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Description of the Functions

Description of Tune Values SM5000

Description for Adjustment of SM5000

Customer:......................Coats

Order No.:.........................................different

Machine:...........................................THIES ES21/ES22

Date:..................................................16.04.03

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ES21-22 - description.doc

Contacts:
Thies Textilmaschinen GmbH & Co Barco Sedo GmbH
Borkener Str. 155 Neuwies 1
D 48653 Coesfeld D 35794 Mengerskirchen
Tel: +49 2541 / 733-0 Tel: +49 6476 / 31-0

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Table of contents:
Table of contents:.....................................................................................................................................................2
Actual software versions:.......................................................................................................................................3
Adjustment:.............................................................................................................................................................3
Calibration.........................................................................................................................................................3
Inverter..............................................................................................................................................................3
SM5000.............................................................................................................................................................3
Documentation of the main functions...................................................................................................................4
GENERAL ENABLE FOR AUTOMATIC USE.................................................................................................4
SPECIAL FUNCTIONS OF BUTTONS..............................................................................................................4
FILLING...............................................................................................................................................................4
HEAT/COOL........................................................................................................................................................5
RINSE TIME only for ES22..........................................................................................................................5
REVERSE A.........................................................................................................................................................6
DRAINING...........................................................................................................................................................6
HT DRAIN............................................................................................................................................................7
Documentation of the parallel functions...............................................................................................................8
FILL STOCK %....................................................................................................................................................8
INJECT STOCK...................................................................................................................................................8
DRAIN STOCK only for ES22..........................................................................................................................9
FILL EXP. % only for ES22..............................................................................................................................9
DOSING EXP. only for ES22............................................................................................................................9
INJECT EXP. only for ES22...........................................................................................................................10
DRAIN EXP. only for ES22............................................................................................................................10
MIXING EXP. only for ES22..........................................................................................................................10
User Keys...............................................................................................................................................................11
Own Notes..............................................................................................................................................................12
Description of Tune Values SM5000..................................................................................................................13
Description for the Adjustment of SM5000........................................................................................................18
Timing diagram for stock tank, expansion tank and dye kitchen...................................................................18
Description for optimizations of the PID controller.......................................................................................19
Control values for the PID controller (control loop – Contrl val)...................................................................20
Description for optimisation DSR controller..................................................................................................22
Control values for the DSR controller (control loop – Contrl val).................................................................24

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Actual software versions:

 SM5000
System software V1.65 since 06/2002 V1.67
Sedomat software V1.65 since 06/2002 V1.67
PLC software V1.65 since 06/2002 V1.67
System version A2.2 since 06/2002 V2.3

 Instruction List
checksum 525F up to 06/2002
checksum 4D7F up to 08/2002
checksum 25FE up to 09/2002
checksum A669 up to 10/2002
checksum A64D up to 11/2002 with differential pressure
checksum 1B82 up to 02/2003 continue process (routine modified)
checksum B68D since 03/2003
checksum xxxx since 04/2003 central dosing system implemented

Adjustment:
Calibration
 All tanks will be calibrated to a set point of 1000 (per thousand)
The tanks will be filled automatically during calibration.

Inverter
 settings of Thies are to use

SM5000
 All tune values must be checked
 (programming as in the enclose documentation)

Contacts:
Thies Textilmaschinen GmbH & Co Barco Sedo GmbH
Borkener Str. 155 Neuwies 1
D 48653 Coesfeld D 35794 Mengerskirchen
Tel: +49 2541 / 733-0 Tel: +49 6476 / 31-0

 Mr. Berndhard Wortmann  Mr. Eric Dings

 Mr. Josef Löbbers  Mr. Klaus Hein
 Mr. Martin Kramer

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Documentation of the main functions

GENERAL ENABLE FOR AUTOMATIC USE
- lid closed
- all alarms which cause a stop must be quitted
- Above 85° degree the functions FILLING ; RINSE TIME ; REVERSE A ; DRAINING are disabled .

SPECIAL FUNCTIONS OF BUTTONS

- Pressing the prepare button for 4 seconds will reset a preparation

- Pressing the quit button (beacon off) for 2 seconds will quit the ‘OPERATOR CALL’ function.

FILLING

Parameters:
WATER TYPE (WATER 1; WATER 2; WATER 1+2)
LEVEL % ( percentage)
TEMP ST.TANK (°C)
STIRRER (ON ; OFF)

· temperature control is switched off.

