Pixsys PL500 Operating manual

PLE500-8AD
PL500 expansion module
Modulo espansione per PL500
Installation and use guide - Guida all’installazione e all’uso

Table of contents
1 Safety guidelines.......................................................................................................................................................... 5
1.1 Organization of safety notices.................................................................................................................. 5
1.2 Safety Precautions ....................................................................................................................................... 5
1.3 Precautions for safe use.............................................................................................................................. 6
1.4 Environmental policy / WEEE .................................................................................................................... 6
2 Model identification .................................................................................................................................................... 6
3 Technical Data.............................................................................................................................................................. 7
3.1 General Features .......................................................................................................................................... 7
3.2 Hardware Features ...................................................................................................................................... 7
3.3 Software features......................................................................................................................................... 7
4 Dimensions and Installation..................................................................................................................................... 8
4.1 Mounting sequence of the PL500 and of the PLE500 expansion modules..................................... 8
5 Electric connections..................................................................................................................................................... 9
5.1 Wiring diagram............................................................................................................................................. 9
6 Leds and key function............................................................................................................................................... 11
6.1 Meaning of status lights (Led)................................................................................................................. 11
7 Controller functions .................................................................................................................................................. 11
7.1 Automatic tuning....................................................................................................................................... 11
7.2 Manual tuning ............................................................................................................................................ 11
7.3 Tuning performed once ............................................................................................................................ 11
7.4 Synchronized Tuning................................................................................................................................. 12
7.5 Automatic / Manual regulation for % output control....................................................................... 12
7.6 Heater Break Alarm on CT (Current Transformer) .............................................................................. 12
7.7 Dual Action Heating-Cooling ................................................................................................................. 13
7.8 Soft-Start function ..................................................................................................................................... 14
7.9 Expansion function.................................................................................................................................... 14
8 Alarm Intervention Modes....................................................................................................................................... 14
9 Configuration parameters table ............................................................................................................................ 17
GROUP A - ANALOGUE INPUT............................................................................................................................ 17
GROUP B - OUTPUT AND REGULATION ........................................................................................................... 18
GROUP C - AUTOTUNING AND P.I.D. ................................................................................................................20
GROUP D - ALARM 1.............................................................................................................................................22
GROUP E - ALARM 2..............................................................................................................................................23
GROUP F - SOFT-START........................................................................................................................................ 24
GROUP G - CURRENT TRANSFORMER ..............................................................................................................24
GROUP H - RETRANSMISSION............................................................................................................................25
GROUP I - SERIAL ...................................................................................................................................................26
GROUP J - EXPANSION .........................................................................................................................................26
10 Inputs, Outputs e Commands................................................................................................................................. 27
10.1 Command setpoint....................................................................................................................................27
10.2 Alarm 1 setpoint .........................................................................................................................................27
10.3 Start / Stop Command ..............................................................................................................................28
10.4 Heating output percentage .....................................................................................................................28
10.5 Cold output percentage............................................................................................................................28
10.6 Cold junction temperature.......................................................................................................................28
10.7 Error Flags ....................................................................................................................................................28
10.8 Real command setpoint ...........................................................................................................................28
10.9 Digital outputs status................................................................................................................................29
10.10 Command output reset ............................................................................................................................29
10.11 Alarms reset .................................................................................................................................................29
10.12 Remote Alarm 1..........................................................................................................................................29
10.13 Autotuning status ......................................................................................................................................29
10.14 Automatic/Manual command ...............................................................................................................29

