Zelio Temperature Controller

Transcription

1 Zelio Temperature Controller Quick Start Guide 11/2010 REG24 REG48 REG96

2 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Schneider Electric assumes no responsibility for any errors that may appear in this document. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage Schneider Electric. All rights reserved Schneider Electric

3 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Contents Controller Overview... 4 Function and Features...4 Applications...4 Product Part Number... 5 REG24 Controllers:...5 REG48/96 Controllers:...5 Terminology... 6 Proportional Integral Derivative (PID)...6 Outputs...7 Regulation Principle...8 Integrated Functions Auto-Tuning...10 Fuzzy Logic...10 Self Control...10 Ramps...10 PID Soft Start...11 Alarms...11 Wiring and Schematics REG24 (12 models)...12 REG48 (14 models)...13 REG96 (14 models)...14 Selection Guide Controller Display REG REG REG Implementation Example Step 1: Select the Controller...18 Step 2: Cabling...18 Step 3: Program the Display...19 Step 4: Functional Test...27 Zelio ControlSoft Application ope Ch 1 screen...31 PID Ch 2 screen...32 PLT Ch 3 screen...33 PRG Ch 4 screen...34 Mon Ch 5 screen...35 SET Ch 6 screen...36 SyS Ch 7 screen...37 ALM Ch 8 screen...38 CoM Ch 9 screen...39 PFb Ch 10 screen...39 PAS Ch 11 screen...40 CFG Ch 13 screen...41 Saving Application Files Schneider Electric 3

4 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Controller Overview Function and Features Zelio Control REG temperature control relays can be used with multiple types of sensors. The relays are equipped with an input (PT100 probe, thermocouple input, or analog input, depending on the model) and with one or two outputs (electromechanical relay, solid-state relay, or analog output, depending on the model) for process heating, cooling, or heating/cooling based on a PID algorithm. The measured temperature and setpoint can be displayed in Celsius or Fahrenheit. Advanced functions are integrated: ramps (up to 16), hysteresis, fuzzy logic, auto-tuning, soft start, and configurable alarms. The relays can be configured through the front control panel or by software used with the entire product line, connected through a built-in Modbus communication port. Through this communication port, the temperature controller can also be integrated into a smart architecture controlled by Magelis terminals or by PLCs (Twido, M340, or Premium), to exchange and transmit data such as setpoints, current values, and alarms. Applications Zelio Control REG relays can be used to control temperatures in a variety of applications: Ovens and furnaces Extrusion lines Plastic and rubber injection presses Thermoforming Production of synthetic fibers and polymerization Food and beverage processing lines Molding presses Environmental chambers, overhead furnaces, and test benches UV and laser technology Spray booths Cold rooms Agriculture Color bath temperature maintenance DANGER / PELIGRO / DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Read and understand this quick start guide before performing any procedure with this equipment. Some electrical terminals operate at line voltage. DO NOT TOUCH. Use only electrically insulated tools. Consult the Temperature Controller User Guide (EIO ) available at for more detailed information. Failure to follow these instructions will result in death or serious injury Schneider Electric

5 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Product Part Number Refer to the product part number to identify the Zelio temperature controller s built-in functions. REG24 Controllers: REG 24 P TP UJ 1 A R L J HU LU Controller Size PID Input type Output number No Modbus Output type Power supply Input type: Modbus function: Output type: Power supply: TP = thermocouples and PT100 UJ = analog signal A = Modbus function is not available. (If the Modbus function is available, the part number does not include A: for example, REG24PTP1RHU.) R = relay L = solid-state relay J = analog interface (4/20 ma) HU = 110/220 Vac LU = 24 Vac/Vdc REG48/96 Controllers: REG P UN 1 2 L R L J HU LU Controller Size PID Input type Output number No Modbus Output type Power supply Input type: Modbus function: Output type: Power supply: UN = universal input, thermocouple/pt100/analog L = Modbus function is not available. (If the Modbus function is available, the part number does not include L: for example, REG48PUN1RHU.) R = relay L = solid-state relay J = analog interface (4/20 ma) HU = 110/220 Vac LU = 24 Vac/Vdc Note: With two outputs, possible combinations include 2 relays, 1 relay and 1 solid-state output, or 1 solid-state output and 1 current output. (This varies by the product. For details, refer to the Temperature Controllers table in the Catalog Numbers section of catalog 8430CT1001.) 2010 Schneider Electric 5