· automatically depressurising of the machine

disabling:
· The function will start, if the temperature is below 80°C and the pressure is low < 0,2bar.

operational sequence:

The stock tank will filled by the selected valves. While the heat level of the stock tank is reached,
heating starts if a temperature is programmed. The stirrer starts if programmed.
After reaching the temperature the amount of the stock tank will transferred to the machine. The pump
starts, if the minimum level of the machine is covered.
In Air pad Mode the function end, when the amount of the stock tank is transferred.
In the Fully Flood Mode the function ends, when the working level of the expansion tank is reached.

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HEAT/COOL

Parameters:
TEMPERATURE (°C)
The value 0 will switch off, the temperature control and starts the holdtime.
GRADIENT ( °C/min)
The value 0 means maximum gradient for heating an cooling.
HOLDTIME (min)

· The temperature control will switched on.

 The pump runs, if the minimum level is covered.

Display:
- Set -, act temperature and remain time will displayed in the status display.
- The temperature curve will logged.

disabling:
· The function will stop, if the pump is not running and the min level not covered.

operational sequence:

The programmed temperature will be reached by heating or cooling. The pump runs, if the minimum
level of the machine is covered.
Air pad Mode the machine will ventilated by V59 and the pump direction changes, if programmed.
In the Fully Flood Mode the dosing pump runs and the liquor will transferred through the expansion
tank.
The function ends, when the temperature is reached and the time is gone.

RINSE TIME only for ES22

Parameters:
WATER TYPE (WATER 1; WATER 2; WATER 1+2)
RINSE TIME (min)

· temperature control is switched off.

· automatically depressurising of the machine

Display:
- remain time will displayed in the status display.

disabling:
· The function will start, if the temperature is below 80°C and the pressure is low < 0,2bar.

operational sequence:

The stock tank will filled by the selected valves. While the middle level of the stock tank is reached,
the pump starts, if the minimum level of the machine is covered.
In Air pad Mode the rinse valve opens.
In the Fully Flood Mode it will rinsed through the expansion tank.

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REVERSE A

Parameters:
LEVEL % (percentage)

· temperature control is switched off.

Display:
-

disabling:
· The function will start, if the temperature is below 80°C and the pressure is below < 0,2bar.

operational sequence:

The stock tank will filled with liquor from the machine by compressed air. Up to the programmed level
of the stock tank is reached.

DRAINING

Parameters:
REMAIN TIME (min)

· temperature control is switched off.

· automatically depressurising of the machine

Display:
- remain time will displayed in the status display. The count down of the remain time starts while the
minimum level of the machine is gone.

disabling:
· The function will start, if the temperature is below 80°C and the pressure is lower than 0,2bar.

operational sequence:

While the machine is in a safe mode (low pressure and low temperature) the drain valve and the
pressurising valve opens. All flap valves will open or the flap cylinder is in middle position. The liquor
drained by compressed air. While the minimum level of the machine is gone, the pressurising valve
closes. The depressurising valve and the residual drain valve opens, as long as the remain time is gone.

In the Fully Flood Mode the expansion tank will also drained.

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HT DRAIN

Parameters:
REMAIN TIME (min)

· temperature control is switched off.

· no depressurising of the machine

Display:
- remain time will displayed in the status display. The count down of the remain time starts while the
minimum level of the machine is gone.

disabling:
· The function will start, at any temperature.

operational sequence:

The drain valve and the pressurising valve opens. All flap valves will open or the flap cylinder is in
middle position. The liquor will drained by compressed air, if the pressure will become low. While the
minimum level of the machine is gone, the pressurising valve closes. The depressurising valve and the
residual drain valve opens, as long as the remain time is gone.

In the Fully Flood Mode the expansion tank will also drained.

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Documentation of the parallel functions

FILL STOCK %

Parameters:
WATER TYPE (WATER 1; WATER 2; WATER 1+2)
LEVEL % ( percentage)
TEMP ST.TANK (°C)
STIRRER (ON ; OFF)
PREPARE TEXT (TEXT for the message)

· the function is running independent of the machine status

disabling:
· The function will start, if the stock tank is empty or the programmed parameters are not reached.

operational sequence:

The stock tank will filled by the selected valves. While the heat level of the stock tank is reached,
heating starts if a temperature is programmed. The stirrer starts if programmed.
After reaching the temperature and level, the function will be quitted.
If a prepare text is programmed, except ‘no call’, a message text will activated as long as the quit button
is not pressed.

