CONTENTS 1. Model number Page 1.1 Model number ----------------------------------------------------------------------------- 5 1.2 How to read the rated label ------------------------------------------------------------ 5 2. Name and functions of the sections ------------------------------------------- 6 3. External dimensions 3.1 External dimensions ---------------------------------------------------------------------- 7 3.
Preface Thank you for purchasing this Temperature controller KT4H/B. This manual contains instructions for the mounting, functions, operations and notes when operating the KT4H/B. For model confirmation and unit specifications, please read this manual carefully before starting operation. To prevent accidents arising from the misuse of this controller, please ensure the operator receives this manual. Notes • This instrument should be used in accordance with the specifications described in the manual.
Precautions 1.
1. Model number 1.
2. Name and functions of the sections (1) Model KT4H or KT4B (3) (4) (2) (5) (6) (7) (8) (9) Bottom view (Fig. 2-1) Display (1) Action indicators : Lights respectively when temperature unit / is selected. T/R : Lights during Serial communication (optional) TX output. AT : Flashes during auto-tuning or auto-reset. OUT1 : Lights when control output is ON or Heating output (optional) is ON. For DC current output type, it flashes corresponding to the manipulated variable in 0.25 second cycles.
3. External dimensions 3.1 External dimensions (Unit: mm)Common to KT4H/B Mounting frame Terminal cover (sold separately) Rubber gasket M3 screw (Fig. 3.1-1) 3.2 Tool cable (AKT4H820) external dimensions (Unit: mm) ø2.5 Plug 3-Pole type USB Plug (Fig. 3.2-1) 3.3 CT (current transformer) external dimensions (Unit: mm) AKT4815 (for 20A) (Fig. 3.
3.4 Terminal cover (AKT4H801) external dimensions (Unit: mm) (Fig. 3.4-1) Note when using a Terminal cover (AKT4H801) When using a Terminal cover (AKT4H801), pass terminal wires numbered 7 to 12 into the holes of the terminal cover. See (Fig. 3.4-2). Terminal cover (Fig. 3.
4. Mounting to the control panel 4.1 Panel cutout (Unit: mm) Caution n×48-3+0.5 0 45 +0.5 0 75 45 +0.5 0 If lateral close mounting is used for the controller, IP66 specification (Dust-proof/Drip-proof) may be compromised, and all warranties will be invalidated. 45 +0.5 0 Lateral close mounting n: Number of units mounted (Fig. 4.1-1) 4.
5. Wiring Warning Turn the power supply to the instrument off before wiring. Working or touching the terminal with the power switched on may result in severe injury or death due to Electric Shock. 5.1 Terminal arrangement • EVT1 : Alarm 1 output • EVT2 : Alarm 2 output (option) or Heater burnout alarm output (option) (Utilize common output terminals.
6. Settings Characters used in this manual Number -1 0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z Indication Alphabet Indication Alphabet Indication 6.1 Setting procedures (1) Setup : Set the Input type, Alarm type, etc. in the Setup mode. (If the users’ specification is the same as the default value of the KT4H/B, it is not necessary to set.) (2) Main setting mode : Set SV in the Main setting mode.
6.4 Operation flowchart This instrument has been classified into the following modes and setting items. For 3 seconds after power on, the PV display indicates the input type, and the SV display indicates input range high limit value (thermocouple, RTD input) or scaling high limit value (DC voltage, current input). Power ON Control output OFF/Manual control [Main setting mode](p.13) SV Control output OFF (Approx. 1sec) Auto/Manual control + [Sub setting mode](p.
6.5 Main setting mode key in the PV/SV display mode. To enter the Main setting mode, press or key, then register the value with key. To set or select each setting item, use Setting item numbers such as [1], [2], etc. are the same as those on the “6.4 Operation flowchart” (p.12). Character Name, Function, Setting range Default value [1] SV setting • Sets SV. • Setting range: Scaling low limit to Scaling high limit [2] SV2 setting 0 • Sets SV2.
6.6 Sub setting mode key while pressing key in the PV/SV display mode. To enter the Sub setting mode, press or key, then register the value with key. To set or select each setting item, use Setting item numbers such as [5], [6], etc. are the same as those on the “6.4 Operation flowchart” (p.12).
