Lumel re72 series User manual

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CONTROLLER 48 x 48 mm
RE72
USER’S MANUAL

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Contents
1. APPLICATION....................................................................... 5
2. CONTROLLER SET ................................................................. 5
3. BASIC REQUIREMENTS, OPERATIONAL SAFETY ............................. 6
4. INSTALLATION ..................................................................... 6
4.1. Controller Installation .................................................... 6
4.2. lectrical Connections ..................................................... 8
4.3. Installation Recommendations ........................................ 10
5. STARTING TO WORK ............................................................. 11
6. SERVICE............................................................................ 12
6.1. Programming Controller Parameters .................................13
6.2. Programming Matrix.....................................................14
6.3. Setting Change ...........................................................16
6.4. Parameter Description ..................................................17
7. CONTROLLER INPUTS AND OUTPUTS......................................... 29
7.1. Main Measuring Inputs..................................................29
7.2. Additional Measuring Inputs ........................................... 29
7.3. Binary Inputs.............................................................. 30
7.4.Outputs ..................................................................... 31
8.CONTROL ............................................................................ 32
8.1. ON-OFF Control...........................................................32
8.2. Innovative SMART PID Algorithm .....................................32
8.2.1 Auto-tuning.........................................................33
8.2.2 Auto-tuning and „Gain Scheduling”............................35
8.2.3 Proceeding Way in Case of a Dissatisfying PID Control.....35
8.3. Step-by-step control ..................................................... 37
8.4. “Gain Scheduling” Function ........................................... 40
8.5. Control of Heating-cooling Type....................................... 41

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9. ALARMS............................................................................ 42
10. TIMER FUNCTION ............................................................... 44
11. CURRENT TRANSFORMER INPUT ............................................ 45
12. ADDITIONAL FUNCTIONS ...................................................... 47
12.1. Control Signal Monitoring............................................. 47
12.2. Manual Control..........................................................47
12.3. Signal Retransmission ................................................ 48
12.4. Set Point Change Rate – Soft Start .................................. 49
12.5. Digital Filter............................................................. 49
12.6. Manufacturer’s Settings ............................................... 50
13. PROGRAMMING CONTROL .................................................... 51
13.1. Description of Programming Control Parameters .................51
13.2. Definition of Set Point Value Programs.............................54
13.3. Control of the Set Point Value Program............................. 57
14. RS-485 INTERFACE WITH MODBUS PROTOCOL ........................... 60
14.1. Introduction.............................................................. 60
14.2. Error Codes .............................................................. 61
14.3. Register Map............................................................ 61
15. SOFTWARE UPDATING ......................................................... 83
16. ERROR SIGNALING.............................................................. 85
17. TECHNICAL DATA................................................................ 87
18. CONTROLLER VERSION CODES............................................... 92
19. MAINTENANCE AND GUARANTEE............................................. 94
(programm version 2.14)

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1. APPLICATION
The RE72 controller is destined for the temperature control in plastics,
food, dehydration industries and everywhere when the temperature
change stabilization is necessary.
The measuring input is universal for resistance thermometers (RTD), ther-
mocouple sensors (TC), or for linear standard signals.
The controller has three outputs enabling the two-step control, step-by-
step three-step control, three-step control of heating-cooling type and
alarm signaling. The two-step control is acc. to the PID or
ON-OFF algorithm.
The innovative SMART PID algorithm has been implemented in the con-
troller.
2. CONTROLLER SET
The delivered controller set is composed of:
1. RE72 controller................................... 1 pc
2. Plug with 6 screw terminals ................ 1 pc
3. Plug with 8 screw terminals ................ 1 pc
4. Screw clamp to fi x the controller
in the panel....................................... 4 pcs
5. Seal..................................................... 1 pc

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3. BASIC REQUIREMENTS, OPERATIONAL
SAFETY
In the safety service scope, the controller meets to requirements of the
EN 61010-1 standard.
Observations Concerning the Operational Safety:
All operations concerning transport, installation, and commissioning
as well as maintenance, must be carried out by qualifi ed, skilled
personnel, and national regulations for the prevention of accidents
must be observed.
 Before switching the controller on, one must check the correctness
of connections to the network.
 Do not connect the controller to the network through an autotransformer.
The removal of the controller casing during the guarantee contract
period may cause its cancellation.
 The controller fulfi lls requirements related to electromagnetic compa-
tibility in the industrial environment
When connecting the supply, one must remember that a switch
or a circuit-breaker should be installed in the room. This switch should
be located near the device, easy accessible by the operator,
and suitably marked as an element switching the controller off.
Non-authorized removal of the casing, inappropriate use, incorrect
installation or operation, create the risk of injury to personnel or meter
damage.
For more detailed information, please study the User’s Manual.
4. INSTALLATION
4.1. Controller Installation
Fix the controller in the panel, which the thickness should not
exceed 15 mm, by means of four screw clamps acc. to the fi g. 1.
The panel cut-out should have 45+0.6 x 45+0.6 mm.