INJECT STOCK

· temperature control is switched off.

· automatically depressurising of the machine
· prepare must be ready, by pressing the quit button.

disabling:
· The function will start, if the machine is empty, the temperature is below 80°C and the pressure is
lower than 0,2bar.
.

operational sequence:

The valves machine inlet and venting are open. While the minimum level of the machine is reached,
the pump starts.
While the total amount of the stock tank is transferred to the machine, the stock tank will rinsed.

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DRAIN STOCK only for ES22

· the function is running independent of the machine status

disabling:
· The function will activated at all conditions.

operational sequence:

The drain valve of the stock tank opens. While the stock tank is empty, it will rinsed.

FILL EXP. % only for ES22

Parameters:
WATER TYPE (WATER 1; WATER 2; WATER 1+2)
LEVEL % ( percentage)
PREPARE TEXT (TEXT for the message)

· the function is running independent of the machine status, for the Air pad Mode.

disabling:
· The function will start, if the expansion tank is empty or the programmed level is not reached.
· for the Fully Flood Mode the function is disabled, by alarm.

operational sequence:

The expansion tank will filled by the selected valves.

After reaching the level, the function will be quitted.
The programmed prepare text will activate a message text as long as the quit button is not pressed.

DOSING EXP. only for ES22

Parameters:
DOSINGTIME (min)
DOSINGCURVE (LINEAR, PROGRESS 10%, DEGRESS 10%, … PROGRESS 90%)

· the function is running while the main pump is active only in the Air pad Mode.
· the tank must be prepared, by pressing the quit button.

disabling:

· for the Fully Flood Mode the function is disabled, by alarm.

operational sequence:

By activation of the function the amount of the exp. tank will mixed by the pump through the mixing
valve. While this time is gone, the actual level of the tank will used as the dosing amount.
The curve will calculated by the parameters.
When the total amount of the exp. tank is dosed, the exp. tank will rinsed (that sequence is described by
the tune value description).

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After rinsing the exp. tank, the function will be quitted.

INJECT EXP. only for ES22

· the function is running while the main pump is active only in the Air pad Mode.
· the tank must be prepared, by pressing the quit button.

disabling:

· for the Fully Flood Mode the function is disabled, by alarm.

operational sequence:

By activation of the function, the amount of the exp. tank will mixed by the pump through the mixing
valve. While this time is gone, the actual level of the tank will transferred to the machine.
When the total amount of the exp. tank is transferred, the exp. tank will rinsed (that sequence is
described by the tune value description).
After rinsing the exp. tank, the function will be quitted.

DRAIN EXP. only for ES22

· the function is running only in the Air pad Mode.

disabling:

· for the Fully Flood Mode the function is disabled, by alarm.

operational sequence:

By activation of this function, the amount of the exp. tank will drained
When the total amount of the exp. tank is drained, the exp. tank will rinsed (that sequence is described
by the tune value description).
After rinsing the exp. tank, the function will be quitted.

MIXING EXP. only for ES22

Parameters:
MIXING TIME (min)

· the function is running only in the Air pad Mode.

disabling:

· for the Fully Flood Mode the function is disabled, by alarm.

operational sequence:

By activation of this function, the amount of the exp. tank will mixed by the pump through the mixing
valve.

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While the programmed time is gone, the function will be quitted.

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User Keys
User keys will activated by the soft key F8.
There are three pages of user keys. This pages are toggled by the F4 soft key, while the user key menu
is active. This user key is called “next”.

First page (stock tank):

F1: “Fill StockT”

By activation of this user key the stock tank will filled. This function can activated all the time.
This user key works like a switch. It is as long active as it will pressed a second time or the maximum
level of the stock tank is reached.

F2: “Mix. StockT”

By activation of this user key the stirrer (mixer) stock tank will run. This function can activated all the
time.
This user key works like a switch. It is as long active as it will pressed a second time.

F3: “Drain StockT” only for ES22

By activation of this user key the stock tank will drained. This function can activated all the time.
This user key works like a switch. It is as long active as it will pressed a second time.

Second page (expansion tank):

This page can only activated, if it is an ES22 machine. This kind of machine will selected by the
according tune value.

F1: “Fill Exp.T.” only for ES22

By activation of this user key the expansion tank will filled. This function can activated all the time,
except dosing.
This user key works like a switch. It is as long active as it will pressed a second time or the maximum
level of the expansion tank is reached.

