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User Manual
only valid in connection with the installation instructions CTR210i/BGI210i
Device software version 2.05
Revision 3
IBS BatchControl GmbH
Im Sträßchen 2–4
53925 Kall
Germany
UM_CTR210i_303_EN.odt
Intrinsically Safe Compact Controller
CTR 210 i
Tel.:
+49 2441 9199801
Fax.:
+49 2441 9199871
Internet:
www.ibs-batchcontrol.com
08.11.2024
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Table of Contents
Related Manuals for IBS BatchControl CTR 210 i
Summary of Contents for IBS BatchControl CTR 210 i
- Page 1 Intrinsically Safe Compact Controller CTR 210 i User Manual only valid in connection with the installation instructions CTR210i/BGI210i Device software version 2.05 Revision 3 IBS BatchControl GmbH Im Sträßchen 2–4 Tel.: +49 2441 9199801 53925 Kall Fax.: +49 2441 9199871...
- Page 2 The manufacturer reserves the right to modify technical data without notice. Repairs, Dangerous Chemicals A note describing the fault must always accompany instruments sent to IBS BatchControl GmbH for repair. Important! The following procedures must be carried out before a controller is sent in for repair: l Remove all residues that may be present.
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Page 3: Table Of Contents
List of Contents List of Contents 1. Operating and Display Elements..6 6.12. Setpoint Ramp time......22 6.13. Time Basis of Setpoint Ramp..23 1.1. Display..........6 6.14. Setpoint ramp interruption....23 1.2. Keypad..........6 6.15. Calculation of the Derivative Term...23 1.2.1. Manual/automatic key......6 1.2.2. Programming key........6 6.16. - Page 4 List of Contents 7.4.1. Manipulated variable start value (lower 10.1.5.3. Example 3......39 output clamp)..........29 10.2. Digital inputs configuration....40 7.4.2. Manipulated variable full-scale value 10.2.1. Function of the digital input....40 (upper output clamp)......29 10.2.2. Direction of action......41 7.4.3. Safety manipulated variable....29 10.3.
- Page 5 List of Contents 13.1. Display..........49 17. Parameter List 2......53 13.2. Display SP, PV, OUT.......49 18. Alarm menu........54 13.3. Adjustment........49 19. Input and Output Configuration...56 13.4. Manual automatic switchover...49 20. Setpoint Ramp Program List..61 14. Fault Indication......49 21. Calibration List......62 15. Structure List.........50 22.
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Page 6: Operating And Display Elements
Operating and Display Elements Operating and Display Elements 1.1. Display The example above shows the tag number at the top. The control difference DEV is shown as a bargraph under the tag number. The setpoint with indication (e. g. SP, SP 1, SP ext...) is shown below the bargraph. Below the setpoint you will find the process variable. -
Page 7: Adjustment Keys
Operating and Display Elements 1.2.3. Adjustment keys enable direct adjustment of the setpoint in automatic mode. In manual mode these keys enable direct adjustment of manipulated variable. In programming mode, they are used to change the displayed value. enable the individual programming levels and parameters to be selec- ted in programming mode. -
Page 8: Programming
Programming Programming It is easy to adapt the controller to the various requirements. No previous knowledge of programming languages is required. The button functions have already been described in section 1.2. You access the programming level by pressing the key. The instrument number and the software version number are then displayed for about two seconds. - Page 9 Programming man. autom. station Setpoint profiler linearisation test calibration structure level configure inputs and outputs configure alarms parameter level 2 parameter Set value Operating mode level...