6 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Terminology Proportional Integral Derivative (PID) The PID algorithm consists of three actions to be performed based on the difference between the setpoint value (SV) and the measured process value (PV). For a proportional action, the error is multiplied by a gain (GR). For an integral action, the error is integrated into a time interval (TI). For a derivative action, the error is derived from the time (TD). GR PID block diagram The PID parameters affect the system response as follows: When GR (proportional action) increases, the rise time decreases but the setpoint overshoot increases. There is minimal change in settling time and the steady-state error improves. When 1/TI (integral action) increases, the rise time decreases but the setpoint overshoot increases. The settling time is longer but there is no steady-state error. When TD (derivative action) increases, the change in rise time is minimal but the setpoint overshoot decreases. Settling time improves, and there is no change in the steady-state error. By configuring the variables, you can set the REG24/48/96 controllers for automatic or manual operation (depending on the model). You can use variables to do the following: Choose the type of sensor (thermocouple probe or PT100, or analog sensor) Choose the type of output, depending on the actuators (electromechanical relay, solid-state relay, or analog output) Choose the regulation function (heating, cooling, or heating and cooling) Reduce the settling time (causes the measured value to reach the setpoint as quickly as possible) Prevent setpoint overshoot (fuzzy logic and PID2) Maintain the temperature as close as possible to the setpoint (reduces hysteresis and deadband) Eliminate the effect of interference Activate alarms (high, low, or delayed) Define the ramps (up to 16 depending on the model) to link the control cycles Obtain information on faults (such as measurement spillover or sensor faults) Lock or authorize changes in parameters via the product s front panel Schneider Electric

7 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Outputs Electromechanical relay: The most common type of output. Solid-state relay: Controls the actuator without noise or frequent switching. Current output: Used to drive an analog actuator, such as a valve. On and Off control: This is a basic algorithm. The setpoint is not anticipated, and control is imprecise with frequent oscillations. Proportional control: The process output is proportional to the deviation from the setpoint. The proportional band can be used to anticipate overshoots Schneider Electric 7

8 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Regulation Principle Proportional P too low P too high P correct oscillations slow rise, major offset proper rise, minor offset Integral The integral function can be used to make up for any deviation (offset) between the setpoint and the process value. In combination with the proportional function, the integral function can be used to reach the setpoint. Derivative Proportional + derivative Proportional only The derivative control counters any deviation created by external interference. PID Combining the proportional, integral, and derivative functions provides optimal control Schneider Electric

9 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide SV Regulation Type 2010 Schneider Electric 9

10 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Integrated Functions Auto-Tuning The auto-tuning function is a PID calculation algorithm that automatically generates the proportional, integral, and derivative settings for the PID function. This calculation is performed over the course of two control cycles. Fuzzy Logic In fuzzy logic reasoning, the value for the command falls between 0 and 100% of the measurement scale. By applying fuzzy logic to the controllers, you can reduce the switching between heating and cooling outputs (based on the various setpoints configured) and prevent setpoint overshoot. Self Control This function automatically recalculates the PID parameters at each setpoint change or after a power-on. Note: This command generates temporary control interference close to the setpoint value. Some applications may be sensitive to this function. Ramps Using ramps (up to 16 for REG48 and REG96), you can establish a sequence of several setpoints and ranges. For each setpoint, you can configure a settling time and a dwell time on the plateau (setpoint value). You can define these times in hours and minutes, or in minutes and seconds Schneider Electric