Indice degli argomenti
1 Norme di sicurezza ....................................................................................................................................................34
1.1 Organizzazione delle note di sicurezza ................................................................................................34
1.2 Note di sicurezza.........................................................................................................................................34
1.3 Precauzioni per l’uso sicuro ..................................................................................................................... 35
1.4 Tutela ambientale e smaltimento dei rifiuti / Direttiva WEEE .........................................................35
2 Identificazione del modello.....................................................................................................................................36
3 Dati tecnici...................................................................................................................................................................36
3.1 Caratteristiche generali ............................................................................................................................36
3.2 Caratteristiche hardware .........................................................................................................................36
3.3 Caratteristiche software...........................................................................................................................36
4 Dimensioni ed installazione.................................................................................................................................... 37
4.1 Sequenza di montaggio del PL500 e dei moduli di espansione PLE500....................................... 37
5 Collegamenti elettrici................................................................................................................................................38
5.1 Schema di collegamento..........................................................................................................................38
6 Funzione dei led e del tasto .....................................................................................................................................40
6.1 Significato delle spie di stato (led)..........................................................................................................40
7 Funzioni del regolatore.............................................................................................................................................40
7.1 Tuning “Automatico”.................................................................................................................................40
7.2 Lancio dell’AutoTuning “Manuale” ........................................................................................................40
7.3 Lancio dell’AutoTuning “Once” ...............................................................................................................40
7.4 Tuning “sincronizzato”.............................................................................................................................. 41
7.5 Regolazione automatico / manuale per controllo % uscita............................................................ 41
7.6 Heater Break Alarm su CT (Trasformatore Amperometrico) ........................................................... 41
7.7 Funzionamento in doppia azione (caldo-freddo)..............................................................................42
7.8 Funzione Soft-Start ....................................................................................................................................43
7.9 Funzione espansione.................................................................................................................................43
8 Modi d’intervento allarme.......................................................................................................................................43
9 Tabella parametri di configurazione.....................................................................................................................46
GRUPPO A - INGRESSO ANALOGICO ................................................................................................................46
GRUPPO B - USCITE E REGOLAZIONE............................................................................................................... 47
GRUPPO C - AUTOTUNING E P.I.D. ....................................................................................................................49
GRUPPO D - ALLARME 1 ...................................................................................................................................... 51
GRUPPO E - ALLARME 2.......................................................................................................................................52
GRUPPO F - SOFT-START......................................................................................................................................53
GRUPPO G - CURRENT TRANSFORMER............................................................................................................ 53
GRUPPO H - RETRANSMISSION..........................................................................................................................54
GRUPPO I - SERIALE...............................................................................................................................................55
GRUPPO J - ESPANSIONE.....................................................................................................................................56
10 Inputs, Outputs e Commands................................................................................................................................. 57
10.1 Setpoint di comando.................................................................................................................................57
10.2 Setpoint allarme 1......................................................................................................................................57
10.3 Comando Start / Stop................................................................................................................................57
10.4 Percentuale uscita caldo...........................................................................................................................57
10.5 Percentuale uscita freddo.........................................................................................................................57
10.6 Temperatura giunto freddo ..................................................................................................................... 57
10.7 Flags errori ...................................................................................................................................................57
10.8 Setpoint di comando reale.......................................................................................................................58
10.9 Stato uscite digitali.....................................................................................................................................58
10.10 Riarmo uscita di comando.......................................................................................................................58
10.11 Riarmo allarmi............................................................................................................................................58
10.12 Allarme 1 remoto........................................................................................................................................58
10.13 Stato autotuning........................................................................................................................................ 59
10.14 Comando automatico / manuale.......................................................................................................... 59

User manual - PLE500-8AD - 5
Introduction
The PLE500-8AD integrates the fundamental elements of the control loop into a single device: reading
of the temperature probe, control of the digital regulation output, reading and control of the current
passing through the load thanks to the input for the current transformer.
The device is completed with functions such as alarms, the management of dual action hot / cold
systems and the possibility of using the PLE500-8AD as a simple PLC-controlled expansion.
1 Safety guidelines
Read carefully the safety guidelines and programming instructions contained in this manual before
connecting/using the device.
Disconnect power supply before proceeding to hardware settings or electrical wirings to avoid risk of
electric shock, fire, malfunction.
Do not install/operate the device in environments with flammable/explosive gases.
This device has been designed and conceived for industrial environments and applications that rely
on proper safety conditions in accordance with national and international regulations on labour
and personal safety. Any application that might lead to serious physical dama ge/ life risk or involve
medical life support devices should be avoided.
Device is not conceived for applications related to nuclear power plants, weapon systems, flight
control, mass transportation systems.
Only qualified personnel should be allowed to use device and/or service it and only in accordance to
technical data listed in this manual.
Do not dismantle/modify/repair any internal component.
Device must be installed and can operate only within the allowed environmental conditions.
Overheating may lead to risk of fire and can shorten the lifecycle of electronic components.
1.1 Organization of safety notices
Safety notices in this manual are organized as follows:
Safety notice Description
Danger! Disregarding these safety guidelines and notices can be life-threatening.
Warning! Disregarding these safety guidelines and notices can result in severe injury or
substantial damage to property.
Information! This information is important for preventing errors.
1.2 Safety Precautions
Danger!
CAUTION - Risk of Fire and Electric Shock
This product is UL listed as Open Type Process Control Equipment. It must be
mounted in an enclosure that does not allow fire to escape externally.
Danger!
If the output relays are used past their life expectancy, contact fusing or burning may
occasionally occur.
Always consider the application conditions and use the output relays within their
rated load and electrical life expectancy. The life expectancy of output relays varies
considerably with the output load and switching conditions.
Warning!
Devices shall be supplied with limited energy according to UL 61010-1 3rd Ed, section
9.4 or LPS in conformance with UL 60950-1 or SELV in conformance with UL 60950-1
or Class 2 in compliance with UL 1310 or UL 1585.
Warning! Loose screws may occasionally result in fire.
For screw terminals, tighten screws to tightening torque between 0.5 and 0.6 Nm
Warning!
A malfunction in the Digital Controller may occasionally make control operations
impossible or prevent alarm outputs, resulting in property damage. To maintain
safety in the event of malfunction of the Digital Controller, take appropriate safety
measures, such as installing a monitoring device on a separate line.