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Page 10: Calibration Menu
Calibration menu Calibration Menu The controller is calibrated via the software. All settings are stored in an FRAM and are retained even if the power supply fails. The controller may only be calibrated if doing so will not cause a malfunc- tion or fault in the plant. -
Page 11: Calibration Of Analogue Outputs
Calibration menu 3.2. Calibration of Analogue Outputs Calibration of analogue outputs ammeter connect a multimeter to analogue output 1 clamps 13 (+) and 14 (-) change level with ▲ adjust 4 mA current with enter analogue output 1 0% with ►... -
Page 12: Linearisation Menu
Linearisation Linearisation Menu With the linearisation table you are able to correct non-linear input signals. In the structure menu 5.29 you can select which analogue input is to be linearised. After this selection the linearisation menu appears. There are 25 linearisation interpolation points available. These linearisation points are distributed in 5% steps across the range from –10% to +110%. -
Page 13: Input And Output Test
Input and Output Test Input and Output Test The controller may only be tested if doing so will not cause a malfunction or fault in the plant. Note that the controller blocked the analogue and digital outputs after entering the test menu and set them to several values. You access the test menu in the same way as the other menus. -
Page 14: Structure Menu
Structure menu Structure Menu The structure menu is called up in the same way as all the other menus. Operation and selection takes place as described in sections 1.2 and 2. 6.1. Controller Type The desired controller type must be select at first. Following controller types are available: Controller Type Description section / page... -
Page 15: Slave Controller
Structure menu 6.1.2. Slave Controller The slave controller is a local setpoint controller with external setpoint. The setpoint can not be set directly at the controller. It is determined by a mA signal at one analogue input. In section 6.7 Input selection for remote setpoint the function for selection the analogue input for the setpoint will be described. -
Page 16: Ratio Controller
Structure menu 6.1.3. Ratio Controller Process Value 1 PV = The ratio process value is displayed as PV. Process Value 2 The process values 1 and 2 are read from the analogue inputs set in input selection (section 6.4). The setpoint sp and the process value pv are shown without units. If the two analogue inputs have different measuring ranges, the correction factor C3 (sec- tion 7.8.3) set the ratio from measuring range 1 to measuring range 2. -
Page 17: Difference Controller
10.2.1 Function of the digital input 6.1.5. Manual automatic station The CTR 210 i could be used as a manual automatic station. Then the CTR has no controller function. Setpoint, process value and/or manipulated variable could be displayed, drag along or set. -
Page 18: Cascade Controller
Structure menu 6.1.6. Cascade controller In the case of cascade controller, two controllers are series connected by the software. Master SP-PV PID1 setpoint Slave SP-PV PID2 The manipulated out from master controller is the setpoint from slave controller. The first parameter set (KP1, Kd1, Tn1, Yo1, Tv1) applies to the master control- ler, the second parameter set (KP2, Kd2, Tn2, Yo2, Tv2) to the slave controller. -
Page 19: Double Loop Controller
Structure menu 6.1.7. Double Loop Controller It is possible to have two independent working controllers in one unit. The first controller uses the parameter settings 1 and the second parameter settings 2. The function of the manipulated output is set in the structure menu (see section 6.10 Manipulated variable by double loop controller). -
Page 20: Tracking By The Setpoint
Structure menu 6.2.3. Tracking by the setpoint The operating point is corrected as the setpoint changes (function 5.2.3). If the manipulated variable is changed in manual mode, the operating point OP1 remains unchanged. DEV = control difference The manipulated variable is Kp = proportional gain calculated from the formula: OP1 = operating point... -
Page 21: Feedforward Control On The Input
Structure menu 6.5. Feedforward control on the input The disturbance value on the selected analogue input is added to the process variable on analogue input before calculating the control difference. SP-PVz setpoint correction factor C1 and C2 The formula is as follows: C1 = function 1.33 PVz=PV Z⋅C1C2 C2 = function 1.34... -
Page 22: Input Selection For Remote Setpoint
Structure menu 6.7. Input selection for remote setpoint You select on which analogue input the remote setpoint is connected (function 5.9). Is “double loop controller” activated, for every controller an external setpoint could be given (additional function 5.10). 6.8. External manipulated variable input You determine on which analogue input the signal for external manipulated variable is active (function 5.11 manual/automatic station). -
Page 23: Time Basis Of Setpoint Ramp
