RWF40... Compact Universal Controllers optimized for temperature and pressure control in connection with modulating or multistage burners User Manual The RWF40... controller and this User Manual are intended for use by OEMs which integrate the controller into their products! CC1B7865en 01.09.
/57 CC1B7865en 01.09.
Contents 1. Introduction ........................................................................................... 6 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 General notes................................................................................................................. 6 Description ..................................................................................................................... 6 Typographical conventions .........................................................................
6. Operation.............................................................................................. 29 6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.3 6.3.1 6.4 6.4.1 Basic display ............................................................................................................... 30 Meaning of the display and buttons .............................................................................. 30 User level ..............................................................................
11. Technical data ..................................................................................... 52 11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.3 11.3.1 11.3.2 11.3.3 Inputs ............................................................................................................................ 52 Analog input 1 (actual value) .........................................................................................
1. Introduction 1.1 General notes ) Please read this User Manual before switching on the controller. Keep the User Manual in a safe place which can be accessed by all users at all times. Please help us improve the information given in the User Manual. Your suggestions will be welcome. * All necessary settings and, where required, the settings to be made inside the unit, are described in this User Manual (applicable to controller software version 126.01.02 and 126.02.01). Ö Section 6.2.
1. Introduction 1.3 Typographical conventions 1.3.
2. Type of unit 2.1 Type field Location The type field is glued onto the housing. The type designation consists of operating voltage and type reference of the unit. Types Type of unit Description RWF40.000A97 Basic version with floating output RWF40.010A97 ¹· RWF40.001A97 With additional analog output RWF40.011A97 ¹· RWF40.
3. Installation 3.1 Installation site and climatic conditions − The installation site should be free from vibrations, dust and corrosive media − The controller should be installed away from sources of electromagnetic fields, such as variable speed drives or high-voltage ignition transformers Relative humidity: < 95 % (noncondensing) Ambient temperature range: -20...+50 °C Storage temperature range: -40...+70 °C 3.
3. Installation 3.3 Side-by-side If several controllers are mounted side-by-side or above one another in a control panel, minimum spacing must be observed: 30.5 mm vertically and 10.5 mm horizontally. 3.4 Mounting in a panel cutout ٭Place the seal supplied with the unit onto the controller housing. * The unit must be installed with the seal so that no water or oil can penetrate the housing! ٭Insert the controller from the front into the panel cutout.
3. Installation 3.5. Cleaning the front The front can be cleaned with normal washing and rinsing agents or detergents. * The front is not resistant to corrosive acids, caustic solutions and abrasive cleaners. Do not clean with high-pressure cleaners! 3.6 Removing the controller module The controller module can be removed from the housing for service.
4. Electrical connections 4.
4. Electrical connections 4.2 Block diagram 3 analog inputs Release of burner Input 1: Actual value for Pt100, Ni100, Pt1000, LG-Ni1000, thermocouples or standard signals Input 3: Outside temperature for Pt1000, LG-Ni1000 Floating output Output 2: -Relay (actuating device open) Output 3: - Relay (actuating device closed) RWF40... Input 2: External setpoint, setpoint shifting for 0...1 kΩ resistor or linearized standard signals Output 1: - Relay (N.O. contact) Limit comparator Output 4: - Relay (N.O.
4. Electrical connections 4.3 Assignment of terminals Electrical connections may only be made by qualified personnel! X1+ CB X1- CG G- CA G+ PE GND D1 L1 D2 N I1 Y2 M1 Q U1 Y1 G1+ Q13 XB6 Q14 M6 XU6 B9 Q63 M9 Q64 7865z07/0603 Outputs Display LED Relay 1: Release of burner Can be used as a thermal reset limit thermostat to DIN 3440 Contact protection: Varistor S07K275 Terminal no. Connection diagram Q14 pole Q14 P S Q13 N.O.
4. Electrical connections Analog input 1 (actual value) Terminals Thermocouple I1 Connection diagram M1 I1 + M1 - 7865a03/1099 Resistance thermometer in 3-wire circuit M1 M1 ϑ G1+ G1+ I1 I1 Resistance thermometer in 2-wire circuit, line compensation via offset correction (OFF1) 7865a04/1099 M1 M1 ϑ G1+ G1+ 7865a05/1099 Current input DC 0...20 mA, 4...20 mA I1 M1 I1 + M1 - 7865a06/1099 Voltage input DC 0...1 V, 0...
