Instruction Manual

(For microprocessor controller)

INDFURR SUPERHEAT FURNACES

179, MOUNT POONAMALLE ROAD, PORUR, CHENNAI 600 116
Visit us : www.indfurr.com Contact us: indfurr@indfurr.com

Content
1.Front panel instruction......P1 2.Operation flow.....P2 3.Operation instruction..P6 4.Programming....P7 5.Error information..... P10 6.Input selection table...... P11 7.Alarm selection table........ P13 8.External wiring diagram......... P15

1.Front Panel Instruction :

MC-2438

3-8

9-12

1-1 Panel Function : 1.PV: process volume and mode display 4 digital red LED 2.SV: setting volume 4 digital green LED 3.OUT1:output 1 (heating) green LED 4.OUT2: output 2 (cooling) green LED 5.AT: auto-tuning yellow LED 6.AL1: alarm 1 red LED 7.AL2: alarm 2 red LED 8.PRO: program yellow LED 9.SET: mode & set key 10. : shift key 11. : down key 12. : up key
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2.Operation Flow :
Level 1 (User level)
Operating state display

Parameter Display Code

OUTL AT AL1

Name
Output

Description
Range of setting:0~100%

Initial Value setting at factory

Press the

Key

percentage Yes/No Auto tuning to be used when setting PID constant by auto-tuning Alarm1 Alarm 2 Alarm 3 Range of setting:0~100%FS Range of setting:0~100%FS Range of setting:0~100%FS

100 No 0.0 0.0 0.0

Press the

Key

AL2
Repeat the same steps as above to display the parameters listed at right.

AL3

Level 2 (PID level)

Parameter Display Code
P1 I1
Operating state display

Name
Main Control Proportional Band Main Control Integral Time Main Control Derivative Time Main Control Dead-band Time Main Control Auto tuning off-set Main Control Proportional Cycle Main Control Hystersis Sub Control Proportional Band Sub Control Integral Time Sub Control Derivative Time Sub Control Proportional Cycle Sub Control Hystersis Main Control Gap (Output 1) Sub Control Gap (Output 2)

Description
Range of setting:0~200% ON/OFF at P=0 Range of setting: 0~3600 Sec Integral off at I=0 Range of setting: 0~900 Sec Derivative off at D=0 Dead-band compensation Range of setting:0~1000 Sec Range of setting :0~USPL When output is SSR, it is set at 1, 4~20mA is set at 0. but output is relay usually it is set at 10. Range of setting:0~150 Sec For ON/OFF control only Range of setting :0~1000 Range of setting:0~200% ON/OFF at P=0 Range of setting: 0~3600 Sec Integral off at I=0 Range of setting: 0~900 Sec Derivative off at D=0 When output is SSR, it is set at 1, 4~20mA is set at 0. but output is relay usually it is set at 10. Range of setting:0~150 Sec For ON/OFF control only Range of setting :0~1000 For 2 output use only Set the volume which will turn OFF early to SV For 2 output use only Set the volume which will turn ON late to SV
LCK = 0101, it cant change any parameter except LCK. LCK = 0001, it can enter level 1 only and change SV only. LCK = 0110, it can enter 1 & 2 and change level 1 parameters only. LCK = 0100, it can enter 1 & 2 and change their parameters. LCK = 0000, it can enter level 1. LCK = 1111, it can enter level 4.

Initial Value setting at factory

3 240 60 100 0 10 0 3 240 60 10 0 0 0

D1 DB1 ATVL CYT1 HYS1 P2

By Pressing the

Key for 5 seconds to level 2

Press the

Key

Repeat the same steps as above to display the parameters listed at right.

