Lumel RE60 User manual

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TEMPERATURE CONTROLLER
MOUNTED ON A 35 MM RAIL
RE60
USER’S MANUAL

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Contents
1. Application ................................................................................5
2. Controller set ............................................................................5
3. Preparing the controller for opereation.....................................6
3.1. Security..............................................................................6
3.2. Controller installation .........................................................9
3.3. Electrical connections......................................................10
3.4. Installation recommendations..........................................12
4. Starting to work.......................................................................13
5. Programming controller parameters....................................... 14
5.1. Diagram of the controller menu .......................................14
5.2. List of controller parameters............................................16
6. Control....................................................................................19
6.1. ON-OFF control ...............................................................19
6.2. PID control.......................................................................20
7. Alarms.....................................................................................23
8. Auxiliary functions...................................................................24
8.1. Displaying the control signal............................................24
8.2. Controller behaviour after sensor damage ......................24
8.3. Factory settings ...............................................................24
9. Error signalling........................................................................25
10. Technical data.......................................................................26
11. Ordering codes ..................................................................... 29
12. Maintenance and warranty ...................................................30

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1. APPLICATION
The REC-ZK60 controller controls the temperature in objects through
turning on and off the electrical controlling device according to
the defined setting by the controller. It cooperates directly with RTD
and TC.
It is destined for the temperature control in telecommunication
cabinets in food and drying industries and everywhere, where there
is the necessity to stabilize the temperature changes.
The controller has one output destined for the control and two alarm
outputs.
2. CONTROLLER SET
Controller - 1 pc
User’s
manual
User’s manual - 1 pc
Warranty card - 1 pc
When unpacking the controller, please check whether the type
and version code on the data plate correspond to the order.
Plug - 2 pcs

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3. PREPARING THE CONTROLLER FOR OPERATION
When unpacking the controller, please check whether the type
and version code on the data plate correspond to the order.
3.1. Security
The REC-ZK60 controller fulfils requirements concerning the
security of electrical measuring automation instruments acc.
to EN 61010-1 standard requirements concerning the resistance again-
st electromagnetic noise acc. to EN 61000-6-2 standard and emission
of electromagnetic noise occurring in the industrial environment
acc. to EN 61000-6-4 standard.
BASIC REQUIREMENTS, SAFETY INFORMATION
Symbols located in this service manual mean:
WARNING!
Warning of potential, hazardous situations.
Especially important. One must acquaint with this
before connecting the instrument.
The non-observance of notices marked by these
symbols can occasion severe injuries of the
personnel
and the damage of the instrument !
CAUTION!
Designates a general useful note. If you observe it,
handling of the controller is made easier.
One must take note of this, when the instrument
is working inconsistently to the expectations.
Possible consequences if disregarded !
In the security scope the REC-ZK60 controller meets the require-
ments of the EN 61010 -1 standard.
Remarks concerning the operator safety:
1. General
- The instrument is destined to be mounted on a 35 mm rail

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- Non-authorized removal of the required housing, inappropriate
use, incorrect installation or operation create the risk of injury to
personnel or damage to equipment. For more detailed information,
please study the present user’s manual.
- All operations concerning transport, installation, and commissioning
as well as maintenance must be carried out by qualified, skilled
personnel and national regulations for the prevention of accidents
must be observed.
- According to this basic safety information, qualified,skilled
personnel are personswho are familiar with the installation,
assembly, commissioning, and operation of the product and who
have qualifications necessary for their occupation.
2. Transport, storage
Please observe the notes on transport, storage and appropriate
handling.
Observe the climatic conditions given in technical data.
3. Installation
- The controller must be installed according to the regulation
and instructions given in this user’s manual
- Ensure proper handling and avoid mechanical stress.
- Do not bend any components and do not change any insulation
distances.
- Do not touch any electronic components and contacts.
- Instruments may content electrostatically sensitive components,
which can easily be damaged by inappropriate handling.
Do not damage or destroy any electrical components since this
might endanger your heath!
4. Electrical connection
- Before switching the instrument on, one must check the correctness
of connection to the network.
- In case of the protection terminal connection with a separate lead
one must remember to connect it before the connection of the
instrument to the mains.
- When working on live instruments, the applicable national regulations
for the prevention of accidents must be observed.