Character [13] [14] [15] , XX.X alternating display [16] , XX.X alternating display Name, Function, Setting range Default value Alarm 1 value setting 0 • Sets action point for Alarm 1 output. Setting the value to 0 or 0.0 disables the function (except Process high and Process low alarm). Not available if No alarm action is selected during Alarm 1 type selection. • Setting range: Refer to (Table 6.6-1). Alarm 2 value setting 0 • Sets action point for Alarm 2 output. Setting the value to 0 or 0.
6.7 Auxiliary function setting mode key for approximately 3 seconds while pressing To enter the Auxiliary function setting mode, press key in the PV/SV display mode. or key, then register the value with key. To set or select each setting item, use Setting item numbers such as [17], [18], etc. are the same as those on the “6.4 Operation flowchart” (p.12). Character Name, Function, Setting range Default value Unlock Set value lock selection [17] [18] • Locks the set values to prevent setting errors.
Character [22] [23] [24] Name, Function, Setting range Default value 7 bits/Even parity Data bit/Parity selection • Selects the data bit and parity. Not available if the Serial communication option is not added or if Contact input option is added. • : 8 bits/No parity : 7 bits/No parity : 8 bits/Even parity : 7 bits/Even parity : 8 bits/Odd parity : 7 bits/Odd parity 1 Stop bit selection • Selects the stop bit.
6.8 Setup mode key while pressing key for approximately 3 seconds in the PV/SV To enter the Setup mode, press display mode. or key, then register the value with key. To set or select each setting item, use Setting item numbers such as [25], [26], etc. are the same as those on the “6.4 Operation flowchart” (p.12).
Character [29] [30] [31] [32] [33] Name, Function, Setting range Default value 0.0 seconds PV filter time constant setting • Sets PV filter time constant. If the value is set too large, it affects control result due to the delay of response. • Setting range: 0.0 to 10.0 seconds 100% OUT1 high limit setting • Sets the high limit value of OUT1. Not available if OUT1 is ON/OFF action.
Character [38] [39] [40] [41] [42] [43] [44] [45] Name, Function, Setting range Default value No alarm action Alarm 1 type selection • Selects an action type for Alarm 1. (Refer to Section “11.4 Alarm action” on p.30.
Character [46] [47] [48] [49] [50] [51] [52] [53] Name, Function, Setting range Default value SV rise rate setting 0 /minute • Sets SV rise rate (rising value for 1 minute). Setting to 0 disables the function. • Setting range: 0 to 10000 /min. ( /min.) Thermocouple, RTD input with a decimal point: 0.0 to 1000.0 /min. ( /min.) DC voltage, current input: 0 to 10000/min. (The placement of the decimal point follows the selection.
Character Name, Function, Setting range Default value [54] PV color selection [55] • Selects PV display color. (Refer to Section “8.4 Changing PV color” on p.26.) • : Green : Red : Orange : When Alarm 1 or Alarm 2 is ON, PV color turns from green to red. : When Alarm 1 or Alarm 2 is ON, PV color turns from orange to red. : PV color changes continuously (Orange Green Red). : PV color changes continuously (Orange Green Red), and at the same time Alarm 1 or Alarm 2 is ON (Red). PV color range setting 5.
7. Operation 7.1 Starting operation After the unit is mounted to the control panel and wiring is completed, operate the unit following the procedures below. (1) Turn the power supply to the KT4H ON. After the power is turned on, the PV display indicates the input type, and the SV display indicates the input range high limit value (for thermocouple, RTD input) or scaling high limit value (for DC input) for approximately 3 seconds. See (Table 7-1) below.
7.3 Auto/Manual control switching Select Auto/Manual control function during [52] OUT/OFF key function selection in the Setup mode. By pressing key in the PV/SV display mode, Auto/Manual control function can be switched. If control action is switched from automatic to manual or vice versa, balance/bumpless function works to prevent a sudden change in manipulated variables. When automatic control is switched to manual control, the MEMO display indicates [ ].
8. Basic usage 8.1 ON/OFF control In ON/OFF control action, the control output is turned ON when PV is lower than SV, and turned OFF when PV exceeds SV. Overshoot, undershoot and hunting phenomenon occur during ON/OFF action. Therefore, ON/OFF action is not suitable for control which requires accuracy. (1) Press key while pressing key in the PV/SV display mode. The unit proceeds to the Sub setting mode, and [5] Auto-tuning/Auto-reset selection item appears. (2) Press key.
