Temperature Controller

Transcription

1 Your Lab Starts Here Temperature Controller Thermolyne LT2416DX1

2 2 Table of Contents: 2

3 3 Introduction The 16 segment, four programmable, furnace (Group D1) consists of a microprocess-based dual-mode PID (Proptional, Integral, Derivative) temperature controller with over-temperature protection and appropriate output switching devices to control the chamber temperature. The digital readout continuously displays the measured chamber temperature (upper display) and the setpoint chamber temperature (lower display) while in user run mode. The display reverts to showing the mnemonic (upper display) and cresponding set value parameter value (lower display) in the set up mode. These programmable controller modules can be utilized as either single setpoint controllers as a single program controllers defined by 16 segments of programming capability. A special feature, the call segment type, can be utilized to link segments from one program to another. This translates to a maximum of 1 program consisting of 64 segments. The controller discussed in this manual is used in a variety of Thermolyne furnace model types. Thermolyne has assigned a unique controller part number that cresponds with a specific Thermolyne furnace model. The control group of these furnace models described in sales literature is D1. A list of the Thermolyne replacement controller part numbers within group D1 are as follows: CN71X75 CN71X84 CN71X87 CN71X90 CN71X92 CN71X98 LT2416DX1 3

4 4 Understanding The Controller: Understanding The Controller: Controller Terminology Mnemonic - Mnemonic is a term used to reference what is shown in the upper display of the controller. Mnemonics will consist of numbers, such as the measured chamber temperature as well as letters, such as list headers. Whether the mnemonic is a group of letters numbers will depend upon what display you have navigated to. Mnemonics cannot be altered using the arrow keys. - is a term used to reference what is shown in the lower display of the controller. s will consist of numbers, such as deviation alarm setpoint as well as letters, such as the holdback function setting. Whether the parameter is a group of letters numbers will depend upon what display you have navigated to. Unlike mnemonics, parameters can be altered using the arrow keys. Value - Value is a term used to describe a parameter, particular a parameter that is associated with numbers. F example, the setpoint temperature, deviation alarm setting, segment number, ect. 4

5 5 Understanding The Controller: Levels of Operation The controller has four levels of operation. 1. Operat Level: Select mnemonics & cresponding parameters can be viewed and/ altered at the operation level. Controllers are facty installed in the furnace with the intent to be operated at this level. The operat level is also commonly referred to as the user run mode. 2. Full Level: All mnemonics & cresponding parameters can be viewed at the operat level, however only select parameters can be altered pending the edit level setting. The full level of operation is passwd protected. 3. Edit Level: Like the full level, the edit level is passwd protected. All mnemonics & cresponding parameters are defined in the edit level as either: - Alterable (ALtr) = Mnemonic & cresponding parameter can be viewed as well as altered at the operat full level. - Promoted (PrO) = Mnemonic & cresponding parameter are promoted to the HOME DISPLAY list & can be altered at the operat full level. - Read Only (read) = Mnemonic & cresponding parameter can be viewed at the operat full level, but cannot be altered. - Hidden (HidE) = Mnemonic & cresponding parameter cannot be viewed at the operat full level and cannot be altered. 4. Configuration Level: This special level is double passwd protected. The fundamental characteristics of the controller are set up at the configuration level. Extreme caution must be used if an operat enters the configuration level. The configuration level may also be referred to as the configuration mode of operation. F me infmation on how to access the various levels of operations see Access List Section. 5

6 6 16 Segment Programmable Models w/otp OP SP 2 REM AUTO RUN Button/Indicat Name Description 1. LED Output 1 Illuminates when controller energizes elements. 2. OP2 LED Output 2 Not activated f furnace operation. 3. SP2 LED Setpoint Not activated f furnace operation REM LED Remote Not activated f furnace operation. Setpoint 5. Upper Display Display Indicates measured chamber temperature mnemonic value (parameter). 6. Lower Display Display Indicates set point chamber temperature mnemonic. 7. Auto/Man Button Not activated f furnace operation. 8. Run/Hold Button once to initiate a program. twice to place a program in hold state. & hold button f 2 seconds to cancel a program in the run state. 9. Auto Mode LED Illuminates to indicate furnace is in operating in auto mode. 10. Manual Mode LED Not activated f furnace operation. 11. Run LED Illuminates to indicate controller is executing a program. 12. Hold LED Illuminates to indicate controller has paused program execution. 13. Page Button to select a new list header. 14. Scroll Button to view a mnemonic and parameter setting within a list header. 15. Down Button to decrease the value in the lower display. 16. Up Button to increase the value in the lower display. 6

7 7 HOME DISPLAY The controller is powered ON when the furnace is powered ON. The controller will perfm a sht power on self-test sequence and automatically revert to the home display of the operat level user run mode. The home display indicates the measured chamber temperature (also known as the process variable) in the upper display window and the chamber set point temperature in the lower display window. NOTE: This is what the home display appears like Measured Chamber Temp Set Point Temp AUTO RUN From the home display you can perfm one of five functions: 1. Adjust the chamber single set point temperature indicated in the lower display using the keys. (NOTE: Can not adjust single set point temperature if a program is being executed in a hold/pause state.) 2. Cycle through the mnemonic parameter/values promoted to the HOME LIST by using the key. 3. Cycle through the mnemonic list headers using the key. 4. Initiate a program by using the RUN button. 5. Place a program in pause mode canceling a program using the button. ( button once to pause a running program. & hold the button to cancel a program.) 7

