soak segment was in progress prior to power-failure, the program resumes with ramping the measured PV (servo-start) to the target setpoint with the corresponding ramp rate (for e.g., Ramp Rate -1 for Target Setpoint -1) and then the balance soak time is executed.

  • Page 41: Tuning

    TUNING SELF-TUNING The PPI model neuro 105 incorporates, as a standard feature, the tune-on-demand tuning, called the Self-Tuning. (The ‘++’ version of the neuro 105 controller also includes dynamic or recursive tuning, called the Adaptive Tuning). Self-tuning is a one-time tuning (or tune-on-demand) that is usually required at the time of initial installation of the controller. If there are no significant changes in the process setpoint or load conditions, re-tuning the controller is seldom required.
  • Page 42 105 User Manual appropriate value for the Cycle Time parameter. 3. Access to PAGE-13. Set the Tune parameter (tUnE) to YES and press ENTER key. 4. The controller now returns to the MAIN display. The upper readout shows the PV and the lower readout continuously flashes tUnE.
  • Page 43 105 User Manual Follow the steps below for tuning the controller manually. 1. Cut-off Integral and Derivative actions by setting the parameter values to 0. Set the value of the control setpoint at which the tuning is desired or slightly below if the overshoots caused by the oscillations near the operating value are damaging.

  • Page 44: Hardware Assembly & Configuration

    105 User Manual Section 15 HARDWARE ASSEMBLY AND CONFIGURATIONS The Figure 15.1 below shows the controller outer-case viewed with front label upright. Figure 15.1 Ventilations Rear Terminals Panel Mounting Clamp Panel Sealing Gasket N / C N / O...
  • Page 45 105 User Manual Figure 15.2 ‘UP’ inscribed on topside CPU PCB N / C N / O N / O L A Y L i n e a r Display N / O N / C L i n...
  • Page 46 105 User Manual Figure 15.3 CPU PCB Pins Shorting Link The Input type and the Output-1 type are user configurable and thus require, besides parameter selections, proper jumper- settings prior to electrical connections. The jumper settings are provided in the form of Pins & Shorting-Link arrangements on the CPU PCB towards the rear end as shown in Figure 15.3.
  • Page 47 105 User Manual Table 15.1 : Output-1 Jumper Settings Jumper Setting - B Jumper Setting - C Output Type Relay SSR Drive DC Linear Current (or Voltage) MOUNTING PLUG-IN MODULES The controller supports up to 3 plug-in modules, viz. Output-2 Module (Relay / SSR or DC Linear), Output-3 Module (Relay / SSR or DC Linear) and Option Module (RS485 Serial Port or Digital Input for Auxiliary Setpoint selection).
  • Page 48 105 User Manual Figure 15.5 Figure 15.6 Relay/SSR Module DC Voltage/Current Module Table 15.2 Output Type Jumper Setting - A Jumper Setting - B Relay DC Linear Voltage / Current Module The DC Linear Module is factory configured for either Current or Voltage output. The current output can be configured for 0-20 mA or 4-20 mA and similarly the voltage output can be configured for 0-5 V or 0-10 V through parameter settings.
  • Page 49 105 User Manual Figure 15.7 Mounting Output-2 Module Plug & Socket Connector Output Module Projected Parts Slots Power Supply Board n e u r o 1 0 Front Label Upright Figure 15.8 Mounting Output-3 Module Plug & Socket Connector...
  • Page 50 105 User Manual The plug for the Serial Communication or Auxiliary SP Selection module is located on the Power-supply PCB. The Figure 15.9 below illustrates how to plug-in the Serial Communication/Auxiliary SP module. To plug (or unplug) the module simply insert (or remove) the socket into (or from) the plug.