6 - PLE500-8AD - User manual
1.3 Precautions for safe use
Be sure to observe the following precautions to prevent operation failure, malfunction, or adverse
affects on the performance and functions of the product. Not doing so may occasionally result in
unexpected events. Do not handle the Digital Controller in ways that exceed the ratings.
• The product is designed for indoor use only. Do not use or store the product outdoors or in any of
the following places.
- Places directly subject to heat radiated from heating equipment.
- Places subject to splashing liquid or oil atmosphere.
- Places subject to direct sunlight.
- Places subject to dust or corrosive gas (in particular, sulfide gas and ammonia gas).
- Places subject to intense temperature change.
- Places subject to icing and condensation.
- Places subject to vibration and large shocks.
• Installing two or more controllers in close proximity might lead to increased internal temperature
and this might shorten the life cycle of electronic components. It is strongly recommended to
install cooling fans or other air-conditioning devices inside the control cabinet.
• Always check the terminal names and polarity and be sure to wire properly. Do not wire the
terminals that are not used.
• To avoid inductive noise, keep the controller wiring away from power cables that carry high voltages
or large currents. Also, do not wire power lines together with or parallel to Digital Controller
wiring. Using shielded cables and using separate conduits or ducts is recommended. Attach a
surge suppressor or noise filter to peripheral devices that generate noise (in particular motors,
transformers, solenoids, magnetic coils or other equipment that have an inductance component).
When a noise filter is used at the power supply, first check the voltage or current, and attach the
noise filter as close as possible to the Digital Controller. Allow as much space as possible between
the Digital Controller and devices that generate powerful high frequencies (high-frequency
welders, high-frequency sewing machines, etc.) or surge.
• A switch or circuit breaker must be provided close to device. The switch or circuit breaker must be
within easy reach of the operator, and must be marked as a disconnecting means for the controller.
• Wipe off any dirt from the Digital Controller with a soft dry cloth. Never use thinners, benzine,
alcohol, or any cleaners that contain these or other organic solvents. Deformation or discoloration
may occur.
• The number of non-volatile memory write operations is limited. Therefore, use EEprom write mode
when frequently overwriting data, e.g.: through communications.
1.4 Environmental policy / WEEE
Do not dispose electric tools together with household waste material.
According to European Directive 2012/19/EU on waste electrical and electronic equipment and its
implementation in accordance with national law, electric tools that have reached the end of their life
must be collected separately and returned to an environmentally compatible recycling facility.
2 Model identification
PLE500-8AD
Power supply 12/24Vdc ±15% (powered by PL500 through the bus) + 1
analogue input + 2 logic autputs 24VDC/50mA + 1 output 0/4..20mA + RS485
+ CT

User manual - PLE500-8AD - 7
3 Technical Data
3.1 General Features
Operating
temperature Temperature: 0-45°C - Humidity 35..95 RH%
Container DIN43880, 18 x 90 x 64 mm
Box Box and front panel: PC UL94V0 self-extinguishing
Sealing IP20 (box and terminals)
Weight Approx. 30 g
3.2 Hardware Features
Power-supply 12/24 VDC ±15% Consumption: 3 VA Max.
Analogue input
1: AI1 Configurable via software.
Input: Thermocouple type K, S, R, J, T, E,
N, B. Automatic compensation of cold
junction from 0..50 °C.
Thermoresistances: PT100, PT500,
PT1000, Ni100, PTC1K, NTC10K (β 3435K).
Input V/I: 0-10 V, 0-20 o 4-20 mA, 0-60
mV.
Input Pot: Configurable 1..150kΩ
1: C.T.: 50 mA AC 50/60 Hz
Tolleranza (25 °C)
+/-0.3% ±1 digit (su F.s.) per
termocoppia, termoresistenza e V / mA.
Precisione giunto freddo 0.1 °C/°C
Impedence:
0-10 V: Ri>110 kΩ
0-20 mA: Ri<50 Ω
4-20 mA: Ri<50 Ω
0-60 mV: Ri>500 kΩ
C.T.: 4096 points / 100 µs
Logic outputs
2SSR.
Configurable as command or alarm
output.
12/24VDC (Power supply) ±15%/ 50mA
3.3 Software features
Regulation
algorithms
ON-OFF with hysteresis.
P, PI, PID, PD with proportional time
Proportional
band 0..999°C o °F
Integral time 0,0..999,9 s (0 excludes)
Derivative time 0,0..999,9 s (0 excludes)
Controller
functions Manual or automatic Tuning, selectable alarm, Start/Stop,
“expansion” function.

8 - PLE500-8AD - User manual
4 Dimensions and Installation
RUN
.1
.2
12
10 1
+
-
3
2
PT1 00
NI1 00
PTC NTC
V/I
+
-
TC 4
6
5
7
9
8
SSR 1
+
-
SSR 2
+
-
CT PO T
PLE500-8AD
DIN RAIL CONTROLLER
1 AI-2 SRR-1 POT-CT CANOPEN
Supply: 24VDC 5VA
P0213999999999 MADE IN
EU
7 8 9
4 5 6
10 11 12
1 2 3
64 mm
Attacco a guida DIN EN50022
Din rail mounting guide EN50022
18 mm
90 mm
4.1 Mounting sequence of the PL500 and of the PLE500
expansion modules
The PL500 with the relevant I/O modules requires mounting and connection via the specific bus
lodged in the hollow of the DIN rail. The I/O modules (series PLE500-xAD) will be automatically
numbered at each power-on, assigning the number 1 to the first I/O module connected to the right
of the PL500, the number 2 to the following one and so on, always moving towards the right side.
The position of the various modules shall thus reflect the sequence set in the LogicLab project in the
definition of the PLCEXP network. For the numbering procedure to work correctly, it is not permitted
to remove devices from the network by releasing them from their own bus and leaving some empty
modules (bus slots) between one module and another. All connection/disconnection operations must
be carried out with power off.
Clik!
Couple all the buses by pushing them towards the DIN
rail, making sure that the male connection faces left
and the female one faces right.
Couple the buses together by sliding them along the
DIN rail.
Insert the various modules in the slots of the buses
starting from the PL500 and continuing to the right
with the I/O modules.