8 8 HOME DISPLAY list of mnemonics and parameter settings: By pressing the key, the mnemonics promoted to the home display will appear in the upper lower display window. The cresponding mnemonic parameter/value will be displayed in the lower window. Some parameters/values can be altered using the keys when displayed and others cannot. The following pages include detailed controller drawings showing the various mnemonics of the home list C Chamber Measured Temperature Indicates all temperature values are expressed in degrees C. Cannot be altered in the HOME DISPLAY. OP Output Power Level Number is a % value of the output power being applied to the heating elements. Cannot be altered in the HOME DISPLAY. C.id Controller Identification Number This number may not be set to 75 on all control modules this manual is written f. The value has no impact on controller operation. Cannot be altered in the HOME DISPLAY. PrG Program Number to change 1-4 Number presents the program. (4 programs total) 8

9 9 AUTO IdHi 2416 RUN 50 High Deviation Alarm 50 to change The parameter number displayed represents the current alarm setpoint. NOTE: The deviation alarm is intended f load protection and should never be set lower than 10 degrees. Setting a lower deviation alarm may interfere with the PID control process. tune 2416 OFF Tune Feature OFF to change Status of tune feature/function is OFF. Can be altered from HOME DISPLAY to initiate a tune. NOTE: Tuning matches the characteristics of the controller to that of the process to eliminate temperature undershoot and/ overshoot of setpoint. Tuning should be initiated with the furnace at room temperature. F me infmation on this feature, please see the Tuning & PID Sections of this manual. 9

10 10 Mnemonic List Headers From the home display, the controller can also be cycled through the various mnemonic list headers by using the key. The various lists contain mnemonics and parameters set values that dictate how the controller operates Measured chamber temperature Set point temperature C AUT O RUN Measured chamber temperature Indicates all temperature values are expressed in degrees C. run 2416 LiSt Run List. The run list contains mnemonics that crespond to a program. You can start, end, place a program in check in the run list. You can also check the status of a running program. - What segment is currently being executed - How much program time has elapsed ProG 2416 LiSt Program List. The program list contains mnemonics that are used specifically to enter a program into the controller. 10

11 11 AL 2416 LiSt Alarm List. The alarm list contains mnemonics that define the alarm setting of the controller. Atun 2416 LiSt Auto Tune List. The auto tune list contains mnemonics that pertain to the tuning feature functions of a controller Pid 2416 LiSt Pid List. The Pid list contains mnemonics that define how well the controller responds to change in der to keep a stable chamber temperature. The proptional bands, integral, and derivative time bands as well as gain scheduling are listed in the Pid. cms 2416 LiSt Communication List (Comms). The communication list contains the address mnemonic that is utilized f RS232 communications. ACCS 2416 LiSt Access List. The Access list is used to enter the configuration mode as well as define mnemonic access levels. The Access list is passwd protected. 11

12 12 Run List Section The Run list contains mnemonics that detail a program. The run list is considered part of the set up mode of at the operat level. When a program is not being executed you can perfm two functions in the Run List. 1. Initiate a program (StAt = run) 2. Activate the display segment feature (SEG.d = YES) Deactivate the display segment feature (SEG.d = no) If you activate the display segment by altering SEG.d to YES, the lower home display will indicate which segment type is being executed in the lower home display window when the program is actually being executed. The segment type will cycle on and off with the temperature. When a program is being executed you can perfm three functions in the Run List. 1. Suspend Pause the program (StAt = hold) 2. Terminate and Reset the program (StAt = OFF) 3. Activate the display segment feature (SEG.d = YES) Deactivate the display segment feature (SEG.d = no) When a program is being executed (run) you can also check the following: 1. Programmer Set Point (PSP = Setpoint temperature of the active segment) 2. Cycles Remaining (CYC = Number of times the cycle has to repeat itself) 3. Segment (SEG = Active segment number of the program being executed) 4. Segment Type (StyP = Active segment type of the program being executed) 5. Segment Time (SEG.t = Amount of time [Expressed in min/hours/sec as defined by ramp and dwell units in the program list] remaining in the active segment in the program.) 6. Target Set Point (tgt = Setpoint temperature of the active segment) 7. Ramp Rate (rate = ramp rate of the active segment [only appears if the active segment type is defined as a ramp rate in the program list]) 8. Program Time (PrG.t = Amount of time [Expressed in hours] remaining in the active program. The following pages will step you through the various displays you will see in the run list. 12

13 13 Run List Mnemonics (run LiSt) (When a program is NOT being executed) run 2416 LiSt Run List Header PrG Program Number Paramete 1-4 Number presents the program. (4 programs total) StAt 2416 OFF Current Status of Program Program paused OFF Program reset & not being executed Program being executed (running) FASt 2416 no Fast Run through program (Facty preset to no) no This feature is not activated f furnace operation, all though the parameter can be changed when a program is not being executed. 13