8.4 Changing PV color (1) In the PV/SV display mode, press key for approximately 3 seconds while pressing key. The unit proceeds to the Setup mode, and the Input type selection item appears. key several times until [54] PV color selection item appears. (2) Press (3) Select the PV color with or key. (Table 8.4-1) or )” is selected during [54] PV color selection, set the (4) If “PV color changes continuously ( value of [55] PV color range. (Fig. 8.4-1) (Fig. 8.
9. Auto-reset and ARW 9.1 Auto-reset Auto-reset is performed to correct the offset at the point at which PV indication is stabilized within the proportional band during the PD action. Since the corrected value is internally memorized, it is not necessary to perform the auto-reset again as long as the process is the same. However, when the OUT1 proportional band (P) is set to 0 or 0.0, the corrected value is cleared. Auto-reset is performed SV Offset span Temperature Offset is corrected Time (Fig. 9.
10. Auto-tuning In order to set each value of P, I, D and ARW automatically, the auto-tuning process should be made to fluctuate to obtain an optimal value. One of 3 types of fluctuation below is automatically selected. For DC input, the auto-tuning process will fluctuate around the SV for conditions of [1], [2] and [3] below. Notice • Perform the PID auto-tuning during the trial run. • During the PID auto-tuning, none of the setting items can be set.
11. Action explanation 11.1 OUT1 PID, PI, PD, P actions PI action : When derivative time is set to “0” PD action : When integral time is set to “0” P action : When both integral and derivative time are set to “0” [8] Integral time and [9] Derivative time can be set in the Sub setting mode. (p.14) [48] Direct (Cooling)/Reverse (Heating) action can be selected in the Setup mode. (p.
11.3 Heater burnout alarm action [15] Heater burnout alarm value and [16] Heater burnout alarm 2 value can be set in the Sub setting mode. (p.15) ON Alarm action OFF Setting Small Output Large Load current 5 5 6 6 Indicator (EVT2) Lit Unlit If Heater burnout alarm, Heater burnout alarm 2 and Alarm 2 are added together, they (EVT2) utilize common output terminals. 11.4 Alarm action [38] Alarm 1 type and [39] Alarm 2 type can be selected in the Setup mode. (p.
11.5 OUT2 (Heating/Cooling control) action [Reverse (Heating) action] Heating P-band (Cooling P-band) ON ON Control action Heating action Heating/Cooling control can be used by adding Heating/Cooling control option. (Cooling action) OFF OFF SV setting Relay contact output (OUT1) 7 7 7 8 8 8 Heating proportional band can be set during [6] OUT1 proportional band setting, and cooling proportional band can be set during [7] OUT2 proportional band setting in the Sub setting mode. (p.
11.7 OUT2 (Heating/Cooling control) action [Reverse (Heating) action] (When setting overlap band) Heating P-band Heating/Cooling control can be used by adding Heating/Cooling control option. Cooling P-band Overlap band ON Control action ON Heating action (Cooling action) OFF Heating proportional band can be set during [6] OUT1 proportional band setting, and cooling proportional band can be set during [7] OUT2 proportional band setting in the Sub setting mode. (p.
11.9 OUT2 (Heating/Cooling control) action [Direct (Cooling) action] (When setting dead band) Dead band Cooling P-band Heating P-band ON ON Heating action (Cooling action) Control action OFF OFF Heating/Cooling control can be used by adding Heating/Cooling control option. SV setting Relay contact output (OUT1) 7 7 7 8 8 8 Cycle action is performed according to deviation.
11.11 SV rise rate, SV fall rate setting action [46] SV rise rate and [47] SV fall rate can be set in the Setup mode. (p.21) When the SV is adjusted, it approaches the new SV by the preset SV rise rate or SV fall rate. When SV is adjusted while SV is rising (or falling), SV at the given time becomes a starting point, and approaches the new SV. When power is turned on, from PV the SV approaches the new SV.
When power is turned on or when control output OFF function is cancelled by the SV changes as follows in relation to PV. (e.g.) SV=200 , SV rise rate=60 /Min, SV fall rate=30 /Min [When SV>PV] Temperature SV=200 C SV display 200 C 25 C (on the SV display) approaches 200 C by the SV rise rate.
