Yudian AI-519 Technical manual

Yudian (H.K.) Automation Technology Co. Ltd.
Website: http://www.yudian.us http://www.yudian.com.hk
Email: [email protected]
Tel: [phone] Fax: [phone]
AI-519 ARTIFICIAL INTELLIGENCE INDUSTRIAL CONTROLLER
Operation Instruction
Ver. 8.2
(Applicable for accurate controls of temperature, pressure, flow, level, humidity etc.)
CONTENTS
1. SUMMARY...............................................................................................................................................................1
1.1 MAIN FEATURES 1
1.2 ORDERING CODE DEFINITION 1
1.3 TECHNICAL SPECIFICATION 4
1.4 REAR TERMINAL LAYOUT AND WIRING 6
2. DISPLAYS AND OPERATIONS ..........................................................................................................................10
2.1 FRONT PANEL DESCRIPTION 10
2.2 D7/E7 RAIL MOUNT PANEL DESCRIPTION 10
2.3 PARAMETER SETTING FLOW CHART 11
2.4 OPERATION DESCRIPTION 11
3. PARAMETERS AND SETTINGS........................................................................................................................12
3.1 PARAMETER LOCK (LOC)AND FIELD PARAMETERS 12
3.2 COMPLETE PARAMETER TABLE 13

Yudian (H.K.) Automation Technology Co. Ltd.
Website: http://www.yudian.us http://www.yudian.com.hk
Email: [email protected]
Tel: [phone] Fax: [phone]
1. SUMMARY
1.1 Main Features
●Universal thermocouples and selectable RTDs and linear current/voltage signals. Integrating non-linear graduation
tables, digital calibration and auto zero technology to achieve accurate and stable measurement.
●Advanced artificial intelligence (AI) control algorithm with auto tuning function without overshooting.
●Auto/manual bumpless switch and soft-start function.
●New generation X3 and X5 current output modules with accuracy 0.2%F.S., improving the precision of control and
retransmission.
●Advanced modular structure giving plenty of output options to satisfy all kinds of applications. Quick delivery and
easy maintenance.
●User-friendly and customized operating interface for easy learning and simple manipulation. All parameters can be
promoted to quick operator access in Field Parameter Table or kept in password protected Full Parameter Table.
●Worldwide power supply of 100-240VAC or 24VDC and various dimensions. Power frequency 50Hz or 60Hz and unit
of ℃/ ℉are selectable in parameter.
●High quality hardware design, using high performance tantalum capacitor or ceramic capacitor. Compared to
competing models, it consumes less electricity, experiences less temperature shifting, provides higher stability and
reliability, and can work in a wider range of temperature.
●ISO9001 and CE certified, achieving world class level of quality, anti-interference ability and safety.
POINTS TO NOTE
●Always adjust parameters according to input / output type and function. Only correctly wired instruments with
appropriate parameters shall be put into use.
1.2 Ordering Code Definition
AI series instruments adopt advanced modularized hardware design. There are maximum five module slots:
multi-function input/output (MIO), main output (OUTP), alarm (ALM), auxiliary output (AUX) and communication (COMM).
The modules can be purchased in bundle with instrument or separately, and can be installed easily. The input type can be
freely set to thermocouple, RTD, or linear current/voltage.
The ordering code of AI-519 series instrument is made up of 8 parts. For example:
AI-519 A N X3 L5 N S4 —24VDC
①②③④⑤⑥⑦⑧
It implies that the model is AI-519, front panel dimension is 96×96mm, no module installed in MIO (Multi-function I/O) slot,
X3 linear current output module installed in OUTP (main output), L5 (dual relay contact output module) in ALM (alarm), no
module installed in AUX (auxiliary output), RS485 communication interface with photoelectric isolation is installed. The
power supply of the instrument is 24VDC.
Order code in details:
①Model of the instrument
AI-519 economical type instrument with measurement accuracy 0.3%F.S. It adopts artificial intelligent control
technology, with functions of auto/manual bumpless switch.
②Front panel dimension
Afront panel 96×96mm(width×height), cut out 92+0.5×92+0.5mm, depth behind mounting surface 100mm.
A2 On top of A, there is additional light bar with 25 segments and 4 levels of luminosity.

