Sensor Therm Regulus RD Manual de usuario

PID Program Controller

Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

User Manual

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Content

1General...............................................................................................................................................3

1.1 Information to this Manual.........................................................................................................3

1.2 CE Conformity...........................................................................................................................3

1.3 Limitation of Liability..................................................................................................................3

1.4 Terms of Warranty ....................................................................................................................3

1.5 Copyright...................................................................................................................................3

1.6 Explanation of Symbols ............................................................................................................4

1.7 Disposal ....................................................................................................................................4

1.8 Intended Use.............................................................................................................................4

1.9 Scope of Delivery......................................................................................................................4

2Safety..................................................................................................................................................5

2.1 General .....................................................................................................................................5

2.2 Electrical Connection................................................................................................................5

2.3 Use of a Pyrometer with Laser Targeting Light ........................................................................5

2.4 Secure start / Enable Front Panel Start....................................................................................5

2.5 Responsibility of the Operators.................................................................................................5

3Electrical Connection........................................................................................................................6

3.1 Pin Assignment.........................................................................................................................6

3.1.1 Thermocouple Types -K and -S...........................................................................................9

3.1.2 Digital Inputs ........................................................................................................................9

3.1.3 Digital Outputs ...................................................................................................................10

3.1.4 Analog Outputs..................................................................................................................11

4Commissioning ...............................................................................................................................11

4.1 Operation Modes ....................................................................................................................11

5SensorTools Software ....................................................................................................................12

5.1 Installation...............................................................................................................................12

1.1 Program Start..........................................................................................................................12

5.1.1 Connecting the Regulus ....................................................................................................12

5.2 General Settings .....................................................................................................................13

5.2.1 Select / Combine Measuring Devices................................................................................13

5.2.2 Pyrometer Alignment .........................................................................................................15

5.2.3 Device Configuration .........................................................................................................15

5.2.4 Start a Control Process in Manual Mode...........................................................................19

5.2.5 Create Program Sequences ..............................................................................................21

5.3 Starting a Program..................................................................................................................24

5.4 Graphical Display / Data Recording........................................................................................25

5.4.1 Data Playback....................................................................................................................27

5.5 Communication / Options........................................................................................................28

5.6 Spot Size Calculator ...............................................................................................................28

6Device Handling ..............................................................................................................................29

6.1 Menu Settings.........................................................................................................................30

6.1.1 Status Messages / Error Codes.........................................................................................32

7Technical Data.................................................................................................................................33

8Communication via Serial Interface / Interface Commands .......................................................34

Index.........................................................................................................................................................38

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

General

1 General

1.1 Information to this Manual

This manual enables the safe and efficient use with the device. The manual is part of the instrument and

has to be kept in a location where users of the controller always have access to.

Read this manual carefully before operating. For secure working all security notes and operation proce-

dures in this manual has to be followed.

Additionally the local accident prevention regulations and common safety regulations of the instruments’

operational area are valid.

The descriptions may differ from the current delivery status, since the pyrometer is continuously devel-

oped. Illustrations in this manual are for basic understanding and can differ from the actual construction.

1.2 CE Conformity

The product conforms to the following standards:

CE conformity: DIN EN 61326-1 (electromagnetic compatibility)

RoHS: 2011/65/EU

1.3 Limitation of Liability

All information and notes in this manual are made under consideration of valid standards and rules,

state of technology and our expert knowledge for many years.

The producer assume no liability for damages due to:

Non-observance of this manual

Usage out of intended use

Assignment of unskilled personnel

Unauthorized modifications

Technical modifications

Usage of spare parts not approved

The responsibilities of the delivery contract are valid as well as our general terms and conditions and

terms of delivery and the valid statutory rule at date of the conclusion of contract.