12. Communication Serial communication and Tool port communication cannot be used together. When performing Serial communication, remove the tool cable (AKT4H820) from the USB port of the PC and tool connector of the KT4H/B. When performing Tool port communication, it is not required to remove the Serial communication cables. However, do not send a command from the master side. 12.1 System configuration Communication converter RS-232C RS-485 KT4H/B No. 1 KT4H/B No. 2 KT4H/B No. 31 Host computer (Fig.
When connecting to a PLC (RS-485) KT4H/B PLC FG Shielded wire FG (Fig. 12.2-3) Shielded wire Connect only one side of the shielded wire to the FG terminal so that current cannot flow to the shielded wire. If both sides of the shielded wire are connected to the FG terminal, the circuit will be closed between the shielded wire and the ground. As a result, current will run through the shielded wire and this may cause noise. Be sure to ground the FG terminal.
12.3 Communication parameter setting Set each parameter following the procedures below. Setting item numbers such as [17, [19], etc. are the same as those on the “6.4 Operation flowchart”. (p.12) (1) Proceed to Auxiliary function setting mode. key while pressing key in the PV/SV display mode. Press The unit proceeds to Auxiliary function setting mode. + (2) [17] Auxiliary function setting mode Press key twice. The unit proceeds to Communication protocol selection.
12.4 Communication procedures Communication starts with command transmission from the host computer (hereafter Master) and ends with the response of the KT4H/B (hereafter Slave). Master Slave Command Data • Response with data When the master sends the reading command, the slave responds with the corresponding set value or current status. Acknowledgement • Acknowledgement When the master sends the setting command, the slave responds by sending an acknowledgement after the processing is terminated.
12.5 MEWTOCOL 12.5.1 Data format Start bit : 1 bit Data bit : 7 bits (8 bits) Selectable Parity : Even (No parity, Odd) Selectable Stop bit : 1 bit (2 bits) Selectable 12.5.2 Command configuration MEWETOCOL of the KT4H/B uses RD and WD commands. Writing and reading of plural word data cannot be carried out. Be sure to read and write one word at a time because continuous reading/writing of plural data is impossible. All commands are composed of ASCII.
Header : Code to represent the beginning of the command or the response. ASCII code % (25H) is used. Instrument number (Address): Numbers by which the master discerns each slave. Decimal 2 digits of instrument number from 1 to 99 and global addresses EE, FF are used. Global addresses are used when the same writing command is sent to all the slaves connected. For the global address EE, instrument number of the response command is EE. For the global address FF, the response is not returned.
12.5.
12.5.5 Communication command and data item table MEWTOCOL Data item command code Use in the system RD DT00100 (Never use WD command. If WD command is sent to the KT4H, the KT4H may not be operable.
MEWTOCOL command code RD/WD RD/WD RD/WD DT00202 DT00204 DT00210 SV rise rate SV fall rate Control output OUT/OFF RD/WD DT00212 Auto/Manual control RD/WD RD/WD DT00214 DT00228 Manual control MV Alarm 1 Energized/Deenergized RD/WD DT00230 Alarm 2 Energized/Deenergized RD/WD DT00236 Input type RD/WD DT00238 Direct/Reverse action RD/WD RD/WD RD/WD DT00242 DT00244 DT00246 AT bias ARW Heater burnout alarm 2 value Data item Data 44 Set value, Decimal point ignored Set value, Decimal point i
MEWTOCOL command code RD/WD DT00260 RD/WD DT00262 RD/WD RD/WD WD DT00264 DT00266 DT00324 RD RD RD RD RD DT00356 DT00358 DT00360 DT00362 DT00366 Data item Data Backlight 0000H: All are backlit 0001H: Only PV display is backlit 0002H: Only SV display is backlit 0003H: Only action indicators are backlit 0004H: PV+SV displays are backlit 0005H: PV+ action indicators are backlit 0006H: SV+ action indicators are backlit PV color 0000H: Green 0001H: Red 0002H: Orange 0003H: When Alarm ON, Green Red 0004
MEWTOCOL command code RD Data item DT00422 Data Instrument specification flag 0000 0000 0000 0000 20: Contact input 0: Not added, 1: Added 21: Serial communication 0: Not added, 1: Added 22: Heater burnout alarm 0: Not added, 1: Added 23: Heater burnout alarm rating 0: 20A, 1: 50A 24: Heater burnout alarm specification 0: Single phase, 1: 3-phase 5 2 : Alarm 2 output 0: Not added, 1: Added 6 2 : Heating/Cooling control output 0: Not added, 1: Added 7 2 to 215: Not used, always 0 Data Note on setting and
12.6 Modbus protocol 12.6.1 Transmission mode There are 2 transmission modes (ASCII and RTU) in Modbus protocol. 12.6.2 ASCII mode Hexadecimal (0 to 9, A to F), which is divided into high order (4-bit) and low order (4-bit) out of 8-bit binary data in command is transmitted as ASCII characters.
