OPERATING INSTRUCTIONS PROGRAM CONTROLLER DIGIT 450 dotherm® Gesellschaft fur Warmetechnik m.b.H.WELDOTHERM Program Controller DIGIT 450 st of Contents 5 1.00 General nformation. 1.01 Purpose ofthe device 1102 Fld of epplicaton. 1103 Control range. 1104 Measucng range 1108 Guarantee . 1106 Commissioning 2.00 Technical Data and Funcions 201 Sensor input 2.02 Contrber utp 203 Alam functions, 2.04 Display 2.05 Conia characteristics values 2.06 Control parameters. 2.07 Communication. 2.08 Other information. 2.09 Function, 3.00 Terminal allocat 3.01 Terminal 44.00 Test functions ‘5.00 Operating the conti. ‘5.01 Program dala input 5.02 Convo sta... 503 Conta stp {8.04 Held mode / Operating mode. ‘505 Programming the suteh-in te 5506 Program sion. 807 Program recall 8.08 Program data correction. 5.09 Autoruning, 8.00 Configuration of Dig 450. 7.00 Master «Slave Operation, 8.00 Ero messages... '80! Error Powe of (EPo). 8.02 Eo Sant Break (ESB; £8.03 Eror of Limi aL) {804 Ertor SLAVE (ESLA), 805 System bus. 8.00 Option: 2 channel entrlor. PAGE 1WELDOTHERM Program Controller DIGIT 450 General 1.01 Purpose ofthe device ‘The DIGIT 450 Program Controler seves to contol heating systems. ‘The device Is provided with one sensor inputs which are. responsible for determining and ‘monitoring the temperature inthe regulation zone, The sensor must be connected correctly and placed. 1.02 Field of application [The contofer must nat be used in environment] \ere thero is danger of explosion. It may not be| lexposed to rain oo other kinds of wet or damp. ‘The DIGIT 450 is intended for use at an ambient temperature of 0 to 60 °C and relative humty of betwoon 10 and 90% Powersupply: 60V..264V AC or 110V..284V DC. {A cables must be shilded when lid. It is absolutely necessary to connect the protective earth (PE). 4103 Control Range “The contol range of the DIGIT 450 is located between 0.1200°C. The set value can be adjusted within this range. 41.04 Measuring range ‘The measuring range is determined between 20°C. 1220°C. 1.05 Guarantee ‘The guarantee period is one year. the device 1s manipulated or changod in any way whatever, the guarantee Immediately becomes nl and vo 4.06 Commissioning Its essential to read the Operating Instnuctions before tuning on the DIGIT. ‘tee wil Up the DIGIT with shielded cables in ‘accordance withthe terminal allocation plan (see 301), Be power supply can be autched on The falowng points should be observed in order to avoid fauts or disturbances nthe device = Wing and cating distances shouldbe short Power supply, conrol and measuring cables should be aid separately = _Earthing must be propery cared out © Contactors, relay cols, selena vaves should be interterence suppressed = Mineaessary, provide mains fier tthe power ‘supply Input cr soparate votage supply vie Isolating transformer When swiching on the mains votage a ,Boot Beam’ ie indicated inthe dot matrix for approx 5 seconds (also if switching over fom configuration ‘modus to normal modus). When commissioning the device forthe fst time, press keys CEIC and Input simuitancously. Ths wll delete any data which may be in the memory ‘The DIGIT is now in emply mode, the controller ame appears in the top data dsplay and the version of the software appears in the bottom ‘splay. In operational or standby mode the point mati: Incleats the conatton ofthe § dgtal outs in the upper left positon ofthe spay. lan outlet is ‘civ dot willbe shown in the point mati. The Classication ofthe outs can be sean Inthe graphics. oo 002 003 ‘Acwal Poe Balance tne Rogram Fow Coraol 7-phase process splay PAGE2WELDOTHERM Program Controller DIGIT 450 2.00 Technical Data and Functions 201 Sensor input amber 7 Resolutio: 155 Bi Measuring inienal [62,5 mS. Type INGEN: Messing range [20.1220 Disa ri Linea.zaton oor [<0:1 56 of measuring range Temperature ort | < 0.13. wirin max environmental temperature [07 of measuring 2.02 Gbntrotter output: Ralay AASV Logic (Opion) [12 Vmax. 20mA (Cycle ime 0.100 seconds 2.03 Alarth functions: ([Rea____—[anra0 changer Lita) 2.04 Display: 2. 4st 7-sogmentcsplay for sot value, actual valu, alarm messages and parameter valves. 157 dot matrix for day of program profile and parameter designations. 