14 14 SEG.d 2416 no AUTO RUN Active Segment Displayed (Facty preset to no) no Active segment is not flashed in the lower display during program execution. Active segment flashes in the lower display during program execution. Run List Mnemonics (run LiSt) (While a program is being executed) run 2416 LiSt Run List Header PrG Program Number 1-4 Program number currently being executed. cannot be adjusted. StAt 2416 run Status of program run Program being executed (running) Program paused Program reset & not being executed 14

15 15 PSP CYC SEG Programmer Set Point 235 This number will increase and decrease as a program is being executed. The oscillation is dictated by the program segment. Cannot be adjusted in this display. Cycles Remaining in the Program 0 The parameter number displayed represents the number of times the program will repeat itself. Cannot be adjusted in this display. Active Segment Number 1 This number represents what segment of the program is currently being executed.. Cannot be adjusted in this display. StyP 2416 rmp.r Active Segment Type rmp.r This parameter represents the segment type that is currently being executed by the controller. Cannot be adjusted in this display. SEG.t Segment Time Remaining 7.1 This number represents the amount of time remaining in the current segment of the program being executed. Defined in minutes, hours, seconds by the program setup. Cannot be adjusted on this display. 15

16 16 NOTE: Pending the segment type currently being executed will dictate what display(s) will appear next. tgt Target Set Point [this window appears only if the segment type is defined as a ramp rate ramp time] 500 This number represents the segment setpoint temperature currently being executed by the controller. Cannot be adjusted on this display. rate 2416 AUTO AUTO AUTO 1.0 RUN PrG.t RUN FASt 2416 no RUN Ramp Rate [this window appears only if the segment type is defined as a ramp rate ramp time] 1.0 This parameter represents the ramp rate of the segment that is currently being executed by the controller. Defined in degrees C per min/hour/sec in the program setup. Cannot be adjusted on this display. Program Time Remaining 0.1 This parameter number represents the amount of time remaining in the current program. Expressed in hours. Cannot be adjusted in this display. Fast Run Through Program (Facty preset to no) no This feature is not activated f furnace operation, all though parameter can be changed. 16

17 17 SEG.d 2416 AUTO no RUN Active Segment Displayed (Facty preset to no) no Active segment is not flashed in the lower display during program execution. Active segment flashes in the lower display during program execution. Program List Section The Program list contains mnemonics that are used to define a custom program. This section explains how to enter a custom program into the controller. A program can only consist of up to 16+ segments with the call feature. Each segment is defined as one of five types. 1. Ramp = Measured chamber temperature ramps linearly from it's current value at either a defined rate within a defined amount of time to a defined setpoint chamber temperature. Note: Measured chamber temperature can be ramped up (temperature increase) ramped down (temperature decrease). If a segment type is set as a ramp rate, mnemonics appear as follows: A) Ramp Rate (rmp.r) = Ramp rate B) Setpoint Temp (tgt) = Defined setpoint temperature. C) Rate of change (rate) = Defined rate of temperature increase decrease. Ramp units (rmp.u) define the time associated (hour, minutes, seconds) with rate of change. If a segment type is set as a ramp time, mnemonics appear as follows: A) Ramp Time (rmp.t) = Ramp time B) Setpoint Temp (tgt) = Defined setpoint temperature. C) Duration (dur) = Defined amount of time in which the measured chamber temp is allowed to reach the setpoint temp. 2. Dwell = A defined amount of time duration that is required to hold the chamber measured temperature constant. If a segment type is set as a dwell, mnemonics appear as follows: A) Dwell (dwell)= Dwell time 17

18 18 B) Duration (dur) = Amount of defined time in which the measured chamber temperature is to be controlled at the setpoint temperature f this segment only. Dwell units (dwl.u) define the time associated (hours, minutes, seconds) with the duration parameter. 3. Step = Step segment allows a new setpoint temperature to be defined. The control module will attempt to achieve the new setpoint temperature instantaneously with no ramping. If a segment type is set as a step, mnemonics appear as follows: A) Step (StEP) = Step Instantaneously. B) Setpoint (tgt) = Defined setpoint temperature 4. End = Defines signals the end of a program. If a segment type is set end, mnemonics appear as follows: A) End (End) = End program. B) End Type (End.t) = Defines what the controller is supposed to do now that the program is done running. There are three settings choices: 1. Dwell (dwell) = Controller holds the last programmed setpoint temp (tgt) of the program. 2. Reset (rset) = Controller resets and reverts to single setpoint operation/mode. 3. Segment Output Power (S OP) = Controller reverts from auto mode of operation to manual mode of operation and controls power to the heating element as expressed in a percentage of output power. WARNING: S OP end type should never be selected! Due to the configuration of the controller Thermolyne could not remove this option from the list of choices of the end type. Selecting S OP will result in uncontrollable chamber temperature and will shten element and thermocouple life span. NOTE: If you desire the chamber temperature to cool down to ambient temp (25C) at completion of the program, you will need to step the setpoint to 25 in the 2 nd to last segment of the program and select (dwell) as the end type OR you will need to reset the single setpoint temperature to 25C pri to initiating the program and select (rset) as the end type. 18