Structure menu 6.13. Time Basis of Setpoint Ramp The time base of setpoint ramp (function 5.16) is in seconds or minutes. The time is set in the parameter menu function 1.14 (section 7.3.5). 6.14. Setpoint ramp interruption In function 5.17 you set how the setpoint ramp works at switching to manual mode. -
Page 24: Direct Setpoint Adjustment
Structure menu 6.20. Direct Setpoint Adjustment You can adjust the currently active setpoint directly using the ▲ ▼ keys (function 5.25) or setpoint adjustment is only possible in the parameter menu. Direct adjustment from the keypad is blocked. 6.21. Additional Functions for the Input Switch-over Additional functions are available when changing inputs over using digital input. -
Page 25: Cascade Controller Break
Structure menu 6.25. Cascade Controller break If the master controller is set to manual mode, following functions (5.30) are available: The slave controller setpoint is equal to the master controller output. • The slave controller setpoint is equal to his process value. •... -
Page 26: Parameter Menu
Parameter menu Parameter Menu The parameter menu is called up in the same way as all other menus. Operations and selections are made as described in Sections 1.2 and 2. If the controller is set up for engineering units, the parameters can also be entered as engineering units. -
Page 27: Operating Point Of P Controller
Parameter menu 7.1.4. Operating Point of P controller Functions 1.4, 2.4, 2.18: OP 1 ( OP 2, OP 3) Setting range: -150,0 bis +150,0 Unit: Factory setting: +000,0 The operating point OP1 is only active in the case of P and PD controllers. 7.1.5. -
Page 28: Full-Scale Value
Parameter menu 7.2.4. Full-scale value Functions 1.9, 2.9: Full scale value 1 (Full scale value 2) Setting range: -9999 bis +9999 Unit: engineering unit (e. g. l, °C, bar, ...) Factory setting: 100,0 Enter the value you want to display to represent 100% of the process variable. The decimal point is displayed as specified. -
Page 29: Setpoint Ramp
Parameter menu 7.3.5. Setpoint ramp Function 1.14 Setting range: 0 bis 9999 Unit: s or min Factory setting: 0000 See structure menu: section 6.12 and 6.13 The setpoint ramp also works when a remote setpoint is configured. 7.4. Manipulated Variable Parameters 7.4.1. -
Page 30: Start Up Manipulated Variable
Parameter menu 7.4.5. Start up manipulated variable Function 1.19: Setting range: -10 % bis +110 % Unit: Factory setting: 000,0 % 7.4.6. Rate of change Function 1.20: rate of change for manipulated variable Setting range: 0 bis 9999 s Unit: Factory setting: 0 s (off) At the activation of the safety manipulated variable or the external manipulated... -
Page 31: Filter
Parameter menu 7.6. Filter Functions 1.24 – 1.26 Setting range: 0,1 to 999,9 s Unit: Factory setting: The controller calculates an average between the set times. 7.7. Setpoints (SP 1 – SP 6) Functions 1.27 – 1.32 Setting range: see section 7.3.1 and 7.3.2 Unit: as measuring range 1 Factory setting:... -
Page 32: Dynamic Manipulated Variable Minimum Limit C4
Parameter menu 7.8.4. Dynamic manipulated variable minimum limit C4 Function 1.36: min. manipul. var. Setting range: -100,0 to +100,0 Unit: Factory setting: -100,0 (off) See structure menu: section 6.17 The minimum manipulated variable is calculated from OUTmin = AIx + C4. 7.8.5. -
Page 33: Heating Run-On Time For Split-Range Operation
Parameter menu 7.8.8. Heating run-on time for split-range operation Function 1.42: Overrun heating Setting range: 0 bis 9999 Unit: Factory setting: A digital output is parameterised to heating ON. This digital output switches as soon as the analogue output 2 outputs a value greater than 0% (4 mA). If the analogue output becomes 0% or 4 mA again, the set time runs. -
Page 34: Alarm Menu
Alarm menu Alarm Menu The six digital outputs and LEDs could be set to several functions. This is done in the input and output menu. If the digital output is set as an alarm the classification is set in the alarm menu. These are the options: Function 3.1 Remark... -
Page 35: Manipulated Variable Slew Rate Limit
Alarm menu 9.1.4. Manipulated variable Slew Rate limit Function 3.28: limit slewrate man.var. Enter the manipulated variable slew rate limit (only the calculated P and D term without I term) in this parameter. 9.1.5. Hysteresis manipulated variable Slew Rate Function 3.29: hyst. slewrate man.var In this parameter is set the accessory hysteresis. -
Page 36: Input And Output Configuration
Input and Output Configuration 10. Input and Output Configuration In this menu the inputs and outputs are configured. 10.1. Analogue Outputs Configuration In this functions (4.1.1 and 4.1.8) various signals can be given out on the analogue output 1 or 2. Function Remark manipulated variable... -
Page 37: Analogue Output Start Current
Input and Output Configuration 10.1.3. Analogue output start current Functions 4.1.4 and 4.1.9: Analogue output start current Setting range: -10 % to 110% Unit: Factory setting: 000,0 % You set the current (in %) at the analogue output start value. With the para- meters start current and end current you are able to change the direction of action. -