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Fig.1 Controller fi xing in the panel
Fig. 2. Controller dimensions.
Controller overall dimensions are presented on the fi g. 2.

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4.2. Electrical Connections
The controller has two separable terminal strips with screw termi-
nals. One strip enables to connect the supply and outputs by a wire
of 2.5 mm2cross-section. The second strip enables to connect input
signals by a wire of 1.5 mm2cross-section.
Fig. 3. View of controller connecting strips
supply
Fig. 4. Supply
3
2
1
Pt100
3
2
1
Jumper
Pt1000
3
2
1
Jumper
Pt100
zwora
3
4
2
+
-
0/4...20 mA
3
1
2
+
-
0...5/10 V
3
2
+
-
RTD Pt100 in two-wire
system
RTD Pt100 in 3-wire
system
Current input 0/4 ... 20 mA Voltage input 0 ... 5/10 V
Thermocouple
RTD Pt1000
3
2
1
Pt100
3
2
1
zwora
Pt1000
3
2
1
zwora
Pt100
3
2
1
Pt100
3
2
1
Jumper
Pt1000
3
2
1
Jumper
Pt100
Jumper
3
4
2
+
-
0/4...20 mA
3
1
2
+
-
0...5/10 V
3
2
+
-
zwora
3
4
2
+
-
0/4...20 mA
3
1
2
+
-
0...5/10 V
3
2
+
-
Fig. 5. Input signals
interface RS-485
input 3/binary input/
transducer supply 24V
output 1
output 2
input signals
supply

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Fig. 7. Control outputs/ alarming
Fig. 6. Additional input signal
Load
OUT1OUT2
supply
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11
10
12
Load
+
-
SSR
OUT1OUT2
supply
9
11
10
12
+
-
0/4...20mA
Laod
max. 500
+
-
OUT1OUT2
911
1012
V
0...10
Load
min.1k
+
-
911
1012
OUT1OUT2
Load
Supply
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OUT3
Output 1, 2 – relay Output 1, 2 – voltage 0/5 V
Output 1, 2 – continuous
current 0/4...20 mA
Output 1, 2 – continuous voltage
0...5/10 V
Output 3 – relay
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Fig. 8. Binary input

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current
transformer
6
5
+
-
Fig. 9. Current transformer input
Fig. 10. RS-485 Interface
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RS-485
B
A
(-)
(+)
Fig. 11. Supply of 24V transducers
4.3. Installation Recommendations
In order to obtain a full fastness against electromagnetic noise, 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
earth circuits,
- apply network fi lters,
- 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 protection
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 groups of wires made at right angle (90º).

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5. STARTING TO WORK
After turning the supply on, the controller carries out the display test,
displays the re72 inscription, the program version and next, displays
measured and set point values.
A character message informing about abnormalities may appear on the
display (table 18).
The PID control algorithm with the proportional range 30oC, inte-
gration time constant of 300 seconds, differentiation time constant
of 60 seconds and pulse period of 20 seconds is set by the manufacturer.
Changing the Set Point Value
One can change the set point value by pressing the
or push-button (fi g. 12). The beginning of change is signaled by
the fl ickering dot of the lower display. One must accept the new set point
value by pressing the push-button during 30 seconds since the
last pressure of the or push-button. In the contrary, the old
value will be restored. The change limitation is set by parameters spll
and splH.
Fig. 12. Fast change
of set point value
to change the set point value press one
of the push-button
change
acceptation
measured
value
setpoint
value
signalling
the change
signalling of output
operation
manual-control
mode
auto-tuning

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Fig. 13. Menu of controller service
6. SERVICE
The controller service is presented on the fi g. 13

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6.1. Programming of controller parameters
The pressure and holding down the push-button
during ca 2 sec. causes the entry in the programming matrix. The pro-
gramming matrix can be protected by an access code. In case when
giving a wrong value of the code, it is only possible to see settings
through – without the possibility of changes.
The fi g 14. presents the transition matrix in the programming
mode. The transition between levels is carrying out by means of
or push-buttons and the level selection by means of the
push-button. After selecting the level, the transition between parameters
is carried out by means of or push-buttons. In order to
change the parameter setting, one must proceed acc. to the section 6.3.
In order to exit from the selected level, one must transit between para-
meters until the symbol [. . .] appears and press the push-button.
In order to exit from the programming matrix to the normal working
mode, one must transit between levels until the symbol [. . .] appears
and press the push-button.
Some controller parameters can be invisible – it depends on
the current confi guration. The table 1 includes the description of para-
meters. The return to the normal working mode follows automatically
after 30 seconds since the last push-button pressure.