19 19 5. Call = The call segment links segment(s) from another program, as a subroutine, to the existing program. If a segment type is set call, mnemonics appear as follows: A) Program number (PrG.n) = Program number linking to. B) Cycle number (cyc.n) = How many times controller is to repeat the linked segment during program execution. The following pages of this section will step you through the various displays you will see in the program list. There is also an example program and spreadsheet you can use to help define your custom program. Program List Mnemonics (ProG LiSt) Programming the Controller The following section explains how to enter a program into the control module with use of an example program. Program protocol: (example) Our example program calls to heat from ambient to 500C at a rate of 10C per minute. Once the furnace reaches 500C, we need to hold the temperature at 500C f 2 hours. After two hours of holding at 500C, we need to increase the chamber temperature to 800C at a rate of 5C per minute. Once the furnace reaches 800C, we need to hold the temperature at 800C f 3 hours. After three hours, we need the chamber temperature to go back to ambient as quickly as possible. Segment 1 rmp.r Segment 2 dwell Segment 3 rmp.r Segment 4 dwell Segment 5 & 6 End Hr 2 Hr 3 Hr 4 Hr 5 Hr 6 Hr 7 Hr 8 Hr 9 Hr 10 Hr (60 Min) (120 Min)(180 Min) (240 Min)(300 Min) (360 Min) (420 Min) (480 Min) (540 Min) (600 Min) To help visualize our example program we chart the chamber temperature (temperature versus time) in a graph. 19

20 20 The Program List (ProG LiSt) contains the mnemonics that are used to define the program. The keystroke procedures required to enter a program, such as the example program are as follows: From the HOME DISPLAY, repeatedly to the Program List window. ProG 2416 LiSt Program List Header Hb 2416 Hi Holdback Disables holdback feature f all segments in a program Holds the program when the measured chamber temperature deviates below set point minus the hold back unit value. Hi Holds the program when the measured chamber temperature deviates above set point plus the hold back unit value. Holds the program when the measured chamber temperature deviates below above the setpoint by me than the holdback unit value. Hb U Hold Back Units 10 The parameter number represents the deviation tolerance from the setpoint temperature f the holdback feature. (value should never be adjusted below 10 f optimal furnace results) 20

21 21 rmp.u 2416 min Ramp Units min Ramp units defined in minutes. Ramp units defined in hours. Ramp units defined in seconds. dwl.u 2416 min Dwell Units min Dwell units defined in minutes. Dwell units defined in hours. Dwell units defined in seconds. CYC.n 2416 AUTO RUN 1 Cycles of Program 1 The parameter number displayed represents the number of time(s) the program will repeat itself. If set to "cont" the program will repeat itself continuously indefinitely NOTE: The previous mnemonics will need to be set f each and every program. They apply to the entire program. NOTE: The following mnemonics actually define the ramp and dwells of our program. 21

22 22 SEG.n Segment Number 1 This parameter number represents the 1 st segment of the program. type 2416 rmp.r Segment Type Ramp to a new setpoint within a defined amount of time rmp.r Ramp to setpoint at defined rate. Our program calls f a ramp rate of 10C per minute. Hold a desired setpoint temperature f a defined amount of time Steps temperature to a new setpoint as quickly as possible. Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] tgt Target Temperature [this window appears only if the segment type is defined as a ramp rate] 500 Setpoint temperature. Our program calls f setpoint of 500C. 22

23 23 rate Rate of temperature change [this window appears only if the segment type is defined as a ramp rate] 10 number represents the rate of temperature change. Our program calls f a rate of 10C per minute. (We defined the time units in rmp.u) SEG.n Segment Number 2 This parameter number represents the 2nd segment of the program. type 2416 dwell Segment Type AUTO RUN Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time dwell Hold a desired setpoint temperature f a defined amount of time. Our program calls to hold the temperature at 500C f 2 hours. Steps temperature to a new setpoint as quickly as possible. Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] 23

24 24 dur Duration [this window appears only if the segment type is defined dwell] 120 Represents the amount of time allowed f the temperature to hold at the 1 st setpoint of 500C (Remember: we set dwl.u to min, which means 2 hours = 120 minutes) SEG.n 2416 AUTO RUN 3 Segment Number 3 This parameter number represents the 3 rd segment of the program. type 2416 rmp.r Segment Type rmp.r Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time Hold a desired setpoint temperature f a defined amount of time Steps temperature to a new setpoint as quickly as possible. Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] 24

25 25 tgt Target Temperature [this window appears only if the segment type is defined as a ramp rate] 800 number represents the target (set point) temperature of 800C. rate Rate of temperature change [this window appears only if the segment type is defined as a ramp rate] 5 number represents the rate of temperature change. Our program calls f a rate of 5C per minute. (We defined the time units in rmp.u) SEG.n Segment Number 4 This parameter number represents the 4 th segment of the program. 25

26 26 type 2416 dwell Segment Type Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time dwell Hold a desired setpoint temperature f a defined amount of time. Our program calls to hold the temperature at 500C f 2 hours. Steps temperature to a new setpoint as quickly as possible. Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] dur Duration [this window appears only if the segment type is defined dwell] 180 Represents the amount of time allowed f the temperature to hold at the 2 nd setpoint of 800C (Remember: we set dwl.u to min, which means 3 hours = 180 minutes) SEG.n Segment Number 5 This parameter number represents the 5 th segment of the program.. 26

27 27 type 2416 StEP Segment Type Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time Hold a desired setpoint temperature f a defined amount of time StEP Steps temperature to a new setpoint as quickly as possible. Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] tgt Target Temperature [this window only appears if the segment type is set to step] 25 Setpoint temperature. By "stepping" the setpoint from 800C to 25C in segment 5, the controller will attempt to achieve the new setpoint as quickly as possible as the program calls f. SEG.n Segment Number 6 This parameter number represents the 6 th segment of the program.. 27