I2 D2 CYT2 HYS2 GAP1 GAP2

LCK 2

Function Lock

0000

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Level 3(Input level)

Parameter Display Code
INP1 Operating state display ANL1 ANH1
By Pressing the key and Key for 5 seconds to level 3

Name
Main input selection Main analog zero set Main analog span set Decimal point Lower set point limit Upper set point limit Second input analog zero set Second input analog span set Alarm mode of AL1 Alarm 1 time set Alarm mode of AL2 Alarm 2 time set Alarm mode of AL3 Alarm 3 time set Hystersis of alarm Output1 zero set Output1 span set Output2 zero set Output2 span set Transmitter zero set Transmitter span set Timer of motor
Use in program for waiting Continued operation

Description
Select the input range, refer to input selection It is used for calibration as main input code are ANI to AN5 Range of setting: LSPL-USPL Same as ANL1 Set the position of decimal point Set lowest point within INP1 Set highest point within INP1 It is used for calibration as second input code are ANI to AN5 Range of setting: LSPL-USPL Same as ANL2 Range of setting:00~19
It is used in program function Range:00~99.59min. 0= flicker alarm. 99.59=continued alarm, others=on delay time

Initial Value setting at factory K2 0 5000 000.0 0.0 400.0 0 5000 11 99.59 0 99.59 0 99.59 0.0 186 3200 186 3200 0 5000 5 0.0 0000 1 2400 0.0 0.0 0.200 0.0 HEAT PID 60HZ

DP LSPL USPL ANL2

Press the

Key

ANH2 ALD1 ALT1 ALD2

Range of setting:00~19
It is used in program function Range:00~99.59min. 0= flicker alarm. 99.59=continued alarm, others=on delay time

Press the

Key

ALT2 ALD3 ALT3 HYSA

Range of setting:00~19
It is used in program function Range:00~99.59min. 0= flicker alarm. 99.59=continued alarm, others=on delay time

Range of setting:00-1000 Calibrate the low value of output1 Range of setting: LSPL-USPL(current output only) Calibrate the high value of output1 Range of setting: 0-9999(current output only) Calibrate the low value of output2 Range of setting: LSPL-USPL(current output only) Calibrate the high value of output2 Range of setting: 0-9999(current output only) Calibrate the low value of transmitter Range of setting: LSPL-USPL(current output only) Calibrate the high value of transmitter Range of setting: 0-9999(current output only)
Full run time of proportional motor (without potentiometer) Range of setting:0~150 Sec

Press the

Key

CLO1 CHO1 CLO2 CHO2

Press the

Key

CLO3 CHO3 RUCY WAIT

0=No wait Other= Wait Volume

1 SET A.1: Reverse AL1 RY if SET 1 2 SET A.2: Reverse AL2 RY if SET 1 3 SET A.3: Reverse AL3 RY if SET 1 1 2 3 used only if MC-2438 alarm needs b contact.) ( 4 . SETA.4=0 is program run alarm, SETA.4=1 is program end alarm 4 Programmable unit only.) (

Press the

Key

SETA ID.NO BAUD

Press the Key

Set function

ID number Band-rate Compensate SV Compensate PV Unit of PV & SV Soft filter Cluster control Action mode Control mode Power Frequency

Communication ID number UART band rate selection Range of setting: 110-9600 BIT/sec Range of setting: -1000~1000 Range of setting: LSPL~USPL Range of setting: C,F,A (analog) Adjust the response time of PV, the bigger the faster Range of setting: 0.05~1.00 dont care Range of setting: 0~1000 Range of setting: heater, cool Range of setting: PID, Fuzzy Range of setting: 50,60 Hz

SVOS PVOS Repeat the same steps as above to display the parameters listed at right. UNIT SOFT CASC OUD OPAD

HZ

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Level 4(Set level)

Operating state display

a. Example:
Press key to change SET 0-9

By Pressing the

Key for 5 seconds to level 2 and set "1111" in "LCK"

0=lock(skip) 1=open (display)

By Pressing the

key and

Key for 5 seconds to level 4

1 2 3 4

First digit Second digit Third digit Fourth digit

Repeat the same steps as above to display the parameters listed at below.

b. Function of set: Parameter Name digit Display Code 1 2 SET1 3 4 1 2 SET2 3

AL1 AL2 AL3 ANL1,ANH1,DP LSPL,USPL

Description
OUTL AT

Parameter Display Code

Name

digit 1 2

Description
CASC OUD OPAD HZ 0=No repeat 1=Program repeat 0=No power failure 1= with power failure 0=Start from 0 1=Start from PV
1=The controller will enter Single Display mode, the PV LED will not display any values. And the LED will display both parameter value and setting value alternately. Please dont operate SET8.4 otherwise the controllers process will be in confusion. 0=None 1=For PV/SV switch (use for single display so please dont set this bit) 0=None 1=It no display RAMP,but it is time change H.M to M.S in programmable unit. 0=None 1=Transmition SV. 0=None 1=Transmition PV.