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Bfront panel 160×80mm(width×height), cut out 152+0.5×76+0.5mm, depth behind mounting surface 100mm.
Cfront panel 80×160mm(width×height), cut out 76+0.5×152+0.5mm, depth behind mounting surface 100mm.
C3 On top of C, there is additional light bar with 50 segments and 2 levels of luminosity.
Dfront panel 72×72mm(width×height), cut out 68+0.5×68+0.5mm, depth behind mounting surface 95mm
D2 front panel 48×48mm(width×height), cut out 45+0.5×45+0.5mm, depth behind mounting surface 95mm, with 10
terminals
D5 width 22.5mm, DIN-Rail mount, external keypad E8 (or communication if address/BAUD rate is correct)
required for display and parameter setting
D6 front panel 48×48mm(width×height), cut out 45+0.5×45+0.5mm, depth behind mounting surface 95mm, with 12
terminals
Efront panel 48×96mm(width×height), cut out 45+0.5×92+0.5mm, depth behind mounting surface 100mm
E2 On top of E, there is additional light bar with 25 segments and 4 levels of luminosity.
E5 48×96mm(width×height), DIN-Rail mount, external keypad E8 (or communication if address/BAUD rate is
correct)) required for display and parameter setting
Ffront panel 96×48mm(width×height), cut out 92+0.5×45+0.5mm, depth behind mounting surface 100mm
③Module type of multiple function I/O (MIO). N means none, no module installed.
I2 Single channel on-off signal input module. When a n external switch is connected, SV=SP1 When the switch is
open; SV=SP2 when the switch is closed.
I4 4~20mA/0~20mA analogue input module, with 24VDC power supply. Directly connecting to 2-wire transmitter.
V24/V12/V10 Isolated 24V/12V/10V DC voltage output module with maximum current of 50mA, supplying power
for external transmitter.
④Module type of main output (OUTP). For control output or SV/PV retransmission.
L1 Large capacity, large size, normal open relay output module (Capacity: 250VAC/2A)
L2 Small capacity, small size, normal open + normal close relay output module (Capacity: 250VAC/1A
recommended for alarm)
L4 Large capacity, small size, normal open + normal close relay output module (Capacity: 250VAC/2A)
K1 “Burnt-proof”single-phase thyristor zero crossing trigger output module, triggering one loop of a TRIAC or a pair
of inverse parallel SCR with current of 5~500A.
K3 “Burnt-proof”three-phase thyristor zero crossing trigger output module, triggering 3-phase circuit. Each loop
can trigger TRIAC or a pair of inverse parallel SCR with current of 5~500A.
K5 “Burnt-proof”single-phase thyristor phase-shift trigger output module, suitable for 200～240VAC power grid.
K6 “Burnt-proof”single-phase thyristor phase-shift trigger output module, suitable for non-standard power
environment below 380VAC.
X3 Photo-electric isolated linear current output module, 0~20mA or 4~20mA, occupying internal 12VDC power.
X5 Photo-electric isolated linear current output module, 0~20mA or 4-20mA. Equipped with isolated power supply
without occupying internal 12VDC power.
W1 TRIAC no contact normal open discrete output module (Capacity: 100~240VAC/0.2A, burnt-proof)
W2 TRIAC no contact normal closed discrete output module (Capacity: 100~240VAC/0.2A, burnt -proof)
GSolid-state relay, SSR voltage output module (DC12VDC/30mA)
⑤Module type of alarm (ALM). For AL1 and AL2 alarm outputs.
L0 Large capacity, large size, normal open relay output module (Capacity: 250VAC/2A, recommended for alarm)
L0/L2/L4 Single relay output alarm, support AL1 one channel alarm
L3 Dual normal open relay output module, support AL1 and AL2 alarm
⑥Module type of auxiliary output (AUX). For AU1 and AU2 alarms and control auxiliary output.
L0/L1/L2/L4 Single relay output alarm
L3 Dual normal open relay output module, supportAL1 andAL2 alarm