4. Electrical connections Binary inputs Terminals Operating mode selector D1 D1 Ö Section 5.2 «High-fire operation» D2 Setpoint shift / changeover Connection diagram D2 Ö Sections 5.4.1...5.4.4 GND Common ground GND Operating voltage, interface Terminals Operating voltage AC 110...240 V +10 % / -10 %, 48...63 Hz, max.
4. Electrical connections 4.4 Galvanic separation The diagram shows the maximum potential differences that may exist between the function modules in the controller. 3 analog inputs Input 1: Actual value for Pt100, Ni100, Pt1000, LG-Ni1000 thermocouples or standard signals Input 2: External setpoint, setpoint shift for resistance 0...1 k Ω , or standard signals Limit comparator Output 4: - Relay (N.O. contact) Release of burner L1, N: Output 1: - Relay (N.O.
5. Operating modes 5.1 Low-fire operation Low-fire operation means that only small amounts of heat are drawn from the boiler. A 2position controller maintains the setpoint, switching the burner on and off like a thermostat. Thermostat function This mode of control is known as the thermostat function. An adjustable switching differential ensures that the burner’s witching frequency can be selected, aimed at reducing wear.
5. Operating modes 5.2.2 Modulating burner, analog output In diagram area (1), the thermostat function is active. In area (2), the controller maintains the adjusted setpoint. B 7865w05/1099 HYS3 W HYS1 q q A A 100% X1 0% (2) (1) The positioning signal is delivered as a standard signal via the analog output. ) The modulating controller must be available and configured in the unit (optional). Ö Section 8.2 «C112 limit comparator, controller type, setpoint «SP1», locking» 5.2.
5. Operating modes 5.2.4 2-stage burner, analog output In this case, a standard binary signal switches the second stage into circuit with analog output «X1» on reaching the switch-on threshold «HYS1» and switches it out of circuit at the lower switch-off threshold «HYS2». B HYS3 HYS2 W HYS1 q 7865w04/1099 q A A 100% X1 0% (1) ) (2) The modulating controller must be available and configured in the unit (optional). Ö Section 8.
5. Operating modes 5.4.1 Setpoint changeover «SP1 / SP2», analog setpoint shift C111: XX1X ... XX3X Outside sensor C111 and C112 are described in chapter 8 Heating curve slope H Setting: 0.0 ... 4.0 Weather-dependent setpoint shift: No Yes C112: XX0X C112: XX1X SP1 via buttons SP1 via outside sensor C111: XXX2 Section 5.4.4 "External setpoint, binary setpoint shift" C111: XXX1 C111: XXX0 Setpoint changeover No function D2 open Setpoint SP2 SP2 via buttons D2 closed + C111: X6XX ...
5. Operating modes 5.4.2 Setpoint changeover «SP1» / external setpoint C111: XX1X ... XX3X Outside sensor C111 and C112 are described in chapter 8 Heating curve slope H Setting: 0.0 ... 4.0 Weather-dependent setpoint shift: No Yes C112: XX0X C112: XX1X SP1 via buttons SP1 from outside sensor C111: X1XX ... X5XX External setpoint C111: XXX2 C111: XXX0 C111: XXX1 No function Setpoint changeover Section 5.4.
5. Operating modes 5.4.3 Setpoint «SP1», analog / binary setpoint shift C111: XX1X ... XX3X Outside sensor C111 and C112 are described in chapter 8 Heating curve slope H Setting: 0.0 ... 4.0 Weather-dependent setpoint shift: No Yes C112: XX0X C112: XX1X SP1 via buttons SP1 via outside sensor C111: X6XX ... XAXX + Analog setpoint shift C111: XXX1 C111: XXX2 Sections 5.4.1 and 5.4.2 "Setpoint changeover ...
5. Operating modes 5.4.4 External setpoint, binary setpoint shift C111: X1XX ... X5XX C111 and C112 are described in chapter 8 External setpoint C111: XXX1 C111: XXX2 Sections 5.4.1 and 5.4.2 "Setpoint changeover ..." Binary setpoint shift C111: XXX0 No function D2 closed + dSP 0 D2 open SPH / oLHi 1) Values dSP and SP1 are entered on the user level Section 6.2 "User level" SPL / oLLo 1) Connection of binary input D2 Section 4.
5. Operating modes 5.5 Weather-dependent setpoint shift The RWF40... can be configured such that if an outside sensor with an LG-Ni1000 sensing element (e.g. QAC22...) is used, a weather-dependent setpoint shift will be implemented. The minimum and maximum setpoint values can be set by the lower setpoint limit «SPL» and the upper setpoint limit «SPH». In addition, with the RWF40.