Page 38: Example 1
Input and Output Configuration 10.1.5.1. Example 1 start value analogue output 1 end value analogue output 1 start current analogue output 1 20 mA 100% end current analogue output 1 4 mA start value analogue output 2 end value analogue output 2 100% start current analogue output 2 4 mA... -
Page 39: Example 3
Input and Output Configuration 10.1.5.3. Example 3 start value analogue output 1 end value analogue output 1 start current analogue output 1 4 mA end current analogue output 1 20 mA 100% start value analogue output 2 end value analogue output 2 100% start current analogue output 2 20 mA... -
Page 40: Digital Inputs Configuration
Input and Output Configuration 10.2. Digital inputs configuration 10.2.1. Function of the digital input In this function (4.21 ...) various signals can be assigned to digital inputs 1 to 6. Function Description / Remark 1 OFF The digital input is without a function. Manipulated variable The digital input blocks the manipulated variable. -
Page 41: Direction Of Action
Input and Output Configuration Function Description / Remark UP keypad function on The digital input operates in the same way as the digital input key. DOWN keypad function The digital input operates in the same way as the on digital input key. -
Page 42: Direction Of Action
Input and Output Configuration Function Description / Remark 6 Setpoint program active The digital output indicates an active programmer. Remote setpoint active The digital output indicates if the remote setpoint is switched on. 8 Digital output off The digital output is without a function. 9 Two-step output The digital output is a two step output Cooling unit after-run ON... -
Page 43: Analogue Input Configuration
Input and Output Configuration 10.4. Analogue Input Configuration This function (4.4) is mainly used for the input selection to adapt the two measuring ranges together. 10.4.1. Measuring range start You set in functions 4.4.1, 4.4.3 and 4.4.5 the measuring value for the start current signal (0%). -
Page 44: User Menu
User menu 11. User menu You can decide which menu items of the parameter menu need to be modified quickly, and you will then not have to enter the parameter menu to make those changes. 11.1. Preparing the User Level You enter the parameter menu in the usual way. -
Page 45: Setpoint Ramp Program
Setpoint Ramp Program Setpoint Ramp Program You can specify a program function when ordering. The program function is only available with fixed setpoint controllers. The program can accept up to 17 time intervals, setpoints and digital outputs settings. If the controller is switched to manual mode at active setpoint profile, the setpoint profile will stop and will have to be restarted after switching back to automatic mode. -
Page 46: Start Program
Setpoint Ramp Program 12.2. Start Program Function 9.2: Start Setting range: NO, YES Factory setting: If you select YES with the arrow keys and confirm this by pressing the keys together, the programmer will start. If you have the user level option (see Section 11), you should transfer Start to this menu. -
Page 47: Start Segment By Rising Process Variable If Control Difference Is Less
Setpoint Ramp Program 12.5.2. Start Segment by rising process variable if control difference is less Reaches the programmer the end of segment by rising process variable, it was checked the value from the control difference (absolute value). If the deviation difference is less in function 9.6 (section 12.6) set the next segment start (if not End is set). -
Page 48: Digital Output Indicate On Led
Setpoint Ramp Program 12.8. Digital Output indicate on LED Funktion 9.7.2, 9.8.2, 9.9.2: Digital output 1 Setting range: OFF, ON You set the indicating from an active digital output at the front LED. 12.9. Programmer Setpoints Funktion 9.7.3...: setpoint x Setting range: -10 bis +110 % Unit:... -
Page 49: Manual Automatic Station
Manual Automatic Station 13. Manual Automatic Station You can use the CTR210i as manual automatic station. As soon you set the controller type in the structure menu to “Man. Autom. Station” a new menu Manual Autom. Station (6.1) appears. If an analogue input is fed to an analogue output, you must set external manipulated variable (section 6.8) to the corresponding analogue input. -
Page 50: Structure List
Structure list 15. Structure List Function see: Function see: set controller type remote setpoint 2. channel 5.10 local setpoint controller 6.1.1 ratio controller 6.1.3 from analogue input 1 difference controller 6.1.4 from analogue input 2 manual / automatic station 6.1.5 from analogue input 3 cascade controller 6.1.6... - Page 51 Structure List Function see: Function see: sensor break AI2 5.20 6.16 interface protocol 5.31 6.26 Modbus RTU Modbus ASCII sensor break AI3 5.21 6.16 baud rate 5.32 6.27 9600 bps 19200 bps 2400 bps manipul. variable limiting 5.22 6.17 4800 bps in manual and auto mode Interface address 5.33...