1.4 Terms of Warranty

A warranty period is 24 months from date of shipment form the Sensortherm facility. The seller will re-

pair or replace the device at its own discretion. Further claims of the buyer against the seller or its

agents are excluded, especially claims for damages that are not incurred in the delivery itself. This shall

not apply in cases of intent, gross negligence, or the absence of assured properties. Damage or misuse

of the product will be determined and void the warranty coverage. Repairs paid by the customer will in-

clude a 180 days warranty from date of shipment. Transportation costs are to be paid by the customer.

Any claims for damage caused by misuse, neglect or tampering with the sensor are excluded.

1.5 Copyright

This manual is protected by copyrights and are intended solely for internal purposes.

It is not permitted to transfer these instructions to third parties, duplication in any kind and form - includ-

ing excerpts - as well as recovery and / or notification of contents without written permission of the man-

ufacturer, except are internal purposes.

Contraventions are liable for damages. All other rights reserved.

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

General

1.6 Explanation of Symbols

The following symbols are used in this manual for restrictions, preventive measures and security notes.

Please pay attention to this symbols for safety reasons.

WARNING: This combination of symbol and signal word indicates a potentially dangerous

situation that can lead to death or serious injury if not avoided.

CAUTION: This combination of symbol and signal word indicates a potentially dangerous

situation that can result in minor or moderate injury if not avoided.

CAUTION, LASER RADIATION: This combination of laser radiation symbol and signal

word indicates the dangers of a laser targeting light.

NOTE: This combination of symbol and signal word indicates a potentially hazardous situa-

tion that can lead to property and environmental damage if not avoided.

INFO: This symbol indicates useful tips, recommendations and information for efficient and

trouble free operation.

1.7 Disposal

Dispose of the product properly when it is no longer usable: pyrometers include electrical and electronic

waste and have to be recycled or disposed environmentally friendly or to send to the manufacturer for

disposal.

1.8 Intended Use

The Regulus RD is a programmable PID temperature controller in table housing. It is optimized for use

with one or two Sensortherm pyrometers as temperature sensor. A second pyrometer can be used for a

second measurement point or to enlarge the overall temperature range when using 2 different ranges.

Types RDS and RDK are additionally equipped with a connection of a thermocouple probe type S or K

(Pt10Rh-Pt, temperature range 0-1750°C or NiCr-Ni, temperature range 0-1300°C), types RDSK, RDKK

or RDSS with 2 thermocouples. Selecting a pyrometer and a temperature probe with different tempera-

ture ranges enables e.g. operation of temperature recording with a pyrometer after temperature probe

recording. This enables a temperature control with a very long temperature range.

Operating the Regulus with a temperature sensor of other manufacturers is only possible via the analog

4-20 mA input.

1.9 Scope of Delivery

Regulus program controller in table housing

4 plug connectors for sensors and electrical connections, inputs/outputs and 2 for relays contacts, 1

USB cable

Software SensorTools

Info: Connection cables are not included in scope of delivery and have to be ordered separately.

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Safety

2 Safety

2.1 General

Any person who is tasked to carry out work with the device must have read and understood the operat-

ing instructions before beginning. Operation and maintenance of the system may only be performed by

trained personnel.

2.2 Electrical Connection

When connecting or when working on the mains voltage, the general safety guidelines are observed,

e.g. when connecting power transformers. Supply voltage can be lethal when touching. Improper instal-

lation can cause serious injury or physical damage. Only qualified personnel are allowed to work with

mains voltage.

2.3 Use of a Pyrometer with Laser Targeting Light

For easy alignment, the pyrometers may be equipped with a laser targeting light, laser class 2 (accord-

ing to IEC 60825-1-3-4) and has a sticker shown on the right. The laser emits a visible red light with a

maximum power of < 1 mW and a wavelength around 650 nm.

Safety precautions:

Never look into the direct or reflected laser beam.

Do not point the laser to anyone.

If laser radiation hits the eye, the eyes must be intentional-

ly closed and the head immediately moved out of the

beam.

2.4 Secure start / Enable Front Panel Start

In factory settings the device is set to secure start (“Enable front panel start”). This means the “controller

start” function of the Regulus can only be activated if an additional push button (must also be connect-

ed) is pressed. The function is helpful to prevent an accidentally controller start after changing a setting.