15% LED (2x6mm) for Bitblay of program stage, 4 xLED (Sx6mm) for dspayeFunits 2.05 Control characteristic values’ (Controtmode TPP PO. 2.08 Control parameters: or ONO Proporional range [XP,0.0.1000% of max value Integral portor: [1.10000 seconds Diferental porion[D 0.10000 seconds: [Cycle time: 0.100 seconds PAGESWELDOTHERM Program Controller DIGIT 460 207 Communication: Interface RS48S, 2uire 2.08 Other information: using Sioa’ pate housing wih plas insert < Dimensions Watt = 96 x 96mm Installation depth: 220 mm ine. connector y 250 mm ind SUB D9 connecter Front pale catout_|@25x025mm ) Weight 43 Kg Protective ass | Fron iP58, Rear wal IPO Data storage. 10 years. rad max ambient | 0..60°C temperature Ambient huriiy [70-9096 Power consumpton_[ appro. TVA. Power suppl BOV...264V ACor 110V_.2E4V DC (Connector typo [8/6781 Y2pole plugin terminal, 2x SUB DS comecor Function “The DIGIT 460 program controller contain one PID controler. ‘The controller can switch hesters on and off ect using contactors and can regulate the heating output by ‘changing the puse-pause relationship. ‘The programmerin set value curve wih max. 8 phases (1 intial me, 4 gracents, 3 holding temperatures holding times) is stored automaticaly {A gradient of 300 Kihour for example means that the contrller wil ase the temperature from ambient temperature, €g. 25°C, up to 325°C within 1 hour. A gradient of 1200ksTour fr example would mean that the set temperature of 1200°C would be reached after 15 minytes already. 40 programs can be stored in the DIGIT 480, ° ‘One alarm relays i available which In case of sensopbreak or on demand, ifthe actual valve ‘doos nat un within the emergency-band (standard adjustment 50 K), 1 a sansor bee (Power fare) is not repaired within a certain peri of tine - standard adjustment 10 (30) minutes - the controller svtches ino standby modus. * v L naeWELDOTHERM Program Controller DIGIT 450 3.00 Terminal allocation 53.01 Terminal allocation DIGIT 450 son rntuctons at orca AD crestneatnpotite cers ‘2 program that has akeady been entered ‘Approach the data to be changed. The selected phase. Is. shown in the process. dspiay by Flashing Ge umarcal say, ris te ety win OD 50 Pour hed ben stapad ote program atin ors it pve ire cas thd wel be ue ye youre Enter the new value wih lang tho relevant sTest,1 Ifthe rogram isin the heating or coaling phate, {he current grade deplayed in the Top dala 30 %, I< 10 seconds or > 5000 seconds) ‘Ate-tuning ended successtuly ‘according to our experience, ‘An ineufcient number of heating elements have been used or the heating rate Is chosen to fst. The setpoint {s then eing much faster han the actual temperature and EOL alarm willbe caused, Inthe case more heating elements must be Used ort he heating must be seo @ smaller value ‘Auttuning does not help at alin tis case by the cor 100,70 OD, ES Before stating an auto tuning please doublecheck ithe conta parameter are set correct. Factory setings: P= 1% 1 = 480 Sek D = 120 Sek PAGE 12AS WELDOTHERM Program Controller DIGIT 450 {6.00 Configuration of DIGIT 450. “The DIGIT 450 is configured ex works. These control parameter have proved oneself since many years in the heat treatment industry Pl We wil only describe how to get to the relevant parameter. Please do not pay any attention to other So = ae % Rar cae acee lea ee ness ennaragous.n SH" SOE 329 | Access to configuration lev PS. :|gooe"""™" |? arms a Boe wD ae 6e 8 hedeenhene hbo tees = pe 1 ’ fir ED va wD ses] 1g 10 a oS . o (0- “ty 480 ve EB at] CTD pena ' ) ber off) o 128 Be Dae (adjustable trom eae ' 30. ¢ a Ene Blo cane we Down (El 7 a FAS Ty De ewacoo | (AGO ten ewe coongaron ioe 34So ; ; Pepe ere | ress siMULTANEOUsLy, |S! 3e9 Sonerp meneaa : powers | &. See ero nea SOO IL. PRESS SIMULTANEOUSLY! le3e9 8y pressing key EB key FED youu back toto provost. PAGE 13™ WELDOTHERM Program Controller DIGIT 450 11.00 Master Slave Operation (Only the master controler has to be programme tis not necessary 10 program the slave conte. ‘Al program controler DIGIT 450/600 inside @ WELDOTHERM heat treatment machine can be linked with feach other by pressing the master-slave buttons. The bus master (Zone 1) cannot be used as @ save controler. Please pay atietion when exchanging the bus