Cascade HEAT MANAGER PRO User manual

Heat Manager Pro User Manual V1.5 Page 1
User manual
HEAT MANAGER PRO

Heat Manager Pro User Manual V1.5 Page 2
Main features
6 or 12 thermocouple inputs
6 or 12 control outputs (relay type or 4-20mA)
6 or 12 programmers or channel 1-6 programmer and channel 7-12 recorder
Up to 5 pieces of 12 channel Heatmanager Pro systems can be interconnected via
ethernet, resulting in a 60 channel system.
Working in degrees Celsius or Fahrenheit
Easy mode programmer: ramp up, soak temperature & time, ramp down and end
temperature
Normal mode programmer: 7 segments, each consisting of a ramp up/down and
soak temperature & time.
Internal trending with historical trending and numerical overview
Auto hold settings
Temperature recorder functionality incl. auto write of measured values to CSV file on
inserted USB stick (when present) or SD-card (when present and only with 4301TAD
screen)
Extra DIO for external temperature, thermocouple break alarms and emergency stop

Heat Manager Pro User Manual V1.5 Page 3
Thank you for choosing “Heat Manager Connect Pro Series”
This manual should enable you to use your machine to full satisfaction.
Every effort has been made to provide you with maximum performance,
ergonomics and benefits from this premium quality product.
Version History:
3-9-2018 Initial version V1.0
01-04-2019 Version 1.1 for software version HmPro V5.05: main-menu and
basic settings menu changed to improve ease of operation,
trending improved (changeable y-axis, historical trending) and auto hold
settings (as well as other settings) changeable in running mode
(previously only possible with all channels stopped)
2.1, 2.2 and 2.5: main menu changed, some parts moved to the basic
settings and some parts moved from basic settings to main menu
2.6 paperless recorder moved to 2.7, more features added, like y-axis
scale change and historical view.
2.7 Data menu added
2.7.1 Export data added (screen simplified)
2.7.2 Show numeric data added
2.7.3 Enter batch data added
2.6 Auto hold settings (moved from basic settings). From version
HmPro V5.05 auto hold settings can also be changed while running.
2.7 Output monitor moved to 2.8
2.8 Channel details moved to 2.9
Chapter 3: extra features in the main menu changed to basic settings
(advanced features)
3.1 easy/normal mode added to basic settings menu
3.1 master-slave settings moved to 3.2
3.5 PID settings moved to 3.3 in the basic settings menu
Hot/cold start settings moved to 3.4 in the basic settings menu
PVoffset moved to 3.5 in the basic settings menu
Language selection moved to 3.6 in the basic settings menu
Date/time settings moved to 3.6 in the basic settings menu
Alarm settings moved to 3.7 in the basic settings menu
Appendix E4 FAQ changed: from V5.05 auto hold settings can be
changed from the main-menu when in both running and stopped state

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29-04-2019 Version 1.2 for software version HmPro V5.06: IP addresses for master-
slave connection changed from 10.0.0.x into 10.0.10.x
3.2 IP addresses 10.0.10.x iso 10.0.0.x
D2 IP addresss 10.0.10.210 used for explanation
15-08-2019 Version 1.3 for software version HmPro V5.08 (and V5.07): extended
recorder functionality (always active selection and auto write to CSV file
on either usb-stick or sd-card)
1.1 Features: added recorder can always be switched on so it can
work as a normal temperature recorder (also active when no pro-
grammer running) and auto write of measured values to CSV file on
usb-stick (when present) or sd-card (when present, only possible with
4301TAD screen)
2.5 Extra explanation on how the CSV auto write starts/stops
2.7 Extra explanation on how the 3 memory backup measurement
buffers work added
2.7 Recorder start/stop and CSV auto write added to data menu
2.7.4 Recorder start/stop item description added
2.7.5 CSV auto write item description added
29-11-2019 Version 1.4 for software version HmPro V5.09: 12 channel programmer
can also be changed in initial setup to channel 1-6 programmer and
channel 7-12 recording only
Main features page 2: added 6 programmer/6 recorder channel
2.7 page 29: indication when 6 programmer/6 recorder selected
2.7 page 30: extra note added for channel 7-12 recorder
23-01-2020 Version 1.5 for software version HmPro V5.10: extra DIO for alarms
and emergency stop
1.1 Features: added alarm/emergency stop with extra DIO
2.1 System startup: emergency stop/DIO output status button added
2.2 Program setings: emergency stop/DIO output status button added
2.5 New main menu: emergency stop/DIO output status button added
2.7 Data menu: new color of CSV auto write button
2.10 Lock/unlock screen: emergency stop/DIO output status button
added
2.12 Emergency stop activate added
2.13 Show digital outputs added
3 Basic settings: new color of date and time button
3.8 Alarm settings: new screen with DIO/event 4 config buttons