11 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide PID 2 Choose a PID that prevents the measured value from overshooting the setpoint during the control phase. Soft Start With machinery that is sensitive to abrupt changes in temperature, use this function to adjust the settling time (that is, the time in which the process value reaches the setpoint). Alarms Depending on the model, 1 to 3 alarms are available. Each alarm is based on an output relay (1 A to 3 A, depending on the model). Two additional alarms, accessible via the Modbus port, are available on certain REG96 models, and 1 additional alarm is available on the REG48 models. You can configure the alarms for activation at a threshold or upon crossing a low or high limit. The alarms can also be time-delayed Schneider Electric 11

12 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Wiring and Schematics REG24 (12 models) REG24PTP Sensor Wiring Thermocouple REG24PTP Sensor Wiring PT Thermocouple (red wire) 1 2 B A 3 + Thermocouple 3 B+ REG24PUJ Sensor Wiring Analog Voltage 1 REG24PUJ Sensor Wiring Analog Current (4 20 ma) 1 2 Voltage 3 + Voltage 2 3 Current 250 Ω / 0.1% * + Current * The resistor is provided with the REG24PUJ Schneider Electric

13 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide REG48 (14 models) REG48 Sensor Wiring Thermocouple REG48 Sensor Wiring Analog Current (0 20 ma, 4 20 ma) REG48 Sensor Wiring PT Current Thermocouple Ω / 0.1% * B+ A 18 Thermocouple (red wire) 18 Current 18 B * The resistor is provided with the REG48. REG48 Sensor Wiring Analog Voltage (all except mv) REG48 Sensor Wiring Analog Voltage (only mv) 15 + Voltage Voltage 18 Voltage 18 Voltage 2010 Schneider Electric 13

14 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 REG96 (14 models) REG96 Sensor Wiring Thermocouple REG96 Sensor Wiring Analog Current (0 20 ma, 4 20 ma) REG96 Sensor Wiring PT Current Thermocouple Ω / 0.1% * B+ A 36 Thermocouple (red wire) 36 Current 36 B * The resistor is provided with the REG96. REG96 Sensor Wiring Analog Voltage (all except mv) REG96 Sensor Wiring Analog Voltage (only mv) 33 + Voltage Voltage 36 Voltage 36 Voltage Schneider Electric

15 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Notes: The D04 and D05 alarm outputs are only accessible via the Modbus port. The type of output(s) depends on the product number (see page 5). The wiring of the solid-state relay or analog outputs and the probe and analog inputs must comply with the wiring schematics, especially the polarity. To verify accessibility to the Modbus port, carefully check the part number and the table shown on page 5. The Modbus port is connected to the screw terminals: 14/15 for REG24 7/8 for REG48 1/2 for REG Schneider Electric 15

16 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Selection Guide When choosing the most appropriate controller, consider the following characteristics resulting from a functional analysis: The sensor type connected to the input (PT100, thermocouple, analog, current, or voltage) The number of outputs: for instance, to meet a requirement to control several actuators for heating and cooling regulation The type of outputs: relay, solid-state relay interface, or analog output (for instance, to control a proportional control valve or a variable speed drive) The number of alarms The number of ramps Operating mode (automatic or automatic/manual) The availability of a Modbus link (the need for multiple controllers, or for communication with a Magelis interface or a controller such as a Twido, M340, or Premium PLC) Advanced, easy-to-configure functions are included on every controller: hysteresis auto-tuning fuzzy logic (see page 10) soft start (on REG48 and REG96) Input type Process output type Number of process outputs REG24 REG48 REG96 -PT100 -PT100 -PT100 -Thermocouple -Thermocouple -Thermocouple J,K,R,B,S,T,E,N,PLII J,K,R,B,S,T,E,N,PLII J,K,R,B,S,T,E,N,PLII -Voltage: 1 5 V -Voltage: 0 5 V,1 5 V,0 10 V, -Voltage: 0 5 V,1 5 V,0 10 V, -Current: 4 20 ma 2 10 V 2 10 V -Current: 0 20 ma, 4 20 ma -Current: 0 20 ma, 4 20 ma -SPDT Relay: 220 Vac, 30 Vac/Vdc 3 A -Solid-state relay: 24 Vdc, 20 ma, 850 -Analog: 4 20 ma (max. 600 ) 1 relay output 1 solid-state relay or 1 analog current output -SPST Relay: 220 Vac, 30 Vac/Vdc, 3 A -Solid-state relay: 24 Vdc, 20 ma, 850 -Analog: 4 20 ma, 0 20 ma (max. 600 ) 1 relay output 2 relay outputs 1 solid-state relay 1 relay output + 1 solid-state relay 1 analog current output or 1 solid-state relay + 1 analog current output Alarms 1 physical or 1 Modbus Modbus Modbus Sampling time 500 ms 200 ms 200 ms Accuracy 0.5% full scale 0.3% full scale Number of ramps 8 16 Hysteresis yes PID yes PID2 no yes Auto-tuning yes Fuzzy logic yes Soft start no yes Operating mode Automatic Automatic and manual Modbus communication Not available if the part number includes A Not available if the part number includes L before the output type (see page 5) Schneider Electric

