Certificate No: 368027

Measurement & Control Instruments

PID CONTROLLER model 2002

2002 controller features:
* Inputs:
- 4 Temperature Inputs - Pt100
* Outputs:
- 4 discrete outputs
* Indication:
- 4-digit red LED display for process value (PV)
- 4-digit green LED display for Set Variable (SV)
- 2-digit green display for symbols
- 7 LEDs
* Mounting:
- Dimensions - 96 x 96 x 135mm
- Panel mountable with panel cutout 92 x 92mm
* Power Supply 90 - 250V AC/DC

GENERAL INFORMATION
Each control relay could be configured for:
- PID control action
- ON/OFF control action
- alarm action
Alarm relay outputs:
The operator has to configure the following properties for those outputs:
1. Set-Point (SPx)
2. Hysteresis (HStx).
3. Type of the Alarm Limit (Lx) - Low or High
The way those relay outputs work is shown on Figure 1 and Figure 2.
PV High Alarm Level
Relay is ON
SPAL- set point
HiSt-hysteresis

time

Relay is OFF

Figure 1
When the Alarm relay is configured as High Limit:
- The relay is switched on when PVx > SPx
- The relay is switched off when PVx <= SPx - HStx
PVx - Process Variable for channel x
SPx - Set-Point for relay output x
HStx - Hysteresis for relay output x
Measurement & Control
Instruments

PV Low Alarm Level

Relay is OFF

HiSt-hysteresis

time

SPAL- set point

Relay is ON

Figure 2

When the Alarm relay is configured as Low Limit:

- The relay is ON when PVx < SPx
- The relay is OFF when PVx >= SPx + HStx
ON/OFF control:
The following parameters have to be set:
1. Set Point (SP)
2. Hysteresis (HSt)
3. Type of the limit level (Lx) - High or Low (Heating or Cooling)
The way the control relay commutates is shown on Figure 3 and Figure 4.

High Limit Level

PV
Relay is OFF
L- set point
h-hysteresis

time

Relay is ON

Figure 3
A typical application of a High Limit Level ON/OFF control action is the heating process control. When
the temperature is above the SP the relay output is not active and there is no heating. The heating
begins when the temperature falls below the SP minus hysteresis (SP - HSt).
PV

Low Limit Level

Relay is ON

h-hysteresis

time
L- set point

Relay is OFF

Figure 4
A typical application of a Low Limit Level ON/OFF control action is a temperature process controlled with
cooling. When the temperature is below the SP the cooling is OFF. When the PV (temperature) is above
SP plus hysteresis (SP + HSt) the relay output is activated and the cooling is started.
If the ON/OFF control action is not satisfactory enough PID control action could be used.
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Instruments

PID control:
The general logic of the action of the PID control is given by the expression:
t

1
dPVn

u(t ) = K en + e (s )ds + Td
Ti 0
dt

where:
e = SP-PVc
en=e/Range

dPVn
dt
K
Ti
Td
u

- The closed loop error; SP - Set Point, PV -Process Variable;

- Normalized error;
- Change of the normalized process variable (not normalized error);
-

Proportional Constant;
Integral Time (Ti);
Derivative Time (Td);
PID normalized output 0-1.0;

The following parameters have to be set:

- SP - Set Point
- K - Proportional Constant
- Ti - Integral Time
- Td - Derivative Time
Auto-Tune function
The operator can start a simple automatic identification of the process only when PID control is used (not
ON/OFF). The identification procedure is "relay feedback identification". An ON/OFF control action
around the SP is used to identify the process properties (ultimate gain, ultimate period), and than to calculate the optimal (if it is possible) PID parameters. The identification procedure is shown on the figure
below. The temperature process has to be without any load disturbances during the identification (i.e. the
temperature process has to be with constant parameters and under constant conditions).
The build-in method could be successful even when processes have a relatively long dead time.
The SP during the identification has to be as close as possible to the working Set-Point. After the parameters are calculated and saved the controller exits the auto-tune function and enters its basic display
mode. Indication for this is the switching off of the blinking "tu" caption on the 2-digit display.
The identification procedure can be stopped manually if there are undesirable effects.
o

tC

End Of Identification. Calculation

of the PID parameters
Set point
Controller
output

ON/OFF

PID

time

Figure 5
Influence of PID parameters to the controlled process:
Another way of writing down the equation that describes the PID action is:

u(t ) = K

SP PV
+I+D
Range

I - Integral Part
D - Differential Part
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Measurement & Control