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TABLE OF CONTENTS
TABLE OF CONTENTS .................................................................................................. 5
Explanation of symbols.................................................................................................... 8
Welding thermocouples................................................................................................... 8
Touchscreen introduction ................................................................................................ 9
Touchscreen maintenance.............................................................................................. 9
Normal every day usage................................................................................................ 10
Touchscreen cleaning.................................................................................................... 10
GLOSSARY ................................................................................................................... 11
1. FEATURES AND OPERATION MODES ................................................................ 13
1.1 Features of the Heatmanager Pro........................................................................... 13
1.2 Principle of operation............................................................................................... 15
1.3 Operation modes: easy or normal........................................................................... 16
2. OPERATION ........................................................................................................... 17
2.1 System startup......................................................................................................... 17
2.2 Program Settings: Set channel configuration ......................................................... 18
2.3 Edit heating profile –easy mode............................................................................. 20
2.4 Edit heating profiles –normal mode ....................................................................... 21
2.5 Operation start/stop channels ................................................................................. 22
2.6 Auto hold settings .................................................................................................... 25
2.7 Paperless recorder/trending.................................................................................... 26
2.7.1. Export data to USB.............................................................................................................. 32
2.7.2. Show numeric data.............................................................................................................. 33
2.7.3. Enter batch data.................................................................................................................. 34
2.7.4. Recorder start/stop.............................................................................................................. 35
2.7.5. .CSV auto write ................................................................................................................... 36
2.8 Output monitor......................................................................................................... 39

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2.9 Channel details........................................................................................................ 40
2.10 Lock/unlock screen................................................................................................ 42
2.11 General information (supplier contact information) .............................................. 43
2.12 Emergency stop activate (only with external DIO and selected in the initial setup)
........................................................................................................................................ 44
2.13 Show digital outputs (only with external DIO and selected in the initial setup)... 47
3. BASIC SETTINGS (ADVANCED FEATURES) ....................................................... 49
3.1 Switch mode (easy/normal mode of the programmer).......................................... 51
3.2 Master-slave configuration (connect multiple heatmanager Pro’s)........................ 52
3.3 PID Settings (temperature control response)......................................................... 56
3.4 PV offset (adjust measured temperatures)............................................................. 58
3.5 Hot/cold start selection (behaviour after power up)................................................ 60
3.6 Language selection.................................................................................................. 61
3.7 Date and time settings............................................................................................. 62
3.8 Alarm settings (for welder light, temperature alarms, burner heat demand control)
........................................................................................................................................ 63
APPENDIX A: Passwords ............................................................................................ 64
APPENDIX B: PID controllers ...................................................................................... 65
B.1 A bit of history.......................................................................................................... 65
B.2 From theory to practice........................................................................................... 66
B.2.1 ON/OFF control action............................................................................................................... 66
B.2.2. Proportional action.................................................................................................................... 67
B.2.3 Integral action ............................................................................................................................ 68
B.2.4 Differential action....................................................................................................................... 69
B.2.5 Cycle time.................................................................................................................................. 69
B.3 Work step-by-step and-by-one ............................................................................... 70
B.4 Auto tuning............................................................................................................... 71
B.5 Write down the newly determined PID values!....................................................... 71
B.6 Common pitfalls....................................................................................................... 72
B.7 More information...................................................................................................... 72

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APPENDIX C: Importing a CSV file into excel 2010 ................................................... 73
APPENDIX D: File transfer between Heatmanager Pro and Windows PC ............... 74
D.1 Disable firewall settings .......................................................................................... 74
D.2 Test communications line....................................................................................... 75
D.3 FTP client ................................................................................................................ 78
D.4 Transfer file(s)......................................................................................................... 79
APPENDIX E: Frequently asked questions ................................................................ 80
E.1 Why can’t I start the channels at first?.................................................................... 80
E.2 How can I quickly check the logged temperatures from the operation screen? ... 80
E.3 How do I advance the temperature quickly (easy mode only)............................... 80
E.4 The Heatmanager Pro does not continue with the running profile........................ 80
E.5 How to change a profile inside a running programmer?........................................ 81
E.6 How do I change a ramp in a running profile? ....................................................... 81
E.7 The operation screen appears locked (lock indicator in right top) how to unlock?81
E.8 Wrong measurements: deviating temperatures..................................................... 81
E.9 Wrong measurements: temperature goes down while heating up........................ 81
APPENDIX F: Notes ...................................................................................................... 82