User manual - PLE500-8AD - 9
.4
.5
.6
.7
.3
.2
.1
.0
.4
.5
.6
.7
.3
.2
.1
.0
+0
+1
1 2 34567 8 9 10 12
QI.0
QI.1
QI.2
QI.3
QI.4
QI.5
QI.6
QI.7
13 14 15 16 17 18 19 20 21 22 23 24
AGND
(0V)
AI0
L+0
AI1
QI.0
QI.1
QI.2
QI.3
QI.4
QI.5
QI.6
QI.7
L+1
AQ.0 AQ.1
AGND
(0V)
10 11 12
1 2 3
10 11 12
1 2 3
Proceed with mounting all the modules according to
the requested order until the plc is completely formed.
.4
.5
.6
.7
.3
.2
.1
.0
.4
.5
.6
.7
.3
.2
.1
.0
+0
+1
1 2 34567 8 9 10 12
QI.0
QI.1
QI.2
QI.3
QI.4
QI.5
QI.6
QI.7
13 14 15 16 17 18 19 20 21 22 23 24
AGND
(0V)
AI0
L+0
AI1
QI.0
QI.1
QI.2
QI.3
QI.4
QI.5
QI.6
QI.7
L+1
AQ.0 AQ.1
AGND
(0V)
10 11 12
1 2 3
It is not possible to leave free slots in the bus between
one module and another.
5 Electric connections
This instrument was designed and built in compliance with the Low Voltage Directives 2006/95/
CE, 2014/35/EU (LVD) and Electromagnetic compatibility 2004/108/EC and 2014/30/EU (EMC). For
installation in industrial environments it is a good rule to follow the precautions below:
• Distinguish the power supply line from the power lines.
• Avoid the proximity with contactor units, electromagnetic contactors, high power motors and use
filters in any event.
• Avoid the proximity with power units, particularly with phase control.
• The use of network filters is recommended on the power supply of the machine in which the
instrument will be installed, particular in case of 230 VAC power supply.
The instrument is devised to be assembled with other machines. Therefore, the EC marking of
the instrument does not exempt the manufacturer of the system from the safety and conformity
obligations imposed for the machine as a whole.
• Wiring of pins use crimped tube terminals or flexible/rigid copper wire with diameter 0.25 to 1.5
mm2 (min. AWG28, max. AWG16, operating temperature: min. 70°C). Cable stripping lenght 7 to 8
mm.
5.1 Wiring diagram
12
10 1
+
-
3
2
PT100
NI100
PTC
NTC
V/I
+
-
TC 4
6
5
7
9
8
SSR1
+
-
SSR2
+
-
CT POT
PLE500-8AD

10 - PLE500-8AD - User manual
5.1.a Analogue Input
+
–
AI
TC
Shield / Schermo
11
10
For thermocouples K, S, R, J, T, E, N, B.
•Comply with polarity
• For possible extensions, use compensated cable and terminals suitable for
the thermocouples used (compensated).
• When shielded cable is used, it should be grounded at one side only.
AI
Rosso
Red
Rosso
Red
Bianco
White
Shield / Schermo
PT/NI100
12
11
10
For thermoresistances PT100, Ni100.
• For the three-wire connection use wires with the same section.
• For the two-wire connection short-circuit terminals 13 and 15
• When shielded cable is used, it should be grounded at one side only.
RED
ROSSO
WHITE
BIANCO
RED
ROSSO 11
12
10
AI
Shield / Schermo
PTC/NTC
12
10
For thermoresistances NTC, PTC, PT500, PT1000 and linear potentiome-
ters.
When shielded cable is used, it should be grounded at one side only to avoid
ground loop currents.
+
–
AI
V
mA
Shield / Schermo
11
10
For linear signals in Volt and mA
• Comply with polarity
• When shielded cable is used, it should be grounded at one side only to
avoid ground loop currents.
5.1.b Examples of connection for linear input
B
C
A
4...20mA
10
11
P :0...100mbar Pmax :3bar T :0..70°C
OUT : 4...20mA IN :9...33VDC
For signals 0/4..20mA with three-wire sensor. (requires external power supply,
for example that of the PL500).
• Comply with polarity
A = Sensor output
B = Sensor ground
C = Sensor power supply
In the picture: pressure sensor. Connect the external power supply to pins C
(+) and B (-).
P
N
P :0...100mbar Pmax :3bar T :0..70°C
OUT : 4...20mA IN :9...33V DC
A
B
4...20mA
11
10
For signals 0/4..20mA with external power of sensor.
• Comply with polarity
A = Sensor output
B = Sensor ground
In the picture: pressure sensor. Connect the external power supply to pins P
and N.
P :0...100mbar Pmax :3bar T :0..70°C
OUT : 4...20mA IN :9...33V DC
A
C
4...20mA
10
11
Per segnali normalizzati in corrente 0/4..20mA con sensore a due fili (requires
external power supply, for example that of the PL500)
• Rispettare le polarità
A = Uscita sensore
C = Alimentazione sensore
In figura: sensore di pressione. Connect the external power supply to pins C
(+) and terminal 10 (-).