SET7 3 4 1 2 SET8
Program use

ANL2,ANH2

1 SET3 2 3 4 1 2 SET4 3 4 1 SET5 2 3 4 1 2 SET6 3 4

ALD1

1 SET9
Transmitter

ALT1 ALD2 ALT2 ALD3 ALT3 use

2 3 4 1 2

0=Non 1=TTL communication SV Output 0 =RAMP 1=Rate of alarm3(ALD3=0) 0=Non 1=Remote SV 0=When motor valve closes b is on. 1= When motor valve closes a is on. Non 10~50mV/4~20mA except programmable unit 0~50mA/0~20mA except programmable unit

SET0
HYSA CL01,CH01 CL02,CH02 CL03,CH03

3 4 0 INP2 1 2
0 1 2 3 4 5

RUCY,WAIT,HYSM IDNO,BAUD SVOS PVOS

OUTY
UNIT SOFT

Single output Double output X Motor valve 1 SCR(single phase control) 3 SCR(three phase control)

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Program Level: (To be ordered)

Operating state display

Parameter Display Code

PTN

Name

Description

By Pressing the

Key once switching to the Level 1

SEG
Press the Key

TIMER SV-1
Press the Key

TM-1 OUT1
Press the Key

Set pattern 1 at first for 8 segments then set pattern 2 for other 8 segments, pattern 1 & pattern 2 can be Set Program performed separately or be linked to make total 16 pattern segments (steps). If it needs to link , set PTN to 0 after pattern 1 & 2 be set. Range of setting:0-2 Program segment Range of setting: (1-0)~(2-8) display Program timer Range time display display Set volume Range of setting: LSPL-USPL for Seg.1 Set time Range of setting: 0~99 hours 99 min for Seg.1 Set output Range:0~100% for Seg.1 Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100% Range of setting: LSPL-USPL Range of setting: 0~99 hours 99 min Range:0~100%

Press the

Key

Set volume for Seg.2 Set time TM-2 for Seg.2 OUT2 Set output for Seg.21 SV-2 Set volume for Seg.3 Set time TM-3 for Seg.3 OUT3 Set output for Seg.3 SV-3 Set volume for Seg.4 Set time TM-4 for Seg.4 OUT4 Set output for Seg.4 SV-4 Set volume for Seg.5 Set time for. TM-5 Seg.5 OUT5 Set output for Seg.5 SV-5 Set volume for Seg.6 Set time TM-6 for Seg.6 OUT6 Set output for Seg.6 SV-6 Set volume for Seg.7 Set time TM-7 for Seg.7 OUT7 Set output for Seg7. SV-7 Set volume for Seg.8 Set time TM-8 for Seg.8 OUT8 Set output for Seg.8 SV-8

Press the

Key

Press the

Key

Press the

Key

Press the

Key

Press the

Key

Press the

Key

Repeat the same steps as above to display the parameters listed at below.

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3.Operation instruction :
Turn on the power the controller will display as following to check the range

3-1 How to set SV (set value) , for example set at 250 Press

: again to

key the SV display will blink from the first digit, then press

move to the third digit... Press Press Press Press key to indicate 5 again to move to the fourth digit.. key to indicat2.. key to finish setting..

3-2 How to set OUTL : OUTL is to be set for output percentage, which is set in factory 100%. Normally this parameter doesnt need to change and is skipped. If the user wants to use, go to level 3(SET level) to change the lock code. OUTL cant be set 0, otherwise the controller will not have output. 3-3 How to set auto tuning (AT) : Press Press Press Press key to indicate. . key to make the digit blink . key to indicate . key to perform auto tuning,

In this case the AT LED on panel will be on and it will be off after auto tuning ends.

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In case of over shoot during auto tuning ATVL parameter in level 2 can be set to offset. For example. AVTL to be set 2, offset is 2 .