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Page 52: Parameter List
Parameter list 16. Parameter List Function see: Function see: Kp1 proportional gain 1 7.1.1 filter analogue input 1 1.24 Kd1 derivative action gain 1 1.2 7.1.2 filter analogue input 2 1.25 Tn1 integral action time 1 7.1.3 filter analogue input 3 1.26 OP1 operating point 1 7.1.4... -
Page 53: Parameter List 2
Parameterliste 2 17. Parameter List 2 Function see: Kp2 proportional gain 2 7.1.1 Kd2 derivative action gain 2 2.2 7.1.2 Tn2 integral action time 2 7.1.3 OP2 operating point 2 7.1.4 Tv2 derivative action time 2 2.5 7.1.5 unit 2 decimal point range 2 7.2.2 start of scale value 2... -
Page 54: Alarm Menu
Alarm menu 18. Alarm menu Function see: Function see: function alarm 1 function alarm 3 process variable 1 process variable 1 process value changing process value changing deviation deviation deviation absolute deviation absolute process variable 2 process variable 2 analogue input 1 analogue input 1 analogue input 2 analogue input 2... - Page 55 Alarm menu Function see: Function see: function alarm 5 3.17.0 9 time base slew rate 3.25 9.1.1 process variable 1 seconds process value changing minutes deviation hours deviation absolute limit slew rate process 3.26 9.1.2 variable process variable 2 Hysteresis slew rate 3.27 9.1.3 analogue input 1...
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Page 56: Input And Output Configuration
Input and Output Configuration 19. Input and Output Configuration Function see: Function see: analogue outputs 10.1 digital inputs 10.2 function analogue output 1 4.1.1 function digital input 1 4.2.1 10.2.1 manipulated variable no function anlog input 1 manipul. variable blocked anlog input 2 1. - Page 57 Input and Output Configuration Function see: Function see: function digital input 2 4.2.3 10.2.1 function digital input 3 4.2.5 10.2.1 no function no function manipul. variable blocked manipul. variable blocked 1. safety manipul. variable 1. safety manipul. variable 2. safety manipul. variable 2.
- Page 58 Input and Output Configuration Function see: Function see: function digital input 4 4.2.7 10.2.1 function digital input 5 4.2.9 10.2.1 no function no function manipul. variable blocked manipul. variable blocked 1. safety manipul. variable 1. safety manipul. variable 2. safety manipul. variable 2.
- Page 59 Input and Output Configuration Function see: Function see: function digital input 6 4.2.11 10.2.1 digital outputs 10.3 no function manipul. variable blocked function output 1 4.3.1 10.3.1 1. safety manipul. variable Alarm 1 2. safety manipul. variable digital input 1 man.mode + safety output 1 manual mode active remote man.var.anal.input...
- Page 60 Input and Output Configuration Function see: manual mode active safety output active function output 3 4.3.11 10.3.1 setpoint ramp active Alarm 3 setpoint program active digital input 3 remote setpoint active manual mode active safety output active remote output active setpoint ramp active setpoint program active direction of action...
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Page 61: Setpoint Ramp Program List
Setpoint Ramp Programmer List 20. Setpoint Ramp Program List Function see: Function see: select program actual setpoint 12.7.1.2 Program 1 12.1 LED = digital output 9.x.2 12.8 Program 2 12.1 Program 3 12.1 Start 12.2 SP-0 start setpoint 9.x.3 12.9 Stop 12.3 digital output segment 1 9.x.4... -
Page 62: Calibration List
Calibration List, Manual automatic station 21. Calibration List 22. Manual automatic station Function No. see: Function see: Analogue Input 1 0% upper indication 10.1 13.1 Analogue Input 1 100% analogue input 1 analogue input 2 Analogue Input 2 0% analogue input 3 Analogue Input 2 100% manipulated variable middle indication... - Page 63 Index Index fault message..........49 absolute control deviation......35 Filter..............31 action of direction...........37 Full-scale value..........28 active setpoint..........28 Function of digital output........41 Adjustment keys..........7 Function of the digital input......40 Alarm indication..........41 Alarm Menu............34 General.............2 Analogue output end........36 automatic operation.........6 hysteresis.............34f. Baud...............25 Input and Output Test........13 bringing into service.........2 input selection..........43 Input selection..........22...
- Page 64 Index Operating point for P controller.....19 Sensor Break Monitoring.......30 Overrun heating..........42 Setpoint............28 setpoint............24 parameter menu..........26 Setpoint full scale value.........28 parameter set..........40 setpoint program..........42 parameter set 2..........18 Setpoint program pause........41 PID term............24 setpoint ramp..........22 power supply fails..........10 Setpoint ramp.........29, 40f. program function..........45 Setpoint start value........28 programmer functions........48 Setpoints............31...
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