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READ THIS FIRST
EXPLANATION OF SYMBOLS
The following signs have been used throughout this manual to draw your attention.
Hint: Useful hints for ease of operation.
Printed in Blue.
Info: Information you should know to fully understand your system and benefit
from its properties.
Printed in green.
Warning: Read these important messages before executing the desired operation.
Printed in red.
Warning: Read these important messages before executing the desired operation.
Printed in red.
WELDING THERMOCOUPLES
Do not weld thermocouples while connected to the system!
This may damage the system.

Heat Manager Pro User Manual V1.5 Page 9
TOUCHSCREEN INTRODUCTION
Your machine has been equipped with a “Human Machine Interface” or HMI or -more popular
called-: A touch screen.
If you are familiar with touch screen operation, found nowadays on modern cell phones,
navigation systems, informational displays etc. you may want to skip this section. If however,
this is the first time you are using a touch screen, please keep in mind that in contradiction with
older fashioned operating panels utilizing mechanical buttons, lamps and displays, both the dis-
plays and images on a touch screen can be interactive too, meaning they will react on a touch
by your finger. The interface on the touch screen is optimized for ergonomic operation. In prac-
tice this means that all objects are
positioned and sized such, that they can be touched easily with your finger without the need for
a stylus or precise positioning. A soft tipped stylus can be used if preferred, but is normally not
required for proper operation.
Touching objects on a touch screen can be compared with a mouse-click on a computer screen.
Based on the shown graphical user interface and your finger’s position on the screen, the sys-
tem can
determine what action it should take when an object is touched.
To prevent accidental, unwanted actions some objects may require a prolonged
touch, meaning you should keep your fingers pressed longer on a certain object
(like a button or display) to invoke the required action.
Example : The RUN/STOP button to start the programmer on the operation screen requires a
prolonged touch for about 1 sec.
TOUCHSCREEN MAINTENANCE
IMPORTANT - READ THIS FIRST
Never operate a machine until you have fully understood it’s safe working
conditions and operating principles.
Never operate the machine unless you are authorized to do so

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NORMAL EVERY DAY USAGE
Your touch screen utilizes a sensitive touch mechanism. The technique used provides reliable
operation, even when the screen is modestly covered with moist and dirt. It also allows the wear
of rubber gloves. And even under these conditions it should normally react already on a gen-
tle touch.
Some buttons may require a prolonged touch to prevent unwanted actions.
If the touch screen fails to respond, ask yourself first whether you have applied a valid com-
mand. If in doubt, you could check the responsiveness of the touch screen by using other com-
mands.
Each valid command will invoke a short beep, confirming the reception of the touch. However,
whether or not the actual action is performed depends also on other conditions
Avoid applying excessive force on the touch screen and never use sharp or hard
objects (e.g. nails, tools, kitchenware or a pencil) to operate it !
In either case you might damage the screen and void your warranty.
TOUCHSCREEN CLEANING
Your touch screen is provided with a durable front sheet which is water, oil and fat resistant. The
best way to clean the front sheet is with a soft, lukewarm and mildly moist cloth.
Special, disposable front cover protection sheets that will reinforce and protect your touch
screen, are available through your dealer.
Never use solvents (e.g. thinner, tri, turpentine) hot water, soda, abrasives or
other aggressive matter for cleaning.