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GSolid-state relay, SSR voltage output module (DC12VDC/30mA)
W1 TRIAC no contact normal open discrete output module (Capacity: 100~240VAC/0.2A, burnt-proof)
W2 TRIAC no contact normal closed discrete output module (Capacity: 100~240VAC/0.2A, burnt -proof)
R RS232 communication interface module, occupying internal 12VDC power.
⑦shows the module type of communication (COMM).
SRS485 photo-electric isolated communication interface module, occupying internal 12VDC power.
S1 RS485 photo-electric isolated communication interface module, occupying internal 24VDC power.
S4 RS485 photo-electric isolated communication interface module, with isolated DC/DC power convertor, without
drawing power from instrument internally.
SL RS485 photo-electric isolated communication interface module + single channel normal open relay output module,
occupying internal 12VDC power.(Only available for D6 panel size)
⑧Power supply of the instrument. If left blank, the power of the instrument is 100-240VAC. 24VDC means the
power supply of 20~32VDC or AC power (24V AC power has to be specified upon order).
POINTS TO NOTE
1. K3 module occupies two slots, OUTP and MIO. MIO cannot be used if K3 is installed. If setpoint switching feature is
required, put I2 module in COMM slot. Then set parameter bAud to 1. Two setpoints switching function can be used
in COMM instead of MIO.
2. The voltage output modules like V24, \/10 or V12 are often used for supplying power for external transducer
or feedback resistance of transmitter. These modules can be installed in any slot except that of D6 dimension
instrument. To standardize the wiring, it is recommended to be installed in the first idle slot in the order of
MIO, AUX, and COMM.
Installation and replacement of modules: Before the instrument delivery, module installation is done on request,
with corresponding parameter set correctly. Users can replace or install modules by themselves when
needed. When replacing a module, you should pull the controller out of the housing at first, insert a
small flat-tip screwdriver into the opening between the original module and the slot on motherboard to
remove the old module, and then install a new module. Changing module type needs to modify the
corresponding parameters.
Electric isolation of the modules: There are a group of 24V and a group 12V power supply built in the instrument
and isolated to the main circuit. The 24V power commonly supplies voltage output module, such as
V24/V12/V10 (24V/12V/10V voltage output module), I2 (on-off signal input module) and I4 (linear current
input module). The 12V power is commonly supplies output or communication module. Generally, the
relay contact output and TRIAC no contact discrete output are self-insulated from the other circuit, no
matter whether other modules are installed or not. SSR voltage output does not need to be insulated
from input circuit, because SSR itself has isolation function. Therefore, only the electric isolation
between the communication interface and the current output should be considered. Those modules, for
example, S (RS485 communication interface), R (RS232 communication interface) and X3 (linear current
output), all need the 12V power supply. If more than one of the above modules are installed, in order to
be electric isolated, only one of them can be module without electric isolation, the other modules should
be S4 or X4, which has its own isolated power supply. For example, if an X module is installed in OUTP
(main output) slot, and an S or X module is installed in COMM (communication interface) slot, then OUTP
and COMM cannot be electric isolated, so S or X should be replaced with S4 or X4.
No contact switch module: W1 and W2 are new types of no contact switch modules which apply the advanced
technology of “burn proof” and zero crossing conduction. It can replace the relay contact switc h.
Compared to the relay contact output module, W1 and W2 have longer life and lower interference. They

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can largely decrease the interference spark of the equipment, and greatly improve the stability and
reliability of the system. Since the driver element is TRIAC, it is suitable for controlling 100-240VAC (not
for DC power) with current up to 80A. For the current larger than 80A, an intermediate relay is needed.
Protection elements are series wound to the output terminals, so it can control continuous current up to
0.2A with maximum allowed instantaneous current 2A.
Relay Module: The relay modules are widely used in industrial control. However, they are the only modules with
life time limit and volume limit and have much electromagnetic interference. There are four types of
relay modules: L1, L2, L3 and L4. For control output, L1 or L4 large capacity module is recommended.
L4 is equipped with high performance relay with small volume and large capacity but it costs higher. L2
module is small in size. Both of its normal open and normal close terminals have varistor spark absorption
but the capacity is small. It is suitable for alarm output. L1 and L are large in size and large capacity.
For those panel size with 48mm width (including D6, E, F and etc). large size modules cannot be installed
in both PCB board. L3 provides dual output to support two loops of alarm, for example, AL1+AL2. If
mechanical switch is not preferred or L3 is not allowed due to size limitation mentioned above, G5 (dual
SSR DC voltage output) with external SSR can be chosen.
Calibration: The instrument applies the technology of automatic zero and digital calibration, and is free of
maintenance. If the error exceeds certain range, generally, cleaning and drying the inside of the
instrument can fix it. If not, send the instrument back to the factory to examine and repair.
Warranty and maintenance: Free repair and maintenance will be given in specified period of time since the
delivery. In order to get full and correct repair, please state clear the phenomena and causes of the
malfunction of the instrument.
1.3 Technical Specification
Input type: (universal input)
Thermocouple: K, S, R, E, J, T, B, N, WRe3-WRe25, WRe5-WRe26 etc
Resistance temperature detector: Cu50, Pt100
Linear voltage: 0～5V, 1～5V, 0～1V, 0～100mV, 0～20mV, 0~500mV etc
Linear current (I4 module in MIO): 0～20mA, 4～20mA, two-wire transmitter etc.
Extended input: By keeping all native input specification, another extra specification can be ordered (gradient table
may be required).
Measurement range
K(-50～+1300℃), S(-50～+1700℃), R(-50～+1700℃), T(-200～+350℃), E(0～800℃), J(0～1000℃),B(200～
1800℃), N(0～1300℃)
Cu50(-50～+150℃), Pt100(-200～+800℃)
Linear Input: -9990～+32000 units defined by user.
Measurement accuracy : 0.3 (0.3%FS ± 0.1℃)
Resolution : 0.1℃for K, E, J, N, Cu50, Pt100; 1℃for S, R
Temperature shift : ≤0.015%FS /℃(typical value is 70ppm/℃)
Sampling cycle : A/D converter sampling 8 times per second
Response time : ≤1s ( when digital filter parameter FILt=1)
Alarm function: Four different alarm type, high limit, low limit, deviation high limit and deviation low limit, optional
with alarm blocking at the beginning of power on.
Control mode:
On-off control mode (Hysteresis adjustable)
Standard PID with auto tuning