  • Page 51: Mechanical Installations

    105 User Manual Section 16 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 52 105 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 16.2. 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 53: Electrical Connections

    105 User Manual Section 17 ELECTRICAL CONNECTIONS WARNING MISHANDLING / NEGLIGENCE CAN RESULT IN PERSONAL DEATH OR SERIOUS INJURY. 1. The user must rigidly observe the Local Electrical Regulations. 2. Do not make any connections to the unused terminals for making a tie-point for other wires (or for any other reasons) as they may have some internal connections.
  • Page 54 105 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.
  • Page 55 105 User Manual Figure 17.3 (b) Drive for SSR DC Voltage level is generated for switching the external SSR (Solid State Relay). Connect (+) and (-) terminals of SSR to controller terminals 6 and 4, respectively. Use Zero-Crossover, 3 to 30 VDC operated SSR, rated approximately 1.5 times the actual load rating.
  • Page 56 105 User Manual SERIAL COMMUNICATION PORT (Terminals : 14 , 15) Figure 17.5 Terminating Resistor Twisted (100 to 150 Ohms) Wire Pair 15 (B-) HOST 14 (B+) Screened Cable Serial Comm. Master Device Terminals (The Option plug-in module is supplied as either RS485 Serial Port or Digital Input for Auxiliary SP Selection).
  • Page 57 105 96X96 User Manual neuro 105 96X96...

  • Page 58: Front Panel Layout

    105 96X96 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 neuro105 Upper Readout Lower Readout Ramp Indicator Soak Indicator...
  • Page 59 105 96X96 User Manual KEYS There are four tactile keys provided on the front panel for configuring the controller, setting-up the parameter values and selecting operation modes. The Table 1.2 below details the key functions. Table 1.2 Symbol Function Press to enter or exit set-up mode.

  • Page 60: Hardware Assembly & Configuration

    105 96X96 User Manual Section 2 HARDWARE ASSEMBLY AND CONFIGURATIONS The Figure 2.1 below shows the controller outer-case viewed with front label upright. ELECTRONIC ASSEMBLY The basic electronics assembly (without any plug-in modules), comprises of 3 Printed Circuit Boards (PCB). When viewed from the front;...
  • Page 61 105 96X96 User Manual Input Jumper Setting For DC Linear Current Inputs (0-20mA or 4-20mA), short the Pins using Shorting-Link as shown in Figure 2.2 (a). For all other Input types, keep the Shorting-Link parked leaving the Pins open, as shown in Figure 2.2 (b).
  • Page 62 105 96X96 User Manual OUTPUT -2 & OUTPUT-3 : Modules and Jumper Settings The Output-2 and Output-3 Modules are identical and, thus, can be fitted interchangeably in Output-2 or Output-3 positions. These modules can be configured for either Relay or SSR output through proper jumper selection. Two jumper settings A and B, as shown in Figure 2.3, are required for Relay or SSR selection.
  • Page 63 105 96X96 User Manual Mounting Output Modules Figure 2.4 Display Output 2 Jumper Setting Output 1 B & C Keys Jumper Settings CPU Board Input Jumper Setting Mounting / Un-Mountion of Modules The Figure 2.4 Illustrates how to mount output-2 & output-3 module, respectively. Notice the orientation of the controller & a few identifying components shown in figure to help locate the plugs for the modules.

  • Page 64: Electrical Connections

    105 96X96 User Manual Section 3 ELECTRICAL CONNECTIONS WARNING MISHANDLING / NEGLIGENCE CAN RESULT IN PERSONAL DEATH OR SERIOUS INJURY. 1. The user must rigidly observe the Local Electrical Regulations. 2. Do not make any connections to the unused terminals for making a tie-point for other wires (or for any other reasons) as they may have some internal connections.
  • Page 65 105 96X96 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.
  • Page 66 105 96X96 User Manual Figure 3.4 (a) Relay 9(18) Potential-free Relay changeover contacts N/O (Normally Open) and C (Common) rated 2A/240 8(17) VAC (resistive load) are provided as Relay output. Use external auxiliary device like contactor with appropriate contact rating for driving the actual load.
  • Page 67 105 96X96 User Manual SERIAL COMMUNICATION PORT (Terminals : 14 , 15) Figure 3.5 Terminating Resistor Twisted (100 to 150 Ohms) Wire Pair 15 (B-) HOST 14 (B+) Screened Cable Serial Comm. Master Device Terminals (The Option plug-in module is supplied as either RS485 Serial Port or Digital Input for Auxiliary SP Selection).
  • Page 68 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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