master controle (zone 1) and set the new controler to [ASET (ep 7, page 13) Only the bus master will be set to ASET! After the start of the program al other linked programmer (slave) wil accept the setpoint ofthe master Controle. During the ele a continaus data transfer occurs between the master andthe slave controller. In ‘ase of a devition outside the alarm band from the master’s setpoint of one of the linked controler the ‘master wil hold the program sequence (H will be shown on the display). When the affected zone is back within the alam band (factory setting: 80 K), the sequence wil contnue. Incase of 9 sensor break in one Zone the program vill col down with the last cocling rate tothe enc, I this defect is not repaired within 10, ‘minutes time, Example 1 Zone1 > master (bus master) Zone2..6 > Slave ‘Compound switch: res ve) (268) [3m], 465 | [516 Example 2 Zone 1 => master (bus master), off Zone 2 = master, off Zone3 > master Zone4 > slave Zone = master Zones = slave ‘Compound switeh PAGE 14WELDOTHERM Program Controller DIGIT 450 ‘2.00 Error messages ‘The conirller possesses afallure memory. You can save up to maximum 10 emors, Each ertor must De ‘coped by key CEIC, 801 Error Power off (Power suppy fare) 38). ‘The erro message EPs indicated oi ifthe contrller was in operational made before power falure. The ceror message is indicated aslong as you accep by key CEIC. 8.02 Error Sensor Break (Sensor break ) In case of sensor break te relay fr heating is swiched of. The alarm ely is activated in sucha case. The ‘error message can only be accepied sie repsiig the ero. this eo snot repaired within 10 minutes, he ‘controle stches ino standby modus (master-slave operation plesse see page 14). ver ange under range 10 io udr : Exceeding (ov) of max. actual valve Under runing (ute) of max actual value. (facery sting 1220°C) (factory sting 20°C) ‘The error signal lapses automaticaly as 600n as the actual value i etumed to temperature range. (03 Error of Limit Liit alarm ) FOS es, Eot ‘Alte leaving the alarm-band (factory settings SOK) the alarm relay is activated. The program stops. I the alarm Feason isnot existing anymore the program runs again. The deplayed EOL must be accepted. As soon as the ‘actual valve is within the alarm-ban again the alarm s focussed 8.04 Error Slave ESLA In the MasterSlave modu the eror of a Slave sincicate at the Master by message .ESLA’. The concerned {ro sncicated at tho contre ofthe concerned zone for instance EOL The Master stops the procedure. In ase a contrl zone has a sensor break the Master swiches into the last cooing eraent of the program (message A2), i the ero isnot elminated within @ certain prio of me (factory setting TO mantes) Aer ‘liminaton ofthis err the displayes message can be accepted. PAGE 1Sa WELDOTHERM Program Controller DIGIT 450 £8.08 system bus ( Communication error) 338° T 336 “The error wil be indicated on the top right comer of the isplay and wll appear inthe flowing events: Interuption ofthe system bus wing Loose contact ‘More than one bus master in one inkage Detecve contri at the system bus ‘Alor leaving the configuration level! ‘The error will nly be cisplayed atthe system bus master (zone 1). That does not necessanly means thatthe tous master is defective. I one has been inthe configuration level please qui his error by pressing CEIC. the system bus master wil be exchanged by anather DIGIT cantraler one has to proceed as follows: “Tum of poner supply Exchange controler ‘Tum on power supply Set new system bus master to°ASE" ‘Tur of power supply “Turn on power supply ‘Tne new system bus master wil now recognize al other conver of the machine \without turning onloff the power supply the controller wil not be recognized property! ‘2.00 Options: 2-channel-controler ‘The controler has 2 thermacouple inpus and 2 conirl outputs avalable. The clamp assignment (3.01) and test. function (.00) changes a8 flows: Relaysheating channel2. > 0003 COM, NO ‘Thermocouple channel 2 => AIOA t= Test, Temp => betiom channel 1, upper channe! 2. STEP KEYS [EXPLANATION DATA + PROCESS DISPLAY Nau must now decide f DIGIT ABD T= “Tuming on supply vatage | supposed fo work as t- 2chamel (09) eon ‘The controller now changes to normal indication. 6