5. Operating modes 5.5.1 Heating curve slope Slope «H» of the heating curve can be used to adjust the setpoint in response to the outside temperature, as shown in the diagram. The common origin of the heating curves is set at (20 °C / 20 °C). The effective range of the weather-dependent setpoint is restricted by the setpoint limits «SPH» and «SPL». H larger Setpoint (°C) oLHi 1) HYS3 SPH H smaller HYS1 SPL oLlo 1) +20 +20 10 0 -10 Outside temperature (°C) 7865d01e/1102 ¹) Only with RWF40.
5. Operating modes 5.6 Response threshold «Q» The response threshold «Q» defines for how long and how low the actual value is allowed to drop before the system switches to high-fire operation. An internal mathematical calculation using an integration function determines the sum of all the areas Qeff = Q1 + Q2 + Q3, as shown in the diagram. This only takes place when the control deviation (x-w) falls below the value of the switching threshold «HYS1». If the actual value increases, integration is stopped.
5. Operating modes 5.7 Cold start of the plant When a heating system is switched off for a longer period of time, the actual value will drop of course. To achieve a faster control response, the controller immediately starts in high-fire operation as soon as the control deviation (x-w) drops below a certain limit value.
6. Operation Assignment of levels PGM All levels can be accessed from the basic display via the button, as shown in the diagram. The upper actual value display (red) shows the actual value and the parameter values for the various levels. The setpoint and parameters are shown in the lower section of the display (green). BASIC DISPLAY 1. USER LEVEL 1. Min. 2 s or time-out (approx. 30 s) Min. 2 s PARAMETER LEVEL 1. Min.
6. Operation 6.1 Basic display The diagram shows the RWF40... after switching power on. This condition is called the basic display. The actual value and the currently active setpoint are shown here. Manual operation, self-setting, the user, parameter and configuration levels can be activated from here. 6.1.
6. Operation Initialization All displays light up. The setpoint display flashes for about 10 seconds after switching power on. Manual operation The upper display shows the actual value. The LED for manual operation is on. Depending on the operating mode and the type of controller, the setpoint or the level of the manual actuator position is shown on the setpoint display (green). Ö Section 6.2.
6. Operation Basic display 60.3 65.0 PGM User level (Display depends on code 111) EXIT 65.0 SP 1 PGM Depending on the configuration of binary input 2: - dSP -Sp2 EXIT 70.0 SP 2 or 10.0 dSP PGM Measurement of the outside temperature via analog input 3 EXIT 10.0 tA PGM Measurement of the external setpoint or a setpoint shift via analog input 2 50.0 SP.E PGM 7865f06e/1199 32/57 CC1B7865en 01.09.
6. Operation 6.2.2 Manual operation, modulating burner ٭Press EXIT for 5 seconds The LED above the hand symbol will light up. Floating controller ٭Change the position of the actuating device with = and > Relay 2 opens the actuating device as long as = is kept depressed. Relay 3 closes the actuating device as long as > is kept depressed. The LEDs for the actuating device indicate if «OPEN» or «CLOSE» is activated.
6. Operation 6.2.4 Start self-setting ٭Start self-setting with PGM +> ٭Cancel with = PGM 7865z10/1199 When «tunE» stops flashing, self-setting has stopped. ٭Accept the parameters that have been determined by pressing = (press the button for at least 2 seconds!) ) It is not possible to start «tunE» in manual operation or thermostat operation. 6.2.
6. Operation 6.3 Parameter level The parameters involved in adapting the controller to the controlled system are set here after the system has been started up. Within the level, you can proceed to the next parameter by pressing ) 6.3.1 Entering parameters PGM . The display of the individual parameters depends on the type of controller. Entry and alteration of the parameters is made through continuous alteration of the value. The longer you keep the button pressed, the faster the rate of change.
7. Parameter settings The parameter is shown on the lower setpoint display (green) and the parameter value on the upper / actual value display (red). AL 10 7865p06/0200 Parameter Display Value range AL -1999...+9999 digit Limit value for limit comparator 1) Factory Remarks setting 0 Output 4 AL HYSt 7865d10e/0300 Measured value w Ö Section 8.2 «C112 – limit comparator, controller type, setpoint «SP1», «locking» HYSt 0...999.9 digit 1 Pb.1 dt 0.1...999.9 digit 10 0...