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GLOSSARY
In this manual we make use of common terminology that is used for temperature control in
general.
Auto hold This function is used to hold the programmer when the measured value of
the programmer (or one of its slaves) deviates more than the adjusted
values from the current actual set value. When all measured values are
within the so-called deviation band the programmer will automatically
continue and start changing the set values.
Burnout Sensor state that occurs when the electrical connections of the sensor
are not correct anymore (e.g. broken thermocouple or badly welded
thermocouple).
CSV file Comma Separated Values file that can be imported into a spreadsheet
program (e.g. Microsoft Excel). See the manual of the corresponding
program for more information on how to do this. Also see the extra
chapter about this at the end of this manual.
History The history refers to information from the past about the actual state of
the process. In the case of the Heat Manager we refer to the measured
process values of a running process which are stored in the non-volatile
memory of the Heatmanager Pro. These values can be exported to a
USB-stick as a so-called CSV file.
Manipulated value The actual output percentage of a controller, also known as the controller
output or MV. This value ranges from 0.0 to 100.0% and depends on the
deviation between the actual set value and process value, corrected with
historical information from the past via the PID settings.
PID Response settings of a controller channel. See the end of this manual for
more detailed information about these settings.
Process value The value that is currently measured inside the process under control,
also known as PV or the measured value.
Profile The profile is a combination of set values over time that the programmer
will send to its slaves. This is also known as a program or a recipe.
Programmer The programmer is a channel that is using the profile for sending set
values to controllers that are connected to its slaves (when present).
Ramp This is the rate of change per hour used by a programmer to increase or
decrease its set value.

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Recorder The recorder registers the actual process values and stores them on
paper or in non-volatile memory. The measurement frequency is
time-interval based and this interval (we call that the sampling interval) is
adjustable.
Set value The desired value you wish to reach with the temperature controller,
also known as SV or set point.
Slave A slave is a controller that receives its set value from a programmer.
Soak A process step in the profile where the set value does not change over
time, also known as a dwell segment.
Trending A graphical overview of the measured process values over time.

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1.FEATURES AND OPERATION MODES
1.1 FEATURES OF THE HEATMANAGER PRO
Heating Profiles
Run and monitor your heating profiles
Up to 12 (or 6) programmers, each running a different profile, in either the easy (2x ramp+soak
segment) or normal (7x ramp+soak segment)
Adjustable auto-hold deviation band so the programmer waits for its slaves.
Channels
6 or 12 universal inputs for use with thermocouples and infrared camera’s with thermocouple
type output.
Trend charts
Record trend charts
Store trend charts to an USB stick as a CSV file, together with the batch data (batch number,
equipment, operator, batch IDs etc.).
Automatic save of temperature measurements to .CSV file on usb-stick (when inserted) or sd-
card (when present, only possible with 4301TAD screen)
Remote Trending
Use the Heat Manager in combination with LogOnline temperature registration service. Major
benefit is that the measured data is authenticated.
You can give a so-called witness account so the customer can follow the process while it is ex-
ecuted on the work piece.
Connection to LogOnline can be established through Wi-Fi, Ethernet or via a GPRS modem.
Safety
Thermocouple polarity protection
Weld discharge protection filter (Optional)
Thermocouple break protection
Alarming through sounder, SMS and/or E-mail or extra external DIO module (thermocouple
break, temperature deviation.
External temperature alarm, thermocouple break and emergency stop signal with extra external
DIO module
User friendly
Graphical user interface optimized for simple and ergonomic operation
Remote Operation
The Heat Manager can be fully remotely controlled with the iPhone/iPad/Android or windows
based app. This can be done over an Ethernet or Wi-Fi connection.

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CasCade Reporter tool: easy reporting of the measured temperatures with just a few
clicks
During a process, or after it has been completed, the measured data can be imported via an
Ethernet/wifi connection to the CasCade Reporter tool for easy verification of the process
results. From the reporter tool you can export it easily with your company logo as watermark as
for example a .PDF file that you can give to your customer, incl. the batch related data that was
entered on the Heatmanager Pro before exporting the file to the inserted USB stick.

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1.2 PRINCIPLE OF OPERATION
To fully understand the Heatmanager Pro operation we will first illustrate this by means of this
schematic diagram that shows you the steps to take.
The operation cycle is as follows:
First we set each channel to the desired function (programmer, slave etc.) and program the
desired profile in the programmer(s). So the system goes forth between 1 and 2 until all 12 (or
6) channels are correctly configured.
After this configuration phase we can go to the OPERATION screen and start the channels that
we wish to use. The actual temperature control process will now start. The actual status can be
followed on the operation screen and on various other monitoring screens.
During operation we also want to see how the process is running in a graphical way. For this we
can go to the TREND. Here we can view the process graphically.
If desired, we can export the data at the end of the process as a .CSV file to a USB stick and
import it into a pc with (e.g.) Microsoft Excel or the free downloadable Openoffice Calc.
We do this by selecting the BASIC SETTINGS/COPY DATA menu item in the main menu.
1. CHANNEL
SET
2. PROFILE
SET
(programmer)
3.
OPERATION
4. TREND
5. EXPORT-
DATA >USB
(.CSV)