28 28 type 2416 AUT O RUN End Segment Type Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time Hold a desired setpoint temperature f a defined amount of time Steps temperature to a new setpoint as quickly as possible. End Ends the program. Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] End.t 2416 rset End Type Ends & resets the program. However, the controller will hold the chamber temperature at the last setpoint (target) of the program. rset Ends & resets the program. Controller will automatically revert to single setpoint operation. Ends & resets the program. However, chamber temperature is controlled by an output power percentage. WARNING: DO NOT SET THE END TYPE OF A PROGRAM TO THE "S OP" PARAMETER. THIS CHOICE COULD NOT BE ELIMINATED AT THE OPERATOR LEVEL HOWEVER. ELEMENT FAILURE IS LIKELY TO OCCUR. THERMOLYNE FURNACES ARE NOT DESIGNED TO OPERATE OFF A PERCENTAGE OF POWER. This completes entering the example program into the controller and hopefully gives you an ideal as to how the programmer list functions. 28

29 29 Call Segment type: Our example program did not execute a "call" segment. The call segment feature allows you to enter custom programs, which consist of me than 8 segments. The following displays are what you can expect to see when you "call" a segment from another program as a subroutine. type 2416 call Segment Type Ramp to a new setpoint at defined rate of increase decrease Ramp to a new setpoint within a defined amount of time Hold a desired setpoint temperature f a defined amount of time Steps temperature to a new setpoint as quickly as possible. Ends the program. call Links segment(s) from one program as a subroutine to the existing program. [This feature allows f me than 16 segments of programmability.] PrG.n 2416 AUT O RUN 2 Program Number cyc.n AUT O RUN 2 represents the program number the controller will call a segment from within. Number of Cycles f the Called Program 1 number represents the number of times the called subroutine segment will repeat itself 29

30 30 SEG.n AUT O RUN Segment Number 9 number represents the segment number of the called program that will be executed next in the program. (The segment number displayed will be in chronological der coinciding with the previous segments of the program.) This completes the list of windows you can expect to see if your custom program requires the call feature to be used as subroutine. 30

31 31 Alarm List Section Understanding Alarm Types: Process Alarms The control module has two process alarms: A process alarm warns there is a problem with the chamber temperature the controller is trying to control. 1. Deviation High Alarm (IdHi) = A deviation alarm can be reset by the operat. Facty preset to 50, means if the chamber measured temperature exceeds the set point temperature at any given time during furnace operation by me than 50 degrees, the controller will alarm. The alarm code will flash on the home display to alert operats and the controller will attempt to remove all power from the heating elements to stop the thermal runaway condition. The deviation alarm is intended f load protection and should never be set lower than 10 degrees. Setting a low deviation alarm (below 10 degrees) may interfere with the PID control process. 2. Full Scale High Alarm (2FSH) = The full scale high alarm is facty preset in the configuration mode and is not visible in the alarm list at the operat level. Unlike the deviation alarm, no attempts by operats to reset this alarm value should be made. This alarm is facty preset to a temperature value that exceeds the maximum recommended operating temperature of the unit. If a thermal runaway condition should occur this alarm protects the furnace from further damage by attempting to remove power from the elements. If the deviation alarm is set properly f the application, this alarm will never be activated in a thermal runaway condition as the deviation alarm will be tripped first. Understanding Process Alarms: What happens when an alarm condition occurs: Events that occur during a process alarm condition: - The home display will flash the alarm err mnemonic with the measured chamber temperature in the lower display to alert operats of the condition. - The controller will stop sending AC power to a mechanical relay contact. As a result the contact will open, effectively de-energizing the heating elements. - Both process alarms are non-latching, which means the controller will reset automatically when the measured chamber temperature is no longer over the defined alarm temperature value. Ultimately this means the controller will cycle power to the mechanical relay and re-energize the elements creating me heat. The controller essentially cycles power to the elements through the mechanical relay instead of the solid-state relay. Thus, the chamber temperature is controlled at the alarm temperature value. 31