7. Parameter settings The parameter is shown on the lower / setpoint display (green) and the parameter value on the upper / actual value display (red). AL 10 7865p06/0200 Display Value range Factory setting tt 10...3000 s 15 s Switch-on threshold for burner stage II 1) HYS1 0...-199.9 digit -5 Ö Section 5.5.1 «Heating curve slope» Switch-off threshold stage II 1) HYS2 0...HYS3 digit 3 Ö Section 5.2 «High-fire operation» Upper switch-off threshold 1) HYS3 0...999.9 digit 5 Ö Section 5.
8. Configuration 8.
8. Configuration 0000 C111 7865p03/0200 Analog input 3 No function Outside sensor Pt1000, 2-wire, IEC 751 Outside sensor Ni1000, 2-wire, DIN 43760 Outside sensor LG-Ni1000, 2-wire 0 1 2 3 Function of binary input «D2» No function Setpoint changeover Setpoint shift (binary) 0 1 2 Factory setting HVAC Products 9 CC1B7865en 01.09.
8. Configuration 8.2 C112 limit comparator, controller type, setpoint «SP1», locking 0000 C112 7865p04/0200 Limit comparator No function (lk off) lk1, input 1 lk2, input 1 lk3, input 1 lk4, input 1 lk5, input 1 lk6, input 1 lk7, input 1 lk8, input 1 lk7, input 2 lk8, input 2 lk7, input 3 lk8, input 3 0 1 2 3 4 5 6 7 8 9 A b C Controller type Floating controller Modulating controller DC 0…20 mA Modulating controller DC 4…20 mA Modulating controller DC 0...
8. Configuration Function Ik1 Window function: Relay «K6» is active when the measured value lies within a window about the setpoint (w). Example: w = 80 °C, AL = 5, HYSt = 2 Measured value rising: Relay «K6» switches on at 76 °C and off at 86 °C. Measured value falling: Relay «K6» switches on at 84 °C and off at 74 °C. Output 4 AL HYSt 7865d10e/0300 Function Ik2 Measured value w Like lk1, but inverted switching function.
8. Configuration Function Ik4 Like lk3, but inverted switching function. Output 4 AL HYSt 7865d03e/0300 Measured value w HYSt = switching differential AL = interval from setpoint Ö Chapter 7 «Parameter settings» Function Ik5 Upper limit signaling Function: Relay inactive when measured value > (setpoint + limit value). Example: w = 80 °C, AL = 10, HYSt = 2 Measured value rising: Relay «K6» switches off at 91 °C. Measured value falling: Relay «K6» switches on at 89 °C.
8. Configuration Function Ik7 The switching point is independent of the controller setpoint; only the limit value «AL» determines the switching point. Function: Relay is active when value measured > limit value. Example: AL = 50, HYSt = 2 Measured value rising: Relay «K6» switches on at 51 °C. Measured value falling: Relay «K6» switches off at 49 °C. Output 4 HYSt 7865d07e/0300 Function Ik8 Measured value AL Like lk7, but inverted switching function.
8. Configuration 8.3 C113 instrument address, dimensional unit, out-of-range * The setting of the decimal place has an impact on the parameters that are dependent on the actual value! 0000 C113 7865p05/0200 Unit address Address 0 Address 1 ... Address 99 * 0 0 0 1 ...
8. Configuration 8.3.1 «SCL» scaling of standard signal range start, analog input 1 Example SCL = 20; SCH = 100 °C 0 mA (start) corresponds to a measured value of 20 °C 0 mA 20 mA 0 °C 20 °C 100 °C Value range: -1999...+9999 digit Factory setting: 0 digit 8.3.2 «SCH» scaling of standard signal range end, analog input 1 Example SCH = 80; SCL = 0 °C 20 mA (end) corresponds to a measured value of 80 °C 0 mA 20 mA 0 °C 80 °C 100 °C Value range: -1999...+9999 digit Factory setting: 100 digit 8.3.
8. Configuration 8.3.4 «SCH2» scaling of standard signal range end, analog input 2 Example SCH2 = 80: 20 mA corresponds to a measured value of 80 °C, as already described Value range: -1999...+9999 digit Factory setting: 100 digit 8.3.5 «SPL» lower setpoint limit The controller restricts the setpoints to the set value. Value range: -1999...+9999 digit Factory setting: 0 digit 8.3.6 «SPH» upper setpoint limit The controller restricts the setpoints to the set value. Value range: -1999...