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AI PID with auto tuning, adoptingAI artificial intelligence algorithm.
Control Period : 0.5～120.0 seconds selectable at interval of 0.5 seconds
Output mode (modularized)
Relay contact output (NO+NC, L1 or L4 module): 250VAC/2A or 30VDC/1A
TRIAC no contact discrete output (NO or NC): 100～240VAC/0.2A (continuous), 2A (20mS instantaneous, repeat
period≥5s)
SSR voltage output: 12VDC/30mA (used to drive SSR).
Thyristor zero crossing trigger output: trigger TRIAC of 5～500A, a pair of inverse paralleled SCRs or SCR power
module.
Linear current output: 0～20mA or 4～20mA (Output voltage ≥11V, maximum load resistance 500ohm, output
precision 0.2%FS)
Electromagnetic compatibility (EMC) : ±4KV/5KHz according to IEC61000-4-4; 4KV according to IEC61000-4-5.
Isolation withstanding voltage : between power, relay contact or signal terminal ≥2300VDC; between isolated
electroweak terminals ≥600VDC
Power Supply : 100～240VAC, -15%, +10% / 50-60Hz; 120～240VDC; or 24VDC/AC, -15%, +10%.
Power consumption: ≤6W
Operating Ambient : temperature -10～60℃; humidity ≤90%RH
Front panel dimension: 96×96mm, 160×80mm, 80×160mm, 48×96mm, 96×48mm, 48×48mm, 72×72mm
Panel cutout dimension: 92×92mm, 152×76mm, 76×152mm, 45×92mm, 92×45mm, 45×45mm, 68×68mm
Depth behind mounting surface: ≤100mm

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
1.4 Rear Terminal Layout and Wiring
Wiring diagram at back side
1: For linear voltage input, if the range is
below 500mV, connect to terminals 19 and
18. 0～5V or 1～5V signal can be input
from terminals 17 and 18.
2: 4～20mA signal can be converted to 1～
5V signal by a 250 ohm resistor and input
from terminals 17 and 18. If I4 module is
installed in MIO slot, 4～20mA signal can
be input from terminals 14+ and 15- and
2-wire transmitter can be input from
terminals 16+ and 14-.
3: The compensation wires for different
kinds of thermocouple are different, and
should be directly connect to the terminals.
When the internal auto compensation
mode is used, connecting the common wire between the compensation wire and the terminals will cause measurement
error.
4: Main output from terminals 13+ 11- as current output, single channel SSR voltage output.
Wiring diagram of D size instruments (72×72mm)
1: Linear voltage signal of range below 500mV input from
terminals 13 and 12. 0～5V and 1～5V input from terminals 11
and 12.
2: 4～20mA linear current signal can be converted to 1～5V
voltage signal by connecting a 250 ohm resistor and input from
terminals 11 and 12.
3: S, S1 or S4 module can be installed in COMM slot for
communication. If relay, TRIAC no contact switch, or SSR
driver voltage output module is installed in COMM, it can be
used as AL1 alarm output. If I2 module is installed in COMM
and parameter “bAud” set to 1, then on-off signal in MIO is simulated. Setpoints SV1 and SV2 can be switched by
connecting an external mechanical switch at terminals 3 and 4.
Note: This graph is for upright
instruments with dimension A, C
or E.
For instruments with dimension
B and F, just clockwise rotate
the graph 90 degree and the
terminal numbers keep the
same.
AU1
M2/MIO
AUX
ALM
COMM
AL2
1
2
3
4
5
6
7
8
9
10
11
12
15
16
17
18
19
20
13
14
AL1
AU2
COM
COM
N/O
N/C
N/O
N/O
+
+
A
B
+
100-240VAC~
+
+
OUTP
COM
COM
N/O
N/C
N/O
N/O
COM
COM
N/O
N/O
N/O
N/C
+
+
OP2
OP1
+
0-5V
1-5V
G1
G2
G1
G2
G1
G2
Thyristor trigger output（K1/K3）
Thyristor trigger output（K3）
Thyristor trigger output（K3）
+
COM
N/C
V+
N/O
+
+
+
RXD
GND
TXD
AU1
AUX
COMM/AL1
1
2
3
4
5
6
7
8
9
11
12
13
14
10
AU2
COM
COM
N/O
N/C
N/O
N/O
+
+
A
B
+
100-240VAC~
+
+
OUTP
COM
COM
N/O
N/C
N/O
N/O
OP2
OP1
+
0-5V
1-5V
G1
G2
Thyristor trigger output（K1）
COM
N/O
+
TXD
RXD
GND