The button has to be connected to one of the digital inputs and activated via software menu (digital in-

puts). Deactivation is possible but not recommended (see 3.1 Pin Assignment).

2.5 Responsibility of the Operators

If the device is used in the commercial sector the operator is subject to the legal responsibilities for

workplace safety.

In addition to the safety instructions in this manual follow the regulations of safety, accident prevention

and environmental protection.

Laser

beam

direction

Laser warning label

on the device

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Electrical Connection

3 Electrical Connection

3.1 Pin Assignment

*)Note connector code: All connectors are coded (red plastic pins) to prevent accidentally inter-

change with other connectors.

Plug Connectors (Manufacturer Phönix Contact)

X1 to X4

Printed-circuit board connector type MC 1,5/12-STF-3,8 Ref.-No. 18 27 800

Cable housing type KGG-MC 1,5/12 Ref.-No. 18 34 440

X5 to X6

Printed-circuit board connector type MSTB 2,5/6-STF Ref.-No. 17 86 873

Cable housing type KGG-MSTB 2,5/6 Ref.-No. 18 03 905

Connectors X1 (Sensortherm pyrometer / external Sensor A) and

X2 (Sensortherm pyrometer / external Sensor B):

Pins

Function

Cable colors

Sensortherm

pyrometers

+24 V power supply for pyrometer / external sensor A or B

White

0 V power supply for pyrometer / external sensor A or B (GND1)

Brown

+I Analog input (4-20 mA) from sensor / pyrometer

Green

–I Analog input (4-20 mA) from sensor / pyrometer (GND1)

Yellow

Not connected

(Grey)

Not connected

(Pink)

Shield

Orange *)

Ground for digital interface RS232/RS485 to external sensor A

(GND1)

Red

TxD/D+/A for RS232/RS485 to external sensor A or B

Black

RxD/D-/B for RS232/RS485 to external sensor A or B

Violet

TxD/D+/A for RS232/RS485 to external sensor A or B

Grey-pink

RxD/D-/B for RS232/RS485 to external sensor A or B

Red-blue

*)Shield connection of a Sensortherm pyrometer: Only connect the pyrometer to system ground,

the orange shield cable is not connected to the Regulus to prevent ground loops and stray electric

currents.

X8: USB to PC

External sensor X1

External sensor X2

X7: RS232

X9: 24 V power supply

Ground

X10+11: Thermocou-

ple connectors

X5+6: Relays outputs

X3+4: Digital inputs /

control output

Pin 13...........24

Pins 1...........12

Pin 37...........48

Pin 25...........36

Pin 55....60

Pin 49....54

Connector codes *)

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Electrical Connection

Regulus

...

>10 kOhm

0 V

+24 V

Input A-F

Switch or push

button, see 3.1.2

Digital Inputs

0 V

+24 V

44 *)

31 *)

Regulus

Internal resistance

0–5 V

0–10 V

Galvanically isolated

from the power supply

0–20 mA

4–20 mA

Setpoint setting

via external

voltage 0–10 V

2 kΩ

Regulus

Internal resistance

40 kΩ

0 V

+10 V reference voltage

(only devices up to SN 1426)

Setpoint

setting via

potentiometer

Voltage

supply

from SN 1427:

+10 V externally

Connector X3 –Digital Inputs / External Setpoint Settings/ Control Output

Function

+ Digital input A

+ Digital input B

+ Digital input C

+ Digital input D

+ Digital input E

+ Digital input F

The inputs are activated with +24 V (can be taken from the power supply or connected externally).

*)Devices up to serial number 1426, these 24 V are available at pin 44

*)Devices up to serial number 1426, these 24 V are available at pin 31

When using an external voltage, 0 V (ground power supply, Pin 45) must be used as a reference

point.