User manual - PLE500-8AD - 11
5.1.c Input for C.T.
9
CT
7
Input for C.T. 50mA
Sampling time 100 µs.
True RMS current measurement for Heater Break Alarm and over-current
alarm functions.
5.1.d Digital output
2
+
–
SSR1
24VDC / 50mA
1
3
+
–
SSR2
24VDC / 50mA
1
Uscita digitale 24VDC ±15%/ 50mA max.
5.1.e Potentiometer
6
POT
4
5Input feedback potentiometer for motorized valves
6 Leds and key function
6.1 Meaning of status lights (Led)
RUN • Flashing during start-up and when PL500 is offline
• Fixed ON with PL500 on RUN
OUT1 • Normally it indicates the status of output OUT1
OUT2 • Normally it indicates the status of output OUT2
7 Controller functions
7.1 Automatic tuning
Select 1 on parameter 31 (Tune).
Automatic tuning is always active and analyses constantly the difference setpoint-process. If this
difference is greater than the value selected on parameter 47 (Max Gap Tune), the PLE500-8AD decides
autonomously when to modify PID parameters.
7. 2 Manual tuning
Select 2 on parameter 31 (Tune).
The manual procedure allows the user a greater flexibility on deciding when to update PID algorithm
parameters .
This procedure is activated writing 1
“Autotuning state” on the Outputs schedule. The reference
threshold to calculate the new PID parameters is given by the result of the following operation:
Tune threshold = Command setpoint - Par.32 (Setpoint Deviation Tune)
Ex.: if setpoint is 100.0°C and Par. 32 is 20.0°C, the threshold to calculate PID parameters is (100.0–20.0)
= 80.0°C.
N.B.: for greater accuracy in the calculation of PID parameters it is recommended to launch the manual
tuning when the process is far from setpoint.
7. 3 Tuning performed once
Select 3 on parameter 31 (Tune). Autotuning procedure is executed only once at next PLE500-8AD
restart. If the procedure doesn’t work, it will be be executed at next restart.

12 - PLE500-8AD - User manual
7.4 Synchronized Tuning
Select 4 on parameter 31 (Tune).
This procedure has been conceived to calculate correct PID values on multi-zone systems, where each
temperature is influenced by the adjacent zones.
Writing on
“Autotuning state” on Outputs schedule, the controller works as follows:
“Autotuning state” value Action
0Tune off
1 Command output OFF
2 Command output ON
3Tune active
4Tune completed: command output OFF (read only)
5Tune not available: softstart function enabled (only reading)
Here below the functioning for regulation loop: the PLC switches-off or turns-on all zones (value 1 or
2 on
“Autotuning state” ) for a time long enough to create inertia on the system.
At this point the autotuning is launched (value 3 on
“Autotuning state” ). The controller executes the
procedure for the calculation of the new PID values. When the procedure ends, the controller switches
off the command output and selects the value 4 on
“Autotuning state” . The Master, always reading
“Autotuning state” , will control the various zones and when all will have finished, it will set to 0 the value
of
“Autotuning state” : the various devices will regulate the temperature independently, with the new
calculated values.
N.B. The PLC must read the
“Autotuning state” at least every 10 seconds or the PLE500-8AD will
automatically exit the autotuning procedure.
7. 5 Automatic / Manual regulation for % output control
This function allows to select automatic functioning or manual command of the output percentage.
With parameter 25 (Automatic/Manual), you can select two methods.
1. The first selection (value 1) allows to modify, through the “Automatic/Manual command state”
on Outputs schedule, the functioning mode: after writing 1 it is possible to modify the output
percentage on
“Output percentage” .
To return to automatic mode, write 0 on “Automatic/Manual command state”.
2. The second selection (value 2) enables the same functioning, but with two important variants:
• If there is a temporary lack of voltage or after switch-off, the manual functioning will be maintained
as well as the previously set output percentage value.
• If the sensor breaks during automatic functioning, the controller moves to manual mode while
maintaining the output percentage command unchanged as generated by the P.I.D. immediately
before breakage.
7.6 Heater Break Alarm on CT (Current Transformer)
This function allows to measure load current to manage an alarm during a malfunctioning with power
in short circuit, always open or partial break of the charge.
To enable this function set 1 (50 Hz) or 2 (60 Hz) on paramater 90 (Current Transformer). Set the value
of the connected transfomer on parameter 91 (Current Transformer Value).
• Select on par. 92 (Heater Break Alarm Threshold) the Heater Break Alarm intervention threshold in
Ampere.
• Select on par. 94 (Heater Break Alarm Delay) the delay time in seconds for the Heater Break Alarm
intervention.
• It is possible to associate the alarm, selecting 10 [Heater Break Alarm] on par. 56 (Alarm 1).
It is possible also to enable an overcurrent control, setting on par. 93 (Overcurrent Alarm Threshold)
the intervention threshold in Ampere.