17 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Controller Display REG24 1. C1: indicator showing that output 1 is on 2. SV or PV indicator: on = setpoint value (SV); off = process value (PV) if configured 3. SEL: selector button 4. Configured value, 4 red digits, 10 mm high 5. Up arrow (increment) 6. Down arrow (decrement) 7. AL1: relay output alarm indicator on REG24PTP1AHU only 8. AL2: Modbus alarm indicator REG48 1. SV: setpoint value indicator 2. PV: process value indicator 3. C1: output 1 indicator (On if lit) 4. C2: output 2 indicator (On if lit) 5. D01: Alarm 1 output indicator (On if lit) 6. D02: Alarm 2 output indicator (On if lit) 7. Process value, 4 red digits, 12 mm high 8. Configured value, 4 green digits, 10 mm high 9. Up arrow (increment) 10. Down arrow (decrement) 11. SEL: selector button 12. A/M: Automatic/Manual mode or configuration key REG96 1. SV: setpoint value indicator 2. PV: process value indicator 3. C1: output 1 indicator (On if lit) 4. C2: output 2 indicator (On if lit) 5. D01: Alarm 1 output indicator (On if lit) 6. D02: Alarm 2 output indicator (On if lit) 7. D03: Alarm 3 output indicator (On if lit) 8. Process value, 4 red digits, 12 mm high 9. Configured value, 4 green digits, 10 mm high 10. Up arrow (increment) 11. Down arrow (decrement) 12. SEL: selector button 13. A/M: Automatic/Manual mode or configuration key 2010 Schneider Electric 17

18 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Implementation Example In this example, the application is to manage a heating system. Initially, the only required function is to adjust the setpoint as precisely as possible. The following parameters apply: The actuator is controlled by a relay and the temperature probe is a PT100, with a range from C. The temperature setpoint is 28 C. The operator can adjust the setpoint from C. The controller must activate an initial alarm when the temperature reaches 32 C and a second alarm when the temperature reaches 36 C. The controller power supply is 220 Vac. Step 1: Select the Controller The need for two alarms requires an REG48 or REG96 model. It is anticipated that Modbus communication will be integrated. The selected model is: REG48 PUN 1 R HU: 1 universal input, 1 relay output, 220 Vac power supply; Modbus communication so that the configuration application can be used Step 2: Cabling RJ45 Connector Connecting to the MODBUS (RS485) Standard Ethernet Cable Thermocouple 220 Vac Schneider Electric

19 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Step 3: Program the Display Programming menus can be accessed through the front face of the controller. Additional parameters can be set or updated in a similar fashion. Refer to user guide EIO for the complete set of parameters. Probe Type Configuration (PT100) The main display screen is shown at left. Press and hold until the screen at left appears. Press and hold until the screen at left appears and displays Ch 6. For Ch 1 functions, refer to the user guide. Press and hold until the screen at left appears. Press and release. The value for PvT begins to flash. Press and hold until the screen at left appears. Press and release to confirm the probe type selection. In this example, the choice is PvT = 1 (PT100 probe) Schneider Electric 19