F2: “Mix. Exp.T.” only for ES22

By activation of this user key the expansion tank will mixed. This function can activated all the time,
except dosing.
This user key works like a switch. It is as long active as it will pressed a second time.

F3: “Drain Exp.T” only for ES22

By activation of this user key the expansion tank will drained. This function can activated all the time,
except dosing.
This user key works like a switch. It is as long active as it will pressed a second time.

Third page (machine):

F1: “Drain mach.”

By activation of this user key the machine will drained. This function can only activated if the controller
is in stop mode, the pump is not running and the machine is in a safe state. This user key works like a
switch. It is as long active as it will pressed a second time.

F2: “Depressurise”
By activation of this user key the machine will depressurised. This function can only activated if the
controller is in stop mod and the pump is not running. This user key works like a button. It is as long
active as this key is pressed.

F2: “Cooling”
By activation of this user key the machine will cool down to 60°C. This function can only activated if
the controller is in stop. This user key works like a switch. It is as long active as it will pressed a second
time or the temperature is below 60°C.

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Own Notes

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Description of Tune Values SM5000

TUNE VALUE 1: LEV. MACHINE [liters]

Level of the machine (not used at present)

TUNE VALUE 2: LEV. ST.TANK [liters]

Level of the addition tank (not used at present)

TUNE VALUE 3: LEV. EXP. T. [liters]

Level of the side tank (not used at present)

TUNE VALUE 4: MESS.RANGE

(not used at present)

TUNE VALUE 5: not used

(not used at present)

TUNE VALUE 6: MACH. MIN [liters]

(not used at present)

TUNE VALUE 7: MACH.MIDDLE [liters]

(not used at present)

TUNE VALUE 8: MACH. MAX [liters]

(not used at present)

TUNE VALUE 9: % Levl/pack. [%]

Level of each package, for the calculation of the filling volume by batch parameters [in
percentage].

TUNE VALUE 10: DELAY PUMP [1/10 SEC]

Delay time for the start of the main pump.

TUNE VALUE 11: ST.T. MIN [‰]

Minimum level of the 100% stock tank (prepare tank) - per thousand.

TUNE VALUE 12: ST.T.MIDDLE [‰]

Middle level of the 100% stock tank (prepare tank) to start the heating and mixing - per
thousand.

TUNE VALUE 13: ST.T. MAX [‰]

Maximum level of the 100% stock tank - per thousand.

TUNE VALUE 14: Refill t FF [1/10 SEC]

Time when the stock tank will filled again, while the min level of the stock tank is gone in fully
flooded mode but the working level in the expansion tank is not reached.

TUNE VALUE 15: LEVEL Exp.FF [%]

Working level of the expansion tank during fully flood mode

TUNE VALUE 16: EXP.T. MIN [‰]

Minimum level of the expansion tank - per thousand.

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TUNE VALUE 17: EXP.T.MIDDLE [‰]

Middle level of the expansion tank - per thousand.

TUNE VALUE 18: EXP.T. MAX [‰]

Maximum level of the expansion tank - per thousand.

TUNE VALUE 19: PRESSUR.TIME [1/10 SEC]

Pressurizing of the machine by this time during Airpad mode, because of no 2bar sensor.

TUNE VALUE 20: ground fill [%]

Value for the calculation of the filling volume

TUNE VALUE 21: top fill [%]

Minimum level of the tank D

TUNE VALUE 22: TEMP LOCK [°C]

Temperature Release for the machine.

TUNE VALUE 23: BACKCOOLER T [°C]

Temperature while back cooler will activated, by cooling down of 10 degrees it will switched
off.

TUNE VALUE 24 Backc. On T [1/10 SEC]

Time while the back cooler will activated, during cooling down.

TUNE VALUE 25 Backc. Off T [1/10 SEC]

Time while the back cooler will switched off, during cooling down.

TUNE VALUE 26 H/C CONt [1/10 SEC]

( CONDENSATE DELAY TIME ) determines the delay time, in which ( after initialization or
cooling ) the steam forces the contents of the heat exchanger through the outflow valve. After
the delay time has elapsed, the condensate valve will be energized and stays in this state,
until cooling is selected or the initialization delay time SBYt has elapsed.
TUNE VALUE 27 H/C CWRt [1/10 SEC]
With cooling, the delay time for the cooling water return valve will be applied to CWRt (COLD
WATER DELAY TIME).