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6.2. Programming Matrix
Fig. 14. Programming matrix
inp
Input
parame-
ters
u ni t
Unit
in.ty
Kind of
main
input
dp
Pos. of
decimal
point
in.lo
Indic.
of lower
threshold
in.Hi
Indic. of
higher
threshold
5Hif
Shift of
mea-
sured
value
i2.ty
Kind of
auxiliary
input
dp2
Pos. of
decimal
point
i2.Lo
Indic.
of lower
threshold
outp
Output
parame-
ters
out1
Function
of output
1
o!ty
Type of
output
1
out2
Function
of
output 2
o@ty
Type of
output 2
out3
Function
of
output 3
fa1l
Ctr signal
type when
defected
Yfl
State
signal when
fa1l=
Yfl
YmH
Upper limit
of the mean
value
Lym
Max sys.
deviation
when
calc. mean
value
ctrl
Control
parame-
ters
alg
Control
algorit-
hm
type
Kind of
control
Hy
Hyste-
resis
Hn
Dead
zone
TMuo
Valve
opening
time
TMuc
Valve
closing
time
MNTu
Min.
running
time
of the
valve
y-lo
Min.
steering
signal
y-Hi
Max.
steering
signal
pid
PID
parame-
ters
Submenu: pid1 Submenu: pid2,
pid3,pid4 Submenu: pidC
pb
Propor-
tional
band
ti
Integra-
tion Time
constant
td
Different
time
constant
y0
Correction
of control
signal
Parameters as for
PID1
pbC
Propor-
tion.
band
tiC
Integration
time
constant
tdC
Different.
time
constant
alar
Alarm
parame-
ters
a!sp
Set
value
alarm 1
a!du
Devia-
tion
for
alarm 1
a!Hy
Hyste-
resis for
alarm 1
a!lt
Memory
alarm 1
a@sp ... a@lt
Parameters for alarm 2
(as for alarm 1)
a#sp... a#lt
Parameters for alarm 3
(as for alarm 1)
hBsp
Set value
of current
alarm
spp
Set-point
value
parame-
ters
spmd
Kind
of set
value
C.prg
Program
No to
carry
out
sp
Set value
SP
sp2
Set
value
SP2
sp3
Set
value
SP3
sp4
Set value
SP4
spl
Lower
limitation
SP
spH
Higher limi-
tation SP
sPrr
Accretion
rate of
set value
prg
Program.
control
parame-
ters
Description
in program-
ming control
chapter
retr
Retrans-
mis.
parame-
ters
aOfn
Retras-
nsmis.
function
aOlo
Lower
retransmis.
threshold
aOHi
Higher
Retrans.
threshold
. . .
Transit
to higher
level
inte
Interface
parame-
ters
addr
Con-
troller
address
baud
Trans-
mis.
rate
prot
Trans-
mis.
protocol
. . .
Transit
to higher
level
seru
Service
parame-
ters
seCU
Access
code
sTfn
Auto-
-tuning
function
timr
Timer
function
time
Count-
down
of timer
time
Di2
Monitor.
auxiliary
output
DCt
Monitor.
heater
current
tout
Exit time
from mo-
nitoring
. . .
Transit
to higher
level
. . .

Exit
from
menu

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Fig. 14. Programming matrix
i2.Hi
Indic. of
higher
thres-
-hold
filt
Time
constant
of fi lter
bNin
Binary
input
function
. . .
Transit
to higher
level
to1
Pulse
time
out1
to2
Pulse
time
out2
to3
Pulse
time
out1
. . .
Transit
to higher
level
Gty
„Gain
Schedul”
function
Gsnb
PID
number
for GS
Gl12
Switching
level
PID1-2
Gl23
Switching
level
PID2-3
Gl34
Switching
level
PID3-4
Gset
Constant
set PID
sTlo
Lower
thres-
hold ST
sTHi
Upper
thres-
-hold
ST
fdb
Rever-
sible
signal
i@fl
state of
the valve
when the
auxiliary
input
error
. . .

Transit
to higher
level
. . .

Transit
to higher
level
hBHy
Hyste-
resis of
current
alarm
oSsp
Set
value of
current
alarm
oSHy
Hyste-
resis of
current
alarm
. . .
Transit
to higher
level
. . .