20 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Setting the PT100 probe range (0 400 C) Setting the minimum value for the PT100 probe Pvb = 0 C After selecting the probe type, press and hold at left appears. until the screen Press and release until the value in green begins to flash. Press and hold until the display shows 0. Press and release to confirm the selection. Setting the maximum value for the PT100 probe PvF = 400 C Press and hold until the screen at left appears. Press and release until the value in green begins to flash. Press and hold until the display shows 400. Press and release to confirm the selection Schneider Electric

21 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Setting the desired decimal value (Pvd) (to display tenths) After setting the probe range, press and hold at left appears. until the screen Press and release until the value in green begins to flash. Press and hold until the display shows 1. Press and release to confirm the selection. Press and release to return to the main display screen. Regulation mode selection Heating on Channel 1 (rev) Press and hold until the screen at left appears. Press and hold until the screen at left appears Schneider Electric 21

22 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Regulation mode selection Heating on Channel 1 (rev) (continued) Press and hold until the screen at left appears. Press and hold until the screen at left appears. Press and release until the green no - - begins to flash. Press and hold until the display shows ru - -. Press and release to confirm the selection. Press and release to return to the main display screen Schneider Electric

23 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Configuration Alarms 1 and 2 Press and hold until the screen at left appears. Press and hold until the screen at left appears. Example: Alarm 1 configuration at 32 C Alarm 2 configuration at 38 C Alarm 1 (AL 1) shown Press and hold until the screen at left appears. Press and release until the value in green begins to flash. Press and hold until the display shows Press and release to confirm the selection for Alarm 1. Press and release once to switch to Alarm 2. Repeat the steps above and adjust the display to show Press and release to return to the main display screen Schneider Electric 23

24 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Configuration of alarm activation upon upper overshoot (do1t) Press and hold until Ch 1 is displayed. Press and release until Ch 7 is displayed. Press and hold to reach the sub-menu. Your screen should look like the display at left. Press and release until you reach the screen at left. Press and release until the value in green begins to flash. Press and release once until the display shows 1. Press and release to confirm the selection. Press and release to return to the main display screen Schneider Electric

25 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Temperature Scale Display REG24 To change the front face display from C to F, follow the steps below. Unmask the proper bit 1. Press and hold until the display shows P-n1. 2. Press and release until the display shows dsp5. 3. Press and release until the display begins to flash. 4. Press and release to change the value from 212 to Press release to exit. Access the parameter 1. Press and hold until the display shows P. 2. Press and release until the display shows P-F. 3. Press and release until the display begins to flash. 4. Press and release or to change the value from C to F. 5. Press and release to exit Schneider Electric 25

26 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Temperature Scale Display REG48/96 To change the front face display from C to F, follow the steps below. Unmask the proper bit 1. Press and hold until the display shows Ch Press and release until the display shows Ch12, dsp. 3. Press and hold. 4. Press and release until the display shows dp Press and release until the display begins to flash. 6. Press and release to change the value from FEB0 to FEA0. 7. Press and release to confirm the new value. 8. Press and release to return to the main display screen. Access the parameter 1. Press and hold until the display shows Ch Press and release until the display shows Ch Press and hold to reach the sub-menu. 4. Press and release until the display shows PvU. 5. Press and release until the display begins to flash. 6. Press and release or to change the value from C to F. 7. Press and release to confirm the new value. 8. Press and release to return to the main display screen Schneider Electric

27 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Step 4: Functional Test If the controller has been configured as in the example, you can now test the actual operation. (The state of the output 1 indicator and alarm 1 and 2 indicators depends on the temperature displayed on the front panel.) You can modify the parameters accessible via the front panel (such as auto-tuning and PID2) using the same navigational principle illustrated in Step 3: Program the Display beginning on page 17. Install the Zelio ControlSoft software The software and respective drivers can be downloaded for free from the U.S. Schneider Electric website: 1. Install the Zelio ControlSoft software (compatible with Windows XP and Vista). 2. Install the TSXCUSB485 driver software. 3. Connect the TSXUSB485 converter to your PC and the controller. Set the rotary switch to OTHER MULTI and polarization to OFF Schneider Electric 27