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- The electrical installation must be carried out according to the
appropriate regulations (cable cross-sections, fuses, PE connection).
Additional information can be obtained from the user’s manual.
- The documentation contains information about installation in
compliance with EMC (shielding, grounding, filters and cables).
These notes must be observed for all CE-marked products.
- The manufacturer of the measuring system or installed devices is
responsible for the compliance with the required limit values
demanded by the EMC legislation.
5. Operation
- MeasuringsystemsincludingREC-ZK60controllersmustbeequipped
with protection devices according to the corresponding standard
and regulations for prevention of accidents.
- After the instrument has been disconnected from the supply
voltage, live components and power connections must not be
touched immediately because capacitors can be charged.
- The housing must be closed during operation.
6. Maintenance and servicing
- Please observe the manufacturer’s documentation and read all
product-specific safety and application notes in this user’s manual.
- Before taking the meter housing out, one must turn the supply off.
- The removal of the instrument housing during the warranty
contract period may cause its cancellation.
When unpacking the controller, please check whether the type
and version code on the data plate correspond to the order.

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3.2. Controller installation
Fix the controller on the 35 mm rail acc. to EN 60715.
The controller housing is made of a self-extinguishing plastics.
Dimensions of the controller and the fixing way is presented on
the fig.1
Fig.1. Dimensions and fixing way of the controller
RE60
120
45
35
100
120,7
93
41
lock
When unpacking the controller, please check whether the type
and version code on the data plate correspond to the order.
Fig.2. View of controller connection strips

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3.3. Electrical connections
Carry out electrical connections to the terminal strips and next insert
strips into controller sockets.
Input
signals
SupplyWY1 A1 A2
1
910 11 12 13 14 15 16
2345678

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in a two-wire system
Pt100 resistance
thermometer
Supply
Fig.4. Connection of the supply and load circuit
When connecting the supply, one must remember that in the buil-
ding installation a circuit-breaker should exist. This element should
be placed near the device, be easy accessible for the operator
and marked as the instrument disconnecting the device.
in a three-wire system
Thermocouple
Output 1
- relay Output 1 - logic voltage for
SSR control
Output 1
- relay Alarm 2
- relay
thermometer
Jumper
Fig.3. Connection of input signals

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3.4. Installation recommendations
In order to obtain a full fastness against electromagnetic noise in
an environment with unknown noise level, it is recommended to
observe following principles:
- do not supply the controller from the network, in the proximity
of devices generating high pulse noise and do not apply common
earthing circuits,
- apply network filters,
- apply metallic shields in the shape of tubes or braids to conduct
supplying wires,
- wires leading measuring signals should be twisted in pairs,
and for resistance sensors in 3-wire connection, twisted of wires
of the same length , cross-section and resistance, and led in
a shield as above,
- all shields should be one-side earthed or connected to the protective
wire, the nearest possible to the controller,
- apply the general principle, that wires leading different signals
should be led at the maximal distance between them (no less
than 30 cm), and the crossing of these group of wires made
at right angle (90o).

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4. STARTING TO WORK
After connecting the supply, what is signalled by the green diode,
the controller displays the type and program version.
After ca three seconds, the controller transits to the control acc. to
set parameters. The controller displays the measured value, the set
point and annunciators of connected outputs.
The on-off control algorythm with hysteresis 2oC is set by the
manufacturer.
A character message informing about abnormalities can be shown
on the display (tab. 2).
Change of the set point
The entry into the set point change mode follows after pressing the
or push-button. The way to change the set point is shown
on the fig. 5. If the set point is not accepted within 30 seconds from
the last pressure of the or push-button, the controller
transits automatically into the normal working mode without the
introduction of a new set point.
Fig.5. Change of set point



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5. PROGRAMMING OF CONTROLLER PARAMETERS
5.1. Diagram of the controller menu
The controller service is presented on the fig.6. after pressing
and holding the push-button during at least 2 seconds, the
programming of parameters is possible. The transition between
parameters is carried out by means of and push-buttons.
Some parameters can be invisible - it depends on the choice of the
control algorythm or the alarm configuration. The table 1 includes the
description of parameters. The return to the normal working mode
follows after pressing the push-button or automatically after 30
seconds from the last push-button pressure.