32 32 Understanding Process Alarms: Troubleshooting In the event of a deviation high alarm (IdHi) condition, operats should first check the alarm value. In some situations, the alarm is merely set to low f the process of the PID control, taking into consideration program parameters and load type/mass. Resetting this alarm to a higher value often times crects the problem. If this alarm condition occurs after the alarm setting has been increased, please call Barnstead International technical suppt f additional troubleshooting procedures. Please obtain the model and serial number of your furnace pri to calling tech suppt. In the event of a full-scale high alarm (2FSH) condition, operats should power off the furnace immediately to avoid further damage and call Barnstead International technical suppt f troubleshooting procedures. Please obtain the model and serial number of your furnace pri to calling tech suppt. Understanding Alarm Types : Diagnostic Alarms The control module has ten diagnostic alarms. A diagnostic alarm warns there this a fault within the controller input module (thermocouple RTD). Please be aware combinations of alarm types can exist simultaneously. If such an occurrence should happen, alarm mnemonics will alter with each other on the display of the controller. The following diagnostic alarms are listed. 1. "S.br" (Sens Break Alarm): The home display will flash "S.br" indicating the thermocouple input is open. In this err state, the controller will not cycle power to the elements to generate any heat. Thermocouple replacement is usually required to resolve this alarm condition. 2. "EE.Er" (Electrically Erasable Memy Alarm): The home display will flash "EE.Er" indicating a mnemonic value in either the operat configuration mode has been crupted. In this err state, the controller will not cycle power to the elements to generate any heat. Controller replacement is usually required to resolve this alarm condition. 3. "TU.Er" (Tune Err Alarm): The home display will flash "TU.Er" indicating the tune procedure has failed. This err condition can only occur during a tune procedure. In this err state, the controller will stop submitting power to the heating element and chamber temperature will drop to ambient conditions. In most situations, the one-shot tune procedure was interrupted resulting in the err. Re-running the one-shot auto tune usually resolves the problem. However, thermocouple and/ controller replacement may be necessary to resolve this alarm condition. 4. "LLLL" (Out of Range Low Reading): The home display will flash "LLLL" indicating the input signal is out of range low. If the thermocouple was 32

33 33 recently replaced, it may not be connected properly connected in reverse polarity causing the err message. If you have verified the thermocouple is the connected properly, controller replacement may be necessary to resolve this alarm condition. 5. "HHHH" (Out of Range High Reading): The home display will flash "HHHH" indicating the input signal is out of range high If the thermocouple was recently replaced, it may not be connected properly connected in reverse polarity causing the err message. If you have verified the thermocouple is the connected properly, controller replacement may be necessary to resolve this alarm condition. 6. "Err1" (ROM Failure): The home display flashes "Err1". Controller replacement is usually required to resolve this alarm condition. 7. "Err2" (RAM Failure): The home display flashes "Err2". Controller replacement is usually required to resolve this alarm condition. 8. "Err3" (Watchdog Failure): The home display flashes "Err3". Controller replacement is usually required to resolve this alarm condition. 9. "Err4" (Keyboard Failure): The home display flashes "Err4". Controller replacement is usually required to resolve this alarm condition. 10. "Err5" (Internal Communication Failure): The home display flashes "Err5". Controller replacement is usually required to resolve this alarm condition. Understanding Diagnostic Alarms: What happens when an alarm condition occurs? When a diagnostic alarm is active, the controller will flash the alarm until the err condition has been crected. The controller will not attempt to cycle power to the heating elements, however the elements may generate heat if a double fault exists in the furnace. Obtain the model and serial number of the furnace and contact Barnstead International technical suppt if a diagnostic alarm condition should occur. 33

34 34 Alarm List Mnemonics (AL LiSt) AL 2416 LiSt Alarm List Header AUTO IdHi 2416 RUN 50 Deviation High Alarm 50 The parameter number displayed represents the current alarm setpoint. NOTE: The deviation alarm is intended f load protection and should never be set lower than 10 degrees. Setting a lower deviation alarm may interfere with the PID control process. 34

35 35 Auto Tune List Section The controller incpates a self-tuning feature, which determines the optimum control parameters (PID values) f best temperature accuracy with your load type. This feature should be used to eliminate temperature undershoot, over-shoot, oscillation conditions. There are two types of automatic tuning. 1. One Shot Auto Tune: The one-shot tuner functions by switching the heating elements on and off as a means to induce temperature oscillation. From the amplitude and period of the temperature fluctuation, the controller can calculate the optimal tuning parameters to help reduce totally eliminate such oscillation. The tuning parameters of the following mnemonics are automatically set f optimal operation as a result of a one shot tune: Mnemonic Meaning/Function Proptional Pb The bandwidth, in display units, over which the output Band power us proptioned between minimum & maximum. Integral ti Determines the time taken by the controller to remove Time steady-state err signals Derivative td Determines how strongly the controller will react to the Time rate of change of the measured chamber temperature. High Hcb The number of display units above set point at which Cutback the controller will cutback the output power, in der to prevent undershoot on cool down. Low Lcb The number of display units below set point at which Cutback the controller will cutback the output power, in der to Prevent overshoot on heat up. 2. Adaptive Tune: Adaptive tuning is a background algithm, which continuously monits the err from the setpoint and analyses the control respond during process disturbances. Adaptive tune is triggered whenever the err from setpoint exceeds a defined trigger level (dra). The tuning parameters changed as a result of an adaptive tune are the Proptional Band (Pb), Integral Time Band (ti), and Derivative Time Band (td) only. WARNING: While we may have not disabled the adaptive tune capability of the controller, it is strongly advised not to attempt this method of tuning, with a Thermolyne box furnace. There are very few applications with a labaty furnace that require this type of tuning. The process is too sensitive, usually causing me problems rather than crecting them. 35

36 36 Auto Tune List Mnemonics (Atun LiSt) AUTO Atun 2416 LiSt RUN Auto Tune List Header tune 2416 OFF Auto Tune (one shot) Auto tune on/initiated OFF Auto tune off/terminated NOTE: The following feature may not be present on all control types. As a result the following windows will not appear. dra 2416 AUT O RUN OFF Auto Tune (adaptive tune) OFF Auto tune off/terminated Auto tune on/initiated dra.t Adaptive Tune Trigger Level 20 Adaptive tune trigger level. Adaptive tune is triggered whenever the err from the setpoint exceeds this trigger level setting. (Only active if dra is set to on). 36