TUNE VALUE 28 H/C SBYt [1/10 SEC]

The initialization delay time will be applied to SBYt ( STANDBY DELAY TIME ). This time
starts to run down, if no heating or cooling is selected. After this time has elapsed, the
outflow will be opened and all other valves of the heat exchanger will be closed.

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TUNE VALUE 29 t_AL TIME [1/10 SEC]

The connection is used to monitor a too flat gradient, caused by external disturbances. If
during an increasing or decreasing gradient, the maximum control output is reached (OUT =
10000), a countdown, based on t_AL, starts.
The output alarm 5 “NOT HOLD GRADIENT” is activated, if the control output does not
decrease before t_AL is passed.

TUNE VALUE 30 DIFF.PR. Y/N [ ]

This is for the detection if there is a differential pressure control.
0 = machine without differential pressure control
1 = machine with differential pressure control

TUNE VALUE 31: PMP% Filling [%]

Pump speed during filling, inject stock tank and manual cooling. This is a fixed speed value.

TUNE VALUE 32: BLOW OUT D.P [1/10 SEC]

Ventilation for the dosing pump (Blow out before running the dosing pump). Only the valve
715 opens during this time.

TUNE VALUE 33: 1 WAITT. ST. [1/10 SEC]

After low level of the stock tank is not covered anymore the first wait time ( 1WTt ) starts. For
this time the injection continues.

TUNE VALUE 34: 1.RINSET ST. [1/10 SEC]

After the first wait time has elapsed, the first cleaning time ( 1CLt ) starts. During this time,
the splash ring is active. In FF-Mode this time is fixed (0,3 sec) for inject.

TUNE VALUE 35: 2.WAITT ST. [1/10 SEC]

After the first cleaning time ( 1CLt ) has elapsed, the second wait time ( 2WTt ) starts. In FF-
Mode this time is fixed (1 sec) for inject.

TUNE VALUE 36: 2.RINSET ST. [1/10 SEC]

After the second wait time has elapsed, the second cleaning time ( 2CLt ) starts. During this
time, the splash ring is active.

TUNE VALUE 37: DRAINT. ST. [1/10 SEC]

After the second cleaning time ( 2CLt ) has elapsed, the drain time ( DRt ) for the stock tank
starts.

TUNE VALUE 38: TimeLvl Rins [1/10 SEC]

Delay time for opening the fill valves, while the middle level is reached. Not used at present.

TUNE VALUE 39: MIXERTIME [1/10 SEC]

Time for mixing the expansion tank by the valve V715, before inject or dosing.

TUNE VALUE 40: 1 WAITT.Exp. [1/10 SEC]

After low level of the expansion tank is not covered anymore the first wait time ( 1WTt )
starts. For this time the injection continues.

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TUNE VALUE 41: 1.RINSET Exp [1/10 SEC]

After the first wait time has elapsed, the first cleaning time ( 1CLt ) starts. During this time,
the splash ring is active.

TUNE VALUE 42: 2.WAITT.Exp. [1/10 SEC]

After the first cleaning time ( 1CLt ) has elapsed, the second wait time ( 2WTt ) starts.

TUNE VALUE 43: 2. RINSET Exp [1/10 SEC]

After the second wait time has elapsed, the second cleaning time ( 2CLt ) starts. During this
time, the splash ring is active.

TUNE VALUE 44: DRAINT. Exp [1/10 SEC]

After the second cleaning time ( 2CLt ) has elapsed, the drain time ( DRt ) for the expansion
tank starts.

TUNE VALUE 45: FLAPS CYLIND [ ]

This is for the selection how the in-out controlling is done.
0 = machine with 4 valves for in/out control (V1,V1.1,V2 and V2.1)
1 = machine with a cylinder for in/out control (V32.1,V32.3 and V2)

TUNE VALUE 46: ES22 Y/N [ ]

This is for the detection about the type of the machine.
0 = machine type ES21 without an expansion tank
1 = machine type ES22 with an expansion tank an some additional valves

TUNE VALUE 47: Dyekitch.Y/N [ ]

This is for the detection if the tanks for the dye kitchen are used for this machine.
0 = machine type ES22 without dye kitchen
1 = machine type ES22 with dye kitchen

TUNE VALUE 48: Dos.Syst.Y/N [ ]

This is for the detection if there is a dosing system in use. Not used at present.