User manual - PLE500-8AD - 13
7.7 Dual Action Heating-Cooling
PLE500-8AD is suitable also for systems requiring a combined heating-cooling action.The command
output has to be configured as PID for Heating (par. 33 -greater than 0), while the alarm 1 has to be
configured as Cooling (value 9 [cool] on par. 56 (Alarm 1)). The command output must be connected
to the actuator responsible for heating, while the alarm will control cooling action.
Parameters to be configured for the heating PID are:
Par. 33: Heating proportional band
Par. 34: Integral time of heating and cooling
Par. 35: Derivative time of heating and cooling
Par. 40: Heating time cycle
Parameters to be configured for the cooling PID are:
Par. 56 = cooL (value 9) Alarm selection (Cooling)
Par. 42: Proportional band multiplier
Par. 43: Overlapping / Dead band
Par. 44: Cooling time cycle
Par. 42 (Proportional Band Multiplier) (that ranges from 1.00 to 5.00) determines the proportional band
of cooling action basing on the formula:
Proportional band for cooling action = Proportional Band * Proportional Band Multiplier
This gives a proportional band for cooling which will be the same as heating band if Par. 42 = 1.00, or
5 times greater if Par. 42 = 5.00.
Integral and derivative time are the same for both actions.
The par. 43 (Overlap/Dead Band) determines the percentage overlapping between the two actions.
For systems in which the heating output and cooling output must never be simultaneously active a
dead band (Par. 43 ≤ 0) must be configured, vice versa you can configure an overlapping (Par. 43 > 0).
The following figure shows an example of dual action P.I.D. (heating-cooling) with integral time and
derivative time = 0.
ACTIVE
ACTIVE
SPV
PV
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 43 < 0
Par. 43 = 0
Par. 43 > 0
Par. 33 (HEAT)
Par. 33 (HEAT)
Par. 33 (HEAT)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
SPV
PV
ACTIVE
ACTIVE
SPV
PV
ACTIVE
ACTIVE
ACTIVE
ACTIVE
SPV
PV
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 43 < 0
Par. 43 = 0
Par. 43 > 0
Par. 33 (HEAT)
Par. 33 (HEAT)
Par. 33 (HEAT)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
SPV
PV
ACTIVE
ACTIVE
SPV
PV
ACTIVE
ACTIVE
ACTIVE
ACTIVE
SPV
PV
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 33 x Par. 42 = COOL
Par. 43 < 0
Par. 43 = 0
Par. 43 > 0
Par. 33 (HEAT)
Par. 33 (HEAT)
Par. 33 (HEAT)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
COMMAND OUTPUT (HEAT)
ALARM OUTPUT (COOL)
SPV
PV
ACTIVE
ACTIVE
SPV
PV
ACTIVE
ACTIVE

14 - PLE500-8AD - User manual
The par. 44 has the same meaning as the heating time cycle.
Par. 41 (Cooling Fluid) pre-selects the proportional band multiplier (Par. 42) and the cooling PID cycle
time ..t. basing on the type of cooling fluid:
Par. 41 Cooling fluid type Par. 42 Par. 44
i  Air 1.00 10
i  Oil 1.25 4
 Water 2.50 2
Once selected the parameter 41, parameters 42, 43 and 44 can however be modified.
7.8 Soft-Start function
PLE500-8AD is provided with two types of softstart selectables on parameter 80 ( “Softstart Type” ).
1 First selection (value 1) enables gradient softstart. At starting the controller reaches setpoint basing
on the rising gradient set on parameter 81 (
“Softstart Gradient” ) in Unit/hour (ex. °C/h). If parameter
84 (
“Softstart Time” ) is different to 0, at starting when the time selected on parameter 84 is elapsed,
the controller stops to follow the gradient and reaches setpoint with the maximum power.
2 Second selection (value 2) enables output percentual softstart. On par. 83 (
“Softstart Threshold” ) it
is possible to set the threshold under which starts the softstart. On par. 82 (
“Softstart Percentage” )
an output percentage is selectable (0 to 100), which controller keeps until the process exceeds the
threshold set on parameter 83 or until the time in minutes set on parameter 84 (
“Softstart Time” )
expires.
7.9 Expansion function
Selecting 1 on par. 121 ( “Expansion Module” ) PLE500-8AD works as a expansion module. Controller
functions (temperature control, alarms, softstart etc..) are disabled and outputs management must
be done by an external PLC. It is possible to configure output status at starting and in case of error,
programming parameters 122 - 131.
8 Alarm Intervention Modes
8.a Absolute Alarm or Threshold Alarm active over (Alarm1 = 1)
Alarm Spv
Pv
O
On On
O
Hysteresis
parameter
 > 0
Time
Alarm
output
Absolute alarm.
Hysteresis value greater than “0” (Par. 58  . .   > 0).
Alarm Spv
O
On On
O
Hysteresis
parameter
 < 0
Time
Alarm
output
Absolute alarm.
Hysteresis value less than “0” (Par. 58  . .   > 0).