28 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/ Check the communication port settings for the TSXCUSB485 driver. a. Open the Windows Control Panel (1). b. Select System > Hardware (2). c. Click Device Manager (3). 5. Start the Zelio ControlSoft application. For this example, select controller REG48/ Schneider Electric

29 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide 6. Ensure that the communication port setting for the TSXCUSB485 driver is set to the same communication port that you chose in Step Set the communications parameters: baud rate, parity, and station number. The settings for these parameters must match the settings for the controller. Verify the values using the CH9 screen on the controller s front display panel. In the example below, the station number is 5, the baud rate is 9600, and the parity is Odd. Configure the communications using Zelio ControlSoft software: 2010 Schneider Electric 29

30 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/ Connect the controller and upload the application Note: Save before closing the program. The Zelio ControlSoft program will not automatically save your work. 9. Zelio ControlSoft main screen Schneider Electric

31 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Zelio ControlSoft Application ope Ch 1 screen Operations: 1 MAn: Switches to Manual mode 2 STby: Controls RUN/STANDBY operation 3 Not used 4 PrG: Ramp soak operation command (Off/Run/Hold) 5 AT: Auto Tuning Command (Off/On/Low) 6 LACh: Output alarm hold 7 Svn: Setpoint preselection (0:Sv0 by default) 8 PLn1: PID preselection (0:pid0 by default) 9 AL1 AL1L: Alarm 1 low limit (example: 32 C) a AL1h: Alarm 1 high limit b AL2 AL2L: Alarm 2 low limit (example: 36 C) AL2h: Alarm 2 high limit c AL3 AL3L: Alarm 3 low limit AL3h: Alarm 3 high limit d AL4 AL4L: Alarm 4 low limit AL4h: Alarm 4 high limit e AL5 AL5L: Alarm 5 low limit AL5h: Alarm 5 high limit f LoC: Front panel keys locked Note: Up to 5 alarms are available through the Modbus connection for REG48 and REG96. Through the product interface, REG48 includes 2 alarms, while REG96 includes 3 alarms. When in auto-tuning mode, the P/I/D/hys/bal/ar settings are automatic Schneider Electric 31

32 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 PID Ch 2 screen Operations : 1 Man switches to manual mode PID configuration: 2 Stby Control RUN/STANDBY 3 NOT USED 1 Sv0: Setpoint 2 P: 4 PrG Proportional Ramp soak factor operation command (Off/Run/hold) 3 i: 5 AT Integral Auto factor Tuning Command (Off/ON/Low) 4 d: 6 LACh Derivation Output factor alarm retain 5 hys: 7 Svn Hysteresis Preselection (0 50% setpoint full scale) (0:Sv0 default value) 6 CoL: Cooling proportional band 8 PLn1 Preselection PID (0:pid0 default value) 7 db: Deadband 8 bal: 9 AL1 Output AL1L convergence Alarm 1 value low limit (example : 32 C) 9 Ar: a AL1h Anti-reset Alarm windup prevents 1 high limit overshoot if PID is inactive a rev: b AL2 Normal/reverse selection AL2L Alarm 2 low limit type (example:( rev; : 36 C) see page 7) b SvL: AL2h SV low Alarm limit (example: 2 high limit 0 C) c Svh: SV high limit (example: 400 C) d TC1: c AL3 OUT AL3L 1 proportional Alarm 3 cycle low (if limit solid-state interface type: maximum switching frequency) e TC2: AL3h OUT Alarm 2 proportional 3 high cycle limit (if solid-state interface type: maximum switching frequency) f PLC1: d AL4 OUT AL4L 1 lower Alarm limit (if 4 analog) low limit g PhC1: AL4h OUT Alarm 1 upper 4 limit high (if analog limit ) h PLC2: OUT 2 lower limit (if analog) e AL5 AL5L Alarm 5 low limit I PhC2: OUT 2 upper limit (if analog) j PCUT: AL5h Select Alarm output 5 limiter high type limit (PLC1/2 PHC1/2) k Not usef d LoC Front face keys locked Note: When Note in auto-tuning : the REG48 mode, includes the P/I/D/hys/bal/ar 2 alarms, settings the REG96 are automatic. 3 alarms. The alarms 4 and 5 are accessible through Modbus only Note : if auto tuning then the setting of P/I/D/hys/bal/ar is automatic Schneider Electric