TUNE VALUE 49: Del.V59Drain [ ]

Delay time for opening of the valve V59, while the minimum level of the machine is gone for
HT-Drain.

TUNE VALUE 50: Mix_time_DK [ ]

(not used at present)

TUNE VALUE 51: min Lvl DK 1 [‰]

Minimum level of the dye kitchen tank 1 - per thousand.

TUNE VALUE 52: max Lvl DK 1 [‰]

Maximum level of the dye kitchen tank 1 - per thousand.

TUNE VALUE 53: min Lvl DK 2 [‰]

Minimum level of the dye kitchen tank 2 - per thousand.

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TUNE VALUE 54: max Lvl DK 2 [‰]

Maximum level of the dye kitchen tank 2 - per thousand.

TUNE VALUE 55: Del.t.Revers [1/10 SEC]

Delay time, while reaching the minimum level of the vessel (N93) during REVERSE A.

TUNE VALUE 56: WAITtime DK1 [1/10 SEC]

After low level of the dye kitchen tank 1 is not covered anymore the wait times ( 1WTt and
2WTt ) are starting. For this time the injection continues.

TUNE VALUE 57: 1.RINSET DK1 [1/10 SEC]

After the first wait time has elapsed, the first cleaning time ( 1CLt ) starts. During this time,
the splash ring is active.

TUNE VALUE 58: 2. RINSET DK1 [1/10 SEC]

After the second wait time has elapsed, the second cleaning time ( 2CLt ) starts. During this
time, the splash ring is active.

TUNE VALUE 59: DRAINT. DK1 [1/10 SEC]

After the second cleaning time ( 2CLt ) has elapsed, the drain time ( DRt ) for the dye kitchen
tank 1 starts.

TUNE VALUE 60: WAITtime DK2 [1/10 SEC]

After low level of the dye kitchen tank 2 is not covered anymore the wait times ( 1WTt and
2WTt ) are starting. For this time the injection continues.

TUNE VALUE 61: 1.RINSET DK2 [1/10 SEC]

After the first wait time has elapsed, the first cleaning time ( 1CLt ) starts. During this time,
the splash ring is active.

TUNE VALUE 62: 2. RINSET DK2 [1/10 SEC]

After the second wait time has elapsed, the second cleaning time ( 2CLt ) starts. During this
time, the splash ring is active.

TUNE VALUE 63: DRAINT. DK2 [1/10 SEC]

After the second cleaning time ( 2CLt ) has elapsed, the drain time ( DRt ) for the dye kitchen
tank 2 starts.

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Description for the Adjustment of SM5000

Timing diagram for stock tank, expansion tank and dye kitchen

The timing diagram shows the different sections of the drain and transfer .

LEVEL

PUMP

CLEAN
WATER

DRAIN

SEC.1 SEC.2 SEC.3 SEC.4 SEC.5

1WTt 1CLt 2WTt 2CLt DRt

In section 1 to 4, the pump is running.

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Adjustment of the control loops SM5000

Description for optimizations of the PID controller

The optimization of the PID controllers is executed according to rising and falling gradient and
because of this, the definition of 6 parameter per used controller.
For the input you can select between the programming unit SEDOMAT 5000 or the PC by the program
PLCPROG.

For the adjusting of parameters, we experienced the following method.

a) Acquirement of the maximum gradient

b) Derivation of the proportional value Kp from the gradient.
c) Improvement of Kp.
d) Completion of Kp.

Acquirement of the maximum gradient

Heating the machine with maximum gradient and note the gradient/minute in a middle temperature
range ( example between 70 till 80°C )
1°C are 66 units.

KP

10000 15000
KP= *100 =
Max. Gradient x 66 Max Gradient

Example: The maximum gradient is 5°C/min. Insert the value 5*66=333 into the equation.
The result is a KP = 3000

For the first controlled heating-up, the calculated value of Kp is taken over.
The parameters for Ti and Td are set to 0, provisionally.

The eventually modification of Kp is resulting, when considering the temperature curve.

If the Kp to large the temperature control oscillates between heating and cooling.

If the Kp to small the temperature control approaches only slowly the set temperature.

Ti ( Control factor )
For removal of the remaining control deviation, the parameter Ti is completed.

When the actual value does not change any more at the moment x, the control output value will be
doubled after 2 * Ti ( in seconds )

If the I-part to lowly, the controller swings to much.