8. Configuration 8.3.12 «oLLo» lower working range limit (only with RWF40.0X2B97) The lower working range limit limits the control range in the downward direction. This limitation is independent of the setpoint adjustment and hysteresis 1. If switch-on threshold «SP + Hyst1 < oLLo» falls below the lower working range limit, the switch-on threshold will be replaced by the lower working range limit. The setpoint does not change.
9. Self-setting function 9.1 Self-setting function in high-fire operation ) «tunE» is only possible in high-fire operation, in the «modulating burner» mode. The self-setting function «tunE» is a proper software function unit that is integrated into the controller. In the «modulating» mode, «tunE» tests the response of the controlled system to steps of the positioning signal according to a special procedure.
9. Self-setting function x Start w 7865d13/1099 t The controlled system data recorded for the forced oscillations are used to calculate the controller parameters «rt, dt, Pb.1» and a filter time constant for actual value filtering that is optimized for this controlled system.
9. Self-setting function 9.2 Checking the controller parameters The optimum adjustment of the controller to the controlled system can be checked by recording a startup sequence with the control loop closed. The following diagrams indicate possible incorrect adjustments, and their correction. Example The response to a setpoint change is shown here for a 3rd order controlled system for a PID controller.
10. What to do if ... 10.1 ...numbers are flashing on the display This is an indication of incorrect measured value acquisition. ) Detection of measured value range crossings depends on the type of sensor used. Ö Section 11.3.2 «Measured value circuit monitoring» Display 1999 Description Actual value display (red) shows «1999» flashing. Setpoint display shows the setpoint. * Cause / controller behavior / remedy Overrange or underrange on analog input 1. Actual value is not measured.
11. Technical data 11.1 Inputs 11.1.1 Analog input 1 (actual value) For resistance thermometers, thermocouples or standard signals with 2nd order digital filter (configurable). Resistance thermometers In 2-wire or 3-wire circuit: Type Pt100, Pt1000, IEC 751 Ni100, Ni1000, DIN 43760 LG-Ni1000 Measured value range -200...+850 °C (-328...+1562 °F) -60...+250 °C (-76...+482 °F) -50...+160 °C (-58...+320 °F) Line resistance: < 30 Ω Line compensation Not required with 3-wire circuit.
11. Technical data 11.1.3 Analog input 3 (outside temperature) For resistance thermometers in a 2-wire circuit, with fixed filter time constants (21 h 18 min for weather-dependent setpoint enable) Resistance thermometer Type Pt1000, IEC 751 Ni1000, DIN 43760 LG-Ni1000 Measured value range -200...+850 °C (-328...+1562 °F) -60...+250 °C (-76...+482 °F) -50...+160 °C (-58...+320 °F) Sampling time: 6 seconds 11.1.
11. Technical data 11.2.4 Output 5, analog output (option) Analog output, electrically isolated from the analog inputs: ∆U < AC 30 V, ∆U < DC 50 V Standard signals DC 0…10 V (short-circuit proof) DC 0…20 mA DC 4…20 mA Load, burden Load = > 500 Ω Burden = < 500 Ω Burden = < 500 Ω Accuracy: ±0.25 % ±50 ppm / K 11.2.5 Transducer supply DC 24 V, 30 mA (short-circuit proof) 11.2.
11. Technical data 11.3.1 Measuring accuracy Resolution: > 15 bit Measuring accuracy Resistance thermometer: ≤ 0.05 % Thermocouples: ≤ 0.25 % Standard signals: ≤ 0.1 % Ambient temperature error ≤ 50 ppm / K ≤ 100 ppm / K ≤ 100 ppm / K Values include linearization tolerances. 11.3.
12. Actual settings 12.1 Process data Parameter Display Value range Factory setting Setpoint 1 1) SP1 SPL-SPH 0 Setpoint 2 (option) 1) SP2 SPL-SPH 0 Digital setpoint shift (optional) 1) dSP SPL-SPH 0 Outside temperature (optional) TA Ö Section 8.1 - SP.E SPL-SPH Predefinition of external setpoint 1) 1) Setting «C111 inputs» - Setting of the decimal places has an impact on these parameters 12.2 Parameter level Parameter Display Value range Factory setting AL -1999...
12. Actual settings 12.3 Configuration level Parameter Display Factory setting Analog input 1, 2 and 3; setpoint changeover / shift C111 9030 Limit comparator; controller type; setpoint 1; locking C112 0010 Unit address; decimal place / unit, signal for out-of-range C113 0110 Measured value range start analog input 1 1. SCL 0 Measured value range analog input 1 1. SCH 100 Measured value range analog input 2 1. SCL2 0 Measured value range analog input 2 1.