ON OFF

ON OFF

ON

ON OFF

ON OFF

ON

Fig1

Fig2

3-4 How to set alarm In user level (1st Level) , the user can press SET key to enter AL1(alarm 1) , AL2(alarm 2)& AL3(alarm 3). When you enter AL1 the display will show if you want to set it you may press key (then the digit will blink) , press key to finish setting. or to increase or decrease your target, and then press

There are 17 kinds of different alarm modes to be selected, the user can enter Input Level (level 3), and select ALD1, ALD2 & ALD3 to set it. For alarm modes please refer to alarm action description on page24.25.

4 Programming:
All models have an optional programming function as with 2 patterns, each of which contains 8 segments and can be linked with each other to16 segments. The segment can be arranged as ramp or soak; ramp is for changing SV with time while soak is for fixing SV with time. Please refer to Fig 10
( J ) 500
SV-1

400
SV-7 SV-8

300
SV-5 SV-6

200
SV-3

SV-4

100

SV-1 SV-2

0
30 Min 30 Min 20 Min 30 Min 20 Min 40 Min 30 Min 20 Min 30 Min

TM-1

TM-2

TM-3

TM-4

TM-5

TM-6

TM-7

TM-8

TM-1

Patter n 1

Patter n 2

Fig 10

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a. Key function: Press

Description

To start program procedure , PRO in panel will flicker. To suspend program procedure, PRO in panel will stop flicker but light. To jump segment. To reset program procedure, if push it in program running the program will return to start. b. alarm function: There are AL1, 2, 3 & ALD 1, 2, 3 to be set. For example: ALD1 to be set 07 (Please refer to alarm selection) AL1 to be set 2 (AL1 = 2. It means alarm while segment 2 ends) ALT1 to be set 00.10 (Alarm time 10 sec) In this case, when program proceeds to the ending of segment 2 , ALM1 relay will be on 10 sec. If ALT1 is to be set 99.59,the alarm relay will be on continuously, but if it is set 0, the alarm relay will be on flickering. c. Ending function: If ALD2 is set 17 (Please refer to alarm selection) and SET A.4 is set 1, this controller will turn off after the program performs 8 steps, or 16 steps if the two patterns are linked . After ending, PV and END will flicker in display window and the alarm will start, but if SET A.4is set 0 the alarm will be converted running alarm. If the program process is less than 8 or 16 steps, please set next segments OUT to 0, in this case, this program will end in the last segment being set, otherwise it will proceed 8 steps or 16 steps. d. Other function:

Program Repeat: set the parameter SET 8.1 to 1. Power Fail Protection: set the parameter SET 8.2 to 1. In this case if the power suspended, the controller will keep memory. It will continue performing program process after the power turns on again. If SET 8.2is set 0, it will perform program process from beginning. Program starts from PV: If the parameter SET8.3 is set 1, the program will start from PV. If it is set to 0, the program will

start from 0. Wait: There is WAIT parameter in Level 3 .The user can set it to 0 for no wait or set waiting temperature, for example, if set 3 the program will wait 3 to PV.
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4-1.Ramp & Soak:(Level 3) All our models can arrange a RAMP and SOAK (except program model) which dont need install any hardware, but need to change some parameters as following. a.

RAMP Please set SET2.1=1, SET4.1=1 at set level. ALD3=9 at input level (Level 3). AL3 will be display.

RAMP 0 0.0 0
b. SOAK

Range G 00.00 ~ 99.99 Unit G J / min (If RAMP not used A set ALD3=0)

ALD1 / ALD2=19. AL1 / AL2 will be display.

AL1 00.00
c. Example

To be used as soak
Range G 00.00 ~ 99.59(Hour.Minute)

SV=100RAMP=10.00 (/min)AL1=00.10 minPV=25

J Time on if PVSV(100J) Time up AL1 on

100J AL1 00.10 00.01 00.10 1sec. SV=SV+RAMP on delay time set time

PV=25J

SV=PV at start RAMP function

Fig 11
power on 5sec.

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5.Error information: Parameter Display Code Description

Open circuit of main control sensor A/D convector failed. Cold junction compensation failed. Open circuit of sub control sensor. PV exceeds USPL PV under LSPL Input signal of sub control exceeds the upper limit. Input signal of sub control under the upper limit. RAM failed. Interface failed. Auto tuning failed

NOTE : If the * marked error occurs, the Temperature Controller needs repair. Please send it to the nearest sales office or retail dealer.