If the I-part to highly, the set temperature is reached after a to long time.

Td ( Control factor)
The higher the value for Td is selected, the higher is the opposite coupling at the control output.
Caused by change of the actual value.

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Control values for the PID controller (control loop – Contrl val)

For the adaptation to the control section, a difference should be made between optimizing and
regulating the operation mode.

Controller modes

MODE

For the adaptation to the regulating unit, it is possible to select different operation modes for the
control output OUT and the outputs HEAT and COOL. The selection is done by connecting a constant
at the input MODE.
The resulting limits, in which the control output can move, are shown in the graphic below.
The indicated status’s of the outputs HEAT and COOL are only valid, if no On/Off control loop is
selected.

Mode 0 Continue 0-20mA

Mode1 Continue 4-20mA
Mode2 Continue splitting mode 0_10/10-20mA
Mode3 Continue splitting mode 4_12/12-20mA

C_ON
Alternatively to the continuous control, the control output can also be expressed by means of a
pulse /pause relation, also called ON/OFF control. The control is done by the two outputs HEAT and
COOL.
Furthermore, the ON/OFF control can be combined with the continuous control. The selection is done
by a constant on the input C_ON and offers the following possibilities:

0 = continuous control
1 = ON/OFF control
2 = ON/OFF control for HEAT and continuous control for COOL.
3 = ON/OFF control for COOL and continuous control for HEAT.

C_t
For adaptation to the regulating unit, a cycle time has to be fixed. Criteria like inertia, wear out, control
accuracy, etc., are influencing this. The cycle time is defined from the moment of switching on, over
the switching off, until the new switching on. It is connected in form of a constant to the input C_t and
is interpreted in seconds.
Example: The cycle time should be 10 seconds

C_t = K10
Please note:
Even without using the ON/OFF control, a value has to be applied to this input.

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C_mt
The values near the maximum or the minimum limits of the ON/OFF control, can not be realised
because of the mechanical inertia. This is the reason for the input C_mt, with which the minimum
switching on and off time is fixed. That means, when the calculated value is below this, it is not
executed. A constant value is applied to the input C_mt and is interpreted in seconds.
Please note:
Even without using the ON/OFF control, a value has to be applied at this input.

Example: The minimum ON time should be 3 seconds.

C_mt = K3

Example Diagram:
The actual analog of the PID controller is 4000 units ( normal range 0...10000 units )
This means for a on/off control mode 4 seconds ON-tine and 6 seconds OFF-time.

Cycle time 10s Cycle time 10s

4s 6s

Delay

WAIT
At switching between HEAT and COOL, the switching of the corresponding outputs can be delayed
with the constant value that is connected to the input WAIT.

BAND
The constant value at the input BAND specifies a tolerance above and below the set point value SET.
The control of the input ACT starts after the set point value was reached.
At leaving the tolerance range, the output A<>S is set. Via connecting an operand with the
identification AL., an alarm can be generated.
Value range
The input BAND is usually connected to a constant value. The proportional relation to the temperature
is dependant on the measuring instrument. When using the FB "PT..." +/- 1°C equals 10000/150.

Example:
The tolerance of the alarm band should be 3°C.

BAND 3°C
=
10000 150°C

3°C * 10000
Band = ----------------------- =200
150°C

The Set value for 3°C must be 200 for the controller input.

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Description for optimisation DSR controller

Example for differential pressure controlling with DSR-controller

The analog output for the frequency converter will be start by zero and goes up step by step.
If the set point of differential pressure is reached the controller hold the actual output value.
Tolerance will be continual adjusted

For a better understanding is it possible.

change the input range for 0...10000 units.

This means a analog input signal 4...20mA (2000...10000) will be changed with function blocks to a
signal 0...10000.

Example: differential pressure input . 0 till 2.5bar = 10000/25 =400 units per 0.1bar

deadband

CF 170 DSR controller board 1

Deadband specifies a tolerance above and below the set point value SET.
If the actual feedback of differential pressure inside this band, the controller output will be constant.

Example:

Set value 1.5bar

selected deadband = +/- 0.1bar

equivalent = 400 PLC-units

Picture A Picture B

deadband Controller
1.4 till 1.6bar output
2.5 max

2.0

1.5 Set value 1.5bar

1.0
Differential pressure
0,5

0.0bar t 0 t

Picture A shows building up the differential pressure. Picture B shows the analog output of the DSR
controller.
If the actual pressure input inside the deadband , the controller output will be constant.
The range of the analog output is dependence from the performance of pump and kind of dyestuff.