37 37 Suggested Tuning Procedure: 1. Load the furnace chamber with material that exhibits similar characteristics as your nmal loads you will be using the furnace to process. Please note: the material may not be of salvageable at completion of this process, however loading the furnace f the tune procedure will result in me accurate tune parameters given the characteristics of the load. 2. Power on the furnace. 3. Set the desired single set point temperature using the arrow keys. (If me than one known single set point temperature is going to be used over the course of time, average the set points together, and enter the average single set point into the controller.) 4. Page key to the atun list. 5. Scroll key to the one-shot tune mnemonic. 6. Use the arrow key to change the OFF to ON. 7. The furnace will heat from ambient to the set point temperature while tuning. The lower display will toggle the set point temperature with the wd "tune" to indicate the process is being executed. 8. When the furnace reaches the set point temp and the wd "tune" stops flashing in the lower display, the tune is complete and the tuner parameters have been automatically set f optimum results. NOTE: Initiating a one-shot tune while the chamber is at ambient usually results in obtaining the optimal PID values f the process, however with some applications, initiating a tune when the furnace actually reaches set point, may produce better results. NOTE: Programs cannot be tuned, only single set points. If you wish to set your PID tuning parameters f program operation, select the mean temperature of the program calculate the average temperature. Enter the mean the average as a single set point and initiate the one-shot auto tune with a mock load in the chamber. The PID tuning values the controller calculates at this value will wk best f the entire program. 37

38 38 PID List Section The PID list contains mnemonics that define the control module's ability to maintain set point with minimal deviation process err from set point. PID Control: What is PID Control? The control algithm is based on proptional gain, an integration action, and a derivative action. Gain, me commonly called, proptional band, simply amplifies the err between set point and measured chamber temperature to establish a power level. The term, proptional band, is one that expresses the gain of the controller as a percentage of the span of the instrument. It determines the magnitude of the response to an err. If the prop band is too small, meaning a high gain, the furnace temperature will oscillate through being over-responsive. If the prop band is too large, meaning low gain, the measured chamber temperature will oscillate due to the lack of response will be slow to react to disturbances. Having the proper gain alone will not allow f accurate control however. The integral action, expressed as the integral band, slowly shifts the output power level as a result of an err between set point and measured chamber temperature. If the measured chamber temperature is below set point the integral action will gradually increase the output power level in an attempt to increase the chamber temperature to meet the set point requirement. Likewise, if the measured chamber temperature is above the set point, the integral action will gradually decrease the output power level in an attempt to lower the chamber temperature to meet the set point requirement. The integral band is expressed as a time constant, meaning the longer the integral band (time constant) the me slowly the power level shift will occur. If set too large, the controller response time may be too slow and sluggish. If the integral band is set to smaller value, the controller essentially shifts the power level me quickly resulting in a faster response. However, if the power level is shifted too quickly it can cause unwanted temperature oscillation due to the load type. The last constant is referred to as the derivative band and like the integral band is expressed as a time constant. The derivative band provides a sudden shit in output power level as a result of a quick change in the measured chamber temperature (f example, opening the chamber do). It also aids the PI control process in dampening chamber temperature oscillation near set point. The derivative time band is typically set to a value equal to one sixth of the integral band. No matter how though discrete the explanation of PID control and the function of each of the three tuning parameters, it is a difficult concept to understand. When the PID tuning parameters are set to optimal values, the controller will heat to set point with minimal temperature overshoot undershoot. Unlike past control models, in which PI values needed to be 38

39 39 calculated long fm by end-users as well as manually entered into the controller, the new versions of PID controllers automatically calculate and set by the values into the controller as a result of a one-shot auto tune discussed in the previous section entitled Auto Tune List Section. Dual PID Control: What does this mean? The control module installed your labaty furnace has dual PID control capability. Due to the wide range of controllable temperatures, one set of PID values can be used f chamber set points below a defined level while a second set can be used f chamber set point above the defined level. The defined level is referred to as the gain set point (G.SP). Facty preset at 700C, means if the chamber set point temperature is below 700C, the controller will activate and use the 1 st set of PID values. If the chamber set point temperature is above 700C, the controller will automatically use the 2 nd set of PID values. The advantage of dual PID control lies in the fact controllers do not require re-tuning as often, saving you time. PID Control & Tuning: When should I tune re-tune my controller? Controllers should be re-tuned from ambient when one of the following events occur: - When the application changes. F example if a the furnace is being used to ash small samples of waste material one day and having a large piece of metal placed in the chamber to heat treat the following day. The mass of the load will exhibit characteristic differences as it absbs heat generated by the furnace. This can cause unwanted temperature over undershoot. - If chamber set point temperature is changed by a significant difference. F example, running at an average set point of 350C to running at an average set point of 900C. - If you are experiencing chamber measured temperature oscillation on the control display. The PID values may drift over time as a result of electrical interference and need to be reset. - If a thermocouple heating element is replaced in the furnace, the controller should be re-tuned. F instructions on how to properly initiate a tune please refer to the Tune List Section of this manual. 39