User manual - PLE500-8AD - 15
8.b Absolute alarm or threshold alarm referred to command setpoint active over (Alarm1 = 6)
O
On
O
Time
Alarm Spv
Hysteresis
parameter
 > 0
Alarm
output
Comand Spv
Absolute alarm referred to command setpoint. Hysteresis
value greater than “0” (Par. 58  . .   > 0).
8.c Band alarm (Alarm1 = 3)
Pv
O O
Hysteresis
parameter
Time
Alarm
output
Band alarm hysteresis value greater than “0” (Par. 58  . .   > 0).
Pv
Alarm Spv
O O O
Hysteresis
parameter
 < 0
Hysteresis
parameter
 < 0
Time
Alarm
output
Alarm Spv
Comand Spv
Band alarm hysteresis value less than “0” (Par. 58  . .   < 0).
8.d Upper deviation alarm (Alarm1 = 4)
Pv
Comand Spv
Alarm Spv
O O
On On
Hysteresis
parameter
 > 0
Time
Alarm
output
Alarm Spv
Comand Spv
Upper deviation alarm value of alarm setpoint greater than “0”
and hysteresis value greater than “0” (Par. 58  . .   > 0).
With hysteresis value less than “0” ( . .   < 0) the dotted line
moves under the alarm setpoint.
Comand Spv
Alarm Spv
O O
On On
Hysteresis
parameter
 > 0
Time
Alarm
output
Comand Spv
Alarm Spv
Alarm Spv
Alarm Spv
Upper deviation alarm value of alarm setpoint less than “0”
and hysteresis value greater than “0” (Par. 58  . .   > 0).
With hysteresis value less than “0” ( . .   < 0) the dotted line
moves upper the alarm setpoint.

16 - PLE500-8AD - User manual
8.e Lower deviation alarm (Alarm1 = 5)
Pv
Comand Spv
Alarm Spv
O O
Hysteresis
parameter
 > 0
Time
Alarm
output
Alarm Spv
Lower deviation alarm value of alarm setpoint greater than “0”
and hysteresis value greater than “0” (Par. 58  . .   > 0).
With hysteresis value less than “0” ( . .   . < 0) the dotted line
moves under the alarm setpoint.
Pv
Comand Spv
Alarm Spv
O O
On On
Hysteresis
parameter
 > 0
Time
Alarm
output
Comand Spv
Comand Spv
Comand Spv
Comand Spv
Alarm Spv
Alarm Spv
Lower deviation alarm value of alarm setpoint less than “0”
and hysteresis value greater than “0” (Par. 58  . .   > 0).
With hysteresis value less than “0” ( . .   . < 0) the dotted line
moves under the alarm setpoint.
9 Configuration parameters table
The PLE500-8AD integrates many features managed by the following configuration parameters.
Set the product parameters so that they are suitable for the system to be controlled. If they are not
suitable, unexpected operations may occasionally cause material damage or accidents.
GROUP A ANALOGUE INPUT
1 Sensor
Analogue input configuration / sensor selection
0 Tc-K -260 °C..1360 °C. (Default)
1 Tc-S -40 °C..1760 °C
2 Tc-R -40 °C..1760 °C
3 Tc-J -200 °C..1200 °C
4 Tc-T -260 °C..400 °C
5 Tc-E -260 °C..980 °C
6 Tc-N -260 °C..1280 °C
7 Tc-B 100 °C..1820 °C
8 Pt100 -100 °C..600 °C
9 Ni100 -60 °C..180 °C
10 NTC10K -40 °C..125 °C
11 PTC1K -50 °C..150 °C
12 Pt500 -100 °C..600 °C
13 Pt1000 -100 °C..600 °C
14 0..10 V
15 0..20 mA
16 4..20 mA
17 0..60 mV
18 Potenziometer (set the value on parameter 5)
2 Degree
0 °C Centigrade (Default)
1 °F Fahrenheit
2 °K Kelvin

User manual - PLE500-8AD - 17
3 Lower Linear Input
Range AN1 lower limit only for linear input. Ex: with input 4..20 mA this parameter takes value
associated to 4 mA.
-32767..+32767, Default: 0.
4 Upper Linear Input
Range AN1 upper limit only for linear input. Ex: with input 4..20 mA this parameter takes value
associated to 20 mA.
-32767. .+32767. Default:10000
5 Potentiometer Value
Select potentiometer value
1..150 kohm. Default: 10kohm
6 Linear Input over Limits
If linear input, allows process to go over limits (Par. 3 and 4).
0 Disabled (Default)
1 Enabled
7 Offset Calibration
Value added / subtracted to the process visualization (usually correcting the value of
environmental temperature).
-10000..+10000 [digit1] (degrees.tenths for temperature sensors). Default 0.
8 Gain Calibration
Percentage value that is multiplied for the process value (allows to calibrated the working point).
Ex: to correct the range from 0..1000°C showing 0..1010°C, set the par. to -1.0.
-1000 (100.0%)...+1000 (+100.0%), Default: 0.0.
9 Latch-On
Automatic setting of limits for linear inputs and potentiometers.
0 Disabled (Default)
1 Standard
2 Virtual zero
3 Linear virtual zero
10 Filter
Analogue input reading filter: increases process stability.
1...50. (Default: 1)
11÷15 Reserved Parameters - Group A
Reserved parameters - Group A