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

 
 
Start of changes
Cancellation
of changes
or
Increase
of value
Decrease
of value
Acceptation
of changes
3sec
Correct
code?
N
T
N
T




Increase of value
or next
evaluated parameter
Decrease of value
or previous
evaluated parameter

























Active
access code 

Start of changes
Cancellation
of changes
Acceptation
of changes
Next
parameter
Previous
parameter
Held up
Monitoring of the
control signal Normal working mode Set point
change mode
Parameter
change mode
Fig.6. Diagram of controller
servicing menu

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5.2. List of parameters
The list of parameters in the menu is presented in the table 1.
Parameter
symbol Parameter description Factory setting Range of parameter changes
 Position of deci-
mal point 
1 decimal point
: without decimal point
:
Lower
limitation SP Min. measu- ring range Measuring range
Upper
limitation SP Max. measu- ring range Measuring range


Control
algorythm
: ON-OFFcontrol
algorythm
:control algorythm P
: control algorytm PD
: control algorythm PID
Proportional
band1) 30.0 0.1...999.9 °C
300 1...9999 s
Integration
time-constant2)




List of configuration parameters Table 1
Differentiation
time-constant 3) 60.0 0.1...999.9 s


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Alarm output
state when
the sensor is
damaged
: output turned off
: output turned on
 
Parameter
symbol Parameter des-
cription Factory setting Range of parameter changes
Pulse repetition
period 1) 20.0 0.5...99.9 s
Hysteresis4) 2.0 0.2...99.9 °C
Configuration
of the control
output
: direct control (cooling)
: inverse control (heating)
Signal control
of output1
when sensor is
damaged
0.0 0.0...100.0%
Alarm 1 typ : lack
: absolute upper
: absolute lower
: relative upper
: relative lower
Set point
of alarm 1 0.0 Measuring range
Deviation from
set point
for alarm 1
0.0 -199.9...199.9 °C
Hysteresis for
alarm 1 2.0 0.2...99.9 °C











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Parameter
symbol Parameter description Factory setting Range of parameter changes
Alarm 2 type
: lack
: absolute upper
: absolute lower
: relative upper
: relative lower
Set point of
alarm 2 0.0 Measuring range
Deviation from
set point
for alarm 2
0.0 -199.9...199.9°C
Hysteresis for
alarm 2 2.0 0.2...99.9 °C
Alarm output
state when
the sensor is
damaged
: output turned off
: output turned on
Shift of
the measured
value
0.0 -99.9...99.9°C
Unit : without unit
: degree centigrade










1) Parameter visible only for P, PD, PID. algorythms.
2) Parameter visible only for PID algorythm.
3) Parameter visible only for PD, PID algorythms.
4) Parameter visible only for ON-OFF algorythm .
Security code 00...9999


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6. CONTROL
6.1. On-Off control
When a high precision of the temperature control is not required,
especially for objects with a high time-constant and a small delay,
one can apply the on-off control with hysteresis. Advantages of this
control way are the simplicity and reliability, however its defect is the
oscillation formation, even at small hysteresis values.
Fig. 7. Output operation way of heating type
for the on-off control

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6.2. PID control
When we want to obtain a better accuracy of the temperature control,
one must apply the PID algorythm. The controller tuning to the object
consists on setting the value of the proportional element, integrating
and differentiating elements, and the output pulse repetition period.
The impulse period is the time which goes by between successive
switchings of the output during the proportional control. The impulse
period duration must be chosen depending on the dynamic object
properties and suitably to the output device. For fast processes it is
recommended to use SSR relays. The relay output is used to steer
contactors in slow-changing processes - recommended impulse
period higher than 20 sec.
6.2.1. Selection of PID settings by the object
identification method
One must read out the object delay time To and the maximal
temperature accretion speed from the dependence:
Vmax =
Calculate the PID settings acc. to the given equations:
Pb=1.1 Vmax .T0- proportional band
ti=2.4 .T0 - integration time-constant
td=0.4 .T0- differentiation time-constant
PVmax
t