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Feedback P

CF 171 DSR controller board 1

The value of this control factor will be adding up to the deadband value in both directions.

Example:

Set value 1.5bar

Selected deadband = +/- 0.1bar

equivalent = 400 PLC-units

Selected feedback P = +/- 0.2bar

equivalent = 800 PLC-units

Picture C Picture D

P-band Controller
1.6 till 1.8bar output
2.5 1.2 till 4bar max

2.0

1.5 Set value 1.5bar

1.0
Differential pressure
0,5

0.0bar t 0 t

Picture C shows building up the differential pressure. Picture D shows the analog output of the DSR
controller.
If the actual pressure input inside the P-band the controller output goes up with delay time.
After reached the deadband the controller output will be constant.

Feedback time

CF 172 DSR Controller board

The feedback time is the delay-time for the controller output, inside the P-band.
Use only a value range from 1 till 3.

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Control values for the DSR controller (control loop – Contrl val)

MODE
For the adaptation to the regulating unit, it is possible to select different operation modes for the
control output OUT and the outputs HEAT and COOL. The selection is done by connecting a constant
at the input MODE.
The resulting limits, in which the control output can move, are shown in the graphic below.
The indicated status’s of the outputs HEAT and COOL are only valid, if no On/Off control loop is
selected.

For the MODE 0 and 1 the modification speed of the output signal is 160/sec. Corresponding to the
above mentioned modes a dynamically behaviour can be achieved via connecting the values 4 and 5
in between the same limits. MODE 4 corresponds to MODE 0 and MODE 5 corresponds to MODE 1.
The modification speed results from the difference between set point and actual value and the
deadband.
D set/actual > 8 * deadband---- 500/sec.
D set/actual < 8 * deadband---- 250/sec.
D set/actual < 4 * deadband---- 160/sec.
D set/actual < 2 * deadband---- 80/sec.

MODE 0 and 1 can be operated with a changed preferred position of the output signal. With a
deactivated GATE or set point 0 the output signal is set to a middle value or maximum value is given.

Preference: middle output value

MODE 8 0 5000 10000
MODE 9 2000 6000 10000

Preference: maximum output value

MODE 16 0 10000
MODE 17 2000 10000

Remark:
The conversion of the output signal to a corresponding current is done by the FB C_OUTx.x.

C_ON
Alternatively to the analogue control the control element can also be digital controlled. The value 1 is
written to the connection C_ON. Through this the interpretation of the two outputs HEAT and COOL is
done. At a control difference > 8*deadband a static signal via HEAT or COOL is set, according to the
direction. The outputs starts to pulse if the difference is smaller. The pulse range or pulse break and
the minimum time of the on and off time are determined via entries at the connections C_t and C_mt.

0 = analog control
1 = digital control´

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C_t
The sum of the switching on and off time can be defined via the connection C_t. For adaptation to the
regulating unit, a cycle time has to be fixed. Criteria like inertia, wear out, control accuracy, etc., are
influencing this. The cycle time is defined from the moment of switching on, over the switching off, until
the new switching on. It is connected in form of a constant to the input C_t and is interpreted in
seconds.
Please note:
Even without using the ON/OFF control, a value has to be applied to this input.

C_mt
The values near the maximum or the minimum limits of the ON/OFF control, can not be realised
because of the mechanical inertia. This is the reason for the input C_mt, with which the minimum
switching on and off time is fixed. That means, when the calculated value is below this, it is not
executed. A constant value is applied to the input C_mt and is interpreted in seconds.
Please note:
Even without using the ON/OFF control, a value has to be applied at this input.

WAIT
At switching between HEAT and COOL, the switching of the corresponding outputs can be delayed
with the constant value that is connected to the input WAIT.

BAND
The constant value at the input BAND specifies a tolerance above and below the set point value SET.
The control of the input ACT starts after the set point value was reached.
At leaving the tolerance range, the output A<>S is set. Via connecting an operand with the
identification AL.., an alarm can be generated.

Value range
The input BAND is usually connected to a constant values. The proportional relation to the pressure is
dependant on the measuring instrument. According to the example in the SET description 0,1bar
equals 10000/25.

Example: for a input range from 0...2.5bar are 0...10000 PLC-units.

Result +/- 0.1bar = 10000/25 = 400

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Own Notes

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