Transit
to higher
level

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6.3. Setting Change
The change of the parameter setting begins after pressing the
push-button during the display of the parameter name. The set-
ting selection is carried out through and push-buttons,
and accepted by the push-button. The change cancellation fol-
lows after the simultaneous pressing of and push-but-
tons or automatically after 30 sec since the last push-button pressure.
The way to change the setting is shown on the fi g. 15.
Fig. 15. Change of number and text parameter settings
Beginning
of changes
Cancelation
of changes
Acceptation
of changes
+

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List of confi guration parameters Table 1
6.4. Parameter Description
The list of parameters in the menu is presented in the table 1.
Parameter
symbol
Parameter
description
Manufac-
turer
setting
Range of parameter changes
sensors Linear input
inp – Input parameters
unit Unit qC qC: Celsius degrees
qf: Fahrenheit degrees
pU: physical units
iNty Kind of main
input
pt1 pt1: Pt100
pt10: Pt1000
t-,: thermocouple of J type
t-t: thermocouple of T type
t-k: thermocouple of K type
t-s: thermocouple of S type
t-r: thermocouple of R type
t-b: thermocouple of B type
t-e: thermocouple of E type
t-n: thermocouple of N type
t-l: thermocouple of L type
0-20: linear current 0-20mA
4-20: linear curren 4-20mA
0-5: linear voltage 0-5 V
0-10: linear voltage 0-10 V
dp Position of the
main input
decimal point
1-dp 0_dp: without
decimal point
1_dp: 1 deci-
mal place
0_dp: without
decimal point
1_dp: 1 deci-
mal place
2_dp: 2 deci-
mal place
iNlo
Indication
for the lower
threshold of
the linear main
input
0.0 - -1999...9999 1)

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iNHi
Indication
for the upper
threshold of
the linear main
input
100.0 - -1999...9999 1)
sHif
measured va-
lue shift of the
main input 0.0 oC-100,0...100,0 oC
(-180,0...180,0 oF) -999...999 1)
i#ty Kind of the
auxiliary input 4-20 0-20: linear current 0-20 mA 4-20: linear current 4-20 mA
dp2 Position of the
decimal point 1-dp -
0_dp: without
decimal place
1_dp: 1 deci-
mal place
2_dp: 2
decimal place
i#lo
Indication
for the lower
threshold of the
auxiliary linear
input
0.0 - -1999...9999 1)
i#Hi
Indication
for the upper
threshold of the
auxiliary linear
input
100.0 - -1999...9999 1)
filt Time constant
of the filter 0.5
off: filter disabled
0.2: time constant 0.2 s
0.5: time constant 0.5 s
1: time constant 1 s
2: time constant 2 s
5: time constant 5 s
10: time constant 10 s
20: time constant 20 s
50: time constant 50 s
100: time constant 100 s

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bNin Binary input
function none
none: none
stop: control stop
Hand: switching into manual
working
sp2: switching SP1 into SP2
rSat: erasing of timer alarm
Psta: program start
Pnst: jump to the next
segment
PHld: stopping to count the
set point in the program
outp – Output parameters
out1 Function of
output 1 y
off: without function
Y: control signal - heating
or control signal „open”
for analog valve
Y0p: control signal for the
stepper control – opening
YCl: control signal for the
stepper control - closing
Cool: control signal - cooling
or control signal „close”
for analog valve
AHi: upper absolute alarm
Alo: lower absolute alarm
dwHi: upper relative alarm
dwlo: lower relative alarm
dwin: inner relative alarm
dwou: outer relative alarm
aLtr: timer alarm
retr: retransmission
eu1: auxiliary output for the
program-following control
eu2: auxiliary output for the
program-following control
aLfl: alarm in case of sensor
failure or exceeding the
measuring range
o1.ty Output type 1 4-20 2) rely: relay output
ssr: voltage output 0/5 V
4-20: continuous current
output 4 – 20 mA
0-20: continuous current
output 0 – 20 mA
0-10: continuous voltage output
0 – 10 V

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out2 Function of
output 2 off
off: without function
Y: control signal - heating
or control signal „open”
for analog valve
Y0p: control signal of stepper
control – opening
YCl: control signal of stepper
control – closing
Cool: control signal cooling
or control signal „close”
for analog valve
AHi: upper absolute alarm
Alo: lower absolute alarm
dwHi: upper relative alarm
dwlo: lower relative alarm
dwin: inner relative alarm
dwou: outer relative alarm
aLtr: timer alarm
aLhb: heater damage alarm
aLos: : controlling element
damage alarm
(short circuit)
retr: retransmission
eu1: auxiliary output for the
program-following control
eu2: auxiliary output for the
program-following control
aLfl: alarm in case of sensor
failure or exceeding the
measuring range
o#ty Output type 2 4-20 2)
rely: relay output
ssr: voltage output 0/5 V
4-20: continuous current
output 4 – 20 mA
0-20: continuous current
output 0 – 20 mA
0-10: continuous voltage output
0 – 10 V