18 - PLE500-8AD - User manual
GROUP B OUTPUT AND REGULATION
16 Command Output
Command output type selection
0 Command Q1; Alarm 1 Q2; Alarm 2 AO (0..20 mA). (Default)
1 Command Q1; Alarm 1 Q2; Alarm 2 AO (4..20 mA).
2 Valve command: Q1 (open) - Q2 (close); Alarm 1 AO (0..20 mA)
3 Valve command: Q1 (open) - Q2 (close); Alarm 1 AO (4..20 mA)
4 Command AO (0...20 mA); Alarm 1 Q1; Allarme 2 Q2.
5 Command AO (4...20 mA); Alarm 1 Q1; Allarme 2 Q2.
Command Alarm 1 Alarm 2
0Q1 Q2 AO (0..20 mA)
1Q1 Q2 AO (4..20 mA)
2Q1(open),Q2(close) AO (0..20 mA) -
3Q1(open),Q2(close) AO (4..20 mA) -
4 AO (0..20 mA) Q1 Q2
5 AO (4..20 mA) Q1 Q2
17 Initial State
Selects controller status at starting.
0 Start (Default)
1 Stop
2 Stored. Backs the controller to the Start/Stop status existing before the switching-off.
18 Action type
0 Heating (N.O.) (Default)
1 Cooling (N.C.)
19 Command Hysteresis
Hysteresis in ON/OFF
-10000..+10000 [digit] (degrees.tenths for temperature sensors). Default 2.
20 Command State Error
State of contact for command output in case of error.
0 0 mA if command on AO. Open contact if command on Q1. Open valve if valve
command. (Default)
1 4 mA if command on AO. Closed contact if command on Q1. Closed valve if valve
command.
2 20 mA if command on AO. Open contact if command on Q1. Open valve if valve
command.
3 21.5 mA if command on AO. Closed contact if command on Q1. Closed valve if valve
command.
21 Command State Stop
State of contact for command output with controller in STOP
0 0 mA if command on AO. Open contact if command on Q1. Open valve if valve
command. (Default)
1 4 mA if command on AO. Closed contact if command on Q1. Closed valve if valve
command.
2 20 mA if command on AO. Open contact if command on Q1. Open valve if valve
command.
3 21.5 mA if command on AO. Closed contact if command on Q1. Closed valve if valve
command.

User manual - PLE500-8AD - 19
22 Command Reset
Type of reset for state of command contact (always automatic in P.I.D. functioning)
0 Automatic reset (Default)
1 Manual reset (see par. 10.10)
2 Manual reset stored (keeps relay status also after an eventual power failure)
23 Command Delay
Command delay (only in ON / OFF functioning).
-3600..+3600 seconds. Default: 0.
Negative: delay in switching off phase.
Positive: delay in activation phase.
24 Valve Time
Valve time.
1...300 seconds. Default: 60.
25 Automatic / Manual
Enable automatic / manual selection.
0 Disabled (Default)
1 Enabled
2 Enabled with memory
26÷30 Reserved Parameters - Group B
Reserved parameters - Group B

20 - PLE500-8AD - User manual
GROUP C AUTOTUNING AND P.I.D.
31 Tune
Autotuning type selection.
0 Disabled. (Default)
1 Automatic. Calculation of P.I.D. parameters at starting and at command setpoint
modification.
2 Manual (P.I.D. with automatic parameters calculation by
“Autotuning state” on Outputs
schedule)
3 Once (P.I.D. with parameters calculation only once at starting)
4 Synchronized.
32 Setpoint Deviation Tune
Selects deviation from command setpoint as threshold used by manual tuning to calculate P.I.D.
parameters.
0-10000 [digit] (
degrees.tenths for temperature sensors ). Default: 300.
33 Proportional Band
Process inertia in units
0 ON / OFF if also t.i . is equal to 0. (Default)
1...10000 [digit] (
degrees.tenths for temperature sensors ).
34 Integral Time
Process inertia in seconds.
0 (0.0s)...20000 (2000.0s) tenths of second (0 = Integral action disabled), Default 0
35 Derivative Time
NDerivative time. Normally ¼ of integral time.
0(0.0s)...10000(1000.0s) tenths of second (0 = Derivative action disabled), Default 0
36 Dead Band
Dead Band.
0...10000 [digit] (
degrees.tenths for temperature sensors ) (Default: 0)
37 Proportional Band Centered
Defines if the proportional band has to be centered on setpoint. In double loop functioning
(heating/cooling) is always disabled.
0 Disabled. Band under (heating) or over (cooling) (Default)
1 Centered band
38 Off Over Setpoint
In P.I.D. functioning enables the command outoput switching off, when passing a specific
threshold (setpoint + Par.37).
0 Disabled. (Default)
1 Enabled
39 Off Deviation Threshold
Selects command setpoint deviation to calculate the intervention threshold of
“Off Over Setpoint”
function.
-10000...+10000 [digit] (degrees.tenths for temperature sensors) (Default: 0)
40 Cycle Time
Cycle time (for PID on teleruptor 15s ; for PID on SSR 2s.)
1-300 seconds (Default:15s)