(2) Error check of ASCII mode After calculating LRC (Longitudinal Redundancy Check) from the slave address to the end of data, the calculated 8-bit data is converted to two ASCII characters and are appended to the end of message. How to calculate LRC 1 Create a message in RTU mode. 2 Add all the values from the slave address to the end of data. This is assumed as X. 3 Make a complement for X (bit reverse). This is assumed as X. 4 Add a value of 1 to X. This is assumed as X.
2 Reading (Address 1, SV) • A request message from the master The number of data means the data item to be read, and it is fixed as 1 (30H 30H 30H 31H).
12.6.2 RTU mode 8-bit binary data in command is transmitted as it is. Data format Start bit : 1 bit Data bit : 8 bits Parity : No parity (Even, Odd) Selectable Stop bit : 1 bit (2 bits) Selectable Error detection: CRC-16 (Cyclic Redundancy Check) Data interval : 3.5 character transmission time or less (1) Message configuration RTU mode is configured to start after idle time processing of more than 3.5 character transmissions and end after idle time processing of more than 3.5 character transmissions. 3.
(2) Error check of RTU mode After calculating CRC-16 (Cyclic Redundancy Check) from the slave address to the end of data, the calculated 16-bit data is appended to the end of message in sequence from low order to high order. How to calculate CRC In the CRC system, the information is divided by the polynomial series. The remainder is added to the end of the information and transmitted. The generation of polynomial series is as follows.
2 Reading (Address 1, SV) • A request message from the master The number of data means the data item to be read, and it is fixed as 1 (0001H). Slave Function Data item Number of data Error check 3.5 idle address code CRC-16 characters (01H) (03H) (0001H) (0001H) (D5CAH) 3.5 idle characters • Response message from the slave in normal status (When SV=600 [0258H]) The number of response byte means number of bytes of the data which has been read, and it is fixed as 2 (02H).
12.6.3 Communication command and data item table Modbus Data item function code Use in the system 03H 0000H (Never use function code 06H. If function code 06H is sent to the KT4H, the KT4H may not be operable.
Modbus function code 03H/06H 03H/06H 03H/06H 0033H 0034H 0037H SV rise rate SV fall rate Control output OUT/OFF 03H/06H 0038H Auto/Manual control 03H/06H 03H/06H 0039H 0040H Manual control MV Alarm 1 Energized/Deenergized 03H/06H 0041H Alarm 2 Energized/Deenergized 03H/06H 0044H Input type 03H/06H 0045H Direct/Reverse action 03H/06H 03H/06H 03H/06H 0047H 0048H 0049H AT bias ARW Heater burnout alarm 2 value Data item Data 54 Set value, Decimal point ignored Set value, Decimal point ig
Modbus function code 03H/06H 0050H Backlight 03H/06H 0051H PV color 03H/06H 03H/06H 06H 0052H 0053H 0070H PV color range Backlight time Key operation change flag clearing 03H 03H 03H 03H 03H 0080H 0081H 0082H 0083H 0085H PV (Process variable) OUT1 MV OUT2 MV SV (When SV rises or falls) Status flag Data item Data 0000H: All are backlit 0001H: Only PV display is backlit 0002H: Only SV display is backlit 0003H: Only action indicators are backlit 0004H: PV+SV displays are backlit 0005H: PV+ action
Modbus function code 03H Data item 00A1H Data Instrument specification flag 0000 0000 0000 0000 20: Contact input 0: Not added, 1: Added 21: Serial communication 0: Not added, 1: Added 22: Heater burnout alarm 0: Not added, 1: Added 23: Heater burnout alarm rating 0: 20A, 1: 50A 24: Heater burnout alarm specification 0: Single phase 1: 3-phase 5 2 : Alarm 2 output 0: Not added, 1: Added 26: Heating/Cooling control output 0: Not added, 1: Added 7 2 to 215: Not used, always 0 Data Note on setting and read
13. Specifications 13.1 Standard specifications Mounting : Flush Setting : Input system using membrane sheet key Display PV display : 11-segment backlight LCD Red/Green/Orange, character size 12.0 x 5.4mm (H x W) SV display : 11-segment backlight LCD Green, character size 6.0 x 3.5mm (H x W) MEMO display : 11-segment backlight LCD Green, character size 4.8 x 2.8mm (H x W) Action indicators : Backlight Orange Accuracy (Setting and Indication): Thermocouple : Within 0.