44 *)

Up to SN 1426: 24 V (parallel to power supply connector X9) for digital inputs

31 *)

From SN 1427: 24 V (parallel to power supply connector X9) for digital inputs

NOTE to “enable front panel start”:

One digital input can be selected for the function “Enable front panel start” (see settings in 3.1.2

Digital Inputs and Software 5.4 Device configuration). This security function avoids the

accidentally start of the controller due to an additional push button which has to be pressed to-

gether with the “Start” button on the controller. A permanent connection of +24 V (pin 31 or 44)

to the desired output deactivates the function (on your own risk, not recommended).

Only devices up to SN 1426:

+10 V reference voltage output

0–10 V analog input for exter-

nal control of the reference

value with potentiometer *

Ground for 0–10 V analog input

for ext. control of the reference

value with potentiometer

(GND1)

Note: External setpoint setting with external voltage or potentiometer: In manual mode the refer-

ence value can be adjusted via external voltage 0–10 V.

For devices up to serial number 1426, this voltage can e.g. can be taken from the 10 V reference

voltage output (pin 31) and a 2 kOhm potentiometer (as a voltage divider to pins 31-33, the internal

resistance of the input is 40 kOhm).

From serial number 1427 this connection has 24 V for use with the digital inputs, therefore a 10 V

reference voltage must be provided externally.

0–20 mA or 4–20 mA

analog control output

0–5 V or 0–10 V

analog control output

Ground for pin 34 and Pin 35

(GND3)

Outputs selectable via software, see 5.4.

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Electrical Connection

Regulus

Output

Max. 100 mA

0 V

+24 V

100 kΩ

Min. 240 Ω

...

Regulus

Internal resistance

0–5 V

0–10 V

0–20 mA

4–20 mA

Galvanically isolated

from the power supply

Connector X4 –Digital Outputs / Actual Value Output

Function

+ Output A

+ Output B

+ Output C

+ Output D

+ Output E

+ Output F

+ Output G

+24 V power supply (connected parallel to power supply connector X9)

e.g for supply the Regulus when the power supply input should not be used.

Ground for power supply (is parallel to the power supply input X9) (GND1)

0–20 mA or 4–20 mA

analog actual value output

0–5 V or 0–10 V

analog actual value output

Ground for pin 46 and pin 47 (GND3)

Outputs selectable via software (see 5.4)

Connectors X5 + X6 –Relays Contacts

X5 and X6 are 4 relay changeover contacts (230 V, 6 A), switched from the outputs A-D.

Function

Center of relays contact RC1

RC 1: Pins 49-50 closed at inactive output A

RC 1: ins 49-51 closed at active output A

Center of relays contact RC2

RC 2: Pins 52-53 closed at inactive output B

RC 2: Pins 52-54 closed at active output B

Center of relays contact RC3

RC 3: Pins 55-56 closed at inactive output C

RC 3: Pi Pins 55-57 closed at active output C

Center of relays contact RC4

RC 4: Pins 58-59 closed at inactive output D

RC 4: Pins 58-60 closed at active output D

Connector X7 –PC Interface

Function

RS232 PC RxD / RS485 PC D-

RS232 PC TxD / RS485 PC D+

Ground for interface (GND2)

49 50 51 52 53 54

55 56 57 58 59 60

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Electrical Connection

3.1.1 Thermocouple Types -K and -S

Please consider the special characteristics of thermocouples if the device is equipped with correspond-

ing connectors. Thermocouple probes are sensitive against temperature variation. Using a Regulus and

a thermocouple with different device temperatures can induce a failure current that results in a tempera-

ture display different of the effective temperature.

Always ensure that temperatures of thermocouple and Regulus are the same to achieve a correct tem-

perature result. Wait a certain time after storage or transport the Regulus and a thermocouple in differ-

ent temperature environments before correct temperature measurement can be achieved. Depending

on the temperature deviations a wait time of 15 to 60 minutes is recommended.

Reduce interference: Induction systems

may cause interferences to the temperature

measured with a thermocouple. To reduce

this, the inductor and the heated object

must be connected to the earth terminal on

the back of the Regulus with a ground wire

of at least 4 mm².