33 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide PLT Ch 3 screen Setpoints and PID configuration: 1 PID 1 Sv1: Setpoint 1 P1: Proportional 1 i1: Integral 1 d1: Derivative 1 hys1: hysteresis 1 CoL1: Cooling proportional band 1 db1: deadband 1 bal1: output convergence 1 Ar1: anti-reset windup 1 rev1: Normal/reverse function selection 2 Identical for PID 2 3 Identical for PID 3 4 Identical for PID 4 5 Identical for PID 5 6 Identical for PID 6 7 Identical for PID 7 8 SvMX: Selectable SV numbers 9 PL1M: Currently select PID Note: You can select up to 7 different PID configurations (parameters 1 7). Use parameters 8 and 9 to select which configuration (1 7) to activate Schneider Electric 33

34 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 PRG Ch 4 screen Ramp configuration: 1 PTn: Ramp/soak pattern ramp number selection 2 TiMU: Ramp/soak time unit (hhmm or mmss) 3 Sv1: Ramp 1 setpoint TM1r: Ramp/soak 1 ramp time TM1S: Ramp/soak 1 soak time 4 Identical for ramp 2 5 Identical for ramp 3 6 Identical for ramp 4 7 Identical for ramp 5 8 Identical for ramp 6 9 Identical for ramp 7 a Identical for ramp 8 b Identical for ramp 9 c Identical for ramp 10 d Identical for ramp 11 e Identical for ramp 12 f Identical for ramp 13 g Identical for ramp 14 h Identical for ramp 15 I Identical for ramp 16 j Mod: Ramp soak mode (0 15) k GSok: Guaranteed soak (On/Off) l GS-L: Guaranteed soak lower limit m GS-h: Guaranteed soak upper limit n PvST: Based on the programmed curve overall (Off) Based on actual value measured for start-up (On) o ConT: 3 options: res/con/ini p PTnM: Sets the maximum pattern selection q PMin: Sets the minimum pattern selection Schneider Electric

35 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide Mon Ch 5 screen Monitor functions: 1 STAT: Ramp soak progress 2 Mv1: Output 1 3 Mv2: Output 2 4 PFb: PFB input value display 5 rsv: RSV input value display 6 Not used 7 TM1: Remaining time on timer 1 8 TM2: Remaining time on timer 2 9 TM3: Remaining time on timer 3 a TM4: Remaining time on timer 4 b TM5: Remaining time on timer 5 c FALT: Fault status error source display d PLno: PID in progress e PTno: Ramp in progress Note: Data used only with the software application. Uniquely updated after each upload Schneider Electric 35

36 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 SET Ch 6 screen Setup: 1 PvT: Sensor type selection (example: 1 PT100 ) 2 Pvb: PV input lower limit (example: 0 C) 3 PvF: PV input upper limit (example: 400 C) 4 Pvd: Decimal position (example: 1) 5 PvU: Unit selection C or F 6 CUT 7 PvoF: PV input shift offset 8 SvoF: SV shift offset 9 TF: PV input filter a AdJO: User zero adjustment b AdJS: User span adjustment c rcj: Junction compensation for thermocouple probe d Not used f C1r: OUT1 range (if OUT 1 is analog) g C2r: OUT2 range (if OUT 2 is analog) h FLo1: OUTPUT 1 set value during fault I FLo2: OUTPUT 2 set value during fault j SFo1: Soft start OUT 1 set value (if Output 1 is digital: 3% = 0, 103% = 1) k SFo2: Soft start OUT 2 set value (if Output 2 is digital: 3% = 0, 103% = 1) l SFTM: Soft start set time m Sbo1: During standby, OUT 1 set value n Sbo2: During standby, OUT 2 set value o SbMd: Standby mode setting state of alarm outputs in standby mode p AoT: Type of AO output (retransmission) Modbus connection only q AoL: AO lower limit scaling Modbus connection only r Aoh: AO upper limit scaling Modbus connection only Schneider Electric