Integral time : 0 to 1000sec (OFF when set to 0) (Default: 200sec) Derivative time : 0 to 300sec (OFF when set to 0) (Default: 50sec) OUT1 proportional cycle : 1 to 120sec (Default: 30sec for Relay contact, 3sec for Non-contact voltage, Not available for DC current) ARW : 0 to 100% (Default: 50%) OUT1 ON/OFF action hysteresis: 0.1 to 100.0 ( ), or 1 to 1000 (Default: 1.
[Burnout] When the thermocouple or RTD input is burnt out, OUT1 and OUT2 are turned OFF (for DC current output type, OUT1 low limit value) and the PV display flashes “ ”. However, for the manual control, the preset MV (manipulated variable) is outputted. ” for 4 to 20mA DC and When the DC current or DC voltage input is disconnected, PV display flashes “ 1 to 5V DC inputs, and “ ” for 0 to 1V DC input.
Accessories included: Mounting frame 1 piece Rubber gasket (Front mounted to the KT4H/B) 1 piece Installation instructions (A3 unfolded, English/Japanese) 1 copy Communication installation instructions (When Serial communication option is added) 1 copy CT (Current transformer) CT1 (AKT4815) (When Heater burnout alarm Single phase 20A option is added) 1piece CT2 (AKT4816) (When Heater burnout alarm Single phase 50A option is added) 1 piece CT1 (AKT4815) (When Heater burnout alarm 3-phase 20A option is added)
Serial communication Cannot be used with Tool port communication. If this option is added, Contact input option cannot be added. The following operations can be carried out from the external computer.
14. Troubleshooting If any malfunctions occur, refer to the following items after checking the power supply to the controller. 14.1 Indication Presumed cause and solution Problem [ ] is indicated on the PV • Control output OFF function is working. Press the key for approx. 1 second to release the function. display. [ ] is flashing on the PV • Burnout of Thermocouple, RTD or disconnection of DC voltage (0 to 1V DC) display. Change each sensor.
• Check whether the input lead wire terminals for DC voltage (0 to 5V DC, 0 to 10V DC) or DC current (0 to 20mA DC) are securely mounted to the instrument input terminals. The indication of PV display is • Check whether sensor input or temperature unit ( or ) is correct. abnormal or unstable. Select the sensor input and temperature unit ( or ) properly. • Sensor correcting value is unsuitable. Set it to a suitable value. • Check whether the specification of the sensor is correct.
14.4 Communication If any malfunctions occur, refer to the following items after checking the power supply to the master and the slave. Problem Presumed cause and solution Communication failure • Make sure that communication connector is securely connected. • Check that wiring of the communication connector is correct. (Refer to Section “12.2 Wiring”.) • Burnout or imperfect contact on the communication cable and the connector. • Communication speed of the slave does not coincide with that of the master.
Revision History Issue Date May, 2005 October, 2005 April, 2007 Manual no. ARCT1F412E ARCT1F412E-1 ARCT1F412E-2 Content of revision First edition 2nd edition P.14 P.15 P.16 P.18 P.19 P.20 P.21 3rd edition P.3 P.32~33 Addition of explanation in detail Addition of explanation in detail Addition of explanation in detail P.34~35 March, 2008 ARCT1F412E-3 4th edition October, 2009 ARCT1F412E-4 5th edition Addition of explanation of “SV rise rate, SV fall rate setting action”.