3.1.2 Digital Inputs

The instrument is equipped with 6 digital inputs to operate the instrument

partially extern. Every input can be assigned to one of these functions (see

Software 5.4 Device configuration).

24 V has to be connected either with a push button or switch to an input to

activate its function (see under 3.1 Connector X3).

Start / Stop controller (push button):

Every trigger starts or stops the controller in turn.

Activate controller (switch):

Controller is active as long as input signal is active (24 V to the desired pin).

Emergency stop (switch):

Controller is active if 24 V is set. Without voltage input controller is deactivated, all outputs will be set

to 0 V or 0 mA (safe condition).

Reset error (push button):

Resets the controller in case of a device error. The controller tries to continue operation.

Program step trigger (push button):

In program mode the next program step can be selected.

Enable front panel start (push button):Front panel can only be done with additionally connected

and pressed push button (see 3.1 Pin Assignment Connector X3). The input for this function can

be selected. Stop function on front panel is always executable.

INFO:

Enable front panel start is a security setting to prevent an accidentally controller start.

Deactivation is possible but not recommended.

External program selection (switch), (only inputs A - E): allows the external selection of the manual

mode or a program. The inputs are binary coded, i.e.:

- With a digital input only a program or "Manual" can be activated. With 2 inputs are 3 programs

available, with 3 inputs 7 programs with 4 inputs and 15 programs with 5 inputs, all 26 programs

are available.

At all combinations not listed, "manual" is activated.

Selectable functions:

Induction system

Regulus

Thermocouple

Ground wire min. 4 mm²

Earth terminal

PID Program Controller Regulus RD / RDS / RDK / RDKS / RDKK / RDSS

Electrical Connection

Activated

program

Digital Input

(1 = input active)

Program

to activate

Digital Input

(1 = input active)

Activated

program

Digital Input

(1 = input active)

Manual

3.1.3 Digital Outputs

The instrument is equipped with 7 digital outputs. Via software every out-

put can be assigned to different functions (see 5.4 Device configuration)

The state of the digital outputs can be adjusted:

NO (normally open): outputs have in active state 24 volts to the pins and

in inactive state 0 V (output max. 100 mA, load min. 300 Ω).

NC (normally closed): outputs have in active state 0 volts to the pins

and in inactive state 24 V (output max. 100 mA, load min. 300 Ω).

Additionally a verification time and hold time in ms can be set (see 5.4 De-

vice configuration):

The verification time defines how long an event is active until the out-

put is activated (for example, the temperature is exceeded).

The hold time defines the time how long the output is hold at least. This feature is useful e.g. if a

PLC error signal requires a signal time of at least 10 ms for a proper recognition.

Selectable Functions

No function

Output is always set to logic 0

Limit value output

If activated a temperature value can be entered from where a contact has to be active (LEDs on the

Regulus show the active state. Additionally outputs A-D are switching the relays). The hysteresis is

the value at how many degree below the limit value the output is switched back. Additionally it can be

selected if the contact is active with exceeding the temperature value or if the contact is inactive (logic

NO or NC).

Message controller active

Output is active if controller is active (in manual mode, program mode or open loop mode).

Message controller ready

Activates the output if a pyrometer or thermocouple is found or the analog input detects a 4 mA signal

(indicates that without connection error the controller is ready to use).

Setpoint limit 1 / Setpoint limit 2

The setpoint limit is a limit temperature above or

below the setpoint temperature that should not

exceeded or to be below. Two setpoints can be

defined. The output is activated if the measured

value exceeds the defined setpoint value. The

output is also activated if the measured value

falls below the defined value. Entry of the set-

point value has to be done relative to the set-

point, positive or negative, e.g. 20°C if the setpoint value is 800°C and the output should be active at

820°C.

Example

Setpoint limit 1

Setpoint band

Setpoint limit 2

Measured value

Selectable functions:

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