Instruments

If the controller is calculating a control action that is either bigger than 1, or smaller than 0, any further
accumulation of the Integral Part is suspended, without so far accumulated Integral Part value to be
zeroed. The band where the output PWM is still not saturated is called Linear Control Band. If both the
Integral and Derivative Parts are zero, the Linear Band within the measured temperature range is given
with the following rules:
- When the temperature is above the Set-point SP, the controller output is 0 (0 % duty cycle, relay
switched off)
- When for the temperature PV applies

PV < SP

Range
K

the output becomes 1 (100% PWM duty cycle, relay switched on continuously).
The overall influence of the different equation parts is shown on the Figure 6. Here are simulated the transients upon the controller initial starting and particular system response to the same kind of load disturbances, when different PID action parameters are set.
18

20

K3

Ci1

K3>K2>K1

Ci1< C i 2<Ci 3

16

18

K2

16

K1

14

K2

12

K1

Ci2
Ci 3

14

Ci 1

12

10
10

K3

Ci 3

0
0

10

15

20

25

30

35

40

Time (Seconds)

0
0

Change of proportional gain K

10

15

20

25

30

Change of integral time Ti

18
Cd1

Cd1<Cd 2<Cd3

16
Cd2
14

Cd3

12
10
8
6
4
2
0
0

10

15

20

25

30

Change of derivative time Td

Figure 6
The above figures can be sumariezed as follows:

The output from the controller is PWM (Pulse With Modulation). The operator has to set the PWM cycle.
The logic of PWM is shown on figure below.
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Measurement & Control