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6.Input Selection table: TYPE CODE RANGE 0.0~200.0/0.0~392.0 0.0~400.0/0.0~752.0 0~600/0~1112 0~800/0~1472 0~1000/0~1832 0~1200/0~2192 0.0~200.0/0.0~392.0 0.0~400.0/0.0~752.0 0~600/0~1112 0~800/0~1472 0~1000/0~1832 0~1200.0/0~2192 0~1600/0~2912 0~1769/0~3216 0~1600/0~2912 0~1769/0~3216 0~1820/0~3308 0~800/0~1472 0~1000/0~1832 0~1200/0~2192 0~1300/0~2372 -199.9~400.0/-199.9~752.0 -199.9~200.0/-199.9~392.0 0.0~350.0/0.0~662.0 0~2000/0~3632 0~2320/0~2372 0~1300/0~2372 0~1390/0~2534 -199.9~600.0/-199.9~999.9 -199.9~200.0/-199.9~392.0 0.0~400.0/0.0~752.0 0~400/0~752 0~800/0~1472

R S B E N

W PL2

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TYPE

CODE

JIS Pt100

DIN Pt100

JIS Pt50

RANGE -199.9~600.0/-199.9~999.9 -199.9~400.0/-199.9~752.0 -199.9~200.0/-199.9~392.0 0~200/0~392 0~400/0~752 0~600/0~1112 -199.9~600.0/-199.9~999.9 -199.9~400.0/-199.9~752.0 -199.9~200.0/-199.9~392.0 0~200/0~392 0~400/0~752 0~600/0~1112 -199.9~600.0/-199.9~999.9 -199.9~400.0/-199.9~752.0 -199.9~200.0/-199.9~392.0 0~200/0~392 0~400/0~752 0~600/0~1112 -10~10mV/-1999~9999 0~10mV/-1999~9999 0~20mV/-1999~9999 0~50mV/-1999~9999 10~50mV/1999~9999

AN1 AN2 AN3 AN4 AN5

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7.Alarm Selection Table:

Code

DESCRIPTION
None Deviation high limit alarm Deviation high limit alarm Deviation low limit alarm Deviation low limit alarm Deviation high / low limit alarm Deviation high / low limit alarm Deviation high / low limit range alarm Absolute value high limit alarm Absolute value high limit alarm Absolute value low limit alarm Absolute value low limit alarm Segment end alarm (use for program model only) Program run alarm(use for program model only) System error alarm-on System error alarm-off On delay timer alarm
13

INHIBIT
YES NO YES NO YES NO NO YES NO YES NO -

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7-1 Alarm action description:

G SV Alarm set value G (inhibit means alarm doesn't work at the first time) 00 10 Non Deviation high alarm inhibit 01
OFF LOW ON HIGH

Absolute high alarm no inhibit 15

LOW OFF ON HIGH

Absolute low alarm inhibit 06

LOW ON OFF HIGH

Absolute low alarm no inhibit 16

LOW ON OFF HIGH

Deviation high alarm no inhibit 11

LOW OFF ON HIGH

Segment end alarm (use for Program Model only) (1) ALD1~3 A set 07 07 (2) AL1~3=alarm segment No.set (3) ALT1~3 if set 0=flicker alarm ALT1~3 if set 99.59=continued alarm ALT1~3 if set others=ON delay time
Program Run alarm(Refer to SETA.4 A P.23) (use for ProgramModel only)

Deviation low alarm inhibit 02

ON LOW OFF HIGH

Deviation low alarm no inhibit 12

ON LOW OFF HIGH

17

RUN ON

END OFF

High low alarm inhibit 03

ON LOW OFF ON HIGH

AL

System error alarm - ON 08

Normal OFF Error ON

High low alarm no inhibit 13

ON LOW OFF ON HIGH

AL

System error alarm - OFF 18

Normal ON Error OFF

Band alarm 04 14 OFF

LOW ON OFF HIGH

AL

09

Absolute high alarm inhibit 05

LOW OFF ON HIGH

On delay timer W hen PV=alarmSV A it keeps a 19 certain period(set time)before alarmaction. Range:00H.00M~99H.59M
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8.External Wiring Diagram: MC-2438

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