40 40 PID List Mnemonics (Pid LiSt) Pid 2416 LiSt PID List Header G.SP Gain Setpoint Pb 2416 ti Gain setpoint level. Level at which PID control switches from the 1 st set of PID values to the 2 nd set. Proptional Band Proptional Band 1 value. Facty preset to 9. Integral Time Band Integral time band 1 value. Facty preset to

41 41 td Pb ti td Derivative Time Band 1 Proptional Band Derivative time band 1 value. Facty preset to Proptional Band 2 value. Facty preset to 5. Integral Time Band Integral time band 2 value. Facty preset to 44. Derivative Time Band Derivative time band 2 value. Facty preset to 7. 41

42 42 Communication List Section The communication list contains only one mnemonic that defines the location of the controller when connected to a computer via RS232. cms 2416 LiSt Communication List Header Addr Address 1-99 number defines the address location of the controller. 42

43 43 Access List Section The access list is the gateway, so to speak of, to the configuration level as well as the Edit & FuLL modes of operation. Configuration Level: This special level is double passwd protected. The fundamental characteristics of the controller are set up in the configuration level. F this reason we have chosen not to supply the passwd necessary to enter the configuration level. If you feel you are required to enter the configuration level of your Thermolyne furnace controller, please obtain the model & serial number of your furnace & call our customer service technical suppt at f further assistance. Full & Edit Levels: The passwd required to enter the FuLL Edit level is the number {25}. FuLL Level: All mnemonics & cresponding parameters can be viewed at the operat level, however only select parameters can be altered pending the edit level setting. Access to the FuLL level of operation is required to change the calibration-offset value (if necessary). Edit Level: All mnemonics & cresponding parameters are defined in the Edit level as either: - Alterable (ALtr) = Mnemonic & cresponding parameter can be viewed as well as altered at the operat full level. - Promoted (PrO) = Mnemonic & cresponding parameter are promoted to the HOME DISPLAY list & can be altered at the operat full level. - Read Only (read) = Mnemonic & cresponding parameter can be viewed at the operat full level, but cannot be altered. - Hidden (HidE) = Mnemonic & cresponding parameter cannot be viewed at the operat full level and cannot be altered. Access to the Edit level of operation is required if you wish to lock out select mnemonics and cresponding parameter settings to prevent unwanted tampering. 43

44 44 Access List Mnemonics (ACCS LiSt) ACCS 2416 LiSt Access List Header code Code Number Passwd 44

45 Eurotherm: Offset Calibration NOTE: There are three imptant aspects you need to know when perfming this procedure: 1. If you do not press a key within a defined amount of time, the display will automatically revert back to the home display. 2. When you press the key, you must wait until the parameter in the lower display "blinks" befe pressing the next instructed key. The "blink" indicates the parameter change has been accepted by the controller. 3. If you press and hold the key, the parameter value in the lower display will toggle quicker ACCS 2416 LiSt code repeatedly to goto 2 to goto 3 repeatedly to goto code code 2416 PASS Goto 2416 FuLL 4 Automatic 5 to goto 6 repeatedly to goto ip 2416 LiSt OFS ** OFS to goto 8 to set offset 9 repeatedly to goto ACCS 2416 LiSt code 2416 PASS Goto 2416 FuLL 10 to goto 11 to goto 12 to goto Goto 2416 OPEr ACCS 2416 LiSt to goto 14 to goto 15 **Calibration offset value must be calculated. See following instructions on how to properly calculate this value. 45

46 46 Calculating a Temperature Offset Value Equipment Required F All Thermolyne Furnace Model Types: - N.I.S.T. traceable type K thermocouple with digital pyrometer. (Thermolyne Cat # AY589X1) Equipment Required F Select Thermolyne Model Types: - Tools necessary to remove the back cover of the furnace chamber (Screwdriver set) - Drill with 3/8" bit. 1. Route the N.I.S.T. traceable type K thermocouple probe into the geometric center of the chamber. a) Route the probe through a 3/8" diameter access pt located on the back wall of select Thermolyne furnace model types [select models must have the chamber back wall insulation drilled out through the access pt] See Pic A. b) Route the probe through a 1" diameter access/vent pt located on the roof of select Thermolyne furnace model types [select models must have the chamber roof insulation drilled out through the access pt] See Pic B. A) B) 2. Power on the furnace. 3. Set the desired single set point temperature. 4. Allow the furnace to heat to set point & stabilize. Stabilization allows the interi surfaces to reach thermal equilibrium resulting in a me accurate response. Pending Thermolyne furnace model type as well as the set point temperature, the time required f stabilization to occur will fluctuate. Please allow two additional hours f stabilization to occur once the set point temperature has been achieved. 5. Recd the measured chamber temperature from the display of the furnace controller. 6. Recd the measured chamber temperature from the digital pyrometer. 7. Subtract the displayed furnace controller temperature from the N.I.S.T. digital pyrometer temperature. The difference becomes the calibration offset value that is to be entered in step 11 of the procedure. EXAMPLE 1 (Negative offset value): 495ºC (N.I.S.T digital pyrometer reading) - 500ºC (Furnace controller measured chamber temp reading) - 5ºC (Calculated calibration offset value) EXAMPLE 2 (Positive offset value): 505ºC (N.I.S.T digital pyrometer reading) - 500ºC (Furnace controller measured chamber temp reading) 5ºC (Calculated calibration offset value) 46