Instruments

u(t)*Tcicle

Relay On

Relay Off
Tcicle

The time Tcycle can be set from the front panel in seconds. The time, in which the relay output is ON, is
calculating like u(t)*Tcycle where u(t) is the PID action output and is from 0 to 1 (or from 0% to 100%).
KEY OPERATIONS
Basic display mode:
When the controller is switched on the display enters its basic mode. The currently measured temperature (Process Variable) is shown on the upper 4 digit display. The assigned Set-Point is shown on the
lower 4 digit display. The reading on the display switches to the next channel every 2 seconds. The number of the currently active channel is visualized on the 2 digit display. The caption Err appears on the
upper display and LED FLT starts blinking when there is an error in the input circuit. No output action is
generated in this case.
LEDs A1, A2, A3 and A4 correspond to the relay outputs. When one of the relay outputs is ON (the normally open contact is closed) the corresponding LED is on.
The automatic scanning of the channels could be deactivated by pressing the MODE button (LED M
switches on and LED A switches off). The manual scanning of the channels is activated. Use the "^" button to change the active channel.
Setting the Set-Point:
Press the MODE button when in basic operating mode to switch to manual scanning mode. Press the
MODE button again to enter the mode for setting the SP. LEDs A and M are deactivated. The caption SP1
oC appears on the lower display. The currently set value of the SP for channel 1 appears on the lower
display and the least significant digit is blinking. Using the "<" and "^" buttons change the current value
to the desired one. The value of the Set-Point is in physical units (oC). Press ENT to save the new value
of the SP. Press MODE to switch to the next channel. Press MODE instead of ENT if you want to switch
to the next channel without changing the SP. Button A/M is similar to the MODE button, but it switches to
the previous channel. Press MODE again after the last channel to enter the basic display mode.
PID controller parameters setting:
ALL PARAMETERS COULD BE CHANGED ONLY AFTER CORRECT IDENTIFICATION OF THE CORRESPONDING PASSWORD.
Password type in: Press MODE and ENT or ENT and "^" simultaneously to exit the instruments basic
operating mode. 0000 is visualized on the upper display of the controller. Using the "<" and "^" buttons
enter the password. Press ENT. After the correct identification of the password the caption PASS appears
on the display. Press MODE to begin the parameters setting.
The value of the desired parameter can be changed with the "<" and "^" buttons. Press ENT to save the
new value. If you press MODE you switch to the next parameter without saving the new value. Pressing
A/M you can switch to the previous parameter. Button A/M switches to the previous parameter when the
instrument is in a display mode different of the basic display mode. The only exception is the calibration
of the feedback. After the last parameter from the menu is viewed the controller enters its basic operating mode.
The parameters are dynamically shown or hidden in the menu depending on the controller's configuration. The full parameter configuration is shown below. Some of the parameters may not be visible in the
menu because of the instruments current configuration.
Entering of PID parameters:
Press MODE and ENT simultaneously and enter one of the following passwords:
1111 - for relay output 1
2222 - for relay output 2
3333 - for relay output 3
4444 - for relay output 4
After the correct identification of the password you can change the following parameters:
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Starting Auto-tune
1. The Set-Point (SP) has to be correctly entered before activation of the auto-tune procedure.
2. The controlled object has to be put to work in constant condition during the identification (without any load
disturbances, with constant parameters, with relatively constant ambient temperature, constant SP, etc.).
3. Press A/M and MODE simultaneously. The number of the active channel starts blinking on the upper
display. Caption Autotu is visualized on the lower display. Using the "^" button choose the channel to
which the auto-tune procedure will be applied. Press ENT to start the auto-tune procedure. The instrument enters its basic operating mode and caption tu starts blinking on the 2-digit display. Press MODE
instead of ENT and the controller enters its basic operating mode without starting the auto-tune procedure.
Press the A/M and MODE buttons again in order to stop the auto-tune procedure. Caption StoP appears
on the upper display. Press ENT to stop the identification without calculating the parameters. Press
MODE (without pressing ENT) to enter the basic operating mode of the instrument without stopping the
auto-tune procedure.
NOTE: As ON/OFF control is implemented in the process, the temperature may rise significantly. The
maximal temperature value that will be reached at that point should not exceed the end of the instrument
measuring range. In case of reaching the end of the range, the Set-Point could be corrected to some
lower value. The identification will take time that is very much dependent on the characteristics of the controlled object. If the identification procedure has been stopped before its completion, new PID parameters
will not be computed. If an error occurs in the measurement or the instrument is switched to its manual
control mode the identification is automatically stopped.

OVERALL DIMENSIONS

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CONNECTION DIAGRAM

Terminal No Description
1, 2, 3
First Pt100 RTD input
4, 5, 6
Second Pt100 RTD input
7, 8, 9
Third Pt100 RTD input
10, 11, 12
Fourth Pt100 RTD input
13, 14
Power supply 90-250V AC/DC
15, 16
First transistor switch - terminal 15 is "+", terminal 16 is "-"
17, 18
Second transistor switch - terminal 17 is "+", terminal 18 is "-"
19, 20
Third transistor switch - terminal 19 is "+", terminal 20 is "-"
21, 22
Fourth transistor switch - terminal 21 is "+", terminal 22 is "-"
SPECIFY ON ORDER
- type of the controlled industrial process - temperature, pressure, level, etc.
- type of the controlled mechanism - motor, valve, heater, etc.
- type of the input signal - TC, Pt100, current 4-20mA, etc.
- type of the output signal (for control) - relay, current
- input for external setting of SV, interface RS485, AUTO-TUNE function, etc.

Office: 23, A. Saharov blvd., Mladost 1, 1784 Sofia, Bulgaria

tel.: (+359 2) 974 62 36, 974 62 37, fax: (+359 2) 974 62 04
E-mail: delta@deltainst.com, deltamm@mail.techno-link.com
http://www.deltainst.com