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Wiring diagram of D2 size instruments (48×48mm)
1: D2 size instruments don not support native 0～
5V or 1～5V linear voltage input. The workaround
is done by voltage divider into 0～500mV or 100～
500mV. External precise resistor 25ohm can be
parallel shunt to convert 4～20mA to 100～500mV
then input from terminals 9 and 8.
2: For COMM/AUX slot,
installing S or S4 communication module provides
communication, installing L2 module provides AU1
alarm output,
installing L2 module provides AU1 alarm output,
installing L3 dual relay module (with parameter bAud=0) provides AU1 and AU2 alarm output,
installing L3 (with parameter bAud=2) provides AU1 and AL1 alarm output,
installing I2 module (with parameter bAud=1) provides MIO on-off input simulation SP1/SP2. The external switch should
be connected to terminal 3 and 5.
Wiring diagram of D6 size instruments (48×48mm)
1: Linear voltage of 500mV below input from
terminal 10, 11. 0～5V or 1～5V linear voltage
input from terminal 9 and 10.
2: External precise resistor 250ohm can be
parallel shunt to convert 4～20mA to 1～5V
then input from terminals 9 and 10.
3: For COMM/AUX slot, installing S or S4
communication module provides
communication,
installing L2 module provides AU1 alarm
output,
installing L3 dual relay module (with parameter
bAud=0) provides AU1 and AU2 alarm output,
installing SL module provides RS485 communication andAU1 alarm output.
1
2
3
4
5
6
7
9
10
8
COM
N/O
+
100-240VAC~
AU1
COMM/AUX
AU2
A
B
COM
COM
N/O
N/C
N/O
N/O
+
G1
G2
Thyristor trigger output（K1）
OUTP
TXD
RXD
GND
Thyristor trigger output (K1)

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Wiring diagram of D5 size instruments
1: D5 size instrument are fixed with one channel alarm and communication.
2: Main output can be selected among G, X5, L2, K1, K5, K6 or W1.
Wiring diagram of D7 size instruments (22.5 x 100mm)
1: Input
0~5V/1~5V input from 12+, 11-
500mV below input from 10+, 11-
4~20mA with 250ohm shunt resistor converted to 1~5V,
input from 12+, 11-
2: Fixed with one channel alarm and communication
3: Main output can be selected among G, X3, L2, K1, K5, K6
or W1. Alarm is mandatorily defined as AU1
4: Instrument power and communication wires are
connected to the back side connectors along the rail.

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Wiring diagram of E7 size instruments (22.5 x 100mm)
1: Input
0~5V/1~5V input from 12+, 11-
500mV below input from 10+, 11-
4~20mA with 250ohm shunt resistor converted to 1~5V, input from 12+, 11-
2: Fixed with one channel alarm and communication
3: Main output can be selected among G, X3, L2, K1, K5, K6 or W1. Alarm is
mandatorily defined as AU1
Thyristor trigger output wiring diagram (applicable for K1, K3, K5 or K6 module)
Load
Thyristor trigger output
100~240VAC
IN4001
1N4001
Load
Thyristor trigger output
SCR X2
5~500A
BX
BX
Capacitor Resistor
Absorber Circuit
Varistor
G1
G2
G1
G2
ZNR
ZNR
V
V
100~240VAC
TRIAC
5~500A
Capacitor Resistor
Absorber Circuit
Varistor
SCR Power Module
1: According to the voltage and current of load, choose suitable varistor to prevent the thyristor. Capacitor resistor
absorber is needed for inductance load or phase-shift trigger output.
2: SCR power module is recommended. A power module includes two SCRs, is similar to the above dashed square.
3: K5 phase-shift trigger module is only suitable for 200～240VAC / 50Hz power. K6 phase-shift trigger module is only for
380VAC below non-standard environment.