37 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide SyS Ch 7 screen System parameters: 1 UkEy: User key assignment setting 2 Not used 3 do1t: DO1 output event setting alarm 1 type configuration 4 dop1: DO1 option function setting hold alarm 1 5 do2t: DO2 output event setting alarm 2 type configuration 6 dop2: DO2 option function setting hold alarm 2 7 do3t: DO3 output event setting alarm 3 type configuration 8 dop3: DO3 option function setting hold alarm 3 9 do4t: DO4 output event setting alarm 4 type configuration a dop4: DO4 option function setting hold alarm 4 b do5t: DO5 output event setting alarm 5 type configuration c dop5: DO5 option function setting hold alarm 5 d rmp: Ramp use on setpoint change e rmpl: Ramp SV decline f rmph: Ramp SV incline g rmpu: Ramp SV slope time unit h SvT: Ramp SV-SV display mode selection I CTrL: Select PID/FUZZY/SELF function j Not used k onof: Hysteresis mode setting l SLFb: PV stable range m STMd: Startup mode selection 2010 Schneider Electric 37

38 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 ALM Ch 8 screen Alarm configuration: 1 A1hy: Alarm 1 hysteresis (0 to 50% full scale) 2 dly1: Alarm 1 delay based on the unit selected 3 dl1u: Alarm 1 time unit (0=second, 1=minute) 4 A2hy: Alarm 2 hysteresis 5 dly2: Alarm 2 delay based on the unit selected 6 dl2u: Alarm 2 time unit (0=second, 1=minute) 7 A3hy: Alarm 3 hysteresis 8 dly3: Alarm 3 delay based on the unit selected 9 dl3u: Alarm 3 time unit (0=second, 1=minute) a A4hy: Alarm 4 hysteresis b dly4: Alarm 4 delay based on the unit selected c dl4u: Alarm 4 time unit (0=second, 1=minute) d A5hy: Alarm 5 hysteresis e dly5: Alarm 5 delay based on the unit selected f dl5u: Alarm 5 time unit (0=second, 1=minute) g Not used h Not used I Not used Schneider Electric

39 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide CoM Ch 9 screen Modbus communication parameters display: 1 Stno: Station number (5 in the example) 2 CoM: Baud rate and parity (here, 96od, which corresponds to 9600 bauds, odd parity) 3 PCoL: Communication type (Modbus, fixed value) 4 SCC: Read/write possible, upload/download (fixed value) Note: For changes to the communication parameters, see page 24. PFb Ch 10 screen Feedback Position: 1 Not used 2010 Schneider Electric 39

40 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 PAS Ch 11 screen Passwords configuration: 1 PAS1: Password 1 (default value = 0000) 2 PAS2: Password 2 (default value = 0000) 3 PAS3: Password 3 (default value = 0000) Schneider Electric

41 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide CFG Ch 13 screen Configuration of environment parameters: 1 ToUT: Time for return to main screen when any key is pressed 2 Not used 3 SoFk 4 ALMF: Flashing or solid status of LEDs on front panel 5 bcon 6 PTnT: Change in ramp execution sequence 7 Not used 8 L-C1: LED function selection 9 L-C2 a Ldo1 b Ldo2 c Ldo3 d L-Sv e L-Mv f LMAn g LSTb h LrEM i L-AT j rst: Controller reset 2010 Schneider Electric 41

42 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Saving Application Files 1 From the menu, select File > Save As. 2 Indicate the path and file name Schneider Electric

43 8540DB1002 Zelio Temperature Controller 11/2010 Quick Start Guide 2010 Schneider Electric 43

44 Zelio Temperature Controller 8540DB1002 Quick Start Guide 11/2010 Schneider Electric USA, Inc Knightdale Blvd. Knightdale, NC USA Square D Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material Schneider Electric