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1.3 OPERATION MODES:EASY OR NORMAL
This part of the manual describes the operation of the Heatmanager Pro in more detail. The
Heatmanager Pro can operate in the so-called normal and easy mode. The normal mode is
more suitable for a stationary oven process whereas the easy mode has been developed for
quick on-site work.
If you want you can also use the easy mode for a stationary kiln, or the normal mode for on-site
welding work. That all depends on the situation and the work-piece. You can quickly adapt the
Heatmanager Pro to this, even on-site, when desired.
The major differences between the normal and easy operation modes are:
Normal mode
Easy mode
Profile up to 7
ramp/soak segments
Simple profile consisting of 1 ramp up, 1 soak, 1 ramp
down and 1 end temperature
For the rest both modes work the same. The main difference is the way you program the
heating-profile.
The following part of the manual describes the operation of the Heatmanager Pro in these
modes. Don’t confuse the easy mode with the normal mode (and vice-versa).

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2.OPERATION
FAMILIARIZE YOURSELF QUICKLY WITH THE INTERACTIVE TOUCHSCREEN CONTROL.
Reading this section learns you in as little as a few minutes how to use the Heatmanager Pro.
The screen contains an online help function for most functions however it
assumes that you have already basic understanding and experience with
interactive touch screen systems.
2.1 SYSTEM STARTUP
Check for clear and safe operating conditions at all times before switching the Heatmanager Pro
on.
First the Heatmanager Pro touch screen will try to communicate with the attached RKC SRZ
temperature control modules. When all goes well a customer logo screen appears.
Touch this and the main menu screen will appear.

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* EMERGENCY STOP ACTIVATE/SHOW DIGITAL OUTPUTS only visible when DIO mod-
ule is present in the system.
2.2 PROGRAM SETTINGS:SET CHANNEL CONFIGURATION
Push program settings for setting the correct type of channel. Remember that channel 1
is always a programmer.

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Select whether you want to set the channel as a programmer, a slave (follower of a pro-
grammer), remote (when you’re interlinking more than 1 Heatmanager Pro’s) or unused
(no function). When you push back you go to the previous screen.
Note that when you select [SLAVE], it will take the setpoint of a the last previous chan-
nel that was set as a programmer. So when channel 1 and 2 are programmers, 3 and 4
are unused and 5 and 6 are slaves, the channel 5 and 6 take the setpoint of channel 2.
After you made a selection, the [NEXT] button appears. With that you continue to the
next channel.
After setting all 6 (or 12) channels, the systems finalizes the setup and continues back
to the main menu.
With the [SLAVE SV OFFSET] function you can enter an adjustment offset that must be
used on top of the programmer set value. This is only used with the channel in slave
mode.

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2.3 EDIT HEATING PROFILE –EASY MODE
When you set a channel to programmer and you push next, there are 2 ways of programming
the profile, in this section the so called –easy mode- will be briefly discussed. This is the mode
that works with a ramp up+soak segment and a ramp down+end segment. When you need
more steps the Heatmanager Pro can be switched to the so-called “normal mode” where up to 7
ramp+soak segments can be programmed.
Here you see a brief overview of the programmed profile.
The profile consists of:
-Ramp up rate (or push the 1 button)
-Soak temperature (or push the 2 button)
-Soak time (or push the 3 button)
-Ramp down rate (or push the 4 button)
-End temperature (when the programmer/profiler reaches this value all channels will
continue controlling until the programmer channel is switched to stop mode by the
operator. (or push the 5 button).
You can change the set values by pushing the corresponding value on the screen (or by push-
ing the corresponding number next to it).
You can push the arrow up button /\ to advance the temperature set value in the first step freely
until 300°C (572°F). Above that temperature a ramp-up is mandatory and this button will
disappear.
When setting the ramp [degr/hour] to 0, the Heatmanager Pro immediately proceeds to the set
temperature without performing a ramp up/down.
By pushing [NEXT] you go to the next channel, by pushing [BACK] you return to the previous
screen (depending on the situation on how you entered this screen.)